Battery terminal, fuse unit, and method for manufacturing fuse unit

A battery terminal includes a terminal main body provided in opposed plates thereof as a pair, formed by folding approximately in a U shape a strip plate made of a conductive metal, respectively with electrode insertion holes in which a rod-like electrode projecting from a terminal attaching surface in a battery is sequentially inserted, and formed to extend toward an outer edge of the terminal attaching surface at time of being connected to the rod-like electrode, and a joint joining the pair of the opposed plates in a state in which the opposed plates surface-contact and overlap each other on an opposite side of a folded part as seen from the electrode insertion hole.

BACKGROUND

Technical Field

The present invention relates to a battery terminal attached to a battery and relaying power supplied from the battery, a fuse unit, and a method for manufacturing the fuse unit.

Related Art

Conventionally, power supply in a vehicle from a battery to a circuit is often performed via a battery terminal (e.g., refer to JP 2011-187301 A).

FIG. 14illustrates a fuse unit including an example of a conventional battery terminal. A fuse unit5illustrated inFIG. 14is directly attached to a rod-like electrode62projecting from a terminal attaching surface61in a battery6and includes a battery terminal51and a fusible link52.FIG. 15illustrates an exploded view of the fuse unit illustrated inFIG. 14.

The battery terminal51is a terminal formed approximately in a rectangular shape in a planar view and is provided on a first end side in a longitudinal direction thereof with an electrode insertion hole511in which the rod-like electrode62of the battery6is to be inserted. A second end side in the longitudinal direction thereof is provided with a screw512adapted to couple the battery terminal51with the fusible link52. The battery terminal51is formed to extend toward an outer edge61aof the terminal attaching surface61at the time of being connected to the rod-like electrode62of the battery6.

The fusible link52includes a power feeding terminal521, two circuit terminals522, and fusible bodies523.

The power feeding terminal521is connected to the battery terminal51and is supplied with power via the battery terminal51. This power feeding terminal521is provided with an insertion hole521ain which the screw512of the battery terminal51is to be inserted. A nut513is tightened on the screw512that has been inserted in this insertion hole521ato cause the battery terminal51to be connected to the power feeding terminal521.

To the two circuit terminals522, circuits operated by power from the battery6are connected, respectively. Each of the circuit terminals522is provided with a screw522ato which a round terminal or the like of an electric wire of the circuit is to be connected.

The fusible bodies523are formed to connect the power feeding terminal521to the two respective circuit terminals522in strip shapes each of which is narrower than the power feeding terminal521and the circuit terminals522. In each of the circuit terminals522, power from the battery6flows from the power feeding terminal521via the fusible body523. When a current having a threshold value or higher flows, the fusible body523fuses to prevent overcurrent from flowing in the circuit.

Also, the fusible link52is formed with the power feeding terminal521, the two circuit terminals522, and the fusible bodies523made of a conductive metal covered with and fixed by (molded with) an insulating resin material. A resin housing524made of the insulating resin material covers and fixes respective parts of the power feeding terminal521, the circuit terminals522, and the fusible bodies523in a state in which respective connecting surfaces of the power feeding terminal521and the circuit terminals522are exposed, and in which windows524aare provided to enable fusing of the fusible bodies523to be visually recognized. Each window524afor visually recognizing fusing is covered with a transparent cover525, and fusing of the fusible body523can be visually recognized through this transparent cover525.

Here, in the above battery terminal51, an area around a part with which another part such as the fusible link52is coupled easily receives load resulting from a part weight and the like. Depending on the degree of the load, the battery terminal51may require higher strength.

Also, in recent years, with the advancement of space saving of a vehicle, a spatial margin around a battery mounted therein is being reduced. On the other hand, in the fuse unit5illustrated inFIGS. 14 and 15, the length from the electrode insertion hole511in which the rod-like electrode62is to be inserted to the circuit terminals522tends to be long. Accordingly, depending on the position of the rod-like electrode62in the battery6, the fuse unit5may protrude significantly to the periphery of the battery6, which can make it difficult to attach the fuse unit5to the battery6.

The present invention takes the above problems into consideration, and an object of the present invention is to provide a battery terminal with heightened strength. Another object of the present invention is to provide a fuse unit enabling protrusion when attached to a battery to be restricted and a method for manufacturing such a fuse unit.

SUMMARY

To solve the above problems, the invention according to a first aspect provides a battery terminal including: a terminal main body provided in opposed plates thereof as a pair, formed by folding approximately in a U shape a strip plate made of a conductive metal, respectively with electrode insertion holes in which a rod-like electrode projecting from a terminal attaching surface in a battery is sequentially inserted, and formed to extend toward an outer edge of the terminal attaching surface at time of being connected to the rod-like electrode; and a joint joining the opposed plates as the pair in a state in which the opposed plates surface-contact and overlap each other on an opposite side of a folded part as seen from the electrode insertion hole.

The invention according to a second aspect provides the battery terminal according to the first aspect, wherein the joint is formed by means of insert molding to cover and fix the opposed plates as the pair with an insulating resin material together on the opposite side.

The invention according to a third aspect provides the battery terminal according to the second aspect, further including: a circuit terminal connected to a circuit operated by power from the battery; and a fusible body connecting the terminal main body to the circuit terminal in a strip shape which is narrower than the terminal main body and the circuit terminal and fusing when current having a threshold value or higher flows, wherein the terminal main body, the circuit terminal, and the fusible body are integrally cut out from a single conductive metal plate and formed, and wherein the joint is formed by covering and fixing respective parts of the circuit terminal and the fusible body with the insulating resin material so that a connecting surface to the circuit in the circuit terminal may be exposed, and so that fusing of the fusible body can be visually recognized.

The invention according to a fourth aspect provides the battery terminal according to the third aspect, wherein the fusible body extends only in an intersecting direction, which intersects with an extending direction of the terminal main body, and which is approximately parallel to the terminal attaching surface, or extends both in the extending direction and in the intersecting direction so that a part extending in the extending direction may be shorter.

