Metal terminal and method of forming metal terminal

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a metal terminal including a wire connection portion to which an electric wire is connectable, and an electrical contact portion to which another metal terminal is connectable. More particularly, the present invention relates to a metal terminal in which the wire connection portion and the electrical contact portion are arranged to assume an L-shaped plan configuration. The present invention also relates to a method of forming the metal terminal.

The present application is based on Japanese Patent Application No. 2000-320906, which is incorporated herein by reference.

2. Description of the Related Art

A wire harness to be mounted on a vehicle, such as an automobile etc., is divided into a plurality of sub-harnesses corresponding respectively to functions of electronic equipments, and these sub-harnesses can be connected together. Therefore, the connection between wires of the sub-harnesses is complicated, and the efficiency of the assembling operation is lowered, and in the worst case, the stable quality is not obtained.

Therefore, in order to facilitate the connection between the electric wires, there has been proposed a plate connector comprising a plurality of plate-like insulating members stacked together, and press-connecting terminals attached to the plate-like insulating members. The plate-like insulating member is made of a synthetic resin. The plate-like insulating member includes a flat plate-like bottom wall, a plurality of partition walls extending upward from this bottom wall, and a plurality of communication holes.

The plurality of partition walls are arranged at equal intervals in parallel relation to one another. Any two adjacent ones of these partition walls jointly form a wire receiving groove therebetween for receiving an electric wire. The communication holes extend through the bottom wall. Each communication hole communicates with a tubular hole in an electrical contact portion of the press-connecting terminal mounted or placed on the bottom wall.

The press-connecting terminal is formed by bending a metal sheet. The press-connecting terminal includes a wire connection portion for connection to the electric wire, and the electrical contact portion of a tubular shape extending from the wire connection portion. The wire connection portion includes pairs of opposed press-connecting blades for being press-connected to the electric wire. A strip-like connection bar of an electrically-conductive nature is inserted in the electrical contact portion. In the press-connecting terminal, the wire connection portion and the electrical contact portion are arranged to assume an L-shaped plan configuration (that is, assume an L-shape when seen from above). The press-connecting terminal is placed on the bottom wall of the plate-like insulating member.

The press-connecting terminals are arranged on the plate-like insulating member in two directions, that is, in the longitudinal direction of the wire receiving grooves and in the direction of juxtaposition of the wire receiving grooves. Namely, the press-connecting terminals are arranged on the bottom wall of the plate-like insulating member in a two-dimensional matrix manner. A plurality of plate-like insulating members, each having the press-connecting terminals arranged in a two-dimensional matrix manner, are stacked one upon another, and the connection bar is inserted in the desired electrical contact portions superposed together. By doing so, the plate connector is obtained.

Thus, in the plate connector, the press-connecting terminals for being press-connected to the electric wires are mounted in desired positions on the bottom wall of each plate-like insulating member, and the connection bars are inserted in the desired electrical contact portions, so that the electric wires are interconnected according to a predetermined pattern.

In the press-connecting terminal used in the plate connector, the wire connection portion and the electrical contact portion are arranged to assume an L-shaped plan configuration. Therefore, in a metal sheet (blank) used for forming this press-connecting terminal, those portions thereof, corresponding respectively to the wire connection portion and the electrical contact portion, are also arranged to assume an L-shape.

Therefore, there is a possibility that during the time when the metal sheet is bent to form the press-connecting terminal, an interconnecting portion of this metal sheet, interconnecting the wire connection portion and the electrical contact portion, is deformed, so that the predetermined relative positional relation between the wire connection portion and the electrical contact portion after the forming operation can not be obtained. In the worst case, there is a possibility that the interconnecting portion is cut off, so that the wire connection portion and the electrical contact portion are separated from each other. Thus, there is a possibility that the yield rate after the forming operation is lowered by such dimensional irregularity.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a metal terminal, as well as a method of forming the metal terminal, in which the yield rate after the forming operation is prevented from being lowered.

To achieve the above object, according to a first aspect of the present invention, there is provided a metal terminal which comprises:

a metal sheet comprising:

a first portion for forming a wire connection portion of the metal terminal to which an electric wire is connectable;

a second portion for forming an electrical contact portion of the metal terminal, in which an insertion member connectable to another terminal is insertable, and which extends from the wire connection portion;

a third portion for forming an interconnecting portion of the metal terminal interconnecting the wire connection portion and the electrical contact portion,

wherein the wire connection portion and the electrical contact portion are disposed at a position assuming an L-shaped plan configuration in the metal terminal; and

a reinforcing interconnection portion which is temporarily formed on the metal sheet so as to interconnect the first portion and the second portion,

wherein when the metal sheet is bent to be formed into a predetermined shape, the reinforcing interconnection portion is removed.

