Fuse unit and method of manufacturing the fuse unit

Abstract

To provide a fuse unit which can reduce manufacturing cost.SOLUTION: A fuse unit 10 includes a first terminal 20 electrically connected to a mating member, a second terminal 30 electrically connected to an electric wire 70, a resin part 40 covering a part of the first terminal 20 and a part of the second terminal 30, and a chip fuse 50. The resin part 40 has a mounting surface 41 on which the chip fuse 50 is mounted between the first terminal 20 and the second terminal 30. The first terminal 20 includes a first connection part 24 exposed from the resin part 40, adjacently to the mounting surface 41. The second terminal 30 includes a fixing part for fixing the electric wire 70 and a second connection part 34 exposed from the resin part 40, adjacently to the mounting surface 41. The chip fuse 50 includes a first electrode 51 mounted on the first connection part 24 and a second electrode 52 mounted on the second connection part 34.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] TECHNICAL FIELD The present disclosure relates to fuse units and methods of manufacturing fuse units. [Background technology]

[0002] High-voltage battery packs used in electric vehicles, hybrid vehicles, and the like typically have a large number of stacked battery cells electrically connected in series or parallel by a wiring module. A known example of such a wiring module is the conductor module described in JP 2019-32928 A (Patent Document 1 below). The conductor module described in Patent Document 1 includes a wiring material and multiple bus bars. The wiring material has multiple wires that electrically connect the bus bars and the battery module monitoring unit, and a fuse provided midway along the wires. Patent Document 1 cites a flexible printed circuit (FPC) as an example of the wiring material. Using an FPC as the wiring material makes it possible to easily provide a fuse on the wiring material by mounting. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-32928 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-described conductor module, when the battery cells, bus bars, etc. are changed, the wiring material must be designed and prepared separately, which makes it difficult to reduce the manufacturing cost of the wiring material. [Means for solving the problem]

[0005] The fuse unit of the present disclosure comprises a first terminal electrically connected to a mating member, a second terminal electrically connected directly or indirectly to a wiring member, a resin part covering a portion of the first terminal and a portion of the second terminal, and a chip fuse, wherein the resin part maintains the spacing between the first terminal and the second terminal, the first terminal comprises a first connection part exposed from the resin part, the second terminal comprises a second connection part exposed from the resin part, and the chip fuse comprises a first electrode mounted on the first connection part and a second electrode mounted on the second connection part.

[0006] In addition, the manufacturing method of the fuse unit disclosed herein includes a terminal forming process for forming a first terminal and a second terminal, a resin part forming process for forming a resin part that covers a portion of the first terminal and a portion of the second terminal by insert molding, and that exposes the outer surface of the first terminal as a first connection part and the outer surface of the second terminal as a second connection part, and an mounting process for mounting the first electrode of a chip fuse having a first electrode and a second electrode to the first connection part and the second electrode to the second connection part. [Effects of the Invention]

[0007] According to the present disclosure, it is possible to provide a fuse unit that can reduce manufacturing costs. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of a fuse unit according to a first embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 2] FIG. 2 is a plan view of the fuse unit connected to the electric wire according to the first embodiment. [Figure 3] FIG. 3 is a cross-sectional view taken along line AA in FIG. [Figure 4] FIG. 4 is a plan view of the first terminal and the second terminal according to the first embodiment. [Figure 5]FIG. 5 is a plan view of the intermediate molded body according to the first embodiment. [Figure 6] FIG. 6 is a plan view of the fuse unit according to the first embodiment. [Figure 7] FIG. 7 is a perspective view of a wiring module including the fuse unit according to the first embodiment. [Figure 8] FIG. 8 is a perspective view of the fuse unit according to the second embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 9] FIG. 9 is a cross-sectional view of the fuse unit according to the second embodiment, and corresponds to FIG. 3 of the first embodiment. [Figure 10] FIG. 10 is a perspective view of the fuse unit according to the third embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 11] FIG. 11 is a cross-sectional view of a fuse unit according to the third embodiment, and corresponds to FIG. 3 of the first embodiment. [Figure 12] FIG. 12 is a cross-sectional view of the fuse unit according to the fourth embodiment, and corresponds to FIG. 3 of the first embodiment. [Figure 13] FIG. 13 is a perspective view of the fuse unit according to the fifth embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 14] FIG. 14 is a plan view of the fuse unit according to the sixth embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 15] FIG. 15 is a cross-sectional view taken along the line BB in FIG. [Figure 16] FIG. 16 is a perspective view of the fuse unit according to the seventh embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 17] FIG. 17 is a plan view of a fuse unit connected to an electric wire according to a seventh embodiment. [Figure 18] FIG. 18 is a cross-sectional view taken along CC in FIG. [Figure 19]FIG. 19 is a view showing a state in which the third terminal is inserted into the cavity in the CC cross section of FIG. [Figure 20] 20 is a view showing a state in which the third terminal is inserted into the cavity and the retainer is in the provisionally locked position, taken along the CC cross section of FIG. [Figure 21] FIG. 21 is a side view of the fuse unit connected to the electric wire according to the seventh embodiment. [Figure 22] FIG. 22 is a cross-sectional view taken along line DD of FIG. 21, and in FIG. 22, the second terminal, the third terminal, and the electric wires are omitted. [Figure 23] FIG. 23 is a side view of the fuse unit according to the seventh embodiment, excluding the third terminal, showing a state in which the retainer is in the temporary locking position. [Figure 24] FIG. 24 is a cross-sectional view taken along the line EE of FIG. [Figure 25] FIG. 25 is a plan view of the first terminal, the second terminal, and the resin portion according to the seventh embodiment. [Figure 26] FIG. 26 is a perspective view of the FF cross section of FIG. [Figure 27] FIG. 27 is a cross-sectional view taken along line GG in FIG. [Figure 28] FIG. 28 is a plan view of the first terminal and the second terminal according to the seventh embodiment. [Figure 29] FIG. 29 is a perspective view of a fuse unit according to a modification of the first embodiment, showing a state in which the fuse unit is connected to an electric wire. [Figure 30] FIG. 30 is a perspective view of a fuse unit according to another embodiment, showing a state in which the fuse unit is connected to a flexible substrate. DETAILED DESCRIPTION OF THE INVENTION

[0009] [Description of the embodiments of the present disclosure] First, embodiments of the present disclosure will be listed and described. [1] The fuse unit of the present disclosure comprises a first terminal electrically connected to a mating member, a second terminal electrically connected directly or indirectly to a wiring member, a resin part covering a part of the first terminal and a part of the second terminal, and a chip fuse, wherein the resin part maintains a distance between the first terminal and the second terminal, the first terminal comprises a first connection part exposed from the resin part, the second terminal comprises a second connection part exposed from the resin part, and the chip fuse comprises a first electrode mounted on the first connection part and a second electrode mounted on the second connection part.

[0010] This configuration allows chip fuses to be easily incorporated into the fuse unit through mounting, and also reduces the manufacturing cost of the fuse unit because it may not be necessary to redesign the fuse unit even if the mating member or wiring member is changed.

[0011] [2] In the above item [1], it is preferable that the resin portion has a portion that protrudes beyond the first connection portion and the second connection portion and includes a peripheral wall portion that is disposed around the chip fuse.

[0012] With this configuration, the chip fuse can be protected by the peripheral wall portion.

[0013] [3] In the above [2], it is preferable that the peripheral wall portion surrounds the first connecting portion and the second connecting portion.