The invention according to a fifth aspect provides the battery terminal according to the first aspect, wherein a first opposed plate out of the opposed plates as the pair has the opposite side formed in a flat plate shape, and wherein a second opposed plate out of the opposed plates as the pair has the opposite side formed in a step-like bent shape in which the second opposed plate extends parallel to the first opposed plate, heads for the first opposed plate, extends parallel to the first opposed plate again, and surface-contacts and overlaps the first opposed plate as a parallel portion.

The invention according to a sixth aspect provides the battery terminal according to the second aspect, wherein a first opposed plate out of the opposed plates as the pair has the opposite side formed in a flat plate shape, and wherein a second opposed plate out of the opposed plates as the pair has the opposite side formed in a step-like bent shape in which the second opposed plate extends parallel to the first opposed plate, heads for the first opposed plate, extends parallel to the first opposed plate again, and surface-contacts and overlaps the first opposed plate as a parallel portion.

The invention according to a seventh aspect provides the battery terminal according to the third aspect, wherein a first opposed plate out of the opposed plates as the pair has the opposite side formed in a flat plate shape, and wherein a second opposed plate out of the opposed plates as the pair has the opposite side formed in a step-like bent shape in which the second opposed plate extends parallel to the first opposed plate, heads for the first opposed plate, extends parallel to the first opposed plate again, and surface-contacts and overlaps the first opposed plate as a parallel portion.

The invention according to an eighth aspect provides the battery terminal according to the fourth aspect, wherein a first opposed plate out of the opposed plates as the pair has the opposite side formed in a flat plate shape, and wherein a second opposed plate out of the opposed plates as the pair has the opposite side formed in a step-like bent shape in which the second opposed plate extends parallel to the first opposed plate, heads for the first opposed plate, extends parallel to the first opposed plate again, and surface-contacts and overlaps the first opposed plate as a parallel portion.

Further, to solve the above problems, a ninth aspect of the present invention provides a fuse unit including: a battery terminal connected at or around a first end thereof to a rod-like electrode projecting from a terminal attaching surface in a battery and extending toward a second end thereof to an outer edge of the terminal attaching surface; a circuit terminal connected to a circuit operated by power from the battery; and a fusible body connecting the battery terminal to the circuit terminal in a strip shape which is narrower than the battery terminal and the circuit terminal and fusing when current having a threshold value or higher flows, wherein the fusible body extends only in an intersecting direction, which intersects with an extending direction of the battery terminal, and which is approximately parallel to the terminal attaching surface, or extends both in the extending direction and in the intersecting direction so that a part extending in the extending direction may be shorter, and wherein the battery terminal, the circuit terminal, and the fusible body are integrally cut out from a single conductive metal plate and formed.

The invention according to a tenth aspect provides the fuse unit according to the ninth aspect, wherein the battery terminal is provided in opposed plates thereof as a pair, formed by folding a strip plate approximately in a U shape, respectively with electrode insertion holes in which the rod-like electrode is sequentially inserted, and is formed, after being cut out in a developed shape from the single plate, by folding a second opposed plate out of the opposed plates as the pair to head for a first opposed plate out of the opposed plates as the pair, while keeping the first opposed plate out of the opposed plates as the pair still, and wherein the fusible body is cut out integrally with the first opposed plate and formed continuously with the first opposed plate.

The invention according to an eleventh aspect provides the fuse unit according to the ninth aspect, wherein the circuit terminal is arranged adjacent to the battery terminal in the intersecting direction.

The invention according to a twelfth aspect provides the fuse unit according to the eleventh aspect, wherein the fusible body extends in the intersecting direction from the battery terminal at a forward position in the extending direction away from the circuit terminal, is then bent backward in the extending direction, and extends to the circuit terminal.

The invention according to a thirteenth aspect provides the fuse unit according to the tenth aspect, wherein the circuit terminal is arranged adjacent to the battery terminal in the intersecting direction.

The invention according to a fourteenth aspect provides the fuse unit according to the thirteenth aspect, wherein the fusible body extends in the intersecting direction from the battery terminal at a forward position in the extending direction away from the circuit terminal, is then bent backward in the extending direction, and extends to the circuit terminal.

Further, to solve the above problems, a fifteenth aspect of the present invention provides a method for manufacturing a fuse unit including: a battery terminal connected at or around a first end thereof to a rod-like electrode projecting from a terminal attaching surface in a battery and extending toward a second end thereof to an outer edge of the terminal attaching surface; a circuit terminal connected to a circuit operated by power from the battery; and a fusible body connecting the battery terminal to the circuit terminal in a strip shape which is narrower than the battery terminal and the circuit terminal and fusing when current having a threshold value or higher flows, wherein, in the fuse unit, the fusible body extends only in an intersecting direction, which intersects with an extending direction of the battery terminal, and which is approximately parallel to the terminal attaching surface, or extends both in the extending direction and in the intersecting direction so that a part extending in the extending direction may be shorter, the method including: a cutting process for integrally cutting out the battery terminal, the circuit terminal, and the fusible body from a single conductive metal plate.

The invention according to a sixteenth aspect provides the method for manufacturing a fuse unit according to the fifteenth aspect, wherein the cutting process includes a first cutting process for integrally cutting out a wide plate portion including the fusible body and wider than the fusible body, the battery terminal, and the circuit terminal from the single plate and a second cutting process for cutting the fusible body from the wide plate portion, and further including: a plating process for plating the battery terminal, the circuit terminal, and the wide plate portion after the first cutting process and before the second cutting process.

The invention according to a seventeenth aspect provides the method for manufacturing a fuse unit according to the fifteenth aspect, wherein the battery terminal is provided in opposed plates thereof as a pair, formed by folding a strip plate approximately in a U shape, respectively with electrode insertion holes in which the rod-like electrode is sequentially inserted, and is formed, after being cut out in a developed shape from the single plate, by folding a second opposed plate out of the opposed plates as the pair to head for a first opposed plate out of the opposed plates as the pair, while keeping the first opposed plate still out of the opposed plates as the pair, and wherein the fusible body is cut out integrally with the first opposed plate and formed continuously with the first opposed plate.

The invention according to an eighteenth aspect provides the method for manufacturing a fuse unit according to the fifteenth aspect, wherein the circuit terminal is arranged adjacent to the battery terminal in the intersecting direction.

