Wire with terminal and manufacturing method for the same, and wire with connector

Abstract

To provide a wire with a terminal and a manufacturing method for the same capable of suppressing insufficient bonding by ultrasonic welding and energy loss during bonding, and to provide a wire with a connector in which such a wire with a terminal possessing these excellent features is stably coupled with a connector.SOLUTION: A wire with a terminal and a manufacturing method for the same, as well as a wire with a connector, has a terminal fitting 3 including a wire connection portion 31 and a wire 2 including a core wire 21 joined to the wire connection portion 31. The wire connection portion 31 has a bottom wall portion to which the core wire 21 is joined along a longitudinal direction TE of the wire 2 and a pair of standing wall portions 35 erected from both ends of the bottom wall portion on both sides of the core wire 21. The height of the pair of standing wall portions 35 differs depending on the position in the longitudinal direction TE of the wire 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an electric wire with a terminal, a method for manufacturing the same, and an electric wire with a connector. [Background technology]

[0002] Wire harnesses have been installed in automobiles to supply power from a power source such as a battery to various electronic devices and to transmit control signals from a control device. The wire harnesses are made up of multiple electric wires with terminals, each of which has electric wires and terminals attached to the ends of the electric wires.

[0003] An electric wire with a terminal includes a core wire formed by twisting together a plurality of conductive wires and an insulating coating covering the core wire. The coating at the end of the electric wire is removed to expose the core wire, which is then welded to a terminal fitting to form the electric wire with a terminal. The welding of the core wire and the terminal fitting is performed by ultrasonic welding using an ultrasonic welding device.

[0004] Ultrasonic welding is performed by placing the core wire of an electric wire on the electric wire connection part of a terminal fitting, clamping and pressurizing it between an anvil and a horn, and then applying ultrasonic vibrations to the horn using a vibrator. The heat generated by the ultrasonic vibrations welds the electric wire connection part and the core wire together. At this time, the ultrasonic vibrations are applied so that the vibration direction (amplitude) is along the longitudinal direction of the electric wire.

[0005] However, if the core wire of the electric wire and the electric wire connection portion of the terminal fitting vibrate in synchronization with the vibration direction of the ultrasonic vibration, the friction between the core wire and the electric wire connection portion will not work sufficiently, resulting in insufficient joining or leading to energy loss during joining. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-18597 Summary of the Invention [Problem to be solved by the invention]

[0007] Therefore, an object of the present invention is to provide an electric wire with a terminal that can suppress insufficient joining due to ultrasonic welding and energy loss during joining, and a method for manufacturing the same. Another object of the present invention is to provide an electric wire with a connector in which the electric wire with a terminal having such excellent characteristics is stably joined to a connector housing. [Means for solving the problem]

[0008] The above object can be achieved by the present invention, which is described below.

[0009] <1> An electric wire with a terminal, the electric wire including a terminal fitting having an electric wire connection portion and an electric wire having a core wire joined to the electric wire connection portion, the electric wire connection portion has a bottom wall portion to which the core wire is joined along a longitudinal direction of the electric wire, and a pair of standing wall portions standing on both sides of the core wire from both ends of the bottom wall portion, The electric wire with a terminal, wherein the height of the pair of standing wall portions varies depending on the position in the longitudinal direction of the electric wire.

[0010] <2> In the longitudinal direction of the electric wire, a height of a midpoint of the pair of standing wall portions is lower than that of both sides of the midpoint. <1> The terminal-attached electric wire according to claim 1.

[0011] <3> In the longitudinal direction of the electric wire, a height of a midpoint of the pair of standing wall portions is higher than that of both sides of the midpoint. <1> The terminal-attached electric wire according to claim 1.

[0012] <4> a terminal fitting arrangement process for arranging a terminal fitting having an electric wire connection portion, the electric wire connection portion comprising a bottom wall portion to which a core wire consisting of a plurality of wires is joined along a longitudinal direction of the electric wire and a pair of upright wall portions erected from both ends of the bottom wall portion, the heights of the pair of upright wall portions varying depending on the position in the longitudinal direction of the electric wire, so that the bottom wall portion is in contact with an anvil and the pair of upright wall portions erect in a direction away from the anvil; a terminal fixing step of fixing the terminal fitting by sandwiching both outer surfaces of the pair of standing wall portions with a pair of terminal fixing blocks having abutment surfaces that abut against both outer surfaces of the pair of standing wall portions; an electric wire arranging step of arranging the electric wire including the core wire so that the core wire is located in a space surrounded by the bottom wall portion and the pair of upright wall portions of the terminal fitting and in a space above the space, and so that a longitudinal direction of the electric wire and an extending direction of the pair of upright wall portions substantially coincide with each other; a welding step of inserting a horn between the pair of upright wall portions and moving it toward the anvil to sandwich and pressurize the core wire and the bottom wall portion between the anvil and the horn, thereby applying ultrasonic vibration to the horn to weld the core wire to the terminal fitting, The pair of terminal fixing blocks have protrusions above the contact surfaces, the protrusions having shapes corresponding to at least a part of the shapes of the upper ends of the pair of upright wall portions, In the terminal fixing step, the protruding portions of the pair of terminal fixing blocks are engaged with upper ends of the pair of standing wall portions.

