Terminal, terminal-equipped electric wire, and method for manufacturing terminal-equipped electric wire
The terminal design with overlapping flat plate and separated semi-cylindrical wire connection portions enhances conductor cross-sectional area and connection workability, addressing the challenge of handling large currents without compromising deformability.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- AUTONETWORKS TECH LTD
- Filing Date
- 2025-11-07
- Publication Date
- 2026-05-21
AI Technical Summary
Existing terminals face a challenge in increasing conductor cross-sectional area to handle large currents while maintaining good connection workability, as thickening the terminal plate can lead to reduced deformability and poor connection quality.
The terminal design includes a first and second plate material portion with overlapping flat plate portions forming a mating connection and separated wire connection portions, featuring semi-cylindrical shapes for the wire connection portions to accommodate the electric wire, allowing for increased conductor cross-sectional area without compromising connection ease.
This design enables a larger conductive path cross-sectional area while maintaining excellent connection workability, facilitating easier wire insertion and reducing resistance during electromagnetic pressure welding.
Smart Images
Figure JP2025039130_21052026_PF_FP_ABST
Abstract
Description
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[0001] The present disclosure relates to a terminal, an electric wire with a terminal, and a method for manufacturing an electric wire with a terminal.
[0002] Patent Document 1 discloses an electromagnetic pressure welding terminal. The electromagnetic pressure welding terminal described in Patent Document 1 includes a terminal plate having a cylindrical portion connected to an electric wire and a box-shaped portion provided at the tip of the cylindrical portion.
[0003] Japanese Unexamined Patent Application Publication No. 2019-186082
[0004] In order to handle large currents, it is desirable to increase the conductor cross-sectional area of the conductive path in the terminal plate. At this time, if the thickness of the terminal plate is increased to increase the conductor cross-sectional area, when connecting the terminal plate to the electric wire, the terminal plate may be less likely to deform, which may deteriorate the connection workability.
[0005] Therefore, an object is to provide a technique that can increase the conductor cross-sectional area of the conductive path in the terminal while suppressing a decrease in the connection workability to the electric wire.
[0006] The terminal of the present disclosure is a terminal for connecting an electric wire and a mating conductor, and includes a first plate material portion including a first flat plate portion and a first electric wire connection plate portion continuous with an end of the first flat plate portion, and a second plate material portion including a second flat plate portion and a second electric wire connection plate portion continuous with an end of the second flat plate portion. A portion where the first flat plate portion and the second flat plate portion overlap so that their main surfaces contact each other forms a mating connection portion connected to the mating conductor, and a portion where the first electric wire connection plate portion and the second electric wire connection plate portion are arranged so that their main surfaces are separated from each other forms an electric wire connection portion connected to the electric wire. A space for accommodating an end portion of the electric wire is formed between the main surface of the first electric wire connection plate portion and the main surface of the second electric wire connection plate portion.
[0007] According to the present disclosure, it is possible to increase the conductor cross-sectional area of the conductive path in the terminal while suppressing a decrease in the connection workability to the electric wire.
[0008] Figure 1 is a perspective view showing a terminal according to Embodiment 1. Figure 2 is a plan view showing a terminal according to Embodiment 1. Figure 3 is a side view showing a terminal according to Embodiment 1. Figure 4 is a cross-sectional view along the line IV-IV in Figure 2. Figure 5 is a cross-sectional view along the line V-V in Figure 2. Figure 6 is a diagram showing the manufacturing process of a terminal according to Embodiment 1. Figure 7 is a diagram showing the manufacturing process of a terminal according to Embodiment 1. Figure 8 is a perspective view showing a terminal according to a first modified example. Figure 9 is a perspective view showing a terminal according to a second modified example. Figure 10 is a perspective view showing a terminal according to a third modified example. Figure 11 is a diagram showing the insertion of an electric wire into the terminal according to the third modified example. Figure 12 is a perspective view showing a terminal according to a fourth modified example. Figure 13 is a perspective view showing a terminal according to a fifth modified example. Figure 14 is a perspective view showing an electric wire with a terminal according to Embodiment 1. Figure 15 is a diagram illustrating the manufacturing process of an electric wire with a terminal according to Embodiment 1. Figure 16 is a diagram illustrating the manufacturing process of an electric wire with a terminal according to Embodiment 1. Figure 17 is a perspective view showing an electric wire with a terminal according to a first modified example. Figure 18 is a diagram illustrating the manufacturing process of an electric wire with a terminal according to a first modified example. Figure 19 is a perspective view showing a terminal-equipped wire according to the second modified example. Figure 20 is a diagram illustrating the manufacturing process of the terminal-equipped wire according to the second modified example.
[0009] [Description of Embodiments of the Disclosure] First, embodiments of the Disclosure will be listed and described.
[0010] The terminals of this disclosure are as follows:
[0011] (1) A terminal for connecting an electric wire and a mating conductor, comprising: a first plate material portion including a first flat plate portion and a first wire connection plate portion connected to the end of the first flat plate portion; and a second plate material portion including a second flat plate portion and a second wire connection plate portion connected to the end of the second flat plate portion, wherein the portion where the first flat plate portion and the second flat plate portion overlap so that their main surfaces are in contact with each other forms a mating connection portion that connects to the mating conductor; the portion where the first wire connection plate portion and the second wire connection plate portion are arranged so that their main surfaces are separated forms a wire connection portion that connects to the electric wire; and a space for accommodating the end of the electric wire is formed between the main surface of the first wire connection plate portion and the main surface of the second wire connection plate portion.
[0012] The terminal in (1) has a conductive path between the electric wire and the mating conductor, which includes a path from the first electric wire connection plate to the first flat plate and a path from the second electric wire connection plate to the second flat plate. This makes it possible to increase the conductor cross-sectional area of the conductive path from the electric wire to the mating conductor while suppressing an increase in the thickness of each plate material. This makes it possible to increase the conductor cross-sectional area of the conductive path at the terminal while suppressing a decrease in the ease of connecting to the electric wire.
[0013] (2) In the terminal of (1), the first wire connection plate portion has a first semi-cylindrical portion formed in a semi-cylindrical shape, and the concave surface of the first semi-cylindrical portion as the main surface faces the main surface of the second wire connection plate portion to form the space. In this case, the wire connection portion is formed in a cylindrical shape. This makes it easier to place the wires into the wire connection portion before connection.
[0014] (3) In the terminal of (2), the second wire connection plate portion has a second semi-cylindrical portion formed in a semi-cylindrical shape, and the concave surface of the first semi-cylindrical portion may face the concave surface of the second semi-cylindrical portion which serves as the main surface, to form the space. In this case, the wire connection portion can be formed in a cylindrical shape with a circular cross-section. This makes it easier to place the wires in the wire connection portion before connection.