In accordance with the first aspect, the interconnecting portion-corresponding portion (i.e., third portion) is prevented from being deformed before the metal terminal is formed, and the relative positional relation between the connection portion-corresponding portion (i.e., first portion) and the contact portion-corresponding portion (i.e., second portion) is prevented from being changed.

According to a second aspect of the present invention, it is preferable that the wire connection portion includes a mounting wall, on which the electric wire can be placed, and a side wall extending upward from the mounting wall, and the electrical contact portion includes a tubular portion for receiving the insertion member, wherein the first portion of the metal sheet includes a fourth portion corresponding to the mounting wall, and a fifth portion corresponding to the side wall, the second portion of the metal sheet includes a sixth portion corresponding to the tubular portion, and wherein the reinforcing interconnection portion of the metal sheet (1) has a strip-like shape, (2) is continuous at one end thereof with the fifth portion, and (3) is continuous at the other end thereof with the sixth portion.

In accordance with the second aspect, the interconnecting portion-corresponding portion (i.e., third portion) is further positively prevented from being deformed before the metal terminal is formed, and the relative positional relation between the connection portion-corresponding portion (i.e., first portion) and the contact portion-corresponding portion (i.e., second portion) is further positively prevented from being changed.

Alternatively, according to a third aspect of the present invention, it is preferable that the wire connection portion includes a mounting wall, on which the electric wire can be placed, and a side wall extending upward from the mounting wall, the interconnecting portion (1) has a strip-like shape, (2) is continuous at one end thereof with the side wall, and (3) is continuous at the other end thereof with the electrical contact portion, wherein the first portion of the metal sheet includes a fourth portion corresponding to the mounting wall, and a fifth portion corresponding to the side wall, and wherein the reinforcing interconnection portion of the metal sheet interconnects the fourth portion and the third portion.

In accordance with the third aspect, the interconnecting portion can more easily be deformed, and besides the relative positional relation between the wire connection portion and the electrical contact portion can be changed more easily. However, the reinforcing interconnection portion interconnects the mounting wall-corresponding portion (i.e., fourth portion) of the connection portion-corresponding portion (i.e., first portion) and the interconnecting portion-corresponding portion (i.e., third portion). Therefore, the interconnecting portion-corresponding portion (i.e., third portion) is positively prevented from being deformed before the metal terminal is formed, and the relative positional relation between the connection portion-corresponding portion (i.e., first portion) and the contact portion-corresponding portion (i.e., second portion) is positively prevented from being changed.

According to a fourth aspect of the present invention, there is provided a method of forming a metal terminal. The method comprises the steps of:

providing a metal sheet which comprises:

a first portion for forming a wire connection portion of the metal terminal to which an electric wire is connectable,

a second portion for forming an electrical contact portion of the metal terminal, in which an insertion member connectable to another terminal is insertable, and which extends from the wire connection portion,

a third portion for forming an interconnecting portion of the metal terminal interconnecting the wire connection portion and the electrical contact portion,

wherein the wire connection portion and the electrical contact portion are disposed at a position assuming an L-shaped plan configuration in the metal terminal, and

a reinforcing interconnection portion which is formed on the metal sheet so as to interconnect the first portion and the second portion;

bending the metal sheet to be formed into a predetermined shape; and

removing the reinforcing interconnection portion.

In accordance with the fourth aspect, the advantageous effects similar to the first aspect are obtained.

According to a fifth aspect of the present invention, it is preferable that the removing step is performed after the second portion is bent to be formed into the electrical contact portion and before the first portion is bent to be formed into the wire connection portion.

In accordance with the fifth aspect, the relative positional relation between the electrical contact portion and the wire connection portion is positively prevented from being changed.

According to a sixth aspect of the present invention, it is preferable that the removing step is performed after the first portion and the second portion are bent to be formed respectively into the wire connection portion and the electrical contact portion.