[0013] <5> <1> and a connector having a connector housing, the terminal fitting includes a terminal body portion connected to the wire connection portion on a side opposite to a side from which the wire extends in a longitudinal direction of the wire, the pair of upright wall portions of the electric wire connection portion have a pair of locking edges whose heights change from a side along which the electric wire extends toward a side of the terminal body portion in the longitudinal direction of the electric wire, The connector housing is provided with an insertion hole into which the terminal metal fitting is inserted from the side of the terminal body portion, A pair of locking projections are provided on opposing inner wall surfaces inside the insertion hole, The terminal fitting is inserted into the insertion hole, and the pair of locking projections abuts against the pair of locking edges to be locked. [Effects of the Invention]

[0014] According to the present invention, it is possible to provide an electric wire with a terminal and a method for manufacturing the same that can suppress insufficient joining due to ultrasonic welding and energy loss during joining. Furthermore, according to the present invention, it is possible to provide an electric wire with a connector in which the electric wire with a terminal having such excellent characteristics and a connector are stably joined. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a perspective view of an electric wire with a terminal according to an embodiment of the present invention. [Figure 2] 2 is a perspective view of an electric wire with a terminal according to an embodiment of the present invention, showing a cross section taken along the line AA in FIG. 1. [Figure 3] 2 is a cross-sectional view of the electric wire with terminal according to the embodiment of the present invention, taken along the line BB in FIG. 1. FIG. [Figure 4] 3 is an enlarged right side view showing the right side surface of the standing wall portion of the electric wire connection portion of the electric wire with terminal according to the embodiment of the present invention. FIG. [Figure 5] 1 is a longitudinal cross-sectional view of an electric wire with a terminal during a manufacturing process and a part of a manufacturing apparatus for illustrating a method for manufacturing an electric wire with a terminal according to an embodiment of the present invention. FIG. [Figure 6] FIG. 2 is a longitudinal cross-sectional view illustrating a state in which an electric wire is joined to a terminal fitting after a welding step, for illustrating a method for manufacturing an electric wire with a terminal according to an embodiment of the present invention. [Figure 7] 1 is an enlarged cross-sectional view of only a main portion of a connector-equipped electric wire using an electric wire with terminal according to an embodiment of the present invention. [Figure 8]FIG. 10 is a perspective view of an electric wire with a terminal according to a first modified example. [Figure 9] 10 is an enlarged right side view showing the right side surface of the standing wall portion of the electric wire connection portion of the electric wire with terminal according to the first modified example. FIG. [Figure 10] FIG. 10 is a perspective view of an electric wire with a terminal according to a second modified example. [Figure 11] 10 is an enlarged right side view showing the right side surface of the standing wall portion of the electric wire connection portion of the electric wire with terminal according to the second modified example. FIG. [Figure 12] FIG. 10 is a perspective view of an electric wire with a terminal according to a third modified example. [Figure 13] FIG. 11 is an enlarged right side view showing the right side surface of the standing wall portion of the wire connection portion of the electric wire with terminal according to the third modified example. DETAILED DESCRIPTION OF THE INVENTION

[0016] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An electric wire with a terminal, a manufacturing method thereof, and an electric wire with a connector according to embodiments of the present invention will be specifically described below with reference to the drawings.

[0017] [Terminal-attached wire] Fig. 1 is a perspective view of an electric wire with terminal according to an embodiment. As shown in Fig. 1, the electric wire with terminal 1 includes a terminal fitting 3 having an electric wire connecting portion 31, and an electric wire 2 having a core wire 21 joined to the electric wire connecting portion 31.

[0018] 1, the tip side (the side of the terminal body) of the electric wire with terminal 1 is indicated by an arrow T (hereinafter referred to as "tip side T"), the opposite side of the tip side T (the side from which the electric wire extends) is indicated by an arrow E (hereinafter referred to as "electric wire extension side E"), the upper side in FIG. 1 is indicated by an arrow U, the lower side by an arrow D, the right side in the width direction in FIG. 1 by an arrow R, and the left side by an arrow L (the same applies to the subsequent figures). In the following text, the longitudinal direction of the electric wire 2 is indicated by the symbol TE (hereinafter, "of the electric wire 2" will be omitted and referred to as "longitudinal direction TE"), the up-down direction by the symbol UD, and the width direction by the symbol RL.

[0019] Fig. 2 shows a perspective view of the electric wire with terminal 1, showing the cross section AA in Fig. 1. In Fig. 2, a terminal fixing block 43, which is a part of an ultrasonic welding device, is also shown as an auxiliary diagram for explaining the manufacturing method of the electric wire with terminal, which will be described later. Furthermore, Fig. 3 shows a cross-sectional view of the electric wire with terminal 1, showing the cross section BB in Fig. 1.

[0020] In the electric wire with terminal 1 according to this embodiment, the electric wire 2 includes a core wire 21 and a covering layer 22 that covers the core wire 21. Near the end of the tip side T of the electric wire 2, the covering layer 22 is peeled off (stripped) to expose the core wire 21. The core wire 21 is made of a plurality of conductive wires and has a substantially round cross section. The core wire 21 is made of a conductive metal such as copper, a copper alloy, aluminum, or an aluminum alloy, and the covering layer 22 is made of an insulating synthetic resin.

[0021] In the electric wire with terminal 1 according to this embodiment, the terminal fitting 3 is formed by bending a metal plate material that has been punched into a predetermined shape, and includes an electric wire connection portion 31 to which the core wire 21 is joined, and a terminal main body portion 32 that is continuous with the electric wire connection portion 31 on the side (tip side T) opposite to the side from which the electric wire 2 extends (electric wire extension side E) in the longitudinal direction TE. The electric wire connection portion 31 and the terminal main body portion 32 are continuous with each other via a connecting portion 33.

[0022] The terminal body 32 has a connection hole 32a that is electrically connected to various electronic devices and the like, and that opens toward the tip side T in the longitudinal direction TE. On the other hand, the wire connection portion 31 has a bottom wall 34 to which the core wire 21 is joined along the longitudinal direction TE, and a pair of standing wall portions 35 that stand upright from both ends of the bottom wall 34 on both sides (the right side R and the arrow L side) of the core wire 21.

[0023] 4 shows an enlarged right side view of the side surface on the right side R of the standing wall portion 35 in the electric wire connection portion 31. The standing wall portion 35 shown in FIG. 4 is the standing wall portion 35 located on the right side R of the pair of standing wall portions 35.

[0024] 4, in the electric wire with terminal 1 according to this embodiment, rectangular notches 36 are formed at the upper ends of the pair of standing wall portions 35 at midpoints in the longitudinal direction TE. That is, in the electric wire with terminal 1 according to this embodiment, the pair of standing wall portions 35 have different heights (lengths from the bottom wall portion 34) depending on the position in the longitudinal direction TE.

