Terminal and electrical wire having the same

Abstract

A terminal includes: a cylindrical box portion into which a mating terminal is inserted; and a spring portion extending from a front end portion to a rear end portion of the box portion in a length direction, and deforming in a bending direction away from a mating terminal when the mating terminal inserted into the box portion is in contact with the spring portion. The spring portion has a pair of protrusions that protrude outward in a width direction orthogonal to the longitudinal direction from a free end portion on the rear end side of the spring portion. The box portion has holes formed in a pair of side walls constituting the box portion. The hole is formed in an arc shape along a trajectory in which the protrusion moves when the spring portion making contact with the mating terminal deforms in the bending direction.

Description

Technical Field

[0001] The present invention relates to a terminal and an electric wire having the terminal. Background Art

[0002] Conventionally, a terminal (e.g., a so-called crimping terminal) attached to the end of an electric wire is used. For example, the terminal includes: a cylindrical box portion into which a mating terminal is inserted; a cantilever beam-shaped spring portion, which is disposed inside the box portion and has a contact portion with the mating terminal; and a fixing portion for fixing the terminal to the electric wire (see JP2014-160544A). Summary of the invention

[0003] In order to electrically connect the above-mentioned electric wire with a terminal to another electric wire, there is a situation where the core wires of the two electric wires are joined to each other by performing an ultrasonic bonding process while the core wires of the two electric wires are in close contact with each other. In this case, the ultrasonic vibration applied to the bonding portion is transmitted to the terminal via the electric wire, which may cause the terminal to vibrate. In particular, since the spring portion is formed in the shape of a cantilever beam, it is likely to cause vibration that repeatedly oscillates upward and downward with the fixed end as a fulcrum. Depending on the degree of vibration, the spring portion may repeatedly be over-bent, etc., which may cause deterioration or plastic deformation of the spring portion. From the perspective of improving the reliability of the electrical connection between the terminal and the mating terminal, it is preferred to suppress such deterioration of the spring portion as much as possible.

[0004] An object of the present invention is to provide a terminal and an electric wire having the terminal, which can suppress deformation of a spring portion due to an external force such as vibration applied from the outside.

[0005] The terminal according to the present invention comprises: a cylindrical box portion, in which a mating terminal is inserted; and a spring portion, which extends from the front end portion to the rear end portion of the box portion in the length direction, and when the mating terminal inserted in the box portion contacts the spring portion, the spring portion is deformed in a flexural direction away from the mating terminal, wherein the spring portion has a pair of protrusions, which protrude outward from the free end portion on the rear end side of the spring portion in a width direction orthogonal to the length direction, the box portion has a hole, which is formed in each of a pair of side walls constituting the box portion and the protrusion is inserted and locked in the hole, and the hole is formed in an arc shape along the trajectory of the protrusion moving when the spring portion in contact with the mating terminal is deformed in the flexural direction.

[0006] The electric wire with a terminal according to the present invention comprises: an electric wire; and a terminal, which is attached to the electric wire, and the terminal comprises: a cylindrical box portion, in which a mating terminal is inserted; and a spring portion, which extends from a front end portion to a rear end portion of the box portion in a length direction, and when the mating terminal inserted into the box portion contacts the spring portion, the spring portion is deformed in a flexure direction away from the mating terminal, wherein the spring portion has a pair of protrusions, which protrude outward from a free end portion on a rear end side of the spring portion in a width direction orthogonal to the length direction, the box portion has a hole, which is formed in a pair of side walls constituting the box portion and the protrusion is inserted and locked in the hole, and the hole is formed in an arc shape along a trajectory of movement of the protrusion when the spring portion in contact with the mating terminal is deformed in the flexure direction.

[0007] The above configuration makes it possible to provide a terminal and an electric wire having the terminal which can suppress deformation of the spring portion due to an external force such as vibration applied from the outside. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of main parts showing an example of a terminal according to the present embodiment.

[0009] Figure 2 : is a side view of a main part showing an example of a terminal according to the present embodiment.

[0010] Figure 3 is a front view showing an example of a terminal according to the present embodiment.

[0011] Figure 4 It is along Figure 3 A cross-sectional view taken along line AA.

