JP3503561B2 - Junction box - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a shunt box connected to an automobile wire harness.

[0002]

2. Description of the Related Art Recently, with the rapid increase in electrical components mounted on automobiles, the number of circuits contained in automobile electrical junction boxes, especially junction boxes, has increased rapidly to form branch circuits with high density. Moreover, the number of parts is extremely large, and the number of assembling steps is also very large.

In the junction box 1 shown in FIG. 9 of the electric connection box for automobiles, the insulating plates A to 4E are interposed between the upper case 2 and the lower case 3 and the bus bar 5 is provided.
A to 5D are stacked and arranged. Further, the insulating plate 15 provided with the wire guide grooves at both upper and lower ends is arranged, and the insulating plate 15 is provided.
Wires 6A and 6B are laid and housed on the upper case 2 and the lower case 3 to accommodate the connector accommodating portion, the relay accommodating portion, the relay 8 fitted in the fuse accommodating portion, the fuse, and the connector terminal from the bus bar. Protruding tab 7
And connecting the electric wires 6A and 6B to a pressure contact terminal (not shown), and connecting the pressure contact terminal to a connector,
It is connected to the relay and fuse terminals. Although not used in the electrical junction box, an FPC having a structure in which a conductor is sandwiched between resin films may be used in combination as an internal circuit.

[0004]

As described above, in the junction box 1, the busbar is connected to the internal circuit of the junction box and the terminals connected to the electric wire terminals, and to the fuse and the relay mounted on the outer surface of the junction box. In many cases, a relay terminal is interposed between a tab that is bent to be bent and / or a pressure contact terminal that is connected to a single-core wire, which results in a complicated structure, which increases the number of parts and the number of assembly steps. It is a cause.

Further, since the junction box accommodates a large number of internal circuits, the size is increased. However, there is a limit to the size increase due to the arrangement space and the like. Therefore, it is demanded that the internal circuits can be provided with high density without increasing the size of the junction box.

The present invention has been made in view of the above problems, and enables an internal circuit to be provided at a high density without increasing the size of the junction box, and the terminals in the connector, the relay, and the fuse terminal. It is an object to simplify the connection with the circuit inside the junction box.

[0007]

In order to solve the above problems, the present invention relates to a junction box which is mounted on a vehicle body by being connected to a wire harness of an automobile, wherein the junction box includes an upper case and / or a lower case. The case is formed by embedding a conductive part made of a highly conductive resin in a main body part made of an insulating resin, with its surface exposed, and integrally molding the conductive part to the outer surface of the case. Expose at the bottom of the housing of the connector, relay or / and fuse to be installed,
There is provided a junction box characterized in that a sharp-angled projection is provided at a tip of a terminal accommodated in the accommodating portion, and the conductive portion is pierced to electrically connect.

It is preferable that a terminal hole is provided on the bottom surface of the accommodating portion, and the terminal is fitted through the terminal hole to the conductive portion located under the bottom surface.

As described above, since the conductive portion is provided in the upper case and / or the lower case in which the accommodating portions of the connector, the relay, and the fuse are projected, the terminal accommodated in the accommodating portion is directly connected to the conductive portion. When they are fitted together, electrical connection can be achieved, a relay terminal or the like is not required, and a simple structure can be obtained.

As described above, according to the present invention, the case formed of the upper case and / or the lower case is also provided with the conductive portion so that the case can be used as a circuit holding body. The number can be reduced, and the size and weight of the junction box can be reduced. Further, when the size of the junction box is the same, it is possible to increase the number of circuit bodies housed inside.

Further, according to the present invention, in the circuit body housed inside the upper case and the lower case of the junction box, the conductive portion made of the highly conductive resin is exposed on the substrate portion made of the insulating resin. A terminal, which is embedded in a state and integrally molded, and which is accommodated in the connector, relay, and / or fuse accommodating portion provided in the case, is fitted into the conductive portion of the circuit body through the terminal hole of the case. They are electrically connected together.

