JP2006050701A - Resin casing for electrical connection, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To not only downsize it but also reduce the cost by greatly reducing the quantity of used resin, in a resin casing for electric connection. <P>SOLUTION: The resin casing 1 for electric connection is constituted by setting a jig (core), wherein fourteen pieces each, a total of forty two pieces of terminals 5A, 5B and 5C in three layers which are insulated, with two sheets of polyimide films 6A and 6B between, are set, in a mold for injection molding thereby insert-molding it. The thickness of the two sheets of polyimide films 6A and 6B is thin, i.e., 50 μm, and the thickness of a conductive part 4 becomes 5 mm or thereabouts, i.e., about half a conventional one of 10 mm or over. The weight of an ECU case 1 as the resin case for electric connection can be reduced, and also the quantity of used resin for injection molding can be reduced greatly, and the manufacture cost can be reduced, too. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a resin case for electrical connection such as a junction box or ECU (Electronic Control Unit) case used in automobiles and the like, and a method for manufacturing the same, and particularly for electrical connection that can be reduced in size, weight, and cost. The present invention relates to a resin case and a manufacturing method thereof.

  Resin cases for electrical connection, such as junction boxes and ECU cases used in automobiles, etc., have internal circuits formed by metal wires (bus bars and terminals for conduction) that are formed by punching a conductive metal plate such as a copper plate. These are formed and laminated by sandwiching them between insulating plates made of synthetic resin. As an example, a laminated structure using a conventional conduction terminal will be described with reference to FIG. FIG. 5 is a longitudinal sectional view showing a laminated structure of a resin case for electrical connection using a conventional conduction terminal.

  As shown in FIG. 5, this laminated structure is formed by bending three types of conductive terminals 10A, 10B, and 10C having a predetermined shape by plating a copper wire of about 0.6 mm square or 1 mm to 2 mm width. After processing and fixing and positioning the insulating plates 11A, 11B, and 11C made of PBT (polybutylene terephthalate) by heat caulking, the three insulating plates 11A, 11B, and 11C are overlapped as shown in the figure. A predetermined resin case for electrical connection was formed by setting in a mold of the resin case for electrical connection and insert-molding PBT resin. For this reason, the laminated structure becomes thick, and an extra PBT resin is used, resulting in an increase in size, weight, and cost.

Therefore, in the invention described in Patent Document 1, conventionally, a bus bar (copper square wire having a thickness of about 0.6 mm × width of about 1 mm) and an insulating plate are alternately stacked and arranged. Or by replacing the whole with FPC (flexible printed circuit) where both sides of the conductive material are covered with insulating film, the number of thick insulating plates can be reduced or eliminated completely, and the resin case for electrical connection can be downsized. And weight reduction.
JP 11-332059 A

  However, in the technique described in Patent Document 1, although the thickness of the laminated structure portion can be reduced, an expensive FPC is used as an insulator, which increases the cost. Further, even if the circuit in the FPC is used as one layer of the conductive layer, the circuit in the FPC is made of a thin foil made of a conductive material, so that a necessary current cannot be passed.

  Accordingly, the present invention provides a resin case for electrical connection that can not only reduce the size and weight but also reduce the cost by making the laminated structure portion much thinner than conventional products, and a method for manufacturing the same. Is an issue.

  A resin case for electrical connection according to the invention of claim 1 includes a conductive layer made of a plurality of conductive metal wires arranged in a plane with a synthetic resin interposed therebetween at a predetermined interval, and the conductive layer. A predetermined number of layers, and a thin insulating material sandwiched between the conductive layers to insulate the conductive layers, the predetermined number of conductive layers and the predetermined number of conductive layers The thin insulating material sandwiched between each of the two is wrapped with the synthetic resin.

