Terminal and connector

Abstract

To provide a terminal and a connector, in which the bonding strength between the terminal and the wire to be used in a high-voltage circuit can be improved while the decrease in yield at the manufacture is suppressed.SOLUTION: In a plan view of a terminal 10, a coupling part 14 includes a first linking part 14a, a second linking part 14b, a first curve part 14c, and a second curve part 14d. The first linking part 14a links to a connection part 11. The second linking part 14b links to an ultrasonic bonding part 13. The first curve part 14c couples one end 14a1 of the first linking part 14a to one end 14b1 of the second linking part 14b in the width direction of the terminal 10 and is curved in a concave shape. The second curve part 14d couples the other end 14a2 of the first linking part 14a to the other end 14b2 of the second linking part 14b in the width direction of the terminal 10 and is curved in a concave shape. In vicinity regions of the first curve part 14c and the second curve part 14d in a bonding part 12, a first reinforcement part 15a and a second reinforcement part 15b are provided, respectively.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to terminals and connectors.

Background Art

[0002] Conventionally, when joining an electric wire to a terminal, an ultrasonic joining method is known.

[0003] In the ultrasonic joining disclosed in Patent Document 1, with the core wire exposed from the insulating coating of the electric wire placed at the joining portion of the terminal, the horn of the ultrasonic joining device is pressed against the core wire inside the joining portion to apply ultrasonic vibration, thereby joining the core wire to the joining portion.

[0004] Thereby, the joining strength between the electric wire and the terminal can be improved.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] By the way, since a large current flows through the electric wire applied to the high-voltage circuit, in order to increase the allowable current, it is necessary to use a thick electric wire with a large cross-sectional area as the electric wire.

[0007] When joining such an electric wire to a terminal using ultrasonic joining, as the cross-sectional area of the core wire increases, it is necessary to apply strong ultrasonic vibration to the core wire.

[0008] For this reason, a load is applied to the joining portion of the terminal, cracks may occur in the joining portion, and the strength of the terminal may be reduced.

[0009] Thus, when joining an electric wire used in a high-voltage circuit to a terminal using ultrasonic bonding, the yield during manufacturing may decrease. Therefore, in order to improve the bonding strength between the electric wire and the terminal used in the high-voltage circuit while suppressing the decrease in the yield during manufacturing, further improvement has been demanded.

[0010] The present invention has been made in view of the problems of such conventional technologies. And an object of the present invention is to provide a terminal and a connector capable of improving the bonding strength between an electric wire and a terminal used in a high-voltage circuit while suppressing a decrease in the yield during manufacturing.

Means for Solving the Problems

[0011] The terminal according to the first aspect of the present invention extends in a predetermined direction and includes a connection portion to which a mating terminal is connected and a bonding portion to which an electric wire used in a high-voltage circuit is bonded. The bonding portion includes an ultrasonic bonding portion where the core wire of the electric wire is ultrasonically bonded and a connecting portion that connects the ultrasonic bonding portion to the connection portion. In a plan view of the terminal, the width direction of the terminal is a direction orthogonal to the direction in which the terminal extends. The connecting portion includes a first connection portion continuous with the connection portion, a second connection portion continuous with the ultrasonic bonding portion, a first curved portion that connects one end of the first connection portion to one end of the second connection portion in the width direction of the terminal and is curved in a concave shape, and a second curved portion that connects the other end of the first connection portion to the other end of the second connection portion in the width direction of the terminal and is curved in a concave shape. The distance between the first curved portion and the second curved portion in the width direction of the terminal becomes smaller as it goes from the ultrasonic bonding portion toward the connection portion. Each of the first curved portion and the second curved portion consists of one curvature. A first reinforcing portion is provided in a vicinity region of the first curved portion in the bonding portion. A second reinforcing portion is provided in a vicinity region of the second curved portion in the bonding portion.

[0012] The connector according to the second aspect of the present invention includes the terminal according to the first aspect and a housing that houses the terminal.

Effects of the Invention

[0013] According to the present invention, it is possible to provide a terminal and a connector that can improve the bonding strength between an electric wire and a terminal used in a high-voltage circuit while suppressing a decrease in the production yield.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6A

Figure 6B

Figure 7A

Figure 7B

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0015] Hereinafter, the terminal and the connector according to the present embodiment will be described in detail with reference to the drawings. Note that the dimensional ratios in the drawings are exaggerated for the convenience of explanation and may be different from the actual ratios.

[0016] [Overall Configuration of the Connector] First, the overall configuration of the connector 1 will be described with reference to FIGS. 1 and 2. FIG. 1 is a perspective view of the connector 1. FIG. 2 is an exploded perspective view of the connector 1.

[0017] The X direction shown in FIGS. 1 and 2 corresponds to the width direction of the connector 1. The Y direction shown in FIGS. 1 and 2 corresponds to the height direction of the connector 1 and is perpendicular to the X direction. The Z direction shown in FIGS. 1 and 2 corresponds to the longitudinal direction of the connector 1 and is perpendicular to the X and Y directions. Note that the Z direction is also referred to as the first direction. The Y direction is also referred to as the second direction. The X direction is also referred to as the third direction.

[0018] The connector 1 is, for example, a high-voltage connector that can be adopted in the power supply system of a rear motor mounted on an electric vehicle or a hybrid vehicle. In this embodiment, the connector 1 is assumed to be attached to the power supply system of a three-phase motor (not shown) serving as a rear motor.

[0019] As the power supply system of the three-phase motor, there are three wires 100, namely, a first wire 100a, a second wire 100b, and a third wire 100c, in advance. The first wire 100a is a wire for the U phase. The second wire 100b is a wire for the V phase. The third wire 100c is a wire for the W phase. Note that each wire 100 is also referred to as a wire used in a high-voltage circuit because it is used as a power supply system.