[0014] With this configuration, the peripheral wall portion can prevent foreign matter and the like from coming into contact with the chip fuse, thereby preventing stress from occurring in the connection portion between the first connection portion and the first electrode, and in the connection portion between the second connection portion and the second electrode.

[0015] [4] Any one of the fuse units [1] to [3] above is Chip fuse It is preferable that the device further includes a cover member for covering the device.

[0016] According to this configuration, the provision of the cover member makes it possible to prevent condensation water and the like from adhering to the chip fuse, thereby making it possible to prevent a short circuit between the first electrode and the second electrode due to condensation water and the like.

[0017] [5] It is preferable that any one of the fuse units [1] to [4] above further comprises a third terminal to which the wiring member is connected, the second terminal comprises a first terminal connection portion connected to the third terminal, and the third terminal comprises a second terminal connection portion connected to the first terminal connection portion by fitting.

[0018] With this configuration, the wiring member and the second terminal can be easily connected.

[0019] [6] Preferably, the fuse unit according to [5] above further includes a retainer that is assembled to the resin portion and holds the third terminal.

[0020] According to this configuration, the third terminal can be held relative to the resin portion, and therefore the position of the third terminal relative to the resin portion can be easily determined.

[0021] [7] In any one of [1] to [6] above, it is preferable that the first terminal or the second terminal has a notch recessed from an outer edge, and the notch defines the first connecting portion or the second connecting portion.

[0022] With this configuration, the first connection portion or the second connection portion is defined by the notch, so that the size of the first connection portion or the second connection portion can be appropriately adjusted, and heat dissipation from the first connection portion or the second connection portion can be controlled when the chip fuse is implemented.

[0023] [8] In the above [7], it is preferable that a groove recessed toward the first connection portion and the second connection portion is formed in the resin portion, the inner surface constituting the groove is continuous with the first connection portion and the second connection portion, and a portion of the groove is arranged inside the notch.

[0024] With this configuration, when forming the resin portion, it is possible to prevent molten resin from migrating through the cutouts to the outer surfaces of the first and second connecting portions, thereby preventing burrs from being formed on the first and second connecting portions.

[0025] [9] The manufacturing method of the fuse unit of the present disclosure includes a terminal forming process for forming a first terminal and a second terminal, a resin part forming process for forming a resin part that covers a part of the first terminal and a part of the second terminal by insert molding, wherein the resin part exposes an outer surface of the first terminal as a first connection part and an outer surface of the second terminal as a second connection part, and an mounting process for mounting the first electrode of a chip fuse having a first electrode and a second electrode to the first connection part and the second electrode to the second connection part.

[0026] According to this method of manufacturing a fuse unit, by forming a resin portion that exposes the first connection portion and the second connection portion in the resin portion forming step, it is possible to easily include a chip fuse in the fuse unit in the mounting step. Furthermore, even if the components to which the first terminal and the second terminal are connected are changed, there may be no need to redesign the fuse unit, thereby reducing the manufacturing cost of the fuse unit.

[0027] [Details of the embodiments of the present disclosure] The following describes embodiments of the present disclosure. The present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims. In the drawings, for the sake of convenience, some components may be exaggerated or simplified. Furthermore, the dimensional ratios of the components may differ between drawings. In this specification, "orthogonal" and "parallel" do not only refer to cases where the components are strictly orthogonal or parallel, but also include cases where the components are roughly orthogonal or parallel within the scope of the functions and effects of the present embodiment.

[0028] In each drawing, three mutually perpendicular directions are shown, and the three directions are respectively indicated as a first direction D1, a second direction D2, and a third direction D3. That is, the first direction D1 and the second direction D2 are perpendicular to each other, the first direction D1 and the third direction D3 are perpendicular to each other, and the second direction D2 and the third direction D3 are perpendicular to each other. By indicating each direction with an arrow on both sides of the solid line, not only the direction of the arrow on the side with the symbol but also the direction of the arrow on the side without the symbol is considered to indicate the corresponding direction.

[0029] <Embodiment 1> (Fuse unit 10) A first embodiment of the present disclosure will be described with reference to Figures 1 to 7. As shown in Figures 1 to 3, a fuse unit 10 of this embodiment includes a first terminal 20, a second terminal 30, a resin part 40, and a chip fuse 50. Note that, for multiple identical components, only some of the components may be designated by reference numerals, and the reference numerals for the other components may be omitted.

[0030] (1st terminal 20) The first terminal 20 is made of a conductive metal. As shown in FIG. 4, the first terminal 20 has a rectangular plate-shaped plate portion 21 and a through-hole 22 penetrating the plate portion 21. The through-hole 22 is disposed near an end of the plate portion 21 in the extension direction. The plate portion 21 has two recesses 21A at both ends in the width direction of the plate portion 21 (a direction perpendicular to both the extension direction and the thickness direction of the plate portion 21). The recesses 21A are recessed from the edge of the plate portion 21 in the width direction. The plate portion 21 has a mating member connecting portion 23 that is electrically connected to a mating member. The mating member is, for example, a bus bar 60 (see FIG. 7). The mating member connecting portion 23 is connected to the mating member by, for example, welding or soldering.

[0031] (2nd terminal 30) The second terminal 30 is made of a conductive metal. The metal constituting the second terminal 30 may be different from the metal constituting the first terminal 20. As shown in FIG. 4, the second terminal 30 includes a rectangular plate-shaped plate portion 31, a through-hole 32 penetrating the plate portion 31, and a barrel portion 33. The barrel portion 33 is formed to be continuous with the plate portion 31 in the extension direction of the second terminal 30. The plate portion 31 has two recesses 31A at both ends in the width direction of the second terminal 30 (a direction perpendicular to both the extension direction of the second terminal 30 and the thickness direction of the plate portion 31). The recesses 31A are formed by being recessed from the edge of the second terminal 30 in the width direction.

[0032] The barrel portion 33 includes a core wire crimping portion 33A and an insulating sheath crimping portion 33B (an example of a fixing portion). The core wire crimping portion 33A is disposed between the plate-shaped portion 31 and the insulating sheath crimping portion 33B in the extension direction of the second terminal 30. As shown in FIG. 3 , the core wire crimping portion 33A is crimped to the core wire of an electric wire 70 (an example of a wiring member). The second terminal 30 is electrically connected to the electric wire 70 by the core wire crimping portion 33A. The insulating sheath crimping portion 33B is crimped to the insulating sheath of the electric wire 70. The insulating sheath crimping portion 33B can fix the electric wire 70 to the second terminal 30. For example, when a tensile stress is applied to the electric wire 70, the insulating sheath crimping portion 33B prevents the tensile stress from being transmitted to the core wire crimping portion 33A. This makes it easier to maintain the electrical connection between the electric wire 70 and the second terminal 30.

[0033] (Resin part 40) The resin portion 40 is made of an insulating synthetic resin. As shown in FIGS. 1 to 3 , the resin portion 40 is disposed between the first terminal 20 and the second terminal 30 and covers a portion of the first terminal 20 and a portion of the second terminal 30. As will be described later, the resin portion 40 is integrally formed with the first terminal 20 and the second terminal 30 by insert molding. As shown in FIGS. 2 and 3 , during insert molding, molten resin, which is the raw material of the resin portion 40, is filled into the through holes 22, 32 and the recesses 21A, 31A, thereby holding the first terminal 20 and the second terminal 30 relative to the resin portion 40. The resin portion 40 positions the first terminal 20 and the second terminal 30 so that they do not come into direct contact with each other. The first terminal 20 and the second terminal 30 are spaced apart in the first direction D1. The first terminal 20 is disposed such that the extension direction of the plate-like portion 21 of the first terminal 20 is the first direction D1. The second terminals 30 are arranged so that the extension direction of the second terminals 30 is the first direction D1.