[0025] Specifically, in the longitudinal direction TE, the height (length from the bottom wall portion 34) h at the midpoint of the pair of standing wall portions 35 (the position where the notch portion 36 is formed) is lower (shorter) than the heights h1 and h2 on both sides of the midpoint (the tip side T and the electric wire extending side E of the notch portion 36 in the longitudinal direction TE).

[0026] The electric wire with terminal 1 according to this embodiment has advantages mainly in terms of manufacturability and connection stability when the connector is connected due to the formation of the cutout portion 36. Below, the "manufacturing method for an electric wire with terminal" and the "electric wire with connector" will be explained, with the former explaining the advantages in terms of manufacturability and other advantages, and the latter explaining the advantages in terms of connection stability when the connector is connected.

[0027] [Manufacturing method for electric wire with terminal] FIG. 5 is a cross-sectional view of an electric wire with terminal and a part of a manufacturing device during the manufacturing process for explaining the manufacturing method of the electric wire with terminal according to this embodiment, and corresponds to the CC cross section of the electric wire with terminal in FIG. 2 or FIG.

[0028] The method for manufacturing the electric wire with terminal 1 according to this embodiment includes a terminal fitting arrangement step, a terminal fitting fixing step, an electric wire arrangement step, and a welding step. Hereinafter, each step of the method for manufacturing the electric wire with terminal 1 according to this embodiment will be described with reference to Figs.

[0029] <Terminal fitting arrangement process> ​5, the terminal fitting arrangement step is a step of arranging the terminal fitting 3 in this embodiment so that the bottom wall portion 34 contacts the anvil 41 and the pair of standing wall portions 35 stand in a direction away from the anvil 41 (upward U direction). That is, the terminal fitting 3 in this embodiment is provided with an electric wire connecting portion 31 shown in FIGS. 1 to 3, which is composed of the bottom wall portion 34 to which the core wire 21 is joined along the longitudinal direction TE of the electric wire 2 having the core wire 21, and a pair of standing wall portions 35 standing from both ends of the bottom wall portion 34, and the heights of the pair of standing wall portions 35 vary depending on the position in the longitudinal direction TE.

[0030] Here, the term "anvil" refers to a platform on which the objects to be ultrasonically welded are placed in an ultrasonic welding device used for ultrasonic welding, and is a component that positions and fixes the objects to prevent the vibration energy from escaping, and is also called a receiving jig or receiving metal. Also, the term "horn," which will be described later, refers to a component that resonates with the vibration of a vibrator provided in the ultrasonic welding device and applies vibration and load to the objects to be welded.

[0031] <Terminal metal fitting fixing process> The terminal fitting fixing process is a process of fixing the terminal fitting 3 by clamping both outer surfaces 35a of the pair of vertical wall portions 35 with a pair of terminal fixing blocks 43 having abutment surfaces 43a that abut against both outer surfaces 35a of the pair of vertical wall portions 35, as shown in Figure 5.

[0032] The pair of terminal-fixing blocks 43 have protrusions 43b above the abutment surfaces 43a (on the side away from the anvil 41, the upper side U) that have a shape that corresponds to part of the shape of the upper ends 35b (edges on the side away from the bottom wall portion 34 (upper side U)) of the pair of standing wall portions 35. Note that the side surfaces of the protrusions 43b, rather than the protruding ends, have a shape that corresponds to part of the shape of the upper ends 35b of the pair of standing wall portions 35 (the same applies to protrusions of the terminal-fixing blocks hereinafter). When the pair of terminal-fixing blocks 43 are moved as indicated by arrow F in FIG. 5, the protrusions 43b fit into the cutout portions 36.

[0033] That is, in this terminal fitting fixing process, the protrusions 43b of the pair of terminal fixing blocks 43 are engaged with the upper ends 35b of the pair of standing wall portions 35. Therefore, the pair of terminal fixing blocks 43 sandwich both outer surfaces 35a of the pair of standing wall portions 35, thereby restricting the movement of the terminal fitting 3 in the left-right direction RL, and also restricting the movement in the longitudinal direction TE due to the engagement between the protrusions 43b of the pair of terminal fixing blocks 43 and the upper ends 35b of the pair of standing wall portions 35.

[0034] The shape of the protrusion 43b in the pair of terminal fixing blocks 43 need only correspond to at least a part of the shape of the upper ends 35b of the pair of vertical wall portions 35, but in the case where the upper ends 35b of the pair of vertical wall portions 35 have a shape in which a cutout portion 36 is formed, as in the terminal-attached wire 1 of this embodiment, it is desirable that the protrusion 43b include a portion that fits into this cutout portion 36.

[0035] <Wire placement process> As shown in FIG. 5, the electric wire arrangement process is a process of arranging an electric wire 2 having a core wire 21 made up of a plurality of wires so that the core wire 21 is positioned in a space S1 surrounded by a bottom wall portion 34 and a pair of vertical wall portions 35 of the terminal fitting 3 and a space S2 above the space S1, and so that the longitudinal direction TE and the extending direction of the pair of vertical wall portions 35 are approximately aligned.

[0036] 5, the core wire 21 has not yet been crushed, and therefore has a substantially round cross-sectional shape similar to the portion covered with the covering layer 22. Therefore, the core wire 21 cannot be contained within the space S1 surrounded by the bottom wall portion 34 and the pair of upright wall portions 35, and protrudes significantly into the space S2 above.

[0037] <Welding process> 5, in the welding process, horn 42 is inserted between the pair of upright wall portions 35 and moved in the direction of arrow G toward anvil 41, thereby sandwiching and pressurizing core wire 21 and bottom wall portion 34 between anvil 41 and horn 42. Then, ultrasonic vibration is applied to horn 42 while pressurizing core wire 21 and bottom wall portion 34.

