Terminal, wire-attached terminal, and connector

Abstract

To provide a terminal, a wire-attached 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.SOLUTION: A terminal 10 includes a connection part 11 to which a counterpart terminal is connected, and a bonding part 12 to which a wire 100, which is used in a high-voltage circuit, is bonded. The bonding part 12 includes an ultrasonic bonding part 13 to which the core wire 101 of the wire 100 is bonded with ultrasonic waves, and a coupling part 14 that couples the ultrasonic bonding part 13 to the connection part 11. The ultrasonic bonding part 13 includes a first ultrasonic bonding wall 13a, and a second ultrasonic bonding wall 13b disposed to face the first ultrasonic bonding wall 13a through a first gap 13d. In addition, the ultrasonic bonding part 13 includes a third ultrasonic bonding wall 13c disposed to face the second ultrasonic bonding wall 13b through a second gap 13e, and a coupling wall 13f that couples the first ultrasonic bonding wall 13a, the second ultrasonic bonding wall 13b, and the third ultrasonic bonding wall 13c.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to terminals, terminals with electric wires, and connectors.

Background Art

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

[0003] In the ultrasonic joining disclosed in Patent Document 1, with the core wire exposed from the insulation 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 within 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 becomes difficult to transmit the ultrasonic vibration energy during ultrasonic joining to the electric wire, so the ultrasonic joining force may decrease. Therefore, in order to improve the joining strength between the electric wire used in the high-voltage circuit and the terminal, further improvement has been demanded.

[0008] The present invention has been made in view of the problems of such prior art. The object of the present invention is to provide a terminal, a terminal with a wire, and a connector that can improve the joining strength between a wire used in a high-voltage circuit and a terminal.

Means for Solving the Problems

[0009] The terminal according to the first aspect of the present invention includes a connection portion to which a mating terminal is connected, and a joining portion to which a wire used in a high-voltage circuit is joined. The joining portion includes an ultrasonic joining portion where the core wire of the wire is ultrasonically joined, and a connecting portion that connects the ultrasonic joining portion to the connection portion. The ultrasonic joining portion includes a first ultrasonic joining wall, a second ultrasonic joining wall arranged to face the first ultrasonic joining wall with a first gap therebetween, a third ultrasonic joining wall arranged to face the second ultrasonic joining wall with a second gap therebetween, and a connecting wall that connects the first ultrasonic joining wall, the second ultrasonic joining wall, and the third ultrasonic joining wall.

[0010] The terminal with a wire according to the second aspect of the present invention includes the terminal according to the first aspect and a wire joined to the terminal. The wire includes a core wire and a covering portion that covers the core wire. The core wire includes an exposed core wire that is exposed from the covering portion. The exposed core wire includes a branched core wire whose tip is branched. The branched core wire includes a first branched core wire that is inserted into the first gap and ultrasonically joined to the first ultrasonic joining wall and the second ultrasonic joining wall, and a second branched core wire that is inserted into the second gap and ultrasonically joined to the second ultrasonic joining wall and the third ultrasonic joining wall.

[0011] The connector according to the third aspect of the present invention includes the terminal according to the first aspect and a housing that houses the terminal.

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

Effects of the Invention

[0013] According to the present invention, it is possible to provide a terminal, a terminal with a wire, and a connector that can improve the bonding strength between the wire and the terminal used in a high-voltage circuit.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

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 orthogonal to the X direction. The Z direction shown in FIGS. 1 and 2 corresponds to the longitudinal direction of the connector 1 and is orthogonal to the X direction and the Y direction. 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 a high-voltage connector that can be adopted, for example, in the power supply system of a rear motor mounted on an electric vehicle or a hybrid vehicle. In the present embodiment, the connector 1 is 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 electric wires 100, namely, a first electric wire 100a, a second electric wire 100b, and a third electric wire 100c, in advance. The first electric wire 100a is a wire for the U phase. The second electric wire 100b is a wire for the V phase. The third electric wire 100c is a wire for the W phase. Note that since each electric wire 100 is used as a power supply system, it is also referred to as a wire used in a high-voltage circuit.

