JP2011004534A - Electrical junction box - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electrical junction box in which yield of a metal material is improved, which matches with an increase in density of circuit wiring and includes a bus bar circuit of a new structure.SOLUTION: The bus bar circuit 26 having a circuit part 30 formed by punching a metallic bar and a connection terminal part 32 obtained by bending an end of the circuit part 30 and integrally forming it and a wire circuit 28 having a circuit part 34 formed by bending a metallic angular wire and connection terminal parts 36 and 38 obtained by bending an end of the circuit part 34 and integrally forming it are placed on an insulating board 18 in the circuit parts 30 and 34. The connection terminal parts 32, 36 and 38 are protrusively installed on the insulating board 18.

Description

  The present invention relates to an electrical junction box mounted on an automobile or the like, and more particularly to an electrical junction box provided with a bus bar circuit.

  2. Description of the Related Art Conventionally, an electric connection box such as a junction box used for automobile wiring or the like has a built-in circuit in which a plurality of bus bars are mounted on an insulating plate. The bus bar is generally formed by punching a strip made of a copper alloy into an arbitrary circuit shape. Since such a bus bar has a large surface area and an excellent heat dissipation effect, it is particularly preferred as a power distribution circuit. In addition, since a tab-like terminal can be integrally formed by bending a part of the bus bar, it is excellent in that it is easy to manufacture as a wiring material.

  By the way, in the electrical junction box, the number of circuits accommodated in the electrical junction box is rapidly increasing with the recent rapid increase in automobile electrical components. Moreover, in addition to the increase in the number of accommodating circuits, further downsizing is required, so that it is necessary to realize a higher-density circuit arrangement in the electrical junction box.

  However, it has been difficult to meet the demand for higher circuit wiring density with only a conventional bus bar circuit. This is because the bus bar is formed by press punching integrally with the tab-shaped terminal, but the tab-shaped terminal is punched out in a developed shape, so that the tab-shaped terminals overlap in one layer, making it optimal for circuit wiring In some cases, the tab-shaped terminal cannot be provided at the position (cannot be punched out). In this case, the number of bus bars is increased and tab terminals are provided on another bus bar layer. However, the increase in the bus bar layer leads to an increase in the size and weight of the electrical connection box.

  In addition, since the bus bar is formed by press stamping a metal strip, there is a limit to the setting of the minimum cross-sectional area. It becomes. In addition, when a relatively thin bus bar corresponding to the electric capacity is adopted, there is a possibility that the yield of the metal material accompanying the press punching process, which was originally bad, may be further deteriorated.

  In JP-A-2000-92660 (Patent Document 1), in addition to a bus bar circuit, a single-core wiring circuit covered with an insulating material is used in combination to increase the density of circuit wiring. Has also been proposed. However, the single core wire needs to be fixed, or the internal core wire needs to be exposed from the covering material and fixed to the press contact terminal or the conductive path, which is troublesome.

JP 2000-92660 A

  The present invention has been made in the background of the above-mentioned circumstances, and its solution problem is a novel configuration in which the yield of the metal material is improved and the circuit wiring can be increased in density. It is an object of the present invention to provide an electric junction box having a bus bar circuit.

A first aspect of the present invention is an electrical junction box, which is integrally formed by bending a circuit portion formed by punching a metal strip and an end portion of the circuit portion. A bus bar circuit having a connection terminal portion; a circuit portion formed by cutting a metal rectangular wire; and a connection terminal portion integrally formed by bending an end portion of the circuit portion. A wire rod circuit; and an insulating plate on which the bus bar circuit and the circuit portions of the wire rod circuit are mounted and mounted so that the bus bar circuit and the connection terminal portions of the wire rod circuit protrude Features.
, Feature.

  According to the present invention, a circuit can be configured by appropriately using a bus bar circuit and a wire material circuit according to required conductivity, spring property, cost, and the like. Thus, for example, by using a wire circuit circuit that can be obtained only by cutting a rectangular wire material in a low-power conductive path, unnecessary material parts such as press punching from a strip material can be reduced. Thus, the yield of the metal material can be remarkably improved. Furthermore, the number of molds for punching strips can be reduced, and the manufacturing cost can be greatly reduced. On the other hand, the conventional conductivity can be ensured by using a bus bar circuit for the high power conductive path.

  In addition, a wire circuit made of a rectangular wire can be formed with a very small cross-sectional area such as a 0.64 mm square, so that high-density wiring with a narrow pitch is possible. Further, since the wire material circuit has a rectangular cross-sectional shape, it can be kept at a desired circuit formation position only by being placed on the insulating plate in the same manner as the strip material press circuit. As a result, it can be easily routed to a desired position without the need for fixing means to an insulating plate such as a single core wire, reducing the number of parts, simplifying the work process, and preventing erroneous wiring. Can be planned.

