JP2010140805A - Fuse unit and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fuse unit simple in structure and simple in manufacturing process, and its manufacturing method. <P>SOLUTION: The fuse unit includes a fuse element 1 which is bent at the bending portion 2 between a first plate 3 and a second plate portion 4 and a resin coated portion 20 which is composed of a first resin layer 21 formed by first insert molding at the first plate 3 and a second resin layer 22 formed by second insert molding at the second plate 4 and the bent portion 2 making the outside of the first resin layer 21 as an inflow face of the molten resin, and in which the first resin layer 21 and the second resin layer 22 are integrated by fused junction. The fuse element 1 is manufactured by a punching process and a bending process bent at the bending portion 2 between the first plate 3 and the second plate 4, and the resin coated portion 20 is manufactured by forming the first resin layer 21 by the first insert molding at the first plate 3, and making the outer face of the first resin layer 21 as an inflow face of the molten resin, forming the second resin layer 22 by the second insert molding at the second plate 4 and the bent portion 2. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a fuse unit in which a fuse element is bent, and a resin unit is provided on the outside of the bent fuse element by insert molding, and a manufacturing method thereof.

  For example, a fuse unit directly attached to a battery mounted on a vehicle has a shape bent at a substantially right angle in consideration of an installation space and the like, and there is one disclosed in Patent Document 1 as this type of conventional fuse unit. .

  As shown in FIGS. 7A and 7B, the fuse unit 100 of Patent Document 1 is directly attached to the battery 140, and is a bent portion between the first plate portion 102 and the second plate portion 103. The fuse element 104 bent at 101, the first resin layer 110 provided by insert molding on the outside of the first plate portion 102 of the fuse element 104, and the insert molding on the outside of the second plate portion 103 of the fuse element 104 The second resin layer 120 is provided. The fuse element 104 has a fusible portion 105, a tab terminal 106, and a plurality of bolt insertion holes 107. A stud bolt 108 for connection is fixed to one bolt insertion hole 107. Inclined surfaces 110a and 120a are formed on the surfaces of the first resin layer 110 and the second resin layer 120 facing each other, and both the inclined surfaces 110a and 120a are abutted. Further, in the vicinity of the inclined surfaces 110a and 120a of the first resin layer 110 and the second resin layer 120, a locking means 130 including a locking portion and a locked portion is provided. The resin layer 110 and the second resin layer 120 are fixed in a substantially right angle state.

Next, a method for manufacturing the fuse unit 100 having the above configuration will be briefly described. As shown in FIGS. 8A and 8B, first, a fuse element 104 having a flat shape and a bent portion 101 which is bent later is manufactured by punching a conductive metal plate material. Next, the first resin layer 110 is formed by insert molding outside the first plate portion 102 of the fuse element 104 while maintaining the flat shape. Next, the second resin layer 120 is formed on the outside of the second plate portion 103 of the fuse element 104 by insert molding. Next, the fuse element 104 is bent at a substantially right angle by the bent portion 101. In this bending process, the inclined surfaces 110 a and 120 a of both the first resin layer 110 and the second resin layer 120 are brought into contact with each other, and the first resin layer 110 and the second resin layer 120 are locked by the locking means 130. As a result, the fuse unit 100 bent at a substantially right angle is produced.
JP 2001-297683 A

  However, in the conventional fuse unit 100, since the fuse element 104 is bent after the first resin layer 110 and the second resin layer 120 are formed on the fuse element 104, the first resin is used to maintain the bent state of the fuse element 104. It is necessary to provide the locking means 130 on the layer 110 and the second resin layer 120, and there is a problem that the configuration becomes complicated.

  Further, it is necessary to bend the fuse element 104 after forming the insert, which causes a problem that the manufacturing process becomes complicated.

  Accordingly, the present invention has been made to solve the above-described problems, and an object of the present invention is to provide a fuse unit that has a simple configuration and that can simplify the manufacturing process, and a manufacturing method thereof.

