JP2000188812A - Electrical connection box - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve connection mode of electrical lines which are divided into an upper case and a lower case and laid. SOLUTION: Electrical wires w-1, w-2, which are laid along the inner surface of a lower case 11 and that of an upper case, respectively, and connected through cold welding with insulation displacement terminal driven into connectors fixed to the lower case 11 and an upper case 12, are connected by peeling the terminal coatings of upper and lower wires which are vertically connected on the side end in the case same side surface direction, exposing cores, and welding and fixing the terminal cores of the upper and the lower wires to the upper and the lower sides of a U-shaped bus bar 10 for connection, arranged on the side surfaces of the lower case 11 and the upper case 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric connection box, and more particularly, to a junction box or the like incorporated in a wire harness for an automobile, as an internal circuit.
In the case where the upper case and the lower case are provided with internal circuits each composed of a combination of an electric wire and a press-contact terminal, the connection form of these electric wires is improved.

[0002]

2. Description of the Related Art Conventionally, in an electric connection box such as a junction box for housing branch circuits at a high density, a circuit combining an electric wire and a press contact terminal may be used alone or in combination with a bus bar. Particularly, when circuits are housed at high density, electric wires are routed along the inner surfaces of the lower case side and the upper case side, and bus bars are arranged with an insulating plate interposed therebetween. That is, electric wires,
The circuit is housed in an electrical junction box with a vertically stacked structure of bus bars and electric wires.

In the case of manufacturing the electric junction box having the above structure, as shown in FIG. 6, the lower case 1 and the upper case 2 are arranged in a state where the lower case 1 and the upper case 2 are developed on the same plane with a required gap C therebetween. The inside faces upward. The connectors 3 and 4 are fixed at required positions on the inner surfaces of the lower case 1 and the upper case 2 facing upward with jigs and the like, and the press contact terminals 5 and 5 are provided in the terminal receiving holes of the connectors 3 and 4 with press contact blades. The slot is installed facing upward. A single electric wire (single core wire) w is drawn along the inner surfaces of the juxtaposed lower case 1 and upper case 2 from the lower case 1 side to the upper case 2 side by one stroke, and conversely, from the upper case 2 side to the lower case 1 side. The wire w is directly driven into the press contact terminals 5 and 5 attached to the connectors 3 and 4 of the lower case 1 and the upper case 2 while laying over the gap C across the lower case 1 and the upper case 2. , Electric wire w
And the press contact terminals 5 and 5 are connected.

[0004] As described above, the reason why the electric wire w is continuously connected to the lower case 1 side and the upper case 2 side by one stroke is that the electric wire w must be connected.

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 to overlap the lower case 1 toward the lower case 1 as shown by an arrow so that the upper case 2 faces the lower case 1 so as to be overlapped with each other.

As shown in FIG. 7, on the lower case 1 side, an insulating plate 6 is disposed above a circuit composed of an electric wire w and a press contact terminal 5, and a bus bar 7 is disposed thereon. After the insulating plate 8 is further disposed on the upper surface of the lower case 1, 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 disposed.

[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 trying to fit the lower case 1 and the upper case 2, 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. 7. It is necessary to fold, and this folded electric wire portion w
There is a problem that -a 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. It is a first object of the present invention to solve the problem that the tab cannot be inserted into the terminal hole of the upper case. Further, it is a second object of the present invention to be able to connect the wires laid to the lower case and the upper case in various patterns.

[0010]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention is directed to a press contact terminal which is laid along inner surfaces of a lower case and an upper case, respectively, and which is driven into a connector attached to the lower case and the upper case. At the side end side in the same side direction of the case, the electric wires to be pressed and connected to each other are peeled at the ends of the upper and lower electric wires to be connected up and down to expose the core wires, and are disposed on the side surfaces of the lower case and the upper case. An electric connection box is provided, wherein terminal cores of the upper and lower electric wires are connected by welding and fixing to upper and lower sides of a connection bus bar having a shape.

As described above, when the wires laid on the lower case side and the upper case side are connected by the connection bus bar arranged on the side of the case, it is not necessary to connect the wires on the lower case side and the upper case side. In addition, since the required wires on the lower case side and the upper case side are connected to each other by the connection bus bar, the connection according to the circuit design can be easily performed, and the design can be easily changed. In addition, since the connection bus bar and the electric wire are connected by welding, electric connection reliability can be improved.