  In addition, in the wire material circuit, the connection terminal portion can be formed integrally simply by bending. This eliminates the need for assembling the press contact terminals and the like as in the case of a single core wire, and further reduces the number of parts and simplifies the process.

  According to a second aspect of the present invention, in the first aspect, the printed circuit board is disposed opposite to at least one surface of the insulating plate, and the wire circuit protrudes on the insulating plate. The connection terminal portion is projected to the printed circuit board side.

  According to the 2nd aspect, it can use as a terminal for a board | substrate only by making the connection terminal part of a wire circuit circuit protrude in the printed circuit board side. As a result, it is possible to eliminate both the pressure contact terminal and the board terminal that are required in the case of a single core wire, and further simplify the number of parts. Also, it is possible to connect the connection terminal part of the wire material circuit through the through hole of the printed circuit board and directly solder it, so that the manufacturing process can be further simplified and the connection stability can be improved. . In addition, it is possible to use the wire material circuit in the same manner as a so-called jumper wire by projecting both connection terminal portions of the wire material circuit from the printed board and connecting conductive paths such as printed wiring to the both connection terminal portions. . As a result, since a relatively large current circuit that has been conventionally wired in a printed circuit board can be configured with a wire material circuit, there is no need to use an expensive thick copper substrate, and an inexpensive substrate can be used, Further cost improvement is achieved.

  According to a third aspect of the present invention, in the device according to the second aspect, the connection terminal portion of the wire circuit projecting toward the printed circuit board is electrically connected to a conductive path of the printed circuit board. In addition, the conductive path is branched.

  According to the third aspect, for example, by connecting the connecting terminal portion of another wire rod circuit to the branch destination of the conductive path, the wire rod circuit configured as a one-to-one single circuit connected at both ends is branched at the conductive path. The branch circuit can be formed using the wire material circuit. Moreover, the connection terminal part of another wire rod circuit or a bus-bar circuit can be connected to the branch destination of the conductive path, or an electrical component can be connected. Thereby, the further improvement of a circuit routing freedom can be aimed at and more circuits can be comprised with a wire material circuit.

  According to a fourth aspect of the present invention, in the one according to any one of the first to third aspects, the square wire forming the wire circuit is a square wire having a constant square cross section. Is. According to the 4th aspect, it can bend in any direction by a square cross section, there is no directionality at the time of a bending, and a more free circuit arrangement | positioning on an insulating board is attained.

  According to a fifth aspect of the present invention, in any one of the first to fourth aspects, the wire rod circuit has a forging pressure portion that is partially flattened by pressing, and in the forging pressure portion, The connecting terminal portion is formed by bending.

  According to the fifth aspect, it is possible to form a tab-like terminal according to the required width dimension regardless of the cross-sectional dimension of the circuit portion. And even if the bending part is composed of a forging pressure part that has been flattened in advance, the strength of the bending part is improved, and even when a fitting force is applied when fitting with the terminal part of another member. The terminal can be held stably. Thereby, the deformation | transformation of a terminal etc. can be prevented and the fitting stability of a connection terminal can be ensured.

  According to the present invention, it is possible to use a bus bar circuit made of a strip material and a wire material circuit made of a rectangular wire material, depending on required conductivity, springiness, and the like. As a result, the yield of the metal material can be improved and the circuit wiring can be made denser.

The disassembled perspective view of the electrical-connection box as one Embodiment of this invention. The top view which shows the lamination | stacking state of the insulation board, bus-bar circuit, wire material circuit, and printed circuit board which comprise the electrical-connection box shown in FIG. III-III sectional drawing in FIG. The top view of a wire rod circuit. The principal part expansion perspective view of the wire circuit. Explanatory drawing for demonstrating the branch structure using a wire circuit.

  Embodiments of the present invention will be described below with reference to the drawings.

  First, FIG. 1 shows a junction box 10 according to an electrical junction box as one embodiment of the present invention. The junction box 10 has a structure in which an insulating plate 18, an energizing circuit 20 arranged on the insulating plate 18, and a printed circuit board 22 are accommodated in a case 16 constituted by an upper case 12 and a lower case 14. Yes.

  The upper case 12 and the lower case 14 are fitted to each other by a locking mechanism or the like (not shown). Although detailed illustration is omitted, each of the upper case 12 and the lower case 14 accommodates tab-like terminals 32 and 36 and pin-like terminals 38, which will be described later, protruding from the energizing circuit 20, respectively, and connectors, fusible links, etc. The terminal accommodating part 24 which connects with these terminals 32, 36, 38 in the accommodation state is formed in an opening.

