Wire harness, method of connecting terminal and coated wire, and mold

A method of connecting a terminal and a coated wire wherein:

• the terminal includes a crimping portion, in which the coated wire is crimped, and a terminal body;
• the crimping portion is formed by rolling up a plate-like material into an approximately cylindrical shape, and joining and welding edges of the plate-like material at a joining part;
• and
• except for a part through which the coated wire is inserted, other parts of the crimping portion are closed, the method comprising:
• inserting the coated wire into the crimping portion;
• using a first mold and a second mold that face each other to press the crimping portion;
• fitting the first mold into an inner part of the second mold;
• crimping a covered portion of the coated wire at the crimping portion;
• and
• forming a protruding portion on the periphery surface of the crimping portion at a position corresponding to a fitting section of the first mold and the second mold, wherein
• a protruding height of the protruding portion from a periphery surface of the crimping portion in a direction perpendicular to a compression direction of the crimping portion on a cross section in a diameter direction of the crimping portion is equal to or less than a body thickness of the crimping portion before crimping;
• a tapered portion or a smoothly connecting tapered portion that is tilted inward to a direction perpendicular to the compression direction of the first mold and the second mold is provided at an end portion of the first mold;
• on the cross section in the diameter direction of the crimping portion, a level difference corresponding to the shape of the end portion of the first mold is formed on the protruding portion between the protruding portion and the periphery surface of the crimping portion;
• a surface perpendicular to the compression direction at the protruding portion is formed to the periphery of the protruding portion;
• a tilted portion or a smoothly connecting tilted portion is formed at a boundary part between the surface perpendicular to the compression direction of the crimping portion at a base part of the protruding portion and an arc surface of the periphery of the crimping portion;
• and
• the joining part and the protruding portion are formed at different positions in a circumferential direction on a periphery surface of the crimping portion.

A mold used for crimping a terminal and a coated wire comprising a first mold and a second mold that face each other, wherein:

• the first mold fits into an inner portion of the second mold so that it is possible to crimp a covered portion of the coated wire with the terminal;
• a tapered portion or a smoothly connecting tapered portion that is tilted inward to a direction perpendicular to a compression direction of the first mold and the second mold is provided at an end portion of the first mold;
• a protruding portion according to a shape of the end part of the first mold is formed along a longitudinal direction of the terminal on a periphery surface of a crimping portion of the terminal that corresponds to a covered portion of the coated wire;
• a level difference is formed between the protruding portion and the periphery surface of the crimping portion on the cross section in the diameter direction of the crimping portion;
• a surface perpendicular to the compression direction at the protruding portion is formed to the periphery of the protruding portion;
• and
• a tilted portion or a smoothly connecting tilted portion is formed at a boundary part between the surface perpendicular to the compression direction of the crimping portion at a base part of the protruding portion and an arc surface of the periphery of the crimping portion, wherein
• the level difference and a joining part of the terminal are formed at different positions in a circumferential direction on a periphery surface of the terminal.