The electric wires laid on the inner surfaces of the lower case and the upper case are laid with a single stroke in a state where the lower case and the upper case are arranged in parallel in an expanded shape, and then cut at a position between the lower case and the upper case. Or the wires separately laid on the lower case side and the upper case side, and the connection bus bar is divided into a plurality of pieces, and each of the divided connection bus bars is a lower case side wire and an upper case side wire. One or more pieces are connected by welding by resistance welding, ultrasonic welding, or laser welding, and the connection bus bar is covered with an insulating resin cover.

As described above, when the lower case and the upper case are wired in a single stroke in a state where the lower case and the upper case are arranged side by side and then cut at a position between the lower case and the upper case, the electric wire on the lower case side and the upper case are disconnected. The wires on the case side can be laid with a single stroke, making it easier to wire the wires.On the other hand, the wires are cut between the lower case and the upper case. Between the upper case and the outer case.Therefore, it is not necessary to rotate the upper case and cover the lower case by rotating the upper case, making it difficult to insert the terminal housed in the case into the terminal hole of the upper case. Disadvantages can be prevented. On the other hand, when the lower case and the upper case are separately wired, the wiring can be performed more easily.

Further, the connecting busbar is divided into a plurality of connecting busbars, and each of the divided connecting busbars connects one or more required number of lower case side electric wires and upper case side electric wires.
For example, one electric wire on the lower case side and one electric wire on the upper case side may be connected by a connecting bus bar (in this case, a so-called short pin form). That is, as described above, when the lower case side and the upper case side are cut out after being laid out with a single stroke in an expanded state, when the cut electric wires are connected one by one corresponding to each other, the same as the one stroke before the cut. It can be a circuit. Also, when the two electric wires on the upper case side and the one electric wire on the lower case side are connected by a connection bus bar without using the same circuit as before cutting, the two electric wires on the upper case side were spliced (joint). State. Similarly, if two or more electric wires on each of the upper case side and the lower case side are connected by one connection bus bar, many circuits can be jointed. As described above, by connecting the wires on the lower case side and the upper case side with the divided connection bus bars arranged on the side of the case, the circuit configuration can be easily changed, and the usability is improved.

Further, since the connecting bus bars attached to the side surfaces of the lower case and the upper case are covered with an insulating resin cover, the connecting bus bars arranged on the outer surface of the case can be protected and insulated.

A bus bar is disposed between the circuits formed by the combination of the electric wires and the pressure contact terminals on the lower case side and the upper case side with an insulating plate interposed therebetween, and the circuit composed of the electric wires and the pressure contact terminals is used in combination with the bus bar circuit. are doing. In addition,
Needless to say, the bus bars may be further stacked and arranged via an insulating plate, and a branch circuit can be provided with high density inside the electric connection box.

[0017]

Embodiments of the present invention will be described below with reference to the drawings. As shown in FIG. 1, the electric connection box of the present invention includes a lower case-side electric wire (single core wire) w-1, an insulating plate 16, and a bus bar 17 inside a case formed by assembling a lower case 11 and an upper case 12. , An insulating plate 18 and an electric wire (single core wire) w-2 on the upper case side are sequentially stacked one above another and arranged. As shown in FIG. 2, the upper case side electric wire w-2 and the lower case side electric wire w-1 arranged in the upper and lower layers are welded and connected to the connection bus bar 10 arranged vertically along one side surface of the case. I have.

First, as shown in FIG. 3A, a lower case 11 and an upper case 12 are opened and a gap C is formed on the same plane in an expanded state as shown in FIG. Lower case 1 facing upwards
The connectors 13 and 14 in which the press-contact terminals 5 are driven are fixed to the upper surfaces of the upper case 12 and the upper case 12 by welding or the like, and the lower case 11 and the upper case 12 arranged side by side are drawn by a single stroke across the gap C between the lower case 11 and the upper case 12. w, and press-fit terminal 5
The electric wire w is directly driven into and press-connected.

Next, the electric wire wa, which is conventionally hinged when the upper case is folded back over the lower case and straddled over the gap C, is connected to the center portion of the electric wire wa as shown in FIG.
Cut as shown in (B). Therefore, the electric wire w drawn in one stroke is separated into the electric wire w-1 on the upper case 12 side and the electric wire w-2 on the lower case 11 side. On the side opposite to the cutting side, the electric wires w-1 and w-2 are shown in FIG.
As shown in FIG.

