JP7833909B2 - Electric wire with connecting fittings and method for manufacturing the same. - Google Patents

Description

This invention relates to a wire with a connecting fitting, such as a connector terminal or busbar, to which a conductor exposed from the end of a covered wire is connected by welding or other means, and to a method for manufacturing the same.

Conventionally, wires with connectors, in which the conductor exposed from the end of the insulated wire is connected to connectors such as terminals and busbars by welding or other means, have been used in various fields.
In electric wires with connecting fittings, the conductor exposed from the end of the insulated wire is connected to the fitting by welding or other means at the connection point, thereby creating electrical conductivity between the fitting and the conductor. Therefore, when an external force acts on the insulated wire extending from the fitting, an external force is also applied to the connection point. While an external force acting in the tensile direction along the direction of extension of the conductor has little effect on the connection state, if an external force acting in a direction intersecting the direction of extension, especially in the direction of delamination that could cause the connection point to peel off, the connection point may be damaged, potentially reducing conductivity.

For example, the electrical connection terminal disclosed in Patent Document 1 has a terminal contact portion and a wire connection portion. The wire connection portion has a welded portion for welding the core wire of the wire and a barrel portion for clamping the wire. To connect a wire to the wire connection portion, the core wire exposed from the end of the wire is welded to the welded portion, and the barrel portion is bent and crimped to fix it in place. This is said to maintain the connection between the wire and the wire connection portion so that even if a tensile force is applied to the wire, that tensile force is not applied to the welded portion of the core wire.

However, as with the electrical connection terminal in Patent Document 1, in order to prevent tensile force from being applied to the welded portion of the core wire, it was necessary to firmly crimp the barrel portion to securely maintain the connection between the electric wire and the electric wire connection portion.

Japanese Patent Application Publication No. 08-185915

Therefore, this invention aims to provide a wire with a connecting fitting and a method for manufacturing the same, which can reduce the impact on the connection point even when an external force acting on the wire in a direction intersecting the extension direction of the connection point, without crimping the insulated wire to the connecting fitting.

The present invention comprises a coated wire having a conductor covered with an insulating coating, the insulating coating being peeled off at the tip to expose the conductor, and a connecting fitting to which the exposed conductor is connected. The connecting fitting is provided with a connecting portion to be connected to an object and a conductor connecting portion to which the conductor is connected. The conductor is arranged and connected to the conductor connecting portion in a predetermined direction. The coated wire to which the conductor is connected extends from the conductor connecting portion, and the conductor connecting fitting is located on the side of the conductor connecting portion from which the coated wire extends. When an external force acting in a cross direction acts on the insulated wire extending from the connecting portion, a conversion portion is provided that contacts the insulated wire via a buffer material and converts the external force into a tensile force along the predetermined direction, acting on the connection point between the conductor and the conductor connection portion. The conversion portion is an insertion conversion portion through which the insulated wire is inserted, and the buffer material is placed between the insertion conversion portion and the insulated wire inserted into the insertion conversion portion. The insertion conversion portion is a wire with a connecting fitting that contacts the insulated wire via the buffer material.

The above connection refers to a state in which the components are integrated in a conductive manner by welding methods such as ultrasonic welding, vibration welding, or laser welding, bonding with conductive adhesive, or crimping.
The external force applied to the insulated wire extending from the aforementioned conductor connection portion is in a direction that intersects with respect to the longitudinal direction of the insulated wire extending from the conductor connection portion, that is, in a direction that intersects with respect to the axial direction of the conductor that is positioned and connected to the conductor connection portion, and includes any of the 360 degrees around the axial direction, such as up, down, left, right, and diagonal directions.

The above-mentioned conversion unit may be positioned to contact the insulated wire extending from the conductor connection unit in any direction, such as along the entire circumference in the cross-sectional direction of the insulated wire, a part of the cross-sectional direction, within a predetermined range, or at multiple locations at predetermined intervals.

This invention reduces the impact on the connection point even when an external force acting on the insulated wire in a direction intersecting the extension direction of the connection point is applied, without crimping the insulated wire to the connection fitting.

More specifically, in the connecting fitting, the conversion part is provided on the side of the conductor connection portion from which the insulated wire extends, where the conductor is connected and the insulated wire extends. Therefore, when an external force acting in a cross direction acts on the insulated wire extending from the conductor connection portion, the insulated wire comes into contact with the conversion part. When the insulated wire comes into contact with the conversion part, the external force acting on the insulated wire is converted and acts as a tensile force along the predetermined direction in which the conductor is arranged in the conductor connection portion, acting at the connection point between the conductor and the conductor connection portion. Therefore, even without crimping the insulated wire to the connecting fitting, the influence of the cross direction external force acting on the insulated wire on the connection point can be reduced.

Furthermore, since the conversion section is an insertion conversion section through which the insulated wire is inserted, even if an external force acting in a cross direction is applied to the insulated wire extending from the conductor connection section, the insulated wire will reliably contact the insertion conversion section, converting the external force acting on the insulated wire and allowing it to act as a tensile force along the predetermined direction at the connection point.

Furthermore, since the buffer material is placed between the insertion conversion section and the insulated wire inserted into the insertion conversion section, when the external force acting on the insulated wire is converted, the buffer material comes into contact with the insertion conversion section, preventing damage to the insulated wire.

In another aspect of this invention, the insertion conversion portion may be formed in a substantially cylindrical shape through which the insulated electric wire of a predetermined length is inserted.
The substantially cylindrical shape through which the insulated electric wire of a predetermined length is inserted includes substantially cylindrical shapes with the longitudinal direction of the insulated electric wire as the height direction, and whose cross-section perpendicular to the longitudinal direction is a closed cross-section such as a circle, ellipse, or polygon, or an open cross-section such as a C-shape, U-shape, or rectangular U-shape that has an opening through which the inserted insulated electric wire cannot pass.

This invention allows a coated wire of a predetermined length to pass through the substantially cylindrical insertion conversion section. Therefore, the external force acting on the coated wire is converted by the insertion conversion section through which the wire passes, and applied as a tensile force along the predetermined direction to the connection point.

In another aspect of this invention, the insertion conversion portion may be formed into a substantially cylindrical shape through which a coated electric wire of a predetermined length is inserted, by bending the barrel portion of the barrel portion having a bottom portion and a barrel portion extending from the bottom portion.
The substantially cylindrical shape through which the insulated electric wire of the predetermined length described above is inserted may be configured as a closed section with a bent barrel piece and a bottom, or as an open section having an opening through which the insulated electric wire cannot pass.

This invention involves bending a barrel section to form a substantially cylindrical shape through which the insulated wire can be inserted, and inserting a predetermined length of the insulated wire through the substantially cylindrical insertion conversion section. Therefore, the external force acting on the insulated wire can be converted by the insertion conversion section through which the wire is inserted, and applied to the connection point as a tensile force along the predetermined direction.

Furthermore, since the insulated wire passing through the interior is not crimped, the barrel piece can be bent to form a roughly cylindrical insertion conversion section before inserting the insulated wire. If the barrel piece is bent to form a roughly cylindrical insertion conversion section before inserting the insulated wire, the connecting fitting is not deformed after connecting the conductor to the conductor connection section. Therefore, stress due to deformation does not occur at the connection point, and the connection state between the conductor connection section and the conductor can be stabilized.

In another aspect of this invention, the conductor connection portion may have a planar portion, and the insertion conversion portion may be in an inclined position such that the side from which the insulated wire extends is inclined with respect to the planar portion.
The side on which the insulated wire extends from the aforementioned planar portion may be inclined in the in-plane direction or out-of-plane direction with respect to the main surface on which the conductor is connected in the planar portion.

This invention causes the insertion conversion portion to be inclined with respect to the planar portion, resulting in bending of the insulated wire extending from the conductor connection portion. This reduces the influence of external forces acting on the connection point between the conductor connection portion and the conductor.

Furthermore, in an embodiment of this invention, the conductor connection portion may have a planar portion, and the insertion conversion portion may be provided at the end of the conductor connection portion on the side from which the insulated wire extends, and may be formed in a frame shape by a separation restricting portion that restricts the movement of the insulated wire in a direction away from the planar portion to which the conductor is connected, and a pair of leg portions that restrict the movement of the insulated wire in a direction intersecting the direction of separation, and may be a frame shape that protrudes from the planar portion.

The direction in which the conductor is separated from the planar portion to which it is connected refers to the direction in which the conductor connected to the planar portion peels off.
The frame shape formed by a separation restricting portion that restricts the movement of the insulated wire in a direction away from the planar portion to which the conductor is connected, and a pair of legs that restrict the movement of the insulated wire in a direction intersecting the direction of separation, may be a rectangular U-shape, U-shape, H-shape, etc., in which the extension directions of the separation restricting portion and the legs are different, or a semicircular, semielliptical, or arc shape in which the separation restricting portion and the legs are continuous, or the intersection of a pair of legs that are inclined toward each other may be used as the separation restricting portion. In other words, the frame shape composed of the separation restricting portion and the pair of legs only needs to be able to restrict the movement of the insulated wire in any direction out of the plane of the main surface of the planar portion in the cross-section of the conductor connected to the planar portion. Note that restricting the movement of the insulated wire means that, under normal conditions, the frame shape and the inserted insulated wire may be in contact, or a gap may be provided.

This invention allows the insulated wire to be easily inserted into the frame-like structure, and the external force acting on the insulated wire inserted into the frame-like structure can be converted by the frame-like structure and applied as a tensile force along the predetermined direction to the connection point.