[0034] (Placement surface 41) As shown in FIG. 3, the resin part 40 is formed to have a mounting surface 41. The mounting surface 41 is located between the first terminal 20 and the second terminal 30. The mounting surface 41 is the surface on which the chip fuse 50 is mounted. The mounting surface 41 is perpendicular to the second direction D2 (hereinafter referred to as the up-down direction). The second direction D2 coincides with the plate thickness direction of the plate-like parts 21, 31.

[0035] (First connection portion 24) A first connection portion 24, which is a part of the outer surface of the plate-shaped portion 21, is exposed from the mounting surface 41. The first connection portion 24 is exposed from the resin portion 40 next to the mounting surface 41. The first connection portion 24 is arranged at an end of the first terminal 20 closer to the second terminal 30 in the first direction D1. The first connection portion 24 is arranged flush with the mounting surface 41. In other words, the first connection portion 24 is parallel to the mounting surface 41 and is arranged at the same position as the mounting surface 41 in the second direction D2. The first connection portion 24 is continuous with the mounting surface 41 in the first direction D1. Here, "flush" refers to a state in which two parallel surfaces are smoothly connected without any steps, but in this specification, it is intended to include not only a state in which they are flush with each other, but also a state that is recognized as being substantially flush with each other. A state that is recognized as being substantially flush means, for example, a state in which a slight step appears between the mounting surface 41 and the first connection portion 24 due to manufacturing tolerances, thermal expansion, etc., or a state in which the mounting surface 41 and the first connection portion 24 slightly intersect and are not strictly parallel.

[0036] (Second connection portion 34) The second connection portion 34, which is part of the outer surface of the plate-shaped portion 31, is exposed from the mounting surface 41. The second connection portion 34 is exposed from the resin portion 40 next to the mounting surface 41. The second connection portion 34 is arranged at an end of the second terminal 30 closer to the first terminal 20 in the first direction D1. The second connection portion 34 is arranged flush with the mounting surface 41.

[0037] (Peripheral wall part 42) As shown in FIG. 1, the resin part 40 has a peripheral wall part 42 that protrudes further than the first connection part 24 and the second connection part 34. The peripheral wall part 42 protrudes, for example, in a direction perpendicular to the first connection part 24 and the second connection part 34. The peripheral wall part 42 also extends, for example, from the mounting surface 41 to one side (upward) in the second direction D2. The peripheral wall part 42 is arranged to surround the chip fuse 50 in a direction perpendicular to the second direction D2. The peripheral wall part 42 is arranged so as not to come into contact with the chip fuse 50. As shown in FIG. 3, the height of the peripheral wall part 42 from the mounting surface 41 (the dimension in the second direction D2) is greater than the height of the chip fuse 50.

[0038] (Chip fuse 50) As shown in FIG. 1, the chip fuse 50 has a first electrode 51 and a second electrode 52. When the chip fuse 50 melts due to a large current flowing through it, the first electrode 51 and the second electrode 52 are electrically insulated from each other. The chip fuse 50 is placed on a mounting surface 41. The first electrode 51 is disposed on the first connecting portion 24, and the second electrode 52 is disposed on the second connecting portion 34. The first electrode 51 and the first connecting portion 24 are connected by soldering. The second electrode 52 and the second connecting portion 34 are connected by soldering. That is, the chip fuse 50 is mounted on an intermediate molded body 43 (see FIG. 5) that includes the first terminal 20, the second terminal 30, and the resin portion 40. Therefore, the chip fuse 50 can be easily incorporated into the fuse unit 10 by a mounting process (see FIG. 6).

[0039] The fuse unit 10 constitutes a member for mounting the chip fuse 50 without using a flexible printed circuit (FPC). That is, the first terminal 20, the second terminal 30, and the resin part 40 form the first connecting part 24 and the second connecting part 34 on which the chip fuse 50 can be mounted. Therefore, the manufacturing cost of the fuse unit 10 can be easily reduced.

[0040] (Wiring module 1) The fuse unit 10 of this embodiment can be used, for example, in an energy storage module mounted on a vehicle such as an electric vehicle or a hybrid vehicle. The energy storage module includes a plurality of energy storage elements (not shown) and a wiring module 1 attached to the plurality of energy storage elements. As shown in FIG. 7 , the wiring module 1 includes the fuse unit 10, a bus bar 60 connected to the mating member connecting portion 23 of the first terminal 20, and an electric wire 70 connected to the barrel portion 33 of the second terminal 30. The bus bar 60 is connected to the electrode terminals of the plurality of energy storage elements. The electric wire 70 is connected to an ECU (Electronic Control Unit) or the like via a connector (not shown). The electric wire 70 functions as a voltage detection line.

[0041] The wiring module 1 including the fuse unit 10 has an electric wire 70 instead of an FPC as a voltage detection line. Therefore, the wiring module 1 can be manufactured at lower cost than a wiring module in which an FPC is used as a voltage detection line.

[0042] (Method of manufacturing fuse unit 10) The above is the configuration of the fuse unit 10. Below, we will explain one example of a method for manufacturing the fuse unit 10. First, a metal plate is pressed to form the first terminal 20 and the second terminal 30 (terminal forming step, see FIG. 4).

[0043] Next, a resin part 40 is insert-molded using a portion of the first terminal 20 and a portion of the second terminal 30 as insert parts (resin part forming process). The first terminal 20 and the second terminal 30 are placed in a mold, and molten resin, which is the raw material of the resin part 40, is filled into the mold. At this time, the first terminal 20 and the second terminal 30 are arranged so that they do not come into direct contact with each other. Furthermore, the first terminal 20 and the second terminal 30 are appropriately positioned in the mold so that the first connecting part 24 and the second connecting part 34 adjacent to the mounting surface 41 are exposed from the resin part 40 and are flush with the mounting surface 41. Once the resin has hardened, the mold is removed, and an intermediate molded body 43 is obtained (see FIG. 5).

[0044] The chip fuse 50 is placed on the placement surface 41 of the intermediate molded body 43, and the first electrode 51 is mounted to the first connection portion 24, and the second electrode 52 is mounted to the second connection portion 34 (mounting step, see FIG. 6). This completes the manufacture of the fuse unit 10.

[0045] (Effects of the first embodiment) (1-1) The fuse unit 10 of the present disclosure comprises a first terminal 20 electrically connected to a mating member (bus bar 60), a second terminal 30 electrically connected directly or indirectly to a wiring member (electric wire 70), a resin part 40 covering a portion of the first terminal 20 and a portion of the second terminal 30, and a chip fuse 50, wherein the resin part 40 maintains a distance between the first terminal 20 and the second terminal 30, the first terminal 20 comprises a first connection part 24 exposed from the resin part 40, the second terminal 30 comprises a second connection part 34 exposed from the resin part 40, and the chip fuse 50 comprises a first electrode 51 mounted on the first connection part 24 and a second electrode 52 mounted on the second connection part 34.