[0015] (4) In the terminals of (3), one circumferential end of the first semi-cylindrical portion may be joined to one circumferential end of the second semi-cylindrical portion, and the other circumferential end of the first semi-cylindrical portion may be joined to the other circumferential end of the second semi-cylindrical portion. The wire connection portion may be connected to the wire by electromagnetic pressure welding. During electromagnetic pressure welding, a large induced current flows instantaneously in the circumferential direction of the wire connection portion. Even in this case, by joining the circumferential ends of the wire connection plate portions, it is possible to suppress the increase in resistance at the boundary between the first wire connection plate portion and the second wire connection plate portion in the conductive path that is continuous in the circumferential direction of the wire connection portion. As a result, a wire connection portion more suitable for electromagnetic pressure welding can be obtained.
[0016] (5) In the terminal of (4), the end face of one end of the first semi-cylindrical portion may be joined to the end face of one end of the second semi-cylindrical portion, and the end face of the other end of the first semi-cylindrical portion may be joined to the end face of the other end of the second semi-cylindrical portion. In the case of electromagnetic pressure welding, it is desirable that the wire connection portion deforms uniformly. Even in this case, by joining the end faces of the semi-cylindrical portions, the inner circumferential shape of the cylindrical wire connection portion and the outer circumferential shape of the wire can be made closer to a perfect circle. As a result, a wire connection portion more suitable for electromagnetic pressure welding can be obtained.
[0017] (6) In any one of the terminals of (3) to (5), the first wire connection plate portion has a first transition portion located between the first semi-cylindrical portion and the first flat plate portion, and the second wire connection plate portion has a second transition portion located between the second semi-cylindrical portion and the second flat plate portion, the first semi-cylindrical portion and the second semi-cylindrical portion have the same radius of curvature, and each of the first transition portion and the second transition portion may be formed such that the radius of curvature gradually decreases toward the side where the first flat plate portion and the second flat plate portion are located. This makes it easier to center the wire inserted into the cylindrical wire connection portion by the first transition portion and the second transition portion.
[0018] (7) Any one of the terminals (1) to (6) may be provided with a connecting portion that connects the first plate portion and the second plate portion, and may be formed from a single plate. This allows the two plate portions to be kept in a predetermined positional relationship by the connecting portion, and simplifies the configuration for maintaining the two plate portions in a combined state.
[0019] In the terminals of (8) and (7), the connecting portion may connect the first flat plate portion and the second flat plate portion. The wire connection plate portion may have a more complex semi-cylindrical shape than the flat plate portion. Even in this case, the absence of a connecting portion in the wire connection plate portion makes it easier to process the plate material into the shape of the wire connection plate portion.
[0020] (9) In addition, in any one of the terminals (1) to (8), the first plate portion or the second plate portion may include a projection that contacts the electric wire and positions the electric wire when the electric wire is located in the space. This allows for more precise positioning of the electric wire and terminal before connection.
[0021] (10) Furthermore, the terminal-equipped wire of the present disclosure is a terminal-equipped wire comprising one of the terminals (1) to (9) and a wire connected to the wire connection portion of the terminal. This makes it possible to provide a terminal-equipped wire that can increase the conductor cross-sectional area of the conductive path at the terminal while suppressing a decrease in the ease of connection to the wire.
[0022] (11) Furthermore, the method for manufacturing a wire with a terminal according to the present disclosure is a method for manufacturing a wire with a terminal that is connected to a mating conductor, comprising: an arrangement step of arranging a terminal and a wire in a predetermined positional relationship; and a connection step of connecting the terminal to the wire, wherein the terminal comprises: a first plate material portion including a first flat plate portion and a first wire connection plate portion connected to the end of the first flat plate portion; and a second plate material portion including a second flat plate portion and a second wire connection plate portion connected to the end of the second flat plate portion, with the main surfaces of each other being the same This is a method for manufacturing a wire with a terminal, wherein the portion where the first flat plate portion and the second flat plate portion overlap so that their ends are in contact forms a mating connection portion that connects to the mating conductor, and the portion where the first wire connection plate portion and the second wire connection plate portion are arranged so that their main surfaces are separated from each other forms a wire connection portion that connects to the wire, and in the arrangement step, the end of the wire fits into the space between the main surface of the first wire connection plate portion and the main surface of the second wire connection plate portion. This makes it possible to provide a wire with a terminal that can increase the conductor cross-sectional area of the conductive path at the terminal while suppressing a decrease in the workability of connecting to the wire.
[0023] [Details of Embodiments of the Disclosure] Specific examples of the terminals of the Disclosure will be described below with reference to the drawings. However, the Disclosure is not limited to these examples and is intended to include all modifications within the meaning and scope of the claims, as indicated by the claims.
[0024] [Embodiment 1] The terminal according to Embodiment 1 will be described below. Figure 1 is a perspective view showing the terminal 10 according to Embodiment 1. Figure 2 is a plan view 23, 43 showing the terminal 10 according to Embodiment 1. Figure 3 is a side view showing the terminal 10 according to Embodiment 1. Figure 4 is a cross-sectional view along the line IV-IV in Figure 2. Figure 5 is a cross-sectional view along the line V-V in Figure 2. In this disclosure, the three mutually orthogonal directions are the X direction, the Y direction, and the Z direction. One direction of the X direction is designated as X1, and the opposite side as X2. One direction of the Y direction is designated as Y1, and the opposite side as Y2. One direction of the Z direction is designated as Z1, and the opposite side as Z2. X1, X2, Y1, Y2, Z1, and Z2 are shown in each figure.
[0025] The terminal 10 is made of a conductor such as copper, copper alloy, aluminum, or aluminum alloy. The material constituting the terminal 10 may be stainless steel or tungsten, etc. The terminal 10 connects the electric wire 80 and the mating conductor 90. The terminal 10 is provided with a mating connection portion 12 that connects to the mating conductor 90 and a wire connection portion 16 that connects to the electric wire 80. The mating connection portion 12 is located at one end of the terminal 10 in the X direction (here, the X1 side), and the wire connection portion 16 is located at the other end of the terminal 10 in the X direction (here, the X2 side). The terminal 10 comprises a first plate portion 20 and a second plate portion 40. The first plate portion 20 and the second plate portion 40 are combined to form the mating connection portion 12 and the wire connection portion 16. Here, the first plate portion 20 and the second plate portion 40 are formed in the same shape as each other and are arranged so as to be mirror images of each other with respect to the XY plane.
[0026] The first plate portion 20 includes a first flat plate portion 22 and a first wire connection plate portion 26. The first flat plate portion 22 is formed in a flat plate shape. The first wire connection plate portion 26 is connected to the end of the first flat plate portion 22. The first flat plate portion 22 has a main surface 23, and the first wire connection plate portion 26 has a main surface 31. The main surface 23 of the first flat plate portion 22 is a plane 23 that extends along the XY plane. The normal direction of the main surface 23 is the Z direction. The Z direction is the thickness direction of the first flat plate portion 22. The main surface 31 of the first wire connection plate portion 26 may or may not be a plane. Here, the main surface 31 of the first wire connection plate portion 26 is not a plane but a concave surface 31.
[0027] The second plate portion 40 includes a second flat plate portion 42 and a second wire connection plate portion 46. The second flat plate portion 42 is formed in a flat shape. The second wire connection plate portion 46 is connected to the end of the second flat plate portion 42. The second flat plate portion 42 has a main surface 43, and the second wire connection plate portion 46 has a main surface 51. The main surface 43 of the second flat plate portion 42 is a plane 43 that extends along the XY plane. The normal direction of the main surface 43 is the Z direction. The Z direction is the thickness direction of the second flat plate portion 42. The main surface 51 of the second wire connection plate portion 46 may or may not be a plane. Here, the main surface 51 of the second wire connection plate portion 46 is not a plane but a concave surface 51.
