Conductive component with terminals

Abstract

To provide a terminal-equipped conductor member that can improve the freedom of wiring and suppress the transmission of vibration from the conductive member to a terminal.SOLUTION: A terminal-equipped conductor member 10 includes a terminal 12, a conductive member 18, and a metal relay portion 34 that electrically connects the terminal 12 and the conductive member 18. The relay portion 34 includes a first fixing portion 20 that is fixed to the terminal 12, a second fixing portion 22 that is fixed to the conductive member 18, and a cylindrical intermediate connecting portion 24 that connects the first fixing portion 20 and the second fixing portion 22. The intermediate connecting portion 24 includes a freely bendable bellows-shaped portion 30 that is formed by alternately connecting multiple peaks 26 and valleys 28 along the axial direction of the intermediate connecting portion 24.SELECTED DRAWING: Figure 1

Description

[[Technical Field]]

[0001] The present disclosure relates to a conductive member with a terminal. [[Background Art]]

[0002] Conventionally, as a current-carrying member between in-vehicle devices, a conductive member with a terminal, in which a terminal is attached to an end of a conductive member such as a coated electric wire or a bus bar, has been widely used. For example, Patent Document 1 discloses an electric wire with a terminal in which a core wire exposed at an end of a coated electric wire is crimped to a barrel portion of the terminal. [[Prior Art Document]] [[Patent Document]]

[0003] [[Patent Document 1]] Japanese Unexamined Patent Application Publication No. 2020-17345 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0004] Incidentally, in order to cope with the increase in current of in-vehicle devices in recent years, the terminals and conductive members in the conductive member with a terminal also tend to increase in size, and their rigidity tends to increase. As a result, it becomes difficult to bend a conductive member such as an electric wire extending from the terminal connected to the mating terminal in accordance with the routing path, leading to a decrease in routing freedom of the conductive member with a terminal. In addition, when the rigidity of the attachment portion between the terminal and the conductive member, such as the crimping portion between the terminal and the electric wire end, is high, vehicle vibration and the like transmitted to the conductive member is easily transmitted to the terminal side, which may cause damage to the counterpart device or the like to which the terminal is connected.

[0005] Therefore, a conductive member with a terminal that can improve routing freedom and suppress vibration transmission from the conductive member to the terminal is disclosed. [[Means for Solving the Problem]]

[0006] The conductive member with a terminal of this disclosure comprises a terminal, a conductive member, and a metal intermediate component that electrically connects the terminal and the conductive member, wherein the intermediate component has a first fixing portion fixed to the terminal, a second fixing portion fixed to the conductive member, and a cylindrical intermediate connecting portion connecting the first fixing portion and the second fixing portion, and the intermediate connecting portion includes a flexible bellows-like portion in which a plurality of peaks and valleys are alternately connected along the axial direction of the intermediate connecting portion. fruit , The conductive member is made of a wire in which a single-core metal wire is insulated, and the second fixing portion is fixed to the single-core wire exposed from the insulation at the end of the wire, and the first fixing portion and the second fixing portion of the relay component each have a cylindrical shape, the first fixing portion is fitted internally or externally to a cylindrical terminal-side fixing portion provided on the terminal and is electromagnetically pressure-welded, and the second fixing portion is fitted externally to a columnar conductive member-side fixing portion provided on the conductive member and is electromagnetically pressure-welded, and the conductive member-side fixing portion is made of the single-core wire. It is. [Effects of the Invention]

[0007] The conductive member with terminals of this disclosure can improve the degree of freedom in cable routing and suppress vibration transmission from the conductive member to the terminals. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing a conductive member with terminals according to Embodiment 1. [Figure 2] Figure 2 is an exploded perspective view of the conductive member with terminals shown in Figure 1. [Figure 3] Figure 3 is a cross-sectional view taken along line III-III in Figure 1. [Figure 4] Figure 4 is a perspective view showing a conductive member with terminals according to Embodiment 2. [Figure 5] Figure 5 is a perspective view showing a conductive member with terminals according to Embodiment 3. [Figure 6] Figure 6 is a perspective view showing a conductive member with terminals according to Embodiment 4. [Figure 7] Figure 7 is a cross-sectional view showing an enlarged view of the VII-VII section in Figure 6. [Figure 8] Figure 8 is a longitudinal cross-sectional view of a conductive member with terminals according to another embodiment, and corresponds to Figure 3. [Figure 9] Figure 9 is a perspective view showing the main parts of a conductive member with terminals according to yet another embodiment. [Modes for carrying out the invention]

[0009] <Description of Embodiments in this Disclosure> First, embodiments of this disclosure will be listed and described. The conductive member with terminals disclosed herein is (1) The device comprises a terminal, a conductive member, and a metal intermediate component that electrically connects the terminal and the conductive member, wherein the intermediate component has a first fixing portion fixed to the terminal, a second fixing portion fixed to the conductive member, and a cylindrical intermediate connecting portion connecting the first fixing portion and the second fixing portion, and the intermediate connecting portion includes a flexible bellows-like portion in which a plurality of peaks and valleys are alternately connected along the axial direction of the intermediate connecting portion.

[0010] In the conductive member with terminals of this disclosure, the terminal and the conductive member are electrically connected via a metal intermediate component. Furthermore, the intermediate component has a cylindrical intermediate connecting portion that connects a first fixing portion fixed to the terminal and a second fixing portion fixed to the conductive member, and is provided with a bendable bellows-like portion. Therefore, by bending the bellows-like portion of the intermediate component placed between the terminal and the conductive member in any direction, it is possible to set the extension direction of the conductive member to any direction. As a result, even when the rigidity of the conductive member is high and bending is difficult, such as when using large-diameter wires or single-core wires, the direction of the conductive member extending from the terminal can be oriented to match the routing path by bending the bellows-like portion of the intermediate component, thereby improving the routing freedom of the conductive member with terminals. In particular, since the intermediate component is made of metal, although it is bendable in the bellows-like portion, it also has excellent ability to maintain the curved shape, and can advantageously maintain an orientation that matches the routing path.