[0020] Each electric 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 electric wire 100 is connected to the three-phase motor, and the other terminal of each electric wire 100 is connected to the connector 1. In each electric wire 100, at the terminal 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, a 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 this embodiment, corresponding to the three-phase motor, there are three terminals 10, namely a first terminal 10a, a second terminal 10b, and a third terminal 10c. The three terminals 10 are respectively connected to the electric wires 100 to form three terminals 50 with electric wires. The first terminal 10a is attached to the end of the first electric wire 100a to form the first terminal 50a with an electric wire. The second terminal 10b is attached to the end of the second electric wire 100b to form the second terminal 50b with an electric wire. The third terminal 10c is attached to the end of the third electric wire 100c to form the third terminal 50c with an electric wire.

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

[0024] The connection portion 11 is a cylindrical portion into which a male terminal in a rod shape can be inserted. In order to stably maintain the conduction state with the male terminal inserted therein, 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. 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 joining 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 joining 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 and the terminal 50 with an electric wire 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 housing portion 21, a second terminal housing portion 22, a third terminal housing portion 23, a base portion 24, and a reinforcing structure portion 25.

[0028] The first terminal housing portion 21 is a cylindrical portion that houses the connection portion 11 of the first terminal 10a. The second terminal housing portion 22 is a cylindrical portion that houses the connection portion 11 of the second terminal 10b. The third terminal housing portion 23 is a cylindrical portion that houses the connection portion 11 of the third terminal 10c. The tip portions of each of the first terminal housing portion 21, the second terminal housing portion 22, and the third terminal housing portion 23 are open in the first direction and do not hinder the entry of the male terminal into the connection portion 11.

[0029] The base portion 24 is a flat plate-like portion that supports the first terminal housing portion 21, the second terminal housing portion 22, and the third terminal housing portion 23. The reinforcing structure portion 25 is a structure formed by combining a plurality of reinforcing ribs in order 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 hinder the arrangement of the joint portions 12 of the respective terminals 10.

[0030] The outer housing 30 is made of synthetic resin and is an insulating member that protects the entire three terminals 10 by housing at least a part of the inner housing 20 and the joint portions 12 of the respective terminals 10. The outer housing 30 has a housing main body portion 31, a connector pitch 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 pitch 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 so as to face the second wire contact portion 45 while being separated from it when a 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 portion 12 of each terminal 10. One annular end of the annular side wall 35 in the first direction is continuous with the peripheral edge 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 electric wire 100, are housed inside the housing main body 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 an annular collar (not shown). 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 long oval cross-section that 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 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 31 and can accommodate the inner housing 20.

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

[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 electric 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 electric wires 100 are led out from the wire lead-out portion 33 are along the first direction with respect to each other.

[0038] The rear cover 40 is made of synthetic resin. This rear cover 40 is an insulating member that covers an opening formed by an open end 35a in a state where each terminal 10 having a terminal portion 101a of a core wire 101 joined to a joint portion 12 is housed together with a terminal portion of an electric wire 100 inside a housing main body portion 31 of an outer housing 30. Further, 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 electric wire contact portion 45.

[0039] The main body wall 41 is a flat plate portion having an outer peripheral edge 41a along an open end 35a of the housing main body portion 31 when the rear cover 40 is attached to the outer housing 30. An inner wall surface 41b of the main body wall 41 faces a 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 a circumferential direction along the outer peripheral edge 41a. Although not shown, a plurality of engaging portions are provided on an outer surface portion of an annular side wall 35 of the housing main body portion 31. Each locking portion 42 engages with an engaging portion on the annular side wall 35 when the rear cover 40 is attached to the outer housing 30, thereby suppressing 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 a 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 a rear cover packing 61 described later. Each packing locking portion 43 engages with an engaging protrusion on the rear cover packing 61 when the rear cover 40 is attached to the outer housing 30, thereby holding the rear cover packing 61 on the rear cover 40.

