JPH0818172A - Electric wiring board and production thereof - Google Patents

Abstract

PURPOSE:To obtain an electric wiring board having simple structure for mounting and connecting electronic devices to constitute an electric circuit at low cost, and to obtain an electric wiring board for a motor having simple structure for connecting the coils wound around the stator or between the coil and an external power supply at low cost while suppressing trouble, e.g. disconnection, at the time of resin molding. CONSTITUTION:A two layer laminate of a conductive layer 14 and an insulating layer 12 is protruding partially while being shifted by means of a press having predetermined shape. The conductive layer 14 in the protruding laminate 16 is insulated from the conductive layer 14 in the laminate 11 which is not protruding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric wiring board on which electronic parts, electronic devices, electric wires, etc. are mounted and connected to form an electric circuit, a manufacturing method thereof, and a stator of an electric motor. The present invention relates to an electric wiring board of an electric motor suitable for connecting between coils wound around a stator and connecting the coil and an external power source.

[0002]

2. Description of the Related Art Conventionally, a so-called printed wiring board has been used as an electric wiring board for mounting an electronic component, an electronic device or the like to form an electric circuit. This printed wiring board generally uses a copper clad laminate in which a thin conductive layer such as a copper foil is laminated on an insulating substrate, and the copper foil in the unnecessary portion is removed by etching or the like. Then, wiring (that is, a conductor pattern) is provided.

Such a printed wiring board has a problem that the manufacturing cost is high because the steps such as the etching process for forming the conductor pattern are complicated. In addition, there is a problem that an acid-resistant material called an etching resist and a dissolved / removed material such as unnecessary copper foil are generated as waste during production.

On the other hand, when the above-mentioned printed wiring board is arranged on the stator of the electric motor and used for connecting the coil and the external power source, the stator is shaped by resin, that is, by the pressure when molding, In some cases, the board may be deformed or cracked, or the conductor pattern may be broken to cause a defect.

Further, the above-mentioned printed wiring board is usually
As an insulating substrate, a composite material such as a so-called FRP in which a base material impregnated with a resin is laminated, such as a glass cloth-based epoxy resin laminated board or a paper-based phenolic resin laminated board, is used. It was also one of the factors that increased the cost of the board.

In view of the above points, the present invention provides a low-cost and easy-to-manufacture electric wiring board, and further, a low-cost and simple-to-manufacture electric motor that does not easily cause defects such as disconnection during molding of a molding resin. It is intended to provide a wiring board.

[0007]

In the electric wiring board according to claim 1 of the present invention, a part of a laminate having a two-layer structure of a conductive layer and an insulating layer is displaced and raised, and the raised portion is raised. The conductive layer of the laminate is insulated from the conductive layer of the laminate that is not raised.

In the electric wiring board according to a second aspect of the present invention, a laminate of two or more layers in which conductive layers and insulating layers are alternately laminated is partly shifted and raised, and the raised laminate is formed. At least one conductive layer of the body is insulated from the conductive layer of the non-raised laminate, which had formed the same layer as the conductive layer before the bulge.

In these electric wiring boards, it is preferable that the conductive layer is plate-shaped, and further that the insulating layer is formed only of resin.

However, the conductive layer may be in the form of a film such as copper foil, and the insulating layer may be a composite of a sheet such as glass cloth and a resin.

An electric wiring board for an electric motor according to a sixth aspect of the present invention is the electric wiring board according to the first or second aspect, wherein the conductive layer is plate-shaped and the insulating layer is formed only of resin.
It is arranged on a stator of an electric motor and connects between a plurality of coils wound around the stator and the coil and an external power source.

According to a seventh aspect of the present invention, there is provided a method of manufacturing an electric wiring board, wherein a laminated board composed of a laminate of two or more layers in which conductive layers and insulating layers are alternately laminated is subjected to a pressing step to form the electric wiring board. A method of manufacturing, wherein the pressing step is performed by a pressing machine having one die having irregularities of a predetermined shape and the other die corresponding thereto, and the step of the irregularities forms at least the laminated plate. The thickness is larger than the thickness of one conductive layer and smaller than the thickness of the laminated plate.