  The resin case for electrical connection according to the invention of claim 2 is a resin case for electrical connection having a plurality of conductive layers therein, and each of the plurality of conductive layers is arranged in a plane at a predetermined interval. The plurality of conductive metal wires are bent into a predetermined shape, arranged on the alignment fixing jig at the predetermined interval, and an adhesive is applied to the upper surface thereof. A thin insulating material is applied so as to cover all the insulating parts of the conductive metal wire, and pressure is applied and bonded. After the same process is performed for all of the plurality of conductive layers, the resin case for electrical connection For the resin case for electrical connection so that the conductive metal wire and the thin insulating material are not displaced or deformed by molding pressure. Multiple positions protruding from injection mold Are strongly pressing is by insert molding in determining pin, but also to the space formed by retracting a plurality of positioning pins just before the end of the insert molding becomes so as to be filled molten resin.

  The resin case for electrical connection according to the invention of claim 3 is the configuration of claim 2, wherein the thin insulating material is not bonded to the uppermost conductive layer of the plurality of conductive layers, and the uppermost conductive layer is not bonded. A plurality of conductive metal wires constituting the core are arranged on the core, and are firmly pressed by a plurality of positioning pins protruding from the upper part of the injection mold, and are arranged in a plane at the predetermined interval. It has been made.

  In the method for manufacturing a resin case for electrical connection according to the invention of claim 4, after the necessary surface treatment is performed on the conductive metal wire, the required number is cut into a plurality of types of predetermined lengths, and a predetermined metal wire shape is obtained. In order to prevent the surface of the conductive metal wire from being damaged, the surface of the conductive metal wire having a predetermined shape is subjected to mirror finishing to prevent the scratching of the conductive metal wire. Then, a step of setting the necessary number of wires for each predetermined length so that the adjacent conductive metal wires do not contact each other on an alignment fixing jig with sufficient R at the corners, or conductive metal wires In order to prevent the conductive metal wire from being scratched by the step of cutting the necessary number into a plurality of types of predetermined lengths after the necessary surface treatment is applied to the conductive metal wire Surface finish with mirror finish Then, after setting the necessary number of wires for each predetermined length so that the adjacent conductive metal wires do not contact each other with a sufficient R at the corners, In order to achieve this, a process for forming and bending the tip is applied, and an adhesive is applied to the conductive metal wires aligned on the alignment fixing jig, and the aligned conductive metal wires are all covered. A thin insulating material cut to a predetermined size is covered, or the conductive metal wires aligned on the alignment fixing jig are covered so as to cover all of the aligned conductive metal wires. Covering the thin conductive material with a sufficient weight and covering the thin conductive material with the thin insulating material cut to the size and having the adhesive applied to the lower surface, and bonding the thin conductive material to the thin insulating material. Type predetermined length A jig that is set as a core in a mold for injection molding, and a plurality of terminals for a plurality of types of necessary terminals are set at predetermined positions. Holes are provided and can be easily pulled out from the molded product after insert molding, and the aligned conductive metal wires are arranged in a predetermined order on a jig having the same material, hardness, and surface roughness as the mold for injection molding. And a step in which the thin insulating material is bonded and inserted into the holes for both terminals of the jig one by one, and the aligned conductive metal wires and the thin insulating material in a predetermined order Set the jig (core) with the glued to the mold for injection molding, in order to ensure the positional accuracy and prevent deformation of the aligned conductive metal wires and the thin insulating material, The alignment is performed with a plurality of positioning pins attached to the injection mold. In order to prevent the conductive metal wire from being securely held from above and below, the step of performing insert molding using a predetermined synthetic resin material, and the loss of waterproofness due to the formation of a hole at the position of the positioning pin, the insert A step of retracting the plurality of positioning pins during molding to form a space and filling with molten resin.

  According to a fifth aspect of the present invention, there is provided a method for manufacturing a resin case for electrical connection according to the fourth aspect of the present invention, wherein the alignment fixing jig is arranged at a predetermined interval in order to align the conductive metal wires without contacting each other. A groove is provided.

  According to a sixth aspect of the present invention, there is provided a method for producing an electrical connection resin case according to the fourth or fifth aspect of the present invention, wherein the conductive case is set at the top of the plurality of types of conductive metal wires having a predetermined length. For metal wires, alignment is performed only by inserting both terminals one by one into the holes for both terminals of a jig set as a core in the injection mold without performing the bonding step. It is something to be made.

