JP2010153135A - Fuse unit and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fuse unit having a strong retaining force for retaining a bending condition. <P>SOLUTION: The fuse element A includes a fuse element 1 made of a conductive metal material which is bent at a bending portion 2 between a first plate part 3 and a second plate part 4, a first resin layer 21 installed by a first insert molding at the outside of the first plate part 3 of the fuse element 1, and a second resin layer 22 installed by a second insert molding at the outside of the second plate part 4 of the fuse element 1. The fuse element includes a first wing portion 12 which extends from the first plate part 3 and projects from the first resin layer 21 and a second wing portion 13 which extends from the second plate part 4 and projects from the second resin layer 22, and the first wing portion 12 and the second wing portion 13 are joined by welding or the like. <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 layer is provided on the outside of the bent fuse element by insert molding and a method for manufacturing the same.

  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 FIG. 9, the fuse unit 100 of Patent Document 1 is directly attached to a battery (not shown), and is bent at a bent portion 101 between the first plate portion 102 and the second plate portion 103. The fuse element 104, 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 resin molding on the outside of the second plate portion 103 of the fuse element 104. And a second resin layer 120. The fuse element 104 has a fusible portion 105, a tab terminal 106, and a plurality of bolt insertion holes 107. Connecting bolts (not shown) for connection are fixed to the two bolt insertion holes 107. The second resin layer 120 is provided with a regulation wall 121, and the regulation wall 121 and the bottom surface 110 a of the first resin layer 110 are abutted against each other. Further, the first resin layer 110 and the second resin layer 120 are provided with a first locking means 130 and a second locking means 131, and the fuse element 104 and consequently the fuse unit 100 are in a substantially right angle state by the locking means 130 and 131. Is held by.

Next, a method for manufacturing the fuse unit 100 having the above configuration will be briefly described. First, a fuse element 104 having a flat shape and a bent portion 101 to be bent later is manufactured by punching a conductive metal plate. 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 outer side of the second plate portion 103 of the fuse element 104 by insert molding (state of FIG. 10). Next, the fuse element 104 is bent at a substantially right angle by the bent portion 101. During this bending process, the bottom surface 110a of the first resin layer 110 and the regulation wall 121 of the second resin layer 120 are brought into contact with each other, and between the first resin layer 110 and the second resin layer 120, the first lock means 130 and the second lock Locked by means 131. The fuse unit 100 is held at a substantially right angle by the locking force of the locking means 130 and 131. As described above, the manufacture of the fuse unit 100 shown in FIG. 9 is completed.
JP 2002-329457 A

  However, the conventional fuse unit 100 has a problem that the first locking means 130 and the second locking means 131 are made of resin and are locked by elastic deformation, so that the locking force is weak. If the locking force is weak, lock breakage or unlocking is likely to occur due to vehicle vibration, load due to bending of the electric wire, load during work, and the like.

  Therefore, the present invention has been made to solve the above-described problems, and an object thereof is to provide a fuse unit having a strong holding force for holding a bent state and a method for manufacturing the same.

  According to a first aspect of the present invention, there is provided a fuse element made of a conductive metal material bent at a bent portion between a first plate portion and a second plate portion, and provided outside the first plate portion of the fuse element by insert molding. A fuse unit comprising: a first resin layer formed; and a second resin layer provided by insert molding on the outside of the second plate portion of the fuse element, wherein the fuse element includes the first plate A first blade portion extending from the first resin layer and projecting from the first resin layer is provided, and a second blade portion extending from the second plate portion and projecting from the second resin layer is provided. A fuse unit in which one blade portion and the second blade portion are joined.

  A second aspect of the present invention is the fuse unit according to the first aspect, wherein the first blade portion and the second blade portion are joined by welding.

  The invention according to claim 3 has a first plate portion and a second plate portion with a bent portion bent in a later step as a boundary, and the first blade portion and the second plate portion from the first plate portion and the second plate portion. A fuse element made of a conductive metal material with blades extending from each other is manufactured, and then formed by first insert molding on the outside of the first plate part of the fuse element, so that the first blade part is exposed. A first resin layer, and a second resin layer formed by insert molding on the outer side of the second plate portion of the fuse element to expose the second blade portion. Next, the fuse In the method of manufacturing a fuse unit, a bending process of bending an element at a position of the bent portion is performed, and then a joining step of joining the first blade portion and the second blade portion is performed.

  Invention of Claim 4 is a manufacturing method of the fuse unit of Claim 3, Comprising: The said joining process joins the said 1st blade | wing part and the said 2nd blade | wing part by welding, The fuse unit characterized by the above-mentioned. It is a manufacturing method.