[0013]

According to the electric wiring board of the present invention, since the conductive layer of the raised laminate is insulated from the conductive layer of the non-raised laminate, one or both of the conductive layers are provided. It can be used as wiring (conductor pattern).

According to another aspect of the electric wiring board of the present invention, at least one conductive layer of the raised laminated body forms the same layer as the conductive layer before the raised one. Since it is insulated from the conductive layer, the raised conductive layer or any other conductive layer can be used as a conductive pattern.

According to the electric wiring board of the electric motor of claim 6,
Arranged in the stator of the electric motor, between the plurality of coils wound around the stator, and connecting those coils and an external power source,
A circuit can be formed that operates the electric motor.

According to a seventh aspect of the present invention, there is provided a method for manufacturing an electric wiring board, wherein a pair of metal molds of a press has irregularities having a predetermined shape, and the unevenness of at least one layer forming a laminated board to be pressed. Since it is larger than the thickness of the conductive layer and smaller than the thickness of the laminated plate, it is possible to form a predetermined conductor pattern on the laminated plate only by pressing.

[0017]

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

FIG. 1 shows an electric wiring board 1 according to an embodiment of the present invention.
FIG. 2 is a view in which a section of 0 is partially omitted, and FIG. 2 is a cross-sectional view of the electric wiring board 10 at the time of manufacturing and before and after that. As will be described later, the electric wiring board 10 includes an insulating layer 12 made of resin, and a conductive layer 14 made of copper or brass (brass) with a small amount of phosphor bronze or the like formed on the upper surface thereof. It is manufactured from a laminated plate 20 which is a laminated body having a two-layer structure. Then, a part of the laminated plate 20 is displaced upward and is raised, and is composed of three pattern portions 16 which are the raised laminated body and the main body 11 which is not raised.

The conductive layer 1 which is the upper layer of the pattern portion 16
4A, 14B and 14C are all conductive layers 1 of the main body 11.
4 is located above and is not in contact with the conductive layer 14. The conductive layers 14A, 14 of this pattern portion 16
B and 14C are arranged in a predetermined position of the main body 11 with a predetermined cross-sectional shape so as to form a conductor pattern which is a wiring of the electric wiring board 10. Of course, the pattern portion 16
Is formed in a straight line like the conductor pattern 14A,
It may be formed by bending like the conductor pattern 14C.

At both ends of the pattern portion 16 having the conductor patterns 14A and 14B, component holes 18 which vertically penetrate the pattern portion 16 are provided. Part of the component is inserted into the component hole 18 for mounting an electronic component or the like.

An electric circuit can be formed by mounting and fixing electronic parts such as resistors and capacitors, electronic devices such as ICs and transistors, and connecting electric wires to the electric wiring board 10. it can. It should be noted that a mounting method and a mounting state of electronic components and the like will be described later.

FIG. 2C shows a cross section of the main part of the electric wiring board 10. Conductor patterns 14A, 14
Each pattern portion 16A, 16B, 16 having B, 14C
C and the main body 11 sandwiched between them and connected,
The layers forming them are connected to each other with a step perpendicular to the horizontal direction, and the respective layers have a fault structure at the connecting surface.

Here, the pattern portion 16A and the pattern portion 1
The main body sandwiched between 6B and 11A, the pattern portion 16B
The main body sandwiched between the pattern portion 16C and the pattern portion 16C is 11B, the distance between the lower surface of the conductive pattern 14A and the upper surface of the main body 11A is h1, the distance between the lower surface of the conductive pattern 14B and the upper surface of the main body 11A is h2, and the conductive pattern 14B is The distance between the lower surface of the conductive pattern 14C and the upper surface of the main body 11B is h3, and the distance between the lower surface of the conductor pattern 14C and the upper surface of the main body 11B is h4. And
Assuming that the horizontal distance between the conductor patterns 14A and 14B is w1 and the horizontal distance between the conductor patterns 14B and 14C is w2, the insulation distance between the conductor patterns 14A and 14B is the creepage distance. (H1 + h2), the space distance is w1, and the insulation distance between the conductor patterns 14B and 14C is the creepage distance (h3 + h4) and the space distance is w2.