  The resin case for electrical connection or the method for producing the resin case for electrical connection according to the invention of claim 7 is the structure of any one of claims 1 to 3 or any one of claims 4 to 6. The thin insulating material is any one of a thin insulating film, a thin insulating sheet, and a thin insulating paper, and has a thickness in the range of about 10 μm to about 500 μm.

  The resin case for electrical connection according to the invention of claim 1 includes a conductive layer composed of a plurality of conductive metal wires arranged in a plane with a synthetic resin interposed therebetween at a predetermined interval, and a conductive layer And a thin insulating material sandwiched between them to insulate the conductive layers, and a predetermined number of conductive layers and the periphery of each thin insulating material sandwiched between them are covered with a synthetic resin.

  Here, examples of the “thin insulating material” include an insulating film, an insulating sheet, and insulating paper, and the thickness thereof is about 10 μm to about 500 μm, preferably about 50 μm to about 100 μm. Therefore, a conductive layer composed of a plurality of conductive metal wires (bus bars, terminals, etc.) arranged in a plane with a synthetic resin between them at a predetermined interval is insulated by sandwiching a thin insulating material. Therefore, even if laminated, it does not become thick and can be formed with the minimum necessary thickness and the amount of synthetic resin, so that not only the size and weight can be reduced, but also the cost can be reduced.

  Thus, by making the laminated structure part much thinner than the conventional product, it becomes an electric connection resin case that can be reduced in size and weight as well as cost.

  The resin case for electrical connection according to the invention of claim 2 is a resin case for electrical connection having a plurality of conductive layers therein, and the plurality of conductive layers are arranged in a plane at a predetermined interval. The conductive metal wires are bent into a predetermined shape, arranged on a jig for alignment and fixing at a predetermined interval, and an adhesive is applied to the upper surface to insulate a plurality of conductive metal wires. A thin insulating material is covered so as to cover all the parts, and pressure is applied to bond them. Thus, the plurality of conductive metal wires forming the conductive layer are arranged at a predetermined interval without contacting each other.

  After the same process is performed for all of the plurality of conductive layers, the conductive metal wires and the conductive metal wires are stacked in a predetermined order on a core disposed in an injection mold for the resin case for electrical connection. The thin insulating material is firmly pressed by a plurality of positioning pins protruding from an injection mold for the resin case for electrical connection so as not to be displaced or deformed, and insert molding is performed. That is, since the molding pressure applied at the time of insert molding reaches several tens of MPa, the arrangement of the conductive metal wires is not maintained by the adhesive force with the thin insulating material, and is firmly formed by a plurality of positioning pins protruding from the injection mold. Can withstand a large molding pressure.

  However, if the conductive metal wire is held down by these multiple positioning pins until the end of insert molding, molten resin will not enter the multiple positioning pin parts, resulting in holes and water resistance. Therefore, the molten resin is filled in the space formed by retracting the plurality of positioning pins immediately before the end of the insert molding.

  In this way, it is possible to embed conductive metal wires as designed, and by making the laminated structure much thinner than conventional products, not only can it be reduced in size and weight, but also can be reduced in cost. It becomes a resin case for connection.

  In the resin case for electrical connection according to the invention of claim 3, a plurality of conductive metal wires constituting the uppermost conductive layer without bonding a thin insulating material to the uppermost conductive layer among the plurality of conductive layers Are arranged in a core and firmly arranged by a plurality of positioning pins protruding from the upper part of the injection mold so that they are arranged in a plane at a predetermined interval.

  When all of the plurality of conductive layers are arranged and arranged on the alignment fixing jig at a predetermined interval and covered with a thin insulating material, the thin insulating material covered on the uppermost conductive layer is attached to the resin case for electrical connection. After completion, it becomes useless and wastes processes and materials. Therefore, the uppermost conductive layer is formed on a thin insulating material bonded to the second conductive layer when it is laminated on the core. Arrangement is ensured by arranging a plurality of conductive metal wires, setting the core in an injection mold, and firmly pressing with a plurality of positioning pins protruding from the upper part of the injection mold.