[0020] Each wire 100 has a core wire 101 that is a conductor and a covering portion 102 that is an insulator covering the core wire 101. One terminal of each wire 100 is connected to the three-phase motor, and the other terminal of each wire 100 is connected to the connector 1. At the terminal of each wire 100 on the side connected to the connector 1, the covering portion 102 is removed, and the core wire 101 composed of a plurality of strands is exposed. Note that in FIG. 2, as will be described later, the terminal portion 101a of the core wire 101 formed by connecting a plurality of strands to each other in the ultrasonic bonding process is drawn.

[0021] The connector 1 includes, as a group of components related to electrical connection, a plurality of terminals 10, an inner housing 20, an outer housing 30, and a rear cover 40. Note that the assembly of the inner housing 20 and the outer housing 30 is also referred to as a housing.

[0022] In the present embodiment, corresponding to a three-phase motor, there are three terminals 10, namely a first terminal 10a, a second terminal 10b, and a third terminal 10c. The first terminal 10a is attached to the end of the first electric wire 100a. The second terminal 10b is attached to the end of the second electric wire 100b. The third terminal 10c is attached to the end of the third electric wire 100c.

[0023] The three terminals 10 are each female terminals made of metal and having the same shape as each other, and have a connection portion 11 and a joint portion 12.

[0024] The connection portion 11 is a cylindrical portion into which a male terminal in the shape of a rod can be inserted. The connection portion 11 has a leaf spring portion that presses a part of the male terminal against the inner wall portion of the connection portion 11 in order to stably maintain the conduction state with the male terminal inserted therein. The leaf spring portion may be a part integrated with the connection portion 11, or may be a separately prepared leaf spring member installed inside the connection portion 11 in advance. Note that the male terminal is also referred to as a mating terminal.

[0025] As will be described later, the joint portion 12 is a flat plate portion to which the terminal portion 101a of the core wire 101 in the electric wire 100 is joined. Assuming that one end in the axial direction of the connection portion 11 is an open end for inserting the male terminal, the joint portion 12 is integrated with the other end in the axial direction of the connection portion 11.

[0026] Details of the configuration of each terminal 10 will be described later.

[0027] The inner housing 20 is made of synthetic resin and is an insulating member that protects each terminal 10 by holding the three terminals 10 inside. The inner housing 20 has a first terminal accommodating portion 21, a second terminal accommodating portion 22, a third terminal accommodating portion 23, a base portion 24, and a reinforcing structure portion 25.

[0028] The first terminal accommodating portion 21 is a cylindrical portion that accommodates the connecting portion 11 of the first terminal 10a. The second terminal accommodating portion 22 is a cylindrical portion that accommodates the connecting portion 11 of the second terminal 10b. The third terminal accommodating portion 23 is a cylindrical portion that accommodates the connecting portion 11 of the third terminal 10c. The tip of each of the first terminal accommodating portion 21, the second terminal accommodating portion 22, and the third terminal accommodating portion 23 is open in the first direction and does not prevent the male terminal from entering the connecting portion 11.

[0029] The base portion 24 is a flat plate portion that supports the first terminal accommodating portion 21, the second terminal accommodating portion 22, and the third terminal accommodating portion 23. The reinforcing structure portion 25 is a structure formed by combining a plurality of reinforcing ribs to ensure the strength of the inner housing 20. The reinforcing structure portion 25 is provided on the back surface of the base portion 24 so as not to obstruct the arrangement of the joint portion 12 of each terminal 10.

[0030] The outer housing 30 is made of synthetic resin and is an insulating member that protects the entire three terminals 10 by accommodating at least a part of the inner housing 20 and the joint portion 12 of each terminal 10. The outer housing 30 has a housing main body portion 31, a connector frontage portion 32, and a wire lead-out portion 33.

[0031] The housing main body portion 31 is formed in a box shape and has a front wall 34, an annular side wall 35, and a plurality of support pieces 36.

[0032] The front wall 34 is a wall portion orthogonal to the first direction, and supports the connector frontage portion 32 and the wire lead-out portion 33 so as to be separated from each other in the second direction. The planar shape of the front wall 34 is a substantially rectangular shape defined by a long side approximately along the second direction and a short side approximately along the third direction. Further, on the wall surface of the front wall 34 facing the inside of the housing main body portion 31, although not shown, a first wire contact portion is provided which faces the second wire contact portion 45 while being separated therefrom when the rear cover 40 described later is attached to the outer housing 30. The shape of the first wire contact portion is approximately symmetric with the shape of the second wire contact portion 45 in the first direction.

[0033] The annular side wall 35, together with the front wall 34, forms an internal space that houses at least the joint portions 12 of the respective terminals 10. One annular end of the annular side wall 35 in the first direction is continuous with the peripheral edge portion of the front wall 34. The other annular end of the annular side wall 35 in the first direction is an open end 35a that forms an opening facing the front wall 34. When assembling the connector 1, the three terminals 10, each attached to the end of the wire 100, are housed inside the housing main body portion 31 through the opening formed by the open end 35a.

[0034] The support piece 36 is provided on the outer wall surface 35b of the annular side wall 35 and has a fitting hole 36a for fitting a non-shown annular collar. The fitting hole 36a penetrates the support piece 36 along the first direction.

[0035] The connector frontage portion 32 has a frontage 32a with a cross-section that is a long round hole and opens in the first direction, and is a cylindrical portion that fits with a part of a mating connector (not shown) having a male terminal when the mating connector is connected to the connector 1. The connector frontage portion 32 is provided so as to protrude from the front wall 34 of the housing main body portion 31 in the first direction. The frontage 32a penetrates between the outside of the outer housing 30 and the inside of the housing main body portion 31 and can accommodate the inner housing 20.

[0036] The wire lead-out portion 33 is a cylindrical portion for leading out three wires 100 from the inside of the housing main body portion 31 to the outside of the outer housing 30 through a through space having an oval long hole-shaped cross section that opens in the first direction. The wire lead-out portion 33 is provided so as to protrude in the first direction from the front wall 34 of the housing main body portion 31.