[0042] The cover reinforcement ribs 44 are provided on the inner wall surface 41b so as not to obstruct the arrangement of the respective terminals 10 and the respective electric wires 100 in order to ensure the strength of the rear cover 40.

[0043] The second 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 wire contact portion 45 has a first contact groove 45a, a second contact groove 45b, and a third contact groove 45c that each extend in the second direction and include a curved surface that conforms to the side surface shape of each electric wire 100 routed inside the housing main body portion 31. 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 wire contact portion 45, as a combination with the first wire contact portion in the housing main body portion 31, constitutes a wire holding portion that holds each electric wire 100 to suppress 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 suppress the intrusion of moisture 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 mouth portion 32 in the outer housing 30. When the external connector is connected to the connector 1, the unit packing 60 seals the space between the outer peripheral surface of the connector mouth portion 32 and the mating surface of the external connector.

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

[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 wire 100. The wire packing 62 seals the space between the inner wall surface of the wire lead-out portion 33 and each 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 holding members for 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 mouth portion 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 31 with the rear cover 40 attached to the outer housing 30. Note that the upper shell 80 may cover at least a part of the connector frontage 32 or the wire lead-out part 33 of the outer housing 30 while housing the housing main body 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 rectangle 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 and the bottom wall 80a together form 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 edge of the bottom wall 80a. The other annular end of the annular side wall 80b in the first direction is an opening 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 housed through the opening formed at the opening end 80c.

[0056] The first support piece 80e is provided, for example, as a part 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 during the assembly of the connector 1.

[0057] The second support piece 80g is provided, for example, as a part where a part protruding from the opening end 80c of the annular side wall 80b is bent, and has a second through hole 80f through which a mounting bolt (not shown) passes when attaching the connector 1 to the housing of the 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 in the outer housing 30 and the wire lead-out portion 33. 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-shaped 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 pulling 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 portion 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 partly covers the tip of the cylindrical portion 81a and is wound so as to integrally cover the three 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 colors (not shown) that are pre-fitted into the fitting holes 36a of the outer housing 30. As described above, a through-hole 81d is provided in the support piece 81c of the lower shell 81. A color is fitted into the fitting hole 36a of the outer housing 30. And a first through-hole 80d is provided in the first support piece 80e of the upper shell 80. The bolt 90 passes through the through-hole 81d, the color 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 Terminal with Wire] Next, with reference to FIGS. 3 to 5, the configuration of the terminal 50 with wire will be described in detail. FIG. 3 is an exploded perspective view of the terminal 50 with wire. FIG. 4 is a perspective view of the terminal 50 with wire. FIG. 5 is a plan view of the terminal 50 with wire. Note that the X1 direction shown in FIGS. 3 to 5 corresponds to the longitudinal direction of the terminal 10. The Y1 direction shown in FIGS. 3 to 5 corresponds to the width direction of the terminal 10 and is orthogonal to the X1 direction. The Z1 direction shown in FIGS. 3 to 5 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 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 one 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 in the axial direction of the connection portion 11 (the other end on the other side of one direction) and is an open end for inserting the male terminal. The second end portion 11b is the other end in the axial direction of the connection portion 11 (one end on one side of one direction) and is continuous with the joining portion 12.

[0067] The joint portion 12 has an ultrasonic joint portion 13 and a connecting portion 14. The connecting portion 14 connects the ultrasonic joint portion 13 to the connecting portion 11. The connecting portion 14 is formed in a substantially rectangular shape symmetric with respect to the width direction of the terminal 10.

[0068] The ultrasonic joint portion 13 has a first ultrasonic joint wall 13a, a second ultrasonic joint wall 13b, and a third ultrasonic joint wall 13c. One end 13a4 on the other side in one direction of the first ultrasonic joint wall 13a is continuously provided with the connecting portion 14, and it has a first surface 13a1 and a second surface 13a2. The first surface 13a1 is one surface in the thickness direction of the terminal 10 in the first ultrasonic joint wall 13a, and it is an open surface to which nothing is joined. The second surface 13a2 is the other surface in the thickness direction of the terminal 10 in the first ultrasonic joint wall 13a, and it is a joint surface to which the terminal portion 101a of the core wire 101 in the electric wire 100 is ultrasonically joined. The first surface 13a1 and the second surface 13a2 are parallel to a plane perpendicular to the thickness direction of the terminal 10. Note that the first ultrasonic joint wall 13a is formed in a substantially rectangular shape symmetric with respect to the width direction of the terminal 10.

