JP4292958B2 - Circuit structure and power distribution unit - Google Patents

Description

  The present invention relates to a circuit configuration body and a power distribution unit for distributing a common in-vehicle power source to a plurality of in-vehicle electronic units, for example, and relates to a circuit configuration body including a fuse connection fuse terminal.

  In recent years, vehicles such as automobiles are equipped with a large number of electronic units, and in order to distribute power to each of these electronic units from a common in-vehicle power source, power distribution units including circuit components that perform energization control are widely used. ing. This power distribution unit incorporates a circuit structure including a plurality of fuse terminals formed by bending a predetermined bus bar among a plurality of bus bars constituting a power circuit, and a fuse is detachably connected to the fuse terminal. It is often done. In general, these fuse terminals are densely arranged in a state of being oriented in one direction in consideration of convenience of attachment and replacement.

The applicant of the present application has also proposed a circuit configuration body and a power distribution unit of this type. For example, Patent Document 1 is formed by bending a predetermined bus bar in a bowl shape among a plurality of bus bars constituting a power circuit. Proposed a circuit structure including a bus bar substrate having fuse terminals, a plurality of fuses connected to the plurality of pairs of fuse terminals, and a plurality of relays connected to the power circuit, and a power distribution unit incorporating the circuit structure is doing. The fuse terminals in the circuit structure are arranged so as to protrude in one direction from one end edge of the bus bar substrate while being densely packed at the edge of the circuit structure.
JP 2002-165336 A

  By the way, in such a power distribution unit, as described above, the fuse terminals are densely arranged, and as a result, the fuses connected to the fuse terminals are also densely arranged. Heat generation, which interferes with each other thermally, which is undesirable in terms of thermal design.

  Therefore, these fuse terminals are assembled for each predetermined number to form a fuse terminal group, and these fuse terminal groups are arranged at a predetermined interval from each other to reduce the thermal influence between the fuses. It is also possible.

  However, in these power distribution units, the occupied volume at the time of installation tends to be reduced year by year, and accordingly, downsizing of the power distribution unit and the circuit structure itself incorporated in the power distribution unit is strongly desired. By the way, if the fuse terminal groups are arranged at a predetermined distance from each other, the space between these fuse terminal groups is wasted, resulting in a result contrary to the above-described demand for miniaturization of the circuit structure and the power distribution unit.

  In view of such circumstances, an object of the present invention is to provide a circuit configuration body and a power distribution unit that can suppress a thermal influence between fuses as much as possible with a simple configuration while maintaining a compact structure.

In order to achieve the above object, a circuit structure according to claim 1 forms a plurality of pairs of fuse terminals for connecting fuses by bending a predetermined bus bar among a plurality of bus bars constituting a power circuit. A bus bar substrate, a plurality of fuses connected to the plurality of pairs of fuse terminals , and one or a plurality of fuses provided on the bus bar substrate and connected to the power circuit as components separate from the fuses In a circuit structure comprising a plurality of circuit components and the control circuit board for controlling the drive of circuit parts arranged in a posture substantially parallel to the bus bar board on the opposite side of the bus bar board across the circuit parts , the fuse is connectable at least in one direction, and so as to be side by side along between the bus bar substrate and the control circuit board, the multiple fuse terminal pair , While being arranged laterally along between the respective substrates in a posture in which mutually face the same outward along the bus bar substrate and substantially parallel to the direction from between the control circuit board and the bus bar substrate, said busbar substrate A part of the circuit components provided above is interposed between specific fuse terminal pairs arranged in the lateral direction between the substrates .

  According to the present invention, since some of the circuit components provided on the bus bar substrate are interposed between the specific fuse terminal pairs, the specific fuse terminal pairs are spaced apart from each other by a predetermined interval. The fuses arranged in the above-mentioned state and connected to the pair of fuse terminals can also be arranged apart from each other, whereby the thermal influence between the fuses can be suppressed as much as possible. In addition, since some of the circuit components provided on the bus bar substrate are interposed between the specific fuse terminal pairs, the circuit can be used by effectively utilizing the space between the spaced apart fuse terminal pairs. The components can be arranged, so that the circuit structure can be maintained in a compact structure. In addition, since the plurality of pairs of fuse terminals are arranged so that the fuses can be connected from at least one direction, workability in maintenance such as fuse replacement is not deteriorated. Further, since it is not necessary to arrange the fuse terminals densely at one place, the bus bars can be easily arranged without requiring a complicated arrangement because the fuse terminals are gathered at one place as in the prior art.

In addition , the circuit parts can be arranged by effectively using the space between the bus bar board and the control circuit board, and the control circuit board can be configured more compactly. A fuse terminal can be provided without forming the. Moreover, the dimension in the height direction can be reduced, and it is not necessary to enlarge the planar area.

In this case, the fuse terminal is preferably configured to include an upstanding portion that rises from the bus bar substrate and an extending portion that extends from the tip of the upright portion along the surface of the bus bar substrate. tip of the detecting portion is preferably disposed near the outer periphery of the busbar substrate in a plan view (claim 2).