[0037] That is, according to the structure of the outer housing 30, in the connector 1, the direction in which the frontage 32a of the connector frontage portion 32 faces, that is, the direction of connection to the external connector, and the direction in which the three wires 100 are led out from the wire lead-out portion 33 are along the same direction as each other. In the present embodiment, the direction in which the frontage 32a of the connector frontage portion 32 faces and the direction in which the three wires 100 are led out from the wire lead-out portion 33 are along each other in the first direction.

[0038] The rear cover 40 is made of synthetic resin and is an insulating member that covers an opening formed by an opening end 35a in a state where each terminal 10 in which the terminal portion 101a of the core wire 101 is joined to the joining portion 12 is housed together with the terminal portion of the wire 100 inside the housing main body portion 31 of the outer housing 30. The rear cover 40 has a main body wall 41, a plurality of locking portions 42, a plurality of packing locking portions 43, a cover reinforcing rib 44, and a second wire contact portion 45.

[0039] The main body wall 41 is a flat plate portion having an outer peripheral edge 41a along the opening end 35a of the housing main body portion 31 when the rear cover 40 is attached to the outer housing 30. The inner wall surface 41b of the main body wall 41 faces the front wall 34 of the housing main body portion 31 when the rear cover 40 is attached to the outer housing 30.

[0040] The plurality of locking portions 42 are respectively provided on the outer peripheral edge 41a of the main body wall 41 at intervals from each other in the circumferential direction along the outer peripheral edge 41a. Although not shown, a plurality of engaging portions are provided on the outer surface portion of the annular side wall 35 of the housing main body portion 31. When the rear cover 40 is attached to the outer housing 30, each locking portion 42 engages with the engaging portion on the annular side wall 35 to prevent the rear cover 40 from falling off the outer housing 30.

[0041] The plurality of packing locking portions 43 are respectively provided on the outer peripheral edge 41a of the main body wall 41 at intervals from each other in the circumferential direction along the outer peripheral edge 41a while avoiding the plurality of locking portions 42. Although not shown, a plurality of engaging protrusions are provided on the rear cover packing 61 described later. When the rear cover 40 is attached to the outer housing 30, each packing locking portion 43 engages with the engaging protrusion on the rear cover packing 61 to hold the rear cover packing 61 on the rear cover 40.

[0042] The cover reinforcing rib 44 is provided on the inner wall surface 41b so as not to obstruct the arrangement of each terminal 10 and each electric wire 100 in order to ensure the strength of the rear cover 40.

[0043] The second electric wire contact portion 45 is a structural portion that contacts each electric wire 100 when the rear cover 40 is attached to the outer housing 30. The second electric wire contact portion 45 has a first contact groove 45a, a second contact groove 45b, and a third contact groove 45c, each having a curved surface that matches the side surface shape of each electric wire 100 routed inside the housing main body portion 31 with the second direction as the extending direction. The first contact groove 45a contacts while accommodating a part of the side surface of the first electric wire 100a. The second contact groove 45b contacts while accommodating a part of the side surface of the second electric wire 100b. The third contact groove 45c contacts while accommodating a part of the side surface of the third electric wire 100c.

[0044] Here, when the rear cover 40 is attached to the outer housing 30, the first contact groove 45a sandwiches the first electric wire 100a together with an equivalent contact groove provided in the housing main body portion 31. Similarly, the second contact groove 45b sandwiches the second electric wire 100b together with an equivalent contact groove provided in the housing main body portion 31. The third contact groove 45c sandwiches the third electric wire 100c together with an equivalent contact groove provided in the housing main body portion 31. That is, the second electric wire contact portion 45 constitutes a wire holding portion that holds each electric wire 100 as a combination with the first electric wire contact portion in the housing main body portion 31, thereby suppressing the vibration transmitted from the outside through the electric wire 100 from reaching the terminal 10.

[0045] Further, the connector 1 includes a unit packing 60, a rear cover packing 61, and a wire packing 62 as waterproof members that prevent moisture from entering from the outside.

[0046] The unit packing 60 is an annular elastic member that is tightly attached to the outer peripheral surface of the connector front end portion 32 in the outer housing 30. The unit packing 60 seals between the outer peripheral surface of the connector front end portion 32 and the fitting surface of the external connector when the external connector is connected to the connector 1.

[0047] The rear cover packing 61 is an annular elastic member that is tightly attached to the opening end 35a of the housing main body portion 31 in the outer housing 30. The rear cover packing 61 seals between the opening end 35a of the housing main body portion 31 and the outer peripheral edge 41a of the rear cover 40 when the rear cover 40 is attached to the outer housing 30.

[0048] The wire packing 62 is an oblong flat plate-shaped elastic member that is tightly attached to the inner wall surface of the wire lead-out portion 33 in the outer housing 30. Further, the wire packing 62 has three through holes 62a that individually penetrate while being in close contact with each electric wire 100. The wire packing 62 seals between the inner wall surface of the wire lead-out portion 33 and each electric wire 100 passing through the through space of the wire lead-out portion 33.

[0049] Also, the connector 1 includes a front holder 70 and a rear holder 75 as members for holding various packings.

[0050] The front holder 70 is made of synthetic resin and is attached to the outer housing 30 to prevent the unit packing 60 from falling off from the connector front end opening 32.

[0051] The rear holder 75 is made of synthetic resin and is attached to the outer housing 30 to prevent the wire packing 62 from falling off from the wire lead-out portion 33.

[0052] Also, the connector 1 includes an upper shell 80, a lower shell 81, and a shield ring 83 as shield members for shielding noise.

[0053] The upper shell 80 is made of metal and covers the housing main body portion 31 with the rear cover 40 attached to the outer housing 30. Incidentally, the upper shell 80 may cover at least a part of the connector front end opening 32 or the wire lead-out portion 33 of the outer housing 30 while accommodating the housing main body portion 31. The upper shell 80 is formed in a box shape and has a bottom wall 80a, an annular side wall 80b, a plurality of first support pieces 80e, and a plurality of second support pieces 80g.