  In this way, by making the laminated structure part much thinner than conventional products, not only can the size and weight be reduced, but also wasteful processes and materials can be reduced to further reduce costs. It becomes a case.

  The manufacturing method of the resin case for electrical connection according to the invention of claim 4 is carried out as follows. First, after conducting necessary surface treatment such as tin plating on conductive metal wires such as copper wire, the required number of pieces are cut into a plurality of predetermined lengths, and forming and bending of the tip are performed. It is a predetermined metal wire shape. The conductive metal wire in the specified shape is mirror-finished to prevent the conductive metal wire from being scratched, surface treatment such as plating is performed, and the corner is provided with an alignment R with sufficient R The necessary number is set for each predetermined length so that adjacent conductive metal wires do not contact each other.

  Or, after conducting the necessary surface treatment such as tin plating on the conductive metal wire, cut the required number to a predetermined length of multiple types and scratch the linear conductive metal wire to the conductive metal wire In order to prevent this, the conductive metal wires adjacent to each other are not in contact with each other for a predetermined length in an alignment fixing jig with a mirror finish and surface treatment such as plating and sufficient corners. The tip is formed and subjected to forming processing and bending processing to form a predetermined metal wire shape.

  Applying an adhesive to the conductive metal wires aligned on the alignment fixture, and then covering with thin insulating material cut to a predetermined size so that all of the aligned conductive metal wires are covered or aligned Cover the conductive metal wires aligned on the fixing jig with a thin insulating material that has been cut to a predetermined size and coated with adhesive on the bottom surface so that all the conductive metal wires aligned are covered. A thin insulating material is bonded to a conductive metal wire aligned with a heavy weight. In addition, when a thermosetting adhesive is used as the adhesive, it is heated to the curing temperature at the same time as applying the weight. After this bonding process is performed for a plurality of types of predetermined lengths, the jig is set as a core in an injection mold, and a plurality of types of necessary terminals are set at predetermined positions. A plurality of holes for both terminals are provided, which can be easily pulled out from the molded product after insert molding, in the same order as the jig with the same material, hardness and surface roughness as the injection mold. A conductive metal wire and a thin insulating material bonded to each other are inserted into the holes for both terminals of the jig one by one and set.

  When the setting is completed, the core is set in an injection molding die, and in order to ensure the positional accuracy and prevent deformation of conductive metal wires and thin insulating materials aligned with an injection molding pressure of several tens of MPa, The conductive metal wires aligned with a plurality of positioning pins attached to the injection mold are securely held from above and below. Then, insert molding is performed using a predetermined synthetic resin material. If the conductive metal wire is held down with a plurality of positioning pins until the end of the insert molding, the molten resin is placed on the plurality of positioning pin portions. Since it becomes a hole without being inserted and becomes a resin case for electrical connection that is inferior in waterproofness, a plurality of positioning pins are retracted during insert molding to create a space and filled with molten resin.

  In this way, it is possible to embed conductive metal wires as designed, and by making the laminated structure part much thinner than conventional products, not only can it be reduced in size and weight, but also electrical connection that can reduce costs It becomes the manufacturing method of the resin case for a car.

  In the manufacturing method of the resin case for electrical connection according to the invention of claim 5, the alignment fixing jig is provided with grooves at predetermined intervals in order to align the conductive metal wires without contacting each other. It is difficult to arrange a plurality of conductive metal wires on a flat alignment fixture upper surface at a predetermined interval even if a mark or the like is attached. Therefore, by providing grooves at a predetermined interval on at least the upper surface of the alignment fixing jig and inserting the conductive metal wires into the grooves one by one, the conductive metal wires can be brought into contact with each other very easily. Can be aligned. Even when a thin insulating material is applied from above and bonded, there is no possibility that the conductive metal wire is displaced.

  In this way, it is possible to embed conductive metal wires as designed, and by making the laminated structure part much thinner than conventional products, not only can it be reduced in size and weight, but also electrical connection that can reduce costs It becomes the manufacturing method of the resin case for a car.

