WO2009096055A1 - 電気回路装置の製造方法及び電気回路装置、金型装置 - Google Patents
電気回路装置の製造方法及び電気回路装置、金型装置 Download PDFInfo
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- WO2009096055A1 WO2009096055A1 PCT/JP2008/063190 JP2008063190W WO2009096055A1 WO 2009096055 A1 WO2009096055 A1 WO 2009096055A1 JP 2008063190 W JP2008063190 W JP 2008063190W WO 2009096055 A1 WO2009096055 A1 WO 2009096055A1
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- electric wire
- electric
- circuit device
- mold
- hole
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/103—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by bonding or embedding conductive wires or strips
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09009—Substrate related
- H05K2201/09118—Moulded substrate
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/10287—Metal wires as connectors or conductors
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/16—Inspection; Monitoring; Aligning
- H05K2203/167—Using mechanical means for positioning, alignment or registration, e.g. using rod-in-hole alignment
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/306—Lead-in-hole components, e.g. affixing or retention before soldering, spacing means
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
Definitions
- the present invention relates to an electric circuit device applied to a wire harness or an electric junction box in an automobile or the like.
- the electric circuit device serves as a base for mounting various electric parts such as absorbing differences in standards between connection wirings, connector relay bases, fuses and relays.
- Such electric circuit devices are used as electrical junction boxes, junction blocks, relay boxes, fuse boxes, and the like.
- Examples of the configuration constituting such an electric circuit device include a press bus bar structure and a PCB structure.
- the press bus bar structure is a configuration in which bus bars obtained by press-molding thick metal plates are combined and used as wiring.
- the PCB structure is a configuration using PCB (Printed Circuit Board) as a circuit, and is a configuration suitable for mounting semiconductor components.
- the press bus bar structure it is difficult to reduce the size and the weight because the bus bar is formed by combining bus bars formed by press-molding a thick metal plate. Further, it is difficult to reduce the pitch of the wiring due to the width dimension of the bus bar itself, and it is also difficult to reduce the pitch of the connector terminals connected thereto.
- a bus bar is obtained by pressing with a press die and a large press, it is necessary to change at least the press die itself in order to cope with a design change. For this reason, it is difficult to easily cope with design changes quickly and at low cost. Further, since the bus bar is obtained by punching a thick metal plate, the material is wasted and the material yield is poor.
- an object of the present invention is to respond to requests for design change ease such as reduction in size and weight, pitch reduction, circuit change, material yield, and compatibility with large currents at a level as high as possible.
- the method of manufacturing the electric circuit device includes a step of arranging an electric wire in a mold, and pouring and solidifying the fluidized resin in the mold. And a step of manufacturing a wiring body module in which the electric wire is embedded in the resin, and a step of mounting an electrical component on the wiring body module.
- the circuit is configured with wired wires, the size and weight can be reduced and the pitch can be reduced as compared with the case where the circuit is configured with a bus bar. Moreover, since it is only necessary to change the wiring arrangement of the electric wires in the mold, it is possible to easily cope with a design change such as a circuit change. Furthermore, since the electric wires are wired in the mold, the electric wires are hardly wasted, and the material yield is excellent. Furthermore, since the circuit is constituted by electric wires, the circuit is more suitable for a large current circuit than in the case of a PCB in which the circuit is constituted by a conductive foil. Accordingly, it is possible to respond to requests regarding design ease such as reduction in size and weight, narrow pitch, circuit change, material yield, and compatibility with large currents at a level as high as possible.
- a method for manufacturing an electric circuit device is the method for manufacturing an electric circuit device according to the first aspect, wherein in the step of arranging an electric wire in the mold, a positioning pin is provided in the mold. The cable is erected and arranged while positioning the electric wire with the positioning pin.
- a method for manufacturing an electric circuit device according to a third aspect is the method for manufacturing an electric circuit device according to the second aspect, wherein the positioning pins are detachably provided in holes formed in the mold. Is.
- a method for manufacturing an electric circuit device is the method for manufacturing an electric circuit device according to the second or third aspect, wherein the positioning pin is erected at a position where the electric component is mounted.
