JP4302405B2

JP4302405B2 - Electrical junction box

Info

Publication number: JP4302405B2
Application number: JP2003035346A
Authority: JP
Inventors: 正和村上; 環高林
Original assignee: THE FURUKAW ELECTRIC CO., LTD.
Current assignee: THE FURUKAW ELECTRIC CO., LTD.
Priority date: 2003-02-13
Filing date: 2003-02-13
Publication date: 2009-07-29
Anticipated expiration: 2023-02-13
Also published as: JP2004248401A

Description

【０００１】
【発明の属する技術分野】
本発明は自動車等に配索されるワイヤーハーネスを分岐接続するのに使用される電気接続箱に関するものである。
【０００２】
【従来の技術】
この種の電気接続箱は、通常、複数の雌端子が収容される外部コネクタが挿入される接続ケースと、接続ケースの基壁に装着され、その基壁に穿設された複数の雄端子挿通穴を通して接続ケース内に突設される複数の雄端子及びこれを支持する回路基板からなるホルダを有する回路形成体とを備え、回路形成体の雄端子が接続ケース内に挿入された外部コネクタの雌端子に挿入されて外部コネクタと接続される構成になっている。（特許文献１参照）。
【０００３】
ワイヤーハーネスに用いられるこの種の電気接続箱は、近年、多極化が進み、回路形成体の雄端子の数が増加する傾向にある。雄端子の数が増加すると、回路形成体の雄端子の寸法、取付け精度にばらつきがあるため、これら雄端子を接続ケースの基壁に穿設された雄端子挿通穴に円滑に通すことが容易でなく、電気接続箱の製造（組立）に手数がかかるほか、雄端子を雄端子挿通穴に通す際、雄端子を変形させたり、傷付けたりして、電気接続箱の性能、品質を低下させる恐れがある。このため、通常、接続ケースの基壁に穿設された雄端子挿通穴はその穴径が雄端子の外径よりも余裕を持たせて大きくなるように形成され、回路形成体の雄端子が雄端子挿通穴内を円滑に通るようにしてある（特許文献１の図１（Ｂ）参照）。
【０００４】
ところで、このように雄端子挿通穴の穴径に余裕を持たせると、回路形成体を接続ケースの基壁に装着することが容易になるが、雄端子と雄端子挿通穴間の隙間（ギャップ）が大きくなって、回路形成体を接続ケースの基壁に的確に位置決めすることが難しく、回路形成体をその基壁に装着したとき、接続ケース内に突設された雄端子が所定位置から偏位し易くなり、外部コネクタを電気接続箱に挿入したとき、雄端子と雌端子が整合しにくくなり、両端子の接続不良を引き起こす恐れがある。
【０００５】
このような問題を解決するために、図５に示すような電気接続箱が提案され、使用されている。この電気接続箱は、上記接続箱と同様に複数の雌端子が収容される外部コネクタ１が挿入される接続ケース２と、接続ケース２の基壁３に装着され、その基壁３に穿設された複数の雄端子挿通穴４を通して接続ケース２内に突設される複数の雄端子６及びこれを支持する回路基板からなるホルダ７を有する回路形成体５とを備え、回路形成体５の雄端子６が接続ケース２内に挿入された外部コネクタ１の雌端子に挿入されて外部コネクタ１と接続される構成のものにおいて、接続ケース２の基壁３の中心部に位置決め突起８が突設され、回路形成体５のホルダ７に位置決め突起８が小さな隙間で挿入されて嵌着される位置決め穴９が穿設され、回路形成体５を接続ケース２の基壁３に装着する際、基壁３側の位置決め突起８を回路形成体５側の位置決め穴９に嵌着することにより回路形成体を位置決めし、接続ケース２内に突設された雄端子６が偏位せずに所定位置に保持されるように構成されるものである。
【０００６】
【特許文献１】
特開２００１−３９２３９号公報（発明の詳細な説明の項の段落００１９乃至段落００２７、図１（Ａ）（Ｂ）及び図５（Ａ））
【０００７】
【発明が解決しようとする課題】
このような電気接続箱は、前記位置決め突起８が位置決め穴９に隙間なく嵌着されるので、回路形成体５を接続ケース２の基壁３に装着する際、回路形成体を的確に位置決めすることができるが、接続ケース２の基壁３に位置決め突起８を突設するスペースと、回路形成体５のホルダ７に位置決め穴９を穿設するスペースを設ける必要があり、また、ホルダ７の回路パターン形状を位置決め穴９を迂回するように大きく外側に広げて配索する必要があるため、接続ケース２及び回路形成体５の形状が大きくなり、電気接続箱が大型になるほか、接続ケース２及び回路形成体５の形状が大きくなり、また、位置決め突起８が突設されるので、材料費が嵩みコストが高くなるという問題があった。
【０００８】
本発明は上記の課題を解決し、回路形成体を接続ケースの基壁に装着する際、位置決め突起と位置決め穴を新たに設けなくても回路形成体を的確に位置決めすることができ、電気接続箱の接続不良を防止して、その性能及び信頼性を向上させると共に、電気接続箱の小型軽量化と低コスト化を図ることができる電気接続箱を提供することを目的とするものである。
【０００９】
【課題を解決するための手段】
上記目的を達成するために、請求項１の発明は、複数の雌端子が収容される外部コネクタが挿入される接続ケースと、接続ケースの基壁に装着され、その基壁に穿設された複数の雄端子挿通穴を通して接続ケース内に突設される複数の雄端子及びこれを支持するホルダを有する回路形成体とを備え、回路形成体の雄端子が接続ケース内に挿入された外部コネクタの雌端子に挿入されて外部コネクタと接続される電気接続箱において、前記接続ケースの基壁に穿設された複数の雄端子挿通穴のうち、一部の雄端子挿通穴が他の雄端子挿通穴よりも小形状に形成された位置決め基準穴であり、前記複数の雄端子は、幅、長さ及び高さが同一寸法で、且つ同一形状に形成されていることを特徴とする。
【００１０】
このような構成によると、前記位置決め基準穴を従来の位置決め穴として、また、位置決め基準穴を通る雄端子を従来の位置決め突起としてそれぞれ利用することができ、回路形成体を接続ケースの基壁に装着する際、幅、長さ及び高さを同一寸法で、且つ同一形状に形成している雄端子をその位置決め基準穴に小さな隙間で通し、回路形成体を所定位置に速やかに誘導して保持することが可能になる。これにより、従来必要とした位置決め突起と位置決め穴を新たに設けなくても、回路形成体を的確に位置決めすることができる。その結果、回路形成体をその基壁に装着したとき、接続ケース内に突設された雄端子が所定位置から偏位することがなくなり、外部コネクタを電気接続箱に挿入したとき、雄端子と雌端子を整合させて、両端子の接続不良を防止し、電気接続箱の性能及び信頼性を向上させることができる。
【００１１】
また、接続ケースの基壁に位置決め突起を突設するスペースと、回路形成体のホルダに位置決め穴を穿設するスペースを設ける必要がなくなるほか、ホルダの回路パターン形状を位置決め穴を迂回するように大きく外側に広げて配索する必要もなくなるので、接続ケース及び回路形成体の形状が小さくなり、電気接続箱を小型軽量にすることができる。更に、接続ケース及び回路形成体の形状が小さくなり、位置決め突起が不要になるので、材料費が節約され、電気接続箱のコストを安くすることができる。
【００１２】
請求項２の発明は、前記位置決め基準穴が接続ケースの基壁の中心近傍に穿設され、該中心近傍に穿設された位置決め基準穴は、前記雄端子が挿通した際に左右上下の隙間が小さくなる程度に小形状に形成されていることを特徴とする請求項１に記載の電気接続箱である。
【００１３】