The invention according to a nineteenth aspect provides the method for manufacturing a fuse unit according to the eighteenth aspect, wherein the fusible body extends in the intersecting direction from the battery terminal at a forward position in the extending direction away from the circuit terminal, is then bent backward in the extending direction, and extends to the circuit terminal.

According to the invention described in the first aspect, the opposed plates as the pair are joined in the state in which the opposed plates surface-contact and overlap each other on the opposite side of the folded part as seen from the electrode insertion hole. Accordingly, even when an area around the opposite part of the folded part receives load such as a part weight, the load is supported by the opposed plates as the pair separately. In other words, according to the aspect of the present invention described in the first aspect, the battery terminal can be heightened in strength against the load applied around an end portion as described above.

Also, according to the second aspect of the invention, the opposed plates as the pair are covered with and fixed by (molded with) the insulating resin material together by means of the insert molding on the opposite side. Accordingly, the opposed plates as the pair can be joined further strongly. Also, since the molding insulating resin material itself functions to support the load, strength of the battery terminal can further be heightened.

Also, according to the third aspect of the invention, the fuse-integrated battery terminal is achieved which is provided with a fuse function and which is reduced in size by integrally cutting out the terminal main body, the circuit terminal, and the fusible body from the single conductive metal plate. Also, molding of the pair of opposed plates is performed with use of the insulating resin material which molds parts of the circuit terminal and the fusible body. Accordingly, molding of the pair of opposed plates and molding of the circuit terminal and the fusible body can be performed by means of one insert molding process, which enables manufacturing cost to be reduced.

Also, according to the fourth aspect of the invention, the fuse-integrated battery terminal can further be reduced in size due to the above shape of the fusible body.

Also, according to the fifth to eighth aspects of the invention, the first opposed plate out of the opposed plates as the pair is formed in the flat plate shape while the second opposed plate is formed in the step-like bent shape. Thus, the terminal main body has different shapes on the front and back surfaces. For example, when the terminal main body is arranged in a mold for the insert molding, erroneous arrangement in which the front and back surfaces are erroneously arranged in terms of the directions can be prevented from occurring. Also, an insert molding machine can be positioned at a setting position with reference to the step-like bent part.

Also, according to the ninth to fifteenth aspects of the invention, the fusible body extends only in the intersecting direction, which intersects with the extending direction of the battery terminal, which heads for the outer edge of the terminal attaching surface in the battery, or extends both in the extending direction and in the intersecting direction so that the part extending in the extending direction may be shorter. This restricts a dimension of the fusible body in the extending direction heading for the outer edge of the terminal attaching surface. Also, since the battery terminal, the circuit terminal, and the fusible body are integrally cut out from the single conductive metal plate and formed, a part adapted to couple the battery terminal, such as the power feeding terminal521illustrated inFIGS. 14 and 15, is dispensed with. Accordingly, a dimension of the fuse unit in the extending direction heading for the outer edge of the terminal attaching surface is reduced, and as a result, protrusion when the fuse unit is attached to the battery can be restricted.

Also, according to the tenth to seventeenth aspects of the invention, since the battery terminal is formed so that the opposed plates as the pair formed by folding approximately in the U shape the strip plate may be respectively provided with the electrode insertion holes in which the rod-like electrode is to be inserted, stability of attachment of the battery terminal (that is, the fuse unit) to the rod-like electrode is improved. Further, since the fusible body is cut out integrally with the first opposed plate and formed continuously with the first opposed plate, when this battery terminal is formed to be folded by means of a process such as pressing so that the second opposed plate out of the opposed plates as the pair may head for the first opposed plate out of the opposed plates as the pair while the first opposed plate may be kept still, load to be applied to the fusible body at the time of the folding process such as vibration can be restricted.

Also, according to the eleventh, thirteenth, and eighteenth aspects of the invention, the circuit terminal is arranged adjacent to the battery terminal in the intersecting direction. Accordingly, a dimension of the fuse unit can further be reduced in the extending direction of the battery terminal, and as a result, protrusion when the fuse unit is attached to the battery can further be restricted.

Also, according to the twelfth, fourteenth, and nineteenth aspects of the invention, the fusible body extends in the intersecting direction from the battery terminal, is then bent backward in the extending direction, and extends to the circuit terminal arranged adjacent to the battery terminal in the intersecting direction. The fusible body needs to have certain length to obtain a resistance value required for fusing. By employing the aforementioned bent shape, the fusible body can be formed to have sufficient length without significantly separating the battery terminal from the circuit terminal in the intersecting direction. Accordingly, a dimension of the fuse unit in the intersecting direction of the battery terminal can also be reduced.

Also, according to the sixteenth aspect of the invention, the second cutting process for cutting the fusible body from the wide plate portion is executed after the plating process. Accordingly, an event such as deformation of the fusible body during plating can be prevented even without care of treating the fusible body at the time of the plating process, and barrel plating (also referred to as rotation plating) for rotating a plating bath containing a plurality of target parts to perform plating inexpensively can thus be employed as the plating process.

DETAILED DESCRIPTION

A battery terminal according to a first embodiment of the present invention will be described with reference toFIGS. 1 to 4B.FIG. 1is a perspective view of a battery terminal according to the first embodiment, andFIGS. 2A and 2Bare a plan view and a side view of the battery terminal illustrated inFIG. 1.FIG. 2Ais the plan view, andFIG. 2Bis the side view. Also,FIG. 3is a perspective view of a structure including a terminal main body, circuit terminals, and fusible bodies of the battery terminal illustrated inFIG. 1, andFIGS. 4A and 4Bare a plan view and a side view of the structure illustrated inFIG. 3.FIG. 4Ais the plan view, andFIG. 4Bis the side view.

A battery terminal1001according to the present embodiment is directly attached to a rod-like electrode1022projecting from a terminal attaching surface1021in a battery1002and includes a terminal main body1011, circuit terminals1012, and fusible bodies1013.

The terminal main body1011is formed to extend toward an outer edge1021aof the terminal attaching surface1021at the time of being connected to the rod-like electrode1022. As illustrated inFIG. 3, opposed plates1111and1112as a pair, formed by folding approximately in a U shape a strip plate1011′ made of a conductive metal, are respectively provided with electrode insertion holes1113and1114in which the rod-like electrode1022is sequentially inserted, to form the terminal main body1011. Meanwhile, in this terminal main body1011, while the first opposed plate1112located on a lower side inFIG. 3out of the opposed plates1111and1112as the pair is kept still, the second opposed plate1111is folded in a direction of an arrow D1001to head for the first opposed plate1112as illustrated inFIG. 3.