[0012] Figure 5 It is along Figure 4 A cross-sectional view taken along line BB.

[0013] Figure 6 is an enlarged schematic diagram showing a hole formed in a side wall of a terminal.

[0014] Figure 7 : is a schematic cross-sectional view showing the terminal in a state before mating.

[0015] Figure 8 It is a schematic cross-sectional view showing the terminal in a mated state.

[0016] Fig. 9 It is a schematic diagram showing a method of manufacturing a wire harness having a joint portion in which core wires of a plurality of electric wires with terminals are joined to each other by ultrasonic joining.

[0017] Fig.10 It is a schematic diagram showing a method of manufacturing a wire harness having a joint portion in which core wires of a plurality of electric wires with terminals are joined to each other by ultrasonic joining. DETAILED DESCRIPTION

[0018] Hereinafter, a terminal and an electric wire having the terminal according to the present embodiment will be described in detail with reference to the accompanying drawings. Note that the dimensional ratios of the drawings are exaggerated for convenience of explanation and may differ from the actual ratios.

[0019] For the convenience of description, the mating terminal (male terminal 40) is mated with one side ( Figure 1 and Figure 2 The left side in the figure is called the end side (front side), and the opposite side ( Figure 1 and Figure 2 The right side in the figure is called the base end side (rear side). Figure 1 and Figure 2 In the drawings, the upper side and the lower side will be referred to as the upper side and the lower side, respectively. In addition, the direction orthogonal to the length direction and the up-down direction of the female terminal 20 will be referred to as the width direction.

[0020] like Fig. 9 and Fig.10 As shown, the female terminal 20 is crimped and fixed to the end of the electric wire 10, and thus the female terminal 20 and the conductor core wire (core wire 11) of the electric wire 10 are electrically connected to each other. The electric wire 10 and the female terminal 20 constitute the electric wire 1 with a terminal, and the electric wire 1 with a terminal constitutes a wiring harness 2 (see FIG. 2 ) arranged in a vehicle such as an automobile. Fig.10 ).

[0021] The electric wire 10 is an insulated electric wire having a core wire 11 and a coating 12 made of resin for covering the core wire 11. For example, the core wire 11 is formed by twisting a plurality of electric wires made of aluminum or an aluminum alloy. By using aluminum or an aluminum alloy to form the core wire 11 of the electric wire 10, the weight of the electric wire 1 with a terminal is reduced, and the weight of the wiring harness 2 formed by including the electric wire 1 with a terminal is also reduced. In particular, the electric wire 1 with a terminal having a reduced weight is suitable for vehicles that frequently use wiring harnesses, such as electric vehicles and hybrid vehicles. The core wire 11 is not limited to being formed by using aluminum or an aluminum alloy, and may be formed by using other materials (such as copper or a copper alloy).

[0022] like Figures 1 to 5 As shown, the female terminal 20 includes a box portion 31 located at the end side, a conductive contact portion 41 (see Figure 7 and Figure 8) is inserted into the box portion 31. In addition, the female terminal 20 includes a first barrel portion (core wire crimping piece 45) and a second barrel portion (cover crimping piece 46) at the base end side of the box portion 31, the first barrel portion (core wire crimping piece 45) being crimped to the core wire 11 exposed from the end of the electric wire 10, and the second barrel portion (cover crimping piece 46) being crimped to the cover 12 (see FIG. 1 ) located at the end of the electric wire 10. Fig. 9 and Fig.10 ).

[0023] The female terminal 20 is formed by stamping (stamping and bending) a metal plate (plate-like body). For example, the core wire 11 is formed of aluminum or an aluminum alloy, and the female terminal 20 is formed of a metal material different from the core wire 11. Specifically, the female terminal 20 is formed using a metal plate (plate-like body) composed of copper or a copper alloy as a base material. The core wire 11 of the electric wire 10 and the female terminal 20 do not necessarily have to be formed of different metal materials, and may be made of the same metal material.