[0028] The portion where the first flat plate portion 22 and the second flat plate portion 42 overlap so that their respective main surfaces 23 and 43 are in contact with each other forms the mating connection portion 12. The portion where the first wire connection plate portion 26 and the second wire connection plate portion 46 are positioned so that their respective main surfaces 31 and 51 are separated forms the wire connection portion 16. A space 17 for accommodating the end of the wire 80 is formed between the main surface 31 of the first wire connection plate portion 26 and the main surface 51 of the second wire connection plate portion 46.
[0029] Here, the first wire connection plate portion 26 includes a first semi-cylindrical portion 30 and a first transition portion 28. The first semi-cylindrical portion 30 is formed in a semi-cylindrical shape. The main surface 31 of the first semi-cylindrical portion 30 is a concave surface 31. The concave surface 31, which serves as the main surface 31 of the first semi-cylindrical portion 30, faces the main surface 51 of the second wire connection plate portion 46, forming a space 17. Here, the first semi-cylindrical portion 30 is formed in a semi-cylindrical shape. In the cross-section of the first semi-cylindrical portion 30, the concave surface 31 is semi-circular. In the cross-section of the first semi-cylindrical portion 30, the concave surface 31 may have a shape other than a semi-circular shape. The first semi-cylindrical portion 30 may be formed in a semi-square cylindrical shape.
[0030] Here, the second wire connection plate portion 46 includes a second semi-cylindrical portion 50 and a second transition portion 48. The second semi-cylindrical portion 50 is formed in a semi-cylindrical shape. The second semi-cylindrical portion 50 has the same radius of curvature as the first semi-cylindrical portion 30. The main surface 51 of the second semi-cylindrical portion 50 is a concave surface 51. The concave surface 31 of the first semi-cylindrical portion 30 faces the concave surface 51 of the second semi-cylindrical portion 50, forming a space 17. Here, the second semi-cylindrical portion 50 is formed in a semi-cylindrical shape. In the cross-section of the second semi-cylindrical portion 50, the concave surface 51 is semi-circular. In the cross-section of the second semi-cylindrical portion 50, the concave surface 51 may have a shape other than a semicircle. The second semi-cylindrical portion 50 may be formed in a half-square cylindrical shape. The portion where the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50 face each other forms the wire connection portion 16.
[0031] In this disclosure, a semi-cylindrical shape refers to a shape that is not an endless annular shape along the circumferential direction around the axis. In the semi-cylindrical portion, one end and the other end exist independently of each other along the circumferential direction around the axis. There is an opening between the one end and the other end along the circumferential direction.
[0032] One circumferential end 32 of the first semi-cylindrical portion 30 is in contact with one circumferential end 52 of the second semi-cylindrical portion 50. The other circumferential end 33 of the first semi-cylindrical portion 30 is in contact with the other circumferential end 53 of the second semi-cylindrical portion 50. As a result, the conductive path of the wire connection portion 16 is formed in an endless annular shape in the circumferential direction around the X axis.
[0033] In the wire connection section 16, the first wire connection plate section 26 and the second wire connection plate section 46 are joined together to form a joint. Here, one circumferential end 32 of the first semi-cylindrical section 30 is joined to one circumferential end 52 of the second semi-cylindrical section 50. This makes it easier to maintain contact between the one circumferential end 32 of the first semi-cylindrical section 30 and the one circumferential end 52 of the second semi-cylindrical section 50. The other circumferential end 33 of the first semi-cylindrical section 30 is joined to the other circumferential end 53 of the second semi-cylindrical section 50. This makes it easier to maintain contact between the other circumferential end 33 of the first semi-cylindrical section 30 and the other circumferential end 53 of the second semi-cylindrical section 50. As a result, it is possible to suppress the increase in the resistance of the endless annular conductive path in the circumferential direction of the wire connection section 16 due to poor contact between the one ends 32, 52 or between the other ends 33, 53.
[0034] The end face of one end 32 of the first wire connection plate portion 26 (here, the first semi-cylindrical portion 30) is joined to the end face of one end 52 of the second wire connection plate portion 46 (here, the second semi-cylindrical portion 50). The end face of the other end 33 of the first wire connection plate portion 26 (here, the first semi-cylindrical portion 30) is joined to the end face of the other end 53 of the second wire connection plate portion 46 (here, the second semi-cylindrical portion 50). As a result, irregularities are less likely to occur in the circumferential direction on the inner surface of the wire connection portion 16, and it is easier to form the shape of the inner surface of the wire connection portion 16 to match the shape of the outer surface of the wire 80. The joining area between the end face of one end 32 of the first wire connection plate portion 26 and the end face of one end 52 of the second wire connection plate portion 46 may be a part of the area where the end faces are in contact, or it may be the entire area. The same applies to the joining region between the end face of the other end 33 of the first wire connection plate portion 26 and the end face of the other end 53 of the second wire connection plate portion 46.
[0035] The joining of the end faces may be done by welding, such as laser welding. In this case, the parts of the end faces that are in contact are directly joined without the need for another member. The joining of the end faces may also be done by brazing, etc., using a joining material other than the end faces. There may be a joint mark at the joint portion 18 of the end faces.
[0036] The first transition section 28 is located between the first flat plate section 22 and the first semi-cylindrical section 30. The first transition section 28 is formed such that its radius of curvature gradually decreases toward the side where the first flat plate section 22 is located. The main surface of the first transition section 28 gradually deforms from the concave surface 31, which is the main surface of the first semi-cylindrical section 30, toward the flat surface 23, which is the main surface of the first flat plate section 22. In the first plate section 20, the end face at the end in the Y direction is designated as the side end face. The side end face of the first flat plate section 22 faces the Y direction. The side end face of the first semi-cylindrical section 30 faces Z2 and becomes the end face that is joined to the second semi-cylindrical section 50. The first transition section 28 is provided to change the orientation of the side end face of the first plate section 20.
[0037] The second transition section 48 is located between the second flat plate section 42 and the second semi-cylindrical section 50. The second transition section 48 is formed such that its radius of curvature gradually decreases toward the side where the second flat plate section 42 is located. The main surface of the second transition section 48 gradually deforms from the concave surface 31, which is the main surface of the second semi-cylindrical section 50, toward the flat surface 43, which is the main surface of the second flat plate section 42. In the second plate section 40, the end face at the end in the Y direction is designated as the side end face. The side end face of the second flat plate section 42 faces the Y direction. The side end face of the second semi-cylindrical section 50 faces Z1 and becomes the end face that is joined to the first semi-cylindrical section 30. The second transition section 48 is provided to change the orientation of the side end face of the second plate section 40.