[0046] With this configuration, the chip fuse 50 can be easily mounted and included in the fuse unit 10. Furthermore, even if the mating member or wiring member is changed, there may be no need to redesign the fuse unit 10, which reduces the manufacturing cost of the fuse unit 10.

[0047] (1-2) In the first embodiment, the resin portion 40 has a peripheral wall portion 42 that has a portion that protrudes beyond the first connection portion 24 and the second connection portion 34 and is disposed around the chip fuse 50 .

[0048] With this configuration, the chip fuse 50 can be protected by the peripheral wall portion 42.

[0049] (1-3) In the first embodiment, the peripheral wall portion 42 surrounds the first connecting portion 24 and the second connecting portion 34.

[0050] With this configuration, the peripheral wall portion 42 can prevent foreign matter and the like from coming into contact with the chip fuse 50, thereby preventing stress from occurring in the connection portion between the first connection portion 24 and the first electrode 51, and the connection portion between the second connection portion 34 and the second electrode 52.

[0051] (1-4) The manufacturing method of the fuse unit 10 of the present disclosure includes a terminal forming process for forming the first terminal 20 and the second terminal 30, a resin part forming process for forming, by insert molding, a resin part 40 that covers a portion of the first terminal 20 and a portion of the second terminal 30, exposing the outer surface of the first terminal 20 as the first connection part 24 and the outer surface of the second terminal 30 as the second connection part 34, and an mounting process for mounting the first electrode 51 of a chip fuse 50 having a first electrode 51 and a second electrode 52 to the first connection part 24 and the second electrode 52 to the second connection part 34.

[0052] According to this method of manufacturing the fuse unit 10, by forming the resin part 40 that exposes the first connecting part 24 and the second connecting part 34 in the resin part formation step, the chip fuse 50 can be easily included in the fuse unit 10 in the mounting step. Furthermore, even if the components to which the first terminal 20 and the second terminal 30 are connected are changed, there may be no need to redesign the fuse unit 10, thereby reducing the manufacturing cost of the fuse unit 10.

[0053] <Embodiment 2> A second embodiment of the present disclosure will be described with reference to Figures 8 and 9. A fuse unit 110 according to the second embodiment is configured similarly to the first embodiment except that it further includes a lid portion 144 (an example of a cover member), and therefore, a description of the same members, functions, and effects as those of the first embodiment will be omitted.

[0054] (Lid part 144) The lid portion 144 is made of insulating synthetic resin, insulating tape, or the like. As shown in Fig. 9, the lid portion 144 is attached to the upper end surface of the peripheral wall portion 42, and closes the opening 42A formed by the peripheral wall portion 42. The lid portion 144 and the chip fuse 50 are disposed with a space between them. The fuse unit 110 of the second embodiment can be manufactured by attaching the lid portion 144 to the fuse unit 10 of the first embodiment.

[0055] According to the configuration of the second embodiment, the lid portion 144 can prevent water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 melts, it is possible to prevent the first connecting portion 24 and the second connecting portion 34 from becoming electrically conductive through the water droplets.

[0056] <Embodiment 3> A third embodiment of the present disclosure will be described with reference to Figures 10 and 11. A fuse unit 210 according to the third embodiment is configured similarly to the first embodiment except that it further includes a sealing portion 245 (an example of a cover member), and therefore, a description of the same members, actions, and effects as those of the first embodiment will be omitted.

[0057] (Sealing portion 245) The sealing portion 245 is made of a curable insulating resin. The sealing portion 245 may be made of a resin different from the synthetic resin that makes up the resin portion 40. The sealing portion 245 may be transparent. The sealing portion 245 of the third embodiment is, for example, a potting agent. As shown in FIG. 11 , the sealing portion 245 is arranged so as to fill the space within the opening 42A of the peripheral wall portion 42. The sealing portion 245 is in close contact with the outer surface of the chip fuse 50, the first connecting portion 24, the second connecting portion 34, and the mounting surface 41. The sealing portion 245 is formed by filling the opening 42A with uncured liquid insulating resin after the mounting process and curing the insulating resin. A bottomed recess is formed inside peripheral wall 42 by the inner circumferential surface of peripheral wall 42, a surface of resin part 40 between first terminal 20 and second terminal 30 that is exposed inside peripheral wall 42, a surface of first terminal 20 that is exposed inside peripheral wall 42, and a surface of second terminal 30 that is exposed inside peripheral wall 42. Therefore, by arranging molten sealing part 245 in this recess, chip fuse 50, the connection part between first connecting part 24 and first electrode 51, and the connection part between second connecting part 34 and second electrode 52 can be easily covered by sealing part 245.

[0058] (Through hole 246) Furthermore, a through hole 246 may be formed in the resin part 40. This through hole 246 penetrates through the mounting surface 41 and the lower surface of the resin part 40. The through hole 246 exposes a part of the outer surface of the chip fuse 50 that is different from the first electrode 51 and the second electrode 52 to the outside. In other words, the entire outer surface of the chip fuse 50 is not covered by the sealing part 245 and the resin part 40. The first electrode 51 and the second electrode 52 are not exposed to the outside through the through hole 246. The through hole 246 may be formed, for example, in the resin part forming process or after the resin part forming process.

[0059] According to the configuration of the third embodiment, the sealing portion 245 can prevent water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 melts, it is possible to prevent the first connecting portion 24 and the second connecting portion 34 from becoming electrically conductive through the water droplets.

[0060] <Embodiment 4> A fourth embodiment of the present disclosure will be described with reference to Fig. 12. A fuse unit 310 according to the fourth embodiment is configured substantially similarly to the third embodiment except for the configuration of a sealing portion 345 (an example of a cover member), and therefore, descriptions of the same members, functions, and effects as those of the first and third embodiments will be omitted.

[0061] (Sealing portion 345) The sealing portion 345 in the fourth embodiment is, for example, a moisture-proof coating agent. The sealing portion 345 is in close contact with the outer surface of the chip fuse 50, the first connecting portion 24, the second connecting portion 34, and the mounting surface 41 within the opening 42A of the peripheral wall portion 42. The sealing portion 345 does not have to fill the entire space within the opening 42A.

[0062] <Embodiment 5> A fifth embodiment of the present disclosure will be described with reference to Fig. 13. A fuse unit 410 according to the fifth embodiment is configured substantially similarly to the first embodiment except for the configuration of the second terminal 430, and therefore, descriptions of the same components, functions, and effects as those of the first embodiment will be omitted.

[0063] (wire holder 435) The second terminal 430 includes a plate-shaped portion 31, an electric wire connecting portion 434, and an electric wire pressing portion 435 (an example of a fixing portion). The electric wire connecting portion 434 is a plate-shaped member extending in the first direction D1 from the plate-shaped portion 31. The electric wire connecting portion 434 is connected to a core wire of the electric wire 70 by soldering. The electric wire pressing portion 435 is disposed on the opposite side of the electric wire connecting portion 434 from the plate-shaped portion 31. The electric wire pressing portion 435 includes a base portion 435A formed continuously from the electric wire connecting portion 434 in the first direction D1, and an extending portion 435B extending in a cantilevered manner from the base portion 435A in a third direction D3 (the width direction of the second terminal 430). The insulating coating of the electric wire 70 is clamped by the base portion 435A and the extending portion 435B bent toward the base portion 435A. This allows the electric wire 70 to be fixed to the second terminal 430. Note that the second terminal 430 does not necessarily have to include the electric wire pressing portion 435.

