JP7803380B2 - Fuse unit and method of manufacturing the fuse unit - Google Patents

Description

This disclosure relates to a fuse unit and a method for manufacturing a fuse unit.

High-voltage battery packs used in electric vehicles, hybrid vehicles, and the like typically consist of a large number of stacked battery cells electrically connected in series or parallel via a wiring module. A known example of such a wiring module is the conductor module described in Japanese Patent Laid-Open Publication No. 2019-32928 (Patent Document 1 below). The conductor module described in Patent Document 1 includes a wiring material and multiple bus bars. The wiring material has multiple wires that electrically connect the bus bars to the battery module monitoring unit, and fuses installed midway along the wires. Patent Document 1 cites a flexible printed circuit (FPC) as an example of the wiring material. Using an FPC as the wiring material makes it easy to install fuses on the wiring material by mounting.

Japanese Patent Application Laid-Open No. 2019-32928

In a conductor module like the one described above, if the battery cells, bus bars, etc. are changed, the wiring material must be designed and prepared separately. This makes it difficult to reduce the manufacturing costs of the wiring material.

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

The disclosed method for manufacturing a fuse unit also includes a terminal formation process for forming a first terminal and a second terminal; a resin part formation process for forming a resin part that covers a portion of the first terminal and a portion of the second terminal by insert molding, the resin part exposing the outer surface of the first terminal as a first connection part and the outer surface of the second terminal as a second connection part; and a mounting process for mounting the first electrode of a chip fuse having a first electrode and a second electrode to the first connection part and the second electrode to the second connection part.

This disclosure makes it possible to provide a fuse unit that allows for reduced manufacturing costs.

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

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

This configuration allows chip fuses to be easily incorporated into fuse units through mounting. Furthermore, even if the mating component or wiring component is changed, there may be no need to redesign the fuse unit, thereby reducing the manufacturing costs of the fuse unit.

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

With this configuration, the peripheral wall portion can protect the chip fuse.

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

With this configuration, the peripheral wall portion prevents foreign matter from coming into contact with the chip fuse, thereby preventing stress from occurring at the connection between the first connection portion and the first electrode, and at the connection between the second connection portion and the second electrode.

[4] It is preferable that the fuse unit of any one of [1] to [3] above further includes a cover member that covers the chip fuse .

With this configuration, the cover member prevents condensation and other contaminants from adhering to the chip fuse. This prevents the first electrode and second electrode from shorting out due to condensation and other contaminants.

[5] Preferably, the fuse unit of any one of [1] to [4] above further includes a third terminal to which the wiring member is connected, the second terminal includes a first terminal connection portion connected to the third terminal, and the third terminal includes a second terminal connection portion connected to the first terminal connection portion by fitting.

This configuration makes it easier to connect the wiring member to the second terminal.

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

With this configuration, the third terminal can be held in place relative to the resin portion, making it easier to determine the position of the third terminal relative to the resin portion.

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

With this configuration, the first connection portion or the second connection portion is defined by the notch, allowing the size of the first connection portion or the second connection portion to be appropriately adjusted, and heat dissipation from the first connection portion or the second connection portion can be controlled when mounting the chip fuse.

[8] In the above [7], it is preferable that the resin part has a groove formed therein that is recessed toward the first and second connection parts, the inner surface of the groove is continuous with the first and second connection parts, and a portion of the groove is located inside the notch.

This configuration prevents molten resin from migrating through the cutouts to the outer surfaces of the first and second connection parts when forming the resin part. This prevents burrs from forming on the first and second connection parts.

[9] The manufacturing method of the fuse unit disclosed herein comprises: a terminal forming process for forming a first terminal and a second terminal; a resin part forming process for forming a resin part by insert molding that covers a portion of the first terminal and a portion of the second terminal, exposing the outer surface of the first terminal as a first connection part and the outer surface of the second terminal as a second connection part; and a mounting process for mounting the first electrode of a chip fuse having a first electrode and a second electrode to the first connection part and the second electrode to the second connection part.

With this fuse unit manufacturing method, by forming a resin portion that exposes the first and second connection portions in the resin portion formation process, chip fuses can be easily incorporated into the fuse unit during the mounting process. Furthermore, even if the components to which the first and second terminals are connected are changed, there may be no need to redesign the fuse unit, thereby reducing the manufacturing costs of the fuse unit.