[0069] The second ultrasonic joint wall 13b has a first surface 13b1 and a second surface 13b2. The first surface 13b1 is one surface in the thickness direction of the terminal 10 in the second ultrasonic joint wall 13b, and it is a joint surface to which the terminal portion 101a of the core wire 101 in the electric wire 100 is ultrasonically joined. This first surface 13b1 faces the second surface 13a2 of the first ultrasonic joint wall 13a in the thickness direction of the terminal 10, and a first gap 13d is formed between the second surface 13a2 of the first ultrasonic joint wall 13a and the first surface 13b1 of the second ultrasonic joint wall 13b. The second surface 13b2 is the other surface in the thickness direction of the terminal 10 in the second ultrasonic joint wall 13b, and it is a joint surface to which the terminal portion 101a of the core wire 101 in the electric wire 100 is ultrasonically joined. The first surface 13b1 and the second surface 13b2 are parallel to a plane perpendicular to the thickness direction of the terminal 10. Note that the second ultrasonic joint wall 13b is also formed in a substantially rectangular shape symmetric with respect to the width direction of the terminal 10.

[0070] The third ultrasonic bonding wall 13c has a first surface 13c1 and a second surface 13c2. The first surface 13c1 is one surface in the thickness direction of the terminal 10 in the third ultrasonic bonding wall 13c, and is a bonding surface where the terminal portion 101a of the core wire 101 in the electric wire 100 is ultrasonically bonded. This first surface 13c1 faces the second surface 13b2 of the second ultrasonic bonding wall 13b in the thickness direction of the terminal 10, and a second gap 13e is formed between the second surface 13b2 of the second ultrasonic bonding wall 13b and the first surface 13c1 of the third ultrasonic bonding wall 13c. The second surface 13c2 is the other surface in the thickness direction of the terminal 10 in the third ultrasonic bonding wall 13c, and is an open surface to which nothing is bonded. The first surface 13c1 and the second surface 13c2 are parallel to a plane perpendicular to the thickness direction of the terminal 10. Note that the third ultrasonic bonding wall 13c is also formed in a substantially rectangular shape symmetric with respect to the width direction of the terminal 10.

[0071] The first ultrasonic bonding wall 13a, the second ultrasonic bonding wall 13b, and the third ultrasonic bonding wall 13c are connected by a connecting wall 13f. In the present embodiment, one end portion 13a3 on one side in one direction of the first ultrasonic bonding wall 13a and one end portion 13b3 on one side in one direction of the second ultrasonic bonding wall 13b are connected by a first connecting wall 13f1. Also, one end portion 13b4 on the other side in one direction of the second ultrasonic bonding wall 13b and one end portion 13c4 on the other side in one direction of the third ultrasonic bonding wall 13c are connected by a second connecting wall 13f2.

[0072] Thus, in this embodiment, the shape of the ultrasonic joint portion 13 is such that a single plate-shaped member extending from the end portion 13a4 on the other side in one direction of the first ultrasonic joint wall 13a to the end portion 13c3 on one side in one direction of the third ultrasonic joint wall 13c is bent twice in the reverse direction, forming a waveform. In other words, the shape of the ultrasonic joint portion 13 is such that it is bent in a substantially Z shape when viewed along the width direction of the terminal 10. And the first ultrasonic joint wall 13a, the second ultrasonic joint wall 13b, and the third ultrasonic joint wall 13c are arranged in a state of being spaced apart in the thickness direction of the terminal 10. By doing so, gaps (the first gap 13d and the second gap 13e) are formed between adjacent ultrasonic joint walls. In this embodiment, the first gap 13d is formed to open on both sides and the other side in one direction in the width direction of the terminal 10, and the second gap 13e is formed to open on both sides and one side in one direction in the width direction of the terminal 10. And when the terminal 10 and the electric wire 100 are ultrasonically joined, the core wire 101 of the electric wire 100 is inserted into each of the first gap 13d and the second gap 13e.