The invention of claim 1 is a fuse element bent at a bent portion between the first plate portion and the second plate portion,
A first resin layer provided by first insert molding on the outside of the first plate portion of the fuse element, and an outer surface of the first resin layer as an inflow surface of the molten resin, and the second plate portion of the fuse element And a second resin layer provided by second insert molding on the outer side of the bent portion, and the first resin layer and the second resin layer are integrated by fusion bonding. It is a fuse unit characterized by this.

  According to a second aspect of the present invention, a fuse element having a first plate portion and a second plate portion with a bent portion as a boundary by punching and bending is produced, and then the fuse element is formed. A first resin layer is produced by first insert molding on the outside of the first plate portion of the element, and then the outer surface of the first resin layer is used as an inflow surface of the molten resin, and the second plate portion of the fuse element And a second resin layer is formed on the outside of the bent portion by second insert molding, and the first resin layer and the second resin layer are integrated by fusion bonding to produce a resin coating portion. This is a method for manufacturing a fuse unit.

  Invention of Claim 3 is a manufacturing method of the fuse unit of Claim 2, Comprising: As for the metal mold | die of said 1st insert molding, the fuse element set inside is in the part which protrudes outside the said metal mold | die, A method for manufacturing a fuse unit is characterized in that a fuse unit having a burr cut portion is used.

  According to the first and second aspects of the invention, the first resin layer and the second resin layer are formed on the outer surface of the fuse element that has been bent in advance, and the first resin layer and the second resin layer are melt-bonded. Therefore, there is no need for a locking means for maintaining the bent state of the fuse element. Also, punching and bending of conductive plate material can be performed at the same time. When producing a fuse element from a conductive plate material, if the bending process is performed simultaneously with the punching process, the fuse element is bent after insert molding. There is no need to process.

  From the above, the structure is simplified because there is no need for a locking means for maintaining the bent state of the fuse element, and since the bending process can be performed simultaneously with the punching process performed when the fuse element is manufactured, The manufacturing process can also be simplified.

  According to the invention of claim 3, when the first resin layer is formed only on the first plate portion side which is a part of the fuse element, the portion in which the fuse element set in the mold protrudes outside the mold If there is a burr in the mold, the burr is removed by the burr cutting part of the mold, so the first resin layer is applied to the first plate part that is a part of the fuse element without performing the burr processing operation. Can be reliably formed. Therefore, it contributes to simplification of the manufacturing process.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  1 to 6 show an embodiment of the present invention. FIG. 1A is a perspective view of a fuse unit A, FIG. 1B is a sectional view of the fuse unit A, and FIG. 3 is a perspective view for explaining the first insert molding using the first mold 30, FIG. 4 is a sectional view showing a state in which the fuse element 1 is set in the first mold 30, and FIG. 5 is the first insert molding. FIG. 6 is a perspective view for explaining the second insert molding using the second mold 40. FIG.

  As shown in FIGS. 1A and 1B, the fuse unit A is directly attached to a battery (not shown) mounted on a vehicle, and covers the fuse element 1 and the outside of the fuse element 1. And a resin coating portion 20 provided on the surface.

  As shown in detail in FIG. 2, the fuse element 1 is a bus bar formed of a conductive plate material, and has a first plate portion 3 and a second plate portion 4 with the bent portion 2 as a boundary. It is bent at a right angle. The 1st board part 3 is comprised from the 1st board piece 3a and the 2nd board piece 3b which were connected through the connection part 3c, and the two bolt insertion holes 5a and 5b are formed in the 1st board piece 3a. . A soluble portion 6 and one bolt insertion hole 7 are formed in the second plate piece 3b. A stud bolt 8 fixed by a first resin layer 21 described below is inserted into one bolt insertion hole 5a of the first plate piece 3a, and the starter motor side connection terminal (see FIG. Not shown) is connected. A battery-side connection terminal (not shown) is connected using another bolt insertion hole 5b of the first plate piece 3a. A stud bolt 9 fixed by a first resin layer 21 described below is inserted into the bolt insertion hole 7 of the second plate piece 3b, and an alternator-side connection terminal (not shown) is used by using the stud bolt 9. Is connected.

