JP2001196762A - Power source unit and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a power source unit where automating is facilitated and packing and occupied space can be reduced, and to provide a manufacturing method of the unit. SOLUTION: This power source unit is provided with an electronic block 1, in which a plurality of electronic components 4 are mounted on a printed board 5, an insulating case 2 accommodating the electronic block 1, and an external connection connector 3 which is collectively integrated with the insulating case 2 and electrically connected with the electronic block 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a power supply unit such as a switching power supply and a lighting inverter and a method of manufacturing the same.

[0002]

2. Description of the Related Art FIG. 8 shows a first conventional igniter block for vehicle lighting. The igniter block includes a mother board 70, a case 71, an output socket 72, and an input connector 73. In this conventional example, the mother board 7
The electric wires 75 and 76 are used for input / output of electric signals and supply / output of electric power to / from a mounting block obtained by mounting and soldering the electronic component 74 to a printed circuit board which is 0. The input and output signals are electrically connected to the motherboard 70 by soldering as input lines 75 and output lines 76, respectively. The board (mounting) block to which the input line 75 and the output line 76 are soldered is housed in the case 71, and the input line 75 and the output line 76 are cut into the notch 79 of the case 71 by the input line grommet 77 and the output line grommet 78, respectively. Will be retained. Each grommet 7
Reference numerals 7 and 78 have a function of holding the electric wires 75 and 76 and preventing leakage of the casting material when the inside of the case 71 is resin-molded.

FIGS. 9 and 10 show a second conventional inverter block for lighting. 82 is a case, 83 is an insulating plate, 84 is a motherboard, and 85 is a cover. Mother board 84
In the figure, 86 is an electronic component, 87 is a direct connector of a part thereof, 88 is an FET fixing spring for fixing the FET 88a of the electronic component 86, 89 is a mother board screw, and 93 is an FET fixing spring screw. In the cover 85, 90 is a mother board fixing boss, 91 is a case screw, 92 is a cap,
94 is a hole closed by the cap 92. An FET fixing spring 88 is fixed with an FET fixing spring screw 93, a mother substrate 84 is fixed to a mother substrate fixing boss 90 with a mother substrate screw 89, and the cover 81 is stored while the mother substrate 84 is housed in a case 82.
Then, the opening of the case 82 is closed, the casting agent is poured from the hole 94 of the cover 81 and the cap 92 is closed.

On the other hand, a signal board is mounted on a mother board 84 of a mounting block in which various electronic components 86 are mounted and soldered on the mother board 84.
The power input / output direct connector 87 is mounted and soldered. The mounting block is housed in a case 82, and at this time, a part of the input / output connector 87 is
Is exposed to the outside. Therefore, the case 82 has a notch 100 so as not to interfere with the connector 87. The inside of the case 82 is resin-molded. At this time, the connector 87 has a groove-shaped engaging portion 102 which engages with the notch 100 as shown in FIG. Stop 1
The O-ring 101 mounted at 02 is pressed against the edge of the notch 100. The locking portion 102 supports an external force applied to the connector 87.

[0005]

In the first conventional example, it is difficult to automate the assembling work and inspection due to the input and output by the electric wires 75 and 76, and it is a packing which aims at preventing leakage at the time of resin molding. Certain grommets 77 and 78 are required, and as shown in FIG.
The reference numeral 6 is disposed on the opposite surface of the case 71, and when it is incorporated into another device, a space for laying wires is required for the two opposite surfaces.

The second conventional example requires an O-ring 101 as a packing for preventing leakage of the casting agent from the direct connector 87 and the case 82 as shown in FIG.

Accordingly, an object of the present invention is to provide a power supply unit which facilitates automation, can reduce packing, and occupies a small space, and a method of manufacturing the same.

[0008]

According to a first aspect of the present invention, there is provided a power supply unit comprising: an electronic block in which a plurality of electronic components are mounted on a printed circuit board; an insulating case for accommodating the electronic block; And an external connector electrically connected to the electronic block.

According to the power supply unit of the first aspect, in the power supply unit using the external connection connector, the number of components can be reduced by integrally molding the external connection connector and the insulating case. There is no need to perform a part leakage prevention process, and packing can be reduced. In addition, automation of connector assembly and inspection is facilitated.

The power supply unit according to the second aspect is the first aspect.
In the above, the printed board is provided with a connection terminal, and the external connection connector has a terminal, and the connection terminal is electrically connected to the terminal of the external connection connector.

