JP2017123733A - Electric connection box - Google Patents

Abstract

PROBLEM TO BE SOLVED: To miniaturize an electric connection box.SOLUTION: An electric connection box 10 includes: a coil device 20 including a coil 21 having a terminal portion 23 capable of being connected to the outside and a core 26 of a magnetic substance which are received in a case 33; a circuit board 11A including a bus bar 13; and a mounting surface 41 on which the coil device 20 and the circuit board 11A are mounted. The circuit board 11A is bonded to the mounting surface 41. The bus bar 13 includes a bus bar terminal 14 connected to the terminal portion 23 and bent portions 13A, 13B in the state where a bus bar terminal 14 side is bent. The coil 21 is wound about an axis A1 passing a plane along the mounting surface 41. A filling portion 38 comprising an insulating resin is filled in the case 33.SELECTED DRAWING: Figure 3

Description

  The technology described herein relates to an electrical junction box.

  An electric junction box such as a DC-DC converter is mounted on a vehicle such as an automobile, and a coil is used as a circuit component of the electric junction box. In the electric junction box of Patent Document 1, a frame-shaped member made of synthetic resin is put on the outer peripheral portion of the heat radiating member. The frame-shaped member accommodates the circuit board and is partitioned by the frame-shaped member. A choke coil is arranged in the part.

JP 2014-103747 A

  By the way, since the region where the coil is arranged on the heat dissipation member cannot mount other electronic components, the region for mounting other electronic components must be secured in the electrical junction box. It was not easy to downsize the electrical junction box. In particular, when a coil capable of energizing a large current is mounted on an electrical junction box, there is a problem that the area occupied by the coil increases due to the increase in size of the coil, and the electrical junction box is likely to be enlarged.

  The technology described in the present specification has been completed based on the above-described circumstances, and aims to reduce the size of the electrical junction box.

An electrical junction box described in the present specification includes a coil device in which a coil having a terminal portion connectable to the outside and a magnetic core are housed in a case, a circuit board having a bus bar, the coil device, An electric connection box including a mounting surface on which the circuit board is mounted, wherein the circuit board is bonded to the mounting surface, and the bus bar is a bus bar terminal connected to the terminal portion. And a bent portion in a state where the bus bar terminal side is bent, and the coil is wound around an axis passing through a plane along the mounting surface, and is insulated in the case. A filling portion made of a conductive resin is filled.
According to this configuration, since the coil is wound around an axis passing through a plane along the placement surface, for example, the coil has a coil wound around an axis orthogonal to the plane along the placement surface. Compared to the configuration in which the coil device is placed on the placement surface, the area of the coil device that occupies the placement surface can be reduced. Thereby, since the area | region which the coil apparatus occupied can be utilized for mounting of another electronic component, it becomes possible to reduce an electrical junction box.
Moreover, since the filling part which consists of insulating resin is filled in the case, the noise by the vibration of a coil can be suppressed.
Furthermore, since the bus bar has a bent portion on the bus bar terminal side, vibration can be absorbed by the bent portion as compared with a configuration in which the bus bar terminal side extends in a straight shape. Thereby, since the vibration from the circuit board side etc. can be absorbed in a bending part, the crack of the filling part etc. by vibration on the circuit board side etc. being transmitted to a filling part can be suppressed.

The following embodiments are preferable as the embodiments of the technology described in this specification.
The coil is an edgewise coil wound so that the short side of the rectangular wire is the inner diameter surface.
In this way, the coil can be energized with a large current, and the length of the coil in the axial direction can be shortened. Therefore, the area of the coil device on the mounting surface can be further reduced. Is possible.

The mounting surface is provided on a heat radiating member that dissipates heat of the coil device, and an accommodation recess in which the coil device is accommodated is formed on the mounting surface.
In this way, since the coil device is housed in the housing recess, the area of the heat radiating member that receives heat from the coil device is increased, so that the heat of the coil device can be efficiently transmitted to the heat radiating member. In addition, since the case of the coil device housed in the housing recess is filled with a filling portion made of an insulating resin, the coil can be reliably insulated from the heat radiating member.