[0038] Fig. 6 shows a vertical cross-sectional view of the state in which the core wire 21 of the electric wire 2 is joined to the electric wire connecting portion 31 of the terminal fitting 3 after the welding process. Fig. 6 is a vertical cross-sectional view of the same cross section as Fig. 5. As shown in Fig. 6, after the welding process, the core wire 21 and the terminal fitting 3 are welded together.

[0039] The ultrasonic vibrations applied to the horn 42 in the welding process vibrate in the longitudinal direction TE. Therefore, if the terminal fitting 3 is prone to movement in the longitudinal direction TE, there is a concern that the core wire 21 of the electric wire 2 and the electric wire connection portion 31 of the terminal fitting 3 may vibrate in synchronization with the vibration direction of the ultrasonic vibrations. If the core wire 21 and the electric wire connection portion 31 vibrate in synchronization with each other, friction between the core wire and the electric wire connection portion may not work sufficiently, resulting in insufficient joining or leading to energy loss during joining.

[0040] However, in this embodiment, when the pair of terminal fixing blocks 43 sandwich both outer surfaces 35a of the pair of standing wall portions 35 in the terminal fixing process, the protrusions 43b of the pair of terminal fixing blocks 43 are engaged with the upper ends 35b of the pair of standing wall portions 35. Therefore, the terminal fitting 3 is fixed to the anvil 41 in the longitudinal direction TE as well, and movement thereof is restricted.

[0041] Because the anvil 41 and the terminal fitting 3 are rigidly fixed in this way, even if ultrasonic vibrations vibrating in the longitudinal direction TE act on the terminal fitting 3, there is no risk that the wire connection portion 31 of the terminal fitting 3 will vibrate in synchronization with the direction of the ultrasonic vibrations. This makes it possible to efficiently generate friction at the interface between the core wire 21 and the wire connection portion 31, which reduces the likelihood of insufficient joining and energy loss during joining.

[0042] Furthermore, in the terminal fitting fixing process, when the terminal fitting 3 is set on the anvil 41, the positioning is achieved by engaging the protrusions 43b of the pair of terminal fixing blocks 43 with the upper ends 35b of the pair of vertical wall portions 35, so that the terminal fitting 3 can be easily and precisely set in the desired position.

[0043] Furthermore, by ensuring that the height of the core wire 21 after welding (length (thickness) from the bottom wall portion 34) is approximately the same as the height of the vertical wall portion 35 at the cutout portion 36 (length from the bottom wall portion 34), the appearance of the joint can be visually determined from the side.

[0044] [Wire with connector] Fig. 7 is an enlarged cross-sectional view of only the essential parts of a connector-attached electric wire having a connector including an electric wire with terminal and a connector housing according to this embodiment. In Fig. 7, the electric wire with terminal 1 is viewed from above (from the direction of arrow D), and the connector housing 5 of the connector is shown cut in a plane parallel to a plane including the longitudinal direction TE and the width direction RL.

[0045] Since the electric wire with terminal 1 is the electric wire with terminal 1 according to the above-described embodiment, all corresponding parts are denoted by the same reference numerals. Therefore, for parts not shown in Fig. 7, please refer to Figs. 1 to 6 as appropriate.

[0046] As shown in FIG. 4, in the electric wire with terminal 1, a pair of upright wall portions 35 in the electric wire connection portion 31 has a pair of locking edges 37 whose height (length from the bottom wall portion 34) changes so that it becomes higher (h1>h) from the side where the electric wire 2 extends in the longitudinal direction TE (electric wire extension side E) to the side of the terminal main body portion 32 (tip side T) (only one of the pair of locking edges 37 is visible in FIG. 4).

[0047] On the other hand, the connector housing 5 is a tube having a rectangular cross section, and Fig. 7 depicts only opposing connector walls 51 of the connector housing 5. The connector housing 5 is provided with insertion holes 53 into which the terminal fittings 3 are inserted from the terminal body 32 side (tip side T). In addition, a pair of locking projections 52 are provided on opposing inner wall surfaces inside the insertion holes 53 (opposing inner surfaces of the connector walls 51).

[0048] When the terminal fitting 3 is moved in the direction of arrow T and inserted into the insertion hole 53, the pair of locking protrusions 52 are first spread apart by the pair of upright walls 35 and placed in a bent state (not shown). As the terminal fitting 3 continues to be moved and inserted, the pair of locking protrusions 52 reach the cutout portions 36 and fall into the holes of the cutout portions 36, eliminating the bend and returning to their original state. Then, the pair of locking protrusions 52 come into contact with and are locked onto the pair of locking edges 37. This engagement between the locking edges 37 and the locking protrusions 52 stably couples the terminal-attached electric wire 1 and the connector housing 5.

[0049] The engagement between the locking edge 37 and the locking projections 52 may be used simply to join the terminal fitting 3 of the electric wire with terminal 1 to the connector housing 5, but the engagement between the locking edge 37 and the locking projections 52 may also be used as a retainer function. That is, the pair of locking projections 52 may be used as part of a retainer that detects when the pair of locking projections 52 reaches the cutout portion 36, which is the position where the terminal fitting 3 is fully inserted into the insertion hole 53, and when the pair of locking projections 52 reaches this position, it is the position where the terminal fitting 3 is not fully inserted. Even in this case, the electric wire with terminal 1 and the connector housing 5 are stably joined to form an electric wire with a connector.

[0050] In this embodiment, the locking edge 37 is a straight edge that rises perpendicularly to the up-down direction UD as shown in Fig. 4, but it may also rise obliquely at an angle to the up-down direction UD, or may have a curved or other shape. The locking edge may be any edge at which the height of the pair of standing wall portions changes so that it increases from the wire extending side E to the tip side T in the longitudinal direction TE.

[0051] In the embodiment described above, an example has been given in which the upper ends 35b of the pair of standing wall portions 35 are formed with rectangular cutout portions 36, but the shape of the upper ends of the pair of standing wall portions is not limited to this. In the present invention, it is sufficient that the heights of the pair of standing wall portions differ depending on the position in the longitudinal direction of the electric wire.