  With this configuration, the dimension in the height direction can be reduced as compared with the case where the fuse terminal is configured as a tab terminal, and the distal end portion of the extending portion is in the vicinity of the outer peripheral edge of the bus bar substrate in plan view. Since they are arranged, the planar area is not enlarged, a compact structure is maintained, and the connectivity with the fuse is not lowered. In particular, when the control circuit board is disposed on the opposite side of the bus bar board with the circuit components provided on the bus bar board, the upright part and the extension part are obstructed by the control circuit board. When a fuse terminal pair having such an extension part is arranged apart from each other, more space is wasted. Therefore, by applying the fuse terminal having the above-described configuration to a circuit configuration board having such a fuse terminal, the thermal effect caused by the fuse can be as much as possible with a simple configuration while maintaining a more compact structure. It can be effectively suppressed.

Here, the circuit component interposed between the fuse terminals is not particularly limited, but the circuit component interposed between the fuse terminals is more energized than the other circuit components connected to the power circuit. Those having a low frequency (Claim 3 ) and those having a calorific value smaller than those of other circuit components connected to the power circuit (Claim 4 ) are preferable. Specifically, on / off switching of energization in the power circuit is preferable. The relay is preferably executed (claim 5 ).

  If comprised in this way, the heat_generation | fever of circuit components itself can be suppressed as much as possible, and the thermal influence which acts on a fuse can further be reduced.

On the other hand, a power distribution unit according to claim 6 has the circuit structure according to any one of claims 1 to 5 , and an opening portion in which the circuit structure is incorporated and opens outward. A case, the fuse terminal is disposed through the opening in the case, and a part of the circuit component provided on the bus bar substrate is interposed between the fuse terminals for each predetermined logarithm. It is characterized by being.

  According to the present invention, since the circuit configuration body is included, it is possible to suppress as much as possible the thermal influence acting between the fuses with a simple configuration while maintaining a compact structure. In addition, since the opening is oriented in one direction, the workability of maintenance work such as replacement of a fuse is improved.

Although the specific use of this power distribution unit is not particularly limited, it can be formed relatively small, and therefore, it is preferably used for energization control for the in-vehicle unit, where the installation space is limited. 7 ).

In this case, it is preferable that at least one circuit component interposed between the fuse terminals for each predetermined logarithm is connected to a power circuit in a notification unit that notifies a passenger of a predetermined state among the in-vehicle units ( Claim 8 ).

  That is, the circuit components connected to the power circuit in the notification unit are not normally energized frequently and generate a small amount of heat, so that they are suitable as circuit components interposed between fuse terminals.

  According to the circuit structure of the first aspect of the present invention, the specific fuse terminal pairs to which the fuses are connected are arranged in a distributed manner, and the thermal influence between the fuses connected to these fuse terminals and having a relatively large amount of heat generation is possible. A compact configuration that suppresses the increase in the size of the circuit structure caused by the distributed arrangement of the fuse terminals by arranging the circuit components by effectively using the space between the specific fuse terminal pairs while suppressing as much as possible. Can be maintained.

According to the power distribution unit of the sixth aspect , the thermal influence caused by the fuse can be suppressed as much as possible with a simple configuration while maintaining a compact structure by the circuit structure, and the fuse is connected. There is no loss of convenience.

  A preferred embodiment of the present invention will be described with reference to the drawings. Here, a power distribution circuit that distributes power supplied from a common power source mounted on the vehicle to a plurality of electrical loads (here, headlight unit, small light unit, horn unit, washer unit, security horn) Although the circuit configuration body and power distribution unit to be configured are shown, the use of the power distribution unit according to the present invention is not limited to this, and it can be widely applied to the case where on / off switching of energization in a power circuit is performed by a circuit component such as a relay. . This circuit structure is incorporated in a power distribution unit 1 as shown in FIG. FIG. 1 is a perspective view showing the power distribution unit upside down.

  The power distribution unit 1 has a substantially rectangular parallelepiped shape and is very compact while having a function of distributing power to a plurality of electrical loads (in this embodiment, five electrical units). In the present embodiment, the power distribution unit 1 is formed so as to be housed in a space having a length of 75 mm, a width of 100 mm, and a height of 25 mm.

  As shown in FIG. 2, the power distribution unit 1 includes a circuit structure 2 including a control circuit board 21, a connector mounting portion 4 and a fuse mounting portion 5 mounted on the circuit configuration body 2, and mounting portions 4, 4. An upper case 6 and a lower case 7 are provided as heat dissipating cases for holding the circuit structure 2 to which 5 is attached from above and below and holding the mounting portions 4 and 5 in an exposed state. In this specification, for convenience of explanation, the side on which the connector mounting portion 4 of the power distribution unit 1 is formed will be referred to as the front side, and the height direction in FIG.

  FIG. 3 is an exploded perspective view of the circuit structure 2. 4 is a sectional view taken along line IV-IV in FIG. 1, and FIGS. 5 to 7 are sectional views taken along lines VV, VI-VI, and VII-VII in FIG.