[0064] <Embodiment 6> A sixth embodiment of the present disclosure will be described with reference to Figures 14 and 15. A fuse unit 510 according to the sixth embodiment is configured substantially similarly to the first embodiment except for the absence of a peripheral wall portion 42 and the configuration of plate-shaped portions 521 and 531, and therefore descriptions of the same components, functions, and effects as those of the first embodiment will be omitted.

[0065] The fuse unit 510 includes a first terminal 520, a second terminal 530, a resin part 540, and a chip fuse 50. As shown in Fig. 15, the resin part 540 does not have a peripheral wall part 42. The upper surface of the resin part 540 serves as the mounting surface 41.

[0066] The plate-shaped portion 521 of the first terminal 520 includes a first plate portion 521A, a second plate portion 521B, and a third plate portion 521C. The second plate portion 521B and the third plate portion 521C are formed narrower than the first plate portion 521A (see FIG. 14). The first plate portion 521A is a plate-shaped member continuous with the mating member connecting portion 23 in the first direction D1. The second plate portion 521B extends upward from an end of the first plate portion 521A opposite the mating member connecting portion 23 in the first direction D1. The third plate portion 521C extends in the first direction D1 from the upper end of the second plate portion 521B. The third plate portion 521C and the first plate portion 521A extend in opposite directions to each other in the first direction D1 relative to the second plate portion 521B. The upper surface of the third plate portion 521C serves as the first connecting portion 24.

[0067] The plate-shaped portion 531 of the second terminal 530 includes a first plate portion 531A, a second plate portion 531B, and a third plate portion 531C. The second plate portion 531B and the third plate portion 531C are formed narrower than the first plate portion 531A (see FIG. 14). The first plate portion 531A is a portion that is continuous with the barrel portion 33 in the first direction D1. The second plate portion 531B extends upward from an end of the first plate portion 531A opposite the barrel portion 33 in the first direction D1. The third plate portion 531C extends in the first direction D1 from the upper end of the second plate portion 531B. The third plate portion 531C and the first plate portion 531A extend in opposite directions to each other in the first direction D1 relative to the second plate portion 531B. The upper surface of the third plate portion 531C serves as the second connection portion 34.

[0068] <Embodiment 7> A seventh embodiment of the present disclosure will be described with reference to Figures 16 to 28. Unlike the first to sixth embodiments, the fuse unit 610 according to the seventh embodiment further includes a third terminal 680, and the second terminal 630 and the electric wire 70 are connected via the third terminal 680. Hereinafter, descriptions of the same components, functions, and effects as those of the first embodiment may be omitted.

[0069] 16 and 17, the fuse unit 610 includes a first terminal 620, a second terminal 630, a resin part 640, and a chip fuse 50. Furthermore, as shown in Fig. 18, the fuse unit 610 includes a third terminal 680 disposed inside the resin part 640. The third terminal 680 is connected to the electric wire 70.

[0070] (First terminal 620, notch 625) 28, the first terminal 620 has a plate-like portion 21, a through hole 22, two recesses 21A, a mating member connecting portion 23, and a first connecting portion 24, similar to the first terminal 20 of the first embodiment. The first terminal 620 also has a notch 625, which is a configuration different from the first terminal 20 of the first embodiment. The notch 625 is formed as a pair by being recessed from an outer edge portion on one side in the extension direction of the first terminal 620. The first connecting portion 24 is defined by the notch 625. In other words, the first connecting portion 24 and the notch 625 are adjacent to each other in the width direction of the first terminal 620. The notch 625 appropriately sets the area of ​​the first connecting portion 24 in a plan view.

[0071] If the notch 625 is not provided, when the first electrode 51 of the chip fuse 50 and the first connection portion 24 are connected by soldering, there is a possibility that the heat transfer to the first terminal 620 will be large. However, in this embodiment, by appropriately adjusting the size of the first connection portion 24 using the notch 625, the heat transfer to the first terminal 620 can be appropriately controlled.

[0072] (Second terminal 630, tab portion 633) Similar to the second terminal 30 of the first embodiment, the second terminal 630 has a plate-shaped portion 31, a through-hole 32, two recesses 31A, and a second connection portion 34. The plate-shaped portion 31 has two recesses 31A at both ends in the width direction of the second terminal 30 (a direction perpendicular to both the extension direction of the second terminal 30 and the thickness direction of the plate-shaped portion 31). The recesses 31A are recessed from the edge of the second terminal 30 in the width direction. The second terminal 630 also has a tab portion 633 (an example of a first terminal connection portion). The tab portion 633 is formed continuous with the plate-shaped portion 31 in the extension direction of the second terminal 630. The tab portion 633 is rod-shaped and extends from the edge of the plate-shaped portion 31 in the extension direction of the second terminal 630.

[0073] (Notch 635) Similar to the first terminal 620, the second terminal 630 is provided with a notch 635. The notch 635 is formed as a pair by being recessed from the outer edge of the second terminal 630 on the side opposite the tab portion 633 in the extension direction. The second connection portion 34 is defined by the notch 635. In other words, the second connection portion 34 and the notch 635 are adjacent to each other in the width direction of the second terminal 630. The notch 635 appropriately sets the area of ​​the second connection portion 34 in a plan view. By appropriately adjusting the size of the second connection portion 34 using the notch 635, it is possible to appropriately control heat conduction to the second terminal 630.

[0074] (3rd terminal 680) The third terminal 680 is made of a conductive metal. The metal constituting the third terminal 680 may be different from the metal constituting the first terminal 620 and the metal constituting the second terminal 630. As shown in FIG. 19 , the third terminal 680 includes a connecting tubular portion 681 (an example of a second terminal connecting portion) connected to the second terminal 630, and a barrel portion 682. The barrel portion 682 is formed continuous with the connecting tubular portion 681 in the extension direction of the third terminal 680. The barrel portion 682 includes a core wire crimping portion 682A crimped to the core wire of the electric wire 70, and an insulating coating crimping portion 682B crimped to the insulating coating of the electric wire 70.

[0075] (Connecting tube part 681) The connecting tube portion 681 includes a tube wall portion 683 having, for example, a rectangular tube shape and a resilient contact piece 684 formed inside the tube wall portion 683. The tube wall portion 683 is open in the first direction D1. The resilient contact piece 684 extends from the inner surface of the tube wall portion 683 and is resiliently deformable in a direction perpendicular to the first direction D1. The connecting tube portion 681 also has a locking hole 683A formed through the tube wall portion 683. As shown in FIGS. 18 to 20 , the tab portion 633 of the second terminal 630 is inserted into the tube wall portion 683, and the resilient contact piece 684 comes into contact with the tab portion 633, thereby electrically connecting the third terminal 680 and the second terminal 630. That is, the connecting tube portion 681 and the tab portion 633 are electrically connected by fitting. Therefore, the second terminal 630 and the electric wire 70 are electrically connected via the third terminal 680.

[0076] In this embodiment, the second terminal 630 is not directly connected to the electric wire 70, but is indirectly connected to the electric wire 70 via the third terminal 680. Therefore, when electrically connecting the fuse unit 610 and the electric wire 70, for example, it is possible to prevent the connection portion between the chip fuse 50 and the second terminal 630 from being damaged by stress or the like. This makes it easier to ensure the reliability of the electrical connection between the fuse unit 610 and the electric wire 70.