[0038] The X1 end of the first transition section 28 is flat, similar to the first flat plate section 22. The X2 end of the first transition section 28 is cylindrical, similar to the first semi-cylindrical section 30. The intermediate section of the first transition section 28 in the X direction is an elliptical cylinder, shorter in the Z direction than in the Y direction. The X1 end of the second transition section 48 is flat, similar to the second flat plate section 42. The X2 end of the second transition section 48 is cylindrical, similar to the second semi-cylindrical section 50. The intermediate section of the second transition section 48 in the X direction is an elliptical cylinder, shorter in the Z direction than in the Y direction.
[0039] The terminal 10 includes a connecting portion 60 that connects the first plate portion 20 and the second plate portion 40. The terminal 10 is formed from a single plate 70 (see Figure 6). The connecting portion 60 is the portion of the plate 70 that has been bent back by 180 degrees. Here, the connecting portion 60 connects the first flat plate portion 22 and the second flat plate portion 42. Here, the connecting portion 60 connects the end of the first flat plate portion 22 opposite to the first wire connection plate portion 26 and the end of the second flat plate portion 42 opposite to the second wire connection plate portion 46. The first wire connection plate portion 26 is connected to the X2 side edge of the first flat plate portion 22. The second wire connection plate portion 46 is connected to the X2 side edge of the second flat plate portion 42. The connecting portion 60 connects the X1-side edge of the first flat plate portion 22 to the X1-side edge of the second flat plate portion 42.
[0040] The connecting portion 60 may connect other parts besides those mentioned above. For example, the connecting portion 60 may connect the side edge (end edge in the Y direction) of the first flat plate portion 22 to the side edge (end edge in the Y direction) of the second flat plate portion 42. Alternatively, for example, the connecting portion 60 may connect the first wire connection plate portion 26 to the second wire connection plate portion 46.
[0041] Here, the side edge of the first transition section 28 and the side edge of the second transition section 48 are not joined. Here, the side edge of the first transition section 28 and the side edge of the second transition section 48 are separated in the Z direction. A clearance CR exists between the side edge of the first transition section 28 and the side edge of the second transition section 48 along the Z direction. In the intermediate section along the X direction, the first transition section 28 and the second transition section 48 are separated from each other. In the intermediate section along the X direction, a clearance CR exists between the first transition section 28 and the second transition section 48. This clearance CR continues along the Y direction from one side edge to the other. Regarding the size of the clearance CR, the size of the clearance CR is largest in the central section along the Y direction, and the size of the clearance CR is smallest at the end (side edge) along the Y direction. The clearance CR gradually decreases from the center towards the ends along the Y direction. The portion where the first transition section 28 and the second transition section 48 face each other is referred to as the transition section 14.
[0042] Here, the main surface 23 of the first flat plate portion 22 and the main surface 43 of the second flat plate portion 42 are only in contact and not joined. The main surface 23 of the first flat plate portion 22 and the main surface 43 of the second flat plate portion 42 may be joined. If the main surface 23 of the first flat plate portion 22 and the main surface 43 of the second flat plate portion 42 are joined, the joining region may be part of the region where the main surface 23 of the first flat plate portion 22 and the main surface 43 of the second flat plate portion 42 are in contact, or it may be the entire region.
[0043] As shown in FIG. 5, the electric wire 80 includes a core wire 82 and an insulating coating 84. The core wire 82 has one or a plurality of strands. The strands are made of a conductor such as copper, a copper alloy, aluminum, or an aluminum alloy. The core wire 82 may be a stranded wire formed by twisting a plurality of strands. The insulating coating 84 covers the outer periphery of the core wire 82. The insulating coating 84 is formed, for example, by extrusion coating a resin material having insulating properties around the core wire 82. The electric wire 80 may be a so-called bare wire without the insulating coating 84.
[0044] At the end of the electric wire 80, a core wire exposed portion is formed where the insulating coating 84 is absent and the core wire 82 is exposed. The core wire exposed portion is inserted into the electric wire connection portion 16 from the X2-side opening of the electric wire connection portion 16. The diameter of the electric wire connection portion 16 is formed slightly larger than the diameter of the core wire 82. The tip 82a of the core wire 82 inserted into the electric wire connection portion 16 abuts against the transition portion 14. The transition portion 14 gradually has a smaller radius of curvature along the X direction. Therefore, when the core wire 82 abuts against the transition portion 14, the core wire 82 can be centered with respect to the space 17. Specifically, in the transition portion 14, the first transition portion 28 and the second transition portion 48 have the same shape as each other and are arranged in opposite directions. The inner surface of the transition portion 14 is symmetric along a plane parallel to the XY plane passing through the center of the space inside the transition portion 14. The inner surface of the transition portion 14 is symmetric along a plane parallel to the XZ plane passing through the center of the space inside the transition portion 14.
[0045] Figure 5 shows a mating conductor 90. The mating conductor 90 is, for example, a terminal 10 of an electrical device, a metal housing, a metal body of a vehicle, or the like. For example, the mating connection portion 12 is fastened to the mating conductor 90 by a bolt 92. A hole for passing the bolt 92 is formed in the mating connection portion 12. Here, a first through hole 24 is formed in the first flat plate portion 22. The first through hole 24 penetrates the first flat plate portion 22 in the Z direction. A second through hole 44 is formed in the second flat plate portion 42. The second through hole 44 penetrates the second flat plate portion 42 in the Z direction. The first through hole 24 and the second through hole 44 communicate with each other to form a hole of the mating connection portion 12. The mating connection portion 12 may be inserted into and connected to the recess of the mating conductor 90 while remaining in a plate shape.
[0046] <Manufacturing Example of Terminal> Figures 6 to 8 are views showing how the terminal 10 according to Embodiment 1 is manufactured.
[0047] First, as shown in FIG. 6, one plate material 70 corresponding to the terminal 10 is prepared. For example, the plate material 70 corresponding to the terminal 10 is cut out from a base material. The plate material 70 has a first region 71 that becomes the first plate material portion 20 and a second region 72 that becomes the second plate material portion 40. The first region 71 has a portion 71a that becomes the first flat plate portion 22, a portion 71b that becomes the first transition portion 28, and a portion 71c that becomes the first semi-cylindrical portion 30. The second region 72 has a portion 72a that becomes the second flat plate portion 42, a portion 72b that becomes the second transition portion 48, and a portion 72c that becomes the second semi-cylindrical portion 50.
[0048] In the plate material 70, the portion 71a that becomes the first flat plate portion 22 and the portion 72a that becomes the second flat plate portion 42 are connected in the X direction. In the plate material 70, the portions 71b and 71c that become the first wire connection plate portion 26 are connected to the portion 71a that becomes the first flat plate portion 22 on the X2 side. In the plate material 70, the portions 72b and 72c that become the second wire connection plate portion 46 are connected to the portion 72a that becomes the second flat plate portion 42 on the X1 side. The portions 71b, 71c that become the first wire connection plate portion 26 and the portions 72b, 72c that become the second wire connection plate portion 46 are wider in the Y direction than the portion 71a that becomes the first flat plate portion 22 and the portion 72a that becomes the second flat plate portion 42.