  2 and 3 show the laminated state of the insulating plate 18, the energization circuit 20, and the printed circuit board 22. FIG. The energization circuit 20 includes a bus bar circuit 26 and a wire material circuit 28. The bus bar circuit 26 is formed by press-punching a metal strip such as a copper alloy having conductivity using a die to form a circuit portion 30 having a desired routing shape. After the punching is completed, the end of the circuit unit 30 is bent perpendicularly to the circuit unit 30 using an appropriate jig or the like, so that the flat tab-shaped terminal 32 as the connection terminal unit is connected to the circuit. It is integrally formed with the part 30.

  On the other hand, the wire rod circuit 28 is formed by cutting a rectangular wire rod with an appropriate length. As the rectangular wire, a metal such as a brass plating material having conductivity is adopted, and a rectangular cross-sectional shape, preferably a square cross-sectional shape, is preferably used. In the present embodiment, any of the wire circuits 28 is formed from a rectangular wire having a constant square cross section. Then, the rectangular wire cut out to an appropriate length is bent into a desired wiring shape using an appropriate jig or the like, thereby forming a circuit portion 34 having a cross-sectional shape of the rectangular wire as it is. Has been.

  Note that the rectangular wire used as the wire circuit 28 is not limited to one type, and in consideration of required conductivity, terminal width dimensions, etc., a plurality of types of rectangular wires having different cross-sectional areas are used. It may be used. As is apparent from FIG. 2, in this embodiment, the wire material circuit 28b provided with the pin-shaped terminals 38, which will be described later, is formed of a rectangular wire material having a cross-sectional area of 0.64 mm square as an example. However, each of the two wire rod circuits 28a provided with the tab-like terminals 36 is formed of a square wire rod having a larger cross-sectional area than the wire rod rod 28b, and the cross-sectional area of the two wire rod circuits 28a is They are different from each other.

  Further, both end portions of the circuit portion 34 are bent perpendicularly to the circuit portion 34 using an appropriate jig or the like, so that the connection terminal portions are integrally formed. In this embodiment, a wire rod circuit 28a having a flat tab-like terminal 36 having a width dimension wider than that of the circuit portion 34 as a connection terminal portion, and a pin-like terminal having a cross-sectional area equal to that of the circuit portion 34 as a connection terminal portion. Two types of wire rod circuit 28b having 38 are used.

  4 and 5 show a wire material circuit 28a having a tab-like terminal 36. FIG. The wire material circuit 28a is pressed by pressing a die once or a plurality of times from both sides in the direction perpendicular to the axis to one or both ends of the circuit portion 34. Thereby, the flat forging pressure part 40 is formed at the end of the circuit part 34. The forging pressure portion 40 has a flat cross-sectional shape having a width dimension (the vertical dimension in FIG. 4) larger than that of the circuit portion 34 and a thickness dimension smaller than that of the circuit portion 34, and the lower surface 42 of the forging pressure portion 40. Is formed on the same plane as the lower surface 44 of the circuit portion 34. Then, the forging pressure portion 40 is bent perpendicularly to the circuit portion 34 with an appropriate jig or the like, so that a tab-like terminal 36 having a flat cross-sectional shape equal to that of the forging pressure portion 40 is formed. When bending the forging portion 40, the forging portion 40 has a flat shape. Therefore, it is possible to stably maintain the contact state with the jig and suppress the rotation of the wire rod circuit 28a during the bending operation. It is possible to perform the bending process stably.

  On the other hand, in the wire material circuit 28b having the pin-shaped terminals 38, one or both ends of the circuit part 34 are bent perpendicularly to the circuit part 34 with an appropriate jig or the like, so that the circuit part 34 A pin-like terminal 38 having the same cross-sectional shape is formed.

  The tip portions of the tab-like terminals 32 and 36 and the pin-like terminals 38 of the bus bar circuit 26 and the wire material circuit 28 are all formed into a tapered shape by pressing or cutting.

  The bus bar circuit 26 and the wire rod circuit 28 are placed on the insulating plate 18. The insulating plate 18 has a plate shape made of synthetic resin, and a housing recess 45 that opens in a shape corresponding to the circuit portions 30 and 34 of the bus bar circuit 26 and the wire material circuit 28 is formed on the upper surface thereof. . Then, the circuit portions 30 and 34 of the bus bar circuit 26 and the wire material circuit 28 are respectively placed on the insulating plate 18 in the accommodated state in the accommodating recess 45, whereby the energizing circuit 20 is routed on the insulating plate 18. At the same time, the tab-like terminals 32 and 36 and the pin-like terminal 38 are projected on the insulating plate 18.