Furthermore, in an embodiment of this invention, the frame-like body may be arranged at a predetermined distance from the end of the conductor connection portion, and each of the legs may be provided with a connecting portion that connects the end of the conductor connection portion. The frame-like body may also be in an inclined position, tilted in one of the predetermined directions.

The above-mentioned connecting portion may be configured as a pair, provided that a pair of legs can be connected to the ends of the conductor connection portion, or a single connecting portion may connect a pair of legs to the ends of the conductor connection portion. Furthermore, in a pair of connecting portions that connect a pair of legs to the ends of the conductor connection portion, the extension direction and cross-sectional shape of each leg and each connecting portion may be continuous or discontinuous.
The inclined posture, which is tilted in any of the predetermined directions, refers to a posture that is tilted either on the side where the conductor connection portion is located or on the opposite side.

This invention allows the insulated wire to be easily inserted into the frame-like structure, and the external force acting on the insulated wire inserted into the frame-like structure can be converted by the frame-like structure and applied as a tensile force along the predetermined direction to the connection point.

Furthermore, because the frame-like body connected to the end of the conductor connection portion at the connecting portion is in an inclined position in one of the predetermined directions, bending occurs in the insulated wire extending from the conductor connection portion, thereby reducing the influence of external forces acting on the connection point between the conductor connection portion and the conductor.

In another aspect of this invention, the conductor exposed on the tip side of the insulating coating of the insulated wire may be inserted into the insertion conversion portion.
With this invention, the conductor of the insulated wire, on which an external force is applied, passes through the insertion conversion part, so that the insertion conversion part can convert the external force and apply it to the connection point as a tensile force along the predetermined direction.

Furthermore, this invention relates to a method for manufacturing a wire with a connector, in which the insulating coating on the tip end of a coated wire, which covers the conductor with an insulating coating, is stripped off to expose the conductor, and the conductor is connected to a connector. The connector is provided with a connection portion to be connected to an object and a conductor connection portion to which the conductor is connected. The conductor connection portion is provided with a conversion portion on the side of the coated wire to which the conductor is connected that extends. When an external force acting in a direction intersecting the coated wire extending from the conductor connection portion is applied, the conversion portion contacts the coated wire and converts the external force into a tensile force acting on the connection point between the conductor and the conductor connection portion in a predetermined direction. The coated wire is positioned on the conversion portion, the conductor is positioned along the predetermined direction relative to the conductor connection portion, and the conductor is connected to the conductor connection portion.

This invention makes it possible to easily manufacture a wire with a connecting fitting, even when an external force acting on the wire in a direction intersecting the extension direction of the connection point, without crimping the insulated wire to the connecting fitting. This reduces the impact on the connection point, compared to the method of crimping the insulated wire.

In an embodiment of this invention, the conversion unit is an insertion conversion unit through which the insulated electric wire is inserted, and the insulated electric wire may be inserted into the insertion conversion unit.
This invention improves the manufacturability of wires with connecting fittings by inserting the insulated wire into the insertion conversion part, which can convert the external force acting on the insulated wire by contact with it and apply it as a tensile force along the predetermined direction to the connection point.

Furthermore, in an embodiment of this invention, the insulated wire, with its conductor exposed at the tip, may be inserted into the substantially cylindrical insertion conversion portion through which the insulated wire of a predetermined length is inserted, toward the conductor connection portion. The conductor may then be positioned along the predetermined direction relative to the conductor connection portion, and the conductor positioned along the predetermined direction may be connected to the conductor connection portion.

This invention improves the manufacturability of wires with connecting fittings by allowing a predetermined length of the insulated wire to be inserted into the substantially cylindrical insertion conversion portion, which converts the external force acting on the insulated wire into a tensile force acting on the connection point in a predetermined direction.

Furthermore, since the insulated wire is inserted into the insertion conversion section toward the conductor connection section, and the conductor is positioned along the predetermined direction relative to the conductor connection section, and then the conductor positioned along the predetermined direction is connected to the conductor connection section, that is, the connecting fitting is not deformed after the conductor is connected to the conductor connection section, no stress due to deformation occurs at the connection point, and the connection state of the connection point between the conductor connection section and the conductor can be stabilized.

Furthermore, in an embodiment of this invention, the insulated electric wire, with its conductor exposed at its tip, may be placed inside the insertion conversion portion, which is formed by a barrel portion having a bottom portion and a barrel piece extending from the bottom portion. The conductor may also be positioned along the predetermined direction relative to the conductor connection portion, the conductor positioned along the predetermined direction may be connected to the conductor connection portion, and the barrel piece may be bent to form a substantially cylindrical shape through which the insulated electric wire of a predetermined length is inserted.

This invention allows the barrel portion to be bent to form a substantially cylindrical shape through which the insulated wire can be inserted. Since the insulated wire of a predetermined length is inserted through the substantially cylindrical insertion conversion section, the external force acting on the insulated wire is converted by the insertion conversion section through which the wire is inserted, and acts as a tensile force along the predetermined direction at the connection point.

The conductor is positioned along the predetermined direction relative to the conductor connection portion, the conductor positioned along the predetermined direction is connected to the conductor connection portion, and the barrel piece is bent to form a substantially cylindrical shape through which the insulated wire of a predetermined length is inserted. However, since it is not necessary to firmly crimp the insulated wire in the barrel portion to prevent tensile force from being applied to the conductor connection point, the bending control of the barrel piece in the barrel portion becomes easier, and the manufacturability of the wire with the connecting fitting can be improved.

In another aspect of this invention, the conductor connection portion may have a planar portion, and the insertion conversion portion through which the insulated wire is inserted may be inclined toward the side extending from the planar portion.
With this invention, since the insertion conversion portion is inclined with respect to the planar portion, bending occurs in the insulated wire extending from the conductor connection portion, thereby reducing the influence of external forces acting on the connection point between the conductor connection portion and the conductor.

Furthermore, in an embodiment of this invention, the conductor connection portion has a planar portion, and the insertion conversion portion is provided at the end of the conductor connection portion on the side from which the insulated wire extends. It is formed in a frame shape by a separation restricting portion that restricts the movement of the insulated wire in a direction away from the planar portion to which the conductor is connected, and a pair of legs that restrict the movement of the insulated wire in a direction intersecting the separation direction. The frame-shaped body protrudes from the planar portion. The insulated wire, with its exposed conductor at the tip end, is inserted into the insertion conversion portion (which is the frame-shaped body) toward the conductor connection portion. The conductor is then positioned along the predetermined direction relative to the conductor connection portion, and the conductor positioned along the predetermined direction is connected to the conductor connection portion.

This invention allows the insulated wire to be easily inserted into a frame-like body that converts the external force acting on the insulated wire into a tensile force acting on the connection point in a predetermined direction, thereby improving the manufacturability of wires with connecting fittings.

Furthermore, in an embodiment of this invention, the frame-like body may be arranged at a predetermined distance from the end of the conductor connection portion, and connecting portions may be provided to connect each of the legs to the end of the conductor connection portion. The frame-like body may also be inclined toward the side where the conductor connection portion is located.

This invention allows the frame-shaped body connected to the end of the conductor connection portion at the connecting portion to be in an inclined position in one of the predetermined directions. This causes bending to occur in the insulated wire extending from the conductor connection portion, thereby reducing the influence of external forces acting on the connection point between the conductor connection portion and the conductor.

This invention provides a wire with a connecting fitting and a method for manufacturing the same, which can reduce the impact on the connection point even when an external force acting on the wire in a direction intersecting the extension direction of the connection point, without crimping the insulated wire to the connecting fitting.

Diagram illustrating the connection of an electrical wire with fittings. Diagram illustrating the connection of an electrical wire with fittings. An explanatory diagram of the manufacturing method for electric wires with connecting fittings. An explanatory diagram showing a method for manufacturing a modified version of an electric wire with a connecting fitting. A diagram illustrating a modified example of an electric wire with a connecting fitting. A diagram illustrating further variations of electric wires with connecting fittings. A diagram illustrating further variations of electric wires with connecting fittings. An explanatory diagram illustrating a manufacturing method for further variations of electric wires with connecting fittings. An explanatory diagram of a wire with a connecting fitting according to the second embodiment. A perspective view from the base end of the electric wire with a connecting fitting according to the second embodiment. An explanatory diagram of the electric wire with a connecting fitting according to the second embodiment. An explanatory diagram of a method for manufacturing an electric wire with a connecting fitting according to the second embodiment. An explanatory diagram of a modified example of a wire with a connecting fitting according to the second embodiment. An explanatory diagram of a modified example of a wire with a connecting fitting according to the second embodiment. An explanatory diagram illustrating a method for manufacturing a modified example of an electric wire with a connecting fitting according to the second embodiment. An explanatory diagram of a wire with a connecting fitting according to the third embodiment. An explanatory diagram of a wire with a connecting fitting according to the third embodiment. An explanatory diagram of a method for manufacturing an electric wire with a connecting fitting according to the third embodiment. An explanatory diagram of a modified example of a wire with a connecting fitting according to the third embodiment. An explanatory diagram of a modified example of a wire with a connecting fitting according to the third embodiment. An explanatory diagram illustrating a method for manufacturing a modified example of an electric wire with a connecting fitting according to the third embodiment. An explanatory diagram of the wire with connecting fittings according to the fourth embodiment. An explanatory diagram of the wire with connecting fittings according to the fourth embodiment. An explanatory diagram of the manufacturing method for an electric wire with a connecting fitting according to the fourth embodiment.

One embodiment of this invention will be described below with reference to the drawings.
(First Embodiment)
First, the electric wire 1 with connecting fittings in the first embodiment will be described using Figures 1 to 3.
Figures 1 and 2 show explanatory diagrams of the wire with connecting fittings 1, and Figure 3 shows an explanatory diagram of the manufacturing method of the wire with connecting fittings 1.