In accordance with the sixth aspect, the relative positional relation between the electrical contact portion and the wire connection portion is more positively prevented from being changed.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the accompanying drawings, wherein:

FIG. 1

is a perspective view showing a first embodiment of a JB (i.e., Junction Block) press-connecting terminal of the present invention;

FIG. 2

is a perspective view of a connection bar for insertion in an electrical contact portion of the JB press-connecting terminal of the above embodiment;

FIG. 3

is a perspective view showing a press-connecting plate to which the JB press-connecting terminals of the above embodiment are attached;

FIG. 4

is a perspective view showing the press-connecting plates of

FIG. 3

superposed together in parallel, spaced relation to each other;

FIG. 5

is a perspective view showing a stack plate connector comprising the press-connecting plates of

FIG. 3

fixed together;

FIG. 6

is a plan view of a portion of a metal sheet for forming the JB press-connecting terminal of

FIG. 1

FIG. 7

is a plan view of the metal sheet of

FIG. 6

, showing a condition in which an electrical contact portion is formed;

FIG. 8

is a plan view of the metal sheet of

FIG. 7

, showing a condition in which a reinforcing interconnection portion is removed therefrom;

FIG. 9

is a plan view of the metal sheet of

FIG. 8

, showing a condition in which a wire connection portion is formed;

FIG. 10

is a plan view showing a condition in which the JB press-connecting terminal is formed from the metal sheet of

FIG. 9

;

FIG. 11

is a perspective view showing a second embodiment of a JB press-connecting terminal of the present invention;

FIG. 12

is a plan view of a portion of a metal sheet for forming the JB press-connecting terminal of

FIG. 11

;

FIG. 13

is a plan view showing a condition in which the JB press-connecting terminal is formed from the metal sheet of

FIG. 12

; and

FIG. 14

is a plan view showing a condition in which the JB press-connecting terminal of

FIG. 13

is cutoff from an interconnecting strip, and a reinforcing interconnection portion is removed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A JB (i.e., Junction Block) press-connecting terminal

50

(which is a first embodiment of a metal terminal of the present invention) will now be described with reference to

FIGS. 1

to

10

. The JB press-connecting terminals (the metal terminals of the first embodiment)

50

are attached to a press-connecting plate (plate-like insulating member)

60

shown in

FIG. 3

, and a plurality of press-connecting plates

60

are stacked together to form a stack plate connector

1

shown in FIG.

5

. The JB press-connecting terminal is a so-called press-connecting terminal to which an electric wire is press-connected.

The JB press-connecting terminal

50

is formed, for example, by bending an electrically-conductive metal sheet

20

(shown in FIG.

6

). As shown in

FIG. 1

, the JB press-connecting terminal

50

includes a wire connection portion

51

for connection to the electric wire

4

(shown in FIG.

3

), an electrical contact portion

52

, a plurality of retaining piece portions

58

, and an interconnecting portion

59

.

The wire connection portion

51

includes a flat mounting wall

55

, on which the electric wire

4

is placed, a pair of side walls

56

a

and

56

b,

a clamping piece portion

53

, and a press-connecting portion

51

a.

The mounting wall

55

has a strip-like shape. Each of the pair of side walls

56

a

and

56

b

has a strip-like shape. The pair of side walls

56

a

and

56

b

extend respectively from opposite side edges of the mounting wall

55

spaced from each other in a direction of the width thereof. The pair of side walls

56

a

and

56

b

extend upward from the mounting wall

55

. The electric wire, press-connected to the press-connecting portion

51

a,

is disposed between the pair of side walls

56

a

and

56

b.

The clamping piece portion

53

extends upward from the mounting wall

55

. The clamping piece portion

53

extends from the widthwise side edge of the mounting wall

55

. The clamping piece portion

53

is bent substantially in overlying relation to the mounting wall

55

, and cooperates with this mounting wall

55

to hold the electric wire therebetween. Namely, the electric wire is press-fastened to the mounting wall

55

by the clamping piece portion

53

.

The press-connecting portion

51

a

includes two pairs of opposed press-connecting blades

54

a

and

54

b.

The press-connecting blades

54

a

and

54

b

are disposed in upstanding relation to the mounting wall

55

. Each pair of press-connecting blades

54

a,

54

b

extend respectively from the inner surfaces of the opposed side walls

56

a

and

56

b

toward each other.

When the electric wire

4

is press-fitted into the gap between each pair of press-connecting blades

54

a,

54

b,

these press-connecting blades cut a sheath of the electric wire

4

to contact a conductor thereof, and therefore are electrically connected to the electric wire

4

. Namely, these press-connecting blades

54

a

and

54

b

are press-connected to the electric wire

4

.

The electrical contact portion

52

is continuous with one widthwise side edge of the mounting wall

55

. Namely, the electrical contact portion

52

is continuous with the wire connection portion

51

. The electrical contact portion

52

and the wire connection portion

51

are disposed at a position assuming an L-shaped plan configuration (that is, an L-shape when seen from above) of the JB press-connecting terminal

50

. The electrical contact portion

52

is disposed substantially perpendicularly to the wire connection portion

51

in offset relation to the longitudinal axis of the electric wire

4

placed on the mounting wall

55

.