[0052] If the heights of the pair of standing wall portions vary depending on the position in the longitudinal direction of the electric wire, by providing the pair of terminal fixing blocks with protrusions having a shape corresponding to a part of the shape of the upper ends of the pair of standing wall portions, the protrusions and the upper ends of the pair of standing wall portions can be fitted together. That is, if the heights of the pair of standing wall portions vary depending on the position in the longitudinal direction of the electric wire, the movement of the terminal fitting in the longitudinal direction of the electric wire can be restricted by the pair of terminal fixing blocks during ultrasonic welding. Therefore, according to the electric wire 1 with terminals according to the embodiment, insufficient joining due to ultrasonic welding and energy loss during joining can be suppressed.

[0053] In order to ensure the restriction of the movement of the terminal fitting in the longitudinal direction of the electric wire, as in the electric wire 1 with terminals according to this embodiment, it is preferable that the upper ends 35b of the pair of standing wall portions 35 have a reverse edge 38 facing the side opposite to the side (electric wire extension side E) towards which the locking edge 37 faces (tip side T) together with the locking edge 37 (see FIG. 4). By having the locking edge 37 and the reverse edge 38 facing in opposite directions at the upper ends 35b of the pair of standing wall portions 35, the movement of the terminal fitting 3 in the longitudinal direction TE can be effectively restricted by the pair of terminal fixing blocks 43 provided with protrusions having a corresponding shape.

[0054] Here, the reverse edge 38 refers to a portion where the height (length from the bottom wall portion 34) of the pair of standing wall portions 35 switches so as to be higher from the tip side T to the electric wire extension side E in the longitudinal direction TE (h < h2) as shown in FIG. 4. Similar to the locking edge 37, the reverse edge 38 may be a straight side rising vertically with respect to the vertical direction UD shown in FIG. 4, may rise obliquely at an angle with respect to the vertical direction UD, or may be curved or other shapes.

[0055] Hereinafter, three modified examples (the first to third modified examples) of electric wires with terminals in which the shapes of the upper ends of the pair of standing wall portions are different will be exemplified.

[0056] (The first modified example) 8 is a perspective view of an electric wire with terminal according to a first modified example. In an electric wire with terminal 101 according to this modified example, part of the shape of the terminal fitting 103 is different from that of the electric wire with terminal 1 according to the embodiment, but the rest is the same.

[0057] Therefore, in Fig. 8 showing the electric wire with terminal 101 according to this modification, each member having the same configuration as that of the electric wire with terminal 1 according to the embodiment is given the same reference numeral as that of the member in the embodiment, and the description of the similar configuration of each member will be omitted. The following mainly describes the differences. In Fig. 8, members having a configuration unique to this modification are given reference numerals in the hundreds, the last two digits of which are the same as those of the corresponding members in the electric wire with terminal 1 according to the embodiment.

[0058] In the electric wire with terminal 101 according to this modification, the terminal fitting 103 is formed by bending a metal plate that has been punched into a predetermined shape, and includes an electric wire connection portion 131 to which the core wire 21 is joined, and a terminal main body portion 32 that is continuous with the side opposite to the electric wire extending side E (tip side T). The electric wire connection portion 131 and the terminal main body portion 32 are continuous via a connecting portion 33. The electric wire connection portion 131 has a bottom wall portion (not shown; see reference numeral 34 in FIG. 2 ) to which the core wire 21 is joined along the longitudinal direction TE, and a pair of upright wall portions 135 that are provided upright from both ends of the bottom wall portion on both sides (the right side R and the arrow L side) of the core wire 21.

[0059] 9 shows an enlarged right side view of the side surface on the right side R of the standing wall portion 135 of the electric wire connecting portion 131. The standing wall portion 135 shown in FIG. 9 is the standing wall portion 135 located on the right side R of the pair of standing wall portions 135.

[0060] 9, in the electric wire with terminal 101 according to this modification, rectangular protruding pieces 136 are formed at the upper ends of the pair of standing wall portions 135 at midpoints in the longitudinal direction TE. That is, in the electric wire with terminal 101 according to this embodiment, the heights (lengths from the bottom wall portions) of the pair of standing wall portions 135 vary depending on the position in the longitudinal direction TE.

[0061] Specifically, in the longitudinal direction TE, the height (length from the bottom wall portion) ha at the midpoint of the pair of standing wall portions 135 (the position where the protruding piece 136 is formed) is higher (longer) than ha1 and ha2 on both sides of the midpoint (the tip side T and the wire extension side E of the protruding piece 136 in the longitudinal direction TE). ha>ha1, ha>ha2.

[0062] As shown in FIG. 9, in the terminal-attached electric wire 101 according to this modified example, a pair of vertical wall portions 135 in the electric wire connection portion 131 have a pair of locking edges 137 whose height (length from the bottom wall portion) changes so that it increases from the electric wire extension side E to the tip side T (ha>ha2) (in FIG. 9, only the locking edge 137 on the right side R of the pair of locking edges 137 is visible).

[0063] 7 in the embodiment, the pair of locking projections 52 come into contact with and lock onto the pair of locking edges 137, thereby stably connecting the electric wire with terminal 101 and the connector housing 5. As in the embodiment, the pair of locking projections 52 may be used as part of a retainer.

[0064] On the other hand, in the electric wire with terminal 101 according to this modification, the heights of the pair of standing wall portions 135 vary depending on the position in the longitudinal direction TE, and therefore, the pair of terminal-fixing blocks can restrict movement of the terminal fitting 103 in the longitudinal direction TE during ultrasonic welding as described in the embodiment with reference to Figures 2, 5, and 6. In this case, the pair of terminal-fixing blocks used for ultrasonic welding must be provided with protrusions having a shape corresponding to at least a part of the shape of the upper ends 135b of the pair of standing wall portions 135 above the abutment surfaces that abut against the outer surfaces 135a of the pair of standing wall portions 135. The electric wire with terminal 101 according to this modification can suppress insufficient joining by ultrasonic welding and energy loss during joining.