このような構成によると、雄端子が挿通した際に左右上下の隙間が小さくなる程度に小形状に形成された位置決め基準穴が回路形成体のほぼ重心近傍の位置に穿設されることになり、回路形成体をバランスよく位置決めすることができ、回路形成体を接続ケースの基壁に容易に装着することができる。
【００１４】
請求項３の発明は、前記位置決め基準穴が接続ケースの基壁の中心近傍及び中心近傍から半径方向に離間した複数個所に穿設された雄端子挿通穴であって、該中心近傍に穿設された位置決め基準穴は、前記雄端子が挿通した際に左右上下の隙間が小さくなる程度に小形状に形成されていることを特徴とする請求項１に記載の電気接続箱である。
【００１５】
このような構成によると、回路形成体の雄端子の個数が増えても、回路形成体をバランスよく位置決めすることができるほか、位置決めの精度を向上させることができる。
【００１６】
本発明の請求項４に記載された発明は、請求項３記載の電気接続箱において、前記位置決め基準穴が接続ケースの基壁の中心近傍から半径方向に離間した複数個所に穿設された雄端子挿通穴であって、Ｘ軸方向に離間した個所に穿設された雄端子挿通穴のＹ軸方向の軸径長と、Ｙ軸方向に離間した個所に穿設された雄端子挿通穴のＸ軸方向の軸径長とを、それぞれ位置決め基準穴以外の他の雄端子挿通穴の相当する軸方向の軸径長よりも短くすることにより小形状に形成されることを特徴とするものである。
【００１７】
このような構成によると、Ｘ軸方向に形成された位置決め基準穴のＹ軸方向における雄端子との隙間と、Ｙ軸方向に形成された位置決め基準穴のＸ軸方向における隙間が小さくなるため、位置決め基準穴に挿入される雄端子のＸ軸方向及びＹ軸方向の横振れ（がたつき）が抑えられ、回路形成体を的確に位置決めすることができる。
【００１８】
また、Ｘ軸方向に形成された位置決め基準穴のＸ軸方向の軸径長と、Ｙ軸方向に形成された位置決め基準穴のＹ軸方向の軸径長は、前記他の雄端子挿通穴の相当する軸径長の軸径長と変わらないため、Ｘ軸方向に形成された位置決め基準穴のＸ軸方向における雄端子との隙間と、Ｙ軸方向に形成された位置決め基準穴のＹ軸方向における雄端子との隙間には余裕ができる。そこで、接続ケースの基壁及び回路形成体の各中心近傍からＸ、Ｙ軸方向に離間するに伴い、雄端子挿通穴と雄端子のＸ、Ｙ軸方向の各ピッチ変動が累積され、対向する雄端子挿通穴と雄端子がＸ、Ｙ軸方向に位置ずれ、即ち、センター不一致（不整合）を生じても、Ｘ、Ｙ軸方向には前記のように隙間に余裕があるため、回路形成体を接続ケースの基壁に装着する際、回路形成体の雄端子を位置決め基準穴に無理なく通すことができ、回路形成体の装着が容易になって、電気接続箱の製造（組立）能率を向上させることができる。
【００１９】
【発明の実施の形態】
次に、本発明の実施形態を図面により詳細に説明する。図１は本発明に係る電気接続箱１１の一実施形態を示す分解斜視図で、これに外部コネクタ１３が挿入される状態のもの、図２は図１の電気接続箱を外部コネクタが挿入される側から見た正面図、図３は電気接続箱１１に外部コネクタ１３が挿入された状態における図２のＳ―Ｓ線矢視一部省略断面図である。
【００２０】
本実施形態の電気接続箱は自動車用ワイヤーハーネスの多極コネクタとして使用されるもので、図１乃至３に示すように、複数の雌端子（図示省略）が収容される外部コネクタ１３が挿入（外挿を含む）される接続ケース（アッパーケース）１５と、接続ケース１５の基壁１７に装着され、その基壁１７に穿設された複数（図示例は１００個）の雄端子挿通穴１９を通して接続ケース１５内に突設される複数（図示例は１００個）の雄端子２３及びこれを支持するホルダ２５を有する回路形成体２１とを備えている。
【００２１】
外部コネクタ１３は、図１に示すように、例えば、ワイヤーハーネス用電線（図示省略）の端末に接続された雌端子（図示省略）を収容する端子収容室２９が複数室（図示例は１０室）単層に併設され、プラスチック成形加工により板状に形成された同一構造、サイズの１０個のコネクタハウジング２７を複数段（図示例は１０段）に積層し、ハウジング連結手段（図示省略）で合体し、最上段のコネクタハウジング２７の上にカバー３１を装着した積層コネクタで構成される。
【００２２】
３３は電気接続箱１１に挿入された外部コネクタ１３が電気接続箱１１から抜け出ないように着脱自在にロック（固定）するために、各コネクタハウジング２７の前端側両側部に設けられた略コ字形状の係合凹部であり、外部コネクタ１３が電気接続箱１１に挿入されたとき、その接続ケース１５側に設けられた後記する係合爪部３５と係合し、外部コネクタ１３がロックされる。なお、外部コネクタ１３は積層コネクタ以外にプラスチック等で形成されたコネクタブロックに複数室の端子収容室２９を設けたもの等種々のタイプのものが適用される。
【００２３】
接続ケース１５は、図１に示すように、４角形状箱型にプラスチック材を成形加工することにより形成され、一方の開口から挿入される外部コネクタ１３を受け入れて収容するコネクタ収容室３７が設けられる。そして、コネクタ収容室３７が設けられている接続ケース１５の両内壁面に、外部コネクタ１３におけるコネクタハウジング２７の両側部が案内されながら挿入される案内溝３９が、接続ケース１５の長手方向、即ち、外部コネクタ１３の挿入方向に沿って、且つ、上下方向に外部コネクタ１３のコネクタハウジング２７の積層間隔に合致する間隔で併設されている。
【００２４】
また、接続ケース１５のコネクタ収容室３７が設けられている両側壁にあって、接続ケース１５に外部コネクタ１３が挿入されたとき、例えば、該コネクタ１３の３段目と８段目のコネクタハウジング２７が案内されながら挿入される案内溝３９のある部位に、先端側に外部コネクタ１３のコネクタハウジング２７に設けられた係合凹部３３に係合する爪３６を有し、弾性片からなる係合爪部３５が片持ち状に設けられている（図１、３参照）。
【００２５】
接続ケース１５のコネクタ収容室３７に突設される１００個の雄端子２３は、図１、３に示すように、銅、銅合金材料等の良導電材料で製作されたピン状接続部材からなる。これら雄端子２３は、例えば、断面正方形状で、幅、高さ及び長さ共に皆同じ寸法に形成されている。雄端子２３の形状は断面矩形状又は断面円形状等としてもよい。また、ホルダ２５はプラスチック等の絶縁板の一面（裏面）に銅箔等の導電体からなる回路パターンが印刷等により設けられた回路基板からなる。そして、雄端子２３は、その基端側がホルダ２５の他面（表面）に、ホルダ２５を貫通して支持されると共に、その回路パターンにはんだ付けされて接続されている。なお、回路形成体２１を構成する雄端子２３及びホルダ２５は銅、銅合金材料等の良導電材料からなるブスバーで構成するようにしてもよい。
【００２６】
回路形成体２１は、図３に示すように、接続ケース１５のコネクタ収容室３７の反対側に基壁１７を隔てて設けられた回路形成体収容室４１に収容され、接続ケース１５の基壁１７に装着されると共に、回路形成体２１の雄端子２３が基壁１７に穿設された雄端子挿通穴１９を通してコネクタ収容室３７内に突設され、外部コネクタ１３の雌端子に挿入されて接続されるようになっている。４３は、図１、３に示すように、接続ケース１５の回路形成体収容室４１の開口部に取り付けられて、回路形成体収容室４１に収容される回路形成体２１を保持すると共に保護するケースカバー（ロアケース）である。
【００２７】
ところで、回路形成体２１を接続ケース１５の基壁１７に装着する際、回路形成体２１を的確に位置決めして装着できるように、接続ケース１５の基壁１７に穿設された複数（図示例は１００個）の雄端子挿通穴１９のうち、一部の雄端子挿通穴１９が他の雄端子挿通穴１９よりも小形状に形成された位置決め基準穴２０に構成されている。
【００２８】