  The second plate portion 4 is provided with four sets of soluble portions 10 and tab terminals 11 in parallel. Two sets of the fusible part 10 and the tab terminal 11 are provided on the first plate piece 3 a of the first plate part 3, and the other two sets of the soluble part 10 and the tab terminal 11 are provided on the second plate of the first plate part 3. Each piece is connected to the piece 3b.

  As shown in FIGS. 1A and 1B, the resin coating portion 20 includes a first resin layer 21 provided by first insert molding on the outside of the first plate portion 3 of the fuse element 1, and the fuse element 1. The second resin layer 22 is provided outside the second plate portion 3 and the bent portion 3c by second insert molding, and the first resin layer 21 and the second resin layer 22 are integrated by fusion bonding. . For convenience of explanation, in the drawings, the boundary between the first resin layer 21 and the second resin layer 22 is indicated by an imaginary line, and the first resin layer 21 and the second resin layer 22 are denoted by reference numerals.

  The first resin layer 21 has openings 23, 24, 25, 26 around each of the boil insertion holes 5 a, 5 b, 7 and around the soluble part 6. The openings 23, 24, and 25 around the bolt insertion holes 5 a, 5 b, and 7 are for enabling connection of mating terminals (not shown), and the openings 26 around the fusible part 6 are This is because the presence or absence of fusing of the soluble part 6 can be confirmed visually.

  The second resin layer 22 has an opening 27 around each soluble portion 10 and a terminal insertion hole 28 that exposes all the tab terminals 11. The opening 27 around each soluble portion 10 is for visual confirmation in the same manner as described above. The terminal insertion hole 28 for exposing the tab terminal 11 is for fitting a mating terminal (not shown).

  Next, the manufacturing procedure of the fuse unit A will be described. As shown in FIG. 2, first, a fuse plate 1 having a first plate portion 3 and a second plate portion 4 is produced by performing punching (die cutting) processing and bending processing on a conductive plate material at the same time. To do.

  Next, as shown in FIGS. 3 and 4, bolts 8 and 9 are inserted into the two bolt insertion holes 5 a and 7 of the first plate portion 3 of the fuse element 1, and the first plate of the fuse element 1 is also inserted. The first mold 30 is set in the part 3. That is, the first mold 30 has a lower mold part 31 and an upper mold part 32, and the first plate part 3 of the fuse element 1 is interposed between the lower mold part 31 and the upper mold part 32. Set with pinch. In this set state, the first injection chamber 33 is formed inside the first mold 30. Further, the lower mold part 31 and the upper mold part 32 of the first mold 30 have burr cutting parts 34 and 35 at the part where the fuse element 1 set inside projects from the mold 30. . Thereby, when a burr exists in the part corresponding to the burr cut parts 34 and 35, the burr is deleted and the 1st plate part 3 is set to the 1st metallic mold 30 without a gap.

  After setting the fuse element 1 in the first mold 30, molten resin is injected into the first injection chamber 33, and the first resin layer 21 is produced by first insert molding outside the first plate portion 3 of the fuse element 1. To do. Thereby, the intermediate insert body B shown in FIG. 5 is made.

  Next, as shown in FIG. 6, two sliders 43 are inserted into the four tab terminals 11 of the intermediate insert B, and the second mold 40 is set on the second plate portion 4 side of the fuse element 1. That is, the second mold 40 includes a lower mold part 41 and an upper mold part 42, and the second plate part 4 of the fuse element 1 is interposed between the lower mold part 41 and the upper mold part 42. Set with pinch. In this set state, a second injection chamber (not shown) is formed inside the second mold 40. In the second injection chamber, the outer surface of the first resin layer 21 is used as a molten resin inflow surface. After the intermediate insert body B is set in the second mold 40, molten resin is injected into the second injection chamber, and the second resin is formed outside the second plate portion 4 and the bent portion 2 of the fuse element 1 by second insert molding. Layer 22 is produced.