[0024] After the above-mentioned stamping process, in order to suppress the corrosion of the core wire 11 of the electric wire 10 to improve the corrosion resistance, it is preferred to plate the female terminal 20 before crimping it to the electric wire 10. For example, the female terminal 20 is plated with tin (Sn) before being crimped to the electric wire 10. Specifically, the female terminal 20 is provided with a plating layer containing tin to cover the outer and inner side surfaces and the side surface formed by the cut surface formed by the stamping process. The surface of the female terminal 20 is not limited to tin (Sn) plating, and other materials (for example, gold (Au), silver (Ag), nickel (Ni) and alloys thereof) may be plated.

[0025] The box portion 31 has a rectangular cylindrical shape extending in the front-to-back direction and penetrating in the front-to-back direction. The box portion 31 includes an upper wall 31a, a bottom wall 31b and a pair of side walls 31c and 31c, and a spring portion (contact spring 32) is integrally formed inside the box portion 31. The contact spring 32 is a cantilever beam-shaped leaf spring extending from the terminal end portion of the bottom wall 31b of the box portion 31 and extending from the terminal end side toward the base end side inside the box portion 31. In addition, the contact spring 32 can be elastically deformed in the up-down direction. In addition, the contact spring 32 extends from the base end portion of the box portion 31 to a predetermined position on the terminal end side. Therefore, the free end 32a of the contact spring 32 is located inside the box portion 31.

[0026] The contact spring 32 is formed with a contact portion 32c which contacts the conductive contact portion 41 of the male terminal 40 at a portion close to the fixed end portion 32b (the terminal end portion of the box portion 31) of the contact spring 32. The contact portion 32c protrudes upward and extends in the width direction. Inside the box portion 31, a terminal portion 33 is formed at a portion opposite to the contact portion 32c of the contact spring 32. The terminal portion 33 protrudes downward and extends in the width direction. When the conductive contact portion 41 of the male terminal 40 (see Figure 7) is inserted from the terminal opening of the box portion 31, the conductive contact portion 41 pushes the contact portion 32c of the contact spring 32 downward, thereby accommodating the conductive contact portion 41c inside the box portion 31 in a state where the contact spring 32 is elastically deformed downward. As a result, the contact portion 32c of the female terminal 20 and the conductive contact portion 41 of the male terminal 40 are kept in contact with each other, thereby electrically connecting the terminal (female terminal 20) and the mating terminal (male terminal 40) to each other (see Figure 8 ).

[0027] The contact spring 32 is formed with a pair of protrusions 34 and 34, which are integrally formed and protrude outward in the width direction from the free end 32a of the contact spring 32. At the same time, a hole 36 is formed in a pair of side walls 31c and 31c of the box portion 31, and the protrusion 34 is inserted and locked in the hole 36. In the present embodiment, the hole 36 is formed in an arc shape along the trajectory of the protrusion 34 moving when the contact spring 32 in contact with the conductive contact portion 41 of the male terminal 40 is deformed in the flexure direction (see Figure 6 ).

[0028] In this embodiment, if Figure 6 As shown, the hole 36 has a retaining surface portion 35 formed in the periphery of the hole 36 and retains the contact spring 32 in a state of elastic deformation in the flexure direction from a natural state. In the present embodiment, the protrusion 34 formed on the contact spring 32 contacts the retaining surface portion 35 formed in the hole 36. Therefore, the contact spring 32 is retained in a state of elastic deformation in the flexure direction from a natural state by the retaining surface portion 35, thereby pushing the free end portion 32a of the contact spring 32 upward. In a state where the upper surface 34a of the protrusion 34 contacts the upper wall surface (retaining surface portion 35) of the hole 36, the gap G between the lower surface 34b of the protrusion 34 and the lower wall surface 37 of the hole 36 is set to, for example, about 0.1 mm.

[0029] Furthermore, the female terminal 20 includes a fixing portion for fixing the female terminal 20 to the electric wire 10. The fixing portion has a first barrel portion (core wire crimping piece 45) and a second barrel portion (cover crimping piece 46) (see Fig. 9 and Fig.10 A pair of core wire crimping pieces 45 extending upward before crimping to the electric wire 10 are formed on a pair of side walls 31c and 31c belonging to the first barrel portion. At the same time, a pair of covering crimping pieces 46 extending upward before crimping to the electric wire 10 are formed on a pair of side walls 31c and 31c belonging to the second barrel portion.