- the connection portion of the electrical component is inserted into the hole formed in the wiring body module as the positioning pin mark and electrically connected to the electric wire. The electrical component is mounted.
- the electrical circuit device manufacturing method is the electrical circuit device manufacturing method according to the fourth aspect, wherein the hole formed in the wiring body module as the positioning pin mark is the electrical component.
- the connecting portion In a state where the connecting portion is inserted into the hole portion, the electric wire exposed on the inner surface of the hole portion and the connecting portion are formed so as to be in pressure contact, and an electric component is mounted on the wiring body module
- the connecting portion and the electric wire are joined in a state where the connecting portion of the electric component is inserted into the hole and the connecting portion is in pressure contact with the electric wire exposed on the inner surface of the hole. Is.
- the connecting portion and the electric wire are coupled in a state where the connecting portion of the electrical component is inserted into the hole and the connecting portion is in pressure contact with the electric wire exposed on the inner surface of the hole. Therefore, it is not necessary to provide a separate structure for pressurization when the coupling is performed, and therefore the coupling can be easily performed.
- a method for manufacturing an electric circuit device is the method for manufacturing an electric circuit device according to any one of the first to fifth aspects, wherein in the step of manufacturing the wiring body module, An electric wire holding member for holding the electric wire so that a portion connected to the electric component is exposed to the outside of the wiring module, or a portion of the electric wire connected to the electric component to the outside of the wiring module.
- the protruding member protruding from the mold surface of the mold so as to be exposed exposes a portion of the wire connected to the electrical component to the outside of the wiring module.
- the portion of the electric wire that is connected to the electric component is exposed to the outside of the wiring body module, so that the electric wire and the electric component can be easily connected when the electric component is mounted.
- An electric circuit device includes: an electric wire wired in a predetermined pattern in a mold; and a resin molded portion molded in a predetermined form in a state where the electric wire wired in a predetermined pattern is embedded.
- a wiring module having a wiring module and an electrical component mounted on the wiring module.
- An electric circuit device is the electric circuit device according to the seventh aspect, wherein the resin molding portion can be provided with a positioning pin for positioning and holding the electric wire in a predetermined pattern. Is formed.
- the resin molded portion can be molded in a state where the electric wire is securely held in a predetermined pattern by the positioning pins.
- An electric circuit device is the electric circuit device according to the eighth aspect, wherein a connecting portion of the electric component is inserted into a hole portion in which the positioning pin can be disposed to electrically connect the electric wire to the electric wire device.
- the electrical component is mounted by being connected to.
- An electric circuit device is the electric circuit device according to the ninth aspect, wherein the hole portion in which the positioning pin can be disposed is such that a connection portion of the electric component is inserted into the hole portion.
- the electric wire exposed on the inner surface of the hole and the connection part are formed in a manner in which pressure contact is possible, and the connection part of the electric component is inserted into the hole part to insert the connection part into the hole.
- the connecting portion and the electric wire are combined in a state where the electric wire exposed to the inner surface of the portion is in pressure contact.
- the connecting portion and the electric wire are coupled in a state where the connecting portion of the electrical component is inserted into the hole and the connecting portion is in pressure contact with the electric wire exposed on the inner surface of the hole. Therefore, it is not necessary to provide a separate structure for pressurization when the coupling is performed, and therefore the coupling can be easily performed.
- the electric circuit device is the electric circuit device according to the seventh to tenth aspects, wherein a portion of the electric wire connected to the electric component is connected to the resin molded portion.
- a wire holding member that holds the wire so as to be exposed to the outside of the wire, or a portion of the wire that is connected to the electrical component protrudes from the die surface of the die so as to be exposed to the outside of the wiring body module.
- position the protruding member which was made is formed.
- a mold apparatus is a mold apparatus for manufacturing an electric circuit device, wherein a resin is provided between a first mold having a first mold surface and the first mold surface.
- a positioning pin capable of positioning a wired wire on at least one of the first mold surface and the second mold surface. Is established.