  Further, the printed circuit board 22 is disposed opposite to the surface of the insulating plate 18 opposite to the surface on which the circuit units 30 and 34 are placed. On the surface of the printed board 22 opposite to the insulating plate 18, electrical components (not shown) are provided, and a printed wiring 46 is formed as a conductive path electrically connected to the electrical components. 46 is electrically connected to a through hole 48 penetrating the printed circuit board 22. A terminal insertion hole 50 is provided in a portion of the insulating plate 18 that overlaps the through hole 48, and one pin-like terminal 38 of the wire material circuit 28 is connected to the printed board 22 side from the insulating plate 18 through the terminal insertion hole 50. And soldered while being inserted into the through hole 48. Thereby, the circuit part 34 of the wire material circuit 28 is electrically connected to the printed wiring 46 of the printed circuit board 22. Thus, the wire material circuit 28 soldered to the printed circuit board 22 has a pair of pin-shaped terminals 38 protruding in opposite directions.

  And the junction box 10 is comprised by accommodating in the case 16 comprised by the upper case 12 and the lower case 14 in the state which the insulating board 18 in which the electricity supply circuit 20 was mounted, and the printed circuit board 22 were piled up. .

  According to the junction box 10 having such a structure, the energizing circuit 20 on the insulating plate 18 is constituted by the bus bar circuit 26 and the wire material circuit 28. As a result, for example, the bus bar circuit 26 is used for a large current conducting path for power supply or the like, while the wire circuit 28 is used for a small current conducting path such as a signal line, or a flexible spring property is required. While the bus bar circuit 26 is used for the road, the bus bar circuit 26 and the wire circuit 28 are appropriately used according to the required characteristics, such as using the wire circuit 28 for the conductive path that requires a hard spring property. I can do it. Since the wire material circuit 28 can be formed only by bending a rectangular wire material, a special mold is not required, and material portions that are not required for circuit formation can be almost eliminated. Therefore, by forming the circuit portion that can satisfy the required performance with the wire circuit 28 with the wire circuit 28 as much as possible, it is possible to reduce the number of dies required for the punching process of the bus bar circuit 26 and to perform the punching process. Therefore, the yield of the metal material can be reduced, and the manufacturing cost can be reduced.

  Furthermore, it is possible to route the wire material circuit 28 with a small cross-sectional area at a narrow pitch, or to arrange the wire material circuit 28 in a punched portion of the bus bar circuit 26, for example, so that a higher-density wiring is possible. As a result, the number of bus bars stacked can be reduced, and as a result, the junction box 10 can be further reduced in size and weight.

  Furthermore, since the wire material circuit 28 has a square cross section, the wire circuit 28 can be bent in any direction, and the circuit portion 34 having a desired wiring shape can be easily formed. And since the formed wiring shape is maintained, a special fixing means is not required like the case where a single core wire is used. Moreover, since the lower surface 44 is made flat by having a square cross section, it can be easily and stably placed on the insulating plate 18. In particular, in the wire rod circuit 28 a having the tab-like terminal 36, the protruding state of the tab-like terminal 36 from the insulating plate 18 can be more stably maintained by being widened by the forging pressure portion 40. Thereby, even when the fitting force with the terminal portion of the other member is applied to the tab-like terminal 36, the tab-like terminal 36 is stably held, and the tab-like terminal 36 is prevented from being deformed and the like, and the fitting stability. Can be secured.

  In addition, the wire material circuit 28 can easily form the tab-like terminal 36 and the pin-like terminal 38 by bending the end portion, and the end of the press contact terminal or the like required for the single core wire can be obtained. The process of assembling to the part becomes unnecessary, and the manufacturing cost can be further reduced by further reducing the number of parts and simplifying the process.

  Furthermore, a board terminal can be configured by merely projecting the tab-like terminal 36 and the pin-like terminal 38 of the wire material circuit 28 toward the printed board 22 side. As a result, both the press contact terminal and the board terminal that are required in the case of the single core wire can be eliminated, and the number of parts can be further simplified. Further, by electrically connecting the tab-like terminal 36 and the pin-like terminal 38 protruding to the printed board 22 side with the printed wiring 46, the board terminal constituted by the tab-like terminal 36 and the pin-like terminal 38 can be obtained. It can also be electrically connected to electrical components on the printed circuit board 22 via the printed wiring 46.