As described above, even when the terminals of the connector, the relay and the fuse are connected to the circuit body housed in the case, the circuit body is provided with the substrate portion made of the insulating resin and the conductive portion made of the highly conductive resin. In the case of the integrally formed structure, the above-mentioned terminals may be fitted into the conductive portion of the circuit body for electrical connection, so that a relay terminal is not required and electrical connection can be easily achieved.

In particular, when both the case and the circuit body housed inside are integrally molded with an insulating resin and a highly conductive resin to provide a conductive portion, the terminals of the connector, relay, and fuse are provided. The branch circuit can be very easily provided by extending the conductive portion of the case to the conductive portion of the circuit body and making a fitting connection.

Between the conductive portion of the case and / or the circuit body and the terminal, the tab of the terminal is inserted into the groove between the hole provided in the conductive portion or the insulating resin portion to make surface contact with the conductive portion. It is electrically connected with.

Alternatively, an acute-angled protrusion may be provided at the tip of the terminal, and the conductive portion may be pierced for electrical connection. The terminal connected to the electric wire may be either a crimp connection type or a pressure connection type.

The conductive resin forming the conductive portion which is a part of the case (and the circuit board) is disclosed in Japanese Patent Laid-Open No. 10-2373.
31 and JP-A-11-342522, a thermoplastic resin mixed with metal fibers made of copper, nickel, iron, etc., lead-free solder (low melting point solder) and Cu It is made of a conductive resin composition in which a low melting point alloy such as powder is dispersed.

Examples of the thermoplastic resin to which the conductive metal fibers are mixed include propylene, polyethylene, polystyrene, acrylonitrile butadiene styrene resin, modified polyphenylene oxide resin, polybutylene terephthalate resin, polyethylene terephthalate resin, polyamide resin, and aromatic resin. Polyamide resin, polyphenylene sulfide resin, liquid crystal polymer, polyetherimide,
Resins such as polybenzimidazole, polyether ether ketone, and polyether sulfone can be used alone or in a blend, and acrylonitrile / butadiene / styrene resin and polybutylene terephthalate resin are particularly preferably used.

As the low melting point alloy which is mixed with the above thermoplastic resin and dispersed and joined in a network form, an alloy having a melting point of 100 ° C. or higher, preferably 200 ° C. or higher, which melts during injection molding is used. Sn-Pb System, Sn-Ag
-Pb system, Sn-Bi system, Sn-Bi-In system, Bi-
Pb type, Bi-Sn type, Sn-Cu type, Sn-Cu-N
i-P system, Sn-Ag system, Sn-Bi-Pb system, Sn-
In-based ones are mentioned.

In the case (and circuit body) in which the above-mentioned highly conductive resin is used as the conductive portion, the first injection molding (first color) by the mold is performed with the insulating resin to mold the main body (substrate portion). An upper case in which the main body (substrate part) and the conductive part are integrated in two steps by performing the second injection molding (second color) with a highly conductive resin for the second part using a different mold for the substrate part to mold the conductive part. Alternatively, and / or the lower case (circuit body) is molded.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an exploded perspective view of a junction box 10 connected to an automobile wire harness.
1 is an upper case, 12 is a lower case, 13 (13
A, 13B) is a circuit body, 14 is a bus bar, 15 is a single core wire for pressure contact, 16 is a pressure contact terminal, and 17 is a conductive pin. Although not shown, an insulating plate is interposed between the circuit body 13A and the bus bar 14 which are adjacently stacked.

The bus bar 14 is used as a large current circuit connected to a power source, the single core wire 15 is used as a medium current circuit, and the circuit body 13 is used as a small current circuit.

As described above, the junction box 1
In No. 0, the internal circuit including the bus bar 14, the single core wire 15 and the pressure contact terminal 16 is also used together with the circuit body 13, but as shown in FIG. 5, the internal circuit may be configured only by the circuit body 13.

As shown in FIG. 2, the upper case 11 is provided with a conductive portion 21 made of a highly conductive resin on the inner surface of a body portion 20 made of an insulating resin in a required circuit pattern.
The surface of the conductive portion 21 is flush with the inner surface of the main body 20,
It is exposed on the inner surface. Further, among the conductive parts, the conductive part connected to the external circuit, the relay, and the conductive part 21 connected to the terminal of the fuse are the bottom surface 11 of the connector housing part 11a (relay housing part, fuse housing part) protrudingly provided on the outer surface of the case.
terminal hole 11c formed on the bottom surface 11b at the bottom of b
It is located opposite to.