- the circuit can be configured by arranging the electric wires in the mold, it is possible to manufacture an electric circuit device that can be reduced in size and weight and can be made narrower than in the case where the circuit is configured with a bus bar. Further, by changing the position by attaching and detaching the positioning pin, it is possible to change the wiring mode of the electric wire in the mold, and thus it is possible to easily cope with a design change such as a circuit change. Furthermore, since the electric wires are wired in the mold, the electric wires are hardly wasted, and the material yield is excellent.
- the circuit is constituted by electric wires
- an electric circuit device suitable for a large current circuit can be manufactured as compared with the case of a PCB in which the circuit is constituted by a conductor foil. Therefore, it is possible to manufacture an electric circuit device capable of meeting the demands regarding the design reduction ease of design such as reduction in size and weight, narrow pitch, circuit change, material yield, and compatibility with large currents at the highest possible level.
- the wiring form of an electric wire can be more reliably hold
- a mold apparatus is the mold apparatus according to the twelfth aspect, wherein the positioning pin is detachably installed in a hole formed in the mold.
- a mold apparatus is the mold apparatus according to the twelfth or thirteenth aspect, wherein at least one of the first mold surface and the second mold surface is connected to the electric wire.
- a wire holding member that holds the electric wire so that a portion connected to the electric component is exposed to the outside of the resin molded portion, or a portion of the electric wire that is connected to the electric component is outside the wiring body module.
- a protruding member protruding from the first mold surface or the second mold surface so as to be exposed is further provided.
- ⁇ Outline of electric circuit device> 1 and 2 are perspective views showing a schematic configuration of the electric circuit device 10.
- This electric circuit device 10 absorbs differences in standards (wire types, etc.) between connection wires in automobiles, etc., and mounts a connector relay base, fuses and relays, semiconductor elements, etc. when connecting connection wires to each other by connector relay It serves as a mounting base for electrical components and is used as a so-called electrical junction box, junction block, relay box, fuse box, electrical unit, and the like.
- the electric circuit device 10 includes a wiring body module 14 and electric components 20, 22, and 24.
- the wiring body module 14 has a predetermined shape in a state where the electric wire 12 (not shown in FIGS. 1 and 2, see FIG.
- the electrical components 20, 22, and 24 are components connected to the circuit of the electrical circuit device 10, and are electrically connected to the electric wire 12 and mounted on the wiring body module 14.
- 2nd connector terminal part 22 mounted in the other side part (here one side part of a long side), and element components, such as a power semiconductor element mounted in the part from the approximate center of the wiring body module 14 24 is assumed.
- the electrical components 20, 22, and 24 may be other various electrical components such as relays, fuses, other control semiconductor elements, capacitors, resistors, and the like.
- the electric circuit device 10 includes a hole 17 and a wire 12 that can be provided with positioning pins 46 described later (that is, the traces of positioning pins 46).
- a recess 18 or the like is formed (see FIG. 10) in which an electric wire pressing member 56 for exposing to the outside can be disposed (that is, an arrangement trace of the electric wire pressing member 56).
- FIG. 3 is a flowchart showing a method for manufacturing the electric circuit device 10.
- the wiring body module 14 is formed by pouring a resin into the molds 40, 50 and solidifying the wiring 12 in the lower mold 40 (wiring process).
- a manufacturing process (inflow solidification process) and a process of mounting the electrical components 20, 22, 24 on the wiring body module 14 (electrical component mounting process) are provided.
- the wires 12 are wired in the mold 40.
- 4 is a schematic cross-sectional view showing the mold apparatus 30
- FIG. 5 is a plan view showing the lower mold 40 in the mold apparatus 30, and
- FIG. 6 shows the upper mold 50 in the mold apparatus 30. It is a bottom view.
- the mold apparatus 30 includes a lower mold 40 as a first mold and an upper mold 50 as a second mold.
- the lower mold 40 has a lower mold surface 42 as a first mold surface
- the upper mold 50 has an upper mold surface 52 as a second mold surface.
- the lower mold surface 42 and the upper mold surface 52 are formed such that a resin can be molded into a predetermined shape therebetween.