[0049] In the plate material 70, the portion 71b that becomes the first transition portion 28 gradually widens in the Y direction toward the portion 71c that becomes the first semi-cylindrical portion 30. In the plate material 70, the portion 72b that becomes the second transition portion 48 gradually widens in the Y direction toward the portion 72c that becomes the second semi-cylindrical portion 50.
[0050] Next, the intermediate product 74 shown in Figure 7 is formed by creating the shape of the first plate portion 20 and the shape of the second plate portion 40 in the plate material 70. For example, a first through hole 24 is formed in the portion that will become the first flat plate portion 22, and a second through hole 44 is formed in the portion that will become the second flat plate portion 42. In addition, the portions 71b and 71c that will become the first wire connection plate portion 26 are bent to form the shape of the first transition portion 28 and the shape of the first semi-cylindrical portion 30. In addition, the portions 72b and 72c that will become the second wire connection plate portion 46 are bent to form the shape of the second transition portion 48 and the shape of the second semi-cylindrical portion 50. Note that the portions 71b and 71c that will become the first wire connection plate portion 26 and the portions 72b and 72c that will become the second wire connection plate portion 46 may have the same plate width as the portion 71a that will become the first flat plate portion 22 and the portion 72a that will become the second flat plate portion 42. In this case, the portions 71b and 71c that become the first wire connection plate portion 26 and the portions 72b and 72c that become the second wire connection plate portion 46 are stretched thin to form the shape of the first wire connection plate portion 26 and the shape of the second wire connection plate portion 46.
[0051] In Figure 7, the center between the first through-hole 24 and the second through-hole 44 (the area indicated by the dashed line) is the portion that becomes the connecting portion 60. The intermediate product 76 shown in Figure 8 is formed when the plate material 70 shown in Figure 7 is folded back 180 degrees at the center position between the first through-hole 24 and the second through-hole 44. This intermediate product 76 has the same configuration as the terminal 10, except that the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50 are not joined together. Note that the first through-hole 24 and the second through-hole 44 may be formed after the plate material 70 has been folded back 180 degrees.
[0052] Next, the terminal 10 shown in Figure 1 is completed by joining the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50. Here, the end face of one end 32 of the first semi-cylindrical portion 30 is joined to the end face of one end 52 of the second semi-cylindrical portion 50. Also, here, the end face of the other end 33 of the first semi-cylindrical portion 30 is joined to the end face of the other end 53 of the second semi-cylindrical portion 50.
[0053] <Modified Terminals> Modified terminals of terminal 10 will be described below. In the following description, components that are the same as those described above will be denoted by the same reference numerals, and their descriptions will be omitted.
[0054] In terminal 10, the first wire connection plate portion 26 and the second wire connection plate portion 46 do not necessarily have to be joined. As described above, the intermediate product 76 shown in Figure 8 has the same configuration as terminal 10, except that the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50 are not joined. Therefore, the intermediate product 76 shown in Figure 8 can be considered as terminal 110 according to the first modified example in which the first wire connection plate portion 26 and the second wire connection plate portion 46 are not joined. Also, Figure 8 can be considered as a perspective view showing terminal 110 according to the first modified example. In terminal 110, the spaces between the one ends 32, 52 and the spaces between the other ends 33, 53 are non-jointed portions. Terminal 110 may be used when connected to a wire 80 by, for example, crimping.
[0055] Figure 9 is a perspective view showing the terminal 210 according to the second modified example.
[0056] In terminal 210, the clearance CR between the first transition portion 28 and the second transition portion 48 at the side edge of terminal 210 is closed. By closing the clearance CR at the side edge of terminal 210, the intrusion of foreign matter such as dust, dirt, or water from the clearance CR into the space 17 of the wire connection portion 16 can be suppressed.
[0057] The contact portion between the first transition portion 28 and the second transition portion 48 at the side edge of the terminal 210 may or may not be joined. In this case, the contact portion between the first transition portion 28 and the second transition portion 48 is joined. Therefore, the joint portion 218 extends along the X direction across the entirety of the first wire connection plate portion 26 and the second wire connection plate portion 46. By joining the contact portion between the first transition portion 28 and the second transition portion 48, the intrusion of foreign matter such as dust, dirt, or water from between the first transition portion 28 and the second transition portion 48 into the space 17 of the wire connection portion 16 can be more reliably suppressed.
[0058] When the contact portion between the first flat plate portion 22 and the second flat plate portion 42 is joined, the gap between the first plate portion 20 and the second plate portion 40 is eliminated in the terminal 210, except for the X2 side opening of the wire connection portion 16. This makes it possible to more reliably suppress the intrusion of foreign matter into the space 17 of the wire connection portion 16.
[0059] Figure 10 is a perspective view showing the terminal 310 according to the third modified example. Figure 11 shows the process of inserting the electric wire 80 into the terminal 310 according to the third modified example.
[0060] The first plate portion 320 or the second plate portion 340 of the terminal 310 includes projections 334 and 354. The projections 334 and 354 contact the electric wire 80 when the electric wire 80 is located in the space 17, thereby positioning the electric wire 80.
[0061] Here, the first plate portion 320 includes one projection 334, and the second plate portion 340 includes one projection 354. The base end of projection 334 protrudes in the X2 direction from the circumferential center of the X2 side end of the first semi-cylindrical portion 30. The tip of projection 334 protrudes radially from the base end of projection 334 toward the radial center. The tip of projection 334 protrudes radially from the inner circumferential surface of the first semi-cylindrical portion 30. The base end of projection 354 protrudes in the X2 direction from the circumferential center of the X2 side end of the second semi-cylindrical portion 50. The tip of projection 354 protrudes radially from the base end of projection 354 toward the radial center. The tip of projection 354 protrudes radially from the inner circumferential surface of the second semi-cylindrical portion 50.
[0062] The tip 82a of the exposed core wire is centered by the transition section 14. The end of the exposed core wire on the insulating coating 84 side is centered by the protrusions 334 and 354. The electric wire 80 is centered at both ends along the X direction with respect to the electric wire connection section 16. This improves the centering accuracy of the electric wire 80.
[0063] Figure 12 is a perspective view showing the terminal 410 according to the fourth modified example.
[0064] In terminal 410, there are four protrusions 434 and 454. The first plate portion 420 includes two protrusions 434, and the second plate portion 440 includes two protrusions 354. Adjacent protrusions 434 and 454 are formed at positions 90 degrees apart. The number of protrusions 434 and 454 is not limited to the above example; there may be three or five or more.
[0065] Figure 13 is a perspective view showing the terminal 510 according to the fifth modified example.
[0066] In terminal 510, the wire connection portion 516 and the internal space 517 are wider. While the conventional terminal 10 was a terminal for round wires, terminal 510 is a terminal for flat wires. Terminal 510 is wider in the Y direction than in the Z direction. The terminal may also be wider in the Z direction than in the Y direction.
[0067] The first semi-cylindrical portion 530 of the terminal 510 includes two quarter portions 530A and one flat portion 530B. The quarter portions 530A are formed in a shape corresponding to one of the four divisions of the cylindrical portion. The two quarter portions 530A are positioned apart in the Y direction and facing opposite directions. The flat portion 530B connects the two quarter portions 530A. The second semi-cylindrical portion 550 also includes two quarter portions 550A and one flat portion 550B, similar to the first semi-cylindrical portion 530. The transition portion 514, mating portion 512, and connecting portion 560 of the terminal 510 also have the same width as the wire connection portion 516.