The busbars 17 arranged with the insulating plates 16 and 18 interposed between the electric wire w-1 of the lower case 11 and the electric wire w-2 of the upper case 12 have terminal holes in the lower case 11 and / or the upper case 12. The tab 17a to be inserted into the upper and lower wires w-
2, a press-contact protrusion 17c provided with a press-contact blade portion 17b that press-connects to w-1.

As described above, by cutting the electric wire w laid across the lower case 11 and the upper case 21, it is not necessary to rotate the upper case 12 toward the lower case 11 and fold it. The problem of interference with the tabs 17a and the projections 17c for pressing on the rotation locus of the upper case, which has conventionally occurred when fitting the upper case 11 to the upper case 12, can be solved. It can be inserted accurately and smoothly into the terminal hole.

However, it is necessary to connect the electric wire w-1 on the lower case 11 side and the electric wire w-2 on the upper case 12 side which have been conventionally connected. Therefore, the cut portions w-1a and w-2a of these electric wires are vertically opposed to each other and protrude from one side surface of the case, and the insulating coating of the wire ends is peeled off to form the core wires w-1b and w-2b. The exposed upper and lower core wires w-1b and w-2b are welded and connected by a plurality of connection bus bars 10 (also referred to as short pins) arranged sideways.

The connection bus bar 10 has upper and lower horizontal portions 10c and 10d bent at right angles at both ends of a vertical portion 10a, and the core wire w-2b of the upper case side electric wire is resistance-welded to the lower surface of the upper horizontal portion 10c. While welding and connecting,
The core wire w-1 of the lower case-side electric wire is provided on the upper surface of the lower horizontal surface 10d.
b is welded and connected by resistance welding. Ultrasonic welding or laser welding may be used instead of resistance welding, as long as the core wire can be welded to the connecting bus bar 10. in this way,
The cut electric wires are connected via connection bus bars 10.

In the present embodiment, as the connection bus bar 10, as shown in FIG.
Fifteen connection bus bars 10-15 are provided.
The first connection bus bar 10-1 to the fifteenth connection bus bar 10-15 have various forms, and are each a bus bar 1 for connecting one electric wire on each of the upper case 12 side and the lower case 11 side.
0-1 etc., upper case 12 side and lower case 11
A bus bar 10-2 and the like for connecting two electric wires are provided on both sides, and the interval between the vertical plate portions is set to a required interval.

As described above, by connecting the lower case side electric wire w-1 and the upper case side electric wire w-2 cut through the connection bus bar 10 and changing the form of the connection bus bar, various circuits are provided. It can be adapted to the configuration. That is, a joint function can be provided by connecting a plurality of cut electric wires with one connection bus bar.

As described above, the electric connection box has the insulating plate 16, the bus bar 17, and the insulating plate 18 stacked on the electric wire w-1 on the inner surface of the lower case 11, and the electric wire w-2 is wired thereon. Assemble with the upper case 12 covered. As shown in FIG. 1, the side walls of the peripheral walls of the lower case 11 and the upper case 12 on the electric wire cutting side have electric wire cutting portions w-1a,
The guides and locks 11a and 12a for locking the connection bus bar 10 are provided in parallel while w-2a is pulled out one by one to the outside. In addition, a large opening may be provided in the side surface of the lower case 11 and the upper case 12, and a groove for drawing out the electric wires one by one and a guide type locking member capable of forming one connecting bus bar may be fitted and fixed to the opening.

Guide / locking portion 11 of lower case 11
From each groove of a, the electric wire cutting part w-1a, the upper case 1
The wire cutting portion w-2a is drawn out from each groove 12a of the second guide / locking portion 12a.

In this state, the terminal buses w-1b and w-2b of the electric wires w-1 and w-2 are respectively connected to the connection bus bars 10-1 to 10-15 and the lower horizontal portion 10d and the upper horizontal portion 10c from the outside.
Are pressed against each other and connected by resistance welding. The press-contact blade 17b provided on the bus bar 17 is connected to the electric wire w.
-1 and w-2.

As described above, after the connection bus bar and the electric wire are welded, a cover 15 made of insulating resin is put on from the side,
The connection bus bar 10 is protected and insulated. The cover 15 locks lock frames 15 a provided on both upper and lower surfaces thereof with lock claws (not shown) of the lower case 11 and the upper case 12. The electric connection box 50 assembled in this manner is in the state shown in FIG.