One of the case and the receiving recess is provided with a guide groove, and the other of the case and the receiving recess is engaged with the guide groove to guide the insertion direction of the coil device into the receiving recess. Guide ribs are provided.
If it does in this way, it will become possible to perform guidance and positioning of insertion to the accommodation crevice of a coil device by engaging a guide slot and a guide rib.

  According to the technique described in this specification, it is possible to reduce the size of the electrical junction box.

The top view which abbreviate | omits and shows a part of electrical junction box of Embodiment 1 AA sectional view of FIG. BB sectional view of FIG. Perspective view showing coil device Plan view showing coil device Front view showing the coil device CC sectional view of FIG. DD sectional view of FIG. DD sectional view of FIG.

<Embodiment 1>
The electrical junction box 10 of Embodiment 1 is demonstrated with reference to FIGS.
The electrical connection box 10 of the present embodiment is arranged in a power supply path between a power source such as a battery of a vehicle such as an electric vehicle or a hybrid vehicle and a load composed of an on-vehicle electrical component such as a lamp or a wiper or a motor. For example, it can be used for a DC-DC converter or an inverter. In the following description, the X direction is right, the Y direction is front, and the Z direction is upward.

(Electric junction box 10)
As shown in FIG. 3, the electrical junction box 10 includes a circuit body 11 on which electronic components (not shown) are mounted, a coil device 20, a heat radiating member 40 that radiates heat from the circuit body 11 and the coil device 20, and And a cover 60 that covers the upper side of the heat radiating member 40.
(Cover 60)
The cover 60 has a box shape with an opening on the lower side, and is fixed to the heat radiating member 40 with screws (not shown).

(Circuit body 11)
The circuit body 11 includes a circuit board 11A and electronic components mounted on the circuit board 11A. 11 A of circuit boards are adhere | attached on the mounting surface 41 of the heat radiating member 40, and are provided with the printed circuit board 12 and the bus-bar 13 piled up on the printed circuit board 12. FIG. In the printed board 12, a conductive path (not shown) made of copper foil is formed on an insulating plate made of an insulating material by a printed wiring technique. The bus bar 13 is formed by punching a metal plate material such as copper or copper alloy into a shape corresponding to the conductive path. The end portion of the bus bar 13 extends to the outside of the peripheral edge of the printed circuit board 12, and the first bent portion 13A (an example of the “bent portion”) and the second bent portion 13B (“bend portion”) are bent at substantially right angles. And an example) are bent into a crank shape. Due to the first bent portion 13A and the second bent portion 13B, the front end portion of the second bent portion 13B is positioned at a height different from that of the bus bar 13 bonded to the mounting surface 41 on the printed circuit board 12 side. A terminal 14 is formed. A circular connection hole 14 </ b> A is formed through the bus bar terminal 14. The printed circuit board 12 and the bus bar 13 are configured to be bonded together with, for example, an adhesive or an adhesive sheet.

(Coil device 20)
The coil device 20 is, for example, a choke coil that smoothes an output voltage, and includes a coil 21, a magnetic core 26, a case 33 that houses the coil 21 and the core 26, and a filling unit 38 that is filled in the case 33. With.

(Coil 21)
The coil 21 is a so-called edgewise coil, which is made of, for example, copper or a copper alloy, and has a strip-like rectangular wire having a flat rectangular cross section, and is spirally formed so that the short side is an inner diameter surface and an outer diameter surface. It is formed by winding and has an enamel coating on the outer surface. The coil 21 includes a winding part 22 wound in a circular shape around the axis A1 (four times in the present embodiment), a pair of terminal parts 23 connected to the outside, a winding part 22 and the like. And a bent portion 25 bent in an L shape with the terminal portion 23.

  The plurality of winding portions 22 are wound with a constant inner diameter and outer diameter, and the coil 21 has a shape that can be elastically deformed in the direction of the axis A1 by the winding portions 22. The pair of terminal portions 23 are both linear and arranged in parallel to each other. A circular connection hole 24 through which a shaft portion of a bolt 53 as a fastening member can be inserted is formed through the tip portion of the terminal portion 23. Since the bending part 25 has connected between the winding part 22 and the terminal part 23 at right angle, the extension direction of a pair of terminal part 23 is substantially the mounting surface 41 of the thermal radiation member 40 mentioned later. It is set as the parallel direction (direction along the mounting surface 41).