In this electric wiring board 10, if a large insulation distance is required, the conductor patterns 14A, 1 will be used unless the intermediate conductor pattern 14B is used as a circuit pattern.
The insulation distance between 4C is (h1 + h2 + h3 +
h4), the spatial distance is (w1 + w2), and the creepage distance can be easily lengthened, which is advantageous.

When a large insulation distance is not required, the conductive layers 14 of the main bodies 11A, 11B are used as a conductive pattern for grounding, power supply, etc. at the same time as the above-mentioned conductive patterns 14A, 14B, 14C. You can also do it.

Next, a method of manufacturing the electric wiring board 10 will be described with reference to FIG.

FIG. 2A is a cross-sectional view of a laminated plate 20 composed of a single insulating layer 12 and a conductive layer 14 formed thereon. The laminated plate 20 can be formed by coating, spraying, or painting a resin on the plate-shaped conductive layer 14, or by laminating the conductive layer 14 and the insulating layer 12.

In FIG. 2B, this laminated plate 20 is
The press 22 is mounted on the press 22 and
0 is configured to form a shear fault of a predetermined shape. The upper mold 24 of the press 22 has a concave portion 26 for forming a predetermined pattern portion 16 and a convex portion 2
7 are provided. The unevenness is set to be larger than the thickness of the conductive layer 14 of the laminated plate 20 and smaller than the thickness of the laminated plate 20. Lower mold 2 of the press 22
In FIG. 8, a convex portion 30 and a concave portion 31 are provided at positions corresponding to the concave portion 26 and the convex portion 27 of the upper mold 24, respectively. Then, the upper mold 24 presses the laminated plate 20 placed on the lower mold 28 downward to form the upper mold 2 on the laminated plate 20.
A shear fault having the same shape as that of No. 4 is formed, and the electric wiring board 10 including the main body 11 and the pattern portion 16 is manufactured.

As a result, as shown in FIG. 2C, the pattern portion 16 and the main body 11 are connected to each other with a predetermined step.

The creeping distance between the conductor patterns 14A, 14B and 14C can be controlled by the step difference of the unevenness of the upper mold 24. Usually, h1 and h2 have the same value, and h3 and h4 also have the same value.

It is not always necessary to manufacture the electrical wiring board 10 from the laminated board 20 by pressing only once, and it may be manufactured by a plurality of presses.

As described above, since the pattern can be formed by a simple pressing process, the manufacturing is easier and the cost can be reduced as compared with the processing such as etching, and the dissolved and removed substances can be removed. No waste is produced during production.

Further, since the electric wiring board 10 can be manufactured by the progressive type, the material of the band-shaped hoop material can be used, and the pressing step for forming the pattern portion 16 and each electric wiring board 10 can be used. The step of separating into two can be performed sequentially or simultaneously.

The press 22 includes the upper mold 2 as described above.
It is not limited to the one in which 4 is pressed downward, and the one in which the lower mold 28 is pressed upward, or the molds provided on the left and right may be horizontally moved and pressed.

Insulating layer 12 of electric wiring board 10 of this embodiment
Is a resin such as a glass cloth-based epoxy resin laminate, a paper-based phenol resin laminate or a glass composite-based epoxy resin laminate, which is usually used in printed wiring boards, impregnated with resin, PBT, PET, It may be formed of only a resin such as nylon resin.

Further, the conductive layer 14 is not limited to a thin film such as a copper foil, but a plate-shaped one such as a relatively thick copper plate can be used.

As described above, the above-mentioned press can be applied to a material in which a film-like conductive layer 14 such as a copper foil is laminated on the insulating layer 12 which is a composite material such as a paper-based phenol resin. It is also possible to use commercially available materials for conventional printed wiring boards.

When the conductive layer 14 is plate-shaped, current density is low, connection resistance is low, and loss is small. Therefore, it can be applied to low voltage and large current specifications.