[0054] The bottom wall 80a is a wall portion orthogonal to the first direction. The planar shape of the bottom wall 80a is a substantially rectangular shape defined by a long side approximately along the second direction and a short side approximately along the third direction.

[0055] The annular side wall 80b, together with the bottom wall 80a, forms an internal space for housing the housing main body 31. One annular end of the annular side wall 80b in the first direction is continuous with the peripheral portion of the bottom wall 80a. The other annular end of the annular side wall 80b in the first direction is an open end 80c that forms an opening facing the bottom wall 80a. When assembling the connector 1, the housing main body 31 with the rear cover 40 attached is accommodated through the opening formed at the open end 80c.

[0056] The first support piece 80e is provided, for example, as a portion where a part of the annular side wall 80b is bent, and has a first through hole 80d through which a bolt 90 passing through the fitting hole 36a provided in the outer housing 30 passes when assembling the connector 1.

[0057] The second support piece 80g is provided, for example, as a portion bent from a piece protruding from the open end 80c of the annular side wall 80b, and has a second through hole 80f through which a mounting bolt (not shown) passes when attaching the connector 1 to the housing of an external connector.

[0058] The lower shell 81 is made of metal and covers a part of the front wall 34 of the housing main body 31 and the wire lead-out portion 33 in the outer housing 30. The lower shell 81 has a cylindrical portion 81a, a flange portion 81b, and a support piece 81c.

[0059] The cylindrical portion 81a covers the wire lead-out portion 33 by accommodating the wire lead-out portion 33 through a through space having an oval cross-section that opens in the first direction. One open end of the cylindrical portion 81a is a fixed end continuous with the flange portion 81b. The other open end of the cylindrical portion 81a is an open end that forms an opening for drawing out each wire 100 from the wire lead-out portion 33 to the outside.

[0060] The flange portion 81b is a flat plate portion orthogonal to the first direction, and covers a part of the front wall 34 by facing a part of the front wall 34.

[0061] The support piece 81c is provided as a part protruding outward from the edge of the flange portion 81b, and has a through hole 81d through which a bolt 90 that penetrates a fitting hole 36a provided in the outer housing 30 during the assembly of the connector 1 is pre-penetrated.

[0062] The shield ring 83 is a metal fastening member for crimping a shield braid (not shown) to the outer peripheral surface of the cylindrical portion 81a of the lower shell 81. The shield braid is a metal braid that partially covers the tip of the cylindrical portion 81a and is wound so as to integrally cover three electric wires 100 drawn out from the cylindrical portion 81a to the outside.

[0063] Furthermore, the connector 1 includes, as members for assembling each component, a plurality of bolts 90 (see FIG. 1) and a plurality of collars (not shown) that are pre-fitted in the fitting holes 36a of the outer housing 30. As described above, the support piece 81c of the lower shell 81 is provided with a through hole 81d. A collar is fitted in the fitting hole 36a of the outer housing 30. And, the first support piece 80e of the upper shell 80 is provided with a first through hole 80d. The bolt 90 passes through the through hole 81d, the collar in the fitting hole 36a, and the first through hole 80d and is fastened, whereby the lower shell 81, the outer housing 30, and the upper shell 80 are integrally assembled.

[0064] [Configuration of Terminals] Next, the configuration of the terminal 10 will be described in detail with reference to FIGS. 3 to 5. FIG. 3 is a plan view of the terminal 10. FIG. 4 is a partially enlarged view of FIG. 3. FIG. 5 is a cross-sectional view taken along the line V-V shown in FIG. 4. Note that the X1 direction shown in FIGS. 3 and 4 corresponds to the longitudinal direction of the terminal 10. The Y1 direction shown in FIGS. 3 and 4 corresponds to the width direction of the terminal 10 and is orthogonal to the X1 direction. The Z1 direction shown in FIGS. 3 and 4 corresponds to the thickness direction of the terminal 10 and is orthogonal to the X1 direction and the Y1 direction.

[0065] As shown in FIG. 3, the terminal 10 extends in the axial direction. The axial direction is the direction along the axis AX of the terminal 10 and is parallel to the longitudinal direction (X1 direction) of the terminal 10. Note that the axial direction is also referred to as a predetermined direction. As described above, the terminal 10 has a connection portion 11 and a joining portion 12. The axial direction of the terminal 10 coincides with the axial direction of the connection portion 11 and the axial direction of the joining portion 12.

[0066] A male terminal is connected to the connection portion 11 as a mating terminal. The connection portion 11 has a first end portion 11a and a second end portion 11b. The first end portion 11a is one end portion of the connection portion 11 in the axial direction and is an open end into which the male terminal is inserted. The second end portion 11b is the other end portion of the connection portion 11 in the axial direction and is continuous with the joining portion 12. Note that since the second end portion 11b is connected to the first connection site 14a of the connecting portion 14 described later, it is shown by a dashed-dotted line in FIG. 3.

[0067] The joining portion 12 has an ultrasonic joining portion 13 and a connecting portion 14. The ultrasonic joining portion 13 has a first surface 13a and a second surface 13b (see FIG. 8). In the present embodiment, the first surface 13a is one surface of the ultrasonic joining portion 13 in the thickness direction of the terminal 10 and is a joining surface to which the terminal portion 101a of the core wire 101 in the electric wire 100 is ultrasonically joined. The second surface 13b is the other surface of the ultrasonic joining portion 13 in the thickness direction of the terminal 10 and is an open surface to which nothing is joined.

[0068] The first surface 13a and the second surface 13b are parallel to a plane perpendicular to the thickness direction of the terminal 10. Hereinafter, "plan view of the terminal 10" refers to a state seen from one side in the thickness direction of the terminal 10, that is, a state seen from the first surface 13a side of the ultrasonic joining portion 13.

[0069] In the plan view of the terminal 10, the ultrasonic joining portion 13 is formed in a rectangular shape symmetric with respect to the width direction of the terminal 10 with the axis AX of the terminal 10 as the axis of symmetry. In the plan view of the terminal 10, the ultrasonic joining portion 13 has a first end portion 13c, a second end portion 13d, a first side portion 13e, and a second side portion 13f.