- the lower mold surface 42 is formed in a shape recessed in a flat, substantially rectangular parallelepiped space
- the upper mold surface 52 is formed in a substantially rectangular surface shape capable of closing the concave upper opening of the lower mold surface 42. Has been.
- the lower mold 40 and the upper mold 50 are disposed so as to be movable toward and away from each other by a mold moving mechanism unit (not shown).
- the lower mold 40 is fixedly installed with the lower mold surface 42 facing upward.
- the upper mold 50 is disposed so as to be movable up and down above the lower mold 40 with the upper mold surface 52 facing downward.
- the resin is formed in a predetermined shape (here, a substantially rectangular plate shape) between the lower mold surface 42 and the upper mold surface 52. ) can be molded.
- the resin molded from the lower mold surface 42 and the upper mold surface 52 can be taken out. ing.
- a guide hole 41 is formed in the lower mold 40, and a guide pin 51 that can be fitted into the guide hole 41 is protruded from the upper mold 50.
- the guide pins 51 are fitted into the guide holes 41 so that the lower mold surface 42 and the upper mold surface 52 are aligned.
- positioning pins 46 that can position the wired wires are erected on the lower mold surface 42 (see FIGS. 4 and 5).
- the lower mold 40 is formed with a through hole 43 penetrating from the lower mold surface 42 to the opposite surface.
- the positioning pin 46 is formed in a substantially rod shape. More specifically, the positioning pin 46 has a small diameter portion 46a that can penetrate the through hole 43 and a large diameter portion 46b that is thicker than the small diameter portion 46a. Then, the small diameter portion 46a is inserted into the through hole 43 from the opposite side of the lower mold surface 42, and the large diameter portion 46b is brought into contact with the surface of the lower mold 40 opposite to the lower mold surface 42. By making contact, the distal end portion of the small-diameter portion 46a of the positioning pin 46 is detachably positioned and fixed in a state of protruding from the lower mold surface 42.
- the standing structure of the positioning pin 46 is not limited to the above example, and may be a structure that is inserted and removed from the lower mold surface 42 side by a screwed structure or the like. Further, the positioning pin 46 is not necessarily detachable, and may be configured to be integrally fixed to the lower mold surface 42.
- the portion disposed in the through hole 43 and the portion protruding from the lower mold surface 42 may not have the same cross-sectional shape or substantially the same size.
- the cross-sectional shape or size of the portion of the positioning pin 46 that protrudes from the lower mold surface 42 is the portion of the portion (connection portion 20a, 22a, 24b) that is inserted into the trace of the positioning pin 46. It is determined appropriately according to the shape and size.
- the positioning pin 46 as described above is erected at a position where the electric wire 12 can be positioned according to the wiring pattern of the electric wire 12 wired on the lower mold surface 42.
- the positioning pins 46 are erected on the lower mold surface 42, but the positioning pins 46 may be erected on the upper mold surface 52, and the lower mold surface 42 and the upper mold surface 52 are also provided. May be erected on both sides.
- the positioning pin 46 is erected on the upper mold surface 52, the wired electric wire 12 can be more reliably positioned with respect to the upper mold surface 52.
- FIG. 5 a part of the wiring pattern of the electric wire 12 wired with respect to the lower mold surface 42 is shown by a two-dot chain line.
- the positioning pin 46 is erected at a position where the electric wire 12 wired along a desired wiring pattern can be positioned, particularly at a position inside the bent portion of the wiring pattern. Thereby, the electric wire 12 to be wired can be positioned along a desired wiring pattern.
- the positioning pins 46 are also erected at positions along the wiring pattern of the electric wires 12 and at positions where the electric components 20, 22, 24 are mounted.
- the electrical component 20 (first connector terminal portion) mounted on one side portion of the wiring body module 14 and the electrical component 22 (second connector terminal portion) mounted on the other side portion of the wiring body module 14.
- a positioning pin 46 is provided upright at a position where the electrical component 24 (element component) to be mounted is mounted at a position near the center of the wiring body module 14.