[0073] In this embodiment, by removing the covering portion 102 of the terminal on the side connected to the connector 1 of the electric wire 100, an exposed core wire 101b is formed in which the core wire 101 composed of a plurality of strands is exposed at the terminal portion 101a of the core wire 101. And by performing a pretreatment on the exposed core wire 101b, the shape of the exposed core wire 101b is adjusted so that the tip 101b1 branches into a bifurcated shape. That is, a bifurcated core wire 101c including a first bifurcated core wire 101d and a second bifurcated core wire 101e facing the first bifurcated core wire 101d with a gap 101g therebetween is formed on the exposed core wire 101b. Note that in this embodiment, the connecting portion 101f connecting the base end 101d2 side of the first bifurcated core wire 101d and the base end 101e2 side of the second bifurcated core wire 101e is also exposed, but the connecting portion 101f can also be covered by the covering portion 102.

[0074] Then, the exposed core wire 101b is inserted into the gap formed in the ultrasonic bonding portion 13 from the tip 101b1 side. Specifically, while inserting the first branched core wire 101d into the first gap 13d from the tip 101d1 side, the second branched core wire 101e is inserted into the second gap 13e from the tip 101e1 side. At this time, the second ultrasonic bonding wall 13b is inserted into the gap 101g formed between the first branched core wire 101d and the second branched core wire 101e. By doing so, the first branched core wire 101d is sandwiched between the first ultrasonic bonding wall 13a and the second ultrasonic bonding wall 13b, and the second branched core wire 101e is sandwiched between the second ultrasonic bonding wall 13b and the third ultrasonic bonding wall 13c.

[0075] Then, with the exposed core wire 101b inserted into the gap formed in the ultrasonic bonding portion 13, the exposed core wire 101b and the ultrasonic bonding portion 13 are joined by ultrasonic bonding to form the terminal 50 with a wire. Specifically, the first branched core wire 101d is ultrasonically bonded to the first ultrasonic bonding wall 13a and the second ultrasonic bonding wall 13b, and the second branched core wire 101e is ultrasonically bonded to the second ultrasonic bonding wall 13b and the third ultrasonic bonding wall 13c to form the terminal 50 with a wire.

[0076] [Example of Ultrasonic Bonding Process] Next, with reference to FIG. 6, an example of the ultrasonic bonding process for joining the core wire 101 of the electric wire 100 to the ultrasonic bonding portion 13 of the terminal 10 will be described. FIG. 6 is a diagram for explaining an example of the ultrasonic bonding process. The X1 direction, Y1 direction, and Z1 direction shown in FIG. 6 are the same as the X1 direction, Y1 direction, and Z1 direction shown in FIGS. 3 to 5, respectively.

[0077] The ultrasonic bonding device 200 includes a horn 201 and an anvil 202. The horn 201 is a member that applies ultrasonic vibration to the bonding target. On the surface portion of the horn 201 that contacts the bonding target, uneven portions 201a are formed to efficiently transmit ultrasonic vibration to the bonding target. Specifically, the uneven portions 201a have a knurl shape in which linear ridges and valleys parallel to each other are alternately and continuously arranged.

[0078] The anvil 202 is a member that is arranged to face the horn 201 and positions and fixes the object to be joined. On the surface portion of the anvil 202 that contacts the object to be joined, uneven portions 202a are formed in order to efficiently transmit ultrasonic vibrations to the object to be joined. Specifically, the uneven portions 202a have a knurl shape in which linear ridges and valleys parallel to each other are alternately and continuously arranged.