  The circuit configuration body 2 constitutes a power circuit that distributes a common in-vehicle power source to each electrical load according to preset conditions. The circuit structure 2 includes a bus bar substrate 20 in which a bus bar layer 30 composed of a plurality of bus bars 22 arranged in a state of being arranged on substantially the same plane is laminated over a plurality of layers via an insulating plate 31. And two kinds of relays 24 and 25 as power circuit components mounted on the bus bar 22 of the bus bar board 20, and the bus bar board 20 so as to interpose the relays 24 and 25 between the bus bar board 20. And a control circuit board 21 arranged at a predetermined interval.

  The circuit structure 2 is a flat block-like body having a substantially square shape in plan view, and a predetermined bus bar 22 is bent in a bowl shape at the front end portion thereof, and a large number of connector terminals 27 are in a square planar area. They are arranged in a state protruding forward from A, and connectors (not shown) can be connected to these connector terminals 27 from the front. On the other hand, a predetermined bus bar 22 is bent and formed at the rear end portion of the circuit structure 2 so that a plurality of fuse terminals 28 protrudes rearward while being substantially contained in the rectangular planar area A. The fuses H are arranged in the left-right direction across the steps, and fuses H can be connected to these fuse terminals 28 from the rear (see FIG. 6). The planar area A is an area that is substantially accommodated in the heat dissipation cases 6 and 7 in plan view.

  A plurality (four in this embodiment) of the first relays 24 are mounted along the longitudinal direction (left-right direction) on the surface side of the bus bar substrate 20 between the connector terminals 27 and the fuse terminals 28. ing. The fuse terminals 28 are formed in a pair of upper and lower sides, and the fuse H is connected to the upper and lower fuse terminals 28, that is, the fuse terminal pair. The pair of fuse terminals 28 are densely arranged in pairs or plural pairs to form a fuse terminal group 29, and the plurality of groups of fuse terminal groups 29 are in a state of being spaced apart from each other by a predetermined distance. ing. A second relay 25 is mounted on the surface side of the bus bar substrate 20 between the fuse terminal groups 29.

  Specifically, the bus bar substrate 20 includes a plurality of bus bar layers 30a to 30c, and a plurality of insulating plates 31a and 31b (insulating layers) are interposed between the bus bar layers 30a to 30c. In the present embodiment, the bus bar substrate 20 in which the bus bar layers 30a to 30c are stacked in three layers is used. However, the number of the bus bar layers is not particularly limited as long as it is a plurality of layers.

  As described above, each of the bus bar layers 30a to 30c is arranged in a state in which a plurality of bus bars 22 are arranged in a predetermined pattern on substantially the same plane, and among the bus bars 22, the predetermined bus bar 22 is bent vertically. Further, the front end portion of the bent portion is folded back horizontally, whereby a connector having standing portions 270 and 280 standing up from the bus bar layers 30a to 30c and extending portions 271 and 281 extending vertically from the standing portions 270 and 280. Terminals 27 and fuse terminals 28 are formed. In particular, the extended portion 281 of the fuse terminal 28 is substantially contained in the planar region A, and the tip thereof is disposed in the vicinity of the outer peripheral edge of the bus bar substrate 20 in plan view.

  In this embodiment, the pair of fuse terminals 28 are terminals included in the power circuit for the headlight unit, the horn unit, the washer unit, the security unit (notification unit), and the small light unit in this order from the front side in FIG. It is configured. Among these fuse terminals 28, the fuse terminal 28 corresponding to the headlight unit and the washer unit has the largest current, followed by the terminals corresponding to the horn unit and the small light unit, and finally the security horn. The current that flows in the order of the terminals corresponding to the units decreases. The arrangement of the fuse terminals 28 is not particularly limited, but the fuses connected to each pair of fuse terminals are preferably arranged so that the fuses are arranged side by side in the left-right direction. It is set as appropriate in consideration of such factors. For example, the fuse terminals 28 that are expected to be frequently or frequently energized are preferably arranged in different fuse terminal groups 29, and among the same fuse terminal group 29, fuse terminals that have a large current to be energized Are preferably spaced apart.

  These fuse terminal groups 29 are formed by gathering one or more pairs of fuse terminals 28. In this embodiment, three pairs, one pair, and one pair of fuse terminals 28 are gathered from the front side of FIG. Thus, three groups of fuse terminals 29 are formed. In other words, a specific pair of fuse terminals (a pair of upper and lower fuse terminals 28) are arranged at a predetermined interval. The interval between the fuse terminal groups 29 is set to such an extent that the second relay 25 can be interposed in the present embodiment. Needless to say, the number of the fuse terminal groups 29 and the number of pairs of the fuse terminals 28 constituting them are not particularly limited, and are appropriately set depending on the type of the power circuit.

  In addition, predetermined bus bars 22 in each of the bus bar layers 30 a to 30 c are folded up so that the pin-like terminals 32 protrude from the upper surfaces of the first and second relays 24, 25. Is connected to the control circuit of the control circuit board 21. Then, an electric signal is sent from the control circuit board 21 through the pin-shaped terminal 32, and drive control of the first and second relays 24 and 25 arranged in predetermined bus bar layers 30a to 30c is performed.