[0011] In addition, even when vehicle vibrations are transmitted to the conductive member, the vibrations can be absorbed by the deformation of the bellows-shaped portion of the intermediate component. As a result, the transmission of vibrations from the conductive member to the terminal can be suppressed, reducing or eliminating the risk of damage to the equipment to which the terminal is connected. Furthermore, the bellows-shaped portion of the intermediate component can also improve tolerance absorption. Moreover, since the terminal and the conductive member are electrically connected by the intermediate component interposed between them, the shape of the second fixing portion is less restricted by the terminal compared to conventional structures such as Patent Document 1, where the terminal and barrel portion are integrated. Therefore, the optimal shape of the first and second fixing portions can be set according to the shape of the terminal and conductive member, as well as the fixing method, thereby advantageously improving the conductivity between the terminal and the conductive member via the intermediate component.

[0012] Furthermore, any conductive material such as insulated wires or busbars can be used as the conductive material. In addition, the bellows-like portion of the intermediate component may be provided along the entire axial length of the intermediate connecting portion, or it may be provided in a part of the axial length of the intermediate connecting portion, or at multiple locations spaced apart from each other.

[0013] (2) In (1) above, it is preferable that the intermediate component is made of a metal flexible pipe having a bellows-shaped portion on the peripheral wall of a hollow cylindrical body, the first and second fixing portions being formed by the ends of the flexible pipe, the intermediate connecting portion being formed by the portion located between the first and second fixing portions, and the bellows-shaped portion being provided along the entire length of the intermediate connecting portion in the axial direction. By using a flexible pipe, it is advantageous to construct an intermediate component having a bellows-shaped portion in the intermediate connecting portion. In particular, since the entire length of the intermediate connecting portion in the axial direction is the bellows-shaped portion, it is possible to secure a long curved portion, and further improvements in the degree of freedom of cable routing can be achieved.

[0014] (3) In (1) or (2) above, it is preferable that the conductive member is constituted by an electric wire in which a single-core metal wire is covered with insulation, and the second fixing portion is fixed to the single-core wire exposed from the insulation coating at an end of the electric wire. When the conductive member is an electric wire in which a single-core wire is covered with insulation, the electric wire tends to be difficult to bend. Therefore, by adopting this configuration in combination with the configuration of (1) above, even when a single-core wire is used, it is possible to advantageously provide a conductive member with a terminal that can improve wiring flexibility and suppress transmission of vehicle vibration. Furthermore, when adopted in combination with the configuration of (2) above, the cylindrical second fixing portion can be externally fitted onto the outer peripheral surface of the single-core wire and stably fixed over the entire circumference, thereby improving the conduction stability of the conductive member with a terminal. For example, a uniform crimped state in the circumferential direction by electromagnetic pressure welding can be advantageously ensured.

[0015] (4) In any one of (1) to (3) above, it is preferable that the first fixing portion and the second fixing portion of the relay component each have a cylindrical shape, the first fixing portion is internally or externally fitted into a cylindrical terminal-side fixing portion provided on the terminal and is electromagnetic pressure-welded, and the second fixing portion is externally fitted onto a columnar conductive member-side fixing portion provided on the conductive member and is electromagnetic pressure-welded. Since the cylindrical first fixing portion is internally or externally fitted to the cylindrical terminal-side fixing portion and electromagnetic pressure-welded, and the cylindrical second fixing portion is externally fitted to the columnar conductive member-side fixing portion and electromagnetic pressure-welded, a uniform crimped state in the circumferential direction by electromagnetic pressure welding can be ensured, and the conductivity between the terminal and the conductive member via the relay component can be advantageously improved.

[0016] (5) In any one of (1), (3) or (4) above, it is preferable that the relay component has a plurality of the bellows portions spaced apart from each other in the axial direction, and a cylindrical portion with a constant diameter disposed between adjacent bellows portions. Since the cylindrical portion with a constant diameter is provided between adjacent bellows portions, the overall amount of deformation can be regulated while securing the degree of freedom in the bending direction of the relay component, and the risk of interference with other members can be suppressed.

[0017] (6) In any one of the above (1) to (5), it is preferable that an inner diameter dimension and an outer diameter dimension of the bellows-shaped portion of the relay component change in the axial direction. By changing the inner and outer diameter dimensions of the bellows-shaped portion in the axial direction, a bellows-shaped large-diameter portion and a bellows-shaped small-diameter portion can be provided at different positions in the axial direction of the relay component, and the bendability of the relay component can be varied in the axial direction. This enables further improvement in routing flexibility.

[0018] <Details of Embodiments of the Present Disclosure> Specific examples of the conductive member with a terminal according to the present disclosure will be described below with reference to the drawings. It should be noted that the present disclosure is not limited to these examples, and is defined by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

[0019] <Embodiment 1> Hereinafter, the conductive member with a terminal 10 according to Embodiment 1 of the present disclosure will be described with reference to FIGS. 1 to 3. The conductive member with a terminal 10 includes a terminal 12, a conductive member (an electric wire 18 to be described later), and a metal relay component (a flexible pipe 34 to be described later) that electrically connects the terminal 12 and the conductive member (the electric wire 18). In Embodiment 1, the conductive member is constituted by an electric wire 18 in which a metal single core wire 14 is covered with an insulating coating 16 made of synthetic resin, and the conductive member with a terminal 10 is routed in a vehicle such as an automobile to form a wire harness, for example. Although the conductive member with a terminal 10 can be arranged in any orientation, in the following description, the front or distal end side refers to the left side in FIG. 3, and the rear or proximal end side refers to the right side in FIG. 3. In addition, the axial direction refers to the left-right direction in FIG. 3, which is the extending direction of the conductive member with a terminal 10. Furthermore, for a plurality of identical members, reference numerals may be given to only some of the members, and reference numerals may be omitted for other members.

[0020] <Conductive member with terminal 10> In the conductive member 10 with terminals, the intermediate component (flexible pipe 34, described later) has a first fixing portion 20 fixed to the terminal 12, a second fixing portion 22 fixed to the conductive member (electric wire 18), and a cylindrical intermediate connecting portion 24 connecting the first fixing portion 20 and the second fixing portion 22. The intermediate connecting portion 24 also includes a flexible bellows-like portion 30 in which a plurality of peaks 26 and valleys 28 are alternately connected along the axial direction of the intermediate connecting portion 24. In Embodiment 1, the intermediate component is constructed using a metal flexible pipe 34 in which a bellows-like portion 30 is provided on the peripheral wall of a hollow cylindrical body 32, and the bellows-like portion 30 is provided along the entire axial length of the intermediate connecting portion 24.