[0065] Further, the wire 101 with a terminal according to this modified example has a reverse edge 138 where the height of the pair of standing wall portions 135 switches so as to increase from the tip side T in the longitudinal direction TE to the wire extension side E (ha1 < ha). The wire 101 with a terminal according to this modified example has, together with the locking edge 137, a reverse edge 138 facing the side opposite to the side where the locking edge 137 faces (the wire extension side E) (the tip side T). By having this, the movement of the terminal fitting 103 in the longitudinal direction TE can be effectively restricted by a pair of terminal fixing blocks (not shown) provided with protruding portions having a corresponding shape.

[0066] Note that, as the shape of the protruding portion in the pair of terminal fixing blocks used for ultrasonic welding, it is only necessary that it corresponds to at least a part of the shape of the upper end 135b of the pair of standing wall portions 135. However, in the case of the shape in which the protruding piece 136 is formed at an intermediate position of the upper end 135b of the pair of standing wall portions 135 as in the wire 101 with a terminal according to this modified example, it is desirable that it includes the portion where the protruding piece 136 fits.

[0067] As described above, even if the shape of the upper end 135b of the pair of standing wall portions 135 is not the notch portion 36 as in the embodiment but the shape of the protruding piece 136 protruding reversely as in this modified example, the same merits as in the embodiment can be enjoyed.

[0068] (Second Modified Example) FIG. 10 is a perspective view of a wire with a terminal according to the second modified example. In the wire 201 with a terminal according to this modified example, a part of the shape of the terminal fitting 203 is different from that of the wire 1 with a terminal according to the embodiment, but the rest is the same.

[0069] Therefore, in FIG. 10 showing the wire 201 with a terminal according to this modified example, for each member having the same configuration as that of the wire 1 with a terminal according to the embodiment, the same reference numerals as those of the respective members in the embodiment are given, and the description of the same configuration and the like in each member is omitted. Hereinafter, mainly the differences will be described. In FIG. 10, members having a configuration peculiar to this modified example are given reference numerals in the two-hundred series with the last two digits being the same as those of the corresponding members in the wire 1 with a terminal according to the embodiment.

[0070] In the electric wire with terminal 201 according to this modification, the terminal fitting 203 is formed by bending a metal plate that has been punched into a predetermined shape, and includes an electric wire connection portion 231 to which the core wire 21 is joined, and a terminal main body portion 32 that is continuous with the side opposite to the electric wire extending side E (tip side T). The electric wire connection portion 231 and the terminal main body portion 32 are continuous with each other via a connecting portion 33. The electric wire connection portion 231 has a bottom wall portion (not shown; see reference numeral 34 in FIG. 2 ) to which the core wire 21 is joined along the longitudinal direction TE, and a pair of upright wall portions 235 that are provided upright from both ends of the bottom wall portion on both sides (the right side R and the arrow L side) of the core wire 21.

[0071] 11 shows an enlarged right side view of the side surface on the right side R of the standing wall portion 235 of the electric wire connecting portion 231. The standing wall portion 235 shown in FIG. 11 is the standing wall portion 235 located on the right side R of the pair of standing wall portions 235.

[0072] 11, in the electric wire with terminal 201 according to this modification, semicircular notches 236 are formed at the upper ends of the pair of standing wall portions 235 at midpoints in the longitudinal direction TE. That is, in the electric wire with terminal 201 according to this embodiment, the heights (lengths from the bottom wall portions) of the pair of standing wall portions 235 vary depending on the position in the longitudinal direction TE.

[0073] Specifically, in the longitudinal direction TE, the height (length from the bottom wall portion) hb at the midpoint (the position where the notch portion 236 is formed) of the pair of standing wall portions 235 is lower (shorter) than hb1 and hb2 on both sides of the midpoint (the tip side T and the electric wire extending side E of the notch portion 236 in the longitudinal direction TE). <hb1,hb<hb2)。

[0074] As shown in Fig. 11, in the electric wire with terminal 201 according to this modification, a pair of upright wall portions 235 in the electric wire connecting portion 231 have a pair of locking edges 237 whose height (length from the bottom wall portion) changes so that it increases from the electric wire extending side E to the tip side T (hb1>hb) (in Fig. 11, only the locking edge 237 on the right side R of the pair of locking edges 237 is visible). In this modification, the shape of the pair of locking edges 237 is curved.

[0075] 7 in the embodiment, the pair of locking projections 52 come into contact with and lock onto the pair of locking edges 237, thereby stably connecting the electric wire with terminal 201 to the connector housing 5. As in the embodiment, the pair of locking projections 52 may be used as part of a retainer.

[0076] On the other hand, in the terminal-attached wire 201 according to this modified example, the height of the pair of vertical wall portions 235 varies depending on the position in the longitudinal direction TE, and therefore, the pair of terminal fixing blocks can restrict the movement of the terminal fitting 203 in the longitudinal direction TE during ultrasonic welding as described in the embodiment using Figures 2, 5 and 6.

[0077] In this case, the pair of terminal fixing blocks used for ultrasonic welding need to be provided with protrusions, the protrusions having a shape corresponding to at least a part of the shape of the upper ends 235b of the pair of standing wall portions 235, above the contact surfaces that contact the outer surfaces 235a of the pair of standing wall portions 235. The electric wire with terminal 201 according to this modification can suppress insufficient joining due to ultrasonic welding and energy loss during joining.

[0078] In addition, the wire with terminal 201 according to this modified example has a reverse edge 238 at which the height of the pair of vertical wall portions 235 switches so as to increase from the tip side T in the longitudinal direction TE to the wire extension side E (hb < hb2). The wire with terminal 201 according to this modified example has, together with the locking edge 237, a reverse edge 238 facing the side opposite to the side (wire extension side E) to which the locking edge 237 faces (tip side T). By having this, the movement of the terminal fitting 203 in the longitudinal direction TE can be effectively restricted by a pair of terminal fixing blocks (not shown) provided with protruding portions having corresponding shapes.