更に詳細に説明すると、例えば、図２に示すものでは、１００個の雄端子挿通穴１９のうち、５個の雄端子挿通穴１９を他の雄端子挿通穴１９よりも小形状とすることにより、位置決め基準穴２０ａ、２０ｂ、２０ｃが形成される。即ち、位置決め基準穴２０ａは接続ケース１５の基壁１７の中心近傍に穿設された雄端子挿通穴１９を小形状にして形成される。また、位置決め基準穴２０ｂは、接続ケースの基壁の中心近傍、位置決め基準穴２０ａから半径方向に離間した複数個所、図示例ではＸ軸方向に離間した左右周辺部（左右側端部）にある各１個、計２個の雄端子挿通穴１９を小形状にして形成される。更に、位置決め基準穴２０ｃは、接続ケースの基壁の中心近傍、位置決め基準穴２０ａから半径方向に離間した複数個所、図示例ではＹ軸方向に離間した上下周辺部（上下端部）にある各１個、計２個の雄端子挿通穴１９を小形状にして形成される。
【００２９】
そして、雄端子挿通穴１９及び位置決め基準穴２０は断面角形状に形成され、位置決め基準穴２０ｂ、２０ｃを除く雄端子挿通穴１９及び位置決め基準穴２０ａは断面正方形状に形成される。位置決め基準穴２０を除く雄端子挿通穴１９は、雄端子２３を容易に挿入し得る程度の隙間を有する大きさの断面正方形状に形成される。
【００３０】
位置決め基準穴２０ａは断面正方形状であるが、位置決め基準穴２０以外の他の雄端子挿通穴１９よりもＸ軸方向の軸径長及びＹ軸方向の軸径長を短くした小形状に形成される。これにより、位置決め基準穴２０ａを通る雄端子２３間の左右上下の隙間が小さくなり、雄端子２３のＸ軸方向及びＹ軸方向の横振れ（がたつき）が抑えられる。
【００３１】
また、左右２個の位置決め基準穴２０ｂは、Ｙ軸方向の軸径長が位置決め基準穴２０以外の他の雄端子挿通穴１９の相当する軸方向（Ｙ軸方向）の軸径長よりも短くした小形状に形成され、Ｙ軸方向における雄端子２３との隙間が小さくなるため、位置決め基準穴２０ｂに挿入される雄端子２３のＹ軸方向の横振れ（がたつき）がより確実に抑えられる。一方、Ｘ軸方向の軸径長は位置決め基準穴２０以外の他の雄端子挿通穴１９の相当する軸方向（Ｘ軸方向）の軸径長と変わらないため、これら位置決め基準穴２０ｂは横長の矩形状になり、位置決め基準穴２０ｂのＸ軸方向における雄端子２３との隙間には余裕ができる。そこで、接続ケース１５の基壁１７及び回路形成体２１の各中心近傍からＸ軸方向に離間するに伴い、雄端子挿通穴１９と雄端子２３のＸ軸方向の各ピッチ変動量が累積され、対向する雄端子挿通穴１９と雄端子２３がＸ軸方向に位置ずれを生じても、雄端子２３を位置決め基準穴２０ｂに容易に通すことができる。
【００３２】
更に、上下２個の位置決め基準穴２０ｃは、Ｘ軸方向の軸径長が位置決め基準穴２０以外の他の雄端子挿通穴１９の相当する軸方向（Ｘ軸方向）の軸径長よりも短くした小形状に形成され、Ｘ軸方向における雄端子２３との隙間が小さくなるため、位置決め基準穴２０ｃに挿入される雄端子２３のＸ軸方向の横振れ（がたつき）がより確実に抑えられる。一方、Ｙ軸方向の軸径長は位置決め基準穴２０以外の他の雄端子挿通穴１９の相当する軸方向（Ｙ軸方向）の軸径長と変わらないため、これら位置決め基準穴２０ｃは縦長の矩形状になり、位置決め基準穴２０ｃのＹ軸方向における雄端子２３との隙間には余裕ができる。そこで、接続ケース１５の基壁１７及び回路形成体２１の各中心近傍からＹ軸方向に離間するに伴い、雄端子挿通穴１９と雄端子２３のＹ軸方向の各ピッチ変動量が累積され、対向する雄端子挿通穴１９と雄端子２３がＹ軸方向に位置ずれを生じても、雄端子２３を位置決め基準穴２０ｃに容易に通すことができる。こうして、回路形成体２１を接続ケース１５の基壁１７に装着する際、回路形成体２１を的確に位置決めすることができるほか、回路形成体２１の装着が容易になり、電気接続箱１１の製造（組立）能率を向上させることができる。なお、雄端子挿通穴１９及び位置決め基準穴２０の形状は断面正方形状、断面矩形状、断面三角形状等の断面角形状のほかに、断面円形状、断面楕円形状等としてもよい。
【００３３】
前記位置決め基準穴２０は、図２に示すもの以外に、接続ケース１５の基壁１７の中心近傍に穿設された１又は複数の雄端子挿通穴１９だけから小形状に形成されるものでもよい。また、基壁１７の中心近傍から半径方向（Ｘ軸方向、Ｙ軸方向、ＸＹ軸方向）の任意の個所まで離間した１又は複数個所に穿設された雄端子挿通穴１９だけから小形状に形成されるものでもよい。更に、中心近傍に穿設された雄端子挿通穴１９と中心近傍からＸ軸方向、Ｙ軸方向又はＸＹ軸方向の任意の個所まで離間した１又は複数個所に穿設された雄端子挿通穴１９とから小形状に形成されるもの等でもよい。
【００３４】
なお、雄端子挿通穴１９から小形状に形成される位置決め基準穴２０が１個の場合には、どの方向に配置される場合でも、その位置決め基準穴２０以外の他の雄端子挿通穴１９よりもＸ軸方向の軸径長及びＹ軸方向の軸径長を短くした小形状にするのが望ましい。また、複数の位置決め基準穴２０が離間して配置される場合でも、Ｘ軸方向又はＹ軸方向だけに配置される場合には、１個の場合と同様に、これら位置決め基準穴２０以外の他の雄端子挿通穴１９よりもＸ軸方向の軸径長及びＹ軸方向の軸径長を短くした小形状にするのが望ましい。
【００３５】
このように、前記接続ケース１５の基壁１７に穿設された複数の雄端子挿通穴１９のうち、一部の雄端子挿通穴１９が他の雄端子挿通穴１９よりも小形状に形成された位置決め基準穴２０で構成されることにより、その位置決め基準穴２０を従来の位置決め穴として、また、位置決め基準穴２０を通る雄端子２３を従来の位置決め突起としてそれぞれ利用することができ、回路形成体２１を接続ケース１５の基壁１７に装着する際、雄端子２３をその位置決め基準穴２０に小さな隙間で通し、回路形成体２１を所定位置に速やかに誘導して保持することが可能になる。これにより、従来必要とした位置決め突起と位置決め穴を新たに設けなくても、回路形成体２１を的確に位置決めすることができる。その結果、回路形成体２１をその基壁１７に装着したとき、接続ケース１５内に突設された雄端子２３が所定位置から偏位することがなくなり、外部コネクタ１３を電気接続箱１１に挿入したとき、雄端子２３と雌端子を整合させて、両端子の接続不良を防止し、電気接続箱１１の性能及び信頼性を向上させることができる。
【００３６】
また、接続ケース１の基壁１７に位置決め突起を突設するスペースと、回路形成体２１のホルダ２５に位置決め穴を穿設するスペースを設ける必要がなくなるほか、ホルダ２５の回路パターン形状を位置決め穴を迂回するように大きく外側に広げて配索する必要もなくなるので、接続ケース１５及び回路形成体２１の形状が小さくなり、電気接続箱１１を小型軽量にすることができる。更に、接続ケース１５及び回路形成体２１の形状が小さくなり、位置決め突起が不要になるので、材料費が節約され、電気接続箱１１のコストを安くすることができる。
【００３７】
また、前記位置決め基準穴２０が接続ケース１５の基壁１７の中心近傍に穿設された雄端子挿通穴１９から小形状に形成されることにより、位置決め基準穴２０が回路形成体２１のほぼ重心近傍の位置に穿設されることになり、回路形成体２１をバランスよく位置決めすることができ、回路形成体２１を接続ケース１５の基壁１７に容易に装着することができる。
【００３８】
また、前記位置決め基準穴２０が接続ケース１５の基壁１７の中心近傍から半径方向に離間した複数個所に穿設された雄端子挿通穴１９から小形状に形成されることにより、回路形成体２１の雄端子２３の個数が増えても、回路形成体２１をバランスよく位置決めすることができるほか、位置決めの精度を向上させることができる。
【００３９】
更に、前記位置決め基準穴２０（２０ｂ、２０ｃ）が接続ケース１５の基壁１７の中心近傍から半径方向に離間した複数個所に穿設された雄端子挿通穴１９であって、Ｘ軸方向に離間した個所に穿設された雄端子挿通穴１９のＹ軸方向の軸径長と、Ｙ軸方向に離間した個所に穿設された雄端子挿通穴１９のＸ軸方向の軸径長とを、それぞれ位置決め基準穴２０以外の雄端子挿通穴１９の相当する軸方向の軸径長よりも短くすることにより小形状に形成されることにより、位置決め基準穴２０（２０ｂ、２０ｃ）に挿入される雄端子２３のＸ軸方向及びＹ軸方向の横振れ（がたつき）が抑えられ、回路形成体２１を的確に位置決めすることができる。