  The manufacturing method of the resin case for electrical connection according to the invention of claim 6 does not carry out the bonding step for the conductive metal wire set at the top of the plurality of types of conductive metal wires of a predetermined length, Alignment is performed only by inserting both terminals one by one into holes for both terminals of a jig set as a core in an injection mold. If a thin insulating material is bonded to a plurality of conductive metal wires set on the uppermost portion, the thin insulating material becomes useless after the resin case for electrical connection is completed, and the process and materials are wasted.

  Therefore, a plurality of terminals attached to the injection mold are aligned by inserting both terminals one by one into the holes for both terminals of a jig set as a core in the injection mold. The conductive metal wires aligned with the positioning pins are firmly held from above. And if the resin case for electrical connection is manufactured by performing insert molding using a predetermined synthetic resin material, it is possible to eliminate waste of processes and materials.

  In this way, by making the laminated structure part much thinner than conventional products, not only can the size and weight be reduced, but also wasteful processes and materials can be reduced to further reduce costs. It becomes the manufacturing method of a case.

  In the manufacturing method of the resin case for electrical connection or the resin case for electrical connection according to the invention of claim 7, the thin insulating material is any one of a thin insulating film, a thin insulating sheet, and a thin insulating paper, and the thickness thereof is about 10 μm. Is within the range of about 500 μm. Since these insulating materials are thin and uniform and can withstand high temperatures during injection molding, they can be obtained at low cost, which contributes to the cost reduction of the resin case for electrical connection. And, as a result of repeated earnest research experiments by the present inventors, it was found that the thickness of the thin insulating material is preferably within a range of about 10 μm to about 500 μm, and the present invention has been completed based on this finding. is there.

  In this way, by making the laminated structure part much thinner than the conventional product, not only can the size and weight be reduced, but also the cost can be further reduced by using an inexpensive material. It becomes a manufacturing method of the resin case for connection.

  Hereinafter, a resin case for electrical connection according to an embodiment of the present invention and a manufacturing method thereof will be described with reference to FIGS.

  FIG. 1 is a perspective view showing an entire configuration of a resin case for electrical connection according to an embodiment of the present invention. FIG. 2 is a longitudinal sectional view showing a section AA in FIG. FIG. 3 is a perspective view showing the terminal alignment state in the resin case for electrical connection and the manufacturing method thereof according to the embodiment of the present invention. FIG. 4 is a longitudinal sectional view showing the laminated structure of the three-layer terminal in the resin case for electrical connection and the manufacturing method thereof according to the embodiment of the present invention.

  As shown in FIG. 1, an ECU case 1 as a resin case for electrical connection according to the present embodiment is made of FRP (fiber reinforced plastic) in which PBT (polybutylene terephthalate) is mainly used and 30% by weight of glass fiber is mixed. Thus, the upper right side is an ECU storage space 2, and a circuit including a bus bar (not shown) for electrical connection with the ECU is provided. On the other hand, a connector portion 3 is provided on the left protruding portion, and a large number of terminal wires 5 pass through the conductive layer portion 4 from the connector portion 3 and protrude downward in the vicinity of the ECU storage space 2. Yes. The projecting terminal wires 5 are connected to a circuit board attached to the lower surface of the ECU case 1 and are connected to an ECU housed in the ECU storage space 2 through the circuit board.

  Next, FIG. 2 which shows the AA cross section of FIG. 1 is demonstrated. As shown in FIG. 2, the connector part 3 of the ECU case 1 is a concave part, and a large number of terminal wires 5 protruding into the connector part 3 are provided on the convex part into which the connector part 3 is fitted as it is. It becomes a pin that fits into the pin hole. A large number of terminal wires 5 have a three-layer structure in the conductive layer portion 4, and these three-layer terminal wires 5A, 5B, 5C are formed of two thin insulating films 6A, 6B in the conductive layer portion 4. Is insulated by.

  As a result, in the ECU case 1 as the resin case for electrical connection according to the present embodiment, the conductive layer portion 4 is thinner and lighter than the conventional three-layer structure shown in FIG. Is done.