[0079] Note that, as the shape of the protruding portion in the pair of terminal fixing blocks used for ultrasonic welding, it only needs to correspond to at least a part of the shape of the upper end 235b of the pair of vertical wall portions 235. However, in the case of the shape in which the notch portion 236 is formed at the middle position of the upper end 235b of the pair of vertical wall portions 235 as in the wire with terminal 201 according to this modified example, it is desirable to include a portion that fits into this notch portion 236.

[0080] As described above, even if the shape of the upper end 235b of the pair of vertical wall portions 235 is not the rectangular notch portion 36 as in the embodiment but the circular notch portion 236 as in this modified example, the same advantages as in the embodiment can be enjoyed.

[0081] (Third Modified Example) FIG. 12 is a perspective view of a wire with terminal according to the third modified example. In the wire with terminal 301 according to this modified example, a part of the shape of the terminal fitting 303 is different from that of the wire with terminal 1 according to the embodiment, but the others are the same.

[0082] Therefore, in FIG. 12 showing the wire with terminal 301 according to this modified example, for each member having the same configuration as that of the wire with terminal 1 according to the embodiment, the same reference numerals as those of the respective members in the embodiment are given, and the description of the same configuration and the like in each member is omitted. Hereinafter, mainly the differences will be described. In FIG. 12, members having configurations peculiar to this modified example are given reference numerals in the three - hundred series with the last two digits being the same as those of the corresponding members in the wire with terminal 1 according to the embodiment.

[0083] In the electric wire with terminal 301 according to this modification, the terminal fitting 303 is formed by bending a metal plate that has been punched into a predetermined shape, and includes an electric wire connection portion 331 to which the core wire 21 is joined, and a terminal main body portion 32 that is continuous with the side opposite to the electric wire extending side E (tip side T). The electric wire connection portion 331 and the terminal main body portion 32 are continuous via a connecting portion 33. The electric wire connection portion 331 has a bottom wall portion (not shown; see reference numeral 34 in FIG. 2 ) to which the core wire 21 is joined along the longitudinal direction TE, and a pair of upright wall portions 335 that are provided upright from both ends of the bottom wall portion on both sides (the right side R and the arrow L side) of the core wire 21.

[0084] 13 shows an enlarged right side view of the side surface on the right side R of the standing wall portion 335 of the electric wire connecting portion 331. The standing wall portion 335 shown in FIG. 31 is the standing wall portion 235 located on the right side R of the pair of standing wall portions 335.

[0085] 13, in the electric wire with terminal 301 according to this modification, two rectangular notches 336, 336' are formed midway in the longitudinal direction TE at the upper ends of the pair of standing wall portions 335. That is, in the electric wire with terminal 301 according to this embodiment, the heights (lengths from the bottom wall portions) of the pair of standing wall portions 335 vary depending on the position in the longitudinal direction TE.

[0086] Specifically, in the longitudinal direction TE, the heights (lengths from the bottom wall portion) hb, hb' at two midpoints (positions where the notched portions 336, 336' are formed) of the pair of standing wall portions 335 are lower (shorter) than the heights hc1 and hc2, hc2 and hc3 on both sides of these midpoints (the tip side T and the electric wire extending side E of each of the two notched portions 336, 336' 236 in the longitudinal direction TE). <hc1,hc<hc2,hc′<hc2,hc′<hc3)。

[0087] As shown in FIG. 13, in the terminal-attached wire 301 according to this modified example, a pair of upright wall portions 335 in the wire connection portion 331 have two pairs of locking edges 337, 337′ whose height (length from the bottom wall portion) changes so that it increases from the wire extension side E to the tip side T (hc1>hc, hc2>hc′) (in FIG. 13, of the two pairs of locking edges 337, only the locking edge 337 on the right side R is visible).

[0088] Therefore, even when the terminal fitting 303 of the electric wire with terminal 301 according to this modification is inserted into the insertion hole 53 of the connector housing 5 described in the embodiment with reference to Fig. 7, the pair of locking protrusions 52 abuts against and locks with either the pair of locking edges 337 or the pair of locking edges 337', thereby stably connecting the electric wire with terminal 301 and the connector housing 5. As in the embodiment, the pair of locking protrusions 52 may be used as part of a retainer. Note that if a connector having two pairs of locking protrusions, each of which is provided with another pair of locking protrusions 52 in the longitudinal direction TE, is used instead of the connector housing 5 shown in Fig. 7, the two pairs of locking protrusions can abut against and lock with the pair of locking edges 337 and the pair of locking edges 337'.

[0089] On the other hand, in the electric wire with terminal 301 according to this modification, the heights of the pair of standing wall portions 335 vary depending on the position in the longitudinal direction TE, and therefore, the pair of terminal-fixing blocks can restrict movement of the terminal fitting 303 in the longitudinal direction TE during ultrasonic welding as described in the embodiment with reference to Figures 2, 5, and 6. In this case, the pair of terminal-fixing blocks used for ultrasonic welding must be provided with protrusions having a shape corresponding to at least a part of the shape of the upper ends 335b of the pair of standing wall portions 335 above the abutment surfaces that abut against the outer surfaces 335a, 335a' of the pair of standing wall portions 335. The electric wire with terminal 301 according to this modification can suppress insufficient joining by ultrasonic welding and energy loss during joining.

[0090] Also, the wire 301 with terminals according to this modified example has reverse edges 338, 338' that switch such that the height of the pair of standing wall portions 335 increases from the tip side T in the longitudinal direction TE to the wire extension side E (hc < hc2, hc' < hc3). The wire 301 with terminals according to this modified example has, together with the locking edges 337, 337', reverse edges 338, 338' that face the side opposite to the side (wire extension side E) where the locking edges 337, 337' face (tip side T). By having these, the movement of the terminal fitting 303 in the longitudinal direction TE can be effectively restricted by a pair of terminal fixing blocks (not shown) provided with protruding portions having corresponding shapes.