[0021] <Terminal 12> The terminal 12 is substantially cylindrical in shape, extending in the front-to-back direction (axial direction), and is made of a metal with excellent conductivity, such as copper (including copper alloys) or aluminum (including aluminum alloys). The front portion of the terminal 12 is provided with a substantially cylindrical connecting portion 36 into which a mating terminal (not shown) is inserted. When the mating terminal is inserted into the connecting portion 36 from the front, the terminal 12 (conductive member 10 with terminal) and the mating terminal are electrically connected. The method of forming the terminal 12 is not limited, but in Embodiment 1, it is formed by bending a metal plate into a predetermined shape by press working or the like.

[0022] Specifically, a substantially cylindrical tubular portion 38 is provided at the rear end of the connecting portion 36 (the central portion in the front-rear direction of the terminal 12), and three elastic contact pieces 40 protruding forward are provided on the circumference of the tubular portion 38. In Embodiment 1, each elastic contact piece 40 is provided at approximately equal intervals at three locations on the circumference. Each elastic contact piece 40 has a predetermined front-rear and circumferential dimension and is independent of each other. As a result, each elastic contact piece 40 is capable of elastic deformation in the radial direction. Furthermore, each elastic contact piece 40 is gradually inclined radially inward as it moves forward, and the connecting portion 36 as a whole is formed as a tapered cylindrical shape with a gradually decreasing diameter towards the front. As a result, when the mating terminal is inserted into the substantially circular insertion opening 42 formed by the front ends of each elastic contact piece 40, each elastic contact piece 40 elastically deforms radially outward, and the elastic restoring force of each elastic contact piece 40 causes each elastic contact piece 40 to press against the outer circumferential surface of the mating terminal.

[0023] Furthermore, the rear end portion of the terminal 12 is provided with a terminal-side fixing portion 44 that is fixed to the first fixing portion 20 of the relay component (flexible pipe 34). The terminal-side fixing portion 44 is formed into a substantially cylindrical shape by bending the rear end portion of a metal plate, and a slit 46 extending along the entire length in the front-rear direction is formed on a part of the circumference of the terminal-side fixing portion 44 (upper part in Figure 3). Note that the diameter of the terminal-side fixing portion 44 can be reduced by bringing the circumferential portions on both sides of the slit 46 closer together. This makes it easier to insert the terminal-side fixing portion 44 of the terminal 12 into the front opening 50 of the first fixing portion 20, which is substantially cylindrical, as will be described later.

[0024] <Conductive material (wire 18)> As described above, in Embodiment 1, the conductive member is made up of a wire 18 in which a single core wire 14 is covered with an insulating coating 16. That is, the wire 18 has a relatively large diameter single core wire (single core wire 14), and in Embodiment 1, the single core wire 14 has a circular cross-section. At the end (tip) of the wire 18, the insulating coating 16 is stripped off over a predetermined area in the axial direction, exposing the single core wire 14. The portion of the single core wire 14 in which the insulating coating 16 is stripped off and exposed to the outside constitutes the conductive member side fixing portion 48, which is fixed to the second fixing portion 22 of the relay component (flexible pipe 34). Therefore, the conductive member side fixing portion 48 is substantially cylindrical in shape with predetermined outer diameter and axial dimensions. The single core wire 14 can be made of a metal with excellent conductivity, for example, copper (including copper alloys) or aluminum (including aluminum alloys).

[0025] <Intermediate component (flexible pipe 34)> As described above, in Embodiment 1, the intermediate component is made of a flexible pipe 34 in which a bellows-like portion 30 is provided on the peripheral wall of a hollow cylindrical body 32. This flexible pipe 34 can be made of a metal with excellent conductivity, for example, copper (including copper alloys) or aluminum (including aluminum alloys). The flexible pipe 34 has a circular front opening 50 at its front end and a circular rear opening 52 at its rear end. In particular, in Embodiment 1, the region over a predetermined axial dimension in the front portion of the cylindrical body 32 is a region that extends substantially straight in the axial direction without having peaks 26 or valleys 28, and the cylindrical first fixing portion 20 is made of the region that extends substantially straight in the front portion. Similarly, the region over a predetermined axial dimension in the rear portion of the cylindrical body 32 extends substantially straight, and the cylindrical second fixing portion 22 is made of the region that extends substantially straight in the rear portion. In other words, the first fixing portion 20 and the second fixing portion 22, which are cylindrical in shape, are formed by both ends of the flexible pipe 34.

[0026] In Embodiment 1, the inner diameter of the first fixing portion 20 before it is fixed to the terminal-side fixing portion 44 is equal to or slightly larger than the outer diameter of the terminal-side fixing portion 44 on the terminal 12. Also, the inner diameter of the second fixing portion 22 before it is fixed to the conductive member-side fixing portion 48 is equal to or slightly larger than the outer diameter of the conductive member-side fixing portion 48 (single-core wire 14) on the conductive member (electric wire 18).

[0027] The intermediate connecting portion 24 is formed by the portion located between the first fixing portion 20 and the second fixing portion 22, and as described above, in Embodiment 1, a bellows-like portion 30 is provided along the entire length of the intermediate connecting portion 24. The method of forming the bellows-like portion 30 is not limited, but for example, the peripheral wall of the axial intermediate portion (corresponding to the intermediate connecting portion 24) of a metal tube (cylindrical body 32) that extends in a substantially straight line is deformed to bulge outward in the radial direction and / or to be pushed inward in the radial direction at a substantially constant pitch in the axial direction. As a result, peaks 26 and valleys 28 can be provided alternately and continuously at a substantially constant pitch in the axial intermediate portion of the cylindrical body 32, and as a result, an intermediate connecting portion 24 with a bellows-like portion 30 can be formed. The bellows-like portion 30 can be curved into any shape by the deformation of the peaks 26 and / or valleys 28. In particular, in Embodiment 1, the peaks 26 and valleys 28 are provided in an annular shape around the entire circumference with substantially constant radial outward and radial inward projection heights, respectively, allowing the bellows-like portion 30 to bend and deform substantially equally in either direction. The first and second fixing portions 20 and 22, which extend substantially straight, have high deformation rigidity and are difficult to bend and deform.