In the electric connection box 50 having the above-described structure, unlike the conventional case, the electric wires do not protrude outward from the sides of the electric connection box, and the cut wires of the lower case 11 and the upper case 12 are connected to the side. Busbar 10 for connection
Connected by Further, at the time of this connection, by the form of the connection bus bar 10, the required electric wires of the electric wire w-1 on the lower case 11 side and the electric wire w-2 on the upper case 12 side can be connected and a joint can be taken, so that the circuit design can be made. Can easily be changed.

In the above embodiment, the lower case and the upper case are arranged side by side in an expanded state, and the electric wires are laid in a single stroke continuously between the lower case and the upper case. It goes without saying that the electric wire w-1 and the electric wire w-2 may be separately and continuously arranged on the inner surface of the upper case 12, respectively.

Further, in the case where electric wires are laid not only on the lower case and the upper case but also on the insulating plate interposed therebetween, the electric wires are welded to the electric wire at the intermediate position provided at the intermediate portion of the connection bus bar arranged on the side. Alternatively, the electric wires arranged in a plurality of layers can be connected by the side connection bus bars.

[0033]

As is apparent from the above description, according to the present invention, since the electric wires laid along the inner surfaces of the lower case and the upper case are connected by the bus bars for connection on the side surfaces, the lower case side and the upper case are connected. Each side can be laid separately, and the wiring work of the electric wire can be facilitated. Further, when the lower case and the upper case are arranged in a developed shape and wired with a single stroke as in the related art, the electric wire can be cut between the lower case and the upper case. Therefore, the electric wire at the hinged side, which has been generated when the cable is laid with a single stroke, protrudes from the case, and the tab accommodated inside the case is the terminal hole on the upper case side along the rotation locus of the upper case. The problem that it becomes difficult to insert into the device can be solved.

The connection bus bar is divided into a plurality of connection bus bars, and each of the divided 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 changed or a short circuit can be taken. In addition, since the bus bar and the core of the electric wire are welded by resistance welding or the like, the reliability of the electrical connection can be improved.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of an electric junction box according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a state in which upper and lower electric wire layers of an internal circuit of the electric connection box are connected by side connection bus bars.

FIGS. 3A and 3B are perspective views showing steps of manufacturing the electric junction box.

FIG. 4 is an enlarged exploded perspective view of a main part of the present invention.

FIG. 5 is a sectional view showing an assembled state of the electric junction box of the embodiment.

FIG. 6 is a perspective view showing a conventional example.

FIG. 7 is a sectional view of a conventional example.

[Explanation of symbols]

 5 Pressure Contact Terminal 10 (10-1 to 10-15) Bus Bar for Connection 10a Vertical Part 10c, 10d Vertical Horizontal Part 11 Lower Case 12 Upper Case 13, 14 Connector 15 Cover 16, 18 Insulating Plate 17 Bus Bar w Electric Wire (Single Core Wire) w -1 Lower case side electric wire w-1a Cut part w-1b Core exposed part w-2 Upper case side electric wire w-2a Cut part w-2b Core exposed part

Claims (2)

[Claims] An electric wire which is laid along inner surfaces of a lower case and an upper case, and which is connected to a press-connecting terminal driven into a connector attached to the lower case and the upper case, is connected to a side end in the same side direction of the case. At the side, the terminal coverings of the upper and lower electric wires to be connected up and down are peeled to expose the core wires, and the upper and lower ends of the upper and lower electric wires are disposed on the upper and lower sides of the U-shaped connection bus bar arranged on the side surfaces of the lower case and the upper case. Electrical connection box characterized by welding and fixing. 2. The electric wires laid on the inner surfaces of the lower case and the upper case are laid in a single stroke in a state where the lower case and the upper case are arranged in parallel in an expanded shape, and then at a position between the lower case and the upper case. It is a cut wire or an electric wire separately laid on the lower case side and the upper case side, and the connection bus bar is divided into a plurality of pieces, and each of the divided connection bus bars is a lower case side electric wire and an upper case. A required number of the side wires is connected by welding at least one each by resistance welding, ultrasonic welding, or laser welding, and the connection bus bar is covered with an insulating resin cover. Electrical connection box as described in.