[0077] (Resin part 640) As shown in FIG. 25 , the resin portion 640 covers a portion of the first terminal 620 and a portion of the second terminal 630. As in the first embodiment, the resin portion 640 is formed integrally with the first terminal 620 and the second terminal 630 by insert molding. The first terminal 620 and the second terminal 630 are each fixed to the resin portion 640. The resin portion 640 has an intermediate portion 641 disposed between the first terminal 620 and the second terminal 630 in the first direction D1. The resin portion 640 maintains a distance between the first terminal 620 and the second terminal 630. The resin portion 640 exposes the first connection portion 24, which is a portion of the outer surface of the plate-shaped portion 21, and the second connection portion 34, which is a portion of the outer surface of the plate-shaped portion 31. The first connection portion 24 and the second connection portion 34 are disposed at a predetermined distance in the first direction D1 by the resin portion 640. Furthermore, the resin part 640 exposes the mating member connecting part 23 to the outside.

[0078] 26, one end face (upper side) of the intermediate portion 641 in the second direction D2 is set as a reference surface 641A. The reference surface 641A is arranged flush with the first connecting portion 24 (outer surface of the plate-shaped portion 21) and the second connecting portion 34 (outer surface of the plate-shaped portion 31). The reference surface 641A is perpendicular to the second direction D2 (up-down direction). The second direction D2 coincides with the plate thickness direction of the plate-shaped portions 21, 31.

[0079] 18, the resin part 640 may have a through hole 246, similar to the third embodiment. The through hole 246 penetrates the intermediate part 641 in the second direction D2.

[0080] 26 and 27, the resin part 640 includes a peripheral wall 42, similar to the first embodiment. The peripheral wall 42 extends from the reference surface 641A to one side (upward) in the second direction D2. That is, the peripheral wall 42 has a portion that protrudes upward beyond the first connection portion 24 and the second connection portion 34. The peripheral wall 42 is disposed around the chip fuse 50. The peripheral wall 42 also surrounds the first connection portion 24 and the second connection portion 34 in a direction perpendicular to the second direction D2.

[0081] (Groove 641B) The intermediate portion 641 has a groove 641B recessed from the reference surface 641A toward the other side (downward) in the second direction D2. The groove 641B is recessed downward relative to the first connecting portion 24 and the second connecting portion 34. As shown in FIG. 26, the groove 641B is composed of a bottom surface BS that is substantially parallel to the reference surface 641A, a first inner surface S1 connecting the bottom surface BS to the first connecting portion 24, a second inner surface S2 connecting the bottom surface BS to the second connecting portion 34, and a third inner surface S3 connecting the bottom surface BS to the reference surface 641A. The groove 641B is adjacent to each of the first connecting portion 24 and the second connecting portion 34 when viewed from a direction (the second direction D2) perpendicular to the first connecting portion 24 and the second connecting portion 34. As shown in FIG. 18, the bottom surface BS faces the chip fuse 50 in the second direction D2. A gap is provided between the bottom surface BS and the chip fuse 50. As shown in FIGS. 26 and 27, a portion of the groove 641B is disposed inside the notches 625 and 635.

[0082] 27, by providing a groove 641B in the resin part 640, a part of the side surface of the first terminal 620 continuing from the outer edge of the first connecting part 24 (hereinafter referred to as the first side surface portion SP1) may be exposed from the resin part 640. The first connecting part 24 and the first inner surface S1 may be connected via the first side surface portion SP1. Similarly, by providing a groove 641B in the resin part 640, a part of the side surface of the second terminal 630 continuing from the outer edge of the second connecting part 34 (hereinafter referred to as the second side surface portion) may be exposed from the resin part 640. The second connecting part 34 and the second inner surface S2 may be connected via the second side surface portion.

[0083] The first connecting portion 24 and the groove 641B The second connecting portion 34 and the groove may be directly connected to each other. 641B It may be directly connected to the inner surface of the

[0084] If the groove 641B were not provided, when the resin portion 640 was formed by insert molding, the molten resin would migrate to the outer surfaces (top surfaces) of the first connecting portion 24 and the second connecting portion 34, which could result in burrs on the first connecting portion 24 and the second connecting portion 34. In such a case, the burrs could cause a poor electrical connection between the first connecting portion 24 and the first electrode 51 or between the second connecting portion 34 and the second electrode 52. However, in this embodiment, the groove 641B is provided in the intermediate portion 641. Therefore, when the resin portion 640 is formed, the molten resin is more likely to migrate into the groove 641B than to the top surfaces of the first connecting portion 24 and the second connecting portion 34. This makes it possible to prevent burrs from being generated on the first connecting portion 24 and the second connecting portion 34.

[0085] 18 and 25, the resin portion 640 includes a housing portion 643 formed continuously with the intermediate portion 641 and the peripheral wall portion 42. The housing portion 643 extends on the opposite side of the intermediate portion 641 from the first terminal 620. The housing portion 643 has a cavity 644 in which the third terminal 680 is accommodated. The cavity 644 extends in the first direction D1 and opens to one side in the first direction D1 (the right side in the figure). The tab portion 633 of the second terminal 630 and a part of the plate-like portion 31 that is the base end of the tab portion 633 are disposed at the end of the cavity 644 on the other side in the first direction D1 (the left side in the figure).

[0086] As shown in FIG. 25, the housing portion 643 includes a bottom wall 643A (see FIG. 18), a pair of side walls 643B, and a ceiling wall 643C. As shown in FIG. 22, the pair of side walls 643B extend from both end portions of the bottom wall 643A in the third direction D3 to one side (upward) in the second direction D2. As shown in FIG. 18, the ceiling wall 643C faces the bottom wall 643A in the second direction D2. As shown in FIG. 25, the ceiling wall 643C connects one end portion (upper end portion) of the pair of side walls 643B in the second direction D2. The cavity 644 is an internal space defined by the bottom wall 643A, the pair of side walls 643B, and the ceiling wall 643C.

[0087] 18, a first communication hole 643C1 is provided in a portion of the top wall 643C closer to the middle portion 641. The first communication hole 643C1 penetrates the top wall 643C in the second direction D2 and communicates with the cavity 644. A second communication hole 643A1 is provided in an end portion of the bottom wall 643A closer to the middle portion 641. The second communication hole 643A1 penetrates the bottom wall 643A in the second direction D2 and communicates with the cavity 644.

[0088] As shown in Fig. 25, a mounting recess 645 for mounting a retainer 690 (described later) is formed in approximately two-thirds of the area on the other side (left side in the figure) of the housing portion 643 in the first direction D1. The mounting recess 645 has a first mounting recess 645A recessed from the outer surface of the ceiling wall 643C and a second mounting recess 645B recessed from the outer surfaces of the pair of side walls 643B. Note that an end of the first mounting recess 645A closer to the intermediate portion 641 extends to the peripheral wall portion 42. As shown in Fig. 18, the first mounting recess 645A communicates with a first communication hole 643C1.

[0089] As shown in FIG. 25, the second mounting recess 645B communicates with the first mounting recess 645A. The housing portion 643 includes a shaft portion 646, a temporary locking portion 647, and a full locking portion 648, which protrude from the inner wall of the second mounting recess 645B in the third direction D3. The shaft portion 646 is generally cylindrical. The shaft portion 646 is disposed on a portion of the inner wall of the second mounting recess 645B closer to the middle portion 641 in the first direction D1. The temporary locking portion 647 and the full locking portion 648 are disposed on an end of the inner wall of the second mounting recess 645B opposite the middle portion 641 in the first direction D1. The temporary locking portion 647 and the full locking portion 648 are disposed close to each other. The temporary locking portion 647 is disposed on one side (the right side in the figure) of the full locking portion 648 in the first direction D1. As shown in FIG. 22, the temporary locking portion 647 is disposed on one side (above) of the full locking portion 648 in the second direction D2.