  According to invention of Claim 1 and Claim 3, since the 1st blade | wing part and the 2nd blade | wing part are strong with the same electroconductive metal material as a fuse element, and the thing of a firm material is joined, it is strong. The bent state of the fuse unit is held by the holding force. Therefore, the bending state of the fuse unit does not change due to vehicle vibration, load due to bending of the electric wire, load during work, and the like.

  According to invention of Claim 2 and Claim 4, a 1st blade | wing part and a 2nd blade | wing part can be joined by welding operation.

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

  1 to 8 show an embodiment of the present invention, FIG. 1 is a perspective view of a fuse unit A, FIG. 2 is an enlarged view of arrow a in FIG. 1, FIG. 3 is an enlarged view of a portion b in FIG. Is a plan view of the fuse element 1 before bending, FIG. 5 is a perspective view of the fuse unit A after the first insert molding and the second insert molding, and FIG. 6 is a diagram after the first insert molding and the second insert molding. 7 is a plan view of the fuse unit A, FIG. 7 is a perspective view showing a state in which the fuse element 1 is bent at a substantially right angle, and FIG. 8 is an enlarged side view of a portion c in FIG.

  As shown in FIG. 1, the fuse unit A is directly attached to a battery (not shown) mounted on a vehicle, and is provided so as to cover the fuse element 1 (see FIG. 4) and the outside of the fuse element 1. The first resin layer 21 and the second resin layer 22 are provided.

  As shown in FIG. 4, the fuse element 1 is a bus bar formed of a conductive metal plate, 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 (FIG. 4 is a plan view before bending). 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 one bolt insertion hole 5 is 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 battery-side connection terminal (not shown) and a starter motor-side connection terminal (not shown) are connected using the bolt insertion hole 5 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.

  In addition, a pair of first blade portions 12 are extended in the vicinity of the bent portion 2 of the first plate portion 3 and on both sides thereof. A pair of second blade portions 13 are extended in the vicinity of the bent portion 2 of the second blade portion 4 and on both sides thereof. Each first blade portion 12 and second blade portion 13 protrude from the first resin layer 21 and the second resin layer 22, respectively. The protruding first blade portion 12 and second blade portion 13 are joined by welding (see FIGS. 2 and 3).

  As shown in FIG. 1, the first resin layer 21 is provided on the outside of the first plate portion 3 of the fuse element 1 by first insert molding. The first resin layer 21 has openings 23, 24 (not shown) around each of the boil insertion holes 5, 7 and around the soluble portion 6. The openings 23 and 24 around the bolt insertion holes 5 and 7 are for enabling connection of mating terminals (not shown). An opening (not shown) around the fusible part 6 is for visually confirming whether the fusible part 6 is melted or not, and is covered with a permeable cover 26.

  The second resin layer 22 is provided outside the second plate portion 4 of the fuse element 1 by second insert molding. The second resin layer 22 has an opening (not shown) around each soluble portion 10 and is formed with terminal insertion holes 28 (shown in FIG. 5) that expose all the tab terminals 11. Openings (not shown) around each fusible part 10 are for visual confirmation in the same manner as described above, and are covered with a permeable cover 27. 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. 4, first, a first plate portion 3 and a second plate portion 4 are formed with a bent portion 2 as a boundary by punching (die cutting) processing from a conductive metal plate material that is bent in a later step. Then, the fuse element 1 of the conductive metal plate material in which the first blade portion 12 and the second blade portion 13 are respectively extended from the first plate portion 3 and the second plate portion 4 is manufactured.

  Next, as shown in FIGS. 5 and 6, a bolt 9 is inserted into one bolt insertion hole 7 of the first plate portion 3 of the fuse element 1, and the first plate portion 3 of the fuse element 1 is inserted into the first plate portion 3. 1 Set a mold (not shown). Molten resin is injected into the first mold, and the first resin layer 21 is produced outside the first plate portion 3 of the fuse element 1 by first insert molding. From the 1st resin layer 21, the 1st blade | wing part 12 of both sides protrudes.

  Next, two sliders (not shown) are inserted into the four tab terminals 11 of the second plate portion 4 of the fuse element 1, and a second mold (not shown) is placed on the second plate portion 4 side of the fuse element 1. ) Is set. Molten resin is poured into the second mold, and the second resin layer 22 is produced by second insert molding outside the second plate portion 4 of the fuse element 1. From the 2nd resin layer 22, the 2nd blade | wing part 13 of both sides protrudes.