According to the power supply unit of the second aspect, the same effect as that of the first aspect is obtained.

According to a third aspect of the present invention, there is provided a power supply unit.
Alternatively, in claim 2, the connection terminal and the terminal of the external connection connector are electrically connected by soldering or welding.

According to the power supply unit of the third aspect, the same effects as those of the first or second aspect can be obtained.

According to a fourth aspect of the present invention, there is provided a power supply unit.
Alternatively, in claim 2, the connection terminal and the terminal of the external connection connector are electrically connected by caulking.

According to the power supply unit of the fourth aspect, in addition to the same effects as those of the first or second aspect, the workability is improved as compared with the soldering, and the cost is reduced because no joining member is required. it can. Also, the component accuracy may be lower than that of laser welding.

According to a fifth aspect of the present invention, there is provided a power supply unit.
Wherein the external connector is connected to the printed circuit board by soldering or laser welding.

According to the power supply unit of the fifth aspect, in addition to the same effects as those of the first aspect, a simpler configuration is obtained by directly connecting the connector terminal of the case and the mother board.
In the case of laser welding, connection reliability is improved.

According to a sixth aspect of the present invention, in the power supply unit according to any one of the first, second, third, fourth, and fifth aspects, an input is provided on a side of the insulating case having a connection port of the external connection connector. Alternatively, an output deriving unit is provided.

According to the power supply unit described in claim 6, claim 1, claim 2, claim 3, claim 4, or claim 5 is provided.
In addition to the same effects as described above, by arranging the connector and the other input / output on the same surface of the insulating case, the occupied space when assembling to another device or apparatus can be reduced.

The power supply unit according to the seventh aspect is the second aspect.
Wherein the terminal of the external connection connector projects toward an opening of the insulating case, and the connection terminal of the printed board has a hole into which the printed board is fitted by disposing the printed board in the case; Is soldered at the part.

According to the power supply unit of the seventh aspect, in addition to the same effects as those of the second aspect, the connection work is facilitated.

The power supply unit according to claim 8 is a power supply unit according to claim 7.
In the above, the external connection connector has a concave portion opened on a side wall forming an opening of the insulating case, and has a contact piece protruding into the concave portion, and the contact piece and the terminal of the external connection connector are connected by L. It is formed of a conductor bent in a letter shape, and an intermediate portion of the conductor is integrally held by the insulating case.

According to the power supply unit of the eighth aspect, in addition to the same effects as those of the seventh aspect, the external force at the time of connection to the external connector can be carried by the bent portion of the conductor with a simple configuration.

According to a ninth aspect of the present invention, in the power supply unit manufacturing method, an electronic block formed by mounting and soldering a plurality of electronic components including connection terminals to a printed circuit board is housed in an insulating case integrally formed with an external connection connector. A terminal of the external connection connector and the connection terminal are electrically connected.

According to the power supply unit manufacturing method of the ninth aspect, the same effect as that of the first aspect is obtained.

[0026]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described with reference to FIGS. That is, this power supply unit is an embodiment of an igniter for vehicle lighting, and includes an electronic block 1, an insulating case 2, and an external connection connector 3.

The electronic block 1 is formed by mounting and soldering a plurality of electronic components 4 to a printed circuit board 5 as a mother board. Also, connection terminals 6 for connector connection are provided on the printed circuit board 5 by mounting and soldering, and as shown in FIG. 3, the printed circuit board 5 is self-supported by a self-standing base 16 and a connection hole 17 is formed at the bent upper end. are doing.
The electronic component 4 includes a transformer 4a and other components 4b.

The insulating case 2 houses the electronic block 1. In the embodiment, it is made of resin, has a substantially rectangular box shape, forms an opening 9 without a top plate, forms a recess 10 in one corner of the surrounding side wall, and faces the one side wall 7 at the position of the recess 10. A connector connection port 11 is protrudingly provided, and an input or output lead-out section 8 is provided in one side wall 7 by notch. The electronic block 1 fixes the printed circuit board 5 with case claws.