[0068] <Electric wire with terminals> Figure 14 is a perspective view showing an electric wire with terminals 100 according to Embodiment 1. Figure 15 is a diagram illustrating the manufacturing process of the electric wire with terminals 100 according to Embodiment 1. Figure 16 is a diagram illustrating the manufacturing process of the electric wire with terminals 100 according to Embodiment 1.
[0069] The terminal-equipped wire 100 comprises the terminal 10 and the wire 80. The wire 80 is connected to the wire connection portion 16 of the terminal 10 to form the terminal-equipped wire 100. The terminal-equipped wire 100 is connected to the mating conductor 90.
[0070] The manufacturing method for the terminal-equipped electric wire 100 comprises an arrangement step and a connection step. The arrangement step is the step of arranging the terminal 10 and the electric wire 80 in a predetermined positional relationship. The connection step is the step of connecting the terminal 10 to the electric wire 80. In the arrangement step, the end of the electric wire 80 is contained in the space 17 between the main surface 31 of the first electric wire connection plate portion 26 and the main surface 51 of the second electric wire connection plate portion 46.
[0071] The connection method in the connection process can be set as appropriate, such as electromagnetic pressure welding, resistance welding, or crimping. Here, in the manufacturing method of the terminal-equipped electric wire 100, electromagnetic pressure welding is used as the connection method in the connection process. In the terminal-equipped electric wire 100, an electromagnetic pressure-welded portion 102 is provided where the electric wire connection portion 16 and the electric wire 80 are electromagnetically pressure-welded.
[0072] As shown in Figure 15, an electromagnetic contact welding device 104 is used for electromagnetic contact welding. The electromagnetic contact welding device 104 is equipped with a discharge coil 105. The wire connection portion 16 of the terminal 10 and the core wire 82 of the wire 80 are placed inside the discharge coil 105, and the core wire 82 fits into the space 17 of the wire connection portion 16. In this state, a discharge current indicated by arrow 105i flows through the discharge coil 105. When the discharge current indicated by arrow 105i flows, a magnetic field H is generated between the discharge coil 105 and a part of the wire connection portion 16 in the direction perpendicular to the plane of the paper in Figure 5. At this time, the electromotive force induced by the magnetic field H generates an induced current indicated by arrow 16i in a part of the wire connection portion 16. Due to the magnetic field H and the induced current indicated by arrow 16i, an electromagnetic force in the direction of diameter reduction indicated by arrow F acts on a part of the wire connection portion 16. As a result, a part of the wire connection portion 16 deforms to reduce its diameter as shown by the dashed line in Figure 5. This causes a portion of the wire connection part 16 and the core wire 82 to be pressed together.
[0073] In the pressure welding using the electromagnetic pressure welding device 104, a portion of the wire connection portion 16 collides with the core wire 82 at a speed close to the speed of sound. It is assumed that if the core wire 82 is left in the air, an oxide film will form on its surface. Similarly, if the terminal 10 is left in the air, an oxide film will form on its surface. It is assumed that the oxide film formed on the surfaces of the core wire 82 and the terminal 10 will be removed by the portion of the wire connection portion 16 collides with the core wire 82 at a speed close to the speed of sound. As a result, a portion of the wire connection portion 16 and the core wire 82 are properly pressure-welded.
[0074] For electromagnetic pressure welding, it is desirable that the wire connection portion 16 and the core wire 82 be centered with high precision. When the wire connection portion 16 and the core wire 82 are centered with high precision, the gap between the wire connection portion 16 and the core wire 82 before pressure welding can be made uniform along the circumferential direction. As a result, the unevenness of the electromagnetic force required for pressure welding between a portion of the wire connection portion 16 and the core wire 82 in the circumferential direction is reduced, and it is assumed that a portion of the wire connection portion 16 and the core wire 82 will be pressure-welded at a similar speed in the circumferential direction. Therefore, it is considered that a portion of the wire connection portion 16 and the core wire 82 will be pressure-welded uniformly in the circumferential direction.
[0075] A jig may be used to center the wire connection part 16 and the core wire 82. In electromagnetic pressure welding, the wire connection part 16 collides with the core wire 82 at a speed close to the speed of sound, so the jig wears out quickly. In terminal 10, the transition part 14 can center the tip 82a of the core wire 82. In the case of terminal 310 or terminal 410, the projections 334, 354 or projections 434, 454 can further center the end of the core wire 82 on the insulating coating 84 side. As described above, by employing the transition part 14 and projections 334, 354 or projections 434, 454 that can center the core wire 82, the jig for centering the core wire 82 can be omitted or simplified.
[0076] Furthermore, if the distance between the wire connection portion 16 and the core wire 82 before crimp welding is short, the wire connection portion 16 and the core wire 82 will come into contact before reaching a speed close to the speed of sound. On the other hand, if the distance between the wire connection portion 16 and the core wire 82 before crimp welding is long, the wire connection portion 16 and the core wire 82 will come into contact at a decelerated speed after reaching a speed close to the speed of sound. For this reason, it is preferable that the distance between the wire connection portion 16 and the core wire 82 before crimp welding is a distance suitable for contact between the wire connection portion 16 and the core wire 82 at a speed close to the speed of sound. If the gap between the wire connection portion 16 and the core wire 82 before crimp welding can be made uniform along the circumferential direction, it becomes easier to maintain a distance suitable for contact between the wire connection portion 16 and the core wire 82. At terminal 10, the end faces of one end 32, 52 are joined together, and the end faces of the other end 33, 53 are also joined together, making it easier to make the gap between the wire connection part 16 and the core wire 82 uniform along the circumferential direction before crimping.
[0077] In electromagnetic pressure welding, it is necessary for current to flow directly between the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50. For this reason, in electromagnetic pressure welding, it is preferable to use a terminal 10 in which the first wire connection plate portion 26 and the second wire connection plate portion 46 are joined, rather than a terminal 110 in which the first wire connection plate portion 26 and the second wire connection plate portion 46 are not joined.
[0078] <Modified Examples of Terminal-Attached Wires> Figure 17 is a perspective view showing a terminal-attached wire 200 according to the first modified example. Figure 18 is a diagram illustrating the manufacturing process of the terminal-attached wire 200 according to the first modified example.
[0079] In the terminal-equipped wire 200, the terminal 10 and the wire 80 are resistance-welded. In the manufacturing method of the terminal-equipped wire 200, resistance welding is used as a connection means in the connection process. In the terminal-equipped wire 200, a resistance-welded portion 202 is provided where the wire connection portion 16 and the wire 80 are resistance-welded.
[0080] As shown in Figure 18, a resistance welding apparatus 204 is used for resistance welding. The resistance welding apparatus 204 is equipped with a first electrode 205 and a second electrode 206. The wire connection part 16 and the wire 80 are positioned between the first electrode 205 and the second electrode 206, and the wire 80 fits into the space 17 of the wire connection part 16. In this state, the first electrode 205 and the second electrode 206 press the wire connection part 16 and the wire 80, and current flows between the first electrode 205 and the second electrode 206. As a result, the heated and softened wire connection part 16 and the wire 80 are welded together.