- the electric wire 12 is in contact with the positioning pin 46 at a location via the positioning pin 46. Therefore, a part of the electric wire 12 is exposed at the trace after the positioning pin 46 is removed. Then, as will be described later, the electric wires 12 wired through the positioning pins 46 are electrically connected to the electrical components 20, 22, 24 using the traces of the positioning pins 46. It is like that.
- the positioning pin 46 only needs to be at a position where the electric wire 12 can be positioned along the wiring pattern assumed in the design as described above, and from the viewpoint of ease of mounting the electrical components 20, 22, 24, Furthermore, it is only necessary to stand up at a position where the electrical components 20, 22, and 24 are mounted. However, in FIG. 5, the positioning pins 46 are erected in addition to the positions along the wiring pattern assumed in the design and the positions where the electrical components 20, 22, 24 are mounted. Thus, the positioning pins 46 that are erected more easily make it possible to cope with changes in the design of the wiring pattern of the electric wires 12, changes in the type or number of the electrical components 20, 22, and 24 to be mounted. This point will be described in detail later.
- FIG. 6 a part of the wiring pattern of the electric wire 12 wired to the lower mold surface 42 in the upper mold surface 52 is indicated by a two-dot chain line.
- the upper mold surface 52 is formed with a hole 53 into which the tip of the positioning pin 46 can be inserted corresponding to each position where the positioning pin 46 is erected.
- the tip of the positioning pin 46 is inserted into the hole 53 so that the hole 17 formed by the positioning pin 46 penetrates the wiring body module 14 more reliably. It is formed.
- an electric wire holding member 56 that presses the electric wire 12 so as to expose the portion of the electric wire 12 connected to the electric parts 20, 22, 24 to the outside of the resin molded portion 16 protrudes. (See FIGS. 4 and 6).
- the upper mold 50 is formed with a through hole 54 penetrating from the upper mold surface 52 to the opposite surface.
- the wire pressing member 56 is formed in a substantially rod shape. More specifically, the electric wire pressing member 56 has a small diameter portion 56a that can penetrate the through hole 54 and a large diameter portion 56b that is thicker than the small diameter portion 56a. Then, the small diameter portion 56a is inserted into the through hole 54 from the opposite side of the upper mold surface 52, and the thick large diameter portion 56b is formed on the surface of the upper mold 50 opposite to the upper mold surface 52. By abutting, the distal end portion of the wire pressing member 56 is detachably positioned and fixed in a state of protruding from the upper mold surface 52.
- the standing structure of the wire pressing member 56 is not limited to the above example, and may be a structure that is inserted and removed with a screwed structure or the like from the upper mold surface 52 side. Further, the wire pressing member 56 does not necessarily need to be detachable, and may be configured to be integrally fixed to the upper mold surface 52.
- the portion disposed in the through hole 54 and the portion protruding from the upper mold surface 52 may not have the same cross-sectional shape or substantially the same size.
- die surface 52 among the thin diameter parts 56a is formed in the elongate plate shape flat in the direction substantially orthogonal to the extension direction of the electric wire 12 used as the object to hold down.
- die surface 52 of this electric wire holding member 56 is a dimension which can expose the said electric wire 12 to the one main surface of the wiring body module 14, and here, the wiring body module 14 of FIG. It is formed to have a dimension that is obtained by subtracting the diameter dimension of the electric wire 12 from the thickness dimension. Then, the portion of the electric wire 12 wired on the lower mold surface 42 is pressed by the tip portion of the electric wire pressing member 56, so that the portion of the electric wire 12 (connected to the electric parts 20, 22, 24). Part) is exposed to the outside on one main surface of the wiring module 14 on the lower mold surface 42 side (see FIGS. 9 and 11).
- wire pressing member 56 may be provided on the lower mold surface 42. Thereby, an electrical component can be easily mounted on the surface of the wiring body module 14 on the lower mold surface 42 side.
- the electric wire 12 is wired in a predetermined pattern on the lower mold surface 42 using the mold apparatus 30 as described above.