More specifically, Figure 1(a) shows a perspective view from the tip side LF of the wire 1 with the connecting fitting, Figure 1(b) shows a cross-sectional view taken along the line A-A shown in Figure 2(a), and Figure 1(c) illustrates another configuration of the cylindrical insertion conversion section 30 in the same cross-section as Figure 1(b).

Figure 2(a) shows a plan view of the wire 1 with a connector, and Figure 2(b) shows a cross-sectional view taken along the line B-B shown in Figure 2(a). Figure 3(a) shows a perspective view of the insulated wire 10 positioned relative to the busbar 20, Figure 3(b) shows a perspective view of the insulated wire 10 inserted through the cylindrical insertion conversion section 30 of the busbar 20, and Figure 4(a) shows a perspective view of the wire 1 with a connector from the base end LB.

In Figure 2, the left-right direction is defined as the longitudinal direction L, the up-down direction in Figure 2(a) is defined as the width direction W, and the up-down direction in Figure 2(b) is defined as the height direction H. Furthermore, in the longitudinal direction L, the left side in Figure 2 is defined as the tip side LF, and the right side in Figure 2 is defined as the base side LB. Also, in the width direction W, the upper side in Figure 2(a) is defined as the left side WL, and the lower side in Figure 2(a) is defined as the right side WR. In the height direction H, the upper side in Figure 2(b) is defined as the upper side HU, and the lower side in Figure 2(b) is defined as the lower side HD.

The electric wire with a connector 1 is constructed by physically and electrically connecting a coated electric wire 10, in which the conductor 11 is covered with an insulating coating 12, and a busbar 20, which is a connector.
The insulated wire 10 consists of a conductor 11 positioned in the center and an insulating coating 12 covering the outside of the conductor 11. At the tip end LF of the insulated wire 10, a portion of the insulating coating 12 is peeled off, exposing the conductor 11. In the longitudinal direction L of the insulated wire 10, the portion at the tip end LF where the conductor 11 is exposed is called the exposed conductor portion 101, and the portion where the insulating coating 12 covers the conductor 11 is called the coated portion 102.

Furthermore, the insulated wire 10 may be either a main wire or a branch wire in a wire harness composed of multiple bundled wires. Also, the insulated wire 10 may be a signal wire, a power wire, or a ground wire.

The busbar 20 is constructed by bending a conductive plate material of an appropriate width W length, with the following components arranged in order from the tip end LF to the base end LB: a connection portion 21 connected to the object to be connected, an intermediate portion 22, and a conductor connection portion 23 to which the conductor 11 of the insulated wire 10 is connected.

The connection portion 21 and the conductor connection portion 23 are formed in a flat plate shape. The intermediate portion 22 is formed to connect the end of the base end LB of the connection portion 21 and the end of the tip end LF of the conductor connection portion 23 in the height direction H. The busbar 20 is formed in a stepped shape.

At the center of the width direction W at the end of the base end LB of the conductor connection portion 23, a cylindrical insertion conversion portion 30 is provided that extends toward the base end LB.
The cylindrical insertion conversion section 30 has a predetermined length in the longitudinal direction L, and as shown in Figure 1(b), it is formed by rolling a plate material from both sides in the width direction W to create a roughly cylindrical shape.

Furthermore, the cylindrical insertion conversion section 30 is bent at the upper HU with a small gap between the ends of the rolled plate material, forming a roughly cylindrical insertion space 30X (see Figure 3(a)) through which the insulated wire 10 is inserted.

The diameter of the substantially cylindrical insertion space 30X through which the insulated wire 10 is inserted, that is, the inner diameter of the cylindrical insertion conversion part 30, is formed to be slightly larger than the outer diameter of the insulated wire 10.
Furthermore, the inner corner of the base end LB of the cylindrical insertion conversion section 30 is provided with a chamfered portion 30Y, which has a cross-sectional arc shape, as shown in the enlarged view of section a in Figure 2(b).

The insulated electric wire 10 is inserted through the cylindrical insertion conversion portion 30 of the busbar 20 formed in this manner. The conductor 11 of the exposed conductor portion 101 of the insulated electric wire 10 is positioned along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 and the conductor 11 are welded together to form a welded portion 40. As shown in Figures 1 and 2, the exposed conductor portion 101 and the welded portion 40 formed by welding are integrated by the welding heat; however, in this specification, they are described as the welded, integrated exposed conductor portion 101 and welded portion 40.

In this way, the conductor connection portion 23 and the conductor 11 are electrically and physically connected by the welded portion 40 extending in the longitudinal direction L, that is, the wire 1 with a connecting fitting is constructed in which the busbar 20 and the insulated wire 10 are electrically and physically connected.
Furthermore, the welding method used to form the welded portion 40 by welding the conductor 11 to the conductor connection portion 23 can be an appropriate welding method such as ultrasonic welding, vibration welding, or laser welding.

In the wire 1 with the connecting fitting configured in this way, although a portion of the insulated portion 102 of the insulated wire 10 is inserted into the insertion space 30X inside the cylindrical insertion conversion part 30, the diameter of the insertion space 30X is formed to be slightly larger than the outer diameter of the insulated portion 102 of the insulated wire 10. Therefore, the inserted insulated portion 102 is not constrained by the cylindrical insertion conversion part 30.

Next, the manufacturing method of the electric wire 1 with connecting fittings will be explained with reference to Figure 3.
A predetermined length of the insulating coating 12 is peeled off from the tip end LF of the insulated wire 10 to form a conductor exposed portion 101 that exposes the conductor 11, and as shown in Figure 3(a), it is placed on the base end LB of the cylindrical insertion conversion portion 30 of the busbar 20.

Then, the insulated wire 10, with the conductor 11 exposed at the conductor exposed portion 101, is inserted from the base end LB of the cylindrical insertion conversion portion 30 into the insertion space 30X of the cylindrical insertion conversion portion 30, and as shown in Figure 3(b), the conductor connection portion 23 of the busbar 20 is positioned along the longitudinal direction L with the conductor exposed portion 101 exposed.
The upper surface of the conductor connection portion 23 and the boundary portion with the conductor 11, which is arranged along the longitudinal direction L, are welded in the longitudinal direction L to complete the electric wire 1 with a connecting fitting.

In this configuration, the wire 1 with the connecting fitting may be subjected to external forces acting on the insulated wire 10 extending from the busbar 20 to the base end LB. When an external force acts on the insulated wire 10, it propagates through the wire 10, acting on the welded joint 40 where the conductor connection portion 23 and the conductor 11 are welded.

Since the welded joint 40 is formed along the longitudinal direction L, it has high resistance to external forces directed toward the base end side LB. However, if an external force acts on the welded joint 40 from the upper side HU where the conductor 11 separates from the conductor connection portion 23, or from the width direction W along the upper surface of the conductor connection portion 23, or from an oblique direction along both the upper side HU and the width direction W, the welded joint 40 may peel off or be damaged from its end in the longitudinal direction L.

Specifically, as shown by the dashed lines and arrows in Figures 1 and 2, an external force F1 may act on the insulated wire 10 at the base end LB from the cylindrical insertion conversion section 30 in any direction within the 360-degree range centered on the longitudinal direction L, such as the upper HU intersecting the longitudinal direction L, the width direction W, or an oblique direction to both the upper HU and the width direction W. When an external force F1 acting on the insulated wire 10 in a direction different from the longitudinal direction L, the force F1 propagates through the insulated wire 10, potentially causing the welded joint 40 to peel or be damaged, as described above.

However, since the insulated portion 102 of the insulated wire 10 is inserted through the insertion space 30X of the cylindrical insertion conversion part 30 of the wire 1 with the connecting fitting, when an external force F1 in a direction different from the longitudinal direction L acts on the insulated wire 10 at the base end LB from the cylindrical insertion conversion part 30, the insulated wire 10 deforms in the direction in which the external force F1 acts. When the insulated wire 10 deforms in the direction in which the external force F1 acts, the insulated wire 10 comes into contact with the end of the base end LB of the cylindrical insertion conversion part 30. Using the point of contact between the end of the base end LB of the cylindrical insertion conversion part 30 and the insulated wire 10 as a fulcrum, the external force F1 changes direction and acts as a conversion external force F2 toward the base end LB on the insulated wire 10 at the tip end LF from the end of the base end LB of the cylindrical insertion conversion part 30. The conversion force F2 propagates from the end of the base end LB through the insulated wire 10 at the tip end LF, acting as a conversion force F2 directed toward the base end LB on the welded joint 40. As described above, since the welded joint 40, which extends along the longitudinal direction L, has high resistance to external forces in the longitudinal direction L, even when the conversion force F2 directed toward the base end LB acts on the welded joint 40, the welded joint 40 can maintain its connection without damage.

Furthermore, at the corner on the inner surface of the base end LB of the cylindrical insertion conversion section 30, which is the contact point and fulcrum between the base end LB of the cylindrical insertion conversion section 30 and the insulated wire 10, a chamfered portion 30Y is provided, as shown in the enlarged view of section a in Figure 2(b), with a cross-sectional arc shape. Therefore, even if an external force F1 acting on the insulated wire 10 at the base end LB of the cylindrical insertion conversion section 30 in a direction different from the longitudinal direction L, and the contact point with the insulated wire 10 becomes the fulcrum, damage to the insulating coating 12 of the insulated wire 10 by the corner of the cylindrical insertion conversion section 30 can be prevented. Note that the chamfered portion 30Y may be a tapered chamfered portion instead of a cross-sectional arc shape.