[0028] In such a flexible pipe 34, the terminal-side fixing portion 44 of the terminal 12 is inserted through the front opening 50 of the first fixing portion 20, and the first fixing portion 20 and the terminal-side fixing portion 44 are fixed together with the first fixing portion 20 fitted onto the terminal-side fixing portion 44. Also, the columnar conductive member-side fixing portion 48 of the conductive member (electric wire 18) is inserted through the rear opening 52 of the second fixing portion 22, and the second fixing portion 22 and the conductive member-side fixing portion 48 are fixed together with the second fixing portion 22 fitted onto the conductive member-side fixing portion 48. This forms a conductive member 10 with a terminal, in which the terminal 12 and the conductive member (electric wire 18) are electrically connected by the relay component (flexible pipe 34). It is preferable that the first fixing portion 20 and the second fixing portion 22 have approximately equal inner diameter, outer diameter, and axial dimensions. This eliminates the need to distinguish between the front side of the flexible pipe 34, which is connected to the terminal 12, and the rear side, which is connected to the conductive member (electric wire 18), thereby improving work efficiency during the manufacturing of the conductive member 10 with terminals.

[0029] Here, the method of fixing the first fixing part 20 to the terminal-side fixing part 44 and the method of fixing the second fixing part 22 to the conductive member-side fixing part 48 are not limited, and they may be fixed by welding such as ultrasonic welding or resistance welding, but in Embodiment 1, both are fixed by electromagnetic pressure welding. As a result, the first fixing part 20 to the terminal-side fixing part 44 and the second fixing part 22 to the conductive member-side fixing part 48 can be fixed substantially uniformly over the entire circumference in the circumferential direction. In particular, in Embodiment 1, since the conductive member-side fixing part 48 is made of a single-core wire 14, the difference in rigidity with the second fixing part 22 is not large compared to when it is made of stranded wire. Therefore, even if the single-core wire 14 and the second fixing part 22 (flexible pipe 34) are made of different metals, effective electromagnetic pressure welding can be performed, and the degree of freedom in selecting materials for each component can be improved.

[0030] <Manufacturing method for conductive member 10 with terminals> The following describes a specific example of a method for manufacturing a conductive member 10 with terminals by fixing terminals 12 and a conductive member (electric wire 18) to a flexible pipe 34. However, the method for manufacturing the conductive member 10 with terminals is not limited to the embodiment described below.

[0031] First, a metal plate made of copper or aluminum is bent into a predetermined shape by pressing or other means to form a terminal 12. Also, at the end of the electric wire 18, the insulating coating 16 is stripped to expose the single-core wire 14, and a columnar conductive member-side fixing portion 48 is provided. Furthermore, in the axial middle portion of a cylindrical body 32 made of a metal tube or the like, alternating peaks 26 and valleys 28 are provided in the axial direction to form a flexible pipe 34.

[0032] Then, the terminal-side fixing portion 44 of the terminal 12 is inserted through the front opening 50 of the first fixing portion 20 of the flexible pipe 34, and the first fixing portion 20 and the terminal-side fixing portion 44 are fixed together by electromagnetic pressure welding. Also, the conductive member-side fixing portion 48 of the conductive member (electric wire 18) is inserted through the rear opening 52 of the second fixing portion 22 of the flexible pipe 34, and the second fixing portion 22 and the conductive member-side fixing portion 48 are fixed together by electromagnetic pressure welding. Note that the electromagnetic pressure welding of the first fixing portion 20 and the terminal-side fixing portion 44, and the electromagnetic pressure welding of the second fixing portion 22 and the conductive member-side fixing portion 48 employs conventionally known electromagnetic pressure welding methods, so a detailed explanation is omitted. With the fixing of the first fixing portion 20 and the terminal-side fixing portion 44, and the fixing of the second fixing portion 22 and the conductive member-side fixing portion 48, the conductive member 10 with terminals is completed.

[0033] Such a conductive member 10 with a terminal includes a metal relay component (flexible pipe 34) that electrically connects the terminal 12 to the conductive member (electric wire 18). This flexible pipe 34 includes a bellows-like portion 30 that can be bent freely at an intermediate connecting portion 24 in the axial middle section. By deforming the bellows-like portion 30, the terminal 12 can be directed in a desired direction regardless of the direction in which the electric wire 18 extends, thereby ensuring a more reliable connection between the terminal 12 and the mating terminal. In other words, the electric wire 18 can be extended in any direction relative to the terminal 12, improving the freedom of routing the conductive member 10 with a terminal. Furthermore, since the flexible pipe 34 is made of metal, it has a certain degree of rigidity and can maintain its shape even when deformed. As a result, even if the terminal 12 is positioned above the electric wire 18, for example, the terminal 12 will not sag downwards due to gravity, making it possible to route the conductive member 10 with a terminal in a three-dimensional manner.

[0034] Furthermore, even when external forces are applied to the conductive member (electric wire 18) due to vehicle vibrations, the deformation of the flexible pipe 34 absorbs the input external force, preventing the external force from reaching the connection between terminal 12 and the mating terminal. This prevents connection failures due to contact wear between terminal 12 and the mating terminal, and avoids damage to equipment to which the mating terminal is attached. In addition, the deformation of the flexible pipe 34 can also provide tolerance absorption, reducing the risk of uncertain connection between terminal 12 and the mating terminal due to tolerances in each component, for example.