In the present embodiment, the lower case 12 is made of insulating resin only and no conductive portion is provided as in the conventional case. However, as shown in FIG.
1 may be provided, and the conductive portion may be provided only on the lower case 12 side.

In the method of manufacturing the upper case 11, the insulating resin is injected into the cavities of the upper and lower molds to form the main body 2
A primary molded product consisting only of 0 is injection molded. In this state, the conductive portion 21 is not provided on the main body portion 20. Next, of the upper and lower molds, the upper mold is changed to another mold, the lower mold is joined and the mold is clamped, and a cavity is formed between the main body 20 and the replaced mold. A highly conductive resin is injected into this cavity and the conductive portion 21 is injection molded. As a result, the upper case 11 including the conductive portion 21 having a desired circuit shape is integrally formed on the surface of the main body portion 20.

The circuit body 13 is molded in the same manner as the upper case 11, and has an integrally molded structure in which a substrate portion 22 made of an insulating resin and a conductive portion 23 are embedded on the surface of the substrate portion 22 in an exposed state.

As shown in FIG. 1, the circuit body 1 is provided inside a case composed of an upper case 11 and a lower case 12.
3 is accommodated together with the bus bar 14 and the like to form the junction box 10.

As shown in FIG. 3A, the conductive portion 21 provided on the upper case 11 and the upper case 11
Connector 3 that fits into the connector accommodating portion 11a protruding from
The connection of the wire w in 5 to the terminal 30 of the terminal is performed by providing a contact portion 30a protruding at an acute angle at the tip of the terminal 30 and piercing the contact portion 30a into the conductive portion 21 through the terminal hole 11c. . Note that a groove having a V-shaped cross section may be provided in advance in the conductive portion 21 so as to make surface contact with the contact portion 30a.

The connection between the terminal 30 in the connector 35 and the circuit body 13 housed in the case is shown in FIG. 3 (B).
As shown in FIG. 3, the tip of the terminal 30 is passed through the terminal hole 11 c ′ provided in the upper case 11, and the conductive portion 23 of the circuit body 13 is
The tip portion 30a is pierced and connected to.

Further, the conductive portion 21 of the upper case 11
When the terminal 30 is connected to both the conductive portion 23 of the circuit body 13 and the conductive portion 23, as shown in FIG.
While providing a, the conductive portion 23 is provided with a recessed portion 23a, and the conductive portions 21 and 23 are connected to each other by surface contact by concave and convex fitting, thereby connecting the conductive portions 21 and 23 to the terminal 30.

Further, as shown in FIGS. 5 and 6, the male terminal 30 'which is normally used is used as the terminal connected to the electric wire w, while the conductive portion 2 of the upper case 11 is used.
1 (and the conductive portion 23 of the circuit body 13) into the tab insertion hole 33.
(34) may be provided, and the tab 30a 'of the male terminal 30' may be inserted into the tab insertion hole 33 to make an electrical connection by surface contact.

Further, as shown in FIG. 7, a groove 36 is provided between the conductive portion 21 and the body portion 20, and the terminal 3 is provided in the groove 36.
The tab 30a ′ of 0 ′ may be inserted to make an electrical connection by surface contact.

The terminal 30 connected to the electric wire w is
The pressure contact terminal is not limited to the crimp terminal, and may be a pressure contact terminal 30 ″ provided with a pressure contact blade 30a ″ as shown in FIGS.

The same applies to the case where the conductive parts of the upper case, the lower case and the circuit body are connected to the terminals of the relay and the fuse.

[0035]

As is apparent from the above description, according to the present invention, the case formed of the upper case and / or the lower case of the junction box is provided with the conductive portion and is used as the circuit holder. It is also possible to easily connect the terminal of the electric wire terminal, the relay terminal, the fuse terminal, and the conductive portion provided on the case, which are fitted to the housing portion such as the connector, the relay, the fuse, etc. Also,
The number of circuit bodies accommodated in the case can be reduced, and the size of the junction box can be reduced accordingly, and the number of circuit bodies accommodated in the case can be increased when the size of the junction box is the same. Can be made.

