JP2000188141A - Bus bar for connecting wire in electrical connection box and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily connect laid wires by dividing them for an upper case and a lower case. SOLUTION: A conductive sheet is blanked and bent into a designated shape to form a bus bar 10 for jointing a wire. The bus bar 10 for electrical connection is disposed on the sides of a lower case 11 and an upper case 12, and is pressure-connected to wires w-1, w-2 laid individually along the inner surface of an electrical connection box, in order to form an internal circuit.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bus bar for connecting electric wires of an electric junction box and a method of manufacturing the same.
Junction boxes incorporated in automotive wiring harnesses, etc., which have internal circuits consisting of a combination of electric wires and press-contact terminals on the upper case side and the lower case side as internal circuits, respectively. And a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in an electric connection box such as a junction box for housing a branch circuit at high density, a circuit formed by combining an electric wire and a press-connecting terminal alone or together with a bus bar is formed. There are cases. In particular,
To accommodate high-density circuits, wires are routed along the inner surfaces of the lower case and upper case, and bus bars are arranged with an insulating plate interposed between them. The circuit is housed in an electrical junction box with a vertically laminated structure of electric wires.

[0003] In the case of manufacturing the electric junction box having the above structure, as shown in Fig. 9, the lower case 1 and the upper case 2 are arranged on the same plane, and are arranged with a predetermined gap C therebetween. It is arranged upward. In the terminal receiving holes of the connectors 3 and 4 on the inner surfaces of the lower case 1 and the upper case 2 facing upward, the press contact terminals 5 and 5 are mounted with the slots provided with the press contact blades facing upward. A single electric wire (single-core wire) w is drawn with one stroke from the lower case 1 side to the upper case 2 side, and conversely, from the upper case 2 side to the lower case 1 side along the inner surfaces of the arranged lower case 1 and upper case 2. And the lower case 1 and the upper case 2 are laid over the gap C, and the press-connecting terminals 5 attached to the connectors 3 and 4 of the lower case 1 and the upper case 2,
5, the electric wire w is directly driven, and the electric wire w and the pressure contact terminal 5,
5 is connected.

As described above, the reason why the electric wire w is continuously wired to the lower case 1 side and the upper case 2 side by one stroke is that it is necessary to connect the electric wire w on the lower case side and the upper case side. .

After the electric wires w are laid on the inner surfaces of the lower case 1 and the upper case 2 as described above and press-connected to the press contact terminals 5 and 5, the electric wires w on the lower case 1 side and the electric wires w on the upper case 2 side are connected. The upper case 2 is rotated and overlapped with the lower case 1 so as to be opposed to the lower case 1 in the direction shown by the arrow in the drawing.

Further, as shown in FIG.
On the side, a first insulating plate 6 was disposed above a circuit composed of the electric wire w and the pressure contact terminal 5, a bus bar 7 was disposed thereon, and a second insulating plate 8 was further disposed on the upper surface of the bus bar 7. In some cases, the lower case 1 and the upper case 2 may be fitted together so that the electric wires w on the upper case 2 side are arranged later.

[0007]

As described above, the electric wire w is laid in a state where the lower case 1 and the upper case 2 are spread on the same surface, so that the lower case 1 and the upper case 2 are arranged.
Has to be laid over the gap C between them. In this state, when the lower case 1 and the upper case 2 are to be fitted to each other, the electric wire portion wa straddling the gap between the lower case 1 and the upper case 2 becomes U-shaped like a hinge as shown in FIG. It is necessary to be folded back, and there is a problem that this folded wire portion wa jumps out.

Further, when the bus bar 7 is interposed, if a tab 7a protruding from the bus bar 7 is present at a position close to the folded side of the upper case 2, when the lower case 1 and the upper case 2 are fitted, the upper case 2 2, there is a problem that the tab 7a of the bus bar 7 cannot be properly inserted into a required terminal hole on the upper case 2 side.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and prevents an electric wire from protruding from one outer surface of a fitting portion between a lower case and an upper case, and rotates the upper case to fit the lower case into the lower case. The first problem is to solve the problem that it is difficult to insert the tab into the terminal hole of the upper case in the case of using the bus bar for electric wire connection. Further, it is a second object of the present invention to efficiently manufacture the bus bar for electric wire connection.

