JP2003032845A - Junction box - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve configuration of a laminated layer circuit and also reduce the number of components and working steps. SOLUTION: The junction box stacks and accommodates a plurality of sheets of insulation plates 11, 12, 13, 14, and 15 in which a single wire 16 insulated with cover is wired in the predetermined shape of circuit. Any one of these insulation plates is used as a base insulation plate 11, and the single wire 16 insulated with cover is wired for continuous wiring over the other insulation plates 12, 13, 13, and 15 from at least two sides provided in orthogonal among the four sides of the base insulation plate 11. The single wire 16 insulated with cover wired over the plates is bent in the folding condition at the circumference of the insulation plates 11, 12, 13, 14, and 15 which are laminated with each other.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a junction box connected to an automobile wire harness, and more particularly to improving a laminated circuit housed inside a case.

[0002]

2. Description of the Related Art Recently, as the number of electrical components mounted on automobiles has increased rapidly, the number of circuits housed inside a junction box has increased sharply and a high density of branch circuits has been formed, resulting in an extremely large number of parts. As a result, the number of assembly steps is extremely high.

The junction box shown in FIG.
A junction box as shown in FIG. 0 is provided, in which a single core wire 2 with an insulating coating is bent by pressure contact between ribs 1a protruding on the inner surface of the case 1 to form a required circuit shape.

As described above, when the insulating coated single core wire 2 is used as the conductive material forming the circuit, it is not necessary to construct a mold for each design as compared with the case where a bus bar is used.
It is possible to flexibly deal with circuit changes and reduce development lead time and development cost.

[0005]

However, in the case where the insulation-coated single-core wire 2 is pressure-bonded to the case 1 as described above, the insulation-coated single-core wire 2 is generally used as a single stroke.
It is difficult to increase the wiring density because the wiring is bent, and the area of the wiring surface increases and the area of the entire junction box also increases.

Further, when the circuits in which single-core wires with insulation coating are laid on the insulating plate are vertically stacked to form an internal circuit, an increase in the area of the internal circuit can be prevented, but the single-core wires in each layer are connected to each other. This requires a relay terminal and the like, resulting in an increase in the number of parts and man-hours. Further, since the manufacturing is performed for each one circuit consisting of the single-core wire with the insulation coating and the insulating plate, when the number of layers forming the internal circuit increases, the number of work steps also increases in proportion thereto.

The present invention has been made in view of the above problems, and it is an object of the present invention to reduce the number of parts and the number of working steps by improving the structure of a laminated circuit housed inside a junction box.

[0008]

In order to solve the above-mentioned problems, the present invention provides a junction box in which a plurality of insulating plates for wiring automobile electric wires in a required circuit shape are stacked and accommodated. , One of the insulating plates to be laminated is used as a base insulating plate, and the automobile electric wire is laid over another insulating plate from at least two orthogonal sides of the four sides of the base insulating plate to continuously wire The junction box is characterized in that the bridged electric wire for an automobile is bent in a folded shape around an insulating plate to be laminated.

With the above-mentioned structure, the above-mentioned automobile electric wire is continuously laid on each insulating plate, and the inter-circuit connection of the automobile electric wires of each layer is directly made without using a relay terminal or the like. The number of parts can be reduced, and the inter-layer connection work is not required, and the work man-hour is also reduced.

Further, since the electric wires for an automobile are collectively and continuously laid on the plurality of insulating plates to be laminated, a circuit is not formed for each insulating plate, and the working efficiency is improved. further,
Since at least two orthogonal sides of the four sides of the base insulating plate are continuously wired to another insulating plate, a maximum of four sides around the base insulating plate can be used to connect to another insulating plate. , Compared to the case where the insulating plates are arranged in series,
The degree of freedom of wiring is increased when continuous wiring is performed on a plurality of insulating plates.

In the present invention, a single core wire with an insulating coating,
A single-core copper wire having no insulation coating, a stranded copper wire having insulation coating, and the like are collectively referred to as an automobile electric wire.