This terminal main body1011is provided with a slit1116residing from the electrode insertion hole1114in the first opposed plate1112via a U-shaped folded part1115through the electrode insertion hole1113in the second opposed plate1111. Each of the electrode insertion holes1114and1113is reduced in diameter by shrinking a width of this slit1116, and a tightening screw1014for shrinking the width of the slit1116is arranged inside the folded part1115in the terminal main body1011. A square washer1015is arranged between a screw head1014aof the tightening screw1014and the folded part1115, and a tip end of the tightening screw1014is screwed in a nut1016arranged with the folded part1115interposed between the nut1016and the square washer1015. When the tightening screw1014is tightened, a distance between the square washer1015and the nut1016is reduced, and the width of the slit1116is thus reduced, to cause the electrode insertion holes1113and1114to be reduced in diameter.

In the terminal main body1011, the tightening screw1014is tightened in a state in which the rod-like electrode1022is inserted in the electrode insertion holes1113and1114, and the electrode insertion holes1113and1114are reduced in diameter, to obtain mechanical fixing and electric connection to the rod-like electrode1022. In the terminal main body1011attached in this manner, the first opposed plate1112is opposed to the terminal attaching surface1021of the battery1002.

Also, in the terminal main body1011, on a side surface thereof, a sidewall1117is folded up from the second opposed plate1111to the first opposed plate1112, and a sidewall1118is folded up from the first opposed plate1112to the second opposed plate1111. The sidewall1117of the second opposed plate1111is provided with a recess1117awhile the sidewall1118of the first opposed plate1112is provided with a protrusion1118ato be inserted into the recess1117a. As illustrated inFIG. 2B, when the tightening screw1014is tightened in a direction of an arrow D1002, the square washer1015is about to turn in the same direction. At this time, the sidewall1117of the second opposed plate1111functions to prevent turning of the square washer1015. As a result, this sidewall1117is pressed by the square washer1015and is trying to move in a direction of an arrow D1003, and the protrusion1118aof the sidewall1118of the first opposed plate1112inserting in the recess1117aof the sidewall1117functions to stop the movement. This prevents deformation of the terminal main body1011when the tightening screw1014is tightened.

Also, in the terminal main body1011, the first opposed plate1112has an opposite part1112aof the folded part1115as seen from the electrode insertion hole1114formed in a flat plate shape. The second opposed plate1111has an opposite part1111aof the folded part1115as seen from the electrode insertion hole1113formed in a step-like bent shape in the following manner. That is, this opposite part1111aextends parallel to the first opposed plate1112, is then bent 90° to head for the first opposed plate1112, is bent 90° again to extend parallel to the first opposed plate1112, and surface-contacts and overlaps with the first opposed plate1112as a parallel portion1111a-1.

The circuit terminal1012is a square plate made of a conductive metal arranged approximately parallel to the terminal attaching surface1021of the battery1002and is provided at a center thereof with an insertion hole1121in which a connection screw1017, adapted to connect a not-illustrated circuit operated by power from the battery1002to this circuit terminal1012, is to be inserted. In the present embodiment, the two circuit terminals1012are provided. The two circuit terminals1012are arranged to be approximately coplanar with the first opposed plate1112in the terminal main body1011. The two circuit terminals1012are also arranged ahead of the terminal main body1011in an extending direction D1004, in which the terminal main body1011extends toward the outer edge1021aof the terminal attaching surface1021, to be arrayed in an intersecting direction D1005, which intersects with the extending direction D1004, and which is approximately parallel to the terminal attaching surface1021. In each of the circuit terminals1012, a round terminal or the like attached to a tip end of an electric wire extending from the not-illustrated circuit inserts the connection screw1017therein to establish connection by means of nut tightening.

The two fusible bodies1013are provided to connect the terminal main body1011to the two respective circuit terminals1012in strip shapes each of which is narrower than the terminal main body1011and the circuit terminals1012. When current having a threshold value or higher flows, each of the fusible bodies1013fuses. Also, each of the fusible bodies1013first extends in the intersecting direction D1005from an end portion of the terminal main body1011on a side of the circuit terminal1012, is then bent approximately 90°, and extends forward in the extending direction D1004to the circuit terminal1012. In each of the fusible bodies1013, a part extending in the extending direction D1004is formed to be shorter than a part extending in the intersecting direction D1005.

Also, as described above with reference toFIG. 3, in the present embodiment, the second opposed plate1111located on an upper side inFIG. 3out of the opposed plates1111and1112as the pair is folded in the direction of the arrow D1001to head for the first opposed plate1112. The two fusible bodies1013are provided to be continuous with the first opposed plate1112.

In the battery terminal1001according to the present embodiment, the terminal main body1011, the two circuit terminals1012, and the fusible bodies1013are integrally cut out from a single conductive metal plate and formed.

Also, the battery terminal1001is formed with the end portion of the terminal main body1011on the side of the fusible bodies1013, the two circuit terminals1012, and the fusible bodies1013covered with and fixed by (molded with) an insulating resin material. A resin housing1018made of the insulating resin material covers and fixes respective parts of the end portion of the terminal main body1011on the side of the fusible bodies1013, the two circuit terminals1012, and the fusible bodies1013in a state in which respective connecting surfaces of the circuit terminals1012are exposed, and in which windows1181are provided to enable fusing of the fusible bodies1013to be visually recognized. This resin housing1018is formed integrally with the terminal main body1011, the two circuit terminals1012, and the fusible bodies1013by means of insert molding. Also, this insert molding is performed in a state in which the connection screws1017are inserted in the insertion holes1121of the circuit terminals1012. Each window1181of the resin housing1018for visually recognizing fusing is covered with a transparent cover1019, and fusing of the fusible body1013is visually recognized through this transparent cover1019.