Further, if the circuit body is also provided with a conductive portion made of a highly conductive resin, the external circuit, the relay and the fuse can be easily connected without using a relay terminal.

[Brief description of drawings]

FIG. 1 is an exploded perspective view of a junction box according to an embodiment of the present invention.

FIG. 2 is a perspective view of the upper case seen from the inner surface side.

3A is a cross-sectional view showing a connection configuration between a conductive portion of an upper case and a connector, and FIG. 3B is a cross-sectional view showing a connection configuration between a conductive portion of a circuit body and a connector.

FIG. 4 is a cross-sectional view showing a connection configuration between an upper case and a conductive portion of a circuit body and a connector.

FIG. 5 is a cross-sectional view showing another modified example.

6A is an enlarged view of a main part of FIG. 5, and FIG. 6B is an enlarged view of a main part of a modified example.

FIG. 7 is a sectional view of another modification.

8A and 8B are drawings showing another modified example.

FIG. 9 is an exploded perspective view of a conventional junction box.

[Explanation of symbols]

10 junction box 11 upper case 12 lower case 13 circuit 14 Busbar 15 Single core wire 17 Conduction pin 20 body 21 Conductive part 22 Board part 23 Conductive part 30 terminals 35 connector w electric wire

─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Yuki Saito 1-14 Nishisuehiro-cho, Yokkaichi-shi, Mie Sumitomo Wiring Systems, Ltd. (56) Reference JP-A-2-139216 (JP, A) JP-A 9-92987 (JP, A) JP 10-189090 (JP, A) JP 2-130892 (JP, A) JP 2000-215709 (JP, A) JP 5-335693 (JP, A) ) JP-A-2-132855 (JP, A) JP-A-2001-177951 (JP, A) JP-A-11-97610 (JP, A) JP-A-11-260858 (JP, A) SAI 63-73993 (JP, U) (58) Fields investigated (Int.Cl. ⁷ , DB name) H02G 3/16 B60R 16/02 H05K 5/00

Claims (5)

(57) [Claims] 1. A junction box, which is connected to a wire harness of an automobile and mounted on a vehicle body, wherein a circuit body housed inside an upper case and a lower case of the junction box is made of an insulating resin. It is made by integrally forming a conductive part made of a highly conductive resin in a substrate part made of, with its surface exposed.
The terminal accommodated in the connector, relay, and / or fuse accommodating part provided in the above case into the terminal hole of the case.
A junction box, characterized in that it is electrically connected to the conductive portion of the circuit body through the through . 2. The upper case and / or the upper case
A case made of insulating resin
A conductive part made of highly conductive resin is integrally molded on the inner surface side.
And, a connector for projecting the conductive portion to said casing outer surface, relay
-Or / and exposed at the bottom of the fuse housing
The terminal accommodated in the accommodating part directly into the conductive part.
The junction box according to claim 1, wherein the junction boxes are electrically connected together. 3. The tab of the terminal is inserted into a groove between the conductive portion of the case or / and the circuit body and the terminal, between a hole provided in the conductive portion or an insulating resin portion,
The junction box according to claim 2 , wherein the junction box is electrically connected to the conductive portion by surface contact. 4. The conductive portion and the terminal of the case or / and circuit body, the sharp-pointed projection provided at the distal end of the terminal, electrically connected to and claims 1 to pierce to the conductive portion The junction box according to any one of paragraphs 3 . 5. A vehicle which is connected to an automobile wire harness.
A junction box mounted on the body, which is the upper case of the junction box or
The case consisting of / and the lower case is not made of insulating resin.
Conductive part made of highly conductive resin is integrated on the inner surface of the main body
It is molded in an integrated manner, and the conductive part is projected on the outer surface of the case.
Connector, relay or / and fuse for installation
Of the terminal to be exposed in the lower part of the container and housed in the housing
A sharp-angled projection is provided at the tip, and the
Junction box characterized by being electrically connected
Su.