  Next, a method for manufacturing the ECU case 1 as the resin case for electrical connection according to the present embodiment having such a structure will be described with reference to FIGS.

  First, after copper copper plating of 0.64 mm square is plated with copper, reflow tin plating on the surface is cut into three types of lengths of about 70 mm, about 80 mm, and about 93 mm. Forming and bending the tip is performed to make the terminal shape. Next, as shown in FIG. 3, the processed terminal 5C is mirror-finished to prevent damage to the terminal 5C, and then subjected to surface treatment such as chrome plating, so that sufficient R is applied to the corner. Are arranged on a jig 7 for alignment and fixing, and 14 lines are aligned at a pitch of 3 mm (14 or more grooves 7a are provided at a pitch of 3 mm on the alignment and fixing jig 7). Adjacent terminals 5C are not in contact with each other, and the alignment accuracy is ± 0.05 mm.

  In addition, square lines cut into three lengths of about 70 mm, about 80 mm, and about 93 mm are set on the alignment fixture 7 in a straight line, and then formed into a predetermined terminal shape and bent. Processing or the like may be performed.

  Next, as shown in FIG. 3, from the top of the terminal 5C aligned on the alignment fixing jig 7, the 14 terminals 5C are thinly cut to a predetermined size so as to cover all of them. Set the insulating film 6B. As the material of the thin insulating film 6B, polyimide that sufficiently satisfies heat resistance and insulating properties was selected, and the thickness of the polyimide film 6B was set to 50 μm from the viewpoint of workability, insulating properties, and subsequent processes. A thermosetting adhesive is applied to a thickness of about 20 μm between the 14 terminals 5C and the polyimide film 6B.

  Then, the heat curing process is performed in a state where the entire polyimide film 6B is pressurized. As a heating / pressurizing condition, a pressure of about 20 kg is applied to the entire polyimide film 6B, and 220 ° C. × 20 seconds. did. As a heating method, a heater is embedded in the pressurizing jig so that it is constantly heated to 220 ° C., and the surface of the pressurizing jig is coated with a fluorine coating in consideration of the peelability from the polyimide film 6B. Has been. The adhesive strength between the terminal 5C thus obtained and the polyimide film 6B was about 15N.

  In the same manner, 14 terminals 5B, which are the second longest, are aligned on an alignment fixing jig having a different length, and a thermosetting adhesive is applied to a thickness of about 20 μm. A polyimide film 6A having a thickness of 50 μm cut into a predetermined dimension so as to cover is set. Then, using a heating / pressurizing jig, the adhesive is cured by heating at 220 ° C. for 20 seconds with a pressure of about 20 kg applied to the entire polyimide film 6A.

  Further, the 14 terminals of the longest terminal 5A may be aligned in the same manner and covered with a polyimide film and fixed by heating. However, the polyimide film placed on the terminal 5A is unnecessary after the ECU case 1 is molded. Therefore, the longest terminal 5A is aligned by another method.

  That is, a jig set as a core in an injection mold of the ECU case 1, and a total of 84 terminals (14 × 3 × 2 =) of terminals 5A, 5B, 5C for three layers are predetermined. 84 holes for terminals to be set at the position are provided, and can be easily pulled out from the molded product after insert molding, and the jig with the same material, hardness and surface roughness as the mold for injection molding, The 14 shortest terminals 5C and the polyimide film 6B are set first, and then the 14 terminals 5B and the polyimide film 6A are set in close contact with each other. Then, the longest terminal 5A is inserted into the holes for both terminals of the jig one by one and is brought into close contact with the polyimide film 6A, and 14 terminals are set so as not to contact the adjacent terminal 5A.

  In this way, as shown in FIG. 4, a jig (core core) in which a total of 42 terminals of three layers 5A, 5B, 5C insulated with two polyimide films 6A, 6B interposed therebetween are set. ) Is set in an injection mold and insert molding is performed. Here, since the mold temperature is 80 ° C., it is necessary to preheat the jig (core), and a method of heating the base plate on which the jig (core) is fixed with a heater is adopted. . The resin used for injection molding of the ECU case 1 is FRP (fiber reinforced plastic) in which PBT (polybutylene terephthalate) is mainly used and 30% by weight of glass fiber is mixed.