  Here, the relays 24 and 25 are mechanical relays, and are therefore energized intermittently. The relays 24 and 25 include the first relay 24 and the second relay 25 according to the magnitude of the current and the frequency of energization. The horn unit, small light unit, security horn unit (notification unit) The second relay 25 is used for the power circuit in each of the electrical loads), and the frequency of energization is lower than that of the first relay 24 and the calorific value is smaller than that of the first relay 24.

  The first and second relays 24 and 25 have substantially rectangular parallelepiped relay bodies 24a and 25a, and a plurality of flat plate-like leg terminals 24b and 25b provided at the lower ends thereof.

  The first relay 24 has a leg-like terminal 24b that extends downward from the lower surface of the relay body 24a and is bent along the layer surface of the bus bar layer 30 to form a superposed portion 24c that is overlapped with a predetermined bus bar 22. . The overlapping portion 24c of the first relay 24 includes an overlapping portion 24c that is overlapped with the bus bar 22 of the first bus bar layer 30a and an overlapping portion 24c that is overlapped with the bus bar 22 of the second bus bar layer 30b.

  On the other hand, the second relay 25 has leg-like terminals 25b extending along the layer surface of the bus bar layer 30 from the lower surface of the relay body 25a. Therefore, the leg-like terminals 25b are connected to the predetermined bus bar 22 of the third bus bar layer 30c. The overlapping portion 25c is configured to be overlapped.

  The first and second relays 24 and 25 are joined to the predetermined bus bar 22 by welding at the overlapping portions 24c and 25c. In this embodiment, the welding is performed by resistance welding in which the base material is melted and joined by resistance heat generated by sandwiching the joint portion between the electrodes and flowing a large current, but the base material such as laser welding is melted and joined. If it does, the specific method is not specifically limited.

  The first and second relays 24 and 25 generate heat as they are driven, and the heat generation amount of the second relay 25 is smaller than the heat generation amount of the first relay 25. Most of this heat is transferred to the bus bar substrate 20 via the leg terminals 24b and 25b, and is mainly radiated from the bottom wall portion 72 of the lower case 7 using the bus bar substrate 20 as a heat conductor.

  On the other hand, the insulating plates 31a and 31b prevent a short circuit between the bus bar layers 30a to 30c and prevent a short circuit between the bus bars 22 arranged in the same bus bar layer 30a to 30c. It is comprised as the flat plate-shaped body formed of the material which has.

  The first insulating plate 31a interposed between the first bus bar layer 30a and the second bus bar layer 30b located above the first bus bar layer 30a is provided on each of the upper and lower (front and back) both surfaces of the first and second bus bar layers 30a and 30b. Are formed, and the bus bar 22 is stored in a positioning state in the bus bar storage groove 310.

  A first terminal insertion hole 311 through which the leg-shaped terminal 24b joined to the bus bar 22 of the first bus bar layer 30a among the leg-shaped terminals 24b of the first relay 24 is inserted at a predetermined position of the first insulating plate 31a. It is formed in a state penetrating in the thickness direction. The first terminal insertion hole 311 is formed substantially corresponding to the shape of the leg-shaped terminal 24b of the first relay 24, and is set to a size substantially equal to the planar shape. In addition, the first terminal insertion hole 311 is set to a size that allows an electrode to be inserted during resistance welding, and resistance welding can be performed by effectively using the first terminal insertion hole 311. Furthermore, when resistance welding is performed on the first insulating plate 31a in the bus bar layer (the second bus bar layer 30b in the present embodiment) above the first insulating plate 31a, the lower electrode is connected to the bus bar layer. An electrode insertion hole 312 is formed so as to be in contact with the predetermined bus bar 22, and a joint portion of the predetermined bus bar 22 of the second bus bar layer 30 b (through the electrode insertion hole 312 (in FIG. 5, the leg-shaped terminal 24 b on the right side of the first relay 24 is formed) And the joint part) are exposed downward.

  The second insulating plate 31b interposed between the second bus bar layer 30b and the third bus bar layer 30c located above the second bus bar layer 30b accommodates each bus bar 22 of the third bus bar layer 30c individually on the upper surface (front surface). A bus bar storage groove 313 is formed, and the bus bar 22 is stored in the bus bar storage groove 313 in a positioned state. A second terminal insertion hole 314 through which the leg-like terminal 24b of the first relay 24 is inserted is formed at a predetermined location of the second insulating plate 31b in a state of penetrating in the thickness direction. A part of the second terminal insertion hole 314 communicates with the first terminal insertion hole 311 in the vertical direction in a state where the insulating plates 31a and 31b are laminated. Through the terminal insertion holes 311, 314, the joint portions of the predetermined bus bar 22 of the first bus bar layer 30a are exposed.

  Further, the second insulating plate 31b is provided with a main body insertion hole 315 that communicates with the second terminal insertion hole 314 and allows the relay main body 24a of the first relay 24 to be inserted, and surrounding ribs surround the main body insertion hole 315. 316 is provided.

  The insulating plates 31a and 31b are provided with mounting portion cutouts 318 corresponding to the fuse terminals 28, and projecting mounting portions 53 (described later) of the fuse mounting portion 5 are fitted into the cutouts 318.