When a copper plate is used as the conductive layer 14, as shown in FIG. 3 (a), a drawing process is performed at the same time as the above-mentioned pressing process, or before or after pressing, to form a laminated structure. The recess 32 can be formed while being held. This drawing is performed by pressing with a drawing die. The recess 32 can be used as a ball housing in which a ball bearing is inserted. Further, it can be formed into a curved surface shape as shown in FIG. 3D by drawing, and can be formed into various shapes by using an appropriate drawing die.

Further, by pressing, as shown in FIG. 3 (b), a bending process is performed to provide a bent portion 34,
Alternatively, as shown in FIG. 3 (c), a punching process may be performed to provide a hole 36 penetrating vertically. By such processing, the three-dimensional wiring can be easily provided on the electric wiring board 10. The vertical through hole 36 can also be used as the component hole 18 described above.

Next, the electric wiring board 50 of the electric motor, which is arranged on the stator of the electric motor and is connected to the coil wound around the stator and the external power source, will be described. This electric wiring board 50
Can be manufactured by a press similar to the electric wiring board 10 shown in FIG.

FIG. 4 (a) is a plan view of the electric wiring board 50, and FIG. 4 (b) is a sectional view taken along line AA. This electric wiring board 50 is used for a brushless motor (not shown), and is placed on a stator (not shown) preliminarily shaped by premolding resin, and then molded together with the stator by molding resin molding. It is what is done.

The electric wiring board 50 of the electric motor is also manufactured from a laminated board having a two-layer structure of the insulating layer 12 and the conductive layer 14. However, the conductive layer 14 is not made of a thin film such as a copper foil, but is made of a plate-shaped relatively thick copper plate. Also, the insulating layer 1
2 is formed only of resin such as PBT, PET, nylon resin.

The electric wiring board 50 has a substantially annular shape having a hollow 56 corresponding to the shape of the upper surface of the stator. The plurality of pattern portions 16 are formed along the circumferential direction from the terminal concentrated portion 57 formed on a part of the outer circumference of the disc 50, and have a predetermined configuration so as to function as a brushless motor. There is. Punching holes 58 are provided at both ends of the pattern portions 16, and predetermined electronic components such as a lead wire of an electric motor are inserted and fixed by soldering.

In FIG. 4B, two motor winding power lines 16S and 16T for supplying electric power to the electric motor and three pole sensor signal lines 16U, 16V and 16W for detecting the magnet of the rotor are shown. Five pattern parts 16
It is shown. As described above, the pattern portions 16 are separated by the main body 11 and are displaced upward from the stacked body of the main body 11 and are raised. Conductor patterns 14S, 14T, 14U, 14V, 1 which are the upper layers of each pattern portion 16.
4W is not in contact with the conductive layer 14 of the main body 11,
It is located above that. A coil lead wire of the stator is inserted from below into a punched hole 58a provided at the tip of the power line 16T, and the conductor pattern 14 is formed.
It is fixed to T by soldering.

Reference numeral 54 is an elongated hole for fixing the electric wiring board 50 on the stator. A pin (not shown) formed of a pre-molded resin of the stator is inserted into the elongated hole 54, and the insertion portion is heat-sealed,
The electric wiring board 50 is fixed on the stator.

Thus, the electric wiring board 50 of this electric motor
Then, in the conductive layer 14 of the pattern portion 16 which is raised upward,
The coil lead wire of the stator, the lead wire of the external power supply, the transistor, etc. are connected and fixed to form a predetermined circuit.

In the electric wiring board 50 of this electric motor, since a copper plate is used instead of a film such as a copper foil, disconnection due to mold pressure is unlikely to occur during molding of the stator. Further, since the current density is low, the connection resistance is small, and the loss is small, it can be applied to low voltage and large current specifications. Further, even if an expensive base material impregnated resin or the like is not used for the insulating layer 12, the electric wiring board 50 is not deformed or cracked by the copper plate, and the insulating layer 12 is formed of only an inexpensive resin. can do. Furthermore, drawing, bending and punching are possible.