  Since the maximum resin pressure applied to the terminals 5A, 5B, 5C during insert molding is about 50MPa, the upper and lower parts of the terminals are made of gold to ensure the positional accuracy and prevent deformation of the terminals 5A, 5B, 5C and the polyimide films 6A, 6B. Hold firmly with the positioning pin attached to the mold. And in order to prevent that a hole arises in the position of a positioning pin and water resistance is impaired, a positioning pin is retracted during shaping | molding and a space is made and it fills with resin. The timing for operating the positioning pin is when the resin filling is about 95% completed. If this timing is too early, the positioning accuracy of the terminal cannot be ensured, and if it is too late, the temperature of the molten resin is lowered and short shots cannot be secured.

  As a characteristic of the ECU case 1 obtained in this way, the thickness of the terminal layer structure portion 4 which has been 10 mm or more in the past is about half of 5 mm. The amount used was greatly reduced, and the manufacturing cost could be reduced.

  In this way, the resin case (ECU case) 1 for electrical connection and the manufacturing method thereof according to the present embodiment can not only reduce the size and weight but also use the resin by making the laminated structure portion 4 much thinner than the conventional product. The amount is greatly reduced, and the cost can be reduced.

  In the present embodiment, an example in which a polyimide film having a thickness of 50 μm is used as the thin insulating films 6A and 6B of the terminal layer structure portion 4 is not limited to this, but a PET (polyethylene terephthalate) film is used. Any film may be used as long as it satisfies the heat resistance and insulation characteristics during injection molding, including PEN (polyethylene naphthalate) film. Further, the insulating film is not limited to a thin insulating film, and may be a thin insulating sheet, a thin insulating paper, and the like. The thickness can be from about 10 μm to about 1 mm, but in consideration of handleability and functionality, about 50 μm to 100 μm is preferable. .

  In carrying out the present invention, the configuration, shape, quantity, material, size, connection relationship, etc. of other parts of the resin case for electrical connection, and other processes of the method for producing the resin case for electrical connection are also included. However, the present invention is not limited to this embodiment.

FIG. 1 is a perspective view showing an entire configuration of a resin case for electrical connection according to an embodiment of the present invention. FIG. 2 is a longitudinal sectional view showing a section AA in FIG. FIG. 3 is a perspective view showing the terminal alignment state in the resin case for electrical connection according to the embodiment of the present invention. FIG. 4 is a longitudinal sectional view showing a laminated structure of three-layer terminals in the resin case for electrical connection according to the embodiment of the present invention. FIG. 5 is a longitudinal sectional view showing a laminated structure of a resin case for electrical connection using a conventional conduction terminal.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Resin case for electrical connection 3 Connector part 4 Conductive layer part 5 Terminal part 6A, 6B Thin insulating film 7 Alignment fixing jig

Claims (7)