[0010]

In order to solve the above-mentioned problems, the present invention is to provide an internal connection circuit comprising a lower case and an upper case. Provided above, is a bus bar for electric wire connection that arranges these layered electric wires on the side of the case, is punched from one conductive plate, and has a vertical plate portion arranged at a required interval in a strip shape, It has a horizontal continuous plate portion that continues the middle part in the vertical direction of these vertical portions, and the horizontal connecting portion is cut at a required position and divided into a plurality, and is bent in the same direction from the upper and lower ends of the vertical portion. The present invention provides a bus bar for electric connection of an electric junction box, which comprises upper and lower horizontal parts, and the upper and lower horizontal parts are connected to the electric wires arranged in layers.

[0011] As described above, by dividing the electric wires constituting the internal circuit into layers, it is possible to prevent the folded electric wire portion from being generated at the time of manufacturing the electric junction box. However, since the lower case and the upper case can be separated from each other, the tabs projecting from the bus bar can be easily inserted into the cases. In addition, in order to form an internal circuit, it is necessary to connect wires of different levels, but by arranging bus bars for wire connection on the side of the case and connecting the wires respectively, the internal circuit can be easily formed. In addition, the connection according to the circuit design can be easily performed, and the circuit can be easily changed.

Since the bus bar for connecting electric wires is formed by punching and bending a single conductive plate, it can be manufactured easily and at low cost. In addition, by adapting the punching shape and bending shape of the conductive plate to the state of division of the electric wire, it is possible to cope with various connection states and a circuit structure of two or more layers.

The electric wires for the internal circuit are electric wires wired along the inner surfaces of the lower case and the upper case, and the cut ends of these electric wires are located at the side ends of the case so that the upper and lower horizontal lines of the connecting bus bar are disposed. Preferably, it is configured to be connected to the unit. Thus, by locating the cut ends of the wires constituting the internal circuit at the side ends of the case, the distance between the wires and the bus bars for wire connection arranged on the side of the case becomes short, and the distance between the wires and the bus bars for wire connection is reduced. Connection can be made more easily.

Further, the electric wire connecting bus bar of the present invention
The connection end of the upper internal circuit wire is bent downward and the connection end of the lower internal circuit wire is cut off while the slot provided with the press-contact blade is cut off at the end of the upper and lower horizontal portions. Are bent upward, and the upper and lower bent portions of these electric wires are inserted into the slots to be connected by pressure contact. By providing the slot provided with the press contact blade at the tip of the electric wire connection bus bar, the connection with the electric wire can be performed by press contact, so that the connection operation can be performed more easily. Further, at the time of connection, by bending the connection end of the electric wire, the positional relationship with the press contact blade can be made more suitable.

Further, it is preferable that the core wire exposed by peeling off the ends of the electric wires is welded to the upper and lower horizontal portions. As described above, instead of providing a pressure contact blade at the distal end of the horizontal portion of the electric wire connection bus bar and performing pressure contact connection, the electric wire and the electric wire connection bus bar are connected by welding, so that the electric wire connection bus bar can be reliably connected in a short time. In addition, resistance welding, ultrasonic welding, and soldering can be used for this welding method.

Further, the present invention relates to a method for manufacturing a connection bus bar for connecting electric wires layered and wired in an electric connection box, wherein the conductive plate is punched to form a strip and a required interval is formed. Vertical parts to be arranged, and a continuous part that continues the middle part in the vertical direction of these vertical parts is provided, and then the upper and lower sides of each vertical part are bent in the same direction to form upper and lower horizontal parts, The present invention provides a method for manufacturing a bus bar for electric wire connection in which a vertical portion and a continuous portion are partially cut away and divided into a plurality of pieces having a required shape.

As described above, in the method of manufacturing the bus bar for connecting electric wires, a basic shape is formed by punching and bending a conductive plate, and then cut and divided into required shapes according to the connection state with the electric wires. The process up to the basic shape can be easily mass-produced, etc., and the subsequent processes can handle various connection situations by processing this basic shape. it can.

Further, in the method for manufacturing a bus bar for electric wire connection according to the present invention, a slot provided with a press-contact blade at the end of the upper and lower horizontal portions is formed by notching. As described above, by using the manufacturing method in which the slot provided with the press-contact blade is cut out, the manufactured wire-connecting bus bar can be connected to the wire by press-connecting.

[0019]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a bus bar 10 for electric wire connection of an electric junction box according to a first embodiment of the present invention, which is formed by punching a conductive plate into a required shape and bending it. The electric wire connection bus bar 10 connects electric wires laid in different upper and lower layers in the electric connection box.