In the battery terminal1001according to the present embodiment, a part of the resin housing1018formed by means of the insert molding serves as a joint1182, in which the opposite parts1111aand1112aof the folded part1115in the pair of opposed plates1111and1112are joined in a state of surface-contacting and overlapping with each other. An area around the opposite parts1111aand1112aof the folded part1115receives load such as a weight of the electric wire of the circuit to be connected to each circuit terminal1012. At this time, since these parts1111aand1112aare joined at the joint1182in the state of surface-contacting and overlapping with each other, the above load is supported by the opposed plates1111and1112as the pair separately. In other words, the battery terminal1001according to the present invention is heightened in strength against the above load.

Also, with the battery terminal1001according to the present embodiment, the pair of opposed plates1111and1112is molded at the opposite parts1111aand1112awith the insulating resin material together by means of the insert molding. Accordingly, the opposed plates1111and1112as the pair can be joined further strongly. Also, since the molding insulating resin material itself functions to support the load, strength of the battery terminal1001is further heightened.

Also, the battery terminal1001according to the present embodiment is provided with a fuse function and is reduced in size since the battery terminal1001is formed by integrally cutting out the terminal main body1011, the circuit terminals1012, and the fusible bodies1013from the single conductive metal plate. Also, molding of the pair of opposed plates1111and1112is performed with use of the insulating resin material which molds parts of the circuit terminals1012and the fusible bodies1013. Accordingly, molding of the pair of opposed plates1111and1112and molding of the circuit terminals1012and the fusible bodies1013can be performed by means of one insert molding process, which enables manufacturing cost to be reduced.

Also, the battery terminal1001according to the present embodiment is further reduced in size as a fuse-integrated battery terminal due to the above shapes of the fusible bodies1013.

Also, with the battery terminal1001according to the present embodiment, the first opposed plate1112out of the opposed plates1111and1112as the pair is formed in a flat plate shape while the second opposed plate1111is formed in the step-like bent shape. Thus, the terminal main body1011has different shapes on the front and back surfaces. For example, when the terminal main body1011is arranged in a mold for the insert molding, erroneous arrangement in which the front and back surfaces are erroneously arranged in terms of the directions can be prevented from occurring. Also, an insert molding machine can be positioned at a setting position with reference to the step-like bent part1111a.

Next, a battery terminal according to a second embodiment of the present invention will be described with reference toFIGS. 5 to 6B.FIG. 5is a perspective view of a battery terminal according to the second embodiment, andFIGS. 6A and 6Bare a plan view and a side view of the battery terminal illustrated inFIG. 5.FIG. 6Ais the plan view, andFIG. 6Bis the side view.

A battery terminal1003according to the second embodiment is provided with no fuse function as in the battery terminal1001according to the first embodiment. In a case in which the battery terminal1003is provided with a fuse function, the battery terminal1003will be coupled with a fusible link1004similar to one illustrated inFIGS. 15 and 14with use of a screw1041and a nut1042.

The battery terminal1003includes a terminal main body1031in which opposed plates1311and1312as a pair, formed by folding approximately in a U shape a strip plate made of a conductive metal, are respectively provided with electrode insertion holes1313and1314. The first opposed plate1312located on a lower side inFIG. 5out of the opposed plates1311and1312as the pair has an opposite part1312aof the folded part1315as seen from the electrode insertion hole1314formed in a flat plate shape. The second opposed plate1311has an opposite part1311aof the folded part1315as seen from the electrode insertion hole1313formed in a step-like bent shape. That is, this opposite part1311aextends parallel to the first opposed plate1312, is then bent 90° to head for the first opposed plate1312, is bent 90° again to extend parallel to the first opposed plate1312, and surface-contacts and overlaps with the first opposed plate1312as a parallel portion1311a-1.

In the parallel portion1311a-1, a pair of nails1311bextending from the second opposed plate1311is swaged in a state of holding the first opposed plate1312. In the present embodiment, the pair of nails1311bserves as a joint, in which the opposite parts1311aand1312aof the folded part1315in the pair of opposed plates1311and1312are joined in a state of surface-contacting and overlapping with each other. Also, this overlapping part is provided with insertion holes1311cand1312bin which the screw1041is to be inserted.

Also, an attaching structure of the terminal main body1031to a not-illustrated rod-like electrode is similar to the attaching structure of the terminal main body1011to the rod-like electrode1022in the aforementioned first embodiment. To the terminal main body1031, a tightening screw1034, a square washer1035, and a nut1036constituting this attaching structure are attached.

It is to be understood that the battery terminal1003according to the second embodiment described above is also heightened in strength against load at the part in which the opposed plates1311and1312as the pair surface-contact and overlap each other.

It is to be noted that the above-described first and second embodiments merely show illustrative embodiments of the present invention, and that the present invention is not limited to these embodiments. That is, the present invention can be modified in various ways and carried out without departing from the spirit of the present invention. Such modification shall be included in the scope of the present invention as long as the modification includes a configuration of the battery terminal according to the present invention.

For example, in the above first embodiment, as an example of the battery terminal according to the present invention, the battery terminal1001in which the two circuit terminals are provided, and in which each of the circuit terminals is provided with one fusible body is raised. However, the battery terminal equipped with the fuse function and provided with the circuit terminal and the fusible body is not limited to this embodiment and may be an embodiment in which one or three or more circuit terminals is/are provided, for example. Also, in a case in which a plurality of circuit terminals are provided, each of the plurality of circuit terminals does not need to be provided with the fusible body, and an embodiment in which only circuit terminals connected to circuits required to be protected by fusing are provided with the fusible bodies is available.

Also, as an example of the fusible body “extending both in the extending direction and in the intersecting direction so that the part extending in the extending direction may be shorter” according to the present invention, the first embodiment illustrates the L-shaped fusible body1013bent 90° in the middle. However, the fusible body according to the present invention is not limited to this and may be one formed in a meandering shape, for example, as long as the part extending in the extending direction is shorter.

Also, as an example of the joint according to the present invention, the joint1182as a part of the resin housing1018formed by means of the insert molding is illustrated in the first embodiment, and the pair of nails1311bserving as the joint by means of swaging is illustrated in the second embodiment. However, the “joint” according to the present invention is not limited to these and may be a welded part in which the opposed plates as the pair are joined by means of spot welding, adhesive joining the opposed plates as the pair, or a rivet or the like joining the opposed plates as the pair. No specific joining method is questioned here.