【００４０】
また、Ｘ軸方向に形成された位置決め基準穴２０ｂのＸ軸方向の軸径長と、Ｙ軸方向に形成された位置決め基準穴２０ｃのＹ軸方向の軸径長は、前記他の雄端子挿通穴１９の相当する軸径長の軸径長と変わらないため、位置決め基準穴２０ｂのＸ軸方向における雄端子２３との隙間と、位置決め基準穴２０ｃのＹ軸方向における雄端子２３との隙間には余裕ができ、雄端子挿通穴１９と雄端子２３がＸ、Ｙ軸方向に位置ずれを生じても、回路形成体２１を接続ケース１５の基壁１７に装着する際、回路形成体２１の雄端子２３を位置決め基準穴２０（２０ｂ、２０ｃ）に無理なく通すことができ、回路形成体の装着が容易になる。
【００４１】
本発明の電気接続箱１１は以上のような構成になっている。この電気接続箱１１を使用する場合には、電気接続箱１１における接続ケース１５のコネクタ収容室３７に、外部コネクタ１３を対向させて、電気接続箱１１と外部コネクタ１３のセンターを合わせて、電気接続箱１１のコネクタ収容室３７に外部コネクタ１３を挿入する。そして、電気接続箱１１側の係合爪部３５の爪３６を外部コネクタ１３側の係合凹部３３に係合して、電気接続箱１１に外部コネクタ１３をロックすると共に、電気接続箱１１側の雄端子２３を外部コネクタ１３側の雌端子に挿入して接続する。
【００４２】
図４に示すものは、例えば、図１乃至３に示す実施形態の電気接続箱１１において、接続ケース１５の外周面の４個所、即ち、Ｘ軸方向の両側面及びＹ軸方向の上面、底面の計４個所に、外部コネクタ１３が挿入される方向に沿って設けられた、例えば、断面Ｖ形状の案内溝４５である。この案内溝４５は、電気接続箱１１に導通検査治具（図示省略）をセンター軸を合わせて円滑に挿入するために設けられるもので、導通検査治具の方には案内溝４５に嵌合する断面Ｖ形状の案内突部が設けられている。
【００４３】
なお、案内溝４５の代わりに案内突部を設け、導通検査治具の方に案内溝を設けるようにしてもよい。また、案内溝、案内突部の形状は断面Ｖ形状に限定されるものではなく、断面半円形状、断面Ｕ形状、断面Ｔ形状、断面コ字形状、断面蟻溝形状等でもよい。更に、案内溝４５、案内突部の個数は１個又は複数（前記４個以外）としてもよい。その他の構成は図１乃至３に記載されたものと同じなので詳細説明を省略する。
【００４４】
このように案内溝４５又は案内突部が設けられていると、電気接続箱１１の導通検査をするために、導通検査治具を挿入する際、該検査治具を円滑に、且つ、的確に挿入することができ、電気接続箱１１の検査精度を向上させることができる。
【００４５】
【発明の効果】
以上説明したように、請求項１の発明の電気接続箱によると、複数の雄端子を幅、長さ及び高さが同一寸法で、且つ同一形状に形成し、接続ケースの基壁に穿設された複数の雄端子挿通穴のうち、一部の雄端子挿通穴を、他の雄端子挿通穴よりも雄端子が挿通した際に左右上下の隙間が小さくなる程度に小形状に形成した位置決め基準穴としたことで、これらの位置決め基準穴を従来の位置決め穴、又位置決め基準穴を通る雄端子を従来の位置決め突起としてそれぞれ利用することができ、回路形成体を接続ケースの基壁に装着する際、雄端子をその位置決め基準穴に小さな隙間で通し、回路形成体を所定位置に速やかに誘導して保持することが可能になる。
これにより、従来必要とした位置決め突起と位置決め穴を新たに設けなくても、回路形成体を的確に位置決めすることができる。その結果、回路形成体をその基壁に装着したとき、接続ケース内に突設された雄端子が所定位置から偏位することがなくなり、外部コネクタを電気接続箱に挿入したとき、雄端子と雌端子を整合させて、両端子の接続不良を防止し、電気接続箱の性能及び信頼性を向上させることができる。
【００４６】
また、接続ケースの基壁に位置決め突起を突設するスペースと、回路形成体のホルダに位置決め穴を穿設するスペースを設ける必要がなくなるほか、ホルダの回路パターン形状を位置決め穴を迂回するように大きく外側に広げて配索する必要もなくなるので、接続ケース及び回路形成体の形状が小さくなり、電気接続箱を小型軽量にすることができる。更に、接続ケース及び回路形成体の形状が小さくなり、位置決め突起が不要になるので、材料費が節約され、電気接続箱のコストを安くすることができる。
【００４７】
請求項２の発明の電気接続箱によると、位置決め基準穴が接続ケースの基壁の中心近傍に穿設され、且つ雄端子が挿通した際に左右上下の隙間が小さくなる程度に小形状に形成されているので、前記小形状に形成された位置決め基準穴は回路形成体のほぼ重心近傍の位置に穿設されることになり、回路形成体をバランスよく位置決めすることができ、回路形成体を接続ケースの基壁に容易に装着することができる。
【００４８】
請求項３の発明の電気接続箱によると、位置決め基準穴が接続ケースの基壁の中心近傍及び中心近傍から半径方向に離間した複数個所に穿設された雄端子挿通穴であり、接続ケースの基壁の中心近傍に穿設された位置決め基準穴は、雄端子が挿通した際に左右上下の隙間が小さくなる程度に小形状に形成されているので、回路形成体の雄端子の個数が増えても、回路形成体をバランスよく位置決めすることができるほか、位置決めの精度を向上させることができる。
【００４９】
本発明の請求項４に記載された電気接続箱によると、前記位置決め基準穴が接続ケースの基壁の中心近傍から半径方向に離間した複数個所に穿設された雄端子挿通穴であって、Ｘ軸方向に離間した個所に穿設された雄端子挿通穴のＹ軸方向の軸径長と、Ｙ軸方向に離間した個所に穿設された雄端子挿通穴のＸ軸方向の軸径長とを、それぞれ位置決め基準穴以外の雄端子挿通穴の相当する軸方向の軸径長よりも短くすることにより小形状に形成されるので、位置決め基準穴に挿入される雄端子のＸ軸方向及びＹ軸方向の横振れ（がたつき）が抑えられ、回路形成体を的確に位置決めすることができる。
【００５０】
また、Ｘ軸方向に形成された位置決め基準穴のＸ軸方向の軸径長と、Ｙ軸方向に形成された位置決め基準穴のＹ軸方向の軸径長は、前記他の雄端子挿通穴の相当する軸径長の軸径長と変わらないため、Ｘ軸方向に形成された位置決め基準穴のＸ軸方向における雄端子との隙間と、Ｙ軸方向に形成された位置決め基準穴のＹ軸方向における雄端子との隙間には余裕ができ、雄端子挿通穴と雄端子がＸ、Ｙ軸方向に位置ずれを生じても、回路形成体を接続ケースの基壁に装着する際、回路形成体の雄端子を位置決め基準穴に無理なく通すことができ、回路形成体の装着が容易になって、電気接続箱の製造（組立）能率を向上させることができる。
【図面の簡単な説明】
【図１】本発明に係る電気接続箱の一実施形態を示す分解斜視図で、これに外部コネクタが挿入される状態のものである。
【図２】図１の電気接続箱を外部コネクタが挿入される側から見た正面図（雄端子省略）である。
【図３】電気接続箱に外部コネクタが挿入された状態における図２のＳ―Ｓ線矢視一部省略断面図である。
【図４】本発明の電気接続箱の他の実施形態を示すもので、外部コネクタが挿入される側から見た正面図である。
【図５】従来の電気接続箱に外部コネクタが挿入された状態における図２のＳ―Ｓ線矢視相当の一部省略断面図である。
【符号の説明】
１１電気接続箱
１３外部コネクタ
１５接続ケース
１７基壁
１９雄端子挿通穴
２０位置決め基準穴
２０ａ位置決め基準穴
２０ｂ位置決め基準穴
２０ｃ位置決め基準穴
２１回路形成体
２３雄端子
２５ホルダ
２７コネクタハウジング
２９端子収容室
３１カバー
３３係合凹部
３５係合爪部
３６爪
３７コネクタ収容室
３９案内溝
４１回路形成体収容室
４３ケースカバー
４５案内溝[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electrical junction box used for branch connection of a wire harness routed in an automobile or the like.