The electrical contact portion

52

includes a tubular portion

52

a

of a square cross-section, and a connection spring piece portion

57

. The tubular portion

52

a

is disposed in communication with a communication hole in the press-connecting plate

60

. A connection bar (insertion member)

80

, as shown in

FIG. 2

, is inserted in the tubular portion

52

a.

This connection bar

80

is made of electrically-conductive metal, and has a strip-like shape. The connection spring piece portion

57

is provided within the tubular portion

52

a.

The connection spring piece portion

57

presses the connection bar

80

toward the inner surface of the tubular portion

52

a.

The connection spring piece portion

57

electrically connects the electrical contact portion

52

to the connection bar

80

.

When the press-connecting plates

60

are stacked together, the superposed JB press-connecting terminals

50

are electrically connected together by the connection bar

80

inserted in the tubular portions

52

a

of the electrical contact portions

52

thereof. Thus, the electrical contact portion

52

connects the JB press-connecting terminal to other JB press-connecting terminals (metal terminals).

The retaining piece portions

58

are formed by stamping predetermined portions of the side walls

56

a

and

56

b.

The retaining piece portions

58

are formed on the side walls

56

a

and

56

b.

Each retaining piece portion

58

extends at one end thereof from the side wall

56

a,

56

b,

and the other end thereof is spaced from the side wall

56

a,

56

b.

Particularly, the other end of each retaining piece portion

58

most projects outwardly from the outer surface of the side wall

56

a,

56

b.

As shown in

FIG. 1

, the retaining piece portion

58

is inclined in such a manner that the distance of this retaining piece portion

58

from the outer surface of the side wall

56

a,

56

b

is increasing gradually in a direction from the one end thereof toward the other end thereof. When the JB press-connecting terminal

50

is attached to the press-connecting plate

60

, the retaining piece portions

58

is retainingly engaged with an inner surface of a partition wall

63

b

(described later).

The interconnecting portion

59

interconnects the wire connection portion

51

and the electrical contact portion

52

. The interconnecting portion

59

has a strip-like shape, and is continuous at one end thereof with the mounting wall

55

. The interconnecting portion

59

is continuous at the other end thereof with the tubular portion

52

a

of the electrical contact portion

52

. The interconnecting portion

59

interconnects the wire connection portion

51

and the electrical contact portion

52

. The interconnection portion

59

has a uniform thickness over an entire length thereof, and is equal in thickness to the mounting wall

55

.

The wire connection portion

51

of the JB press-connecting terminal

50

is received in a groove main portion

61

a

of a wire receiving groove

61

(described later) in the press-connecting plate

60

, and the electrical contact portion

52

is received in a receiving portion

64

(described later) of the wire receiving groove

61

. The JB press-connecting terminal

50

is press-fitted into the groove main portion

61

a

and the receiving portion

64

, with the retaining piece portions

58

resiliently deformed in such a direction that the distance between the other ends of the opposed retaining piece portions

58

is reduced. When the JB press-connecting terminal

50

is thus press-fitted into the groove main portion

61

a

and the receiving portion

64

, this terminal is received in (or held in or attached to) the press-connecting plate

60

.

The press-connecting plate

60

is made of an insulative synthetic resin or the like, and has a plate-like or flat plate-like shape. As shown in

FIGS. 3

to

5

, the press-connecting plate

60

includes a rectangular plate body

62

, the plurality of wire receiving grooves

61

, and the communication holes (not shown). The plate body

62

includes a substantially flat bottom wall

63

a,

a rear wall

65

, a pair of side walls

67

, the plurality of partition walls

63

b

extending upward from the bottom wall

63

a,

and a flange portion

68

.

The rear wall

65

is continuous with one edge (disposed at the rear side in the drawings) of the bottom wall

63

a.

The rear wall

65

extends upward from the bottom wall

63

a.

The pair of side walls

67

are continuous with opposite side edges of the bottom wall

63

a,

respectively, and are continuous with the rear wall

65

. The pair of side walls

67

extend upward from the bottom wall

63

a.

The pair of side walls

67

are parallel to each other.

The partition walls

63

b

are parallel to one another, and are spaced from one another. The partition walls

63

b

are parallel to the pair of side walls

67

. The partition walls

63

b

extend in the longitudinal direction of the plate body

62

.

The flange portion

68

projects outwardly from the peripheral edge of the bottom wall

63

a

of the plate body

62

. The flange portion

68

projects outwardly beyond the outer surfaces of the rear wall

65

and the side walls

67

. The flange portion

68

is formed on the bottom wall

63

a

over the entire periphery thereof. The flange portion

68

increases the rigidity of the bottom wall

63

a

and hence the rigidity of the plate body

62

, thereby preventing the bottom wall

63

a

and hence the plate body

62

from being curved or warped.