Locking projections and locked recesses are provided on the facing surfaces of the insulating plates of the respective layers, and the stacked state is obtained by press-fitting and locking the locking projections in the facing locked recesses. Positioning and holding is preferable because handling is improved when the sheets are housed inside the case of the junction box after stacking.

The base insulating plate and the other insulating plate are integrated through a bendable hinge portion, and the other insulating plates are sequentially folded from each side of the base insulating plate through the hinge portion. There is.

As described above, if the base insulating plate and the other insulating plate are integrated with each other at the hinge portion, each insulating plate is held at a required interval when the automobile electric wires are continuously laid. There is no need to leave it, improving workability. The hinge part may be provided integrally with each insulating plate, or a separate sheet may be provided between the insulating plates to form the hinge part.

Alternatively, the base insulating plate and the other insulating plate are formed separately, and only the automobile electric wire is bridged between the base insulating plate and the other insulating plate to form the base insulating plate. It is also possible to bend the above-mentioned electric wire for automobile from each side and to fold other insulating plates.

With the above-mentioned structure, since only the automobile electric wire is laid between the base insulating plate and the other insulating plate, the insulating plate can be a separate insulating plate as in the conventional case.
Since no special structure is required for each insulating plate, processing cost is suppressed. In this case, at the time of laying the electric wire for an automobile before folding, by interposing a jig between the insulating plates, the other insulating plates are set to have a required interval centered on the base insulating plate. be able to.

The above-mentioned two base insulating plates are provided, and one side of these base insulating plates is connected through a long electric wire for an automobile, and the other side of each base insulating plate is connected through an electric wire for an automobile respectively. For an automobile in which an insulating plate to be folded is connected to the insulating plate, and the two base insulating plates are positioned at the uppermost layer and the lowermost layer by bending the long electric wire for automobiles and wired to these base insulating plates. The terminals to be pressure-welded to the electric wires are connected to the connectors, fuses and / or relays mounted on the upper and lower surfaces of the case.

With the above structure, since the base insulating plates connecting the insulating plates are further connected to each other, the number of laminated insulating plates for continuously arranging the single core wire or the like can be increased. The work efficiency is improved even when the number of stacked layers increases. Also, when folding the base insulating plates with the insulating plates folded, many other insulating plates will be interposed between them, so the single core wire or the like connecting the base insulating plates should be long. So, it is laminated smoothly.

Further, since one base insulating plate is located at the uppermost layer and the other base insulating plate is located at the lowermost layer, the terminals pressed against the automobile electric wires on these base insulating plates are
It can be easily connected to the connectors, fuses and / or relays on the upper and lower surfaces of the case.

In the above construction, the number of base insulating plates is two, and a maximum of eight insulating plates can be stacked. However, by connecting three or more base insulating plates, the number of stacked plates can be further increased. Needless to say.

[0021]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to the drawings. 1 to 5 show a first embodiment. Figure 1
3 is a drawing of a developed state of the internal circuit 10 housed in the junction box before stacking, in which insulating plates 12, 13, 14, 15 are provided adjacent to each other in a cross shape with the base insulating plate 11 as a center. Plates 11, 12, 13, 1
A single-core wire 16 with an insulating coating is laid in a desired circuit shape on the upper surfaces of 4 and 15.

Base insulating plate 11 and other insulating plates 12, 1
3, 14, 15, hinge portions 17, 18, 19,
20 are integrally provided, and hinge portions 17, 18, 1
A single core wire 16 with an insulation coating is laid over the upper portions of the insulation plates 9 and 20 so that the other insulation plate 1 is centered on the base insulation plate 11.
A single-core wire 16 with an insulating coating is laid across 2, 13, 14, and 15.

The hinge portions 17, 18, 19, 20 are
Assuming that the width of the hinge portion 17 is L1, the width of the hinge portion 18 is L2, the width of the hinge portion 19 is L3, and the width of the hinge portion 20 is L4, the relationship of L1 <L2 <L3 <L4 is satisfied. In addition, of the single-core wire 16 with insulating coating, the base insulating plate 11
As shown in FIG. 2, the lengths of the portions 16a, 16b, 16c, 16d bridged between the insulating plates 12, 13, 14, 15 and the corresponding insulating plates 12, 13, 14, 15 respectively correspond to the corresponding hinge portions 17, 18, 1, respectively.
The width is set to be longer than the widths L1, L2, L3, and L4 of 9, 20 to allow a margin.