[0035] The flexible pipe 34 is formed by cylindrical first fixing portion 20 and second fixing portion 22 at both ends, and an intermediate connecting portion 24 is formed by the portion located between the first fixing portion 20 and the second fixing portion 22, with a bellows-like portion 30 provided along the entire axial length of the intermediate connecting portion 24. Since the first fixing portion 20 and the second fixing portion 22 are cylindrical and have relatively high rigidity, stable fixing to the terminal 12 and the conductive member (electric wire 18) can be achieved, respectively. Furthermore, since the bellows-like portion 30 is provided along the entire axial length of the intermediate connecting portion 24, a large deformable area of ​​the flexible pipe 34 can be secured, and the effects of bending deformation of the flexible pipe 34 can be stably enjoyed.

[0036] The second fixing portion 22 is fixed to the single-core wire 14 exposed from the insulating coating 16 at the end of the electric wire 18. When a single-core wire with a relatively large outer diameter is used as the core of the electric wire, if the terminal and the single-core wire are connected directly, bending the electric wire may be difficult due to the rigidity of the single-core wire. However, by connecting the single-core wire 14 and the terminal 12 via a flexible pipe 34 having a bellows-like portion 30 that is easily bendable, bending deformation of the conductive member 10 with terminal can be easily achieved. As a result, even when the core of the electric wire 18 is a single-core wire 14, the effects associated with the bending deformation of the flexible pipe 34 can be stably enjoyed.

[0037] The first fixing portion 20 is substantially cylindrical, and the terminal-side fixing portion 44 is substantially cylindrical, with the first fixing portion 20 fitted onto the terminal-side fixing portion 44 and fixed by electromagnetic pressure welding. Similarly, the second fixing portion 22 is substantially cylindrical, and the conductive member-side fixing portion 48 is substantially cylindrical, with the second fixing portion 22 fitted onto the conductive member-side fixing portion 48 and fixed by electromagnetic pressure welding. Since the first fixing portion 20 and the terminal-side fixing portion 44, and the second fixing portion 22 and the conductive member-side fixing portion 48 are substantially corresponding in shape and are fixed by electromagnetic pressure welding in a radially overlapping state, substantially uniform fixing can be achieved over the entire circumference. Therefore, sufficient fixing strength can be ensured between the first fixing portion 20 and the terminal-side fixing portion 44, and between the second fixing portion 22 and the conductive member-side fixing portion 48. Furthermore, the conductive performance at the connection points between the first fixing portion 20 and the terminal-side fixing portion 44, and between the second fixing portion 22 and the conductive member-side fixing portion 48 can be improved.

[0038] <Embodiment 2> Next, the conductive member 60 with terminals of Embodiment 2 of this disclosure will be described with reference to Figure 4. The conductive member 60 with terminals of Embodiment 2 differs from the conductive member 10 with terminals of Embodiment 1 in that the shape of the flexible pipe 62 as an intermediate component is different, while the shapes of the terminals 12 and conductive members (electric wires 18) provided at both ends of the flexible pipe 62 are the same as in Embodiment 1. Therefore, in the following description, the flexible pipe 62, which has a different shape from that of Embodiment 1, will be described in detail, and components and parts that are substantially the same as those of Embodiment 1 will be denoted by the same reference numerals in the figures as in Embodiment 1, and detailed descriptions will be omitted.

[0039] <Intermediate component (flexible pipe 62)> In Embodiment 1, a bellows-like portion 30 was provided along the entire length of the intermediate connecting portion 24 that connects the first fixing portion 20 and the second fixing portion 22 at both ends in the axial direction. In Embodiment 2, however, a plurality of bellows-like portions 66 are arranged in the intermediate connecting portion 64, spaced apart from each other in the axial direction, and a cylindrical portion 68 with a constant diameter is arranged between adjacent bellows-like portions 66, 66. In particular, in Embodiment 2, two bellows-like portions 66 (a first bellows-like portion 66a on the front side and a second bellows-like portion 66b on the rear side) are provided in the intermediate connecting portion 64, spaced apart from each other in the front-rear direction, and these first and second bellows-like portions 66a and 66b are connected by a cylindrical portion 68. That is, first and second bellows-like portions 66a and 66b having predetermined axial dimensions are provided at both ends in the axial direction of the intermediate connecting portion 64, and a cylindrical portion 68 is provided in the axial middle portion of the intermediate connecting portion 64.

[0040] As mentioned above, it is preferable that the first and second fixing portions 20 and 22 have substantially the same shape (substantially equal inner diameter, outer diameter, and axial dimensions), and that the first bellows portion 66a and the second bellows portion 66b also have substantially the same shape. That is, it is preferable that the first bellows portion 66a and the second bellows portion 66b have substantially the same inner diameter, outer diameter, and axial dimensions. This eliminates the need to distinguish the front and back of the flexible pipe 62, thereby improving work efficiency when manufacturing the conductive member 60 with terminals. Here, the inner diameter of the first bellows portion 66a and the second bellows portion 66b is the inner diameter of a hypothetical cylinder connecting the radially inward ends of each valley portion 28, and the outer diameter of the first bellows portion 66a and the second bellows portion 66b is the outer diameter of a hypothetical cylinder connecting the radially outward ends of each peak portion 26.

[0041] Furthermore, the inner and outer diameters of the cylindrical portion 68 in the flexible pipe 62 are not limited, but may be approximately equal to the inner and outer diameters of the first and second fixing portions 20 and 22, for example. That is, when forming the flexible pipe 62 from a metal pipe, by performing diameter expansion and / or diameter reduction processing only in the formation areas of the first and second bellows portions 66a and 66b, a cylindrical portion 68 can be formed with inner and outer diameters approximately equal to those of the first and second fixing portions 20 and 22. And, since the cylindrical portion 68 extends approximately straight in the axial direction, similar to the first and second fixing portions 20 and 22, it has high deformation rigidity and is difficult to bend. Therefore, in the flexible pipe 62 of Embodiment 2, the first and second bellows portions 66a and 66b, which are separated from each other in the front-rear direction, can be easily bent, while bending deformation is almost impossible in the cylindrical portion 68 between them.