  Furthermore, since the pin-like terminal 38 of the wire circuit 28 can be inserted into the through hole 48 and directly soldered, the manufacturing process can be further simplified and the connection stability can be further improved. Further, for example, the pin-like terminals 38 at both ends of the wire material circuit 28 are protruded toward the printed circuit board 22 and soldered to the through holes 48, so that the wire material circuit 28 is connected to the printed wiring 46 like a so-called jumper wire. Can be used as part. Thus, for example, when it is necessary to form a high-current conductive path on the printed circuit board 22, instead of the printed wiring 46, the wire circuit 28 is used as a large-current conductive path, thereby increasing the thickness of the printed wiring 46. Meat can be avoided. Thereby, it is not necessary to employ an expensive thick copper substrate, and the manufacturing cost can be further reduced.

  As mentioned above, although embodiment of this invention was explained in full detail, this invention is not limited by the specific description. For example, the wire material circuit 28 has a one-to-one single circuit configuration connected at both ends thereof, but as shown in FIG. 6, the pin-like terminal 38 is inserted into the through hole 48 of the printed circuit board 22 and the printed wiring 46 is inserted. The printed wiring 46 is branched, and the branch destination of the printed wiring 46 is electrically connected to the pin-like terminals 38 of the other wire circuit 28b. It is also possible to realize the circuit configuration. Further, the branch destination of the printed wiring 46 may be connected to the tab-like terminal 32 of the bus bar circuit 26 or other electric circuit mounted on the printed board 22. In this way, the degree of freedom of circuit routing using the wire material circuit 28 can be further improved.

  Moreover, in the said embodiment, although the bus-bar circuit 26 and the wire material circuit 28 were all mounted on the insulating board 18, it is also possible to insert-mold to the insulating board 18, for example. And since both the bus-bar circuit 26 and the wire material circuit 28 have a rod-shaped metal flat plate shape, it is possible to insert-mold simultaneously. If it does in this way, the insulating board 18 and the electricity supply circuit 20 can be handled integrally, and the reduction of the man-hour regarding assembly | attachment and component management will be aimed at.

  Furthermore, in the above-described embodiment, the insulating plate 18 and the energizing circuit 20 are illustrated in a single layered state, but the insulating plate 18 and the energizing circuit 20 are alternately arranged as in the conventional multi-layer bus bar laminate. Of course, a plurality of laminated structures are possible. In this way, the energization circuit 20 can be stably held between the insulating plates 18 to be laminated.

  Further, in the wire material circuit 28, a tab-like terminal 36 may be formed at one of both ends, and a pin-like terminal 38 may be formed at the other. Furthermore, a plurality of wire rod circuits 28 may be directly connected to each other. In order to directly connect the wire material circuit 28, resistance welding, cold welding, or the like can be employed.

  Furthermore, the bus bar circuit 26 and the wire material circuit 28 are not necessarily formed independently of each other. For example, the bus bar circuit 26 and the wire material circuit 28 are electrically or physically connected to form a circuit. You may do it.

10: Junction box (electrical connection box), 18: Insulating plate, 22: Printed circuit board, 26: Bus bar circuit, 28: Wire material circuit, 30: Circuit part, 32: Tab-shaped terminal (connection terminal part), 34: Circuit part , 36: tab-like terminal (connection terminal part), 38: pin-like terminal (connection terminal part), 40: forging pressure part, 46: printed wiring (conductive path)

Claims (5)

A bus bar circuit having a circuit portion formed by punching a metal strip, and a connection terminal portion integrally formed by bending an end portion of the circuit portion;
A wire circuit having a circuit portion formed by cutting a metal square wire, and a connection terminal portion integrally formed by bending an end portion of the circuit portion;
The bus bar circuit and the wire part circuit are mounted on the circuit parts, and the bus bar circuit and an insulating plate mounted in a state where the connection terminal parts of the wire circuit protrude. Connection box.   The printed circuit board is disposed opposite to at least one surface of the insulating plate, and the connection terminal portion of the wire circuit protruding on the insulating plate protrudes toward the printed circuit board. The electrical junction box described.   The electrical connection box according to claim 2, wherein the connection terminal portion of the wire circuit projecting toward the printed circuit board is electrically connected to a conductive path of the printed circuit board, and the conductive path is branched. .   The electrical junction box according to any one of claims 1 to 3, wherein the square wire forming the wire circuit is a square wire having a constant square cross section.   The wire rod circuit has a forging pressure portion that is partially flattened by pressing, and the connection terminal portion is formed by bending at the forging pressure portion. The electrical junction box described in the section.

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