[0070] The first end portion 13c is one end side in the axial direction at the ultrasonic bonding portion 13 and is parallel to the width direction of the terminal 10. A part of the first end portion 13c is continuous with the connecting portion 14. Note that since a part of the first end portion 13c is connected to the second connection portion 14b of the connecting portion 14 described later, it is indicated by a dashed line in FIG. 3. The second end portion 13d is the other end side in the axial direction at the ultrasonic bonding portion 13 and is parallel to the width direction of the terminal 10.

[0071] The first side portion 13e is one end side in the width direction of the terminal 10 at the ultrasonic bonding portion 13 and is parallel to the axial direction. The first side portion 13e is on one side in the width direction of the terminal 10 and connects one end of the first end portion 13c to one end of the second end portion 13d in the width direction of the terminal 10. Note that the corner where the first side portion 13e connects to one end of the first end portion 13c is chamfered to form a rounded surface. Similarly, the corner where the first side portion 13e connects to one end of the second end portion 13d is chamfered to form a rounded surface.

[0072] The second side portion 13f is the other end side in the width direction of the terminal 10 at the ultrasonic bonding portion 13 and is parallel to the axial direction. The second side portion 13f is on the other side in the width direction of the terminal 10 and connects the other end of the first end portion 13c to the other end of the second end portion 13d in the width direction of the terminal 10. Note that the corner where the second side portion 13f connects to the other end of the first end portion 13c is chamfered to form a rounded surface. Similarly, the corner where the second side portion 13f connects to the other end of the second end portion 13d is chamfered to form a rounded surface.

[0073] The connecting portion 14 connects the ultrasonic bonding portion 13 to the connecting portion 11. In a plan view of the terminal 10, the connecting portion 14 is formed in a shape symmetric with respect to the width direction of the terminal 10 with the axis AX of the terminal 10 as the axis of symmetry. In a plan view of the terminal 10, the connecting portion 14 has a first connection portion 14a, a second connection portion 14b, a first curved portion 14c, and a second curved portion 14d.

[0074] The first connecting part 14a is one end side in the axial direction of the connecting part 14 and is parallel to the width direction of the terminal 10. The first connecting part 14a is continuous with the connecting part 11. The second connecting part 14b is the other end side in the axial direction of the connecting part 14 and is parallel to the width direction of the terminal 10. The second connecting part 14b is continuous with the ultrasonic bonding part 13.

[0075] The first bending part 14c is one end side in the width direction of the terminal 10 in the connecting part 14 and is curved in a concave shape. Specifically, the first bending part 14c is composed of an arc with a central angle of 90 degrees and forms a corner radius. In this way, the first bending part 14c consists of one curvature.

[0076] The first bending part 14c is on one side in the width direction of the terminal 10 and connects one end 14a1 of the first connecting part 14a to one end 14b1 of the second connecting part 14b in the width direction of the terminal 10. Note that one end 14a1 of the first connecting part 14a and one end 14b1 of the second connecting part 14b respectively coincide with one end and the other end of the first bending part 14c in the axial direction of the connecting part 14.

[0077] The second bending part 14d is the other end side in the width direction of the terminal 10 in the connecting part 14 and is curved in a concave shape. Specifically, the second bending part 14d is composed of an arc with a central angle of 90 degrees and forms a corner radius. In this way, the second bending part 14d consists of one curvature.

[0078] The second bending part 14d is on the other side in the width direction of the terminal 10 and connects the other end 14a2 of the first connecting part 14a to the other end 14b2 of the second connecting part 14b in the width direction of the terminal 10. Note that the other end 14a2 of the first connecting part 14a and the other end 14b2 of the second connecting part 14b respectively coincide with one end and the other end of the second bending part 14d in the axial direction of the connecting part 14.

[0079] In the width direction of the terminal 10, the distance between the first curved portion 14c and the second curved portion 14d decreases as it goes from the ultrasonic joint portion 13 toward the connection portion 11. As described above, in a plan view of the terminal 10, the connecting portion 14 is formed in a shape symmetric with respect to the width direction of the terminal 10 with the axis AX of the terminal 10 as the axis of symmetry. For this reason, the first curved portion 14c and the second curved portion 14d have the same configuration as each other with the axis AX of the terminal 10 as the axis of symmetry.

[0080] In the vicinity regions of the first curved portion 14c and the second curved portion 14d in the joint portion 12, a first reinforcing portion 15a and a second reinforcing portion 15b are provided, respectively. Each of the first reinforcing portion 15a and the second reinforcing portion 15b is formed by pushing up the joint portion 12 in one direction in the thickness direction of the joint portion 12 by bead processing.

[0081] In the present embodiment, each of the first reinforcing portion 15a and the second reinforcing portion 15b is formed by pushing up the joint portion 12 in the direction from the second surface 13b toward the first surface 13a. Thus, each of the first reinforcing portion 15a and the second reinforcing portion 15b is formed in a convex shape on the surface including the first surface 13a in the joint portion 12.

[0082] In a plan view of the terminal 10, the first reinforcing portion 15a and the second reinforcing portion 15b are formed in a shape symmetric with respect to the width direction of the terminal 10 with the axis AX of the terminal 10 as the axis of symmetry. The first reinforcing portion 15a has an inner portion 15a1 located on the first curved portion 14c side and an outer portion 15a2 located on the side opposite to the first curved portion 14c. Similarly, the second reinforcing portion 15b has an inner portion 15b1 located on the second curved portion 14d side and an outer portion 15b2 located on the side opposite to the second curved portion 14d.

[0083] Here, with reference to FIGS. 4 and 5, the configuration of the first reinforcing portion 15a will be described in detail. As described above, since the second reinforcing portion 15b has the same configuration as the first reinforcing portion 15a, the description of the configuration of the second reinforcing portion 15b will be omitted.