Further, since the conductor pattern is formed by pressing, it is possible to manufacture by progressive die, and the material of hoop material can be used.

In this way, the electric wiring board 50 of this electric motor
Are high quality, easy to manufacture and low cost.

Next, an example in which electronic parts are mounted on the electric wiring board 10 will be shown. The electric wiring board 50 of the electric motor can be mounted in the same manner.

In FIG. 5A, the two connection pins 62 of the electronic component 60 are inserted from below the component holes 18 provided in the two pattern portions 16 and connected to the conductor pattern 14 by soldering. It is fixed. That is, the electronic component 6
0 is arranged below the electric wiring board 10.

In FIG. 5B, the two connection pins 62 of the electronic component 60 are inserted from above the component holes 18 of the two pattern portions 16 and are connected and fixed to the conductor pattern 14 by soldering. There is. The electronic component 60 is arranged above the electric wiring board 10.

FIG. 5C shows an example in which the electronic component 60 is mounted on the two pattern portions 16 having no component hole. The connection pins 62 of the electronic component 60 are arranged on the conductor patterns 14 of the two pattern portions 16 and are connected and fixed by soldering. The electronic component 60 is mounted above the electrical connection board 10. ing.

As described above, when the component hole 18 is punched in the pattern portion 16, the mounting surface of the electronic component 60 can be freely selected above or below the electric wiring board 10.

The electric wiring board 1 of the embodiment described above
Each of 0 and 50 is composed of a laminate having a two-layer structure of the insulating layer 12 and the conductive layer 14, but the electric wiring board of the present invention is not limited to two layers, and three or more layers are included. It may be a laminate.

The electric wiring board 70 of FIG. 6C is manufactured from a laminated board 75 having a three-layer structure including two insulating layers 12 and one conductive layer 14 sandwiched therebetween.

The electric wiring board 80 of FIG. 7 (c) is manufactured from a laminated board 85 having a three-layer structure including two conductive layers 14 and one insulating layer 12 sandwiched therebetween.

In the electric wiring board 90 shown in FIG. 8C, three conductive layers 14 and two insulating layers 12 are alternately laminated.
It is manufactured from a laminated plate 95 having a layered structure.

These electric wiring boards 70, 80, 90 are also
It can be manufactured in the same manner as the method shown in FIG.
That is, each of the laminated plates 75, 85 and 95 may be pressed by the press 22 including the upper mold 24 and the lower mold 28 having a predetermined shape. Of course, even in this case,
At least the specific conductive layers 14 in the original laminates 75, 85, 95 must be displaced to a position where they become a fault structure in the shear plane of the press and do not contact each other.

In the electric wiring board 90 shown in FIG. 8C, a part of the conductive layer 14a located at the uppermost position before pressing is
With a part of the conductive layer 14b located in the middle, the intermediate conductive layer 14b and the lowermost conductive layer 14c of the stacked body which is shifted downward by the pressing and is not shifted downward, respectively, It is connected in series at each shear plane.

In the electric wiring boards 70, 80, 90 of these three examples, any of the plurality of conductive layers 14 may be used as the conductor pattern, or all the conductive layers 14 may be used as the conductor pattern. For example, in FIG. 8C, a conductor forming an electric circuit by mounting an electronic component, an electronic device, or the like on the uppermost conductive layer 14a protruding upward and the lowermost conductive layer 14c protruding downward. It is also possible to use it as a pattern and use the above-mentioned series of two conductive layers (14b + 14a) and (14c + 14b) located in the middle as a ground or a power supply.

[0063]

According to the electric wiring board of the present invention, since the conductor pattern can be formed only by pressing, there is no need to perform a step such as an etching treatment and the cost is low.

If the conductive layer is plate-shaped, the current density is low, the connection resistance is small, and the loss is small, so that it can be applied to low voltage and large current specifications. Bending, drawing and punching are possible. It can be manufactured in a progressive type, and a hoop material can also be used. The insulating layer can be formed only of resin and is inexpensive. Further, when it is used as an electric wiring board of an electric motor, when the stator is molded, disconnection due to molding pressure is less likely to occur.