(Core 26)
The core 26 is made of a magnetic material having high permeability such as ferrite, and is configured by combining a pair of divided members 27 and 27. As shown in FIG. 7, each of the divided members 27 and 27 includes a columnar column part 29, a side wall part 30 having an inner surface curved in an arc shape, and the column part 29 and the side wall part 30 connected to each other to form the coil 21. And a plate-like connection support portion 31 to be supported, and these are integrally formed.

(Case 33)
The case 33 is made of a synthetic resin having insulating properties, and includes a rectangular tube-shaped rectangular tube portion 34 and a back wall portion 36 that closes the rectangular tube portion 34 as shown in FIGS. 5 and 8. Yes. A rectangular opening 34A through which the core 26 to which the coil 21 is attached is inserted is formed at the front end of the rectangular tube 34, and the front end of the rectangular tube 34 is a tension projecting outward. A protruding portion 35 is formed. A through hole 35A through which the shaft portion of the screw 56 is inserted is formed through the overhang portion 35, and as shown in FIG. Screwed with a screw 56. The back wall portion 36 covers the back surface of the rectangular tube portion 34 without a gap, and a convex portion 36A that protrudes outward according to the shape of the winding portion 22 and a concave portion 36B that is recessed from the convex portion 36A are formed. Has been. An inner surface side of the recess 36 </ b> B is a receiving portion 36 </ b> C that receives the core 26. The core 26 is placed in the case 33 by the core 26 being placed on the receiving portion 36C. As shown in FIG. 7, a pair of guide ribs 37 extend in the vertical direction on the left and right outer surfaces of the rectangular tube portion 34. The guide rib 37 extends over the entire length of the side wall of the rectangular tube portion 34.

(Filling part 38)
As shown in FIG. 2, the filling portion 38 is filled with a filler so as to fill a space between the coil 21 and the core 26 where the coil 21 and the core 26 are not disposed. It enters a gap, a gap between the core 26 and the case 33, and the like. In the present embodiment, for example, an epoxy resin is used as the filler, but is not limited thereto, and other known materials can be used. The filler is a liquid when injected into the case 33. For example, a thermosetting resin that is solidified by heating after pouring into the case 33 or a room temperature curable resin that is cured without being heated may be used. Further, as the filler, a material having a viscosity that can retain the shape to some extent without being cured after being injected into the case 33 may be used. The viscosity of the filler may be such that the filler in a liquid state enters the gap between the coil 21 and the core 26, and depends on the size of the gap such as the coil 21 and the core 26. Suitable viscous material can be used.

(Heat dissipation member 40)
The heat radiating member 40 is made of a metal having high thermal conductivity such as aluminum or aluminum alloy formed by aluminum die casting or the like, and as shown in FIG. 3, the upper surface is formed by the coil device 20 and the circuit body 11. A plurality of heat radiation fins 49 are arranged in a comb shape on the lower surface side.

  The placement surface 41 has a flat region on which the circuit body 11 is placed, and an accommodation recess 42 is formed in another region. The housing recess 42 includes a bottom surface 42 </ b> A on which the coil device 20 is placed and a wall surface 42 </ b> B that faces the side surface of the coil device 20, and forms a substantially rectangular parallelepiped space in the heat radiating member 40. As shown in FIG. 2, a protrusion 45 corresponding to the recess 36 </ b> B of the case 33 is formed on the bottom surface 42 </ b> A of the housing recess 42. Fastening portions 48 capable of screwing the overhang portions 35 of the case 33 are formed on upper portions of the left and right wall surfaces 42B. The fastening portion 48 is formed in a recessed shape from the placement surface 41 according to the dimension of the overhang portion 35, and can be screwed with a screw 56. A pair of guide grooves 44 (see FIG. 1) that respectively engage with the pair of guide ribs 37 extend in the vertical direction on the left and right wall surfaces 42B of the housing recess 42.