[0084] As shown in FIG. 4, in the plan view of the terminal 10, the inner part 15a1 of the first reinforcing part 15a includes an inner part 16 facing the first curved part 14c. The inner part 16 is curved in a concave shape along the first curved part 14c. The inner part 16 has one end 16a in the width direction of the terminal 10 and the other end 16b in the width direction of the terminal 10.

[0085] In the plan view of the terminal 10, the outer part 15a2 of the first reinforcing part 15a includes an outer part 17 facing the inner part 16. The outer part 17 is curved in a concave shape along the first curved part 14c. The outer part 17 has one end 17a in the width direction of the terminal 10 and the other end 17b in the width direction of the terminal 10.

[0086] In the present embodiment, the inner part 16 is an arc of a sector with a central angle AN1 centered on the center of curvature CN1 of the first curved part 14c. Similarly, the outer part 17 is an arc of a sector with a central angle AN2 centered on the center of curvature CN1 of the first curved part 14c. Thus, the first curved part 14c of the connecting part 14, the inner part 16 of the first reinforcing part 15a, and the outer part 17 of the first reinforcing part 15a have the same center of curvature. Also, in the order of the first curved part 14c, the inner part 16 of the first reinforcing part 15a, and the outer part 17 of the first reinforcing part 15a, the curvature becomes smaller. The center of curvature CN1 is located outside the terminal 10.

[0087] Note that the positional relationship among the first curved part 14c, the inner part 16 of the first reinforcing part 15a, and the outer part 17 of the first reinforcing part 15a is not limited to this. As long as the inner part 16 and the outer part 17 are curved in a concave shape along the first curved part 14c, other positional relationships may be possible.

[0088] FIG. 5 is a cross-sectional view taken along the V-V line shown in FIG. 4. The V-V line is a straight line passing through the center of curvature CN1 and intersecting the inner part 16 and the outer part 17. As shown in FIG. 5, the first reinforcing part 15a is gently curved convexly on the surface including the first surface 13a at the joint part 12, and is gently curved concavely on the surface including the second surface 13b at the joint part 12.

[0089] In this embodiment, the first reinforcing portion 15a curves along an arc of a sector with a central angle AN11, centered on the center of curvature CN11 located on the surface side including the first surface 13a at the joint portion 12, from the side of the first curved portion 14c. Subsequently, the first reinforcing portion 15a curves along an arc of a sector with a central angle AN12, centered on the center of curvature CN12 located on the surface side including the second surface 13b at the joint portion 12. Finally, the first reinforcing portion 15a curves along an arc of a sector with a central angle AN13, centered on the center of curvature CN13 located on the surface side including the first surface 13a at the joint portion 12. Note that the cross-sectional shape of the first reinforcing portion 15a is not limited to this.

[0090] Thus, by providing the first reinforcing portion 15a in the vicinity of the first curved portion 14c, the terminal 10 can reinforce the vicinity of the first curved portion 14c.

[0091] The configuration of the first reinforcing portion 15a has been described in detail above.

[0092] Regarding the second reinforcing portion 15b as well, similar to the first reinforcing portion 15a, the inner portion 15b1 and the outer portion 15b2 each have an inner portion 16 and an outer portion 17. The inner portion 16 faces the second curved portion 14d and curves in a concave shape along the second curved portion 14d. The outer portion 17 faces the inner portion 16 and curves in a concave shape along the second curved portion 14d. In this embodiment, the second curved portion 14d of the connecting portion 14, the inner portion 16 of the second reinforcing portion 15b, and the outer portion 17 of the second reinforcing portion 15b have the same center of curvature.

[0093] The inner portion 16 and the outer portion 17 of the first reinforcing portion 15a are also referred to as the first inner portion and the first outer portion, respectively. The inner portion 16 and the outer portion 17 of the second reinforcing portion 15b are also referred to as the second inner portion and the second outer portion, respectively.

[0094] [An example of ultrasonic bonding process] Next, an example of an ultrasonic bonding process for bonding the core wire 101 of the electric wire 100 to the ultrasonic bonding portion 13 of the terminal 10 will be described with reference to FIGS. 6A to 8. FIGS. 6A to 7B are diagrams for explaining an example of the ultrasonic bonding process. Specifically, FIGS. 6A and 6B are, respectively, an end view and a front view of the electric wire 100 at the start of the ultrasonic bonding process. FIGS. 7A and 7B are, respectively, an end view and a front view of the electric wire 100 during the ultrasonic bonding process. FIG. 8 is a diagram showing a state in which the terminal portion 101a of the core wire 101 in the electric wire 100 is ultrasonically bonded to the terminal 10. In FIGS. 6B and 7B, only the ultrasonic bonding portion 13 of the terminal 10 is shown.

[0095] The X1 direction, Y1 direction, and Z1 direction shown in FIGS. 6A to 7B are the same as the X1 direction, Y1 direction, and Z1 direction shown in FIGS. 3 and 4. The electric wire 100 ultrasonically bonded to the terminal 10 shown in FIGS. 6A to 7B is specifically the second electric wire 100b ultrasonically bonded to the second terminal 10b shown in FIG. 2 (see FIG. 8).

[0096] The ultrasonic bonding apparatus 200 includes a horn 201, a wall portion 202, and an anvil (not shown). The horn 201 is a member that applies ultrasonic vibration to the bonding target. Concavo-convex portions are formed on the surface portion of the horn 201 that contacts the bonding target in order to efficiently transmit ultrasonic vibration to the bonding target. Specifically, the concavo-convex portions have a knurl shape in which linear ridges and valleys parallel to each other are alternately and continuously arranged.

[0097] The anvil is a member that is arranged to face the horn 201 and positions and fixes the bonding target. The wall portion 202 is a member that surrounds the periphery of the bonding target arranged between the horn 201 and the anvil. In FIGS. 6A and 7A, the illustration of the wall portion 202 is omitted. In addition, a first reinforcing portion 15a and a second reinforcing portion 15b are formed convexly on the surface including the first surface 13a. For this reason, recesses (not shown) for accommodating the first reinforcing portion 15a and the second reinforcing portion 15b are formed in the region of the lower surface of the wall portion 202 that faces the first reinforcing portion 15a and the second reinforcing portion 15b.