First, a method of manufacturing the electric wire connection bus bar 10 will be described. As shown in FIG. 2A, one H-shaped conductive plate D such as a brass plate or a copper alloy plate is arranged in a horizontal line. It is punched using a punching press machine or the like so as to form a shape arranged in a row. The above-mentioned substantially H shape has a shape including a vertical portion 10a arranged in a strip shape at a required interval, and a continuous portion 10b which is continuous with a vertical intermediate portion 10g of the vertical portion 10a. In addition, the vertical portion 1
Slots 10e, 10e provided with pressure contact blades at the upper and lower ends of 0a
f is formed by notching. The slot 10e,
The formation of 10f may be performed separately from the punching of the shape.

Thereafter, as shown in FIGS. 2B and 2C,
The upper and lower ends of each vertical portion 10a are bent at 90 degrees in the same direction using a bending machine or the like to perform bending, thereby forming upper and lower horizontal portions 10c and 10d. Lastly, a vertical portion 10a which is a portion (hatched portion in FIGS. 2A and 2B) that becomes unnecessary in connection with an electric wire or a circuit configuration.
In addition, a part of the continuous portion 10b is cut off by using a punching press machine or the like to form the wire connecting bus bar 10 divided into a plurality of required shapes shown in FIG. In addition, the said manufacturing method
The order may be appropriately changed in consideration of productivity and the like. For example, the upper and lower horizontal portions may be formed by cutting unnecessary portions first.

As shown in FIG. 3, the electric connection box using the electric wire connection bus bar 10 formed as described above is composed of a lower case 11 and an upper case 12, and the lowermost electric wire w-1 is provided inside these cases. , First insulating plate 16, bus bar 17, second insulating plate 18, and electric wire w of the uppermost layer
-2 is accommodated. As described above, the electric wires w-1 and w-2 for the internal circuit are vertically divided into two layers, such as a lowermost layer and an uppermost layer.

As shown in FIG. 4, the method of manufacturing the electric junction box is similar to that of the prior art, in which the lower case 11 and the upper case 12 are arranged in an unfolded state on the same plane with a gap C therebetween so that the lower case is turned upward. 11 and upper case 12
The press contact terminals 15 are driven into the connectors 13 and 14 on the upper surface of the connector. An electric wire (single-core wire) w is drawn with a single stroke across the gap C between the lower case 11 and the upper case 12 arranged side by side.
, And the electric wire w is directly driven into the press contact terminal 15 to be press contacted and connected to the inner surface of the electric connection box in a horizontal direction.

Next, when the upper case is folded back to the lower case, the electric wire portion wa, which is conventionally wired over the gap C, is hinged and the center portion thereof is indicated by a two-dot chain line in the figure. Cut into pieces. Therefore, the electric wire w drawn in one stroke is separated into the electric wire w-2 on the upper case 12 side and the electric wire w-1 on the lower case 11 side.

The cut portion w-1a of the electric wire w-1 on the lower case 11 side cut as described above is as shown in FIG.
While being located at the side end 11b of the lower case 11, FIG.
As shown in the figure, it is bent upward and bent to bend w-
1b is provided. On the other hand, the electric wire w-2 on the upper case 12 side also has the cut portion w-2a positioned at the side end 12b of the upper case 12 as shown in FIGS. Part w-2b
Is provided.

After the electric wires are laid as described above, as shown in FIG. 3, the first insulating plate 16 and the bus bar 1 are provided between the electric wire w-1 of the lower case 11 and the electric wire w-2 of the upper case 12.
7. The second insulating plate 18 is stacked and arranged. In this arrangement, by cutting the electric wire w laid across the lower case 11 and the upper case 12, the upper case 1 is cut.
Since it is not necessary to rotate the cover 2 toward the lower case 11 and fold it, the tab 17 a of the bus bar 17 can be accurately and smoothly inserted into the terminal hole of the upper case 12.

After the first insulating plate 16 and the like are arranged as described above, as shown in FIGS. 3 and 5, the electric wire connecting bus bar 10 is arranged on the side of the case, and the electric wires w-1 and w
-2 is press-connected to the upper and lower refracting portions w-1b and w-2b. That is, the bent portion w-2b of the upper case 12 which is bent downward is inserted into the slot 10e of the upper horizontal portion 10c, and is pressed and connected by the pressing blade. Similarly, the bending portion w-1b on the lower case 11 side bent upward is inserted into the slot 10f of the lower horizontal portion 10d, and is press-connected by the press-contact blade. As described above, the cut wires are connected via the connection bus bar 10 by press-connecting the cut wires at the upper and lower horizontal slots.