  On the other hand, the control circuit board 21 includes a control circuit for controlling the driving of the first and second relays 24 and 25 as the circuit components. For example, a printed circuit board (a conductor constituting the control circuit on an insulating board is printed wiring) Are made up of). The control circuit board 21 is a plate-like body that is slightly larger than the bus bar board 20, and is supported by the connector mounting portion 4 and the fuse mounting portion 5 with both front and rear edges facing the top wall portion of the upper case 6. (See FIG. 6). The control circuit board 21 includes a plurality of semiconductor elements 210 mounted on both front and back surfaces (upper and lower surfaces in FIG. 5), a sub-board 211 disposed on the back surface, and a connector connected to the control circuit. A pin-like terminal 212.

  Specifically, the semiconductor element 210 includes an LSI (Large Scale Integrated Circuit) 210 a as a microprocessor provided at the approximate center on the front surface side of the control circuit board 21, and both left and right end portions on the back surface side of the control circuit board 21. The circuit component that includes the FET 210b provided in the circuit board and that generates a relatively large amount of heat generated by the driving is disposed at the peripheral edge of the circuit component 2. By disposing the circuit component having a relatively large amount of heat generation in the peripheral portion of the circuit structure 2 in this way, the heat dissipation efficiency of the circuit component can be improved.

  Further, the LSI 210a is sealed with a potting agent filled between the control circuit board 21 and the top wall portion of the upper case 6, and heat generated by driving the LSI 210a is generated by using the potting agent as a heat conductor. It is supposed to transfer heat exclusively to the top wall. On the other hand, the FET 210b is bonded to the side wall portion 73 of the lower case 7, and is directly connected to the side wall portion 73 so as to be able to conduct heat.

  Similar to the control circuit board 21, the sub board 211 is configured by a printed circuit board, and forms a part of a control circuit that controls the various circuit components. The sub board 211 is a plate-like body arranged between the bus bar board 20 and the control circuit board 21, and is arranged along the longitudinal direction of the control circuit board 21. In this way, a part of the control circuit formed on the control circuit board 21 is formed on the sub board 211, and the sub board 211 is placed between the bus bar board 20 and the control circuit board 21 with respect to the boards 20 and 21. By arranging the first and second relays 24 and 25 so as to be vertical, the space between the boards 20 and 21 on which the first and second relays 24 and 25 are arranged can be effectively used to reduce the size of the circuit component 2. it can. Such a sub-board 211 can be omitted as appropriate, and in this case, all control circuits are formed on the control circuit board 21.

  The control circuit board 21 is provided with through holes (not shown) at predetermined locations, and pin-like terminals 32, connector pin-like terminals 212 and the like standing from the bus bar 22 are inserted into these through-holes. These are joined by soldering at their ends.

  On the other hand, the connector mounting portion 4 is a synthetic resin molded product, and the height and the length in the left-right direction are formed substantially equal to those of the circuit component 2. The connector mounting portion 4 is provided with a connector terminal insertion hole 40 through which the connector terminal 27 and the connector pin-like terminal 212 are inserted, and through the connector terminal insertion hole 40, the connector terminal 27 and the connector pin-like terminal 212 are provided. The front end of the connector protrudes into the connector mounting portion 4 so that it can be connected from the outside. Further, the connector mounting portion 4 is provided with a case fitting groove 41 on the peripheral surface portion thereof, and the front end edges of the upper case 6 and the lower case 7 are fitted into the case fitting groove 41 and assembled to the cases 6 and 7. It is done. Further, the control circuit board 21 is placed on the upper surface of the rear end portion of the connector mounting portion 4.

  On the other hand, the fuse mounting portion 5 is also a synthetic resin molded product, and the height and the length in the left-right direction are formed substantially equal to those of the circuit component 2. In the fuse mounting portion 5, corresponding to the fuse terminal group 29, projecting mounting portions 53 projecting forward are arranged in the left-right direction. The projecting mounting portion 53 is for mounting the fuse H. The fuse terminal is opened to the rear for mounting the fuse H, and the extension portion 281 of the fuse terminal 28 is inserted into the rear end surface. An insertion hole 50 (see FIG. 6) is provided, and the fuse H can be connected to the extension portion 281 protruding from the fuse terminal insertion hole 50 through the opening of the protruding attachment portion 53.

  In addition, the fuse mounting portion 5 is provided with a case fitting groove 51 in the front peripheral surface portion thereof, and the rear end edges of the upper case 6 and the lower case 7 are fitted into the case fitting groove 51 so that the fuse mounting portion 5 It is assembled to the cases 6 and 7 in a state in which most of them are stored. Further, the control circuit board 21 is placed on the upper surface of the front end portion of the fuse mounting portion 5.

  The upper case 6 is a downward-opening dish-like body having a top wall portion that is substantially rectangular in plan view, and is made of a material having good thermal conductivity such as an aluminum-based metal. The upper case 6 is filled with a potting agent such as silicon resin in advance, and various circuit components including the LSI 210a mounted on the surface (upper surface) of the control circuit board 21 are sealed with the potting agent. A pair of front and rear locking bulges 60 are provided on the left and right side surfaces of the upper case 6, and locking holes 70 provided on the left and right side walls of the lower case 7 are locked to lock the upper case 6 and the lower case. 7 is assembled in a state in which the circuit structure 2 is accommodated.