[0030] like Fig. 9 and Fig.10As shown, the electric wire 10 is arranged in the female terminal 20 before being crimped to the electric wire 10, so that the core wire 11 exposed from the end of the electric wire 10 is sandwiched between the pair of core wire crimping pieces 45, and the coating 12 as the end of the electric wire 10 is sandwiched between the pair of coating crimping pieces 46. In this state, the pair of core wire crimping pieces 45 and the pair of coating crimping pieces 46 are crimped using a predetermined crimping machine, thereby obtaining Fig. 9 and Fig.10 An electric wire 1 with a terminal is shown.

[0031] Fig. 9 and Fig.10 The electric wires 1 with terminals shown constitute, for example, a wiring harness 2. Fig.10 As shown, the wiring harness 2 has a branch connection portion (joining portion 13) in which the exposed core wires 11 of the electric wires 10 of a plurality of electric wires 1 with terminals (in the figure, two electric wires 1 with terminals) are ultrasonically joined to each other. The wiring harness 2 may have a joining portion 13 in which the exposed core wires 11 of three or more electric wires 10 are ultrasonically joined to each other. In addition, terminals other than the female terminals 20 may be attached to some of the electric wires 10 constituting the wiring harness 2, or terminals may not be attached thereto.

[0032] The bonding machine 50 for forming the bonded portion 13 will be described below.

[0033] like Fig. 9 As shown, the bonding machine 50 includes: a pair of bonding pressure heads (referred to as anvil 51 and welding head 52) facing each other in the up-down direction; and a control device (not shown) for controlling the bonding energy (ultrasonic excitation) applied between the pair of bonding pressure heads (anvil 51 and welding head 52). A bonding space is defined by the pair of bonding pressure heads (anvil 51 and welding head 52), and the exposed core wires 11 of the plurality of electric wires 10 are arranged in the bonding space.

[0034] In a state where the plurality of core wires 11 are sandwiched between the anvil 51 and the horn 52, a predetermined amount of energy (ultrasonic excitation) is applied between the anvil 51 and the horn 52. By subjecting the plurality of core wires 11 to ultrasonic bonding in this manner, a bonding portion 13 (see FIG. 1 ) in which the plurality of core wires 11 are bonded is formed. Fig.10 ).

[0035] On the outer surface of the joint portion 13 of the plurality of core wires 11 joined to each other, a joint trace formed by ultrasonic joining is formed. In the present embodiment, the joint trace has a shape of the concave and convex surfaces of the anvil 51 and the welding head 52 transferred for ultrasonic joining, and can be identified from the outer surface of the joint portion 13.

[0036] Furthermore, preferably, Fig.10The protective member 3 shown by the double-dashed line in the figure is mounted on the joint portion 13 of the plurality of core wires 11 joined to each other so as to cover the entire outer surface of the joint portion 13. Therefore, it is possible to suppress damage to the joint portion 13 due to contact between the joint portion 13 and surrounding components, and it is possible to suppress the occurrence of an unexpected short circuit due to contact between the joint portion 13 and the surrounding conductive components.

[0037] As described above, the terminal (female terminal 20) according to the present embodiment includes a cylindrical box portion 31, into which a mating terminal (male terminal 40) is inserted. The terminal (female terminal 20) includes a spring portion (contact spring 32) extending from the front end portion to the rear end portion of the box portion 31 in the length direction, and when the mating terminal (male terminal 40) inserted into the box portion 31 makes contact with the spring portion, the spring portion is deformed in a bending direction away from the mating terminal (male terminal 40). The spring portion (contact spring 32) has a pair of protrusions 34 and 34, which protrude outward from the free end portion 32a of the rear end side of the spring portion (contact spring 32) in the width direction orthogonal to the length direction. The box portion has a hole 36, which is formed in a pair of side walls 31c and 31c constituting the box portion 31 and the protrusion 34 is inserted and locked in the hole 36. The hole 36 is formed in an arc shape along a locus along which the protrusion 34 moves when the spring portion (contact spring 32 ) that makes contact with the mating terminal (male terminal 40 ) is deformed in the flexure direction.