  The first insert molding and the second insert molding may be performed simultaneously, or the first insert molding may be performed after the second insert molding.

  Next, as shown in FIGS. 7 and 8, a bending process is performed in which the bent portion 2 of the fuse element 1 is bent at a substantially right angle. Thereby, as shown in detail in FIG. 8, the directions of the first blade portion 12 and the second blade portion 13 located on the same side are substantially perpendicular.

  Next, as shown in FIGS. 1 to 3, the first blade portion 12 and the second blade portion protruding from the first resin layer 21 and the second resin layer 22 are bent so that they are in close contact with each other. . And it welds to this contact | adherence location, and the 1st blade | wing part 12 and the 2nd blade | wing part 13 of the same side are joined, respectively. Thus, the manufacture of the fuse unit A shown in FIG. 1 is completed.

  As described above, the first blade portion 12 and the second blade portion 13 are made of the same conductive metal plate material as the fuse element 1 and are made of strong materials that are joined together. The bent state of unit A is maintained. Therefore, the bent state of the fuse unit A does not change due to vehicle vibration, a load caused by bending of the electric wire, a load during work, or the like. In addition, since the first plate portion 3 and the second plate portion 4 are also electrically connected via the first blade portion 12 and the second blade portion 13, the energization cross-sectional area increases accordingly, and the circuit Resistance decreases. Thereby, there is also an advantage that the heat generation of the fuse unit A is suppressed.

  In the above-described embodiment, the first blade portion 12 and the second blade portion 13 are bent so as to be in surface contact with each other and directly welded. However, the first blade portion 12 and the third blade portion 13 are not bent and face both sides. You may weld the connection member and between the 1st blade | wing part 12 and the 2nd blade | wing part 13 using the connection member which contacts.

  Moreover, in the said embodiment, between the 1st blade | wing part 12 and the 2nd blade | wing part 13 was joined by welding, but the joining means may be other joining means, such as ultrasonic joining.

1 is a perspective view of a fuse unit according to an embodiment of the present invention. FIG. 2 shows an embodiment of the present invention, and is an enlarged view taken in the direction of arrow a in FIG. FIG. 3 shows an embodiment of the present invention and is an enlarged view of part b of FIG. 2. FIG. 2 is a plan view of the fuse element according to the embodiment before the fuse element is bent. It is a perspective view of a fuse unit after showing one embodiment of the present invention and performing the first insert molding and the second insert molding. It is a top view of the fuse unit after showing one embodiment of the present invention and performing the first insert molding and the second insert molding. 1 is a perspective view showing a state in which a fuse element 1 is bent at a substantially right angle, showing an embodiment of the present invention. FIG. 8 shows an embodiment of the present invention and is an enlarged side view of a portion c in FIG. 7. It is a perspective view of the fuse unit of a prior art example. It is a top view of the fuse unit before showing a prior art example and bending a fuse element.

Explanation of symbols

A fuse unit 1 fuse element 2 bent portion 3 first plate portion 4 second plate portion 12 first blade portion 13 second blade portion 21 first resin layer 22 second resin layer

Claims (4)

A conductive metal material fuse element bent at a bent portion between the first plate portion and the second plate portion;
A first resin layer provided by insert molding on the outside of the first plate portion of the fuse element;
A fuse unit comprising a second resin layer provided by insert molding outside the second plate portion of the fuse element;
The fuse element is provided with a first blade portion extending from the first plate portion and protruding from the first resin layer, and extending from the second plate portion and protruding from the second resin layer. A fuse unit comprising a second blade portion, wherein the first blade portion and the second blade portion are joined. The fuse unit according to claim 1,
The fuse unit, wherein the first blade portion and the second blade portion are joined by welding. It has a first plate portion and a second plate portion with a bent portion bent in a later step as a boundary, and the first blade portion and the second blade portion are respectively extended from the first plate portion and the second plate portion. A conductive metal material fuse element,
Next, a first resin layer is formed on the outside of the first plate portion of the fuse element by insert molding, and the first blade portion is exposed, and at the outside of the second plate portion of the fuse element. Forming a second resin layer formed by insert molding and exposing the second blade portion;
Next, performing a bending process of bending the fuse element at the position of the bent portion,
Next, the manufacturing method of the fuse unit characterized by performing the joining process which joins the said 1st blade | wing part and the said 2nd blade | wing part. A method of manufacturing a fuse unit according to claim 3,
The said joining process joins the said 1st blade | wing part and the said 2nd blade | wing part by welding, The manufacturing method of the fuse unit characterized by the above-mentioned.

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