[0002]
[Prior art]
This type of electrical junction box is usually connected to a connection case into which an external connector that accommodates a plurality of female terminals is inserted, and a plurality of male terminal insertion holes that are attached to the base wall of the connection case and drilled in the base wall. A circuit forming body having a plurality of male terminals projecting into the connection case through holes and a holder made of a circuit board for supporting the male terminals, and an external connector in which the male terminals of the circuit forming body are inserted into the connection case It is configured to be inserted into a female terminal and connected to an external connector. (See Patent Document 1).
[0003]
In recent years, this type of electric junction box used for a wire harness has been increasingly multipolar, and the number of male terminals of a circuit formed body tends to increase. As the number of male terminals increases, the dimensions and mounting accuracy of the male terminals of the circuit formed body vary, so it is easy to smoothly pass these male terminals through the male terminal insertion holes drilled in the base wall of the connection case. In addition, it takes time to manufacture (assemble) the electrical junction box, and when the male terminal is passed through the male terminal insertion hole, the male terminal is deformed or damaged, thereby reducing the performance and quality of the electrical junction box. There is a fear. For this reason, normally, the male terminal insertion hole drilled in the base wall of the connection case is formed so that the hole diameter is larger than the outer diameter of the male terminal, and the male terminal of the circuit forming body is It passes smoothly through the male terminal insertion hole (see FIG. 1B of Patent Document 1).
[0004]
By the way, when the hole diameter of the male terminal insertion hole is provided with a margin in this way, it becomes easy to attach the circuit formed body to the base wall of the connection case, but the gap between the male terminal and the male terminal insertion hole (gap) ) Becomes larger, and it is difficult to accurately position the circuit formed body on the base wall of the connection case. When the circuit formed body is mounted on the base wall, the male terminal protruding in the connection case When the external connector is inserted into the electrical connection box, it is difficult for the male terminal and the female terminal to be aligned with each other, which may cause poor connection between the two terminals.
[0005]
In order to solve such a problem, an electrical junction box as shown in FIG. 5 has been proposed and used. The electrical connection box is mounted on the base wall 3 of the connection case 2 into which the external connector 1 that accommodates a plurality of female terminals is inserted, and the base wall 3 of the connection case 2 in the same manner as the above-mentioned connection box. A plurality of male terminals 6 projecting into the connection case 2 through the plurality of male terminal insertion holes 4 and a circuit forming body 5 having a holder 7 made of a circuit board that supports the male terminals 6. In the configuration in which the male terminal 6 is inserted into the female terminal of the external connector 1 inserted into the connection case 2 and connected to the external connector 1, the positioning projection 8 protrudes at the center of the base wall 3 of the connection case 2. A positioning hole 9 is provided in which the positioning projection 8 is inserted and fitted into the holder 7 of the circuit forming body 5 with a small gap, and when the circuit forming body 5 is attached to the base wall 3 of the connection case 2, The positioning projection 8 on the base wall 3 side is connected to the circuit forming body 5 side. Positioning the circuit forming body by fitting the positioning holes 9, in which the male terminals 6 which protrude into the connection case 2 is configured to be retained in position without excursion.
[0006]
[Patent Document 1]
JP 2001-39239 A (paragraphs 0019 to 0027 in the Detailed Description of the Invention, FIGS. 1A and 1B and FIG. 5A)
[0007]
[Problems to be solved by the invention]
In such an electrical junction box, the positioning protrusion 8 is fitted into the positioning hole 9 without a gap, so that when the circuit forming body 5 is mounted on the base wall 3 of the connection case 2, the circuit forming body is accurately positioned. However, it is necessary to provide a space for projecting the positioning projection 8 on the base wall 3 of the connection case 2 and a space for drilling the positioning hole 9 in the holder 7 of the circuit forming body 5. Since the circuit pattern shape needs to be widened and routed so as to bypass the positioning hole 9, the shape of the connection case 2 and the circuit forming body 5 becomes large, the electric connection box becomes large, and the connection case 2 and the shape of the circuit forming body 5 are increased, and the positioning protrusion 8 is provided so as to increase the material cost and increase the cost.
[0008]
The present invention solves the above problems, and when the circuit formed body is mounted on the base wall of the connection case, the circuit formed body can be accurately positioned without newly providing positioning protrusions and positioning holes. An object of the present invention is to provide an electrical junction box that can prevent poor connection of the box, improve its performance and reliability, and reduce the size, weight, and cost of the electrical junction box.
[0009]
[Means for Solving the Problems]
  In order to achieve the above object, the invention of claim 1 is provided with a connection case into which an external connector accommodating a plurality of female terminals is inserted, a base wall of the connection case, and a hole formed in the base wall. An external connector comprising a plurality of male terminals projecting into a connection case through a plurality of male terminal insertion holes and a circuit forming body having a holder for supporting the male terminals, the male terminals of the circuit forming body being inserted into the connection case In the electrical connection box that is inserted into the female terminal and connected to the external connector, among the plurality of male terminal insertion holes formed in the base wall of the connection case, some male terminal insertion holes are other male terminals. It is a positioning reference hole formed smaller than the insertion hole, and the plurality of male terminals are,Same width, length and heightAnd the same shapeIt is formed by.
[0010]
  According to such a configuration, the positioning reference hole can be used as a conventional positioning hole, and the male terminal passing through the positioning reference hole can be used as a conventional positioning protrusion, and the circuit formed body can be used as the base wall of the connection case. When mounting, the same dimensions for width, length and heightAnd the same shapeIt is possible to pass the male terminal formed in the first through the positioning reference hole with a small gap and promptly hold the circuit formed body at a predetermined position. As a result, the circuit formed body can be accurately positioned without newly providing positioning protrusions and positioning holes that are conventionally required. As a result, when the circuit forming body is mounted on the base wall, the male terminal protruding in the connection case is not displaced from the predetermined position, and when the external connector is inserted into the electrical connection box, By aligning the female terminals, it is possible to prevent poor connection between the two terminals and improve the performance and reliability of the electrical junction box.
[0011]
In addition, there is no need to provide a space for projecting the positioning protrusion on the base wall of the connection case and a space for drilling the positioning hole in the holder of the circuit forming body, and the circuit pattern shape of the holder is bypassed from the positioning hole. Since there is no need to greatly extend and route the wiring case, the shapes of the connection case and the circuit forming body are reduced, and the electrical connection box can be reduced in size and weight. Furthermore, since the shapes of the connection case and the circuit forming body are reduced and positioning protrusions are not required, material costs are saved, and the cost of the electrical connection box can be reduced.
[0012]
  According to a second aspect of the present invention, the positioning reference hole is formed in the vicinity of the center of the base wall of the connection case, and the positioning reference hole formed in the vicinity of the center has a gap between left and right and up and down when the male terminal is inserted. The electrical junction box according to claim 1, wherein the electrical junction box is formed in a small shape so as to be small.
[0013]
  According to such a configuration, when the male terminal is inserted, the positioning reference hole formed in a small shape so that the left and right and upper and lower gaps are reduced is drilled at a position near the center of gravity of the circuit forming body. The circuit formed body can be positioned with good balance, and the circuit formed body can be easily attached to the base wall of the connection case.
[0014]
  According to a third aspect of the present invention, the positioning reference hole is a male terminal insertion hole formed at a plurality of locations in the vicinity of the center of the base wall of the connection case and at a plurality of locations spaced radially from the center. 2. The electrical connection box according to claim 1, wherein the positioning reference hole is formed in a small shape such that a gap between left and right and up and down is reduced when the male terminal is inserted.
[0015]
According to such a configuration, even if the number of male terminals of the circuit formed body is increased, the circuit formed body can be positioned with good balance and the positioning accuracy can be improved.
[0016]
According to a fourth aspect of the present invention, in the electric junction box according to the third aspect, the positioning reference hole is formed at a plurality of locations spaced radially from the vicinity of the center of the base wall of the connection case. The terminal insertion hole, the axial length in the Y-axis direction of the male terminal insertion hole drilled at a location separated in the X-axis direction, and the male terminal insertion hole drilled in a location separated in the Y-axis direction. It is characterized in that it is formed in a small shape by making the axial diameter length in the X-axis direction shorter than the corresponding axial diameter length of the male terminal insertion hole other than the positioning reference hole. is there.
[0017]
According to such a configuration, the gap between the positioning reference hole formed in the X-axis direction and the male terminal in the Y-axis direction and the gap in the X-axis direction of the positioning reference hole formed in the Y-axis direction are reduced. Lateral shake (rattle) in the X-axis direction and Y-axis direction of the male terminal inserted into the positioning reference hole is suppressed, and the circuit formed body can be positioned accurately.