[0038] In the present embodiment, the protrusion 34 formed on the contact spring 32 is locked in the hole 36 formed in the side wall 31c of the box portion 31, and the contact spring 32 is deformed in the up-down direction within the range in which the protrusion 34 contacts the upper wall surface (holding surface portion 35) or the lower wall surface 37 of the hole 36. In addition, the hole 36 formed in the side wall 31c of the box portion 31 is formed based on the trajectory drawn by the protrusion 34 when the contact spring 32 is elastically deformed in the flexure direction by the conductive contact portion 41 of the male terminal 40 inserted into the box portion 31. Therefore, the movement of the protrusion 34 directly above or directly below is restricted by the periphery (upper wall surface and lower wall surface 37) of the hole 36. Therefore, unless an external force is applied to the protrusion 34, the contact spring 32 in which the protrusion 34 is inserted and locked in the hole 36 will not be deformed even with respect to the rear side in the length direction of the box portion 31. This makes it possible to suppress deformation of the contact spring 32 in the flexing direction due to an external force other than the force acting on the contact spring 32 when the conductive contact portion 41 of the male terminal 40 is inserted into the box portion 31 .

[0039] As described above, the present embodiment makes it possible to provide a terminal (female terminal 20 ) capable of suppressing deformation of the spring portion (contact spring 32 ) due to an external force such as vibration applied from the outside.

[0040] In the terminal (female terminal 20 ), the hole 36 may have a holding surface portion 35 formed in the periphery of the hole 36 and holding the spring portion (contact spring 32 ) in a state elastically deformed in the flexure direction from a natural state.

[0041] In the present embodiment, with the protrusion 34 inserted and locked into the hole 36, the contact spring 32 is elastically deformed in the flexing direction (downward), which causes the protrusion 34 formed on the contact spring 32 and the holding surface portion 35 formed in the periphery of the hole 36 to come into contact with each other. By causing the protrusion 34 formed on the contact spring 32 and the holding surface portion 35 formed in the periphery of the hole 36 to come into contact with each other, it is possible to suppress the upward deformation of the contact spring 32 due to an external force such as ultrasonic vibration during ultrasonic bonding. In addition, an elastic force (biasing force) is generated in the contact spring 32, and even in the downward direction, the contact spring 32 is not deformed unless an external force equal to or greater than the elastic force (biasing force) generated by the contact spring 32 is applied, and therefore the contact spring 32 is hardly deformed even in the downward direction.

[0042] In addition, the electric wire 1 with a terminal according to one aspect of the present embodiment is provided with the electric wire 10 and the terminal (female terminal 20) attached to the electric wire 10. The terminal (female terminal 20) includes a cylindrical box portion 31 into which a mating terminal (male terminal 40) is inserted. The terminal (female terminal 20) includes a spring portion (contact spring 32) extending from the front end portion to the rear end portion of the box portion 31 in the length direction, and when the mating terminal (male terminal 40) inserted into the box portion 31 makes contact with the spring portion, the spring portion is deformed in a bending direction away from the mating terminal (male terminal 40). The spring portion (contact spring 32) has a pair of protrusions 34 and 34, which protrude outward in a width direction orthogonal to the length direction from a free end portion 32a on the rear end side of the spring portion (contact spring 32). The box portion has a hole 36 formed in a pair of side walls 31c and 31c constituting the box portion 31 and the protrusion 34 is inserted and locked in the hole 36. The hole 36 is formed in an arc shape along a trajectory along which the protrusion 34 moves when the spring portion (contact spring 32) that makes contact with the mating terminal (male terminal 40) is deformed in the flexure direction.

[0043] In the present embodiment, the protrusion 34 formed on the contact spring 32 is locked in the hole 36 formed in the side wall 31c of the box portion 31, and the contact spring 32 is deformed in the up-down direction within the range in which the protrusion 34 contacts the upper wall surface (holding surface portion 35) or the lower wall surface 37 of the hole 36. In addition, the hole 36 formed in the side wall 31c of the box portion 31 is formed based on the trajectory drawn by the protrusion 34 when the contact spring 32 is elastically deformed in the flexure direction by the conductive contact portion 41 of the male terminal 40 inserted into the box portion 31. Therefore, the movement of the protrusion 34 directly above or directly below is restricted by the periphery (upper wall surface and lower wall surface 37) of the hole 36. Therefore, unless an external force is applied to the protrusion 34, the contact spring 32 in which the protrusion 34 is inserted and locked in the hole 36 will not be deformed even with respect to the rear side in the length direction of the box portion 31. This makes it possible to suppress deformation of the contact spring 32 in the flexure direction due to external forces other than the force acting on the contact spring 32 when the conductive contact portion 41 of the male terminal 40 is inserted into the box portion 31. Since the contact spring 32 is hardly deformed by external forces such as ultrasonic bonding generated when manufacturing the wire harness 2, the above-mentioned ultrasonic bonding method can be applied to the electric wire 1 with a terminal without reducing the reliability of electrical contact.

