Electrical wire-connecting structure and method for manufacturing electrical wire-connecting structure

A method for manufacturing an electrical wire-connecting structure including a terminal having a tubular portion and an insulated electrical wire having a conductor portion, the terminal and the conductor portion being crimped at the tubular portion, the method comprising:

• preparing the terminal by punching out a plate-like material and bending the plate-like material into an approximately cylindrical shape, and joining and welding edges of the plate-like material at a joining part to form the tubular portion, the terminal having the tubular portion in which a conductor insertion portion into which the conductor portion is inserted is formed with a smaller diameter than a covering insertion portion into which a covering portion of the insulated electrical wire is inserted, and an inner diameter of the covering insertion portion is in a range of 1.0 to 1.7 times an outer diameter of the covering portion;
• collapsing and welding closed an end portion of the tubular portion remote from an electrical wire insertion opening so as to form a closed cylindrical body in which portions aside from the electrical wire insertion opening are closed off from the end portion toward the electrical wire insertion opening:
• inserting the insulated electrical wire into the tubular portion;
• and
• compressively crimping the covering insertion portion and the covering portion.