[0079] As shown in FIG. 6, when performing the ultrasonic joining process, first, with the core wire 101 of the electric wire 100 in contact with the ultrasonic joining portion 13, the ultrasonic joining portion 13 is arranged between the horn 201 and the anvil 202. In the present embodiment, the first branched core wire 101d is sandwiched between the first ultrasonic joining wall 13a and the second ultrasonic joining wall 13b, and the second branched core wire 101e is sandwiched between the second ultrasonic joining wall 13b and the third ultrasonic joining wall 13c. By doing so, the core wire 101 is in a state of being in contact with the ultrasonic joining portion 13. Then, the second surface 13c2 of the third ultrasonic joining wall 13c faces the horn 201, and the first surface 13a1 of the first ultrasonic joining wall 13a faces the anvil 202.

[0080] Next, in this state, the surface portion of the horn 201 is brought into contact with the ultrasonic joining portion 13, and while applying pressure, ultrasonic vibrations are applied from the horn 201 to the core wire 101 through the ultrasonic joining portion 13 to start the ultrasonic joining process. In the present embodiment, the ultrasonic joining process is performed in a state where the uneven portion 201a of the horn 201 is in contact with the second surface 13c2 of the third ultrasonic joining wall 13c and the uneven portion 202a of the anvil 202 is in contact with the first surface 13a1 of the first ultrasonic joining wall 13a.

[0081] Thus, when the ultrasonic bonding process is started, ultrasonic vibrations are transmitted into the core wire 101, and while a plurality of strands are bonded to each other, the core wire 101 is bonded to the surface of the ultrasonic bonding portion 13. In this embodiment, the first branched core wire 101d is to be bonded to the second surface 13a2 of the first ultrasonic bonding wall 13a and the first surface 13b1 of the second ultrasonic bonding wall 13b. Also, the second branched core wire 101e is to be bonded to the second surface 13b2 of the second ultrasonic bonding wall 13b and the first surface 13c1 of the third ultrasonic bonding wall 13c.

[0082] Then, when the ultrasonic bonding process is completed, the terminal portion 101a of the core wire 101 is bonded to the ultrasonic bonding portion 13.

[0083] [Operation and Effect] Hereinafter, the characteristic configurations of the terminal, the terminal with wire, and the connector shown in the above embodiment and the effects obtained thereby will be described.

[0084] The terminal 10 shown in the above embodiment includes a connection portion 11 to which a mating terminal is connected and a bonding portion 12 to which a wire 100 used in a high-voltage circuit is bonded.

[0085] The bonding portion 12 includes an ultrasonic bonding portion 13 to which the core wire 101 of the wire 100 is ultrasonically bonded and a connecting portion 14 that connects the ultrasonic bonding portion 13 to the connection portion 11.

[0086] The ultrasonic bonding portion 13 includes a first ultrasonic bonding wall 13a and a second ultrasonic bonding wall 13b that is arranged to face the first ultrasonic bonding wall 13a with a first gap 13d therebetween. Further, the ultrasonic bonding portion 13 includes a third ultrasonic bonding wall 13c that is arranged to face the second ultrasonic bonding wall 13b with a second gap 13e therebetween, and a connecting wall 13f that connects the first ultrasonic bonding wall 13a, the second ultrasonic bonding wall 13b, and the third ultrasonic bonding wall 13c.

[0087] Thus, in the terminal 10 shown in the above embodiment, the ultrasonic joint portion 13 is configured to include a first ultrasonic joint wall 13a, a second ultrasonic joint wall 13b, and a third ultrasonic joint wall 13c. At this time, a first gap 13d is formed between the first ultrasonic joint wall 13a and the second ultrasonic joint wall 13b, and a second gap 13e is formed between the second ultrasonic joint wall 13b and the third ultrasonic joint wall 13c. Then, in a state where the first gap 13d and the second gap 13e are formed, the first ultrasonic joint wall 13a, the second ultrasonic joint wall 13b, and the third ultrasonic joint wall 13c are connected by a connecting wall 13f.

[0088] By doing so, the core wire 101 of the electric wire 100 can be sandwiched between the first ultrasonic joint wall 13a and the second ultrasonic joint wall 13b, and between the second ultrasonic joint wall 13b and the third ultrasonic joint wall 13c, so that the electric wire 100 and the terminal 10 can be ultrasonically joined. That is, the electric wire 100 and the terminal 10 can be ultrasonically joined in a state where a part of the core wire 101 is inserted into the first gap 13d and another part of the core wire 101 is inserted into the second gap 13e.