The wire receiving groove

61

is formed by the two adjacent partition walls

63

b

and the bottom wall

63

a.

The wire receiving groove

61

includes the groove main portion

61

a,

and the receiving portions

64

. The groove main portion

61

a

is formed by the inner surfaces of the two adjacent partition walls

63

b

and the surface of the bottom wall

63

a.

The groove main portion

61

a

extends along the side walls

67

and the partition walls

63

b.

The groove main portion

61

a

receives the wire connection portions

51

of the JB press-connecting terminals

50

.

The receiving portions

64

are formed in recessed relation to the partition wall

63

b

so as to increase the distance between the two adjacent partition walls

63

b.

The receiving portions

64

are formed in the two adjacent partition walls

63

b

forming one wire receiving groove

61

therebetween. The receiving portions

64

, formed in one of the two adjacent partition walls

63

b,

and the receiving portions

64

, formed in the other partition wall

63

b,

are arranged alternately in the longitudinal direction of the groove main portion

61

a.

Thus, the plurality of receiving portions

64

are arranged in a juxtaposed manner in the longitudinal direction of the groove main portion

61

a

of the wire receiving groove

61

. The receiving portion

64

receives the electrical contact portion

52

of the JB press-connecting terminal

50

therein. The communication hole is formed in each of the receiving portions

64

. The communication holes extend through the bottom wall

63

a

of the plate body

62

.

The press-connecting plate

60

includes a plurality of retaining projections

66

and a plurality of retaining reception projections (not shown). The retaining projections

66

can be retainingly engaged with the corresponding retaining reception projections, respectively. When forming the stack plate connector

1

, the retaining projections

66

are retainingly engaged with the corresponding retaining reception projections, respectively, thereby fixing the press-connecting plates

60

to one another.

The JB press-connecting terminals

50

are arranged on the bottom wall

63

a

of the press-connecting plate

60

in two directions, that is, in the longitudinal direction of the groove main portions

61

a

of the wire receiving grooves

61

and in the direction of juxtaposition of these wire receiving grooves

61

. Namely, the JB press-connecting terminals

50

are arranged on the bottom wall

63

a

of the press-connecting plate

60

in a two-dimensional matrix manner.

For assembling the stack plate connector

1

, first, the JB press-connecting terminals

50

are attached to each press-connecting plate

60

. At this time, the JB press-connecting terminal

50

is moved toward the bottom wall

63

a,

and is attached to the plate body

62

. The JB press-connecting terminal

50

is received in the wire receiving groove

61

, with the retaining piece portions

58

retained by the inner surfaces of the partition walls

63

b,

so that the terminal

50

is fixed to the press-connecting plate

60

.

Then, the electric wire

4

is press-connected to the JB press-connecting terminal

50

, received in the groove main portion

61

a

and the receiving portion

64

. At this time, the electric wire

4

is press-fitted in the gap between each pair of press-connecting blades

54

a,

54

b

of the wire connection portion

51

. In this condition, the press-connecting plates

60

are superposed together, with the plate bodies

62

disposed in parallel, spaced relation to each other, as shown in FIG.

4

.

Then, any two adjacent press-connecting plates

60

are moved toward each other, so that the retaining projections

66

are retainingly engaged with the corresponding retaining reception projections, respectively, thereby fixing the press-connecting plates to each other. Each connection bar

80

is inserted and passed through the predetermined communication holes and tubular portions

52

a

of the electrical contact portions

52

, thereby forming the stack plate connector

1

as shown in FIG.

5

.

The positions of mounting of the JB press-connecting terminals

50

on the bottom wall

63

a

and the positions of insertion of the connection bars

80

are selected, and by doing so, the stack plate connector

1

can interconnect the electric wires

4

, press-connected to the JB press-connecting terminals

50

, according to a predetermined pattern. The stack plate connector

1

, when mounted within an electric connection box having, for example, relays and fuses mounted thereon, connect the electric wires

4

to these relays and fuses according to a predetermined pattern.

The JB press-connecting terminal

50

is formed by bending the metal sheet

20

shown in FIG.

6

. The metal sheet (blank)

20

is blanked from an electrically-conductive metal sheet. The metal sheet

20

has a substantially rectangular shape when seen from above.

As shown in

FIG. 6

, the metal sheet

20

includes terminal-corresponding portions

21

, each to be formed into the JB press-connecting terminal

50

by bending, and a band-like (strip-like) interconnecting strip

22

. The metal sheet

20

includes the plurality of terminal-corresponding portions

21

arranged in a juxtaposed manner. The terminal-corresponding portions

21

are interconnected by the interconnecting strip

22

. When the JB press-connecting terminals

50

, formed respectively by the terminal-corresponding portions

21

, are mounted on the press-connecting plate

60

, these JB press-connecting terminals

50

are cut off from the interconnecting strip

22

.