Also, in the first embodiment, as an example of the circuit terminal according to the present invention, the square-plate-shaped circuit terminal1012arranged approximately parallel to the terminal attaching surface1021of the battery1002is raised. However, the circuit terminal according to the present invention may be one arranged approximately parallel to a side surface of the battery perpendicular to the terminal attaching surface, one bent in an L shape, or the like. That is, in the circuit terminal according to the present invention, no specific arrangement or shape thereof is questioned as long as the circuit terminal is a terminal to which a circuit operated by power from a battery is connected.

Next, a fuse unit according to a third embodiment of the present invention will be described with reference toFIGS. 7 to 10B.FIG. 7is a perspective view of a fuse unit according to the third embodiment, andFIGS. 8A and 8Bare a plan view and a side view of the fuse unit illustrated inFIG. 7.FIG. 8Ais the plan view, andFIG. 8Bis the side view. Also,FIG. 9is a perspective view of a structure including a battery terminal, circuit terminals, and fusible bodies of the fuse unit illustrated inFIG. 7, andFIGS. 10A and 10Bare a plan view and a side view of the structure illustrated inFIG. 9.FIG. 10Ais the plan view, andFIG. 10Bis the side view.

A fuse unit2001according to the present embodiment is directly attached to a rod-like electrode2022projecting from a terminal attaching surface2021in a battery2002and includes a battery terminal2011, circuit terminals2012, and fusible bodies2013.

The battery terminal2011is connected around a first end thereof to the rod-like electrode2022projecting from the terminal attaching surface2021in the battery2002and extends toward a second end thereof to an outer edge2021aof the terminal attaching surface2021. As illustrated inFIG. 9, opposed plates2111and2112as a pair, formed by folding approximately in a U shape a strip plate2011′ made of a conductive metal, are respectively provided with electrode insertion holes2113and2114in which the rod-like electrode2022is sequentially inserted, to form the battery terminal2011. Meanwhile, in this battery terminal2011, while the first opposed plate2112located on a lower side inFIG. 9out of the opposed plates2111and2112as the pair is kept still, the second opposed plate2111is folded in a direction of an arrow D2001to head for the first opposed plate2112as illustrated inFIG. 9.

This battery terminal2011is provided with a slit2116residing from the electrode insertion hole2114in the first opposed plate2112via a U-shaped folded part2115through the electrode insertion hole2113in the second opposed plate2111. Each of the electrode insertion holes2113and2114is reduced in diameter by shrinking a width of this slit2116, and a tightening screw2014for shrinking the width of the slit2116is arranged inside the folded part2115in the battery terminal2011. A square washer2015is arranged between a screw head2014aof the tightening screw2014and the folded part2115, and a tip end of the tightening screw2014is screwed in a nut2016arranged with the folded part2115interposed between the nut2016and the square washer2015. When the tightening screw2014is tightened, a distance between the square washer2015and the nut2016is reduced, and the width of the slit2116is thus reduced, to cause the electrode insertion holes2113and2114to be reduced in diameter.

In the battery terminal2011, the tightening screw2014is tightened in a state in which the rod-like electrode2022is inserted in the electrode insertion holes2113and2114, and the electrode insertion holes2113and2114are reduced in diameter, to obtain mechanical fixing and electric connection to the rod-like electrode2022. In the battery terminal2011attached in this manner, the first opposed plate2112is opposed to the terminal attaching surface2021of the battery2002.

Also, in the battery terminal2011, on a side surface thereof, a sidewall2117is folded up from the second opposed plate2111to the first opposed plate2112, and a sidewall2118is folded up from the first opposed plate2112to the second opposed plate2111. The sidewall2117of the second opposed plate2111is provided with a recess2117awhile the sidewall2118of the first opposed plate2112is provided with a protrusion2118ato be inserted into the recess2117a. As illustrated inFIG. 8B, when the tightening screw2014is tightened in a direction of an arrow D2002, the square washer2015is about to turn in the same direction. At this time, the sidewall2117of the second opposed plate2111functions to prevent turning of the square washer2015. As a result, this sidewall2117is pressed by the square washer2015and is about to move in a direction of an arrow D2003, and the protrusion2118aof the sidewall2118of the first opposed plate2112inserting in the recess2117aof the sidewall2117functions to stop the movement. This prevents deformation of the battery terminal2011when the tightening screw2014is tightened.

The circuit terminal2012is a square plate made of a conductive metal arranged approximately parallel to the terminal attaching surface2021of the battery2002and is provided at a center thereof with an insertion hole2121in which a connection screw2017, adapted to connect a not-illustrated circuit operated by power from the battery2002to this circuit terminal2012, is to be inserted. In the present embodiment, the two circuit terminals2012are provided. The two circuit terminals2012are arranged to be approximately coplanar with the first opposed plate2112in the battery terminal2011. The two circuit terminals2012are also arranged ahead of the battery terminal2011in an extending direction D2004, in which the battery terminal2011extends toward the outer edge2021aof the terminal attaching surface2021, to be arrayed in an intersecting direction D2005, which intersects with the extending direction D2004, and which is approximately parallel to the terminal attaching surface2021. In each of the circuit terminals2012, a round terminal or the like attached to a tip end of an electric wire extending from the not-illustrated circuit inserts the connection screw2017therein to establish connection by means of nut tightening.

The two fusible bodies2013are provided to connect the battery terminal2011to the two respective circuit terminals2012in strip shapes each of which is narrower than the battery terminal2011and the circuit terminals2012. When current having a threshold value or higher flows, each of the fusible bodies2013fuses. Also, each of the fusible bodies2013first extends in the intersecting direction D2005from an end portion of the battery terminal2011on a side of the circuit terminal2012, is then bent approximately 90°, and extends forward in the extending direction D2004to the circuit terminal2012. In each of the fusible bodies2013, a part extending in the extending direction D2004is formed to be shorter than a part extending in the intersecting direction D2005.

Also, as described above with reference toFIG. 9, in the present embodiment, the second opposed plate2111located on an upper side inFIG. 9out of the opposed plates2111and2112as the pair is folded in the direction of the arrow D2001to head for the first opposed plate2112. The two fusible bodies2013are provided to be continuous with the first opposed plate2112.