[0018]
Also, the axial diameter length of the positioning reference hole formed in the X-axis direction in the X-axis direction and the axial diameter length of the positioning reference hole formed in the Y-axis direction in the Y-axis direction are the same as those of the other male terminal insertion holes. Since it is not different from the corresponding shaft diameter length, the gap between the positioning reference hole formed in the X-axis direction and the male terminal in the X-axis direction and the Y-direction of the positioning reference hole formed in the Y-axis direction There is room in the gap with the male terminal. Accordingly, as the base case of the connection case and the vicinity of each center of the circuit forming body are separated in the X and Y axis directions, the pitch variations of the male terminal insertion hole and the male terminal in the X and Y axis directions are accumulated and face each other. Even if the male terminal insertion hole and the male terminal are misaligned in the X and Y axis directions, that is, center mismatch (misalignment) occurs, there is a clearance in the X and Y axis directions as described above. When the body is mounted on the base wall of the connection case, the male terminal of the circuit formed body can be easily passed through the positioning reference hole, which facilitates the mounting of the circuit formed body, and the manufacturing (assembly) efficiency of the electrical connection box Can be improved.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is an exploded perspective view showing an embodiment of an electrical junction box 11 according to the present invention, in a state where an external connector 13 is inserted, and FIG. 2 is an electrical connector box of FIG. FIG. 3 is a partially omitted cross-sectional view taken along the line S—S in FIG. 2 in a state where the external connector 13 is inserted into the electrical connection box 11.
[0020]
The electrical junction box of this embodiment is used as a multipolar connector for an automobile wire harness, and an external connector 13 in which a plurality of female terminals (not shown) are accommodated is inserted as shown in FIGS. A connection case (upper case) 15 that includes an extrapolation, and a plurality (100 in the illustrated example) of male terminal insertion holes 19 that are attached to the base wall 17 of the connection case 15 and are formed in the base wall 17. And a circuit forming body 21 having a plurality of (100 in the illustrated example) male terminals 23 and holders 25 for supporting the male terminals 23.
[0021]
As shown in FIG. 1, the external connector 13 includes, for example, a plurality of terminal accommodating chambers 29 for accommodating female terminals (not illustrated) connected to terminals of wire harness wires (not illustrated) (in the illustrated example, 10 chambers). ) Ten connector housings 27 of the same structure and size, which are provided in a single layer and formed into a plate shape by plastic molding, are stacked in a plurality of stages (in the illustrated example, 10 stages), and the housing connecting means (not shown) It is composed of a laminated connector in which the cover 31 is mounted on the uppermost connector housing 27.
[0022]
33 is a substantially U-shape provided on both sides of the front end side of each connector housing 27 in order to detachably lock (fix) the external connector 13 inserted in the electrical connection box 11 so as not to come out of the electrical connection box 11. When the external connector 13 is inserted into the electrical connection box 11, it engages with an engagement claw portion 35 provided later on the connection case 15 side, and the external connector 13 is locked. . The external connector 13 may be of various types such as a connector block formed of plastic or the like and provided with a plurality of terminal accommodating chambers 29 in addition to the laminated connector.
[0023]
As shown in FIG. 1, the connection case 15 is formed by molding a plastic material into a quadrangular box shape, and is provided with a connector housing chamber 37 for receiving and housing the external connector 13 inserted from one opening. It is done. Then, guide grooves 39 inserted into both inner wall surfaces of the connection case 15 provided with the connector housing chamber 37 while guiding both side portions of the connector housing 27 in the external connector 13 are arranged in the longitudinal direction of the connection case 15, that is, These are provided along the insertion direction of the external connector 13 and in the vertical direction at intervals matching the stacking interval of the connector housings 27 of the external connector 13.
[0024]
Further, when the external connector 13 is inserted into the connection case 15 on both side walls where the connector housing chamber 37 of the connection case 15 is provided, for example, the third and eighth stage connector housings of the connector 13 An engagement portion made of an elastic piece has a claw 36 that engages with an engagement recess 33 provided in the connector housing 27 of the external connector 13 at a tip side at a portion where a guide groove 39 is inserted while being guided 27. The nail | claw part 35 is provided in the cantilever shape (refer FIG. 1, 3).
[0025]
As shown in FIGS. 1 and 3, the 100 male terminals 23 projecting from the connector housing chamber 37 of the connection case 15 are made of pin-like connection members made of a highly conductive material such as copper or a copper alloy material. . These male terminals 23 have, for example, a square cross section and are formed to have the same dimensions in width, height, and length. The male terminal 23 may have a rectangular cross section or a circular cross section. The holder 25 is made of a circuit board in which a circuit pattern made of a conductor such as copper foil is provided on one surface (back surface) of an insulating plate such as plastic by printing or the like. The male terminal 23 is supported on the other surface (front surface) of the holder 25 by penetrating the holder 25 and soldered to the circuit pattern. The male terminal 23 and the holder 25 constituting the circuit forming body 21 may be constituted by a bus bar made of a highly conductive material such as copper or a copper alloy material.
[0026]
As shown in FIG. 3, the circuit forming body 21 is housed in a circuit forming body housing chamber 41 provided on the opposite side of the connector housing chamber 37 of the connection case 15 with the base wall 17 therebetween. 17 and the male terminal 23 of the circuit forming body 21 protrudes into the connector housing chamber 37 through the male terminal insertion hole 19 formed in the base wall 17 and is inserted into the female terminal of the external connector 13. Connected. As shown in FIGS. 1 and 3, 43 is attached to the opening of the circuit forming body housing chamber 41 of the connection case 15 to hold and protect the circuit forming body 21 housed in the circuit forming body housing chamber 41. It is a case cover (lower case).
[0027]
By the way, when the circuit forming body 21 is mounted on the base wall 17 of the connection case 15, a plurality of (illustrated examples) drilled in the base wall 17 of the connection case 15 so that the circuit forming body 21 can be positioned and mounted accurately. Among the 100 male terminal insertion holes 19, some of the male terminal insertion holes 19 are configured as positioning reference holes 20 that are smaller than the other male terminal insertion holes 19.
[0028]
More specifically, for example, in the case shown in FIG. 2, among the 100 male terminal insertion holes 19, the five male terminal insertion holes 19 are made smaller than the other male terminal insertion holes 19. Positioning reference holes 20a, 20b, and 20c are formed. That is, the positioning reference hole 20a is formed by reducing the male terminal insertion hole 19 formed in the vicinity of the center of the base wall 17 of the connection case 15 to a small shape. Further, the positioning reference holes 20b are located near the center of the base wall of the connection case, at a plurality of locations spaced in the radial direction from the positioning reference holes 20a, in the illustrated example, in the left and right peripheral portions (left and right side end portions) spaced in the X-axis direction. Each of the two male terminal insertion holes 19 is formed in a small shape. Further, the positioning reference holes 20c are located in the vicinity of the center of the base wall of the connection case, at a plurality of locations spaced in the radial direction from the positioning reference holes 20a, and in the illustrated example, the upper and lower peripheral portions (upper and lower ends) spaced in the Y-axis direction. A total of two male terminal insertion holes 19 are formed in a small shape.
[0029]
The male terminal insertion hole 19 and the positioning reference hole 20 are formed in a square cross section, and the male terminal insertion hole 19 and the positioning reference hole 20a excluding the positioning reference holes 20b and 20c are formed in a square cross section. The male terminal insertion hole 19 excluding the positioning reference hole 20 is formed in a square cross section having a size enough to allow the male terminal 23 to be inserted easily.
[0030]
The positioning reference hole 20a has a square cross section, but is formed in a small shape in which the axial diameter length in the X-axis direction and the axial diameter length in the Y-axis direction are shorter than those of the male terminal insertion holes 19 other than the positioning reference hole 20. The As a result, the left and right upper and lower gaps between the male terminals 23 passing through the positioning reference hole 20a are reduced, and the lateral shaking (rattle) of the male terminals 23 in the X-axis direction and the Y-axis direction is suppressed.