The external connection connector 3 has a connector connection port 11
Thus, the electronic block 1 is provided integrally with the insulating case 2 and is electrically connected to the electronic block 1. That is, the external connection connector 3 has a contact piece 13 protruding into a concave portion of the connector connection port 11 opened on the side wall 7 forming the opening 9 of the insulating case 2.
The contact piece 13 and the terminal 1 of the external connector 3
4 are formed by a conductor 15 bent in an L-shape, and the bent intermediate portion 15a is integrally held in the insulating case 2 by simultaneous molding. Connector terminal 14 of insulating case 2
The connection terminals 6 of the electronic block 1 are arranged so as to be close to each other when the electronic block 1 is assembled into the insulating case 2, and the terminals after the assembly are electrically connected by soldering or welding by laser or the like. It can be connected to. Here, the connector terminal 14 protrudes toward the opening 9 of the insulating case 2, and the printed circuit board 5 is disposed in the insulating case 2, so that the hole 17 of the connection terminal 6 becomes the terminal 14 as shown in FIG.
And is soldered at the hole 17.

In this manner, the connection terminal 6 and the terminal 14 of the external connection connector 3 are incorporated with the terminal of the external connection connector 3, and the connection terminal 6 and the terminal 14 incorporated in the external connection connector 3 are connected to each other by soldering or laser. Electrical connection by welding.

Output socket 20 connected to output line 19
Includes an interlock wiring for safety, a grommet 21 is passed through an intermediate portion of the output line 19, and an end of the output line 19 is connected to the printed circuit board 5 and the transformer 4a by soldering. The connection is made by soldering or the like to the electronic components such as the printed circuit board 5 and the transformer 4a as in the conventional example. Further, the grommet 21 is attached to the lead-out section 8.

For all inputs and outputs, the external connection connector 3 and the connection terminal 14 formed integrally with the insulating case 2 are provided.
Can also be used.

According to the method of assembling and manufacturing the power supply unit, the electronic block 1 of the printed circuit board 5 in which the plurality of electronic components 4 including the connection terminals 6 are mounted and soldered in the insulating case 2 integrally formed with the external connection connector 3 is housed. Then, the terminal 14 of the external connection connector 3 and the connection terminal 6 are electrically connected.
Next, a casting agent is injected into the insulating case 2 and resin molding is performed.

According to the first embodiment, the assembling and inspection can be automated by the direct connector 3, and when the external connector 3 and the insulating case 2 are integrally molded, the case 2 is resin-molded. Leak prevention measures are no longer required. Also, since the direct connector 3 and the output socket 20 are arranged on the same side surface 7 of the insulating case 2, FIG.
As shown in FIG. 5B, the output line 30 connected to the connector 3 extends in the same direction as the output socket 20 as compared with the conventional example shown in FIG. Therefore, the size of the device or the device 25a can be reduced more than the device 25b applied to the conventional example.

A second embodiment of the present invention will be described with reference to FIG. In the first embodiment, the connection terminal 6 and the terminal 14 of the connector are electrically connected by caulking.
That is, as shown in FIG. 7A, a cutout or an end of the connection terminal 6 is formed in a bifurcated shape 17a instead of the hole 17 of the connection terminal 6 in the first embodiment, and FIG. As shown, the tapered tip of the terminal 14 is passed between the forked portions 17a, and the width of the forked portion 17a is reduced, and the tip of the terminal 14 is swaged. Second
According to the embodiment, workability is improved as compared with soldering, and costs can be reduced because members for joining are unnecessary. Further, the accuracy of the parts may be lower than that of laser welding.

The other points are the same as in the first embodiment.

A third embodiment of the present invention will be described with reference to FIG. In the first embodiment, the terminals 14 of the external connector 3 are directly and electrically connected to the mother board 5 by soldering, and the connection terminals 6 of the first embodiment are omitted. That is, when the electronic block 1 is housed in the insulating case 2, the connector terminal 14 approaches the connection portion of the printed circuit board 5. For example, in the case of soldering, the connector terminal 14 penetrates through holes formed in the printed board 5 and solders on the back surface of the printed board 5. For this reason, the electronic component 4 side is inserted toward the bottom of the insulating case 2 so that the solder surface of the printed board 5 is on the opening side of the insulating case 2. After that, they are connected by soldering.

Although there is no connection terminal 6 as compared with the first embodiment, the cost can be reduced. However, since the solder surface of the mother substrate 5 is provided on the opening side of the insulating case 2, a cover for protecting the same is provided. 33 are provided. Others are the same as in the first embodiment.

The terminal 14 of the external connector 3 can be connected to the printed circuit board 5 by laser welding. The placement accuracy is higher than soldering, but connection reliability is improved. 34 is a lead wire of the electronic component 4.