[0090] (Retainer 690) As shown in FIGS. 16 to 18 , the fuse unit 610 of this embodiment includes a retainer 690 that is attached to the resin part 640. The retainer 690 is made of insulating synthetic resin. The retainer 690 is configured to be attached to the resin part 640 at a temporary locking position (see FIG. 23 ) and a full locking position (see FIG. 21 ). As shown in FIG. 22 , the retainer 690 has a generally gate-like shape when viewed from the first direction D1. As shown in FIG. 16 , the retainer 690 includes a main body 691, a pair of locking pieces 692, and a pair of side walls 693. The pair of locking pieces 692 and the pair of side walls 693 extend from both ends of the main body 691 in the third direction D3. The locking pieces 692 are disposed on one side (the right side in the figure) of the side walls 693 in the first direction D1. As shown in FIG. 22 , the main body 691 is configured to be housed in the first mounting recess 645A. The pair of lock pieces 692 and the pair of side walls 693 are adapted to be housed in the second mounting recess 645B.

[0091] 18, the retainer 690 includes a lance 694 and a retaining portion 695. The lance 694 extends from the main body portion 691 to the other side in the first direction D1 (to the left in the figure) and also to the other side (downward) in the second direction D2. The lance 694 is elastically deformable with respect to the main body portion 691. The retaining portion 695 protrudes from the main body portion 691 to the other side (downward) in the second direction D2. The retaining portion 695 is generally block-shaped.

[0092] 19 and 20, when retainer 690 is in the temporary locking position, retaining portion 695 does not enter cavity 644, and only the tip of lance 694 enters cavity 644 via first communicating hole 643C1. When retainer 690 is in the temporary locking position, third terminal 680 is allowed to be inserted from the opening on one side (the right side in the figure) of cavity 644 in the first direction D1. This is because retaining portion 695 is not positioned to interfere with third terminal 680, and lance 694 can elastically deform even if it interferes with third terminal 680.

[0093] As shown in FIG. 18 , when the retainer 690 is in the full locking position, the lance 694 and the retaining portion 695 are disposed within the cavity 644 via the first communicating hole 643C1. When the third terminal 680 is disposed in the correct position within the cavity 644, the lance 694 engages with the inner wall of the locking hole 683A of the third terminal 680. The retaining portion 695 engages with an end portion of the connecting tube portion 681 on one side (the right side in the figure) in the first direction D1. This allows the third terminal 680 to be held within the cavity 644. That is, the third terminal 680 can be held relative to the resin portion 640. Note that the third terminal 680 abuts against an edge (see FIG. 25 ) of the plate-like portion 31 of the second terminal 630 disposed within the cavity 644, thereby restricting movement of the third terminal 680 from the correct position within the cavity 644 to the other side (the left side in the figure) in the first direction D1. Whether the third terminal 680 is in a normal position in the cavity 644 or is in a partially inserted state can be confirmed by the second communication hole 643A1.

[0094] 21 and 23, retainer 690 has an insertion hole 693A that penetrates side wall 693 in third direction D3. Shaft 646 is inserted into insertion hole 693A. Retainer 690 is rotatable about shaft 646, and is movable between a partial locking position and a full locking position.

[0095] As shown in Fig. 24, retainer 690 has a locking protrusion 692A that protrudes from the tip of lock piece 692 toward the inner wall of second mounting recess 645B. Locking protrusion 692A is disposed between temporary locking portion 647 and full locking portion 648, thereby holding retainer 690 in the temporary locking position. As shown in Fig. 22, locking protrusion 692A is disposed on the other side (downward) of full locking portion 648 in the second direction D2, thereby holding retainer 690 in the full locking position. In detail, when retainer 690 is in the full locking position, locking protrusion 692A is engaged with full locking portion 648, thereby preventing retainer 690 from rotating counterclockwise in Fig. 21 from the full locking position. Furthermore, the engagement between the main body 691 and the inner wall of the first mounting recess 645A prevents the retainer 690 from rotating clockwise in FIG. 21 from the main engagement position.

[0096] (Method of manufacturing fuse unit 610) The above is the configuration of the fuse unit 610, and below, an example of a method for manufacturing the fuse unit 610 will be described. First, as in the example of a method for manufacturing the fuse unit 10 of embodiment 1, the resin part 640 is integrally molded with the first terminal 620 and the second terminal 630 by insert molding (see FIG. 25). Then, the first electrode 51 and the second electrode 52 of the chip fuse 50 are mounted on the first connecting part 24 and the second connecting part 34, respectively.

[0097] Next, retainer 690 is attached to resin part 640, and retainer 690 is placed in the temporary locking position. That is, shaft part 646 is inserted into insertion hole 693A, and locking protrusion 692A is placed in the gap between temporary locking part 647 and full locking part 648.

[0098] With retainer 690 in the temporary locking position, third terminal 680, which is formed in advance from a metal plate and connected to electric wire 70, is inserted (see FIG. 19). During the insertion of third terminal 680, lance 694 interferes with connecting tubular portion 681 and is elastically deformed. When third terminal 680 is inserted into the correct position in cavity 644, lance 694 elastically returns to its original position and enters locking hole 683A (see FIG. 20).

[0099] Once the third terminal 680 is positioned properly in the cavity 644, the retainer 690 is moved to the full-locking position. When the retainer 690 is rotated clockwise in FIG. 23 from the partial-locking position, the locking piece 692 is elastically deformed, and the locking protrusion 692A moves over the full-locking portion 648. When the locking protrusion 692A moves toward the other side (downward) in the second direction D2 relative to the full-locking portion 648, the locking piece 692 elastically returns to its original position, and the retainer 690 reaches the full-locking position (see FIG. 22). During this time, the lance 694 enters the depth of the locking hole 683A, and the lance 694 and the inner wall of the locking hole 683A are arranged to be engageable with each other (see FIG. 18). The retaining portion 695 is arranged on one side (the right side in the figure) of the connecting tube portion 681 in the first direction D1, and is arranged to be engageable with the connecting tube portion 681. This causes the third terminal 680 to be held in the cavity 644. This completes the manufacturing of the fuse unit 610.

[0100] (Effects of the Seventh Embodiment) (7-1) The fuse unit 610 according to the seventh embodiment further includes a third terminal 680 to which a wiring member (electric wire 70) is connected, the second terminal 630 includes a first terminal connection portion (tab portion 633) connected to the third terminal 680, and the third terminal 680 includes a second terminal connection portion (connection tube portion 681) connected to the first terminal connection portion by fitting.

[0101] With this configuration, the wiring member and the second terminal 630 can be easily connected.

[0102] (7-2) The fuse unit 610 according to the seventh embodiment further includes a retainer 690 that is assembled to the resin part 640 and holds the third terminal 680 .

[0103] With this configuration, the third terminal 680 can be held relative to the resin part 640, and therefore the position of the third terminal 680 relative to the resin part 640 can be easily determined.

[0104] (7-3) In the seventh embodiment, the first terminal 620 or the second terminal 630 has a notch 625 or 635 recessed from the outer edge, and the notch 625 or 635 defines the first connecting portion 24 or the second connecting portion 34.