  When the second resin layer 22 is produced, the first resin layer 21 and the second resin layer 22 are integrated by fusion bonding to produce the resin coating portion 20. This completes the manufacture.

  As described above, the first resin layer 21 and the second resin layer 22 are formed on the outer surface of the fuse element 1 that has been bent in advance, and the first resin layer 21 and the second resin layer 22 are fused and integrated. Therefore, the locking means for maintaining the bent state of the fuse element 1 is not necessary. Moreover, the punching process and the bending process of the conductive plate material can be performed simultaneously. When the fuse element 1 is manufactured from the conductive plate material, if the bending process is performed simultaneously with the punching process, the fuse element 1 is formed after the insert molding. There is no need to perform the bending process. As described above, since the locking means for holding the bent state of the fuse element 1 is not required, the configuration is simplified, and the bending process can be performed simultaneously with the punching process when the fuse element 1 is manufactured. The manufacturing process can be simplified.

  As the first mold 30 of the first insert molding, a fuse element 1 set inside has a burr cutting part 34, 35 at a part where the fuse element 1 protrudes outside the first mold 30. Accordingly, when the first resin layer 21 is formed only on the first plate portion 3 side that is a part of the fuse element 1, the fuse element 1 set in the first mold 30 is placed outside the first mold 30. If burrs are present in the protruding portion, the burrs are deleted by the burr cutting portions 34 and 35 of the first mold 30, so that they are part of the fuse element 1 without performing the burr processing operation. The first resin layer 21 can be reliably formed on the first plate portion 3. Therefore, it contributes to simplification of the manufacturing process.

1A and 1B show an embodiment of the present invention, in which FIG. 1A is a perspective view of a fuse unit, and FIG. 1 is a perspective view of a fuse element according to an embodiment of the present invention. It is a perspective view which shows one Embodiment of this invention and demonstrates the 1st insert molding using a 1st metal mold | die. It is sectional drawing which shows one Embodiment of this invention and shows the state which set the fuse element to the 1st metal mold | die. It is a perspective view of the intermediate insert body which showed one Embodiment of this invention and was produced by 1st insert molding. It is a perspective view which shows one Embodiment of this invention and demonstrates the 2nd insert molding using a 2nd metal mold | die. A prior art example is shown, (a) is a plan view of a fuse unit, and (b) is a front view of the fuse unit. A prior art example is shown, (a) is a plan view of a fuse element, and (b) is a front view of the fuse element. A conventional example is shown, (a) is a plan view in which a first resin layer and a second resin layer are molded on a fuse element, and (b) is a front view in which a first resin layer and a second resin layer are molded on a fuse element. .

Explanation of symbols

A fuse unit 1 fuse element 2 bent portion 3 first plate portion 4 second plate portion 20 resin coating portion 21 first resin layer 22 second resin layer 30 first mold (die)
34, 35 Burr cutting part

Claims (3)

A fuse element bent at a bent portion between the first plate portion and the second plate portion;
A first resin layer provided by first insert molding on the outside of the first plate portion of the fuse element, and an outer surface of the first resin layer as an inflow surface of the molten resin, and the second plate portion of the fuse element And a second resin layer provided by second insert molding on the outer side of the bent portion, and the first resin layer and the second resin layer are integrated by fusion bonding. Fuse unit characterized by By punching and bending, a fuse element that has a first plate portion and a second plate portion with the bent portion as a boundary, and is bent at the bent portion,
Next, a first resin layer is produced by first insert molding outside the first plate portion of the fuse element,
Next, an outer surface of the first resin layer is used as a molten resin inflow surface, and a second resin layer is formed by second insert molding outside the second plate portion and the bent portion of the fuse element,
A method of manufacturing a fuse unit, characterized in that a resin coating portion is produced by integrating the first resin layer and the second resin layer by fusion bonding. A method for manufacturing a fuse unit according to claim 2,
The method of manufacturing a fuse unit, wherein the first insert-molding die has a burr cutting portion at a portion where a fuse element set inside projects from the die.

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