As described above, the electric wiring board of the present invention has high quality, is easy to manufacture, and is inexpensive.

In the electric wiring board of the present invention, the conductive layer may be a film such as copper foil, and the insulating layer may be a composite of a sheet such as glass cloth and a resin. Materials for plates can also be used as a laminate.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view of an electric wiring board 10 according to an embodiment of the present invention.

2A and 2B are views for explaining the method for manufacturing the electric wiring board 10, wherein FIG. 2A is a longitudinal sectional view of a main part of the laminated body 20 before pressing, and FIG. 2B is a vertical sectional view of a main part at the time of pressing. FIG. 1C is a vertical cross-sectional view of a main part of the electric wiring board 10.

FIG. 3 is an enlarged vertical sectional view of an essential part showing another processing example of the electric wiring board 10, wherein (a) and (d) are drawing processing and (b) is a drawing.
Is a bending process, and (c) is a punching process.

FIG. 4 shows an electric wiring board 10 arranged on a stator of an electric motor, in which (a) is a plan view thereof and (b) is A- of (a).
It is a vertical sectional view taken along line A.

5A and 5B are vertical cross-sectional views of the electric wiring board 10 on which the electronic component 60 is mounted, where FIG. 5A is a component mounting surface of a lower surface of the electric wiring board 10 and FIG. 5B is a component mounting surface of the electric wiring board 10. The upper surface of
In (c), the component mounting surface is on the upper surface of the electric wiring board 10.

6A and 6B are vertical cross-sectional views of an essential part of an electric wiring board 70 according to another embodiment of the present invention, where FIG. 6A is before pressing, FIG. 6B is during pressing, and FIG. .

FIG. 7 is a longitudinal sectional view of an essential part of an electric wiring board 80 according to another embodiment of the present invention, in which (a) is before pressing, (b) is during pressing, and (c) is after pressing. .

FIG. 8 is a longitudinal sectional view of an essential part of an electric wiring board 90 according to another embodiment of the present invention, where (a) is before pressing, (b) is during pressing, and (c) is after pressing. .

[Explanation of symbols]

 10 ... Electric wiring board 11 ... Main body 12 ... Insulating layer 14 ... Conductive layer 16 ... Pattern part 20 ... Laminated plate 22 ... Press 24 ... Upper mold 26 ... Upper mold recess 27 ... … Convex part of upper mold 28 …… Lower mold

Claims (7)

[Claims] 1. A laminated body having a two-layer structure of a conductive layer and an insulating layer is partly displaced and raised, and the conductive layer of the raised laminated body is a conductive layer of the non-raised laminated body. An electric wiring board characterized by being insulated from. 2. A laminate of two or more layers in which conductive layers and insulating layers are alternately laminated is partly shifted and raised, and at least one conductive layer of the raised laminate is An electric wiring board characterized by being insulated from a conductive layer of a non-raised laminated body, which was formed with the same layer as the conductive layer before the rising. 3. The electric wiring board according to claim 1, wherein the conductive layer is in the form of a film such as copper foil, and the insulating layer is a composite of a sheet such as glass cloth and a resin. 4. The conductive layer has a plate shape.
The electric wiring board described in. 5. The electric wiring board according to claim 4, wherein the insulating layer is formed only of resin. 6. The electric wiring board according to claim 1, wherein the conductive layer is plate-shaped, the insulating layer is made of resin only, and is arranged on a stator of an electric motor. An electric wiring board of an electric motor for connecting a plurality of coils wound around a stator and connecting the coils with an external power source. 7. A method for producing an electric wiring board by subjecting a laminate comprising a laminate of two or more layers in which conductive layers and insulating layers are alternately laminated to each other to produce an electric wiring board, wherein the pressing step is a predetermined step. It is made by a press machine having one die having a shape irregularity and the other die corresponding thereto, and the step of the irregularity forms at least 1 of the laminated plate.
A method for manufacturing an electric wiring board, wherein the thickness is larger than the thickness of the conductive layer and smaller than the thickness of the laminated board.