- FIG. 7 is a schematic plan view showing a state in which the electric wire 12 is wired
- FIG. 8 is a schematic side view showing a state in which the electric wire 12 is wired.
- the wiring head 60 supported so as to be movable within a predetermined plane by an XY movement mechanism (not shown) is disposed above the lower mold surface 42 on which the positioning pins 46 are erected as described above. To do. Then, the wire 12 is continuously supplied from the wiring head 60 while moving the wiring head 60 vertically and horizontally with respect to the lower mold surface 42 according to a predetermined wiring pattern set in accordance with a circuit designed in advance. .
- a wiring apparatus various configurations including a conventionally known wiring apparatus can be used. Thereby, the electric wire 12 is wired with the predetermined wiring pattern on the lower mold surface 42.
- the electric wire 12 can be wired while being positioned so as to be hooked on the positioning pin 46. Therefore, the electric wire 12 is kept in a state where it is more reliably positioned at a predetermined position.
- the electric wire 12 used here includes at least a conductive wire, and it is preferable to use an enameled wire or the like in which the periphery of the conductive wire is covered with an insulating material.
- an enameled wire or the like in which the periphery of the conductive wire is covered with an insulating material.
- FIG. 9 is a schematic explanatory view showing the main part of the casting solidification step.
- a resin supply (not shown) is supplied into the space between the lower mold surface 42 and the upper mold surface 52 with the upper mold 50 moved close to the lower mold surface 42 and clamped.
- the fluidized resin is poured from a nozzle or the like and solidified.
- the electric wire 12 is in contact with the positioning pin 46 so as to be hooked.
- the wire pressing member 56 presses the electric wire 12 from the upper mold surface 52 side so as to contact the lower mold surface 42. Yes. Therefore, in this part, the part of the electric wire 12 is exposed in the hole 17 of the positioning pin 46 trace, and is also exposed on the main surface on the lower mold surface 42 side of the wiring body module 14.
- FIG. 10 is a schematic plan view showing the wiring body module 14 manufactured as described above. In this figure, the location where the electric wire 12 and the electrical components 20, 22, 24 are mounted is indicated by a two-dot chain line.
- the hole portion 17 that is the trace of the positioning pin 46 is formed in the resin molded portion 16 in a penetrating manner, and the concave portion 18 that is the trace of the wire pressing member 56 is formed in a bottomed hole shape. Is formed.
- the electric wire 12 does not necessarily have to be entirely embedded in the resin molded portion 16, and may be partially embedded in the resin molded portion 16. In short, it is only necessary that the electric wire 12 is embedded in the resin molded portion 16 in such a manner that it can be maintained in a predetermined wiring pattern.
- the electric wire 12 is molded as described above, the electric wire 12 is in close contact with the resin molded portion 16, which is different from the configuration in which the electric wire 12 is wired after molding of the resin component.
- an electrical component mounting process is executed.
- the electrical components 20, 22, and 24 are mounted using the holes 17 formed as the positioning pin 46 traces.
- the first connector terminal portion 20 as the electrical component 20 is integrated by a resin portion 21 or the like in a predetermined arrangement state (here, an arrangement state in a row at intervals) (see FIG. 1). And the connection part 20a in a base end part among the 1st connector terminal parts 20 is inserted in the hole 17 formed in the position where the said connector terminal part 20 should be mounted.
- FIG. 11 is an explanatory diagram showing one process of mounting the first connector terminal portion 20 on the wiring body module 14. As shown in the figure, regarding the predetermined hole 17 formed in the wiring body module 14, as described above, the portion of the electric wire 12 is exposed in the hole 17.
- the portion of the electric wire 12 is exposed to one main surface of the wiring body module 14 (here, the surface opposite to the surface on which the electrical components 20, 22, and 24 are mounted) by the pressing action by the electric wire pressing member 56. Yes.
- the positioning pin 46 in which the hole 17 is formed is formed in substantially the same shape and substantially the same size as the connection portion 20a, or a shape that is slightly smaller (here, slightly) than the connection portion 20a. And in the state which inserted the connection part 20a in the said hole part 17, the electric wire 12 exposed in the said hole part 17 and the connection part 20a are comprised so that a press contact is possible.