The insulating coated single-core wire 16 has ribs 11a, 12 on the upper surfaces of the insulating plates 11, 12 as shown in FIG.
Pressure contact wiring is provided between a. The same applies to the remaining insulating plates 13, 14, and 15 not shown in FIG. On the upper surface of the base insulating plate 11, the pressure contact slot 21a of the terminal 21 for connecting to a connector, a fuse or / and a relay which is an external circuit is pressure contact connected to the insulating coated single core wire 16.

Next, the procedure for laminating the internal circuit 10 will be described. Insulating plate 12 → 1 centered on the base insulating plate 11
Fold in the order of 3 → 14 → 15 toward the back of the paper of FIG. At this time, the widths L1, L2, L3, and L4 of the hinge portions 17, 18, 19, and 20 are also increased in this order, so that all the insulating plates 12, 13, 14, and 15 are positioned directly below the base insulating plate 11. Can be laminated smoothly. That is, for example, when the insulating plate 15 is finally folded, the insulating plates 12, 13, 14 are provided below the base insulating plate 11.
Since they have already been laminated, the insulating plate 15 must be folded further downward by the thickness thereof. Therefore, by increasing the width L4 of the hinge portion 20, it is possible to fold it to a position directly below the insulating base plate 11.

Further, in the above-mentioned laminated state, as shown in FIG. 4, the monofilamentary wire 16 with the insulation coating is bent and laminated so that the single-core wire 16 with the insulating coating is the outer surface rather than the hinge portions 17, 18, 19, 20. However, single-core wires 16a, 16b, 16c, 1 with insulation coating located at the hinge portions 17, 18, 19, 20
6d is the width L1, L of the hinge portions 17, 18, 19, 20
Since the length is set longer than the lengths of L, L3, and L4, the single core wire 16 with the insulation coating can be smoothly folded without applying tension.

Also, the insulating plates 11, 12, 13, when laminated,
The facing surfaces of 14 and 15 have a locking structure. Specifically, as shown in FIG. 3, locked recesses 15a are provided at two corners of the facing surface of the insulating plate 15 with the insulating plate 14. Holes are provided, and locking projections 14b are provided at two corners of the insulating plate 14 that face the locked recesses 15a, and press-fit and lock each other to position and hold the stacked state. Other insulating plates 11, 12, 13, 14
The locking structure between them is similar to the above. In this embodiment, two locking points are provided for each insulating plate, but it goes without saying that three or more locking points may be provided.

The internal circuit 10 is housed inside the upper case 22 and the lower case 23 of the junction box, and the terminals 21 on the upper surface of the internal circuit 10 are projected into the connector housing 22a, the relay housing 22b, and the fuse housing 22c. There is.

Although the hinge portion is integrally provided in this embodiment, the insulating portion may be a separate body and the insulating plates may be connected by a sheet or the like to replace the hinge portion. Further, a coated electric wire may be used in place of the insulating coated single core wire, and in that case, the coating may be peeled off at the same time as the pressure contact using the pressure contact slot of the terminal 21 as a pressure contact blade.

6 and 7 show the second embodiment. The difference from the first embodiment is that the hinge portions are not provided as separate insulating plates.

FIG. 6 shows a jig 23 for forming an internal circuit.
Insulating plate installation parts 24, 25, 26, 27, 28 are provided in a recess. The ribs 23a, 23b, 23c, and 23d between the base insulating plate installation part 28 and the other insulating plate installation parts 24, 25, 26, and 27 provided at the center have a width L
If 1 ', L2', L3 ', L4', then L1 '<L
The relationship is 2 '<L3'<L4'.