[0042] In the conductive member 60 with terminals of Embodiment 2, which employs the flexible pipe 62 described above, a bellows-shaped portion 66 (first and second bellows-shaped portions 66a, 66b) is provided in the intermediate connecting portion 64 that connects the first fixing portion 20 and the second fixing portion 22, so that the same effects as in Embodiment 1 can be achieved. In particular, in Embodiment 2, a plurality (two) of bellows-shaped portions 66 (first and second bellows-shaped portions 66a, 66b) are provided spaced apart from each other in the axial direction, and a cylindrical portion 68 with a constant diameter is provided between the first and second bellows-shaped portions 66a, 66b. As a result, the flexible pipe 62 can be locally bent in the formation regions of the first and second bellows-shaped portions 66a, 66b, and the flexible pipe 62 can be curved into a desired shape while suppressing excessive deformation of the flexible pipe 62.

[0043] <Embodiment 3> Next, the conductive member 70 with terminals according to Embodiment 3 of the present disclosure will be described with reference to Figure 5. In the conductive member 70 with terminals of Embodiment 3, the basic structure is the same as that of Embodiment 1 and Embodiment 2, and the conductive member 70 with terminals includes a metal relay part 76 that electrically connects the terminal 72 and the electric wire 74, which is a conductive member. Furthermore, the front end portion of the relay part 76 is provided with a first fixing portion 78 that is fixed to the terminal 72, and the rear end portion of the relay part 76 is provided with a second fixing portion 80 that is fixed to the electric wire 74, and a flexible bellows-like portion 84 is provided in the intermediate connecting portion 82 between these first and second fixing portions 78 and 80. In particular, in Embodiment 3, the bellows-like portion 84 is provided along the entire length of the intermediate connecting portion 82.

[0044] <Terminal 72> In Embodiment 3, the terminal 72 is formed from a busbar that is generally flat, and a terminal-side fixing portion 86 is formed at the rear end of the terminal 72. Specifically, the terminal 72 has a straight portion 88 that extends generally straight in the front-rear direction, and a bent portion 90 is provided at the front end of the straight portion 88, from which an extension portion 92 extends in a direction perpendicular to the axial direction (front-rear direction). That is, the terminal 72 is generally L-shaped, and the area at the rear end of the straight portion 88 that spans a predetermined axial dimension is the terminal-side fixing portion 86 to which the first fixing portion 78 is fixed. In addition, a through hole 94 that penetrates in the plate thickness direction is formed at the extension end of the extension portion 92 (the end opposite to the bent portion 90).

[0045] Then, for example, the extension portion 92 of terminal 72 and a mating terminal (not shown) are superimposed and bolted together using the through hole 94, thereby fixing terminal 72 and the mating terminal. Here, the manner in which terminal 72 and the mating terminal are fixed by bolting is not limited; for example, the through hole 94 of terminal 72 and the mating terminal may be superimposed and fastened together with a bolt inserted through the through hole 94, or if the mating terminal is made of a stud bolt, the terminal 72 and the mating terminal may be fixed by inserting the stud bolt through the through hole 94 and fastening a nut. Note that the through hole 94 is not required to fix terminal 72 and the mating terminal, and terminal 72 and the mating terminal may be fixed by adhesive or welding.

[0046] <Conductive component (wire 74)> The conductive member in Embodiment 3 is also composed of a wire 74 consisting of a single core wire 14 and an insulating coating 16. However, in Embodiment 3, the front end portion of the single core wire 14, which is exposed to the outside when the insulating coating 16 is stripped at the end of the wire 74, is made into a substantially flat plate shape by pressing or the like. This flat plate-shaped front end portion of the single core wire 14 is the conductive member side fixing portion 96.

[0047] <Intermediate component 76> As described above, the intermediate component 76 of Embodiment 3 is provided with first and second fixing portions 78 and 80 at both axial ends, and a bellows-like portion 84 is provided along the entire length of the intermediate connecting portion 82 in the axial middle section. In particular, in Embodiment 3, the first and second fixing portions 78 and 80 are each substantially flat. That is, the first and second fixing portions 78 and 80 in Embodiment 3 are constructed by press-forming the substantially cylindrical first and second fixing portions 20 and 22 in the flexible pipe 34 shown in Figure 2 above into a substantially flat shape. Therefore, the substantially flat first and second fixing portions 78 and 80 each have a predetermined axial dimension.

[0048] Then, the terminal-side fixing portion 86 of the terminal 72 and the conductive member-side fixing portion 96 of the conductive member (electric wire 74) are superimposed and fixed to these first and second fixing portions 78 and 80, respectively, thereby forming the conductive member with terminals 70. The method of fixing the first fixing portion 78 to the terminal-side fixing portion 86 and the method of fixing the second fixing portion 80 to the conductive member-side fixing portion 96 are not limited, but can be fixed by conventionally known welding methods such as ultrasonic welding or resistance welding.

[0049] In the conductive member 70 with terminals of Embodiment 3, which has the structure described above, the intermediate component 76 is provided with first and second fixing parts 78 and 80 at both axial ends, and the intermediate connecting part 82 connecting them has a bellows-shaped part 84, so the same effects as in Embodiments 1 and 2 can be achieved. In particular, in Embodiment 3, the first fixing part 78 and the terminal-side fixing part 86, and the second fixing part 80 and the conductive member-side fixing part 96 are welded by ultrasonic welding or resistance welding, etc., and compared to the case where the first fixing part 20 and the terminal-side fixing part 44, and the second fixing part 22 and the conductive member-side fixing part 48 are fixed by electromagnetic pressure welding, for example, as in Embodiments 1 and 2, the equipment for manufacturing the conductive member with terminals 70 can be made simpler.

[0050] <Embodiment 4> Next, the conductive member 100 with terminals according to Embodiment 4 of this disclosure will be described with reference to Figures 6 and 7. In the conductive member 100 with terminals of Embodiment 4, the basic structure is the same as that of Embodiment 1 and Embodiment 2, and the conductive member 100 with terminals includes a metal relay part 102 that electrically connects the terminal 12 and the conductive wire 74. In Embodiment 4, the terminal 12 from Embodiment 1 and the conductive member (wire 74) from Embodiment 3 are used, and by denoting their reference numerals in the figures, the explanation of the terminal 12 and the conductive member (wire 74) will be omitted. Furthermore, a first fixing part 20 with the same shape as in Embodiment 1 is provided at the front end of the relay part 102, and a second fixing part 104 with a different shape from that of Embodiment 1 and Embodiment 3 is provided at the rear end of the relay part 102. Furthermore, a bellows-like portion 108 is provided in the intermediate connecting portion 106 between the first fixing portion 20 and the second fixing portion 104, but the shape of the peaks 110 that constitute the bellows-like portion 108 is different from that of Embodiments 1 to 3.