As shown in

FIG. 6

, the terminal-corresponding portion

21

includes a connection portion-corresponding portion

23

, corresponding to the wire connection portion

51

, a contact portion-corresponding portion

24

, corresponding to the electrical contact portion

52

, and an interconnecting portion-corresponding portion

25

, corresponding to the interconnecting portion

59

, and a reinforcing interconnection portion

26

.

The connection portion-corresponding portion

23

includes a mounting wall-corresponding portion

31

, corresponding to the mounting wall

55

, and a pair of side wall-corresponding portions

32

corresponding respectively to the sidewalls

56

a

and

56

b.

The mounting wall-corresponding portion

31

has a strip-like shape, and is continuous at one end thereof with the interconnecting strip

22

. The longitudinal axis of the mounting wall-corresponding portion

31

intersects the longitudinal axis of the intersecting strip

22

. In the illustrated embodiment, the longitudinal axis of the mounting wall-corresponding portion

31

perpendicularly intersects the longitudinal axis of the interconnecting strip

22

.

The pair of side wall-corresponding portions

32

have a strip-like shape, and extend respectively from opposite side edges of the mounting wall-corresponding portion

31

. Press-connecting blade-corresponding portions

33

, corresponding respectively to the press-connecting blades

54

a

and

54

b,

are formed on each of the side wall-corresponding portions

32

. A clamping piece-corresponding portion

39

, corresponding to the clamping piece portion

53

, is formed on one side wall-corresponding portion

32

.

The connection portion-corresponding portion

23

is bent along bending lines

34

(indicated in dot-and-dash lines in

FIG. 6

) to be formed into the wire connection portion

51

. The mounting wall-corresponding portion

31

corresponds to the mounting wall

55

of the wire connection portion

51

formed by bending the connection portion-corresponding portion along the bending lines

34

. The side wall-corresponding portions

32

correspond respectively to the side walls

56

a

and

56

b,

and the press-connecting blade-corresponding portions

33

correspond to the press-connecting blades

54

a

and

54

b.

The contact portion-corresponding portion

24

includes a tube-corresponding portion

35

, corresponding to the tubular portion

52

a,

and a spring piece-corresponding portion

36

corresponding to the connection spring piece portion

57

. The tube-corresponding portion

35

is continuous with the connection portion-corresponding portion

23

through the interconnecting portion-corresponding portion

25

. The tube-corresponding portion

35

is continuous with that end of the mounting wall-corresponding portion

31

remote from the interconnecting strip

22

. The tube-corresponding portion

35

has a strip-like shape, and extends longitudinally in parallel relation to the interconnecting strip

22

. The spring piece-corresponding portion

36

has a strip-like shape, and extends from the tube-corresponding portion

35

. The spring piece-corresponding portion

36

extends parallel to the longitudinal axis of the mounting wall-corresponding portion

31

.

The contact portion-corresponding portion

24

is bent along bending lines

37

(indicated in dot-and-dash lines in FIG.

6

), so that the tube-corresponding portion

35

is formed into the tubular portion

52

a.

The bending lines

37

extend parallel to the mounting wall-corresponding portion

31

and the spring piece-corresponding portion

36

. The spring piece-corresponding portion

36

is bent, and is inserted into the tubular portion

52

a.

Thus, the electrical contact portion

52

is formed. The connection portion-corresponding portion

23

and the contact portion-corresponding portion

24

are disposed in a position assuming an L-shaped plan configuration (that is, an L-shape when seen from above) of the terminal-corresponding portion

21

.

The interconnecting portion-corresponding portion

25

has a strip-like shape, and is continuous at one end thereof with the mounting wall-corresponding portion

31

of the connection portion-corresponding portion

23

, and is continuous at the other end thereof with the tube-corresponding portion

35

of the contact portion-corresponding portion

24

. The interconnecting portion-corresponding portion

25

is bent a long a bending line

38

(indicated by a dot-and-dash line in FIG.

6

), so that the electrical contact portion

52

is disposed in upstanding relation to the mounting wall

55

.