[0081] In resistance welding, current flows from the first electrode 205 to the second electrode 206 via the first semi-cylindrical portion 30, the core wire 82, and the second semi-cylindrical portion 50. Therefore, in resistance welding, it is not necessary for current to flow directly between the ends 32 and 33 of the first semi-cylindrical portion 30 and the ends 52 and 53 of the second semi-cylindrical portion 50. For this reason, in resistance welding, the terminal 110, in which the ends 32 and 33 of the first semi-cylindrical portion 30 and the ends 52 and 53 of the second semi-cylindrical portion 50 are not joined, is more suitable for resistance welding than electromagnetic pressure welding. However, if the ends 32 and 33 of the first semi-cylindrical portion 30 and the ends 52 and 53 of the second semi-cylindrical portion 50 are joined, as in terminal 10, the resistance value between the first electrode 205 and the second electrode 206 can be reduced, thereby increasing the current value. For this reason, even in resistance welding, terminal 10 is more suitable for resistance welding than terminal 110.
[0082] Figure 19 is a perspective view showing a terminal-equipped wire 300 according to a second modification. Figure 20 is a diagram illustrating the manufacturing process of the terminal-equipped wire 300 according to the second modification.
[0083] In the terminal-equipped wire 300, the terminal 110 and the wire 80 are crimped together. In the manufacturing method of the terminal-equipped wire 300, crimping is used as a connection means in the connection process. In the terminal-equipped wire 300, a crimped portion 302 is provided in which the wire connection portion 116 and the wire 80 are crimped together.
[0084] As shown in Figure 20, a crimping device 304 is used for crimping. The crimping device 304 comprises a crimper 305 and an anvil 306. The wire connection portion 116 and the wire 80 are positioned between the crimper 305 and the anvil 306, and the wire 80 fits into the space 17 of the wire connection portion 116. In this state, as shown by the arrow in Figure 20, the crimper 305 moves toward the anvil 306, and the crimper 305 and anvil 306 press the wire connection portion 116 and the wire 80. As a result, the outer surfaces of the wire connection portion 116 and the wire 80 are plastically deformed to the shape corresponding to the inner surfaces of the crimper 305 and anvil 306, and the wire connection portion 116 and the wire 80 are crimped together.
[0085] In crimping, it is not necessary for current to flow between the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50. Therefore, even if the above-mentioned terminal 110 is used in crimping, a good connection can be obtained. Of course, even in crimping, a terminal like the above-mentioned terminal 10, in which the first wire connection plate portion 26 and the second wire connection plate portion 46 are connected, may also be used.
[0086] <Effects, etc.> With terminals 10, 110, 210, 310, 410, and 510 configured as described above, the conductive path between the electric wire 80 and the mating conductor 90 has a path from the first electric wire connection plate portion 26 to the first flat plate portion 22 and a path from the second electric wire connection plate portion 46 to the second flat plate portion 42. This makes it possible to increase the conductor cross-sectional area of the conductive path from the electric wire 80 to the mating conductor 90 while suppressing an increase in the thickness of each plate material portion. This makes it possible to increase the conductor cross-sectional area of the conductive path in terminals 10, 110, 210, 310, 410, and 510 while suppressing a decrease in the workability of connecting to the electric wire 80.
[0087] Furthermore, since the shape of the mating connection portion 12 can be changed by changing the shape of the plate material 70, the mating connection portion 12 offers a high degree of flexibility. For example, the mating connection portion 12 may be formed in an L-shape when viewed from the Z direction. Also, since the terminals 10, 110, 210, 310, 410, and 510 can be formed using the plate material 70, cost increases can be suppressed.
[0088] Furthermore, the concave surface 31, which serves as the main surface of the first semi-cylindrical portion 30, faces the main surface 51 of the second wire connection plate portion 46, forming a space 17. In this case, the wire connection portion 16 is formed in a cylindrical shape. This makes it easier to position the wire 80 in the wire connection portion 16 before connection.
[0089] Furthermore, the concave surface 31 of the first semi-cylindrical portion 30 faces the concave surface 51 of the second semi-cylindrical portion 50, which serves as the main surface, forming a space 17. In this case, the wire connection portion 16 can be formed in a cylindrical shape with a circular cross-section. This makes it easier to position the wire 80 in the wire connection portion 16 before connection. Also, since the mating connection portion 12 is located at the center of the wire connection portion 16 in the Z direction when viewed from the Y direction, bending of the mating connection portion 12 at the boundary with the transition portion 14 can be suppressed when connecting the wire connection portion 16 to the wire 80.
[0090] Furthermore, with respect to terminals 10, 210, 310, 410, and 510, one circumferential end 32 of the first semi-cylindrical portion 30 is joined to one circumferential end 52 of the second semi-cylindrical portion 50, and the other circumferential end 33 of the first semi-cylindrical portion 30 is joined to the other circumferential end 53 of the second semi-cylindrical portion 50. The wire connection portion 16 may be connected to the wire 80 by electromagnetic pressure welding. During electromagnetic pressure welding, a large induced current flows instantaneously in the circumferential direction of the wire connection portion 16. Even in this case, by joining the circumferential ends of the wire connection plate portions, it is possible to suppress the increase in resistance at the boundary between the first wire connection plate portion 26 and the second wire connection plate portion 46 in the conductive path that is continuous in the circumferential direction of the wire connection portion 16. As a result, a wire connection portion 16 more suitable for electromagnetic pressure welding can be obtained.
[0091] Furthermore, the end face 32 of one end of the first semi-cylindrical portion 30 is joined to the end face 52 of one end of the second semi-cylindrical portion 50, and the end face 33 of the other end of the first semi-cylindrical portion 30 is joined to the end face 53 of the other end of the second semi-cylindrical portion 50. In the case of electromagnetic pressure welding, it is desirable that the wire connection portion 16 deforms uniformly. Even in this case, by joining the end faces of the wire connection plate portions, it becomes easier to bring the inner circumferential shape of the cylindrical wire connection portion 16 closer to the outer circumferential shape of the wire 80. As a result, a wire connection portion 16 more suitable for electromagnetic pressure welding can be obtained.
[0092] Furthermore, the first semi-cylindrical portion 30 and the second semi-cylindrical portion 50 have the same radius of curvature, and the first transition portion 28 and the second transition portion 48 are formed such that the radius of curvature gradually decreases toward the side where the first flat plate portion 22 and the second flat plate portion 42 are located. This makes it easier to center the electric wire 80 inserted into the cylindrical electric wire connection portion 16 using the first transition portion 28 and the second transition portion 48.
[0093] Furthermore, terminals 10, 110, 210, 310, 410, and 510 are equipped with connecting parts 60 that connect the first plate portion 20 and the second plate portion 40, and are formed from a single plate 70. This allows the two plate portions to be maintained in a predetermined positional relationship by the connecting parts 60, and simplifies the configuration for maintaining the two plate portions in a combined state.