[0051] <Intermediate component 102> As shown in Figures 6 and 7, the second fixing portion 104 of the relay component 102 is a substantially rectangular cylindrical shape that fits onto the conductive member side fixing portion 96 of the electric wire 74. This second fixing portion 104 has a predetermined axial dimension, and before being fixed to the conductive member side fixing portion 96, it has an opening width dimension (left-right dimension in Figure 7) and an opening height dimension (up-down dimension in Figure 7) that are equal to or slightly larger than the conductive member side fixing portion 96. The substantially rectangular cylindrical second fixing portion 104 can be formed, for example, by press-forming the substantially cylindrical second fixing portion 22 of Embodiment 1 into a substantially rectangular cylindrical shape. Then, the conductive member side fixing portion 96 of the conductive member (electric wire 74) is inserted through the rear opening 52 of the second fixing portion 104, and the second fixing portion 104 and the conductive member side fixing portion 96 are fixed to each other by crimping the second fixing portion 104 by press working or welding by ultrasonic welding or resistance welding.

[0052] Furthermore, in Embodiment 4, a bellows-like portion 108 is provided along the entire length of the intermediate connecting portion 106, but the bellows-like portion 108 is composed of a peak portion 110 with a notch portion 112 provided on a part of the circumference (the upper part in Figure 7). That is, in Embodiment 1 and the like, the peak portion 26 was provided in an annular shape along the entire circumference with a substantially constant radial outward projection height, but in Embodiment 4, the peak portion 110 is provided over a region that is less than one full circumference with a substantially constant radial outward projection height. In other words, in Embodiment 4, the outer diameter dimension of the peak portion 110 is different in the circumferential direction.

[0053] The shape of the notch 112 is not limited, but for example, as shown in Figure 7, it can be approximately triangular in an axial view (projection in the front-to-back direction). Such a peak 110 may be formed by cutting a part of the circumferential direction of a ring-shaped peak 26, as in Embodiment 1, to provide the notch 112, or the peak 110 may be formed in a metal tube by deforming a region less than one full circumference radially outward. By providing a notch 112 on a part of the circumference of the peak 110 in the bellows-like portion 108, when the bellows-like portion 108 is bent in the direction in which the notch 112 was formed (upward in Figure 7 in Embodiment 4), adjacent peaks 110, 110 do not come into contact with each other, making it easier to bend the bellows-like portion 108 in a predetermined direction.

[0054] In the conductive member 100 with terminals of Embodiment 4, which has the structure described above, the intermediate component 102 is provided with first and second fixing portions 20 and 104 at both axial ends, and the intermediate connecting portion 106 connecting them has a bellows-shaped portion 108, so the same effects as in Embodiments 1 to 3 can be achieved. In particular, by making the second fixing portion 104 substantially rectangular cylindrical, it is possible to cover the entire circumference of the conductive member-side fixing portion 96, which is substantially flat, thereby improving the fixing strength between the second fixing portion 104 and the conductive member-side fixing portion 96. Furthermore, by providing a notch 112 on a part of the circumference of the peak portion 110 that constitutes the bellows-shaped portion 108, it is possible to make it easier to bend and deform the bellows-shaped portion 108 in the direction in which the notch 112 is formed.

[0055] <Variation> While Embodiments 1 to 4 have been described in detail above as specific examples of the present disclosure, the present disclosure is not limited by these specific descriptions. Modifications, improvements, etc., to the extent that they can achieve the objectives of the present disclosure are included in the present disclosure. For example, the following modifications of embodiments are also included in the technical scope of the present disclosure.

[0056] (1) In the above embodiment, the outer diameter dimensions of each peak 26, 110 and the inner diameter dimensions of each valley 28 constituting the bellows-shaped portions 30, 66, 84, 108 of the flexible pipes 34, 62 and the intermediate components 76, 102 were kept substantially constant in the axial direction, but the embodiment is not limited to this. That is, as shown in the conductive member with terminals 120 in Figure 8, in the flexible pipe 122 as an intermediate component, the outer diameter dimensions of each peak 126 and the inner diameter dimensions of each valley 128 constituting the bellows-shaped portion 124 may differ in the axial direction. This makes it possible to vary the curvature of the bellows-shaped portion 124 in the axial direction, and further improves the degree of freedom of routing of the conductive member with terminals 120. Such intermediate components (flexible pipes 122) may be formed, for example, by providing peaks and valleys with substantially constant protrusion dimensions radially outward and radially inward to a metal pipe whose axial middle portion is tapered or a metal pipe whose diameter is gradually increased or decreased in the axial direction, or by providing peaks and valleys with different protrusion dimensions radially outward and radially inward in the axial direction to a straight metal pipe.

[0057] In the embodiment shown in Figure 8, the outer diameter of the peaks 126 and the inner diameter of the valleys 128 are progressively increased from front to rear. That is, the bellows-shaped portion 124 is provided with first to fourth regions 129a to 129d in which the outer and inner diameters are progressively increased, and each of these first to fourth regions 129a to 129d has a predetermined axial dimension. In another embodiment, the outer diameter of the peaks and the inner diameter of the valleys may be progressively increased from front to rear, in other words, the outer and inner diameters may be continuously increased in the axial direction in the first to fourth regions 129a to 129d. By making the front portion of the flexible pipe 122 smaller in diameter than the rear portion, it is possible to ensure a certain degree of rigidity in the rear portion while exhibiting better bendability in the front portion. Furthermore, the intermediate components may have outer and inner diameters that decrease progressively or gradually from front to rear.