[0098] As shown in FIGS. 6A and 6B, at the start of the ultrasonic bonding process, with the core wire 101 of the electric wire 100 in contact with the first surface 13a of the ultrasonic bonding portion 13, the ultrasonic bonding portion 13 is disposed between the horn 201 and the anvil. In this state, the surface portion of the horn 201 is brought into contact with the core wire 101, and ultrasonic vibration is applied from the horn 201 to the core wire 101 while applying pressure.

[0099] As shown in FIGS. 7A and 7B, when the ultrasonic bonding process is started, the ultrasonic vibration is transmitted into the core wire 101, and a plurality of strands are joined to each other to form the terminal portion 101a. At the same time, the terminal portion 101a is joined to the ultrasonic bonding portion 13 at the first surface 13a of the ultrasonic bonding portion 13. At this time, the ultrasonic vibration transmitted into the core wire 101 is also transmitted to the ultrasonic bonding portion 13 and vibrates on the anvil.

[0100] As shown in FIG. 8, when the ultrasonic bonding process is completed, the terminal portion 101a of the core wire 101 is formed, and the terminal portion 101a is joined to the ultrasonic bonding portion 13. By the ultrasonic bonding process, the terminal portion 101a is formed in a flat plate shape having a substantially rectangular planar shape. Further, when the side joined to the first surface 13a in the terminal portion 101a is defined as the inner surface portion by the ultrasonic bonding process, the shape of the uneven portion formed on the surface portion of the horn 201 is transferred to the outer surface portion 101b on the side opposite to the inner surface portion. That is, the outer surface portion 101b of the terminal portion 101a becomes a knurled uneven portion (see FIG. 8). In FIG. 2, the illustration of the uneven portion is omitted.

[0101] Note that the terminal portion 101a of the core wire 101 may be separately formed before starting the ultrasonic bonding process. In this case, at the start of the ultrasonic bonding process, with the terminal portion 101a of the core wire 101 in contact with the first surface 13a of the ultrasonic bonding portion 13, the ultrasonic bonding portion 13 is disposed between the horn 201 and the anvil.

[0102] [Operation and Effect] According to this embodiment, the terminal 10 extends in a predetermined direction and includes a connection portion 11 to which a mating terminal is connected and a joining portion 12 to which a wire 100 used in a high-voltage circuit is joined. The joining portion 12 includes an ultrasonic joining portion 13 where the core wire 101 of the wire 100 is ultrasonically joined and a connecting portion 14 that connects the ultrasonic joining portion 13 to the connection portion 11.

[0103] In a plan view of the terminal 10, the width direction of the terminal 10 is a direction orthogonal to the direction in which the terminal 10 extends. The connecting portion 14 has a first connection site 14a, a second connection site 14b, a first curved portion 14c, and a second curved portion 14d. The first connection site 14a is continuous with the connection portion 11. The second connection site 14b is continuous with the ultrasonic joining portion 13. The first curved portion 14c connects one end 14a1 of the first connection site 14a to one end 14b1 of the second connection site 14b in the width direction of the terminal 10 and curves in a concave shape. The second curved portion 14d connects the other end 14a2 of the first connection site 14a to the other end 14b2 of the second connection site 14b in the width direction of the terminal 10 and curves in a concave shape.

[0104] The distance between the first curved portion 14c and the second curved portion 14d in the width direction of the terminal 10 decreases as it goes from the ultrasonic joining portion 13 toward the connection portion 11. Each of the first curved portion 14c and the second curved portion 14d has one curvature. A first reinforcing portion 15a is provided in a vicinity region of the first curved portion 14c in the joining portion 12. A second reinforcing portion 15b is provided in a vicinity region of the second curved portion 14d in the joining portion 12.

[0105] With the above-described configuration, in a plan view of the terminal 10, a first reinforcing portion 15a and a second reinforcing portion 15b are provided in the vicinity regions of the first curved portion 14c and the second curved portion 14d in the joining portion 12, respectively. Therefore, during ultrasonic joining, the vicinity regions of the first curved portion 14c and the second curved portion 14d are less likely to vibrate than the other regions of the joining portion 12.

[0106] Here, a comparative example will be described with reference to FIG. 9. FIG. 9 is a plan view of the terminal 301 according to the comparative example. As shown in FIG. 9, the terminal 301 is not provided with the first reinforcing portion 15a and the second reinforcing portion 15b as compared with the terminal 10.

[0107] In the terminal 301, since the shape of the terminal 301 changes abruptly at the first bending portion 14c and the second bending portion 14d, stress is likely to concentrate in the vicinity of the first bending portion 14c and the second bending portion 14d during ultrasonic bonding. Therefore, when strong ultrasonic vibration is applied to the core wire 101 of the electric wire 100 during ultrasonic bonding, there is a high possibility that cracks CL will occur in the vicinity of the first bending portion 14c and the second bending portion 14d.

[0108] On the other hand, in the present embodiment, as described above, during ultrasonic bonding, the vicinity of the first bending portion 14c and the second bending portion 14d is less likely to vibrate than other regions of the joint portion 12 due to the first reinforcing portion 15a and the second reinforcing portion 15b. Therefore, even when strong ultrasonic vibration is applied to the core wire 101 of the electric wire 100 during ultrasonic bonding, it is possible to prevent cracks from occurring in the vicinity of the first bending portion 14c and the second bending portion 14d.

[0109] Therefore, according to the terminal 10 of the present embodiment, it is possible to improve the bonding strength between the electric wire 100 used in the high-voltage circuit and the terminal 10 while suppressing a decrease in the production yield.

[0110] According to the present embodiment, each of the first reinforcing portion 15a and the second reinforcing portion 15b is formed by pushing up the joint portion 12 in one direction in the thickness direction of the joint portion 12.

[0111] With the above-described configuration, the first reinforcing portion 15a and the second reinforcing portion 15b can be easily provided in the vicinity of the first bending portion 14c and the second bending portion 14d.