  The lower case 7 is an upper opening type box-like body, and is made of a material having good thermal conductivity, such as an aluminum-based metal, like the upper case 6. Further, the lower case 7 has a substantially notched entire front and rear side wall portion, and the connector mounting portion 4 and the fuse mounting portion 5 are assembled to the notch portion 71. As described above, the circuit component 2 is bonded to the upper surface of the bottom wall portion of the lower case 7 with an adhesive having good electrical insulation such as an epoxy resin. The interior of the lower case 7 is also filled with a potting agent such as silicon resin, and the leg-like terminals 24b and 25b of the first and second relays 24 and 25 are sealed with the potting agent. The left and right side wall portions 73 of the lower case 7 are provided with a pair of front and rear locking holes 70 for locking the locking bulge portion 60.

  Next, a method for manufacturing the circuit configuration body 2 and the power distribution unit 1 having the above-described configuration will be described.

  First, the bus bar substrate 20 on which the first and second relays 24 and 25 are mounted is manufactured (bus bar substrate forming step, relay mounting step). In the present embodiment, the second relay 25 is mounted on a predetermined bus bar 22 in the process of forming the bus bar substrate 20, while the first relay 24 is formed after the bus bar substrate 20 on which the second relay 25 is mounted is formed. The relays 24 and 25 may be mounted on the relays 24 and 25 after the bus bar substrate 20 is formed, or may be mounted together in the process of forming the bus bar substrate 20. However, in the case where at least one of the first and second relays 24 and 25 is mounted after the bus bar substrate 20 is formed, insulation is performed corresponding to the relay mounted after the bus bar substrate 20 is formed, as described above. It is necessary to provide a terminal insertion hole in the plate and, if necessary, an electrode insertion hole for inserting an electrode for resistance welding.

  Specifically, in the present embodiment, before the bus bar 22 of the bus bar constituting plate corresponding to the third bus bar layer 30c is laminated on the second insulating plate 31b, the second bus bar 22 of the bus bar constituting plate is preliminarily attached to the predetermined bus bar 22 of the bus bar constituting plate. A relay 25 is mounted.

  The second relay 25 is mounted by overlapping the second relay 25 with the overlapping portion 25c of the leg-shaped terminal 25b on the predetermined bus bar 22 of the third bus bar layer 30c, and the overlapping portion of the overlapping portion 25c and the bus bar 22 Is sandwiched between the upper electrode D1 and the lower electrode D2 for resistance welding, and both are joined by resistance welding.

  Then, after manufacturing the bus bar substrate 20 on which the first and second relays 24 and 25 are mounted as shown in FIG. 8, the bus bar on which the first and second relays 24 and 25 are mounted as shown in FIG. The connector mounting portion 4 and the fuse mounting portion 5 are attached to the substrate 20 (mounting portion mounting step). Specifically, the connector terminal 27 of the bus bar substrate 20 is inserted into the remaining connector terminal insertion hole 40 of the connector mounting portion 4 in which the connector pin-like terminal 212 is inserted in part of the connector terminal insertion hole 40 in advance. Thus, the connector mounting portion 4 is attached to the front end portion of the bus bar substrate 20. Further, by inserting the fuse terminal 28 of the bus bar substrate 20 into the fuse terminal insertion hole 50 of the fuse mounting portion 5, the fuse mounting portion 5 is attached to the rear end portion of the bus bar substrate 20. At this time, the second relay 25 is interposed between the protruding mounting portions 53 of the fuse mounting portion 5, that is, between the fuse terminal groups 29.

  And the lower case 7 shown in FIG. 10 is attached after the said mounting part attachment process (lower case attachment process). In the present embodiment, in the lower case attaching step, the lower case 7 in which the FET 210b of the control circuit board 21 is attached in advance to a predetermined location on the inner surface of the left and right side walls 73 is used. In this way, since the FET 210b that generates heat as it is driven is attached to the lower case 7 by bonding, the FET 210b and the lower case 7 can be reliably connected thermally (heat transferable), and the heat dissipation efficiency of the FET 210b can be improved. Can be improved.

  The lower case 7 is attached by engaging the edge portions of the cutout portions 71 of the lower case 7 with the case fitting grooves 41 and 51 of the connector mounting portion 4 and the fuse mounting portion 5 attached to the bus bar substrate 20. This is performed by bonding the back surface (lower surface) of the bus bar substrate 20 to the upper surface of the bottom wall 72 of the lower case 7 with an adhesive. In the case where the lower case 7 is formed of a conductive material, an adhesive having an electrical insulation property is used as described above. For example, an adhesive containing an epoxy resin or a silicon resin is used. Can be used. Note that the bus bar substrate 20 and the lower case 7 may be bonded not only by an adhesive but also to the lower case 7 via an insulating layer such as an insulating plate bonded to the back surface of the bus bar substrate 20. Good.

  The lower case 7 is filled with a potting agent to a predetermined height, and the leg terminals 24b and 25b of the first and second relays 24 and 25 are sealed. As the potting agent to be filled, one having excellent thermal conductivity is employed, for example, a silicon-based resin having excellent electrical insulation is employed.