[0031]
In addition, the two left and right positioning reference holes 20b have a shorter axial diameter in the Y-axis direction than the corresponding axial length (Y-axis direction) of the male terminal insertion hole 19 other than the positioning reference hole 20. Since the gap between the male terminal 23 and the male terminal 23 in the Y-axis direction is reduced, the lateral deflection (rattle) in the Y-axis direction of the male terminal 23 inserted into the positioning reference hole 20b is more reliably suppressed. It is done. On the other hand, since the axial diameter length in the X-axis direction is not different from the corresponding axial diameter length (X-axis direction) of the male terminal insertion hole 19 other than the positioning reference hole 20, these positioning reference holes 20b are horizontally long. It has a rectangular shape, and there is a margin in the gap between the positioning reference hole 20b and the male terminal 23 in the X-axis direction. Therefore, as the base wall 17 of the connection case 15 and the vicinity of each center of the circuit forming body 21 are separated from each other in the X-axis direction, the pitch variation amounts in the X-axis direction of the male terminal insertion hole 19 and the male terminal 23 are accumulated. Even if the opposing male terminal insertion hole 19 and male terminal 23 are displaced in the X-axis direction, the male terminal 23 can be easily passed through the positioning reference hole 20b.
[0032]
Furthermore, the upper and lower two positioning reference holes 20 c have a shorter axial diameter in the X-axis direction than the corresponding axial diameter (X-axis direction) of the male terminal insertion hole 19 other than the positioning reference hole 20. Since the gap between the male terminal 23 and the male terminal 23 in the X-axis direction is reduced, lateral vibration (rattle) in the X-axis direction of the male terminal 23 inserted into the positioning reference hole 20c is more reliably suppressed. It is done. On the other hand, since the shaft diameter length in the Y-axis direction is not different from the corresponding shaft diameter length (Y-axis direction) of the male terminal insertion hole 19 other than the positioning reference hole 20, these positioning reference holes 20c are vertically long. It has a rectangular shape, and there is a margin in the gap between the positioning reference hole 20c and the male terminal 23 in the Y-axis direction. Therefore, as the base wall 17 of the connection case 15 and the vicinity of each center of the circuit forming body 21 are separated from each other in the Y-axis direction, each pitch variation amount in the Y-axis direction of the male terminal insertion hole 19 and the male terminal 23 is accumulated. Even if the opposing male terminal insertion hole 19 and male terminal 23 are displaced in the Y-axis direction, the male terminal 23 can be easily passed through the positioning reference hole 20c. Thus, when the circuit forming body 21 is mounted on the base wall 17 of the connection case 15, the circuit forming body 21 can be accurately positioned, and the mounting of the circuit forming body 21 is facilitated. (Assembly) Efficiency can be improved. Note that the male terminal insertion hole 19 and the positioning reference hole 20 may have a cross-sectional circular shape, a cross-sectional elliptical shape, or the like in addition to a cross-sectional square shape such as a cross-sectional square shape, a cross-sectional rectangular shape, or a cross-sectional triangular shape.
[0033]
The positioning reference hole 20 may be formed in a small shape only from one or a plurality of male terminal insertion holes 19 formed near the center of the base wall 17 of the connection case 15 other than the one shown in FIG. . Further, only the male terminal insertion hole 19 formed in one or a plurality of locations spaced from the vicinity of the center of the base wall 17 to any location in the radial direction (X-axis direction, Y-axis direction, XY-axis direction) has a small shape. It may be formed. Further, the male terminal insertion hole 19 formed in the vicinity of the center and the male terminal insertion hole 19 formed in one or a plurality of positions spaced from the vicinity of the center to an arbitrary position in the X axis direction, the Y axis direction, or the XY axis direction. It may be formed into a small shape.
[0034]
When there is one positioning reference hole 20 formed in a small shape from the male terminal insertion hole 19, the male terminal insertion hole 19 other than the positioning reference hole 20 is arranged in any direction. Also, it is desirable to make the shape small by shortening the axial diameter length in the X-axis direction and the axial diameter length in the Y-axis direction. Further, even when a plurality of positioning reference holes 20 are arranged apart from each other, when they are arranged only in the X-axis direction or the Y-axis direction, as in the case of one, other than the positioning reference holes 20 It is desirable to make the X-axis direction axial length and the Y-axis direction axial diameter length smaller than the male terminal insertion hole 19.
[0035]
As described above, among the plurality of male terminal insertion holes 19 formed in the base wall 17 of the connection case 15, some male terminal insertion holes 19 are formed to be smaller than the other male terminal insertion holes 19. By forming the positioning reference hole 20, the positioning reference hole 20 can be used as a conventional positioning hole, and the male terminal 23 passing through the positioning reference hole 20 can be used as a conventional positioning protrusion. When the body 21 is mounted on the base wall 17 of the connection case 15, the male terminal 23 can be passed through the positioning reference hole 20 with a small gap so that the circuit forming body 21 can be quickly guided to a predetermined position and held. . As a result, the circuit forming body 21 can be accurately positioned without newly providing positioning protrusions and positioning holes that are conventionally required. As a result, when the circuit forming body 21 is mounted on the base wall 17, the male terminal 23 protruding in the connection case 15 is not displaced from a predetermined position, and the external connector 13 is inserted into the electrical connection box 11. When it does, the male terminal 23 and the female terminal can be aligned, the connection failure of both terminals can be prevented, and the performance and reliability of the electrical connection box 11 can be improved.
[0036]
Further, it is not necessary to provide a space for projecting the positioning projection on the base wall 17 of the connection case 1 and a space for drilling the positioning hole in the holder 25 of the circuit forming body 21, and the circuit pattern shape of the holder 25 can be changed to the positioning hole. Therefore, the connection case 15 and the circuit forming body 21 can be reduced in shape, and the electrical connection box 11 can be made smaller and lighter. Furthermore, since the shapes of the connection case 15 and the circuit forming body 21 are reduced and positioning protrusions are not required, material costs are saved, and the cost of the electrical connection box 11 can be reduced.
[0037]
Further, the positioning reference hole 20 is formed in a small shape from the male terminal insertion hole 19 formed in the vicinity of the center of the base wall 17 of the connection case 15, so that the positioning reference hole 20 is substantially at the center of gravity of the circuit forming body 21. The circuit forming body 21 can be positioned with good balance, and the circuit forming body 21 can be easily attached to the base wall 17 of the connection case 15.
[0038]
The positioning reference hole 20 is formed in a small shape from male terminal insertion holes 19 formed in a plurality of locations spaced radially from the center of the base wall 17 of the connection case 15, thereby forming a circuit forming body 21. Even if the number of male terminals 23 increases, the circuit formed body 21 can be positioned with good balance, and the positioning accuracy can be improved.
[0039]
Further, the positioning reference holes 20 (20b, 20c) are male terminal insertion holes 19 drilled at a plurality of locations spaced radially from the vicinity of the center of the base wall 17 of the connection case 15, and are spaced apart in the X-axis direction. The axial length in the Y-axis direction of the male terminal insertion hole 19 drilled in the portion and the axial diameter in the X-axis direction of the male terminal insertion hole 19 drilled in the location separated in the Y-axis direction, Each male terminal insertion hole 19 other than the positioning reference hole 20 is formed in a small shape by making it shorter than the corresponding axial length of the axial direction, so that the male inserted into the positioning reference hole 20 (20b, 20c). Lateral shake (rattle) in the X-axis direction and Y-axis direction of the terminal 23 is suppressed, and the circuit forming body 21 can be accurately positioned.
[0040]
Further, the axial diameter length of the positioning reference hole 20b formed in the X-axis direction in the X-axis direction and the axial diameter length of the positioning reference hole 20c formed in the Y-axis direction in the Y-axis direction are the other male terminal insertion lengths. Since the axial length of the corresponding axial diameter of the hole 19 is not changed, the clearance between the positioning reference hole 20b and the male terminal 23 in the X-axis direction and the clearance between the positioning reference hole 20c and the male terminal 23 in the Y-axis direction When the circuit forming body 21 is mounted on the base wall 17 of the connection case 15 even if the male terminal insertion hole 19 and the male terminal 23 are misaligned in the X and Y axis directions, The male terminal 23 can be easily passed through the positioning reference hole 20 (20b, 20c), and the circuit forming body can be easily mounted.
[0041]
The electrical junction box 11 of the present invention is configured as described above. When using this electrical connection box 11, the external connector 13 is opposed to the connector housing chamber 37 of the connection case 15 in the electrical connection box 11, and the electrical connection box 11 and the center of the external connector 13 are aligned, The external connector 13 is inserted into the connector housing chamber 37 of the connection box 11. Then, the claw 36 of the engagement claw portion 35 on the electrical connection box 11 side is engaged with the engagement recess 33 on the external connector 13 side to lock the external connector 13 to the electrical connection box 11 and the electrical connection box 11 side. The male terminal 23 is inserted into the female terminal on the external connector 13 side and connected.