In the present embodiment, as the connection bus bar 10, as shown in FIG. 5, the first connection bus bar 10-
Eleven of the first to eleventh connection bus bars 10-11 are provided.

The first connection bus bars 10-1 to 11
The connection bus bar 10-11 has various forms, and is a bus bar 10-2 that connects one bending portion w-2b on the upper case 12 side and one bending portion w-1b on the lower case 1 side.
10-5, 10-6, 10-7, 10-8, 10-9,
10-11, Two Upper Case Side Refraction Parts w-2b
Bus bar 10-1 for connecting the two bending portions w-2b and w-1b on the upper case side and the lower case side, respectively. -4, 10-10, and at a required interval in the horizontal direction.

As described above, when connecting the lower case side electric wire w-1 and the upper case side electric wire w-2 cut via the connecting bus bar 10, the connecting bus bar may be formed into various required shapes. Thus, it is possible to cope with various circuit configurations. That is, a joint function can be provided by connecting a plurality of cut electric wires with one connection bus bar. Further, the connection bus bar 10 connected by pressure contact is fixed by the guide portions 11a and 12a of the lower case 11 and the upper case 12, and
A cover 15 is attached for protection or the like. Note that the cover 15 need not be mounted unless protection is required.

FIG. 6 shows an electric wire connecting bus bar 20 according to a second embodiment of the present invention. The electric wire connecting bus bar 10 according to the first embodiment has no slots at the ends of the upper and lower horizontal portions 10c and 10d. Is the case. The configuration of other parts is the same as in the first embodiment. Therefore, in the manufacturing process of the connection bus bar 20, no slot is formed in the punching process of FIG. 2A, and the other manufacturing method is the same as that of the first embodiment.

The arrangement and cutting of the electric wires w-10 and w-20 in the electric junction box and the like are the same as those in the first embodiment, but the cut portion w
-10a, w-20a are not provided with a bent portion, and the insulating coating of the terminal to be connected is peeled off, and core wires w-10c, w-2 are removed.
0c is exposed. Also, the first insulating plate, busbar,
The accommodation of the second insulating plate in the electric connection box and the like are the same as in the first embodiment.

FIG. 7 shows the bus bar 20 for connecting the electric wire and the electric wire w-.
10 shows the connection status with w-20, and the connection is made by welding. The electric wire w-10 is arranged so that the core wire w-10c is in contact with the lower horizontal portion 20d of the electric wire connecting bus bar 20, and the core wire w-10c and the lower horizontal portion 20d are connected by welding. As welding methods that can be used, there are resistance welding, ultrasonic welding, and soldering, and the above various welding methods are adopted in consideration of required connection strength, connection reliability, and the like. Similarly, the electric wire w-20 is also welded to the upper horizontal portion 20c of the electric wire connecting bus bar 20. The attachment to the case to the wire connection bus bar 20 and the like are the same as in the first embodiment.

FIG. 8A shows a third embodiment of the present invention, in which an electric wire connection bus bar 30 is used when electric wires are arranged in four layers inside an electric connection box. The wire connecting bus bar 30 is provided with second upper and lower horizontal portions 30h and 30i in addition to the upper and lower horizontal portions 30c and 30d, and is formed by cutting out slots 30j and 30k each having a press-contact blade at its tip.

In the method of manufacturing the electric wire connection bus bar 30, as in the first embodiment, one conductive plate is punched into the shape shown in the figure, bent, and formed by removing unnecessary portions. The electric connection box is formed by laminating electric wires and insulating plates mutually, and arranging electric wires divided into four layers each. Further, a bus bar for a power supply or the like may be sandwiched between the above-mentioned laminated structures. The wires arranged in this way and the bus bar 30 for wire connection are press-connected by slots 30e, 30f, 30j and 30k. Further, as in the second embodiment, the electric wire connection bus bar 30 may be connected to the electric wire by welding without notching the slot.

FIG. 8B shows a modification of the third embodiment, in which electric wires arranged in four layers are vertically and
An electric wire connection bus bar 30 'is shown in the case of connecting on a straight line. The manufacturing method and the connection with the electric wires are the same as in the above embodiment. In this way, by appropriately changing the punching shape and the bent shape, the electric wire connecting busbar can cope with electric wires arranged in three layers, or in the case of five or more layers.

[0037]

As is apparent from the above description, according to the present invention, since the wires laid along the inner surfaces of the lower case and the upper case are connected by the wire connecting bus bars on the side surfaces, the wires can be separated. Therefore, it is possible to solve the problem that the wire at the folded portion protrudes from the case, and the tab accommodated in the case is difficult to be inserted into the terminal hole on the upper case side along the rotation locus of the upper case.