[0094] Furthermore, the connecting portion 60 connects the first flat plate portion 22 and the second flat plate portion 42. The wire connection plate portions 26 and 46 may have a more complex semi-cylindrical shape compared to the flat plate portions 22 and 42. Even in this case, the absence of the connecting portion 60 on the wire connection plate portions 26 and 46 makes it easier to process the plate material 70 into the shape of the wire connection plate portions 26 and 46.
[0095] Furthermore, with respect to terminals 310 and 410, the first plate portion 320, 420 or the second plate portion 340, 440 includes projections 334, 354, 434, and 454 that contact the electric wire 80 and position it when the electric wire 80 is located in the space 17. This allows for more precise positioning of the electric wire 80 and terminals 310 and 410 before connection.
[0096] Furthermore, the terminal-equipped wires 100, 200, and 300 configured as described above, and their manufacturing methods, provide terminal-equipped wires 100, 200, and 300 that can increase the conductor cross-sectional area of the conductive path at the terminal 10 while suppressing a decrease in the workability of connecting to the wire 80.
[0097] [Note] Up to this point, the second wire connection plate portion 46 has been described as having a second semi-cylindrical portion 50, but this is not an essential configuration. The second wire connection plate portion may be formed in a flat shape and serve as a lid to close the opening of the first semi-cylindrical portion 30.
[0098] Furthermore, both the first wire connection plate portion and the second wire connection plate portion may have a flat connection plate portion, and at least one of the first wire connection plate portion and the second wire connection plate portion may have a transition portion that offsets the two connection plate portions in the Z direction.
[0099] Furthermore, in the terminal, the first plate portion and the second plate portion may be made of different plate materials.
[0100] Furthermore, some or all of the terminal surfaces may be plated with tin or the like. If some of the terminal surfaces are plated, for example, the mating connection portion 12 may be plated, while the wire connection portion 16 may not be plated.
[0101] Furthermore, the configurations described in each of the above embodiments and modifications can be combined as appropriate, as long as they do not contradict each other. The configuration of one of the terminals 10, 110, 210, 310, 410, and 510 can be applied to the other terminals, as long as they do not contradict each other.
[0102] 10, 110, 210, 310, 410, 510 Terminals 12, 512 Mating connection parts 14, 514 Transition parts 16, 516 Wire connection parts 16a Inner surface 17, 517 Space 18, 218 Joint parts 20, 320, 420 First plate material part 22 First flat plate part 23, 43 Plane (main surface) 24 First through hole 26 First wire connection plate part 28 First transition part 30, 530 First semi-cylindrical part 31, 51 Concave surface (main surface) 32, 52 One end 33, 53 Other end 40, 340, 440 Second plate material part 42 Second flat plate part 44 Second through hole 46 Second wire connection plate part 48 Second transition part 50, 550 Second semi-cylindrical section 60, 560 Connecting section 70 Plate material 71 First region 72 Second region 74, 76 Intermediate manufactured product 75 Fold 80 Electric wire 82 Core wire 82a Outer surface 84 Insulation coating 90 Mating conductor 100, 200, 300 Electric wire with terminal 102 Electromagnetic pressure contact section 104 Electromagnetic pressure contact device 105 Discharge coil 202 Resistance welding section 204 Resistance welding device 205, 206 Electrode 302 Crimping section 304 Crimping device 305 Crimper 306 Anvil 334, 354, 434, 454 Projection 530A, 550A Quarter section 530B, 550B Flat plate section CR Clearance
Claims
1. A terminal for connecting an electric wire and a mating conductor, comprising: a first plate material portion including a first flat plate portion and a first wire connection plate portion connected to the end of the first flat plate portion; a second plate material portion including a second flat plate portion and a second wire connection plate portion connected to the end of the second flat plate portion, wherein the portion where the first flat plate portion and the second flat plate portion overlap so that their main surfaces are in contact with each other forms a mating connection portion that connects to the mating conductor; the portion where the first wire connection plate portion and the second wire connection plate portion are arranged so that their main surfaces are separated forms a wire connection portion that connects to the electric wire; and a space for accommodating the end of the electric wire is formed between the main surface of the first wire connection plate portion and the main surface of the second wire connection plate portion.
2. A terminal according to claim 1, wherein the first wire connection plate portion has a first semi-cylindrical portion formed in a semi-cylindrical shape, and the concave surface of the first semi-cylindrical portion, which serves as the main surface, faces the main surface of the second wire connection plate portion to form the space.
3. A terminal according to claim 2, wherein the second wire connection plate portion has a second semi-cylindrical portion formed in a semi-cylindrical shape, and the concave surface of the first semi-cylindrical portion faces the concave surface of the second semi-cylindrical portion which serves as the main surface, forming the space.
4. A terminal according to claim 3, wherein one circumferential end of the first semi-cylindrical portion is joined to one circumferential end of the second semi-cylindrical portion, and the other circumferential end of the first semi-cylindrical portion is joined to the other circumferential end of the second semi-cylindrical portion.
5. A terminal according to claim 4, wherein the end face of one end of the first semi-cylindrical portion is joined to the end face of one end of the second semi-cylindrical portion, and the end face of the other end of the first semi-cylindrical portion is joined to the end face of the other end of the second semi-cylindrical portion.
6. A terminal according to any one of claims 3 to 5, wherein the first wire connection plate portion has a first transition portion located between the first semi-cylindrical portion and the first flat plate portion, the second wire connection plate portion has a second transition portion located between the second semi-cylindrical portion and the second flat plate portion, the first semi-cylindrical portion and the second semi-cylindrical portion have the same radius of curvature, and each of the first transition portion and the second transition portion is formed such that the radius of curvature gradually decreases toward the side where the first flat plate portion and the second flat plate portion are located.
7. A terminal according to any one of claims 1 to 5, comprising a connecting portion for connecting the first plate portion and the second plate portion, and formed from a single plate.
8. A terminal according to claim 7, wherein the connecting portion connects the first flat plate portion and the second flat plate portion.
9. A terminal according to any one of claims 1 to 5, wherein the first plate portion or the second plate portion includes a projection that strikes the electric wire and positions the electric wire when the electric wire is located in the space.
10. A wire with a terminal, comprising a terminal according to any one of claims 1 to 5, and a wire connected to the wire connection portion of the terminal.
11. A method for manufacturing a wire with a terminal that is connected to a mating conductor, comprising: an arrangement step of arranging a terminal and a wire in a predetermined positional relationship; and a connection step of connecting the terminal to the wire, wherein the terminal comprises: a first plate material portion including a first flat plate portion and a first wire connection plate portion connected to the end of the first flat plate portion; a second plate material portion including a second flat plate portion and a second wire connection plate portion connected to the end of the second flat plate portion, wherein the portion where the first flat plate portion and the second flat plate portion overlap so that their main surfaces are in contact with each other forms a mating connection portion that is connected to the mating conductor; the portion where the first wire connection plate portion and the second wire connection plate portion are arranged so that their main surfaces are separated forms a wire connection portion that is connected to the wire, and in the arrangement step, the end of the wire is contained in the space between the main surface of the first wire connection plate portion and the main surface of the second wire connection plate portion.