The wire with connecting fittings 1, configured in this way, comprises a covered wire 10 with an insulating coating 12 covering the conductor 11, and the insulating coating 12 at the tip end LF being peeled off to expose the conductor 11; and a busbar 20 to which the exposed conductor 11 is connected. The busbar 20 is provided with a connection portion 21 to which it is connected to the object to be connected, and a conductor connection portion 23 to which the conductor 11 is connected. The conductor 11 is positioned and connected to the conductor connection portion 23 along the longitudinal direction L. Furthermore, the covered wire 10, to which the conductor 11 is welded to the conductor connection portion 23, extends from the conductor connection portion 23. A cylindrical insertion conversion portion 30 is provided at the base end LB of the conductor connection portion 23. When an external force F1 acts on the covered wire 10 extending from the conductor connection portion 23, the covered wire 10 comes into contact with it, converting the external force F1 into a converted external force F2 along the longitudinal direction L, which acts on the welded portion 40 between the conductor 11 and the conductor connection portion 23.

With the above configuration, even if an external force F1 acting on the insulated wire 10 in a direction intersecting the longitudinal direction L along which the welded joint 40, which connects the conductor 11 exposed from the tip side LF of the insulated wire 10 to the busbar 20, extends, the effect on the welded joint 40 can be reduced, without crimping the insulated wire 10 to the busbar 20.

More specifically, in the busbar 20, a cylindrical insertion conversion section 30 is provided at the base end LB of the conductor connection section 23, where the conductor 11 is connected and the insulated wire 10 extends. Therefore, when an external force F1 acts on the insulated wire 10 extending from the conductor connection section 23, the insulated wire 10 comes into contact with the cylindrical insertion conversion section 30. When the insulated wire 10 comes into contact with the cylindrical insertion conversion section 30, the external force F1 acting on the insulated wire 10 acts as a conversion external force F2 along the longitudinal direction L in which the conductor 11 is arranged in the conductor connection section 23, and acts on the welded joint 40 between the conductor 11 and the conductor connection section 23. Thus, even without crimping the insulated wire 10 to the busbar 20, the influence of the external force F1 acting on the insulated wire 10 on the welded joint 40 can be reduced.

Furthermore, because the insulated wire 10 is inserted into the cylindrical insertion conversion section 30, even if an external force F1 acts on the insulated wire 10 extending from the conductor connection section 23, the insulated wire 10 reliably contacts the cylindrical insertion conversion section 30, converting the external force acting on the insulated wire 10 and allowing it to act as a converted external force F2 along the longitudinal direction L on the welded section 40.

Furthermore, since a coated wire 10 of a predetermined length is inserted through a cylindrical insertion conversion section 30, which is formed in a substantially cylindrical shape, the external force acting on the coated wire 10 can be converted by the cylindrical insertion conversion section 30 through which the coated wire 10 is inserted, and acted on the welded joint 40 as a converted external force F2 along the longitudinal direction L.

Furthermore, as a method for manufacturing a wire with a connecting fitting 1 in which the insulating coating 12 of the tip end LF of a covered wire 10, which covers the conductor 11 with an insulating coating 12, is stripped off to expose the conductor 11 and connect it to a busbar 20, the covered wire 10 is placed in a cylindrical insertion conversion section 30 provided on the busbar 20, the conductor 11 is placed along the longitudinal direction L relative to the conductor connection section 23, and the conductor 11 is welded to the conductor connection section 23 to connect them.

Therefore, without crimping the insulated wire 10 to the busbar 20, it is possible to easily manufacture a wire with a connecting fitting 1 that reduces the effect on the welded joint 40 even when an external force F1 acting on the insulated wire 10 in a direction intersecting the longitudinal direction L along which the welded joint 40 extends, connecting the conductor 11 exposed from the tip side LF of the insulated wire 10 to the busbar 20. This is possible compared to the case where the insulated wire 10 is crimped.

Furthermore, the insulated wire 10, with its tip end LF conductor 11 exposed, is inserted into the cylindrical insertion conversion section 30, which is formed in a substantially cylindrical shape through which an insulated wire 10 of a predetermined length is inserted, toward the conductor connection section 23. The conductor 11 is then positioned along the longitudinal direction L relative to the conductor connection section 23, and the conductor 11 positioned along the longitudinal direction L is welded to the conductor connection section 23. In other words, since the busbar 20 is not deformed after the conductor 11 is connected to the conductor connection section 23, no stress due to deformation occurs in the welded section 40, and the connection state of the welded section 40 between the conductor connection section 23 and the conductor 11 can be stabilized.

In addition, the cylindrical insertion conversion section 30 in the above-described connecting fitting-equipped electric wire 1 was bent so that there was a small gap between the ends of the rolled plate material at the upper HU, as shown in Figure 1(b). However, it may also be bent so that the ends of the rolled plate material come into contact with each other. Furthermore, the ends of the rolled plate material may be formed to face each other in an appropriate direction, such as in the width direction W, rather than at the upper HU, as shown in Figure 1(c).
Even in these cases, the same effect as the wire with connecting fitting 1 described above can be achieved.

Furthermore, in the above-described wire with connecting fittings 1, the cylindrical insertion conversion portion 30 extends toward the base end LB relative to the conductor connection portion 23 of the busbar 20. However, as shown in Figure 4(b), an inclined insertion conversion portion 30a that is inclined relative to the conductor connection portion 23 may also be used. A wire with connecting fittings 1a in which the inclined insertion conversion portion 30a is inclined relative to the conductor connection portion 23 will be explained with reference to Figures 4 and 5.

Figure 4 shows an explanatory diagram of a manufacturing method for wire 1a with a connecting fitting, which is a modified example of wire 1 with a connecting fitting, and Figure 5 shows an explanatory diagram of wire 1a with a connecting fitting, which is a modified example of wire 1 with a connecting fitting.
More specifically, Figure 4(a) shows a perspective view from the base end LB of the wire 1 with a connector fitting as described above, and Figure 4(b) shows a perspective view from the base end LB of the wire 1a with a connector fitting in which the inclined insertion conversion part 30a is inclined with respect to the conductor connection part 23. Figure 5(a) shows a cross-sectional view of the wire 1 with a connector fitting taken along the line B-B shown in Figure 2(a), and Figure 5(b) shows a cross-sectional view of the wire 1a with a connector fitting at the same cross-sectional position.
In the following description of the wire with connecting fittings 1a, the same reference numerals are used for components identical to those of the wire with connecting fittings 1 described above, and their descriptions are omitted.

Unlike the wire with a connecting fitting 1, in which the cylindrical insertion conversion section 30 connected to the base end LB of the conductor connection section 23 extends toward the base end LB, the wire with a connecting fitting 1a has an inclined insertion conversion section 30a connected to the base end LB of the conductor connection section 23 that is inclined downward toward the base end LB, becoming the lower HD. Since the configuration is the same as the cylindrical insertion conversion section 30 described above, except for the inclined orientation of the inclined insertion conversion section 30a, its explanation is omitted.

As shown in Figures 4 and 5, the wire with a connecting fitting 1a in which the inclined insertion conversion section 30a is in an inclined position can be configured by inclining the end of the base end LB of the cylindrical insertion conversion section 30 in the wire with a connecting fitting 1 described above so that it is lowered to the lower HD. Alternatively, in the busbar 20, before inserting the insulated wire 10 into the cylindrical insertion conversion section 30, the cylindrical insertion conversion section 30 may be inclined relative to the conductor connection section 23, the insulated wire 10 may be inserted, the conductor 11 of the exposed conductor portion 101 may be positioned along the longitudinal direction L relative to the conductor connection section 23, and then welded to form a welded section 40 to constitute the wire with a connecting fitting 1a.

The wire with connecting fittings 1a configured in this way provides the same effects as the wire with connecting fittings 1 described above. Specifically, even if an external force F1 acts on the insulated wire 10 at the base end LB from the inclined insertion conversion section 30a, the insulated wire 10 comes into contact with the end of the base end LB of the inclined insertion conversion section 30a, converting the external force F1 acting on the insulated wire 10. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded section 40 that welds the conductor 11 to the conductor connection section 23, thus maintaining the connection without damaging the welded section 40.

Furthermore, in the wire 1a with the connecting fitting, the conductor connection portion 23 is planar, and the inclined insertion conversion portion 30a is in an inclined position where the base end LB is inclined downwards (HD) relative to the planar conductor connection portion 23. Therefore, as shown in Figure 5(b), bending occurs in the insulated wire 10 extending from the conductor connection portion 23, reducing the influence of external forces acting on the welded portion 40 between the conductor connection portion 23 and the conductor 11.

Furthermore, since a chamfered portion 30Y, which is chamfered in a circular arc shape in cross-section, is provided at the corner of the inner surface end of the base end LB of the inclined insertion conversion portion 30a, where it contacts the insulated wire 10 and acts as a fulcrum, even if an external force F1 acting in a direction different from the longitudinal direction L acts on the insulated wire 10 of the base end LB from the inclined insertion conversion portion 30a, and the contact point with the insulated wire 10 acts as a fulcrum, it is possible to prevent the corner of the inclined insertion conversion portion 30a from damaging the insulating coating 12 of the insulated wire 10. Note that the chamfered portion 30Y may be a tapered chamfered portion instead of a circular arc in cross-section.

In the above description of the wire with connecting fittings 1a, the inclined insertion conversion section 30a of the wire with connecting fittings 1a was inclined downwards toward the base end side LB, with the lower side HD being the lower side. However, it may also be inclined in either direction in the width direction W, the upper side HU, or diagonally in the height direction H and the width direction W. Furthermore, the inclined insertion conversion section 30a may be configured so that the direction of inclination changes at a point along the longitudinal direction L.