In the fuse unit2001according to the present embodiment, the battery terminal2011, the two circuit terminals2012, and the fusible bodies2013are integrally cut out from a single conductive metal plate and formed.

Also, the fuse unit2001is formed with the end portion of the battery terminal2011on the side of the fusible bodies2013, the two circuit terminals2012, and the fusible bodies2013covered with and fixed by (molded with) an insulating resin material. A resin housing2018made of the insulating resin material covers and fixes respective parts of the end portion of the battery terminal2011on the side of the fusible bodies2013, the two circuit terminals2012, and the fusible bodies2013in a state in which respective connecting surfaces of the circuit terminals2012are exposed, and in which windows2181are provided to enable fusing of the fusible bodies2013to be visually recognized. This resin housing2018is formed integrally with the battery terminal2011, the two circuit terminals2012, and the fusible bodies2013by means of insert molding. Also, this insert molding is performed in a state in which the connection screws2017are inserted in the insertion holes2121of the circuit terminals2012. Each window2181of the resin housing2018for visually recognizing fusing is covered with a transparent cover2019, and fusing of the fusible body2013is visually recognized through this transparent cover2019.

With the aforementioned fuse unit2001according to the third embodiment, each fusible body2013extends both in the extending direction D2004of the battery terminal2011and in the intersecting direction D2005intersecting with the extending direction D2004so that the part extending in the extending direction D2004may be shorter than the part extending in the intersecting direction D2005. This restricts a dimension of the fusible body2013in the extending direction D2004heading for the outer edge2021aof the terminal attaching surface2021of the battery2002. Also, since the battery terminal2011, the circuit terminals2012, and the fusible bodies2013are integrally cut out from the single conductive metal plate and formed, a part adapted to couple the battery terminal, such as the power feeding terminal521illustrated inFIGS. 14 and 15, is dispensed with. Accordingly, a dimension of the fuse unit2001in the extending direction D2004heading for the outer edge2021aof the terminal attaching surface2021is reduced, and as a result, protrusion when the fuse unit2001is attached to the battery2002can be restricted.

Also, with this fuse unit2001, since the battery terminal2011is formed so that the opposed plates2111and2112as the pair formed by folding approximately in the U shape the strip plate2011′ may be respectively provided with the electrode insertion holes2113and2114in which the rod-like electrode2022is to be inserted, stability of attachment of the battery terminal2011(that is, the fuse unit2001) to the rod-like electrode2022is improved. Further, since the fusible bodies2013are cut out integrally with the first opposed plate2112and formed continuously with the first opposed plate2112, when this battery terminal2011is formed to be folded by means of a process such as pressing so that the second opposed plate2111out of the opposed plates2111and2112as the pair may head for the first opposed plate2112, load to be applied to the fusible bodies2013at the time of the folding process such as vibration can be restricted.

Next, a method for manufacturing a fuse unit, in which the fuse unit2001illustrated inFIGS. 7 to 10Bis manufactured, will be described with reference toFIG. 11.FIG. 11is a flowchart schematically illustrating a method for manufacturing a fuse unit, in which the fuse unit2001illustrated inFIGS. 7 to 10Bis manufactured.

In this method for manufacturing a fuse unit, in step S1, a first cutting process for cutting a single conductive metal plate in the following manner is first executed. In the first cutting process, a wide plate portion2013′ in a state in which a gap between the two circuit terminals2012and between the fusible bodies2013is filled and the battery terminal2011are cut out from a single conductive metal plate. The wide plate portion2013′ corresponds to an example of “a wide plate portion including the fusible body and wider than the fusible body” according to the present invention. The battery terminal2011is cut out in a not-illustrated developed shape. Also, in step S1, a folding process for folding and processing the metal plate from the developed shape into a desired shape by means of a process such as pressing is executed for the battery terminal2011.

Subsequently, in step S2, a plating process for plating the wide plate portion2013′ including the two circuit terminals2012and the fusible bodies2013and the battery terminal2011is executed. In the present embodiment, as the plating process, barrel plating (also referred to as rotation plating) for rotating a plating bath containing a plurality of target parts to perform plating inexpensively is employed.

In step S3, subsequent to the plating process in step S2, a second cutting process for removing a part corresponding to the gap between the two circuit terminals2012and between the fusible bodies2013from the wide plate portion2013′ to cut out the two circuit terminals2012and the fusible bodies2013is executed.

Finally, in step S4, a molding process by means of insert molding is executed to form the resin housing2018. This insert molding is performed in a state in which the connection screws2017are inserted in the insertion holes2121of the circuit terminals2012. After the molding process, a part attaching process for covering the windows2181for visually recognizing fusing of the fusible bodies2013with the transparent covers2019and attaching the tightening screw2014, the square washer2015, and the nut2016to the battery terminal2011is performed, to complete the fuse unit2001.

Meanwhile, the insertion holes2121of the circuit terminals2012may be opened in the first cutting process (step S1) or in the second cutting process (step S3). When to open the insertion holes2121is not specified. In a case in which the insertion holes2121are opened in the first cutting process (step S1), the insertion holes2121can be used as reference holes for positioning when the two circuit terminals2012and the fusible bodies2013are cut out in the second cutting process (step S3).

According to the aforementioned method for manufacturing a fuse unit, the second cutting process (step S3) for cutting the fusible bodies2013from the wide plate portion2013′ is executed after the plating process (step S2). Accordingly, an event such as deformation of the fusible bodies2013during plating can be prevented even without care of treating the fusible bodies2013at the time of the plating process, and the barrel plating can thus be employed as the plating process in the present embodiment.

Next, a fuse unit according to a fourth embodiment of the present invention will be described with reference toFIGS. 12 and 13.FIG. 12is a perspective view of a fuse unit according to the fourth embodiment, andFIG. 13is a perspective view illustrating a state in which a resin housing and a tightening screw are removed from the fuse unit illustrated inFIG. 12.

In a fuse unit2003according to the present embodiment, circuit terminals2032are arranged adjacent to a battery terminal2031configured similarly to the battery terminal2011according to the third embodiment in the following manner. That is, the circuit terminals2032are arranged adjacent to the battery terminal2031in an intersecting direction D2007, which intersects with an extending direction D2006in which the battery terminal2031connected to a rod-like electrode2042of a battery2004extends toward an outer edge2041aof a terminal attaching surface2041, and which is approximately parallel to the terminal attaching surface2041.