[0042]
4 shows, for example, in the electrical junction box 11 of the embodiment shown in FIGS. 1 to 3, four locations on the outer peripheral surface of the connection case 15, that is, both side surfaces in the X-axis direction and top and bottom surfaces in the Y-axis direction. These are, for example, guide grooves 45 having a V-shaped cross section provided along the direction in which the external connector 13 is inserted at a total of four locations. The guide groove 45 is provided to smoothly insert a continuity inspection jig (not shown) in the electrical connection box 11 with the center axis aligned, and the continuity inspection jig is fitted into the guide groove 45. A guide projection having a V-shaped cross section is provided.
[0043]
A guide protrusion may be provided instead of the guide groove 45, and the guide groove may be provided toward the continuity inspection jig. Further, the shape of the guide groove and the guide protrusion is not limited to the V-shaped cross section, and may be a semicircular cross section, a U-shaped cross section, a T-shaped cross section, a U-shaped cross section, a dovetail cross-sectional shape, or the like. Furthermore, the number of guide grooves 45 and guide protrusions may be one or more (other than the four). Since other configurations are the same as those described in FIGS. 1 to 3, detailed description thereof will be omitted.
[0044]
When the guide groove 45 or the guide protrusion is provided in this way, when inserting the continuity inspection jig in order to inspect the continuity of the electrical connection box 11, the inspection jig can be smoothly and accurately inserted. Therefore, the inspection accuracy of the electrical junction box 11 can be improved.
[0045]
【The invention's effect】
  As described above, according to the electrical junction box of the invention of claim 1, a plurality of male terminalsTheSame width, length and heightAnd the same shapeFormed intoAndAmong the multiple male terminal insertion holes drilled in the base wall of the connection case, some male terminal insertion holes,A positioning reference hole that is formed in a small shape so that the gap on the left, right, top and bottom is smaller when the male terminal is inserted than the other male terminal insertion holes.ThatThese positioning reference holes can be used as conventional positioning holes, and the male terminals passing through the positioning reference holes can be used as conventional positioning projections, respectively, and when the circuit forming body is mounted on the base wall of the connection case, It is possible to pass through the positioning reference hole with a small gap and quickly guide and hold the circuit formed body at a predetermined position.
  As a result, the circuit formed body can be accurately positioned without newly providing positioning protrusions and positioning holes that are conventionally required. As a result, when the circuit forming body is mounted on the base wall, the male terminal protruding in the connection case is not displaced from the predetermined position, and when the external connector is inserted into the electrical connection box, By aligning the female terminals, it is possible to prevent poor connection between the two terminals and improve the performance and reliability of the electrical junction box.
[0046]
In addition, there is no need to provide a space for projecting the positioning protrusion on the base wall of the connection case and a space for drilling the positioning hole in the holder of the circuit forming body, and the circuit pattern shape of the holder is bypassed from the positioning hole. Since there is no need to greatly extend and route the wiring case, the shapes of the connection case and the circuit forming body are reduced, and the electrical connection box can be reduced in size and weight. Furthermore, since the shapes of the connection case and the circuit forming body are reduced and positioning protrusions are not required, material costs are saved, and the cost of the electrical connection box can be reduced.
[0047]
According to the electrical junction box of the invention of claim 2, the positioning reference hole is formed in the vicinity of the center of the base wall of the connection case, and is formed in a small shape so that the left and right and upper and lower gaps become smaller when the male terminal is inserted. Therefore, the positioning reference hole formed in the small shape will be drilled at a position near the center of gravity of the circuit forming body, and the circuit forming body can be positioned with good balance. It can be easily attached to the base wall of the connection case.
[0048]
According to the electrical junction box of the invention of claim 3, the positioning reference hole is a male terminal insertion hole formed at a plurality of locations in the vicinity of the center of the base wall of the connection case and at a plurality of locations spaced radially from the center. The positioning reference hole drilled in the vicinity of the center of the base wall is formed in a small shape so that the left and right and top and bottom gaps become small when the male terminal is inserted, so the number of male terminals of the circuit forming body increases. However, the circuit forming body can be positioned with good balance, and the positioning accuracy can be improved.
[0049]
According to the electrical connection box described in claim 4 of the present invention, the positioning reference hole is a male terminal insertion hole formed in a plurality of locations spaced radially from the vicinity of the center of the base wall of the connection case, The axial length in the Y-axis direction of the male terminal insertion hole drilled at a location spaced in the X-axis direction and the axial diameter length in the X-axis direction of the male terminal insertion hole drilled in a location spaced in the Y-axis direction Are made smaller than the corresponding axial diameter of the male terminal insertion hole other than the positioning reference hole, so that the male terminal inserted into the positioning reference hole and Lateral shake (rattle) in the Y-axis direction is suppressed, and the circuit formed body can be accurately positioned.
[0050]
Also, the axial diameter length of the positioning reference hole formed in the X-axis direction in the X-axis direction and the axial diameter length of the positioning reference hole formed in the Y-axis direction in the Y-axis direction are the same as those of the other male terminal insertion holes. Since it is not different from the corresponding shaft diameter length, the gap between the positioning reference hole formed in the X-axis direction and the male terminal in the X-axis direction and the Y-direction of the positioning reference hole formed in the Y-axis direction When the circuit forming body is mounted on the base wall of the connection case even if the male terminal insertion hole and the male terminal are displaced in the X and Y axis directions, the circuit forming body The male terminal can be easily passed through the positioning reference hole, the mounting of the circuit forming body is facilitated, and the manufacturing (assembling) efficiency of the electrical junction box can be improved.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view showing an embodiment of an electrical junction box according to the present invention, in which an external connector is inserted.
FIG. 2 is a front view (male terminal omitted) of the electrical junction box of FIG. 1 as viewed from the side where an external connector is inserted.
3 is a partially omitted cross-sectional view taken along the line S-S in FIG. 2 in a state where an external connector is inserted into the electrical junction box.
FIG. 4 is a front view showing another embodiment of the electrical junction box according to the present invention as seen from the side where an external connector is inserted.
5 is a partially omitted cross-sectional view corresponding to the view taken along the line SS of FIG. 2 in a state where an external connector is inserted into a conventional electrical junction box.
[Explanation of symbols]
11 Electrical junction box
13 External connector
15 Connection case
17 Base wall
19 Male terminal insertion hole
20 Positioning reference hole
20a Positioning reference hole
20b Positioning reference hole
20c Positioning reference hole
21 Circuit forming body
23 Male terminal
25 Holder
27 Connector housing
29 Terminal compartment
31 Cover
33 Engaging recess
35 engaging claw
36 nails
37 Connector compartment
39 Guide groove
41 Circuit forming body accommodation chamber
43 Case cover
45 Guide groove

Claims

A connection case into which an external connector accommodating a plurality of female terminals is inserted;
A circuit forming body having a plurality of male terminals mounted on a base wall of the connection case and projecting into the connection case through a plurality of male terminal insertion holes formed in the base wall and a holder for supporting the male terminals. In the electrical connection box in which the male terminal of the circuit forming body is inserted into the female terminal of the external connector inserted into the connection case and connected to the external connector,
Among the plurality of male terminal insertion holes drilled in the base wall of the connection case, some male terminal insertion holes are positioning reference holes formed smaller than other male terminal insertion holes,
The electrical connection box, wherein the plurality of male terminals have the same width, length, and height and are formed in the same shape .

The positioning reference hole is drilled near the center of the base wall of the connection case;
2. The electrical connection according to claim 1, wherein the positioning reference hole drilled in the vicinity of the center is formed in a small shape such that a gap between left and right and up and down is reduced when the male terminal is inserted. box.

The positioning reference hole is a male terminal insertion hole drilled at a plurality of locations spaced radially from the center vicinity and the center vicinity of the base wall of the connection case,
2. The electrical connection according to claim 1, wherein the positioning reference hole drilled in the vicinity of the center is formed in a small shape such that a gap between left and right and up and down is reduced when the male terminal is inserted. box.

The positioning reference hole is a male terminal insertion hole drilled in a plurality of locations spaced radially from the vicinity of the center of the base wall of the connection case,
A shaft diameter length in the Y-axis direction of the male terminal insertion hole drilled at a location separated in the X-axis direction,
The axial length in the X-axis direction of the male terminal insertion hole drilled at a location separated in the Y-axis direction is greater than the corresponding axial diameter in the axial direction of the male terminal insertion hole other than the positioning reference hole. 4. The electrical junction box according to claim 3, wherein the electrical junction box is formed in a small shape by shortening.