Furthermore, in the above-described wires with connecting fittings 1 and 1a, the insulated portion 102 of the insulated wire 10 is inserted through the insertion conversion portion 30 and 30a. However, as shown in Figures 6 and 7, the exposed conductor portion 101 of the insulated wire 10 may also be inserted through the cylindrical insertion conversion portion 30. A wire with connecting fittings 1b, in which the exposed conductor portion 101 is inserted through the cylindrical insertion conversion portion 30, will be described with reference to Figures 6 and 7.

Figures 6 and 7 show explanatory diagrams of a further modified example of the wire with connector 1, namely the wire with connector 1b, and Figure 8 shows an explanatory diagram of a method for manufacturing the wire with connector 1b, which is yet another modification of the wire with connector 1.
In the following description of the wire with connecting fittings 1b, the same reference numerals are used for components identical to those of the wire with connecting fittings 1 described above, and their descriptions are omitted.

Unlike the above-described wire with a connecting fitting 1 in which the insulated portion 102 of the insulated wire 10 is inserted into the insertion space 30X of the cylindrical insertion conversion portion 30, in this case, the conductor exposed portion 101, where the insulating coating 12 has been peeled off and the conductor 11 is exposed, is inserted into the insertion space 30X of the cylindrical insertion conversion portion 30.
More specifically, the wire 1b with the connecting fitting has a buffer material 50 attached to the conductor 11 of the insulated portion 102 and is inserted into the insertion space 30X of the cylindrical insertion conversion portion 30.

The cushioning material 50 is made of a material that has appropriate cushioning properties, such as sponge, rubber, or fabric, and is formed in a cylindrical shape with a diameter slightly larger than the inner surface of the cylindrical insertion conversion section 30 and longer than the longitudinal length L of the cylindrical insertion conversion section 30.
By attaching the cushioning material 50 described above to the conductor 11 and inserting it into the insertion space 30X of the cylindrical insertion conversion part 30, the gap between the conductor 11, which has a smaller diameter than the outer diameter of the insulated wire 10, and the inner surface of the cylindrical insertion conversion part 30 can be filled.

The wire 1b with the connecting fitting described above is manufactured as shown in Figure 8.
Specifically, as shown in Figure 8(a), the insulating coating 12 of a predetermined length is peeled off from the tip side LF to expose the conductor 11, and the insulating coating 12 is peeled off to a length longer than the insulated wire 10 of the wire 1 with a connecting fitting, and a cushioning material 50 is attached to the conductor 11 of the exposed conductor portion 101 of the insulated wire 10b where the longer conductor 11 is exposed.

Furthermore, the length of the insulating coating 12 to be stripped for the insulated wire 10b, that is, the length of the exposed conductor portion 101 where the conductor 11 is exposed, is formed by adding the length of the insulating coating 12 to the length of the cylindrical insertion conversion portion 30 in the longitudinal direction L, with an additional margin.

Furthermore, the cushioning material 50 is attached from the tip side LF of the conductor 11 in the exposed conductor portion 101 to the base end side LB by the length corresponding to the length to be placed in the conductor connection portion 23.
Then, as shown in Figure 8(b), the insulated wire 10b is inserted through the cylindrical insertion conversion section 30 from the base end LB to the tip end LF, and the conductor 11 is positioned along the longitudinal direction L at the conductor connection section 23. At this time, the cushioning material 50 attached to the conductor 11 in the conductor exposed portion 101 is positioned so that it is exposed from both ends of the cylindrical insertion conversion section 30 along the longitudinal direction L. In this state, the conductor 11 positioned on the upper surface of the conductor connection section 23 and the conductor connection section 23 are welded together to form a welded section 40, and the insulated wire 10b is completed.

The wire 1b with the connecting fitting configured in this way provides the same effect as the wire 1 with the connecting fitting described above. Specifically, even if an external force F1 acts on the insulated wire 10b at the base end LB from the cylindrical insertion conversion section 30, the insulated wire 10b comes into contact with the end of the base end LB of the cylindrical insertion conversion section 30 via the buffer material 50, converting the external force F1 acting on the insulated wire 10b. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded section 40 that welds the conductor 11 to the conductor connection section 23, allowing the welded section 40 to remain undamaged and maintain the connection.

Furthermore, since a buffer material 50 is positioned between the cylindrical insertion conversion section 30 and the insulated wire 10b inserted into the cylindrical insertion conversion section 30, when the external force F1 acting on the insulated wire 10b is converted, the buffer material 50 is used to contact the cylindrical insertion conversion section 30, preventing damage to the insulated wire 10b.

(Second Embodiment)
Next, the electric wire 1c with a connecting fitting in the second embodiment will be described with reference to Figures 9 to 12.

Figure 9 shows an explanatory diagram of the wire 1c with a connecting fitting of the second embodiment, Figure 10 shows a perspective view of the wire 1c with a connecting fitting of the second embodiment from the base end LB, Figure 11 shows an explanatory diagram of the wire 1c with a connecting fitting of the second embodiment, and Figure 12 shows an explanatory diagram of the manufacturing method of the wire 1c with a connecting fitting of the second embodiment.
In the following description of the wire with connecting fittings 1c, components that are the same as those in the wires with connecting fittings 1, 1a, and 1b of the above embodiment will be denoted by the same reference numerals and their descriptions will be omitted.

Unlike the wires 1-1b with connecting fittings, which connect the insulated wires 10-10b to the busbar 20 equipped with cylindrical insertion conversion sections 30, 30a, the wire 1c with connecting fittings, as described later, is equipped with a barrel insertion section 30c, which is formed by bending the barrel piece 32 of the barrel section 31, as the insertion conversion section.

More specifically, the configuration of the connection portion 21, intermediate portion 22, and conductor connection portion 23 in the busbar 20c having the barrel insertion portion 30c is the same as that of the busbar 20 described above.
The barrel insertion portion 30c of the conductor connection portion 23 of the busbar 20c, which extends from the end of the base end LB to the base end LB, is composed of a barrel portion 31.

The barrel portion 31 constituting the barrel insertion portion 30c is composed of a bottom portion 33 extending from the center of the conductor connection portion 23 in the width direction W to the base end side LB, and a pair of barrel pieces 32 extending diagonally from both sides of the barrel piece 32 in the width direction W toward the outside and upper side HU in the width direction W. Before deformation of the barrel pieces 32, the barrel portion 31 is formed in a roughly U-shape when viewed from the base end side LB (see Figures 12(a) and (b)).

Thus, the barrel portion 31, formed in a roughly U-shape when viewed from the base end LB by the barrel piece 32 and the bottom portion 33, is bent back in a semicircular shape when viewed from the base end LB, with each barrel piece 32 facing inward in the width direction W and its tip facing downward HD. As shown in Figures 9(b) and 10, it is formed into a cylindrical shape with a roughly heart-shaped cross-section and a predetermined length.

A method for manufacturing a wire with a connecting fitting 1c, which is formed by connecting an insulated wire 10 to a busbar 20c with the above configuration, will be explained with reference to Figure 12.
First, as shown in Figure 12(a), the insulated wire 10 is placed on the base end LB of the busbar 20c, which has a barrel portion 31 with a pair of barrel pieces 32 extending outward in the width direction W from both sides of the bottom portion 33 to the upper side HU in the width direction W.

The insulated wire 10 is positioned at the bottom 33 of the barrel portion 31, starting from the base end LB of the barrel portion 31. At this time, the exposed conductor portion 101 is positioned along the longitudinal direction L at the conductor connection portion 23, and a portion of the insulated portion 102 is positioned inside the barrel portion 31 (see Figure 12(b)).

Then, the conductor 11 of the exposed conductor portion 101, which is arranged along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded together in the longitudinal direction L to form a welded portion 40. At the same time, the barrel portion 31 is crimped using a crimping device (not shown), that is, the barrel piece 32 of the barrel portion 31 is bent to form the barrel insertion portion 30c with the aforementioned cross-section, thus completing the electric wire 1c with a connecting fitting (see Figure 12(c)).

The wire with connecting fittings 1c configured in this way provides the same effects as the wire with connecting fittings 1 described above. Specifically, even if an external force F1 acts on the insulated wire 10 at the base end LB from the barrel insertion portion 30c, the insulated wire 10 abuts against the end of the base end LB at the barrel insertion portion 30c, converting the external force F1 acting on the insulated wire 10. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded portion 40 where the conductor 11 is welded to the conductor connection portion 23. As a result, the welded portion 40 remains undamaged, and the connection can be maintained.

Furthermore, the barrel insertion portion 30c of the wire 1c with a connecting fitting is formed by bending the barrel piece 32 of the barrel portion 31, which has a bottom portion 33 and a barrel piece 32 extending from the bottom portion 33, to create a substantially cylindrical shape through which a coated wire 10 of a predetermined length is inserted. Therefore, the coated wire 10 of a predetermined length passes through the substantially cylindrical barrel insertion portion 30c. As a result, the external force F1 acting on the coated wire 10 can be converted by the barrel insertion portion 30c through which the coated wire 10 is inserted, and acted on the welded portion 40 as a converted external force F2 along the longitudinal direction L.

Furthermore, the conductor 11 is positioned along the longitudinal direction L relative to the conductor connection portion 23, and the conductor 11 positioned along the longitudinal direction L is welded to the conductor connection portion 23. The barrel piece 32 is then bent to form a roughly cylindrical shape through which a predetermined length of insulated wire 10 is inserted. However, since it is not necessary to firmly crimp the insulated wire 10 in the barrel portion 31 to prevent the conversion external force F2 from being applied to the welded portion 40 of the conductor 11, the bending control of the barrel piece 32 in the barrel portion 31 becomes easier, improving the manufacturability of the wire 1c with the connecting fitting.