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

In each drawing, three mutually perpendicular directions are shown, and these three directions are respectively designated as the first direction D1, the second direction D2, and the third direction D3. That is, the first direction D1 and the second direction D2 are mutually perpendicular, the first direction D1 and the third direction D3 are mutually perpendicular, and the second direction D2 and the third direction D3 are mutually perpendicular. By depicting arrows on both sides of the solid line indicating each direction, not only the direction of the arrow on the side with the symbol, but also the direction of the arrow on the side without the symbol, is intended to indicate the corresponding direction.

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

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

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

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

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

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

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

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

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

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

The fuse unit 10 constitutes a component for mounting the chip fuse 50 without using a flexible printed circuit (FPC). That is, the first terminal 20, second terminal 30, and resin part 40 form the first connection part 24 and second connection part 34 on which the chip fuse 50 can be mounted. This makes it easy to reduce the manufacturing cost of the fuse unit 10.

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

The wiring module 1 including the fuse unit 10 has an electric wire 70 instead of an FPC as a voltage detection line. Therefore, the wiring module 1 can be manufactured at a lower cost than wiring modules that use an FPC as a voltage detection line.

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

Next, the resin part 40 is insert-molded using a portion of the first terminal 20 and a portion of the second terminal 30 as inserts (resin part formation process). The first terminal 20 and the second terminal 30 are placed in a mold, and the mold is filled with molten resin, which is the raw material for the resin part 40. During this process, the first terminal 20 and the second terminal 30 are positioned so that they do not come into direct contact. The first terminal 20 and the second terminal 30 are appropriately positioned within the mold so that the first connection part 24 and the second connection part 34 adjacent to the mounting surface 41 are exposed from the resin part 40 and are flush with the mounting surface 41. Once the resin has hardened, the mold is removed, yielding an intermediate molded body 43 (see Figure 5).

The chip fuse 50 is placed on the mounting surface 41 of the intermediate molded body 43, and the first electrode 51 is mounted to the first connection portion 24, and the second electrode 52 is mounted to the second connection portion 34 (mounting process, see Figure 6). This completes the manufacturing of the fuse unit 10.

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

This configuration allows the chip fuse 50 to be easily incorporated into the fuse unit 10 through mounting. Furthermore, even if the mating component or wiring component is changed, there may be no need to redesign the fuse unit 10, thereby reducing the manufacturing cost of the fuse unit 10.

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

With this configuration, the peripheral wall portion 42 can protect the chip fuse 50.

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

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

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

This method of manufacturing the fuse unit 10 allows the chip fuse 50 to be easily included in the fuse unit 10 during the mounting process by forming the resin part 40 that exposes the first connection part 24 and the second connection part 34 during the resin part formation process. Furthermore, even if the components to which the first terminal 20 and the second terminal 30 are connected are changed, there may be no need to redesign the fuse unit 10, thereby reducing the manufacturing cost of the fuse unit 10.

<Embodiment 2>
A second embodiment of the present disclosure will be described with reference to Figures 8 and 9. The fuse unit 110 according to the second embodiment has the same configuration as the first embodiment except that it further includes a lid portion 144 (an example of a cover member). Therefore, a description of the same components and effects as those of the first embodiment will be omitted.

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

According to the configuration of embodiment 2, the lid portion 144 can prevent water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 melts, electrical continuity between the first connection portion 24 and the second connection portion 34 through water droplets can be prevented.

<Embodiment 3>
A third embodiment of the present disclosure will be described with reference to Figures 10 and 11. A fuse unit 210 according to the third embodiment has the same configuration as that of the first embodiment, except that it further includes a sealing portion 245 (an example of a cover member). Therefore, a description of the same components and effects as those of the first embodiment will be omitted.

(Sealing portion 245)
The sealing portion 245 is made of a curable insulating resin. The sealing portion 245 may be made of a resin different from the synthetic resin that makes up the resin portion 40. The sealing portion 245 may be transparent. The sealing portion 245 of embodiment 3 is, for example, a potting agent. As shown in FIG. 11 , the sealing portion 245 is arranged so as to fill the space within the opening 42A of the peripheral wall portion 42. The sealing portion 245 is in close contact with the outer surface of the chip fuse 50, the first connecting portion 24, the second connecting portion 34, and the mounting surface 41. The sealing portion 245 is formed by filling the opening 42A with uncured liquid insulating resin after the mounting process and curing the insulating resin. A bottomed recess is formed inside the peripheral wall 42 by the inner circumferential surface of the peripheral wall 42, a surface of the resin part 40 between the first terminal 20 and the second terminal 30 that is exposed inside the peripheral wall 42, the surface of the first terminal 20 that is exposed inside the peripheral wall 42, and the surface of the second terminal 30 that is exposed inside the peripheral wall 42. Therefore, by arranging the molten sealing part 245 in this recess, the chip fuse 50, the connection part between the first connection part 24 and the first electrode 51, and the connection part between the second connection part 34 and the second electrode 52 can be easily covered by the sealing part 245.