The reinforcing interconnection portion

26

has a strip-like shape, and is continuous at one end thereof with the other side wall-corresponding portion

32

of the connection portion-corresponding portion

23

, and is continuous at the other end thereof with the tube-corresponding portion

35

of the contact portion-corresponding portion

24

. The reinforcing interconnection portion

26

interconnects the other side wall-corresponding portion

32

of the connection portion-corresponding portion

23

and the tube-corresponding portion

35

of the contact portion-corresponding portion

24

. The longitudinal axis of the reinforcing interconnection portion

26

is parallel to the longitudinal axis of the mounting wall-corresponding portion

31

, and substantially coincides with the longitudinal axis of the spring piece-corresponding portion

36

. In FIG.

6

and other, the reinforcing interconnection portion

26

is indicated by hatching.

For forming the JB press-connecting terminal

50

, the tube-corresponding portion

35

of the terminal-corresponding portion

21

of the metal sheet

20

of the above construction is first bent along the bending lines

37

to form the tubular portion

52

a,

and the spring piece-corresponding portion

36

is bent, and is inserted into the tubular portion

52

a.

The electrical contact portion

52

is formed as shown in FIG.

7

.

Then, a stamping operation or the like is applied to the terminal-corresponding portion

21

, thereby removing the reinforcing interconnection portion

26

from the connection portion-corresponding portion

23

and the electrical contact portion

52

, as shown in FIG.

8

. The connection portion-corresponding portion

23

is bent along the bending lines

34

to form the wire connection portion

51

as shown in FIG.

9

. Then, the interconnecting portion-corresponding portion

25

is bent along the bending line

38

, thereby bringing the electrical contact portion

52

into an upstanding condition relative to the wire connection portion

51

, as shown in FIG.

10

. Thus, the JB press-connecting terminal

50

is formed.

In this embodiment, the reinforcing interconnection portion

26

of the metal sheet

20

, which is to be removed when the JB press-connecting terminal

50

is formed, interconnects the side wall-corresponding portion

32

of the connection portion-corresponding portion

23

and the tube-corresponding portion

35

of the contact portion-corresponding portion

24

. Therefore, the interconnecting portion-corresponding portion

25

, corresponding to the interconnecting portion

59

, is prevented from being deformed during the forming operation and others, and the relative positional relation between the connection portion-corresponding portion

23

and the contact portion-corresponding portion

24

is prevented from being changed.

Therefore, the relative positional relation between the wire connection portion

51

and the electrical contact portion

52

after the formation of the terminal is prevented from being changed, and besides the interconnecting portion

59

is prevented from being broken, thereby preventing the separation of the wire connection portion

51

and the electrical contact portion

52

from each other. Therefore, the yield rate after the forming operation is prevented from being lowered.

After the electrical contact portion

52

is formed, the reinforcing interconnection portion

26

is removed, and therefore the relative positional relation between the wire connection portion

51

and the electrical contact portion

52

is positively prevented from being changed during the formation of the electrical contact portion

52

. Therefore, the relative positional relation between the wire connection portion

51

and the electrical contact portion

52

is prevented from being changed after the formation of the JB press-connecting terminal

50

. Therefore, the yield rate after the forming operation is more positively prevented from being lowered.

Next, a JB (Junction Block) press-connecting terminal

50

(which is a second embodiment of a metal terminal of the present invention) will be described with reference to

FIGS. 11

to

14

. Those portions of this embodiment, identical in construction to their respective corresponding portions of the first embodiment, will be designated by identical reference numerals, respectively, and explanation thereof will be omitted.

As shown in

FIGS. 11 and 14

, an interconnecting portion

59

of the JB press-connecting portion

50

of this embodiment is continuous at one end thereof with a side wall

56

b

remote from an electrical contact portion

52

, and is continuous at the other end thereof with the electrical contact portion

52

.

With respect to a terminal-corresponding portion

21

of a metal sheet

20

, a reinforcing interconnection portion

26

interconnects a mounting wall-corresponding portion

31

and an interconnecting portion-corresponding portion

25

, as shown in FIG.

12

. In

FIGS. 12 and 13

, the reinforcing interconnection portion

26

is indicated by hatching.

In this embodiment, the terminal-corresponding portion

21

is bent along bending lines

34

,

37

and

38

to form the JB press-connecting terminal

50

as shown in FIG.

13

. The JB press-connecting terminal

50

, when in a condition of

FIG. 13

, is connected to an interconnecting strip

22

. Immediately before the press-connecting terminal

50

is attached to the press-connecting plate

60

, it is cut off from the interconnecting strip

22

, and the reinforcing interconnection portion

26

is removed from a mounting wall

55

and the interconnecting portion

59

.

In this embodiment, the interconnecting portion

59

has a strip-like shape, and interconnects the side wall

56

b

of a wire connection portion

51

and the electrical contact portion

52

. Therefore, the interconnecting portion

59

can be deformed more easily, and besides the relative positional relation between the wire connection portion

51

and the electrical contact portion

52

can be changed more easily.