[0040]

According to the power supply unit of the first aspect,
By integrally molding the external connector and the insulating case in the power supply unit using the external connector, it is possible to reduce the number of components, and it is not necessary to prevent the connector from leaking when the inside of the case is resin-molded, thereby reducing packing. In addition, automation of connector assembly and inspection is facilitated.

According to the power supply unit of the second aspect, the same effects as those of the first aspect are obtained.

According to the power supply unit of the third aspect, the same effects as those of the first or second aspect can be obtained.

According to the power supply unit of the fourth aspect, in addition to the same effects as those of the first or second aspect, workability is improved as compared with soldering, and the cost is reduced because no joining member is required. it can. Also, the component accuracy may be lower than that of laser welding.

According to the power supply unit of the fifth aspect, in addition to the same effects as those of the first aspect, a simpler configuration can be obtained by directly connecting the connector terminal of the case and the mother board.
In the case of laser welding, connection reliability is improved.

According to the power supply unit of claim 6, claim 1, claim 2, claim 3, claim 4, or claim 5 is provided.
In addition to the same effects as described above, by arranging the connector and the other input / output on the same surface of the insulating case, the occupied space when assembling to another device or apparatus can be reduced.

According to the power supply unit of the seventh aspect, in addition to the same effects as those of the second aspect, the connection work is facilitated.

According to the power supply unit of the eighth aspect, in addition to the same effects as those of the seventh aspect, the external force at the time of connection to the external connector can be carried by the bent portion of the conductor with a simple configuration.

According to the method of manufacturing the power supply unit of the ninth aspect, the same effect as that of the first aspect can be obtained.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a first embodiment of the present invention.

FIG. 2 is a plan view showing a state where the electronic block is housed in an insulating case.

FIG. 3 is a sectional view thereof.

FIG. 4 shows a connection portion between a connection terminal and a connector terminal;
(A) is a partial plan view, (b) is a partial perspective view.

5A and 5B show a state in which the power supply unit is housed in a housing of the device, wherein FIG. 5A is a sectional view of a conventional example, and FIG. 5B is a sectional view of the first embodiment.

6A and 6B show a connection portion between a connection terminal and a connector terminal according to the second embodiment, wherein FIG. 6A is a partial plan view, and FIG. 6B is a partial plan view in a swaged state.

FIG. 7 is a cross-sectional view of the third embodiment.

FIG. 8 is an exploded perspective view of a first conventional example.

FIG. 9 is an exploded perspective view of a second conventional example.

FIG. 10 is a partial sectional view of an exposed portion of the connector.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Electronic block 2 Insulating case 3 External connection connector 4 Electronic component 5 Printed circuit board 6 Connection terminal 7 Side wall 8 Outgoing part 9 Opening 10 Depression 11 Connector connection port 13 Contact piece 14 Terminal 15 Conductor 17 Hole

Claims (9)

[Claims] 1. An electronic block comprising a plurality of electronic components mounted on a printed circuit board, an insulating case for housing the electronic block, and an external unit provided integrally with the insulating case and electrically connected to the electronic block. A power supply unit with a connector. 2. The power supply unit according to claim 1, wherein the printed board is provided with a connection terminal, the external connection connector has a terminal, and the connection terminal is electrically connected to the terminal of the external connection connector. 3. The power supply unit according to claim 1, wherein the connection terminal and the terminal of the external connection connector are electrically connected by soldering or welding. 4. The power supply unit according to claim 1, wherein the connection terminal and the terminal of the external connection connector are electrically connected by caulking. 5. The power supply unit according to claim 1, wherein the external connector is connected to the printed circuit board by soldering or laser welding. 6. The input, output, or output portion is provided on a side surface of the insulating case where the connection port of the external connector is provided. Power supply unit. 7. The terminal of the external connection connector projects toward an opening of the insulating case, and the connection terminal of the printed circuit board has a hole into which the printed circuit board is fitted by arranging the printed circuit board in the case. 3. The power supply unit according to claim 2, wherein said holes are soldered. 8. The external connection connector has a concave portion opened on a side wall forming an opening of the insulating case, and has a contact piece projecting into the concave portion, and the contact piece and the terminal of the external connection connector. 8. The power supply unit according to claim 7, wherein the power supply unit is formed by a conductor bent in an L shape, and an intermediate portion of the conductor is integrally held by the insulating case. 9. An electronic case including a plurality of electronic components including connection terminals mounted on a printed circuit board and soldered in an insulating case integrally formed with an external connection connector, wherein the terminal of the external connection connector and the connection terminal are connected. And a method of manufacturing a power supply unit.