[0091] Note that, as the shape of the protruding portions in the pair of terminal fixing blocks used for ultrasonic welding, it is only necessary that it corresponds to at least a part of the shape of the upper ends 335b of the pair of standing wall portions 335. However, in the case of a shape in which a plurality of notch portions 336, 336' are formed at an intermediate position of the upper ends 335b of the pair of standing wall portions 335 like the wire 301 with terminals according to this modified example, it is desirable to include a portion that fits into at least any one of these notch portions 336, 336'.

[0092] As described above, even if the shape of the upper ends 335b of the pair of standing wall portions 335 is not one rectangular notch portion 36 as in the embodiment, but two notch portions 336, 336' as in this modified example, the same advantages as in the embodiment can be enjoyed. The number of these notch portions may be three or more.

[0093] The embodiments and the three modified examples described above merely show examples of typical forms of the present invention, and the present invention is not limited to the above embodiments and modified examples. For example, in the above embodiments and modified examples, as the shape of the terminal body portion, a rectangular one in a right side view having a rectangular connection hole 32a at the tip portion is given as an example, but it is not limited to this, and the present invention can be adopted for terminal body portions of any shape.

[0094] In the first modified example, one rectangular protruding piece 136 is formed midway along the upper ends of the pair of standing wall portions 135, but the shape of the protruding piece may be semicircular or another polygonal shape, or may be an irregular or arbitrary shape, and the number of protruding pieces may be two or more. Furthermore, the shape of the upper ends of the pair of standing wall portions 135 may be a combination of two or more of the shapes of the notches and protruding pieces in the above embodiment and three modified examples.

[0095] In addition, those skilled in the art can implement various modifications in accordance with conventionally known knowledge without departing from the gist of the present invention. As long as such modifications still provide the configuration of the electric wire with terminal and its manufacturing method, and the electric wire with connector of the present invention, they are of course included in the scope of the present invention. [Explanation of symbols]

[0096] 1,101,201,301: Wires with terminals, 2: Electric wire, 3,103,203,303: Terminal fittings, 5: Connector housing, 21: Core wire, 22: Covering layer, 31, 131, 231, 331: Wire connection part, 32: Terminal body, 32a: connection hole, 33: Connection part, 34: bottom wall portion, 35, 135, 235, 335: vertical wall section, 35a, 135a, 235a, 335a: outer surface, 35b,135b,235b,335b: Upper end, 36,236,336,336′: notch, 37,137,237,337,337′: locking edge, 38,138,238,338,338′: Opposite edge, 41: Anvil, 42: Horn, 43: Terminal fixing block, 43a: contact surface, 43b: protrusion, 51: Connector wall, 52: Locking protrusion, 53: Insertion hole, 136:Protruding piece

Claims

1. An electric wire with a terminal, the electric wire including a terminal fitting having an electric wire connection portion and an electric wire having a core wire joined to the electric wire connection portion, the electric wire connection portion has a bottom wall portion to which the core wire is joined along a longitudinal direction of the electric wire, and a pair of standing wall portions standing on both sides of the core wire from both ends of the bottom wall portion, The electric wire with a terminal, wherein the height of the pair of standing wall portions varies depending on the position in the longitudinal direction of the electric wire.

2. The electric wire with terminal according to claim 1 , wherein a height of a midpoint of the pair of standing wall portions in a longitudinal direction of the electric wire is lower than that of both sides of the midpoint.

3. The electric wire with terminal according to claim 1 , wherein a height of a midpoint of the pair of upright wall portions in a longitudinal direction of the electric wire is higher than that of both sides of the midpoint.

4. a terminal fitting arrangement process for arranging a terminal fitting having an electric wire connection portion, the electric wire connection portion comprising a bottom wall portion to which a core wire consisting of a plurality of wires is joined along a longitudinal direction of the electric wire and a pair of upright wall portions erected from both ends of the bottom wall portion, the heights of the pair of upright wall portions varying depending on the position in the longitudinal direction of the electric wire, so that the bottom wall portion is in contact with an anvil and the pair of upright wall portions erect in a direction away from the anvil; a terminal fixing step of fixing the terminal fitting by sandwiching both outer surfaces of the pair of standing wall portions with a pair of terminal fixing blocks having abutment surfaces that abut against both outer surfaces of the pair of standing wall portions; an electric wire arranging step of arranging the electric wire including the core wire so that the core wire is located in a space surrounded by the bottom wall portion and the pair of upright wall portions of the terminal fitting and in a space above the space, and so that a longitudinal direction of the electric wire and an extending direction of the pair of upright wall portions substantially coincide with each other; a welding step of inserting a horn between the pair of upright wall portions and moving it toward the anvil to sandwich and pressurize the core wire and the bottom wall portion between the anvil and the horn, thereby applying ultrasonic vibration to the horn to weld the core wire to the terminal fitting, The pair of terminal fixing blocks have protrusions above the contact surfaces, the protrusions having shapes corresponding to at least a part of the shapes of the upper ends of the pair of upright wall portions, In the terminal fixing step, the protruding portions of the pair of terminal fixing blocks are engaged with upper ends of the pair of standing wall portions.

5. A connector-attached electric wire comprising the terminal-attached electric wire according to claim 1 and a connector having a connector housing, the terminal fitting includes a terminal body portion connected to the wire connection portion on a side opposite to a side from which the wire extends in a longitudinal direction of the wire, the pair of upright wall portions of the electric wire connection portion have a pair of locking edges whose heights change from a side along which the electric wire extends toward a side of the terminal body portion in the longitudinal direction of the electric wire, The connector housing is provided with an insertion hole into which the terminal metal fitting is inserted from the side of the terminal body portion, A pair of locking projections are provided on opposing inner wall surfaces inside the insertion hole, The terminal fitting is inserted into the insertion hole, and the pair of locking projections abuts against the pair of locking edges to be locked.

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