A conductive layer composed of a plurality of conductive metal wires arranged in a plane with a synthetic resin interposed therebetween at a predetermined interval;
The conductive layer is laminated in a predetermined number of layers, and comprises a thin insulating material sandwiched between the conductive layers to insulate the conductive layers,
A resin case for electrical connection, wherein the synthetic resin is wrapped around the thin insulating material sandwiched between the predetermined number of conductive layers and the predetermined number of conductive layers. A resin case for electrical connection having a plurality of conductive layers therein,
Each of the plurality of conductive layers is composed of a plurality of conductive metal wires arranged in a plane at a predetermined interval, and after bending into a predetermined shape, the alignment fixing jig is subjected to the predetermined fixing The adhesive is applied to the upper surface and covered with a thin insulating material so as to cover all of the insulating portions of the plurality of conductive metal wires, and is bonded by applying pressure. After being performed on all of the plurality of conductive layers, the conductive metal wires and the thin layer are stacked in a predetermined order on a core disposed in the injection mold for the resin case for electrical connection, and at a molding pressure. The plurality of positioning pins are firmly pressed by a plurality of positioning pins protruding from the injection mold for the resin case for electrical connection so that the insulating material is not displaced or deformed, and the positioning is performed immediately before the end of the insert molding. Pull the pin Electrical connection resin case, characterized in that also so as to be filled molten resin Umate resulting space.   The uppermost conductive layer of the plurality of conductive layers is not bonded to the thin insulating material, and a plurality of conductive metal wires constituting the uppermost conductive layer are arranged in the core, and the injection is performed. 3. The resin case for electrical connection according to claim 2, wherein the resin case for electrical connection according to claim 2, wherein the resin case is planarly arranged at the predetermined interval by being firmly pressed by a plurality of positioning pins protruding from the upper part of the molding die. After performing the necessary surface treatment on the conductive metal wire, cutting the necessary number into a plurality of types of predetermined length, forming the tip to form a predetermined metal wire shape, a step of performing bending,
Subsequently, the conductive metal wire having a predetermined shape is mirror-finished to prevent the conductive metal wire from being scratched and subjected to surface treatment, and a corner is provided with sufficient R for alignment and fixing. In a tool, a step of setting the necessary number for each predetermined length so that the adjacent conductive metal wires do not contact each other;
Alternatively, after performing the necessary surface treatment on the conductive metal wire, a step of cutting the necessary number into a plurality of predetermined lengths,
Subsequently, the conductive metal wire having a linear shape is mirror-finished to prevent scratches on the conductive metal wire, surface-treated, and an alignment fixing jig with a sufficient R at the corner. A step of forming and bending the tip to form a predetermined metal wire shape after setting the necessary number of adjacent conductive metal wires so as not to contact each other for each predetermined length; and
After applying an adhesive to the conductive metal wires aligned on the alignment fixing jig, a thin insulating material cut to a predetermined size is covered so that the aligned conductive metal wires are all covered. Or a thin insulation in which the conductive metal wires aligned on the alignment fixing jig are cut to a predetermined size so as to cover all of the aligned conductive metal wires and adhesive is applied to the lower surface. Covering the material and applying sufficient weight to bond the aligned conductive metal wires and the thin insulating material; and
Performing the bonding step for each of the predetermined lengths of the plurality of types;
A jig that is set as a core in a mold for injection molding, and is provided with a plurality of holes for both terminals in which a plurality of terminals corresponding to the required number of the plurality of types are set at predetermined positions. After molding, it can be easily pulled out from the molded product, and the aligned conductive metal wires and the thin insulating material are arranged in a predetermined order on a jig whose material, hardness, and surface roughness are the same as the mold for injection molding. Inserting and setting the bonded terminals one by one into the holes for both terminals of the jig; and
A jig (core) in which the aligned conductive metal wires and the thin insulating material are bonded in a predetermined order is set in an injection mold, and the aligned conductive metal wires And securing the aligned conductive metal wires from above and below with a plurality of positioning pins attached to the mold for injection molding in order to ensure positional accuracy and prevent deformation of the thin insulating material,
A step of performing insert molding using a predetermined synthetic resin material;
A step of retracting the plurality of positioning pins during the insert molding to create a space and filling with molten resin in order to prevent a hole from being generated at the position of the positioning pin and impairing the waterproof property. Manufacturing method of resin case for electrical connection.   5. The method of manufacturing a resin case for electrical connection according to claim 4, wherein the alignment fixing jig is provided with grooves at predetermined intervals so as to align the conductive metal wires without contacting each other. .   The conductive metal wire set at the top of the plurality of types of conductive metal wires having a predetermined length is not subjected to the bonding step, and is set as a core in the injection mold. 6. The method for producing a resin case for electrical connection according to claim 4, wherein the terminals are aligned only by inserting both terminals one by one into the holes for both terminals of the tool.   The thin insulating material is any one of a thin insulating film, a thin insulating sheet, and a thin insulating paper, and has a thickness in a range of about 10 μm to about 500 μm. The method for manufacturing the resin case for electrical connection according to claim 1 or the resin case for electrical connection according to any one of claims 4 to 6.

Images