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

According to the configuration of embodiment 3, the sealing portion 245 can prevent water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 melts, electrical continuity between the first connection portion 24 and the second connection portion 34 through water droplets can be prevented.

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

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

<Embodiment 5>
A fifth embodiment of the present disclosure will be described with reference to Fig. 13. The fuse unit 410 according to the fifth embodiment has substantially the same configuration as that of the first embodiment except for the configuration of the second terminal 430, and therefore, a description of the same components and effects as those of the first embodiment will be omitted.

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

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

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

The plate-shaped portion 521 of the first terminal 520 includes a first plate portion 521A, a second plate portion 521B, and a third plate portion 521C. The second plate portion 521B and the third plate portion 521C are formed narrower than the first plate portion 521A (see Figure 14). The first plate portion 521A is a plate-shaped member that is continuous with the mating member connecting portion 23 in the first direction D1. The second plate portion 521B extends upward from the end of the first plate portion 521A opposite the mating member connecting portion 23 in the first direction D1. The third plate portion 521C extends in the first direction D1 from the upper end of the second plate portion 521B. The third plate portion 521C and the first plate portion 521A extend on opposite sides of the second plate portion 521B in the first direction D1. The upper surface of the third plate portion 521C serves as the first connection portion 24.

The plate portion 531 of the second terminal 530 includes a first plate portion 531A, a second plate portion 531B, and a third plate portion 531C. The second plate portion 531B and the third plate portion 531C are formed narrower than the first plate portion 531A (see FIG. 14). The first plate portion 531A is a portion that is continuous with the barrel portion 33 in the first direction D1. The second plate portion 531B extends upward from the end of the first plate portion 531A opposite the barrel portion 33 in the first direction D1. The third plate portion 531C extends in the first direction D1 from the upper end of the second plate portion 531B. The third plate portion 531C and the first plate portion 531A extend on opposite sides of the second plate portion 531B in the first direction D1. The upper surface of the third plate portion 531C forms the second connection portion 34.

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

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

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

If the notch 625 were not provided, there is a possibility that the heat transfer to the first terminal 620 would be large when connecting the first electrode 51 of the chip fuse 50 and the first connection portion 24 by soldering. However, in this embodiment, by appropriately adjusting the size of the first connection portion 24 using the notch 625, it is possible to appropriately control the heat transfer to the first terminal 620.

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

(Notch 635)
The second terminal 630 has a notch 635, similar to the first terminal 620. The notch 635 is formed as a pair by being recessed from the outer edge of the second terminal 630 on the side opposite the tab portion 633 in the extension direction. The second connection portion 34 is defined by the notch 635. In other words, the second connection portion 34 and the notch 635 are adjacent to each other in the width direction of the second terminal 630. The notch 635 appropriately sets the area of the second connection portion 34 in a plan view. By appropriately adjusting the size of the second connection portion 34 using the notch 635, heat conduction to the second terminal 630 can be appropriately controlled.

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

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

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

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

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

As shown in FIG. 18 , the resin portion 640 may have a through hole 246, similar to embodiment 3. The through hole 246 penetrates the intermediate portion 641 in the second direction D2.

As shown in Figures 26 and 27, the resin part 640 includes a peripheral wall part 42, similar to embodiment 1. The peripheral wall part 42 extends from the reference surface 641A to one side (upward) in the second direction D2. That is, the peripheral wall part 42 has a portion that protrudes upward beyond the first connection part 24 and the second connection part 34. The peripheral wall part 42 is disposed around the chip fuse 50. Furthermore, the peripheral wall part 42 surrounds the first connection part 24 and the second connection part 34 in a direction perpendicular to the second direction D2.

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

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

The first connecting portion 24 may be directly connected to the inner surface of the groove 641B , and the second connecting portion 34 may be directly connected to the inner surface of the groove 641B .

If groove 641B were not provided, molten resin could migrate to the outer surfaces (top surfaces) of the first and second connection portions 24 and 34 when forming the resin portion 640 by insert molding, resulting in the formation of burrs on the first and second connection portions 24 and 34. In such cases, the burrs could cause poor electrical connection between the first connection portion 24 and the first electrode 51 or between the second connection portion 34 and the second electrode 52. However, in this embodiment, groove 641B is provided in the intermediate portion 641. Therefore, when forming the resin portion 640, molten resin is more likely to migrate into groove 641B than onto the top surfaces of the first and second connection portions 24 and 34. Therefore, the formation of burrs on the first and second connection portions 24 and 34 can be suppressed.

