Method for manufacturing terminal, and terminal

• US 9,293,906 B2
• Filed: 11/05/2013
• Issued: 03/22/2016
• Est. Priority Date: 12/03/2012
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Kawashima, Seizaburou
• Primary Examiner(s): Nguyen, Phuongchi T
• Application Number:
  US14/424,457
• Publication Number:
  US 20150214712A1
• Time in Patent Office: 868 Days
• Field of Search: 439/274, 439/275, 439/587, 439/588, 439/589
• US Class Current: 1/1
• CPC Class Codes: G01F 23/38 using magnetically actuated indicating means
• CPC Class Codes: H01R 13/521 Sealing between contact members and housing, e.g. sealing insert
• CPC Class Codes: H01R 43/16 for manufacturing contact members, e.g. by punching and by bending
• CPC Class Codes: H02G 15/04 Cable-end sealings
• CPC Class Codes: Y10T 29/49224 with coating

Abstract

A method for manufacturing a terminal includes: an electrically conductive member that has electrical connections, which are respectively formed at end portions of the electrically conductive member, wherein the electrical connections are respectively connectable with a lead wire and a terminal of a Hall IC; and a seal film that is formed in a surface of an intermediate portion of the electrically conductive member. In the method for manufacturing, end portions of a planar rod having a rectangular cross section are respectively used as the electrical connections, and an intermediate portion of the planar rod is processed such that corners of the rectangular cross section are rounded. Thereafter, a liquid seal agent is coated on the intermediate portion. Furthermore, the coated liquid seal agent is solidified to form a seal film.

Claims

1. A method for manufacturing a terminal that includes:

an electrically conductive member that has an electrical connection, which is formed at an end portion of the electrically conductive member, wherein the electrical connection is connectable with an external electrical conductor; and

a seal film that is formed in a surface of a predetermined portion of the electrically conductive member, which is other than the electrical connection, the method comprising;

forming the electrically conductive member by processing a planar rod, which has a rectangular cross section, such that each of four corners of the rectangular cross section of a corresponding portion of the planar rod, which is other than an end portion of the planar rod, is rounded to form the predetermined portion of the electrically conductive member, while the end portion of the planar rod, which has the rectangular cross section, is made as the electrical connection;

coating a liquid seal agent on the predetermined portion; and

solidifying the liquid seal agent, which is coated on the predetermined portion, to form the seal film.

2. The method for manufacturing according to claim 1, comprising forming an intermediately shaped product, which includes the planar rod as one of a plurality of planar rods connected together, through press working of a plate material before the forming of the predetermined portion of the electrically conductive member, wherein:

the forming of the electrically conductive member includes simultaneously rounding the four corners of the rectangular cross section of the corresponding portion in each of the plurality of planar rods through press working of the intermediately shaped product.

3. The method for manufacturing according to claim 1, wherein the forming of the electrically conductive member includes simultaneously rounding the four corners of the rectangular cross section of the corresponding portion through press working of the planar rod by using a pair of dies that have four press surfaces, each of which is opposed to a corresponding one of the four corners of the rectangular cross section of the corresponding portion and is configured into an arcuate shape.

4. The method for manufacturing according to claim 1, wherein the forming of the electrically conductive member includes forming a groove in at least one of two end surfaces of the rectangular cross section of the corresponding portion, which are opposed to each other in a longitudinal direction of the rectangular cross section, simultaneously with the rounding of each of the four corners of the rectangular cross section of the corresponding portion through press working of the planar rod.

5. The method for manufacturing according to claim 4, wherein the coating of the liquid seal agent includes coating the liquid seal agent in the groove such that a recess, which is recessed along the groove, is formed in the seal film.

6. A terminal comprising:

an electrically conductive member that has an electrical connection which is formed at an end portion of the electrically conductive member, wherein the electrical connection is connectable with an external electrical conductor; and

a seal film that is formed in a surface of a predetermined portion of the electrically conductive member, which is other than the electrical connection, wherein;

a cross section of the electrical connection has a rectangular shape; and

a cross section of the predetermined portion has a shape that is formed by rounding each of four corners of a rectangle; and

the seal film, which is coated on the predetermined portion, is a liquid seal agent.

7. The terminal according to claim 6, wherein:

the terminal is placed to extend from an inside to an outside of a housing that is placed in an environment exposed to liquid fuel; and

the seal film seals between the housing and the electrically conductive member.

8. The terminal according to claim 6, wherein:

a groove is formed in at least one of two end surfaces of the cross section of the predetermined portion, which are opposed to each other in a longitudinal direction of the cross section; and

the seal film is formed in a surface of the predetermined portion, which includes the groove.

9. The terminal according to claim 6, wherein a recess, which is recessed along the groove, is formed in the seal film.