[0089] In this way, the thickness of the core wire 101 can be reduced, so that the ultrasonic vibration energy from the ultrasonic joint portion 13 can be more easily transmitted to the core wire 101. Furthermore, the ultrasonic vibration energy can be transmitted to the core wire 101 not only from one surface of the first ultrasonic joint wall 13a and the third ultrasonic joint wall 13c but also from both surfaces of the second ultrasonic joint wall 13b.

[0090] Thus, in the terminal 10 shown in the above embodiment, the first ultrasonic bonding wall 13a, the second ultrasonic bonding wall 13b, and the third ultrasonic bonding wall 13c are formed so that the first gap 13d and the second gap 13e are formed. By configuring the ultrasonic bonding portion 13 in this way, while reducing the thickness of the core wire 101, the transmission location and transmission area of the ultrasonic vibration energy of the core wire 101 are increased. By doing so, it becomes easier to transmit the ultrasonic vibration energy from the ultrasonic bonding portion 13 to the core wire 101, and the bonding strength between the electric wire 100 and the terminal 10 by ultrasonic bonding can be further improved.

[0091] Therefore, if the terminal 10 shown in the above embodiment is used, the bonding strength between the electric wire 100 used in the high-voltage circuit and the terminal 10 can be improved.

[0092] Further, the connecting wall 13f may include a first connecting wall 13f1 that connects the end portion 13a3 on one side in one direction of the first ultrasonic bonding wall 13a and the end portion 13b3 on one side in one direction of the second ultrasonic bonding wall 13b. And the connecting wall 13f may include a second connecting wall 13f2 that connects the end portion 13b4 on the other side in one direction of the second ultrasonic bonding wall 13b and the end portion 13c4 on the other side in one direction of the third ultrasonic bonding wall 13c.

[0093] In this way, by simply bending a single plate-like member, the first ultrasonic bonding wall 13a, the second ultrasonic bonding wall 13b, and the third ultrasonic bonding wall 13c can be formed. Therefore, it becomes possible to more easily obtain the ultrasonic bonding portion 13 that can improve the bonding strength between the electric wire 100 used in the high-voltage circuit and the terminal 10.

[0094] Also, since the connecting wall 13f exists on one end side and the other end side in one direction, when the electric wire 100 and the terminal 10 are ultrasonically bonded, it is possible to suppress the core wire 101 of the electric wire 100 from being displaced in one direction with respect to the ultrasonic bonding portion 13. As a result, it becomes possible to more reliably and firmly ultrasonically bond the electric wire 100 and the terminal 10.

[0095] The terminal with wire 50 shown in the above embodiment includes the above-described terminal 10 and a wire 100 joined to the terminal 10. This wire 100 includes a core wire 101 and a covering portion 102 that covers the core wire 101. Further, the core wire 101 includes an exposed core wire 101b that is exposed from the covering portion 102, and the exposed core wire 101b includes a branched core wire 101c whose tip 101b1 branches.

[0096] And the branched core wire 101c includes a first branched core wire 101d that is inserted into the first gap 13d and ultrasonically joined to the first ultrasonic joining wall 13a and the second ultrasonic joining wall 13b. Further, the branched core wire 101c includes a second branched core wire 101e that is inserted into the second gap 13e and ultrasonically joined to the second ultrasonic joining wall 13b and the third ultrasonic joining wall 13c.

[0097] In this way, a terminal with wire 50 capable of improving the joining strength between the wire 100 and the terminal 10 used in a high-voltage circuit can be obtained.

[0098] The connector 1 shown in the above embodiment includes the above-described terminal 10 and an inner housing 20 and an outer housing 30 that house the terminal 10. Also, the connector 1 shown in the above embodiment includes the above-described terminal with wire 50 and an inner housing 20 and an outer housing 30 that house the terminal with wire 50.