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

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

As shown in FIG. 18, a first communication hole 643C1 is provided in the portion of the ceiling wall 643C closer to the middle portion 641. The first communication hole 643C1 penetrates the ceiling wall 643C in the second direction D2 and communicates with the cavity 644. A second communication hole 643A1 is provided in the end of the bottom wall 643A closer to the middle portion 641. The second communication hole 643A1 penetrates the bottom wall 643A in the second direction D2 and communicates with the cavity 644.

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

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

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

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

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

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

As shown in Figures 21 and 23, the retainer 690 has an insertion hole 693A that penetrates the side wall 693 in the third direction D3. The shaft 646 is inserted into the insertion hole 693A. The retainer 690 is rotatable around the shaft 646, and can move between a temporary locking position and a full locking position.

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

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

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

With the retainer 690 in the provisionally locked position, the third terminal 680, which has been previously formed from a metal plate and connected to the wire 70, is inserted (see Figure 19). During insertion of the third terminal 680, the lance 694 interferes with the connecting tube portion 681 and elastically deforms. When the third terminal 680 is inserted into the correct position within the cavity 644, the lance 694 elastically returns to its original position and enters the locking hole 683A (see Figure 20).

Once the third terminal 680 is properly positioned within the cavity 644, the retainer 690 is moved to the full-locking position. When the retainer 690 is rotated clockwise in FIG. 23 from the partial-locking position, the locking piece 692 elastically deforms, causing the locking protrusion 692A to move over the full-locking portion 648. When the locking protrusion 692A moves toward the other side (downward) in the second direction D2 relative to the full-locking portion 648, the locking piece 692 elastically returns, and the retainer 690 reaches the full-locking position (see FIG. 22). During this time, the lance 694 penetrates the depth of the locking hole 683A, allowing the lance 694 to engage with the inner wall of the locking hole 683A (see FIG. 18). The retaining portion 695 is positioned on one side (the right side in the figure) of the connecting tube portion 681 in the first direction D1, allowing it to engage with the connecting tube portion 681. This holds the third terminal 680 in the cavity 644. This completes the manufacturing of the fuse unit 610.

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

This configuration makes it easier to connect the wiring member to the second terminal 630.

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

With this configuration, the third terminal 680 can be held relative to the resin part 640, making it easier to determine the position of the third terminal 680 relative to the resin part 640.

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

With this configuration, the first connection portion 24 or the second connection portion 34 is defined by the notches 625, 635, allowing the size of the first connection portion 24 or the second connection portion 34 to be appropriately adjusted, and heat dissipation from the first connection portion 24 or the second connection portion 34 can be controlled when mounting the chip fuse 50.

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

This configuration prevents molten resin from migrating through the notches 625, 635 to the outer surfaces of the first and second connecting portions 24, 34 when forming the resin portion 640. This prevents burrs from forming on the first and second connecting portions 24, 34.

(Other embodiments)
The above-described first to seventh embodiments can be modified as follows: The above-described first to seventh embodiments and the following modifications can be combined with each other to the extent that no technical contradiction occurs.

- The shapes and relative arrangement of the first terminal, second terminal, and resin portion are not limited to those described in embodiments 1 to 7 above, and may be modified as appropriate within the scope of achieving the objectives of this disclosure.

- In the above-described first embodiment, the end faces of the first terminal 20 and the second terminal 30 in the third direction D3 were substantially flush with the end face of the resin part 40 in the third direction D3 (see FIG. 1), but the end faces of the first terminal and the second terminal in the third direction D3 do not have to be substantially flush with the end face of the resin part in the third direction D3. For example, as a modification of the first embodiment, as shown in FIG. 29, a configuration may be adopted in which the resin part 40 covers the end faces of the first terminal 20 and the second terminal 30 in the third direction D3.

- In the first embodiment described above, the mating member was a bus bar 60, but the mating member does not have to be a bus bar and may be, for example, an electrode terminal.

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

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

- In the first embodiment described above, the resin part 40 had a mounting surface 41 on which the chip fuse 50 was placed, but the resin part does not have to have a mounting surface. In other words, the resin part does not have to have a surface that contacts the chip fuse, as long as the first electrode and second electrode of the chip fuse are connected to the first connection portion of the first terminal and the second connection portion of the second terminal, respectively.

- In the seventh embodiment described above, the fuse unit 610 includes a retainer 690 that is attached to the resin portion 640, but the fuse unit does not need to include a retainer. If a retainer is not provided, the housing portion may be provided with a retaining portion for holding the third terminal within the cavity.