[0058] (2) In the above embodiments, the conductive members were all made of electric wires 18 and 74, but the conductive members may be made of flat busbars 130, for example as shown in Figure 9, and one end of the busbar 130 may form a conductive member side fixing portion 132, and the intermediate portion excluding one end and the other end may be covered with an insulating coating 134. In the embodiment shown in Figure 9, the relay component 76 shown in Embodiment 3 is used, and the conductive member side fixing portion 132, which is made of one end of the busbar 130, is superimposed on the second fixing portion 80 and fixed by welding or the like, but as in Embodiment 4, the second fixing portion may be fitted on the outside and then fixed to the second fixing portion by welding or the like.

[0059] (3) In the above embodiment, the core wires of the conductive members, the electric wires 18 and 74, were made of relatively large diameter single core wires 14, but multiple smaller diameter core wires may be twisted together.

[0060] (4) The cross-sectional shape of a single core wire may be, for example, elliptical, or if multiple core wires are twisted together, they may be twisted together so that the overall shape is elliptical. This ensures that the fixing portion on the conductive member side has an elliptical cross-section. Similarly, the fixing portion on the terminal side may also have an elliptical cross-section. In that case, it is preferable that the first fixing portion and the second fixing portion have an elliptical cylindrical shape corresponding to the shape of the fixing portion on the terminal side and the fixing portion on the conductive member side, and for example, the cylindrical body constituting the flexible pipe may have an elliptical cylindrical shape. That is, the bellows-like portion (peaks and valleys) constituting the intermediate connecting portion and the cylindrical portion located between adjacent bellows-like portions may also have an elliptical cylindrical shape.

[0061] (5) In the embodiments 1 and 2 described above, the terminal-side fixing portion 44 of the terminal 12 was inserted (fitted) into the first fixing portion 20, and the conductive member-side fixing portion 48 of the conductive member (electric wire 18) was inserted (fitted) into the second fixing portion 22. However, the embodiment is not limited to this. For example, the terminal-side fixing portion and the conductive member-side fixing portion may be cylindrical and fitted onto the first fixing portion and the second fixing portion, in which case the first fixing portion and the second fixing portion may be columnar or flat.

[0062] (6) The terminals 12 and 72 described in the above embodiments and in the aspect of Figure 8 are merely examples, and any shape and configuration may be adopted for the terminals in this disclosure. Similarly, the conductive members (wires 18 and 74, busbars 130) described in the above embodiments and in the aspect of Figures 8 and 9 are merely examples, and any shape and configuration may be adopted for the conductive members in this disclosure as long as they are conductive.

[0063] (7) The flexibility (bendability) and conductivity of the intermediate components can be adjusted by changing their shape (plate thickness, pitch of the bellows section, etc.) and material. In addition, the intermediate components, terminals, and core wires (for example, single-core wires) exposed from the insulating coating may be subjected to conventional surface treatments such as plating. [Explanation of Symbols]

[0064] 10 Conductive member with terminals (Embodiment 1) 12 terminals 14 Single core wire 16 Insulating coating 18. Electric wires (conductive materials) 20 First fixing part 22 Second fixing part 24 Intermediate connecting section 26 Yamabe 28 Tanibe 30 Bellows-like section 32 Cylindrical body 34 Flexible pipe (intermediate component) 36 Connection part 38 Cylindrical part 40 Elastic contact pieces 42 Insertion opening 44 Terminal side fixed part 46 slits 48. Attachment portion on the conductive member side 50 Front opening 52 Rear opening 60 Conductive member with terminals (Embodiment 2) 62 Flexible pipe (intermediate component) 64 Intermediate connecting section 66 Bellows-like section 66a First bellows-like section 66b Second bellows section 68 Cylindrical part 70 Conductive member with terminals (Embodiment 3) 72 terminals 74. Electric wires (conductive materials) 76 Intermediate parts 78 First fixing part 80 Second fixing part 82 Intermediate connecting section 84 Bellows-like section 86 Terminal side fixed part 88 Straight section 90 Bending section 92 Extension part 94 Through holes 96. Fitting portion on the conductive member side 100 Conductive member with terminals (Embodiment 4) 102 Intermediate parts 104 Second fixing part 106 Intermediate connecting section 108 Bellows-like section 110 Yamabe 112 Notch 120 Conductive component with terminals (Figure 8) 122 Flexible pipe (intermediate component) 124 Bellows-like section 126 Yamabe 128 Tanibe 129a~129d 1st area~4th area 130 Busbar (conductive component) 132 Conductive member side fixing part 134 Insulating coating

Claims

1. Terminals and Conductive material and The device comprises a metal relay component that electrically connects the terminal and the conductive member, The relay component has a first fixing portion fixed to the terminal, a second fixing portion fixed to the conductive member, and a cylindrical intermediate connecting portion connecting the first fixing portion and the second fixing portion. The intermediate connecting portion includes a flexible bellows-like section in which a plurality of peaks and valleys are alternately connected along the axial direction of the intermediate connecting portion. The conductive member is made up of a wire in which a single metal core is insulated, and the second fixing portion is fixed to the single metal core exposed from the insulating coating at the end of the wire. The first fixing portion and the second fixing portion of the aforementioned relay component each have a cylindrical shape. The first fixing portion is fitted inside or outside a cylindrical terminal-side fixing portion provided on the terminal and is electromagnetically pressure-welded. The second fixing portion is fitted onto a columnar conductive member-side fixing portion provided on the conductive member and is electromagnetically pressure-welded. A conductive member with a terminal, wherein the fixing portion on the conductive member side is made of the single-core wire.

2. The aforementioned relay component is constructed using a metal flexible pipe in which the bellows-like portion is provided on the peripheral wall of a hollow cylindrical body. The conductive member with a terminal according to claim 1, wherein the flexible pipe has two ends that form a cylindrical first fixing portion and a second fixing portion, the portion located between the first fixing portion and the second fixing portion forms an intermediate connecting portion, and the bellows-shaped portion is provided along the entire axial length of the intermediate connecting portion.

3. The conductive member with terminals according to claim 1, wherein the relay component has a plurality of bellows-shaped portions arranged apart from each other in the axial direction, and a cylindrical portion with a constant diameter arranged between adjacent bellows-shaped portions.

4. The conductive member with terminals according to claim 1 or claim 2, wherein the inner diameter and outer diameter of the bellows-shaped portion of the relay component change in the axial direction.

Images