Furthermore, a chamfered portion 30Y may be provided on the inner corner of the base end LB in the barrel insertion portion 30c of the wire 1c with the connecting fitting. By providing a chamfered portion 30Y on the inner corner of the base end LB in the barrel insertion portion 30c, the same effect as that achieved by providing a chamfered portion 30Y on the cylindrical insertion conversion portion 30 of the wire 1 with the connecting fitting described above can be achieved.

Furthermore, in the description of the wire with connector 1c above, the insulated wire 10 was inserted into the barrel insertion portion 30c of the wire with connector 1c. However, as shown in Figures 13 to 15, the insulated portion 102 with the cushioning material 50 attached may also be inserted into the barrel insertion portion 30c. The wire with connector 1d, in which the insulated portion 102 with the cushioning material 50 attached is inserted into the barrel insertion portion 30c, will be described with reference to Figures 13 to 15.

Figures 13 and 14 show explanatory diagrams of a modified wire with a connector, namely wire 1d, which is a modified example of wire 1c with a connector from the second embodiment, and Figure 15 shows an explanatory diagram of a method for manufacturing wire 1d with a connector, which is a modified example of wire 1c with a connector from the second embodiment.
In the following description of the wire with connecting fittings 1d, components that are the same as those in the wires with connecting fittings 1 to 1c of the above embodiment will be denoted by the same reference numerals and their descriptions will be omitted.

The electric wire 1d with a connecting fitting has a cushioning material 50 attached to the corresponding portion of the insulated part 102 that is inserted into the barrel insertion part 30c, and is then inserted into the barrel insertion part 30c.
Therefore, as shown in Figure 13(b), a buffer material 50 is interposed between the covering portion 102 and the inner surface of the barrel insertion portion 30c.

As shown in Figure 15(a), the wire 1d with the connecting fitting is configured such that a buffer material 50 is pre-attached to the portion of the insulated wire 10 that is inserted into the barrel insertion portion 30c, and is positioned on the base end LB of the busbar 20c.

Then, the portion of the covering 102 to which the cushioning material 50 is attached is positioned at the bottom 33 of the barrel portion 31, and the conductor 11 constituting the exposed conductor portion 101 is positioned along the longitudinal direction L at the conductor connection portion 23 (see Figure 15(b)).

Then, the conductor 11 of the exposed conductor portion 101, which is arranged along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded together in the longitudinal direction L to form a welded portion 40. At the same time, the barrel portion 31 is crimped using a crimping device (not shown), that is, the barrel piece 32 of the barrel portion 31 is bent to form the barrel insertion portion 30c with the aforementioned cross-section, thus completing the electric wire 1d with a connecting fitting (see Figure 15(c)).

The wire with connecting fittings 1d configured in this way provides the same effect as the wire with connecting fittings 1c described above. Specifically, even if an external force F1 acts on the insulated wire 10 at the base end LB from the barrel insertion portion 30c, the insulated wire 10 comes into contact with the end of the base end LB at the barrel insertion portion 30c via the buffer material 50, converting the external force F1 acting on the insulated wire 10. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded portion 40 that welds the conductor 11 to the conductor connection portion 23, thus maintaining the connection without damaging the welded portion 40.

Furthermore, in the electric wire 1d with a connecting fitting, a buffer material 50 is placed between the barrel insertion portion 30c, which is formed by the barrel portion 31, and the insulated electric wire 10b (102) inserted into the barrel insertion portion 30c. Therefore, damage to the insulated electric wire 10b can be prevented when converting the external force F1 acting on the insulated electric wire 10b or when bending the barrel piece 32 of the barrel portion 31 to form the barrel insertion portion 30c.

Furthermore, in the manufacturing method of the wires 1c and 1d with connecting fittings described above, the conductor 11 of the exposed conductor portion 101, which is arranged along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded in the longitudinal direction L to form a welded portion 40, and the barrel portion 31 is crimped with a crimping device (not shown). However, the barrel portion 31 may be crimped with a crimping device (not shown), and then the conductor 11 of the exposed conductor portion 101, which is arranged along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded in the longitudinal direction L to form a welded portion 40.

(Third Embodiment)
Next, the electric wire 1e with connecting fittings in the third embodiment will be described with reference to Figures 16 to 18.

Figures 16 and 17 show explanatory diagrams of the wire 1e with connecting fittings according to the third embodiment, and Figure 18 shows an explanatory diagram of the manufacturing method of the wire 1e with connecting fittings according to the third embodiment.
In the following description of the wire with connecting fittings 1e, components that are the same as those in the wires with connecting fittings 1 to 1d of the above embodiment will be denoted by the same reference numerals and their descriptions will be omitted.

In the above description of the wires with connecting fittings 1 to 1d, the insulated wire 10 was inserted through a cylindrical insertion conversion section 30. However, as will be described later, the wire with connecting fittings 1e is equipped with a frame-shaped insertion conversion section 30e as the insertion conversion section.

More specifically, the configuration of the connection portion 21, intermediate portion 22, and conductor connection portion 23 in the busbar 20e having a frame-shaped insertion conversion portion 30e is the same as that of the busbar 20 described above.
The frame-shaped insertion conversion section 30e, which extends from the end of the base end LB of the conductor connection section 23 of the busbar 20e to the upper HU, is positioned on the upper HU at a predetermined distance from the upper surface of the conductor connection section 23 and is formed in a gate-like shape by a spacing direction restricting section 34 that extends in the width direction W and a pair of leg sections 35 that extend from both sides of the width direction W of the spacing direction restricting section 34 to the lower HD.

The frame-shaped insertion conversion section 30e, formed in a gate-like shape by the separation direction restricting section 34 and a pair of leg sections 35, is provided to protrude from the end of the base end side LB of the conductor connection section 23 toward the upper side HU. The insulated portion 102 of the insulated electric wire 10 can be inserted through the internal opening 30Xe enclosed by the separation direction restricting section 34 and the pair of leg sections 35.

The frame-shaped insertion conversion section 30e is integrally formed from the end of the base-side LB of the conductor connection section 23 toward the base-side LB, and then bent toward the upper-side HU. Therefore, the frame-shaped insertion conversion section 30e is formed with a thickness in the longitudinal direction L that is the same as the thickness in the height direction H of the busbar 20e.

The insulated electric wire 10, inserted through the internal opening 30Xe of the frame-shaped insertion conversion section 30e configured in this way, has its movement from the conductor connection section 23 towards the upper HU restricted by the separation direction restricting section 34, and its movement from the conductor connection section 23 towards the width direction W restricted by the leg section 35.

The wire with a connecting fitting 1e, which is formed by connecting the insulated wire 10 to the busbar 20e configured in this way, is manufactured by the manufacturing method shown in Figure 18.
Specifically, as shown in Figure 18(a), the insulated wire 10 is placed on the base end LB of the frame-shaped insertion conversion section 30e. Then, as shown in Figure 18(b), the insulated wire 10 is inserted into the frame-shaped insertion conversion section 30e from the base end LB, and the conductor 11 of the exposed conductor portion 101 is positioned along the longitudinal direction L at the conductor connection section 23 (see Figure 18(b)).
Then, the conductor 11 of the exposed conductor portion 101, which is arranged along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded together in the longitudinal direction L to form a welded portion 40, thereby completing the electric wire 1e with a connecting fitting.

The wire with connecting fittings 1e configured in this way provides the same effects as the wire with connecting fittings 1 described above. Specifically, even if an external force F1 acts on the insulated wire 10 at the base end LB from the frame-shaped insertion conversion part 30e, the insulated wire 10 comes into contact with the frame-shaped insertion conversion part 30e, converting the external force F1 acting on the insulated wire 10. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded part 40 that welds the conductor 11 to the conductor connection part 23, thus maintaining the connection without damaging the welded part 40.

Furthermore, the wire 1e with connecting fittings has a planar conductor connection portion 23. The frame-shaped insertion conversion portion 30e is provided at the end of the base end LB of the conductor connection portion 23 and is formed in a gate shape with a separation direction restricting portion 34 that restricts the movement of the insulated wire 10 of the upper HU from the planar portion to which the conductor 11 is connected, and a pair of leg portions 35 that restrict the movement of the insulated wire 10 in the width direction W. Because it protrudes from the planar portion, the insulated wire 10 can be easily inserted into the frame-shaped insertion conversion portion 30e. The frame-shaped insertion conversion portion 30e can convert the external force F1 acting on the insulated wire 10 inserted into the frame-shaped insertion conversion portion 30e into a converted external force F2 acting on the welded portion 40 along the longitudinal direction L.

Furthermore, the frame-shaped insertion conversion section 30e, which is provided at the end of the base end LB of the conductor connection section 23, is formed in a gate shape by a separation direction restricting section 34 that restricts the movement of the insulated wire 10 of the upper HU from the planar portion to which the conductor 11 is connected, and a pair of leg portions 35 that restrict the movement of the insulated wire 10 in the width direction W. The insulated wire 10 with the conductor 11 exposed at the tip end LF is inserted towards the conductor connection section 23, and the conductor 11 is positioned along the longitudinal direction L relative to the planar conductor connection section 23. Since the conductor 11 positioned along the longitudinal direction L is welded to the conductor connection section 23, the external force F1 acting on the insulated wire 10 can be converted and acted as a converted external force F2 along the longitudinal direction L on the welded portion 40. This allows for easy insertion of the insulated wire 10 into the frame-shaped insertion conversion section 30e, improving the manufacturability of the wire 1e with the connecting fitting.