[0044] As described above, the present embodiment makes it possible to provide the electric wire with terminal 1 which can suppress the spring portion (contact spring 32 ) from being deformed due to an external force such as vibration applied from the outside.

[0045] In the electric wire with terminal 1, the hole 36 may have a holding surface portion 35 which is formed in the periphery of the hole 36 and holds the spring portion (contact spring 32) in a state elastically deformed in the flexure direction from a natural state.

[0046] In the present embodiment, with the protrusion 34 inserted and locked into the hole 36, the contact spring 32 is elastically deformed in the flexing direction (downward), which causes the protrusion 34 formed on the contact spring 32 and the holding surface portion 35 formed in the periphery of the hole 36 to come into contact with each other. By causing the protrusion 34 formed on the contact spring 32 and the holding surface portion 35 formed in the periphery of the hole 36 to come into contact with each other, it is possible to suppress the upward deformation of the contact spring 32 due to an external force such as ultrasonic vibration during ultrasonic bonding. In addition, an elastic force (biasing force) is generated in the contact spring 32, and even in the downward direction, the contact spring 32 is not deformed unless an external force equal to or greater than the elastic force (biasing force) generated by the contact spring 32 is applied, and therefore the contact spring 32 is hardly deformed even in the downward direction.

[0047] Although specific embodiments have been described, these embodiments are disclosed only by way of example and are not intended to limit the scope of the invention. In fact, the novel embodiments described herein may be implemented in various other forms; in addition, various omissions, substitutions, and changes in the embodiment forms described herein may be made without departing from the spirit of the invention. The attached claims and their equivalents are intended to cover such forms or modifications that fall within the scope and spirit of the invention.

Claims

1. A terminal, comprising: a cylindrical box portion into which the mating terminals are inserted; as well as A spring portion extending in the length direction from the front end portion to the rear end portion of the box portion, and when the mating terminal inserted into the box portion contacts the spring portion, the spring portion is deformed in a bending direction away from the mating terminal, wherein The spring portion has a pair of protrusions that protrude outward from a free end portion on a rear end side of the spring portion in a width direction orthogonal to the longitudinal direction. The box portion has a hole formed in each of a pair of side walls constituting the box portion, and the protrusion is inserted into and locked in the hole, and The hole is formed in an arc shape along a locus along which the protrusion moves when the spring portion that comes into contact with the mating terminal is deformed in the flexure direction.

2. The terminal according to claim 1, in, The hole has a retaining surface portion which is formed in a peripheral edge of the hole and retains the spring portion in a state elastically deformed in the flexing direction from a natural state.

3. An electric wire with a terminal, comprising: electric wire; and a terminal attached to the electric wire, and The terminal comprises: a cylindrical box portion into which the mating terminals are inserted; and A spring portion extending in the length direction from the front end portion to the rear end portion of the box portion, and when the mating terminal inserted into the box portion contacts the spring portion, the spring portion is deformed in a bending direction away from the mating terminal, wherein The spring portion has a pair of protrusions that protrude outward from a free end portion on a rear end side of the spring portion in a width direction orthogonal to the longitudinal direction. The box portion has a hole formed in a pair of side walls constituting the box portion, and the protrusion is inserted into and locked in the hole, and The hole is formed in an arc shape along a locus along which the protrusion moves when the spring portion that comes into contact with the mating terminal is deformed in the flexure direction.

4. The electric wire with a terminal according to claim 3, in, The hole has a retaining surface portion which is formed in the periphery of the hole and retains the spring portion in a state elastically deformed in the flexing direction from a natural state.

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