The above-described electric wire connection bus bar is divided into a plurality of pieces, and each of the divided electric wire connection bus bars connects at least one required number of the lower case side electric wire and the upper case side electric wire. The circuit configuration can be easily made by using, and the circuit can be easily changed. Also, the connection with the electric wire can be performed by appropriately selecting the press connection and the welding connection in consideration of the workability and the reliability of the connection. Furthermore, the basic shape of the bus bar for wire connection can be efficiently produced by punching and bending, and by processing based on this basic shape, it is possible to easily cope with various connection situations. it can.

[Brief description of the drawings]

FIG. 1 is a perspective view of a bus bar for electric wire connection according to a first embodiment of the present invention.

FIGS. 2A, 2B, and 2C are schematic diagrams showing a process of manufacturing a bus bar for electric wire connection.

FIG. 3 is an exploded perspective view of an electric connection box using the bus bar for electric wire connection of the present invention.

FIG. 4 is a perspective view showing a manufacturing process of the electric junction box.

FIG. 5 is a perspective view showing a connection relationship between an electric wire connection bus bar and electric wires.

FIG. 6 is a perspective view showing a connection relationship between an electric wire and a bus bar for electric wire connection according to a second embodiment of the present invention.

FIG. 7 is a perspective view showing connection of the electric wire connection bus bar to the electric wire by welding.

8A and 8B are an exploded view and a perspective view of an electric wire connecting bus bar according to a third embodiment of the present invention, wherein FIG. 8A is a developed view and a perspective view of an electric wire connecting bus bar corresponding to four layers, and FIG. And a perspective view.

FIG. 9 is a perspective view showing a manufacturing process of a conventional electric junction box.

FIG. 10 is a sectional view showing a conventional electric junction box.

FIG. 11 is a schematic view showing a problem of a conventional electric junction box.

[Explanation of symbols]

 1, 11 Lower case 2, 12 Upper case 5, 15 Pressure contact terminal 10, 20, 30 Bus bar 10a for electric wire connection 10a Vertical portion 10c, 10d Vertical horizontal portion 10e, 10f Pressure contact slot 13, 14 Connector w Electric wire (single core wire) w- 1 lower case side electric wire w-1a cutting part w-1b bending part w-2 upper case side wiring w-2a cutting part w-2b bending part

Claims (6)

[Claims] An electric circuit box comprising a lower case and an upper case is provided with two or more layers of internal circuit wires vertically arranged on an inner surface of an electric connection box formed of a lower case and an upper case. A bus bar for connecting electric wires to be arranged, wherein a vertical portion which is stamped from one conductive plate and arranged at a required interval in a strip shape, and an intermediate portion in the vertical direction of these vertical portions are continuously formed. The horizontal connecting portion is cut at a required position and is divided into a plurality of portions, and the upper and lower horizontal portions are bent in the same direction from the upper and lower ends of the vertical portion. The electric connection box has a bus bar for connecting electric wires, the electric wires being arranged and connected. 2. The electric wire for an internal circuit is an electric wire wired along each inner surface of a lower case and an upper case,
2. The electric connection box according to claim 1, wherein the cut ends of the electric wires are located at the side ends of the case and are connected to the upper and lower horizontal portions of the connection bus bar. 3. A slot provided with a press-contact blade at an end of the upper and lower horizontal portions is cut off, while a connection-side end of the upper-layer internal circuit wire is bent downward and a lower-layer internal circuit wire is cut. The connection end of the wire is bent upward,
The electric connection box according to claim 1 or 2, wherein the upper and lower bent portions of the electric wires are inserted into the slots to be press-connected. 4. An electric connection box according to claim 1, wherein the upper and lower horizontal portions are welded to the exposed core wires by peeling off the ends of the electric wires. 5. A method of manufacturing a connection bus bar for connecting electric wires layered and wired in an electric junction box, wherein the conductive plate is stamped and arranged in a strip shape at a required interval. A vertical portion and a continuous portion that connects the vertical intermediate portions of the vertical portions are provided.The upper and lower sides of each vertical portion are bent in the same direction to form an upper and lower horizontal portion. A method for producing a bus bar for electric wire connection, in which a part of a part is cut off and divided into a plurality of parts having a required shape. 6. The method for manufacturing a bus bar for electric wire connection according to claim 5, wherein a slot provided with a cutting blade on an inner peripheral surface is cut out from a tip of the upper and lower horizontal portions.