Furthermore, since the insulated wire 10 is inserted through the frame-shaped insertion conversion section 30e and the conductor 11 is welded to the conductor connection section 23 to form a welded section 40, the wire 1e with the connecting fitting is completed. Because the busbar 20 is not deformed after the conductor 11 is welded to the conductor connection section 23, no stress due to deformation occurs in the welded section 40 connecting the conductor 11 and the conductor connection section 23, and the connection state of the welded section 40 connecting the conductor connection section 23 and the insulated wire 10 can be stabilized.

Furthermore, a chamfered portion 30Y may be provided at the inner corner of the base end LB in the frame-shaped insertion conversion section 30e of the wire 1e with connecting fittings. By providing a chamfered portion 30Y at the inner corner of the base end LB of the frame-shaped insertion conversion section 30e, the same effect as that achieved by providing a chamfered portion 30Y in the cylindrical insertion conversion section 30 of the wire 1 with connecting fittings described above can be achieved.

Furthermore, in the description of the wire with connecting fittings 1e above, the insulated wire 10 was inserted into the frame-shaped insertion conversion section 30e of the wire with connecting fittings 1e. However, as shown in Figures 19 to 21, the insulated portion 102 with the cushioning material 50 attached may also be inserted into the frame-shaped insertion conversion section 30e. The wire with connecting fittings 1f, in which the insulated portion 102 with the cushioning material 50 attached is inserted into the frame-shaped insertion conversion section 30e, will be described with reference to Figures 19 to 21.

Figures 19 and 20 show explanatory diagrams of a modified wire with a connector, namely wire 1f, which is a modified example of wire 1e with a connector from the third embodiment, and Figure 21 shows an explanatory diagram of a method for manufacturing wire 1f, which is a modified example of wire 1e with a connector from the third embodiment.
In the following description of the wire with connecting fittings 1f, components that are the same as those in the wires with connecting fittings 1 to 1e of the above embodiment will be denoted by the same reference numerals and their descriptions will be omitted.

The electric wire 1f with a connecting fitting has a buffer material 50 attached to the corresponding portion of the covering 102 that is inserted into the frame-shaped insertion conversion section 30e, and is then inserted into the frame-shaped insertion conversion section 30e.
Therefore, as shown in Figure 19(b), a buffer material 50 is interposed between the covering portion 102 and the inner surface of the frame-shaped insertion conversion portion 30e.

As shown in Figure 21(a), the wire 1f with the connecting fitting is configured such that a buffer material 50 is pre-attached to the portion of the insulated wire 10 that is inserted into the frame-shaped insertion conversion part 30e, and is positioned on the base end LB of the busbar 20e.

Then, the portion of the covering 102 to which the cushioning material 50 is attached is inserted into the internal opening 30Xe of the frame-shaped insertion conversion portion 30e, and the conductor 11 constituting the exposed conductor portion 101 is arranged along the longitudinal direction L in the conductor connection portion 23 (see Figure 21(b)).

Then, the conductor 11 of the exposed conductor portion 101, which is positioned along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded together in the longitudinal direction L to form a welded portion 40, thereby completing the electric wire 1f with a connecting fitting (see Figure 21(c)).

The wire with connecting fittings 1f configured in this way provides the same effect as the wire with connecting fittings 1e described above. Specifically, even if an external force F1 acts on the insulated wire 10 at the base end LB from the frame-shaped insertion conversion part 30e, the insulated wire 10 comes into contact with the frame-shaped insertion conversion part 30e via the buffer material 50, converting the external force F1 acting on the insulated wire 10. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded part 40 that welds the conductor 11 to the conductor connection part 23, thus maintaining the connection without damaging the welded part 40.

Furthermore, since the connecting wire 1f has a buffer material 50 positioned between the frame-shaped insertion conversion section 30e and the insulated wire 10 inserted into the frame-shaped insertion conversion section 30e, when converting the external force F1 acting on the insulated wire 10, the buffer material 50 is used to contact the frame-shaped insertion conversion section 30e, preventing damage to the insulated wire 10.

The frame-shaped insertion conversion section 30e described above is positioned on the upper HU at a predetermined distance from the upper surface of the conductor connection section 23. It is formed in a gate-like shape with a spacing direction restricting section 34 extending in the width direction W and a pair of legs 35 extending from both sides of the spacing direction restricting section 34 in the width direction W to the lower HD. However, as shown in Figure 16(d), the spacing direction restricting section 34 and the pair of legs 35 may be formed in a continuous arc shape. Even with such arc-shaped legs 35, the same effects as the gate-shaped legs 35 can be achieved.

(Fourth Embodiment)
Furthermore, the electric wire 1g with a connecting fitting in the fourth embodiment will be explained with reference to Figures 22 to 24.

Figures 22 and 23 show explanatory diagrams of the wire 1g with connecting fittings according to the fourth embodiment, and Figure 24 shows an explanatory diagram of the manufacturing method of the wire 1g with connecting fittings according to the fourth embodiment.
In the following description of the wire with connecting fittings 1g, components that are the same as those in the wires with connecting fittings 1 to 1d of the above embodiment will be denoted by the same reference numerals and their descriptions will be omitted.

In the above description of the wire with connecting fittings 1e, the insulated wire 10 was inserted through the internal opening 30Xe of the gate-shaped frame-shaped insertion conversion part 30e. However, as will be described later, the wire with connecting fittings 1g is equipped with a frame-shaped insertion conversion part 30g formed in the shape of a frame as the insertion conversion part.
More specifically, the configuration of the connection portion 21, intermediate portion 22, and conductor connection portion 23 in the busbar 20g having a frame-shaped insertion conversion portion 30g is the same as that of the busbar 20 described above.

Unlike the busbar 20e, which has a frame-shaped insertion conversion section 30e protruding from the end of the base end LB of the conductor connection section 23 toward the upper HU, the busbar 20g of the wire 1g with a connecting fitting has a gate-shaped section 36 composed of a spacing direction restricting section 37 extending in the width direction W and a pair of leg sections 38 extending toward the lower HD from both sides of the spacing direction restricting section 34 in the width direction W. This gate-shaped section 36 is positioned at a predetermined distance from the end of the base end LB of the conductor connection section 23, and the ends of the lower HD of the leg sections 38 and the end of the base end LB of the conductor connection section 23 are connected by a pair of connecting sections 39. Furthermore, the gate-shaped section 36 connected to the end of the base end LB of the conductor connection section 23 by the connecting sections 39 is in a forward-leaning position with the upper HU inclined toward the tip end LF.

The wire with a connecting fitting 1g, which is formed by connecting the insulated wire 10 to the busbar 20g configured in this way, is manufactured by the manufacturing method shown in Figure 24.
Specifically, as shown in Figure 24(a), the insulated wire 10 is placed on the base end LB of the frame-shaped insertion conversion section 30g. Then, as shown in Figure 24(b), the insulated wire 10 is inserted into the frame-shaped insertion conversion section 30g from the base end LB, and the conductor 11 of the exposed conductor portion 101 is positioned along the longitudinal direction L at the conductor connection section 23 (see Figure 24(b)).

Then, the conductor 11 of the exposed conductor portion 101, which is positioned along the longitudinal direction L at the conductor connection portion 23, and the conductor connection portion 23 are welded together in the longitudinal direction L to form a welded portion 40 (see Figure 24(c)). The wire 1g with the connector is then completed by tilting the gate-shaped portion 36 so that the upper HU becomes the tip side LF.

The wire 1g with the connecting fitting configured in this way provides the same effect as the wire 1e with the connecting fitting described above. Specifically, even if an external force F1 acts on the insulated wire 10 at the base end LB from the frame-shaped insertion conversion part 30g, the insulated wire 10 comes into contact with the frame-shaped insertion conversion part 30g, converting the external force F1 acting on the insulated wire 10. This converts the force F1 to act as a converted external force F2 directed towards the base end LB at the welded part 40 that welds the conductor 11 to the conductor connection part 23, thus maintaining the connection without damaging the welded part 40.

Furthermore, the wire 1g with connecting fittings has a gate-shaped portion 36 positioned at a predetermined distance from the end of the conductor connection portion 23, and is provided with connecting portions 39 that connect each of the leg portions 38 to the end of the conductor connection portion 23. Since the gate-shaped portion 36 is in an inclined position that tilts toward the tip side LF, the insulated wire 10 can be easily inserted through the gate-shaped portion 36. The gate-shaped portion 36 can then convert the external force acting on the insulated wire 10 inserted through the gate-shaped portion 36 into a converted external force F2 acting on the welded portion 40 along the longitudinal direction L.

Furthermore, because the gate-shaped portion 36, which is connected to the end of the conductor connection portion 23 at the connecting portion 39, is in an inclined position that tilts toward the tip side LF, as shown in Figure 23(c), bending occurs in the insulated wire 10 extending from the conductor connection portion 23, thereby reducing the influence of external forces acting on the welded portion 40 between the conductor connection portion 23 and the conductor 11.

Furthermore, the gate-shaped portion 36 constituting the frame-shaped insertion conversion section 30g is positioned spaced apart from the end of the base-side LB of the conductor connection section 23, and the legs 38 of the gate-shaped portion 36 are connected to the conductor connection section 23 by the connecting portion 39. This reduces the bending of the insulated wire 10, thereby reducing the load on the insulated wire 10.