[0099] In this way, a connector 1 capable of improving the joining strength between the wire 100 and the terminal 10 used in a high-voltage circuit can be obtained.

[0100] [Others] 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.

[0101] For example, in the above embodiment, an example is shown in which the shape of the ultrasonic joint portion 13 is bent into a substantially Z shape when viewed along the width direction of the terminal 10. However, the shape of the ultrasonic joint portion 13 is not limited to such a shape, and various shapes are possible. For example, it is also possible to make the shape of the ultrasonic joint portion 13 bifurcate into three branches when viewed along the width direction of the terminal 10. In this case, each of the first ultrasonic joint wall 13a, the second ultrasonic joint wall 13b, and the third ultrasonic joint wall 13c will be connected by the connecting wall 13f on the other side in one direction.

[0102] Also, the first ultrasonic joint wall 13a, the second ultrasonic joint wall 13b, and the third ultrasonic joint wall 13c do not need to extend in the longitudinal direction (X1 direction) of the terminal 10, and can extend in various directions.

[0103] Moreover, it is also possible to have an ultrasonic joint portion having four or more ultrasonic joint walls, and the shapes of the ultrasonic joint walls can also be various.

[0104] Also, the connection part, the electric wire, and other detailed specifications (shape, size, layout, etc.) can be changed as appropriate.

Explanation of Reference Numerals

[0105] 1 Connector 10 Terminal 11 Connection Part 12 Joint Part 13 Ultrasonic Joint Portion 13a First Ultrasonic Joint Wall 13a3 End Portion on One Side in One Direction 13b Second Ultrasonic Joint Wall 13b3 End Portion on One Side in One Direction 13b4 End Portion on the Other Side in One Direction 13c Third Ultrasonic Joint Wall 13c4 End Portion on the Other Side in One Direction 13d First Gap 13e Second Gap 13f Connecting Wall 13f1 First connecting wall 13f2 Second connecting wall 14 Connecting part 20 Inner housing 30 Outer housing 50 Terminal with wire 100 Electric wire 101 Core wire 101b Exposed core wire 101b1 Tip 101c Branch core wire 101d First branch core wire 101e Second branch core wire 102 Coating part

Claims

1. a connection part to which a mating terminal is connected; a joint part to which an electric wire used in a high-voltage circuit is joined; comprising; the joint part; an ultrasonic joint part where the core wire of the electric wire is ultrasonically joined; a connecting part that connects the ultrasonic joint part to the connection part; comprising; the ultrasonic joint part; a first ultrasonic joint wall; a second ultrasonic joint wall arranged to face the first ultrasonic joint wall with a first gap therebetween; a third ultrasonic joint wall arranged to face the second ultrasonic joint wall with a second gap therebetween; a connecting wall that connects the first ultrasonic joint wall, the second ultrasonic joint wall, and the third ultrasonic joint wall; comprising; a terminal.

2. the connecting wall; a first connecting wall that connects one end on one side in one direction of the first ultrasonic joint wall and one end on one side in the same direction of the second ultrasonic joint wall; a second connecting wall that connects the other end on the other side in the one direction of the second ultrasonic joint wall and the other end on the other side in the one direction of the third ultrasonic joint wall; comprising; the terminal according to Claim 1.

3. the terminal according to Claim 1 or 2; an electric wire joined to the terminal; comprising; the electric wire; the core wire; a covering part that covers the core wire; comprising; the core wire includes an exposed core wire that is exposed from the covering part; the exposed core wire includes a branched core wire whose tip is branched; the branched core wire; a first branched core wire inserted into the first gap and ultrasonically joined to the first ultrasonic joint wall and the second ultrasonic joint wall; a second branched core wire inserted into the second gap and ultrasonically joined to the second ultrasonic joint wall and the third ultrasonic joint wall; comprising; a terminal with an electric wire.

4. the terminal according to Claim 1 or 2; a housing that houses the terminal; comprising; a connector.

5. the terminal with an electric wire according to Claim 3; a housing that houses the terminal with an electric wire; comprising; a connector.

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