The installation parts 24, 25, 26 of the jig 23,
When insulating plates are installed on 27 and 28, for example, as shown in FIG. 7, the gap between the insulating plate 11 ′ and the insulating plate 12 ′ is the rib 2
Since the width L1 'is set to 3a, the portion 16a' of the insulating coated single-core wire 16 'located in the gap can be set to a required length by simply bridging it. In this way, the gap between the insulating plates is regulated to the correct distance by the jig 23, and thereafter, it may be folded and laminated as in the first embodiment. Since other configurations are similar to those of the first embodiment, description thereof will be omitted.

8 and 9 show the third embodiment. The difference from the first embodiment is that the base insulating plates 31 and 35 are connected to each other to increase the number of laminated layers.

FIG. 8 is a drawing of the internal circuit 30 accommodated in the junction box in a developed state before stacking. In the left half of the figure, the hinge portions 40, 41, 42 are formed on the three sides of the base insulating plate 31 as the center. Through the insulating plates 32, 33, 3
4 are provided adjacent to each other, and hinge portions 43, 44, 45 are provided on three sides of the right half of the drawing with the insulating base plate 35 as the center.
Insulating plates 36, 37, and 38 are provided adjacent to each other via a base plate, and the base insulating plates 31 and 35 are connected to each other via a hinge portion 46. Then, these insulating plates 31, 32, 33, 34, 35, 36, 37,
On the upper surface of 38, a single-core wire 39 with an insulating coating is laid in a desired circuit shape.

Widths L1, L of the hinge portions 40, 41, 42
2 and L3 have a relationship of L1 <L2 <L3, and the widths of the hinge portions 43, 44 and 45 are also L1, L2 and L3.
Has become. The width L5 of the hinge portion 46 connecting the base insulating plates 31 and 35 is L3 << L5.

Further, on the upper surfaces of the base insulating plates 31 and 35, terminals 47 and 48 for connecting to connectors, fuses, and relays, which are external circuits, are pressure-contact connected to the insulating coated single-core wire 39 so as to project upward. .

Next, the procedure for laminating the internal circuit 30 will be described. Insulating plate 32 → 3 centered on the base insulating plate 31
In the order of 3 → 34, the sheet is folded back in the plane of FIG. 8 and then the insulating plate 36 → 37 → is centered around the insulating base plate 35.
The sheets are folded in the order of 38 toward the back of the paper of FIG. Then, as shown in FIG. 9 (A), the circuit body 100 and the circuit body 101 have a hinge portion 46 and a single-core wire 39g with an insulating coating.
It will be connected by. Therefore, when the circuit body 101 is further folded below the circuit body 100 according to the arrow in the figure, all the insulating plates 31, as shown in FIG.
32, 33, 34, 35, 36, 37, 38 are in a stacked state. Although the insulating plate 50 is interposed between the circuit body 100 and the circuit body 101 where the insulating coated single-core wires 39 face each other, the insulating plate 50 may not be interposed.

In this embodiment, the base insulating plates 31, 35 are used.
A single core wire 39 with an insulation coating is continuously wired all together on a total of eight insulating plates that connect two circuit bodies 100 and 101 centering on each other to make the circuit formation more efficient. Needless to say, it is possible to continuously wire single-core wires with an insulating coating on a larger number of insulating plates.

Further, instead of the above-mentioned single wire with insulation coating,
A single-core copper wire without insulation coating or a stranded copper wire with insulation coating may be used.

[0040]

As is apparent from the above description, according to the present invention, since the interlayer connection of the laminated circuit is directly performed by the continuous electric wire for automobile without using the relay terminal or the like,
The number of parts and work man-hours can be reduced. Further, since the electric wires for automobiles are continuously laid together on a plurality of insulating plates, it is not necessary to manufacture each insulating plate individually, and the work efficiency is improved.

Furthermore, the base insulating plate can be connected to other insulating plates using up to four sides with the center being the center, and the wiring can be freely set in the continuous wiring on a plurality of insulating plates as compared with the case where the insulating plates are arranged in series. The degree increases. In addition, since the locking projections and the locked recesses are provided on the facing surfaces of the insulating plates of the respective layers, the stacked states can be positioned and held by press-fitting and locking each other, and the handleability is improved.