[0105] With this configuration, the first connection portion 24 or the second connection portion 34 is defined by the notches 625, 635, so that the size of the first connection portion 24 or the second connection portion 34 can be appropriately adjusted, and heat dissipation from the first connection portion 24 or the second connection portion 34 can be controlled when the chip fuse 50 is implemented.

[0106] (7-4) In embodiment 7, a groove 641B is formed in the resin part 640, which is recessed toward the first connecting part 24 and the second connecting part 34, and the inner surfaces (first inner surface S1 and second inner surface S2) constituting the groove 641B are continuous with the first connecting part 24 and the second connecting part 34, and a portion of the groove 641B is arranged inside the cutouts 625, 635.

[0107] With this configuration, when forming the resin portion 640, it is possible to prevent the molten resin from migrating to the outer surfaces of the first connecting portion 24 and the second connecting portion 34 through the cutouts 625, 635. This makes it possible to prevent burrs from being formed on the first connecting portion 24 and the second connecting portion 34.

[0108] (Other embodiments) The above-described first to seventh embodiments can be modified as follows: The above-described first to seventh embodiments and the following modifications can be combined and implemented as long as no technical contradiction occurs.

[0109] The shapes of the first terminal, the second terminal, and the resin portion, as well as their relative arrangement, are not limited to those described in the first to seventh embodiments, and can be modified as appropriate within the scope of achieving the object of the present disclosure.

[0110] In the first embodiment, the end faces of the first terminal 20 and the second terminal 30 in the third direction D3 are substantially flush with the end face of the resin part 40 in the third direction D3 (see FIG. 1 ), but the end faces of the first terminal and the second terminal in the third direction D3 do not have to be substantially flush with the end face of the resin part in the third direction D3. For example, as a modification of the first embodiment, as shown in FIG. 29 , the resin part 40 may cover the end faces of the first terminal 20 and the second terminal 30 in the third direction D3.

[0111] In the first embodiment, the mating member is the bus bar 60, but the mating member does not have to be a bus bar and may be, for example, an electrode terminal.

[0112] In the first embodiment, the wiring member is an electric wire 70, but the wiring member does not have to be an electric wire. For example, as shown in FIG. 30 , a fuse unit 710 may include a second terminal 730 connected to a flexible substrate 770, which is an example of a wiring member. Here, the flexible substrate 770 is, for example, a flexible printed circuit board or a flexible flat cable. The flexible substrate 770 and the second terminal 730 may be connected by, for example, soldering.

[0113] In the above-described first embodiment, the mounting surface 41 of the resin part 40 is flush with the first connection portion 24 of the first terminal 20 and the second connection portion 34 of the second terminal 30, but the mounting surface may be formed to have a step relative to the first connection portion and the second connection portion.

[0114] In the first embodiment, the resin part 40 has the mounting surface 41 on which the chip fuse 50 is mounted, but the resin part does not have to have a mounting surface. In other words, the resin part does not have to have a surface that comes into contact with the chip fuse, as long as the first electrode and second electrode of the chip fuse are connected to the first connection part of the first terminal and the second connection part of the second terminal, respectively.

[0115] In the seventh embodiment, the fuse unit 610 includes the retainer 690 attached to the resin part 640, but the fuse unit does not have to include a retainer. If a retainer is not provided, the housing part may be provided with a retaining part for holding the third terminal in the cavity.

[0116] In the seventh embodiment, the tab portion 633 is exemplified as the first terminal connection portion, and the connecting tube portion 681 is exemplified as the second terminal connection portion. However, for example, the first terminal connection portion may be the connecting tube portion, and the second terminal connection portion may be the tab portion.

[0117] The shape of the retainer 690 in the seventh embodiment is merely an example, and the shape of the retainer may be changed as desired as long as it functions to secure the third terminal to the resin portion. For example, in the seventh embodiment, the retainer 690 is held at a temporary locking position and a full locking position relative to the resin portion 640. However, it is also possible to set only the full locking position and omit the temporary locking position. Furthermore, the retainer may move linearly rather than rotate relative to the resin portion. [Explanation of symbols]

[0118] 1: Wiring module 10: Fuse unit 20: 1st terminal 21: Plate-shaped part 21A: Recess 22: Through hole 23: Connection part of mating member 24: First connection 30: 2nd terminal 31: Plate-shaped part 31A: Recess 32: Through hole 33: Barrel 33A: Core crimping section 33B: Insulation coating crimping part (fixed part) 34: Second connection part 40: Resin part 41: Placement surface 42: Peripheral wall part 43: Intermediate molding 50: Chip fuse 51: 1st electrode 52: 2nd electrode 60: Busbar (mating component) 70: Electric wire (wiring material) 110: Fuse unit 144: Lid (cover) 210: Fuse unit 245: Sealing part (cover member) 246: Through hole 310: Fuse unit 345: Sealing part (cover member) 410: Fuse unit 430: 2nd terminal 434: Wire connection 435: Wire holder (fixing part) 435A: Base 435B: Extension 510: Fuse unit 520: 1st terminal 521: Plate-shaped part 521A: 1st plate part 521B: 2nd plate part 521C: Third plate part 530: 2nd terminal 531: Plate-shaped part 531A: 1st plate part 531B: 2nd plate part 531C: Third plate part 540: Resin part 610: Fuse unit 620: 1st terminal 625: Cutout 630: 2nd terminal 633: Tab part (first terminal connection part) 635: Cutout 640: Resin part 641: Middle section 641A: Reference plane 641B: Groove 643: Housing 643A: Bottom wall 643A1: 2nd communication hole 643B: Side wall 643C: Ceiling Wall 643C1: 1st communication hole 644: Cavity 645: Mounting recess 645A: First mounting recess 645B: Second mounting recess 646: Shaft 647: Temporary locking part 648: Main locking part 680: 3rd terminal 681: Connection tube part (second terminal connection part) 682: Barrel 682A: Core crimping section 682B: Insulation crimping part 683: Cylinder wall 683A: Locking hole 684: Elastic contact piece 690: Retainer 691: Main body 692: Lock Piece 692A: Locking protrusion 693: Side wall 693A: Through hole 694: Lance 695: Retaining part 710: Fuse unit 730: 2nd terminal 770: Flexible PCB (wiring material) BS: Bottom S1: First inner surface S2: Second inner surface S3: Third inner surface SP1: 1st side part D1: 1st direction D2: Second direction D3: Third direction

Claims

1. a first terminal electrically connected to a mating member; a second terminal electrically connected directly or indirectly to the wiring member; a resin portion covering a portion of the first terminal and a portion of the second terminal; a chip fuse; the resin portion maintains a distance between the first terminal and the second terminal; the first terminal includes a first connection portion exposed from the resin portion, the second terminal includes a second connection portion exposed from the resin portion, the chip fuse includes a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion; At least one of the first terminal and the second terminal has a through hole, The resin portion is disposed within the through hole, a groove recessed relative to the first connecting portion and the second connecting portion is formed in the resin portion; The fuse unit has an inner surface that defines the groove and is continuous with the first connecting portion and the second connecting portion.

2. The fuse unit according to claim 1 , wherein the resin portion includes a peripheral wall portion that has a portion that protrudes beyond the first connection portion and the second connection portion and is disposed around the chip fuse.

3. The fuse unit according to claim 2 , wherein the peripheral wall portion surrounds the first connection portion and the second connection portion.

4. The fuse unit according to claim 1 , further comprising a cover member covering said chip fuse.

Images