However, the reinforcing interconnection portion

26

interconnects the mounting wall-corresponding portion

31

and the interconnection portion-corresponding portion

25

. Therefore, the interconnecting portion-corresponding portion

25

, corresponding to the interconnecting portion

59

, is prevented from being deformed during the forming operation and others, and the relative positional relation between a connection portion-corresponding portion

23

and a contact portion-corresponding portion

24

is prevented from being changed.

Therefore, the relative positional relation between the wire connection portion

51

and the electrical contact portion

52

after the formation of the terminal is prevented from being changed, and besides the interconnecting portion

59

is prevented from being broken, thereby preventing the separation of the wire connection portion

51

and the electrical contact portion

52

from each other. Therefore, the yield rate after the forming operation is prevented from being lowered.

After the wire connection portion

51

and the electrical contact portion

52

are formed, the reinforcing interconnection portion

26

is removed, and therefore the relative positional relation between the connection portion-corresponding portion

23

and the contact portion-corresponding portion

24

is positively prevented from being changed during the formation of the JB press-connecting terminal

50

. Therefore, the yield rate after the forming operation is more positively prevented from being lowered.

As described above, in the embodiments, the reinforcing interconnection portion of the metal sheet, which is to be removed when the metal terminal is formed, interconnects the connection portion-corresponding portion, corresponding to the wire connection portion, and the contact portion-corresponding portion corresponding to the electrical contact portion. Therefore, the interconnecting portion-corresponding portion, corresponding to the interconnecting portion, is prevented from being deformed before the metal terminal is formed, and the relative positional relation between the connection portion-corresponding portion and the contact portion-corresponding portion is prevented from being changed.

Therefore, the relative positional relation between the wire connection portion and the electrical contact portion after the formation of the terminal is prevented from being changed, and the wire connection portion and the electrical contact portion are prevented from being separated from each other. Therefore, the yield rate after the forming operation is positively prevented from being lowered.

In the embodiment, the reinforcing interconnection portion interconnects the side wall-corresponding portion of the connection portion-corresponding portion and the tube-corresponding portion of the contact portion-corresponding portion. Therefore, the interconnecting portion-corresponding portion is positively prevented from being deformed before the metal terminal is formed, and the relative positional relation between the connection portion-corresponding portion and the contact portion-corresponding portion is positively prevented from being changed.

Therefore, the relative positional relation between the wire connection portion and the electrical contact portion after the formation of the terminal is prevented from being changed, and the wire connection portion and the electrical contact portion are prevented from being separated from each other. Therefore, the yield rate after the forming operation is more positively prevented from being lowered.

In the embodiment, the interconnecting portion has a strip-like shape, and interconnects the side wall of the wire connection portion and the electrical contact portion. Therefore, the interconnecting portion can be deformed more easily, and besides the relative positional relation between the wire connection portion and the electrical contact portion can be changed more easily.

However, the reinforcing interconnection portion interconnects the mounting wall-corresponding portion of the connection portion-corresponding portion and the interconnection portion-corresponding portion. Therefore, the relative positional relation between the wire connection portion and the electrical contact portion is positively prevented from being changed after the formation of the metal terminal, and the wire connection portion and the electrical contact portion are prevented from being separated from each other. Therefore, the yield rate after the forming operation is more positively prevented from being lowered.

In the embodiment, the reinforcing interconnection portion is removed after the electrical contact portion is formed, and therefore the relative positional relation between the electrical contact portion and the wire connection portion is positively prevented from being changed. Therefore, the relative positional relation between the wire connection portion and the electrical contact portion is prevented from being changed after the formation of the metal terminal. Therefore, the yield rate after the forming operation is more positively prevented from being lowered.

In the embodiment, the reinforcing interconnection portion is removed after the electrical contact portion and the wire connection portion are both formed, and therefore the relative positional relation between the electrical contact portion and the wire connection portion is more positively prevented from being changed. Therefore, the relative positional relation between the wire connection portion and the electrical contact portion is prevented from being changed after the formation of the metal terminal. Therefore, the yield rate after the forming operation is more positively prevented from being lowered.

It is contemplated that numerous modifications may be made to the metal terminal, and the method of forming a metal terminal, of the present invention without departing from the spirit and scope of the invention as defined in the following claims.

Number	Name	Date	Kind
5000699	Nadin	Mar 1991	A
5219294	Marsh et al.	Jun 1993	A
6406338	Endo et al.	Jun 2002	B1

Metal terminal and method of forming metal terminal

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

Priority Claims (1)

US Referenced Citations (3)