If the base insulating plate and the other insulating plate are integrated by the hinge portion, it is not necessary to hold each insulating plate at a required interval, and workability is improved. Alternatively, if the base insulating plate and the other insulating plate are separated and only the automobile electric wire is laid between the base insulating plate and the other insulating plate, the insulating plate may have a conventional structure. Processing costs are suppressed.

By providing two base insulating plates to which insulating plates are connected and connecting these to each other, it is possible to continuously wire automobile electric wires on a larger number of insulating plates and to increase the number of laminated layers. Work efficiency is improved. In addition, by making the single core wire or the like connecting the base insulating plates long, the base insulating plates can be smoothly laminated even if many other insulating plates are interposed between the base insulating plates. Further, by arranging the two base insulating plates in the uppermost layer and the lowermost layer, respectively, the terminals pressed against the single core wire or the like on these base insulating plates can be directly connected to the upper and lower connectors, fuses and / or relays.

[Brief description of drawings]

FIG. 1 is a perspective view of an internal circuit according to a first embodiment of the present invention before stacking.

FIG. 2 is a perspective view of a main part of the first embodiment.

FIG. 3 is a perspective view of a main part of the first embodiment.

FIG. 4 is a perspective view of the internal circuit of the first embodiment after being laminated.

5A is a perspective view of the junction box of the first embodiment, FIG. 5B is a cross-sectional view of a main part, and FIG. 5C is a perspective view of a terminal.

FIG. 6 is a perspective view of a jig according to a second embodiment.

FIG. 7 is a perspective view of a main part of the second embodiment.

FIG. 8 is a perspective view of an internal circuit of a third embodiment before being laminated.

9A is a perspective view of the internal circuit according to the third embodiment during lamination, and FIG. 9B is a perspective view after lamination.

FIG. 10 is a plan view of an internal circuit of a conventional junction box.

[Explanation of symbols]

10, 30 Internal circuit 11 Base insulation plate 12, 13, 14, 15 Insulation plate 14a, 15a Locked recess 14b Locking protrusion 16 Single-core wire with insulation coating 17, 18, 19, 20 Hinge part 21 terminals 23 Jig 23a, 23b, 23c, 23d rib 24, 25, 26, 27, 28 Installation section 100, 101 circuit body

Claims (5)

[Claims] 1. A junction box in which a plurality of insulating plates in which electric wires for automobiles are laid out in a required circuit shape are stacked and accommodated, wherein one of the stacked insulating plates is a base insulating plate, The electric wire for an automobile is laid on another insulating plate from at least two orthogonal sides of the four sides of the base insulating plate to be continuously wired, and the laid electric wires for the automobile are laminated and arranged. A junction box characterized by being bent back around the insulating plate. 2. The laminated structure is provided with locking projections and locked recesses on the opposing surfaces of the insulating plates of the respective layers, and the locking projections are press-fitted into the opposed locked recesses. The junction box according to claim 1, which holds and holds the state. 3. The base insulating plate and the other insulating plate are integrated via a bendable hinge portion, and the other insulating plate is sequentially folded from each side of the base insulating plate via the hinge portion. The junction box according to claim 1 or 2, which is provided. 4. The base insulating plate and the other insulating plate are separate members, and only the automobile electric wire is bridged between the base insulating plate and the other insulating plate. The junction box according to claim 1 or 2, wherein the automobile electric wire is bent from each side of the other insulation plate and the other insulating plate is folded. 5. The two base insulating plates are provided, and one side of these base insulating plates is continuous with a long electric wire for an automobile, and the other side of each base insulating plate is connected with an electric wire for the automobile, respectively. And connecting the insulating plates that are folded on the base insulating plate, and bending the long electric wires for automobiles to position the two insulating base plates on the uppermost layer and the lowermost layer, and wire them to the base insulating plates. The junction box according to any one of claims 1 to 4, wherein a terminal to be pressure-welded to an electric wire for an automobile is connected to a connector, a fuse, and / or a relay mounted on the upper and lower surfaces of the case.