  An insulating layer (not shown) is stacked on the mounting surface 41 to insulate between the heat dissipation member 40 and the circuit body 11. The insulating layer is formed by curing a resin such as a liquid adhesive, and a material having high thermal conductivity and insulating properties is used. With the insulating adhesive applied on the mounting surface 41, the circuit board 11A is mounted on the (adhesive) of the mounting surface 41, and the circuit board 11A is mounted using, for example, a jig or the like. The circuit board 11 </ b> A can be bonded to the mounting surface 41 by pressing against the surface 41 side. As shown in FIG. 3, a terminal block 50 is fixed near the coil device 20 on the mounting surface 41. The terminal block 50 is made of an insulating synthetic resin and is formed at a predetermined height corresponding to the height of the terminal portion 23. The terminal block 50 is formed with a holding recess 51 that holds the nut 54 in a state in which the rotation of the nut 54 is restricted. The holding recess 51 is shaped to escape the shaft portion of the bolt 53. On the upper surface of the terminal block 50, as shown in FIG. 1, a positioning part 52 through which the terminal part 23 is inserted and positioned in the left-right direction protrudes upward. The bus bar terminal 14 and the terminal portion 23 are arranged on the terminal block 50 so as to overlap each other, and are fastened with bolts 53 and nuts 54 as fastening members, so that the bus bar terminal 14 and the terminal portion 23 are connected and fixed. The In addition, although the terminal block 50 can be used as an independent component, it is not restricted to this, For example, you may form integrally in the flame | frame which is covered on the outer edge part of the thermal radiation member 40.

Next, assembly of the coil device 20 will be described.
The coil 21 is placed on one of the split members 27 constituting the core 26, and the upper and lower split members 27, 27 are fitted together, and the coil 21 and the core 26 in this state are accommodated in the case 33 (FIG. 4). Next, the filler is injected from the opening 34 </ b> A of the case 33 by an injector (not shown). When the filling material is filled to a predetermined depth of the case 33, the injection is finished. When the filler is solidified, a filling portion 38 is formed and the coil device 20 is formed. Next, the coil device 20 is inserted into the housing recess 42 of the heat radiating member 40 while the guide rib 37 is engaged with the guide groove 44. When the coil device 20 is inserted to a predetermined depth, the terminal portion 23 is disposed on the terminal block 50. Then, when the overhanging portion 35 is screwed to the fastening portion 48 with screws 56 and the circuit body 11 is placed on the adhesive applied to the placement surface 41 of the heat radiating member 40, the bus bar terminals 14 of the circuit body 11. And the terminal part 23 of the coil 21 will be in the state which overlapped. Then, the bus bar terminal 14 and the terminal portion 23 are fastened with the bolt 53 and the nut 54. Thereby, it becomes the electrical junction box 10 in the state where the coil device 20 is assembled.

According to the present embodiment, the following operations and effects are achieved.
The electrical junction box 10 of the present embodiment includes a coil device 20 in which a coil 21 having a terminal portion 23 connectable to the outside and a magnetic core 26 are accommodated in a case 33, and a circuit board 11A having a bus bar 13. The electrical connection box 10 includes a coil device 20 and a mounting surface 41 on which the circuit board 11A is mounted. The circuit board 11A is bonded to the mounting surface 41, and the bus bar 13 includes a terminal portion. 23, and the bent portions 13A and 13B in a state where the bus bar terminal 14 side is bent, and the coil 21 is wound around an axis A1 passing through a plane along the mounting surface 41. The case 33 is filled with a filling portion 38 made of an insulating resin.

According to the present embodiment, since the coil 21 is wound around the axis A1 passing through the plane along the placement surface 41, for example, the coil 21 is wound around the axis A1 orthogonal to the plane along the placement surface 41. Compared with the coil device 20 having the rotated coil 21, the area of the coil device 20 on the placement surface 41 can be reduced. Thereby, since the area | region which the coil apparatus 20 occupied can be utilized for mounting of another electronic component, it becomes possible to reduce the electrical junction box 10 in size.
Moreover, since the inside of the case 33 is filled with the filling portion 38 made of resin, abnormal noise due to vibration of the coil 21 can be suppressed.
Furthermore, since the bus bar 13 has the bent portions 13A and 13B on the bus bar terminal 14 side, the bent portions 13A and 13B can absorb vibration compared to a configuration in which the bus bar terminal 14 side extends straight. Thereby, the crack etc. of the filling part 38 by the vibration from the circuit board 11A side etc. being transmitted to the filling part 38 can be suppressed.