[0112] According to this embodiment, in a plan view of the terminal 10, the first reinforcing portion 15a has an inner portion 16 and an outer portion 17. The inner portion 16 of the first reinforcing portion 15a faces the first curved portion 14c and is curved in a concave shape along the first curved portion 14c. The outer portion 17 of the first reinforcing portion 15a faces the inner portion 16 and is curved in a concave shape along the first curved portion 14c.

[0113] The second reinforcing portion 15b has an inner portion 16 and an outer portion 17. The inner portion 16 of the second reinforcing portion 15b faces the second curved portion 14d and is curved in a concave shape along the second curved portion 14d. The outer portion 17 of the second reinforcing portion 15b faces the inner portion 16 and is curved in a concave shape along the second curved portion 14d.

[0114] With the above-described configuration, since the first reinforcing portion 15a and the second reinforcing portion 15b are provided along the first curved portion 14c and the second curved portion 14d, respectively, when strong ultrasonic vibration is applied to the core wire 101 of the electric wire 100 during ultrasonic bonding, it is possible to surely prevent cracks from occurring in the vicinity regions of the first curved portion 14c and the second curved portion 14d.

[0115] According to this embodiment, the first curved portion 14c, the inner portion 16 of the first reinforcing portion 15a, and the outer portion 17 of the first reinforcing portion 15a have the same center of curvature. The second curved portion 14d, the inner portion 16 of the second reinforcing portion 15b, and the outer portion 17 of the second reinforcing portion 15b have the same center of curvature.

[0116] With the above-described configuration, the first reinforcing portion 15a and the second reinforcing portion 15b can be easily curved along the first curved portion 14c and the second curved portion 14d, respectively.

[0117] According to this embodiment, each of the first curved portion 14c and the second curved portion 14d is formed of an arc having a central angle of 90 degrees.

[0118] With the above-described configuration, a rounded corner is formed at the boundary (connection part 14) between the connection part 11 and the ultrasonic bonding part 13. Even when strong ultrasonic vibrations are applied to the core wire 101 of the electric wire 100 during ultrasonic bonding, it is possible to prevent cracks from occurring in the vicinity of the first bending part 14c and the second bending part 14d.

[0119] According to the present embodiment, the connector 1 includes the terminal 10 described above, and an inner housing 20 and an outer housing 30 that house the terminal 10.

[0120] With the above-described configuration, according to the connector 1 of the present embodiment, it is possible to improve the bonding strength between the electric wire 100 used in the high-voltage circuit and the terminal 10 while suppressing a decrease in the production yield.

[0121] [Modification Example] In the above-described embodiment, each of the first reinforcing part 15a and the second reinforcing part 15b is formed by pushing up the joint part 12 in the direction from the second surface 13b toward the first surface 13a, but the present invention is not limited thereto. Each of the first reinforcing part 15a and the second reinforcing part 15b may be formed by pushing up the joint part 12 in the direction from the first surface 13a toward the second surface 13b. In this case, the first surface 13a may be an open surface to which nothing is joined, and the second surface 13b may be a joint surface to which the terminal part 101a of the core wire 101 in the electric wire 100 is ultrasonically joined.

[0122] Although the present embodiment has been described above, the present embodiment is not limited to these, and various modifications are possible within the scope of the gist of the present embodiment.

Description of Reference Numerals

[0123] 1 Connector 10 Terminal 11 Connection Part 12 Joint Part 13 Ultrasonic Bonding Part 14 Connection Part 14a First Connection Site 14a1 One End 14a2 The Other End 14b Second connection part One end of 14b1 The other end of 14b2 14c First bending part 14d Second bending part 15a First reinforcing part 15b Second reinforcing part 16 Inner part 17 Outer part 20 Inner housing 30 Outer housing 100 Electric wire 101 Core wire

Claims

1. A terminal extending in a predetermined direction, comprising: a connection portion to which a mating terminal is connected; a joining portion to which a wire used in a high-voltage circuit is joined; and the joining portion includes: an ultrasonic joining portion where the core wire of the wire is ultrasonically joined; a connecting portion connecting the ultrasonic joining portion to the connection portion; and in a plan view of the terminal, the width direction of the terminal is a direction orthogonal to the direction in which the terminal extends, the connecting portion includes: a first connecting portion continuous with the connection portion; a second connecting portion continuous with the ultrasonic joining portion; a first curved portion that connects one end of the first connecting portion to one end of the second connecting portion in the width direction of the terminal and is curved in a concave shape; a second curved portion that connects the other end of the first connecting portion to the other end of the second connecting portion in the width direction of the terminal and is curved in a concave shape; and in the width direction of the terminal, the distance between the first curved portion and the second curved portion decreases from the ultrasonic joining portion toward the connection portion, each of the first curved portion and the second curved portion has a single curvature, a first reinforcing portion is provided in a region near the first curved portion in the joining portion, a second reinforcing portion is provided in a region near the second curved portion in the joining portion, a terminal.

2. The terminal according to claim 1, wherein each of the first reinforcing portion and the second reinforcing portion is formed by pushing up the joining portion in one direction in the thickness direction of the joining portion.

3. In a plan view of the terminal, the first reinforcing portion includes: a first inner portion facing the first curved portion and curved in a concave shape along the first curved portion; a first outer portion facing the first inner portion and curved in a concave shape along the first curved portion; and the second reinforcing portion includes: a second inner portion facing the second curved portion and curved in a concave shape along the second curved portion; a second outer portion facing the second inner portion and curved in a concave shape along the second curved portion; The terminal according to claim 2, having.

4. The first curved portion, the first inner portion, and the first outer portion have the same center of curvature, The second curved portion, the second inner portion, and the second outer portion have the same center of curvature, the terminal according to claim 3.

5. The terminal according to claim 1, wherein each of the first curved portion and the second curved portion is formed of an arc having a central angle of 90 degrees.

6. The terminal according to any one of claims 1 to 5, and A housing that houses the terminals, A connector including the same.

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