  Next, as shown in FIGS. 11A and 11B, the circuit structure 2 is manufactured by assembling the control circuit board 21 to the bus bar board 20 (control board arranging step). That is, the control circuit board 21 on which various circuit components including the LSI 210a are mounted is established above the bus bar board 20 with a predetermined distance from the bus bar board 20 and proper electrical connection is established. Assemble in the state. Specifically, the connector pin-shaped terminal 212 inserted through the connector terminal insertion hole 40 of the connector mounting portion 4 and the pin-shaped terminal 32 formed by folding the predetermined bus bar 22 are bonded to the lower case 7. The FET 210b and the like are properly connected to the electric circuit including the control circuit of the control circuit board 21 and controlled so that the front and rear end edges of the control circuit board 21 are supported by the upper surfaces of the connector mounting portion 4 and the fuse mounting portion 5. The circuit board 21 is assembled to the bus bar board 20. At this time, the sub-board 211 is also attached in a state of being electrically connected to the back side of the control circuit board 21. In the circuit structure 2 manufactured in this way, the bus bar substrate 20 and the control circuit substrate 21 are arranged in a state of being spaced apart by a predetermined interval, and the first and second relays 24, 25 are arranged with high density.

  Finally, as shown in FIG. 12, the upper case 6 is assembled to the lower case 7 to manufacture the power distribution unit 1 (upper case assembling step). Specifically, the upper case 6 is filled with a potting agent in advance, and the potting agent is cured to a state having a certain shape retaining property and elasticity, and is assembled to the lower case 7 in this state. As the potting agent to be filled, one having excellent thermal conductivity is employed, and for example, a silicon resin having excellent electrical insulation is employed.

  The assembly to the lower case 7 is performed by engaging the front and rear end edges of the upper case 6 with the case fitting grooves 41 and 51 of the connector mounting portion 4 and the fuse mounting portion 5, and the upper case 6 on the left and right side walls 73 of the lower case 7. And the locking bulging portion 60 of the upper case is locked in the locking hole 70 of the lower case 7.

  And the fuse H is mounted | worn through the back opening of the protrusion attachment part 53 of the fuse mounting part 5, and as shown in FIG. 6, the power distribution unit 1 of the said structure can be manufactured.

  According to the power distribution unit 1 configured as described above, a plurality of pairs of fuse terminals 28 having the same connection direction of the fuses H are provided for each predetermined number, and a plurality of fuse terminal groups 29 are provided in a state of being separated from each other. Since the second relay 25 is interposed between the fuse terminal groups 29 on the bus bar substrate 20, the fuse terminals 28 are separated for each predetermined fuse terminal group 29, and the heat between the fuse terminal groups 29 is determined. In addition, since the second relay 25 is interposed between the fuse terminal groups 29 on the bus bar substrate 20 as much as possible, the second relay 25 is effectively used to make the second effect. The relay 25 can be provided, and thus the circuit structure 2 can be maintained in a compact structure. In addition, since the plurality of pairs of fuse terminals 28 are arranged so that the fuse H can be connected from the rear, workability in maintenance such as replacement of fuses is not deteriorated. Further, since the fuse terminals 28 do not need to be densely arranged at one place, it is possible to easily arrange the bus bars 22 without requiring complicated arrangement of the bus bars 22 in order to collect them at one place as in the prior art. it can.

[Other Embodiments]
In addition, although the circuit structure body and power distribution unit which concern on this embodiment were demonstrated above, the circuit structure body etc. which concern on this invention are not limited to the said embodiment, In the range which does not deviate from the meaning, It can be changed. For example, the following changes are possible.

  (1) In the above embodiment, one or three pairs of fuse terminal groups 29 are provided, and the fuse relay terminal groups 29 are spaced apart so that the second relay 25 can be disposed. However, the fuse terminal pairs may be spaced apart from each other by a predetermined distance, and predetermined circuit components (for example, the second relay 25 and the first relay 24) may be provided between the fuse terminal pairs. Good.

  (2) In the above embodiment, a mechanical relay is interposed as a circuit component between the fuse terminal groups 29, but the circuit component interposed between the fuse terminal groups 29 is not particularly limited. Other circuit components such as a capacitor may be used. However, since the space between the fuse terminal groups 29 is used as a space for thermal buffering of the fuse H connected to the fuse terminal 28, for example, circuit components that are intermittently energized or circuits with a relatively small amount of heat generation. Preferably it is a part.

  (3) In the above embodiment, the fuse terminal group 29 is configured by the fuse terminal 28 having the rising portion 280 rising from the bus bar substrate 20 and the extending portion 281. However, the fuse terminals constituting the fuse terminal group are specifically described. A structure is not specifically limited, For example, the tab-shaped terminal comprised by the standing part which stands | starts up from the bus-bar board | substrate 20 may be sufficient. However, since the dimension in the height direction can be reduced and the planar area is not enlarged, it is preferable to use the fuse terminal 28 having the upright portion 280 and the extending portion 281 as in the above embodiment. .