The coil 21 is an edgewise coil 21 wound so that the short side of the rectangular wire is the inner diameter surface.
In this way, the coil 21 can be energized with a large current, and the length of the coil 21 in the direction of the axis A1 can be shortened. Therefore, the coil device 20 that occupies the mounting surface 41 further. It is possible to reduce the area of.

In addition, the mounting surface 41 is provided on a heat radiating member 40 that radiates heat from the coil device 20, and the mounting surface 41 is formed with an accommodation recess 42 in which the coil device 20 is accommodated.
If the coil device 20 is housed in the housing recess 42 in this way, the area of the heat radiating member 40 that receives heat from the coil device 20 is increased, and therefore the heat of the coil device 20 is efficiently transmitted to the heat radiating member 40. be able to. Further, since the case 33 is filled with the filling portion 38 made of an insulating resin, the coil 21 can be reliably insulated from the heat radiating member 40. Moreover, since the outer side of the coil apparatus 20 is covered with the metal of the heat radiating member 40, the leakage magnetic flux generated from the gap of the magnetic body is shielded by the metal. Thereby, the influence on other electronic components by leakage magnetic flux can be suppressed.

Further, a guide groove 44 is provided in (one of the housing 33) and the housing recess 42 (one), and the housing 33 (and the other of the housing recess 42) is engaged with the guide groove 44 to receive the housing recess of the coil device. Guide ribs 37 are provided to guide the direction of insertion into 42.
In this way, the guide groove 44 and the guide rib 37 are engaged to guide and position the coil device 20 to be inserted into the housing recess 42.

<Other embodiments>
The technology described in the present specification is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the technology described in the present specification. .
(1) It is good also as a structure provided with the bobbin which consists of an insulating synthetic resin etc., and it is good also as a structure which hold | maintains between the coil 21 and the core 26 with a bobbin.

(2) Although the coil device 20 is a choke coil that smoothes the output voltage, it may be a coil device used for other purposes.

(3) The number of times the winding part 22 is wound is not limited to the number of times of the above embodiment. For example, it may be 1-3 times, 5 times or more. However, the smaller the number of times the winding part 22 is wound, the smaller the dimension of the coil device 20 in the direction of the axis A1, and thus the electrical junction box 10 can be further downsized.

(4) Although the guide groove 44 is provided in the housing recess 42 and the guide rib 37 is provided in the case 33, the present invention is not limited thereto, and the guide groove 37 may be provided in the case 33 and the guide rib 37 may be provided in the housing recess.

10: Electrical connection box 11: Circuit part 11A: Circuit board 12: Printed circuit board 13: Bus bar 13A: First bent part (bent part)
13B: 2nd bending part (bending part)
14: Busbar terminal 20: Coil device 21: Coil 23: Terminal part 26: Core 33: Case 37: Guide rib 38: Filling part 40: Heat radiating member 41: Mounting surface 42: Housing recess 44: Guide groove 50: Terminal block 53 : Bolt 54: Nut

Claims (4)

A coil device in which a coil having a terminal portion connectable to the outside and a magnetic core are housed in a case, a circuit board having a bus bar, and a mounting surface on which the coil device and the circuit board are mounted An electrical junction box comprising:
The circuit board is bonded to the mounting surface,
The bus bar has a bus bar terminal connected to the terminal part, and a bent part in a state where the bus bar terminal side is bent,
The coil is wound around an axis passing through a plane along the placement surface,
An electrical junction box filled with a filling portion made of an insulating resin in the case. The electrical junction box according to claim 1, wherein the coil is an edgewise coil wound so that a short side of a rectangular wire is an inner diameter surface. The said mounting surface is provided in the heat radiating member which radiates the heat | fever of the said coil apparatus, The accommodation recessed part in which the said coil apparatus is accommodated is formed in the said mounting surface. 2. The electrical junction box according to 2. One of the case and the receiving recess is provided with a guide groove, and the other of the case and the receiving recess is engaged with the guide groove to guide the insertion direction of the coil device into the receiving recess. The electrical junction box according to claim 3, wherein a guide rib is provided.

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