A fusible body2033extends in the intersecting direction D2007from the battery terminal2031at a forward position in the extending direction D2006away from the circuit terminal2032, is then bent backward in the extending direction D2006, and extends to the circuit terminal2032. Here, in the present embodiment, the fusible body2033is arranged at a position one level below the circuit terminal2032to prevent interference with an electric wire or the like of a not-illustrated circuit connected to the circuit terminal2032. Thus, an end portion of the circuit terminal2032on a side of the fusible body2033is bent 90° downward and is connected to the fusible body2033. Similarly, an end portion, on the side of the fusible body2033, of a lower opposed plate2312inFIG. 12out of opposed plates2311and2312as a pair constituting the battery terminal2031, is also bent 90° downward and is connected to the fusible body2033. The fusible body2033is provided with a base part2331connected to the end portion of the lower opposed plate2312and is provided at both ends of the base part2331with fusible parts2332and2333formed to be narrower than the base part2331and fusing when current having a threshold value or higher flows. Also, out of the fusible parts2332and2333connected to the respective circuit terminals2032, the left fusible part2332inFIG. 12is formed to be narrower than the right fusible part2333inFIG. 12. Accordingly, the left fusible part2332inFIG. 12functions as a small-capacity fuse which fuses due to lower current than current causing the right fusible part2333to fuse.

An attaching structure of the battery terminal2031to the rod-like electrode2042is similar to the attaching structure of the battery terminal2011to the rod-like electrode2022in the aforementioned third embodiment. To the battery terminal2031, a tightening screw2034, a square washer2035, and a nut2036constituting this attaching structure are attached.

Also, the fuse unit2003according to the present embodiment is formed with the end portion of the battery terminal2031on the side of the fusible body2033, the two circuit terminals2032, and the fusible body2033molded with an insulating resin material. A resin housing2038made of the insulating resin material covers and fixes respective parts of the end portion of the battery terminal2031on the side of the fusible body2033, the two circuit terminals2032, and the fusible body2033in a state in which respective connecting surfaces of the circuit terminals2032are exposed, and in which windows2381are provided to enable fusing of the fusible body2033to be visually recognized. This resin housing2038is formed integrally with the battery terminal2031, the two circuit terminals2032, and the fusible body2033by means of insert molding. Also, this insert molding is performed in a state in which connection screws2037are inserted in insertion holes2321of the circuit terminals2032. Each window2381of the resin housing2038for visually recognizing fusing is covered with a transparent cover2039, and fusing of the fusible body2033is visually recognized through this transparent cover2039.

With the aforementioned fuse unit2003according to the fourth embodiment, the circuit terminals2032are arranged adjacent to the battery terminal2031in the intersecting direction D2007. Accordingly, a dimension of the fuse unit2003can be reduced in the extending direction D2006of the battery terminal2031further than in a case in which the circuit terminals2032are arranged forward in the extending direction D2006of the battery terminal2031, and as a result, protrusion when the fuse unit2003is attached to the battery2004can further be restricted.

Also, with this fuse unit2003, the fusible body2033extends in the intersecting direction D2007from the battery terminal2031, is then bent backward in the extending direction D2006, and extends to the circuit terminal2032arranged adjacent to the battery terminal2031in the intersecting direction D2007. The fusible body2033needs to have certain length to obtain a resistance value required for fusing. By employing the aforementioned bent shape, the fusible body2033can be formed to have sufficient length without significantly separating the battery terminal2031from the circuit terminal2032in the intersecting direction D2007. Accordingly, a dimension of the fuse unit2003in the intersecting direction D2007of the battery terminal2031can also be reduced.

It is to be noted that the above-described third and fourth embodiments merely show illustrative embodiments of the present invention, and that the present invention is not limited to these embodiments. That is, the present invention can be modified in various ways and carried out without departing from the spirit of the present invention. Such modification shall be included in the scope of the present invention as long as the modification includes a configuration of the fuse unit according to the present invention or a configuration of the method for manufacturing a fuse unit.

For example, in the above third embodiment, as an example of the fuse unit according to the present invention, the fuse units2001and2003in which the two circuit terminals are provided, and in which each of the circuit terminals is provided with one fusible body are raised. However, the fuse unit according to the present invention is not limited to this embodiment and may be an embodiment in which one or three or more circuit terminals is/are provided, for example. Also, in a case in which a plurality of circuit terminals are provided, each of the plurality of circuit terminals does not need to be provided with the fusible body, and an embodiment in which only circuit terminals connected to circuits required to be protected by fusing are provided with the fusible bodies is available.

Also, as examples of the fusible body “extending both in the extending direction and in the intersecting direction so that the part extending in the extending direction may be shorter” according to the present invention, the third embodiment illustrates the L-shaped fusible body2013bent 90° in the middle, and the fourth embodiment illustrates the fusible body2033including the L-shaped fusible parts2332and2333each bent 90° in the middle. However, the fusible body according to the present invention is not limited to these and may be one formed in a meandering shape, for example, as long as the part extending in the extending direction is shorter.

Also, in the aforementioned fourth embodiment, as an example of the fusible body connecting the battery terminal to the circuit terminal arranged adjacent to the battery terminal in the intersecting direction, the fusible body2033including the L-shaped fusible parts2332and2333each bent 90° in the middle is raised. However, the fusible body connecting the battery terminal to the circuit terminal arranged as above is not limited to this and may be one formed to straightly extend only in the intersecting direction from a side surface of the battery terminal to the circuit terminal.

Also, in the third and fourth embodiments, as examples of the circuit terminal according to the present invention, the square-plate-shaped circuit terminals2012and2032arranged approximately parallel to the terminal attaching surfaces2021and2041of the batteries2002and2004are raised. However, the circuit terminal according to the present invention may be one arranged approximately parallel to a side surface of the battery perpendicular to the terminal attaching surface, one bent in an L shape, or the like. That is, in the circuit terminal according to the present invention, no specific arrangement or shape thereof is questioned as long as the circuit terminal is a terminal to which a circuit operated by power from a battery is connected.