- In the seventh embodiment described above, the tab portion 633 is exemplified as the first terminal connection portion, and the tubular connection portion 681 is exemplified as the second terminal connection portion. However, for example, the first terminal connection portion may be the tubular connection portion, and the second terminal connection portion may be the tab portion.

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

1: Wiring module 10: Fuse unit 20: First terminal 21: Plate-shaped portion 21A: Recess 22: Through hole 23: Mating member connection portion 24: First connection portion 30: Second terminal 31: Plate-shaped portion 31A: Recess 32: Through hole 33: Barrel portion 33A: Core wire crimping portion 33B: Insulation coating crimping portion (fixing portion)
34: Second connection portion 40: Resin portion 41: Mounting surface 42: Peripheral wall portion 43: Intermediate molded body 50: Chip fuse 51: First electrode 52: Second electrode 60: Bus bar (mating member)
70: Electric wire (wiring member)
110: Fuse unit 144: Lid portion (cover member)
210: Fuse unit 245: Sealing portion (cover member)
246: Through hole 310: Fuse unit 345: Sealing portion (cover member)
410: Fuse unit 430: Second terminal 434: Electric wire connection portion 435: Electric wire holding portion (fixing portion)
435A: Base portion 435B: Extension portion 510: Fuse unit 520: First terminal 521: Plate portion 521A: First plate portion 521B: Second plate portion 521C: Third plate portion 530: Second terminal 531: Plate portion 531A: First plate portion 531B: Second plate portion 531C: Third plate portion 540: Resin portion 610: Fuse unit 620: First terminal 625: Notch 630: Second terminal 633: Tab portion (first terminal connection portion)
635: Notch 640: Resin portion 641: Middle portion 641A: Reference surface 641B: Groove 643: Housing portion 643A: Bottom wall 643A1: Second communication hole 643B: Side wall 643C: Ceiling wall 643C1: First communication hole 644: Cavity 645: Mounting recess 645A: First mounting recess 645B: Second mounting recess 646: Shaft portion 647: Provisional locking portion 648: Full locking portion 680: Third terminal 681: Connection tube portion (second terminal connection portion)
682: Barrel portion 682A: Core wire crimping portion 682B: Insulation coating crimping portion 683: Cylindrical wall portion 683A: Locking hole 684: Elastic contact piece 690: Retainer 691: Main body portion 692: Locking piece 692A: Locking protrusion 693: Side wall 693A: Insertion hole 694: Lance 695: Retaining portion 710: Fuse unit 730: Second terminal 770: Flexible substrate (wiring member)
BS: Bottom surface S1: First inner surface S2: Second inner surface S3: Third inner surface SP1: First side surface D1: First direction D2: Second direction D3: Third direction

Claims (5)

a first terminal electrically connected to a mating member;
a second terminal indirectly electrically connected to the wiring member;
a resin portion covering a portion of the first terminal and a portion of the second terminal;
Chip fuses and
a third terminal to which the wiring member is connected;
a retainer that is assembled to the resin portion and holds the third terminal,
the resin portion maintains a distance between the first terminal and the second terminal;
the first terminal includes a first connection portion exposed from the resin portion,
the second terminal includes a second connection portion exposed from the resin portion and a first terminal connection portion connected to the third terminal,
the chip fuse includes a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion;
the third terminal includes a second terminal connection portion that is connected to the first terminal connection portion by fitting ;
a groove recessed relative to the first connecting portion and the second connecting portion is formed in the resin portion;
The fuse unit has an inner surface that defines the groove and is continuous with the first connecting portion and the second connecting portion . The fuse unit described in claim 1, wherein the resin portion has a peripheral wall portion disposed around the chip fuse, the peripheral wall portion having a portion that protrudes beyond the first connection portion and the second connection portion. The fuse unit described in claim 2, wherein the peripheral wall portion surrounds the first connection portion and the second connection portion. The fuse unit of claim 1, further comprising a cover member covering the chip fuse. a terminal forming step of forming a first terminal and a second terminal;
a resin part forming process for forming a resin part by insert molding, the resin part covering a part of the first terminal and a part of the second terminal, the resin part exposing an outer surface of the first terminal as a first connection part and exposing an outer surface of the second terminal as a second connection part;
a mounting step of mounting the first electrode of a chip fuse having a first electrode and a second electrode on the first connection portion and mounting the second electrode on the second connection portion;
a step of inserting a third terminal connected to a wiring member into a cavity of the resin portion, and connecting the third terminal to the second terminal by fitting;
and a step of assembling a retainer to the resin portion to hold the third terminal in the cavity.