Furthermore, a chamfered portion 30Y may be provided on the inner corner of the tip-side LF of the frame-shaped insertion conversion section 30g of the wire 1g with connecting fittings. By providing a chamfered portion 30Y on the inner corner of the base-side LB of the frame-shaped insertion conversion section 30g, the same effect as that achieved by providing a chamfered portion 30Y on the cylindrical insertion conversion section 30 of the wire 1 with connecting fittings described above can be obtained.

In the correspondence between the structure of this invention and the embodiments described above,
The conductor of this invention corresponds to the conductor 11,
The same applies to the following:
The insulating coating corresponds to the insulating coating 12.
The tip side corresponds to the tip side LF,
The insulated wires correspond to insulated wires 10 and 10b.
The connecting fittings are compatible with busbars 20, 20c, and 20e.
The connecting part corresponds to the connecting part 21.
The conductor connection part corresponds to the conductor connection part 23.
The predetermined direction corresponds to the longitudinal direction L.
The side on which the insulated wire extends corresponds to the base end LB,
External forces in the intersecting direction correspond to external force F1,
The tensile force corresponds to the converted external force F2,
The connection point corresponds to the welded joint 40.
The conversion section corresponds to the cylindrical insertion conversion section 30, the inclined insertion conversion section 30a, the barrel insertion section 30c, and the frame-shaped insertion conversion sections 30e and 30g.
The wires with connecting fittings correspond to wires 1, 1a, 1b, 1c, 1d, 1e, 1f, and 1g with connecting fittings.
The insertion conversion section corresponds to the cylindrical insertion conversion section 30, the inclined insertion conversion section 30a, the barrel insertion section 30c, and the frame-shaped insertion conversion sections 30e and 30g.
The bottom corresponds to the bottom 33.
The barrel piece corresponds to the barrel piece 32,
The barrel section corresponds to the barrel section 31.
The direction of separation corresponds to the upper HU,
The separation regulating section corresponds to the separation direction regulating sections 34 and 37.
The direction of intersecting with respect to the direction of separation corresponds to the width direction W.
The leg section corresponds to leg sections 35 and 38.
The frame shape corresponds to the gate shape.
The frame-shaped body corresponds to the frame-shaped insertion conversion section 30e and the gate-shaped section 36.
The connecting part corresponds to the connecting part 39,
One of the predetermined directions corresponds to the tip side LF,
The cushioning material corresponds to the cushioning material 50, but this invention is not limited to the configuration of the above-described embodiment, and many embodiments can be obtained.

For example, although the conductor 11 is positioned along the longitudinal direction L relative to the conductor connection portion 23, it may also be positioned along the width direction W or diagonally. Similarly, although the insulated wires 10 and 10b are extended from the conductor connection portion 23 toward the base end LB, they may also be bent and extended in the height direction H or the width direction W.

Furthermore, while the busbars 20, 20c, and 20e described above are formed in a stepped shape by arranging the connection portion 21, intermediate portion 22, and conductor connection portion 23 in that order, they may also be composed of electrode terminals constituting the positive or negative electrode, and multiple busbars may be arranged on the case to form a battery module. In that case, two connection portions 21 and intermediate portions 22 may be provided for the conductor connection portion 23, forming a bifurcated busbar. Moreover, instead of plate-shaped busbars 20, 20c, and 20e, the connection terminals may be equipped with insertion conversion portions 30, 30a, 30c, 30e, and 30g, to which insulated wires 10 and 10b may be connected.

Furthermore, although the conductor 11 was welded to the conductor connection portion 23 to form a welded portion 40 for connection, the conductor 11 may also be integrated with the conductor connection portion 23 in a conductive manner by bonding with a conductive adhesive or by crimping.

The aforementioned insertion conversion sections 30, 30a, 30c, 30e, and 30g are formed to surround the entire circumference in the cross-sectional direction so that the insulated wires 10 and 10b extending from the conductor connection section 23 can be inserted through them. However, for example, at the end of the base end LB of the conductor connection section 23, a support column extending to the upper HU and a spacing restricting section extending in the width direction W from the tip of the support column may be formed in an inverted L-shape or T-shape when viewed from the longitudinal direction L, and the insulated wires 10 and 10b can be inserted through the space substantially enclosed by the support column, the spacing restricting section, and the conductor connection section 23.

Furthermore, the aforementioned insertion conversion sections 30, 30a, and 30c may be formed with cross-sections perpendicular to the longitudinal direction L that are not circular, but rather elliptical, polygonal closed cross-sections, or open cross-sections such as C-shaped, U-shaped, or rectangular U-shaped sections with openings that prevent the inserted insulated wires 10 and 10b from passing through.

Furthermore, although the barrel insertion portion 30c formed by the barrel portion 31 described above is configured as a substantially closed cross-section where the ends of the bent barrel pieces 32 are in substantially contact with each other, it may also be configured as an open cross-section with a gap that prevents the insulated electric wires 10, 10b, through which the ends of the barrel pieces 32 are inserted, from passing.
Although the inclined insertion conversion section 30a described above is inclined downward HD toward the base end side LB with respect to the planar conductor connection section 23, the insertion conversion sections 30 and 30c may also be inclined in the width direction W or diagonally.

The frame-shaped insertion conversion section 30e and the gate-shaped section 36 are formed in a gate shape by the separation direction restricting sections 34 and 37 that restrict the movement of the insulated wires 10 and 10b of the upper HU from the planar section to which the conductor 11 is connected, and by a pair of leg sections 35 and 38 that restrict the movement of the insulated wires 10 and 10b in the width direction W. However, the separation direction restricting sections 34 and 37 and the leg sections 35 and 38 may be formed in a U-shape, H-shape, or semicircular or semi-elliptical shape. Furthermore, the intersection of the pair of leg sections 35 and 38, which are inclined toward each other, may be formed into a roughly triangular shape with the separation direction restricting sections 34 and 37.

Furthermore, in the electric wire 1g with connecting fittings, a pair of connecting portions 39 connect each of the pair of leg portions 38 constituting the gate-shaped portion 36 to the end of the base end side LB of the conductor connection portion 23. However, the pair of leg portions 38 may also be connected by a single connecting portion 39 extending from the center in the width direction W of the conductor connection portion 23.
Furthermore, although the gate-shaped portion 36 of the wire 1g with connecting fittings is inclined toward the tip side LF, it may also be inclined toward the base side LB.

1, 1a, 1b, 1c, 1d, 1e, 1f, 1g...Wire with connecting fittings 10, 10b...Insulated wire 11...Conductor 12...Insulating coating 20, 20c, 20e...Bus bar 21...Connecting part 23...Conductor connecting part 30...Cylindrical insertion conversion part 30a...Inclined insertion conversion part 30c...Barrel insertion part 30e, 30g...Frame-shaped insertion conversion part 31...Barrel part 32...Barrel piece 33...Bottom part 34, 37...Separation direction restricting part 35, 38...Leg part 36...Gate-shaped part 39...Connecting part 40...Welded part 50...Cushioning material L...Longitudinal direction LB...Base end side LF...Tip side F1...External force F2...Conversion external force HU...Upper side W...Width direction

Claims (7)

A covered wire in which a conductor is covered with an insulating coating, and the insulating coating at the tip is peeled off to expose the conductor,
The exposed conductor is connected to a connecting fitting,
The aforementioned connecting fitting is provided with a connecting portion to be connected to the object to be connected and a conductor connecting portion to which the conductor is connected.
The conductor is arranged and connected to the conductor connection portion along a predetermined direction.
The insulated wire, to which the conductor is connected at the conductor connection, extends from the conductor connection.
On the side of the conductor connection portion on which the insulated wire extends,
When an external force acting in a cross direction acts on the insulated wire extending from the conductor connection portion, a conversion unit is provided that contacts the insulated wire via a buffer material and converts the external force into a tensile force along the predetermined direction, acting at the connection point between the conductor and the conductor connection portion.
The conversion unit is an insertion conversion unit through which the insulated wire is inserted.
The cushioning material is placed between the insertion conversion section and the insulated electric wire inserted into the insertion conversion section.
The insertion conversion section is a wire with a connecting fitting that contacts the insulated wire via the cushioning material. The aforementioned insertion conversion unit is,
A wire with a connecting fitting according to claim 1, which is formed in a substantially cylindrical shape through which a covered wire of a predetermined length is inserted. The aforementioned insertion conversion unit is,
The electric wire with a connecting fitting according to claim 1, wherein the barrel portion having a bottom and a barrel piece extending from the bottom is bent to form a substantially cylindrical shape through which a covered electric wire of a predetermined length is inserted. The conductor connection portion has a planar portion,
The wire with a connecting fitting according to claim 2 or 3, wherein the insertion conversion portion is in an inclined position such that the side on which the insulated wire extends is inclined with respect to the planar portion. The conductor connection portion has a planar portion,
The aforementioned insertion conversion unit is,
The insulated wire is provided at the end of the conductor connection portion on the side from which it extends,
The wire with a connecting fitting according to claim 1, which is a frame-shaped body formed by a separation restricting portion that restricts the movement of the insulated wire in a direction away from the planar portion to which the conductor is connected, and a pair of legs that restrict the movement of the insulated wire in a direction intersecting the direction of separation, and which protrudes from the planar portion. The frame-like body is positioned at a predetermined distance from the end of the conductor connection portion.
A connecting portion is provided that connects each of the aforementioned legs to the end of the aforementioned conductor connection portion,
The electric wire with a connecting fitting according to claim 5, wherein the frame-like body is in an inclined position that is tilted in any of the predetermined directions. The wire with a connecting fitting according to any one of claims 1 to 6, wherein the conductor exposed on the tip side of the insulating coating of the insulated wire is inserted into the insertion conversion portion.