  (4) In the above-described embodiment, the overlapping portion 24c of the leg-like terminal 24b of the first relay 24 is exposed through the first terminal insertion hole 311 and the second terminal insertion hole 314 in the circuit configuration body 2, but this circuit configuration The specific configuration of the body 2 is not particularly limited. For example, as shown in FIG. 13, the body 2 is formed on the bus bar 22 below the first bus bar layer 30 c (the first and second bus bar layers 30 a and 30 b). A second insulating plate 310b is laminated on the overlapping portion 24c of the leg-like terminal 24b of the first relay 24 to be bonded so as to cover the connecting portion between the bus bar 22 and the overlapping portion 24c, and the second insulating plate 310b. You may comprise so that the bus-bar 22 of the 3rd bus-bar layer 30c may be arrange | positioned on the top. In this case, also in the manufacturing method of the circuit structure 2, unlike the above-described embodiment, the first relay 24 is mounted on the predetermined bus bar 22 of the bus bar substrate 20 in the process of forming the bus bar substrate 20. In addition, since the first relay 24 is mounted in the process of forming the bus bar substrate 20 as described above, the first insulating plate 310a is not formed with an electrode insertion hole for resistance welding unlike the above embodiment.

It is a perspective view shown in the state where the power distribution unit concerning this invention was turned upside down. It is a disassembled perspective view of the power distribution unit. It is a disassembled perspective view of the circuit structure of the power distribution unit. It is the IV-IV sectional view taken on the line of FIG. It is the VV sectional view taken on the line of FIG. It is the VI-VI sectional view taken on the line of FIG. It is the VII-VII sectional view taken on the line of FIG. It is sectional drawing which shows the bus-bar board | substrate with which the 1st and 2nd relay was mounted. It is explanatory drawing which shows the process of attaching each mounting part to the bus-bar board | substrate. It is sectional drawing which shows the lower case used for the power distribution unit which concerns on this invention. It is explanatory drawing which shows the process of assembling a control circuit board to the bus-bar board | substrate in the power distribution unit. It is explanatory drawing which shows the assembly | attachment process of the upper case in the power distribution unit. It is sectional drawing which shows the bus-bar board | substrate in the power distribution unit which concerns on other embodiment which concerns on this invention in the state by which the circuit component was mounted.

Explanation of symbols

1 Power Distribution Unit 2 Circuit Structure 5 Fuse Mount 6 Upper Case (Heat Dissipation Case)
7 Lower case (heat dissipation case)
20 Busbar substrate 22 Busbar 25 Second relay (circuit parts)
28 Fuse terminal 29 Fuse terminal group 50 Fuse terminal insertion hole 280 Standing portion 281 Extending portion 318 Notch A Plane region H Fuse

Claims (8)

A bus bar substrate on which a plurality of pairs of fuse terminals for connecting fuses are formed by bending a predetermined bus bar among a plurality of bus bars constituting the power circuit, and a plurality connected to the plurality of pairs of fuse terminals A fuse, one or a plurality of circuit components provided on the bus bar substrate and connected to the power circuit as components different from the fuse, and opposite to the bus bar substrate with the circuit components interposed therebetween. In the circuit structure comprising the control circuit board for circuit component drive control arranged on the side of the bus bar board in a posture substantially parallel to the bus bar board ,
The fuse is connectable at least in one direction, and so that a side-by-side along between the bus bar substrate and the control circuit board, the multiple fuse terminal pair, and the control circuit board and the bus bar substrate One of the circuit components provided on the bus bar substrate and arranged in the lateral direction between the substrates in a posture that faces the same outward from each other along a direction substantially parallel to the bus bar substrate. The circuit structure is characterized in that a portion is interposed between a pair of specific fuse terminals arranged in a lateral direction between the substrates . 2. The circuit structure according to claim 1 , wherein the fuse terminal includes a rising portion that rises from the bus bar substrate, and an extending portion that extends from a tip of the rising portion along the surface of the bus bar substrate. A circuit structure characterized in that a front end portion is disposed in the vicinity of an outer peripheral edge of the bus bar substrate in a plan view. In the circuit arrangement of claim 1 or claim 2, the circuit component interposed between the fuse terminal are those energized less frequently than other circuit components connected to said power circuit A characteristic circuit structure. The circuit component according to any one of claims 1 to 3 , wherein the circuit component interposed between the fuse terminals generates less heat than the other circuit components connected to the power circuit. A circuit structure characterized by being a thing. In the circuit construction according to any one of claims 1 to 4, characterized in that the circuit component interposed between the fuse terminal is a relay that performs on-off switching of the energization in the power circuit A circuit structure. A circuit structure according to any one of claims 1 to 5 and a case having the circuit structure incorporated therein and an opening that opens outwardly, the opening of the case being included in the case. A power distribution unit, wherein the fuse terminals are arranged through the openings, and some of the circuit components provided on the bus bar substrate are interposed between the fuse terminals for each predetermined logarithm. The power distribution unit according to claim 6, wherein the circuit configuration body is used for energization control with respect to a plurality of in-vehicle units. 8. The power distribution unit according to claim 7 , wherein at least one circuit component interposed between the fuse terminals for each predetermined logarithm is connected to a power circuit for a notification unit that notifies a passenger of a predetermined vehicle state among the on-vehicle units. Power distribution unit characterized by being.

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