- the connecting portion 20a is press-fitted into the hole portion 17 as described above, and the electric wire 12 exposed in the hole portion 17 and the connecting portion 20a are coupled and electrically connected.
- the connection between the electric wire 12 and the connecting portion 20a can be performed by laser welding, resistance welding, soldering, or the like, and is particularly preferably performed by laser welding.
- the connecting operation can be performed without separately providing a workpiece pressurizing means for connecting.
- the part of the electric wire 12 is exposed to one main surface of the wiring body module 14, the coupling
- a portion N indicated by a two-dot chain line in FIG. 11 indicates a weld nugget N formed by welding.
- the coating removal and the joining operation can be performed by a single joining operation. If a material that cannot be removed at the same time as the insulation coating of the electric wire 12 is used, the coating operation is performed after the coating removal operation (laser light irradiation or the like that can remove the coating) is performed for the purpose of the insulation coating removal. Can be done.
- the coating removal operation laser light irradiation or the like that can remove the coating
- the second connector terminal portion 22 as the electrical component 22 is incorporated in a connector housing 23 having a predetermined shape and integrated in a predetermined arrangement state, and a connection portion 22a at the base end portion of the second connector terminal portion 22 is provided.
- a connector housing 23 having a predetermined shape and integrated in a predetermined arrangement state
- a connection portion 22a at the base end portion of the second connector terminal portion 22 is provided.
- the 2nd connector terminal part 22 is also mounted similarly to the above (refer to Drawing 1 and Drawing 2).
- the element component as the electrical component 24 has a connection portion 24a called a so-called lead terminal, and is mounted on the wiring body module 14 in the same manner as described above (see FIGS. 1 and 2).
- the electrical circuit device 10 is manufactured by mounting the electrical components 20, 22, 24 on the wiring body module 14.
- the circuit is configured with the wired wires 12, and thus the circuit is configured with the bus bar as in the past. Compared to the configuration, it is possible to reduce the size and weight and the pitch.
- the wiring pattern of the electric wires 12 on the lower mold surface 42 may be changed, such a change in the wiring pattern is configured when the circuit is formed by the bus bar and the circuit is formed by the conductive foil of the PCB. Compared with the case where it has done, it can respond to design changes, such as a circuit change, easily. Such an effect is realized even in the configuration in which the electric wire 12 is positioned by the positioning pin 46, even when the standing position of the positioning pin 46 cannot be changed and is determined corresponding to the wiring pattern designed in the initial stage. Can do. That is, even in such a case, the positioning pin 46 that was initially set up is not used within the range of the position of the positioning pin 46 that was set up at the initial stage, or is set up at the initial stage. This is because it is easy to change the wiring pattern of the electric wire 12 by hooking another electric wire 12 on the positioning pin 46 that has been used.
- the circuit is formed by arranging the wires 12, the wires 12 are hardly wasted and the material yield is excellent.
- the circuit is constituted by the electric wires 12, a configuration suitable for a large current circuit can be achieved as compared with the case of a PCB in which the circuit is constituted by a conductive foil.
- design changes such as miniaturization and weight reduction, narrow pitch, and circuit change can be prepared to meet the demand for material yield and high current compatibility at the highest possible level.
- the resin molded portion 16 can be molded in a state where the wiring form of the electric wire 12 is more securely held by the positioning pins 46 erected on the lower mold surface 42.
- the electrical parts 20, 22, 24 a are electrically connected to the electric wires 12 by connecting the connecting parts 20 a, 22 a, 24 a of the electrical parts 20, 22, 24 using the holes 17 formed by the positioning pins 46. Since 24 is mounted on the wiring body module 14, the electrical component 20 can be easily mounted. Thereby, the function expansion (function expansion in the electric circuit device 10) by mounting the electrical components 20, 22, 24 can be easily realized.
- the wiring structure of the electric wire 12 is adopted. By adopting a configuration in which the hole 17 is used for mounting, there is a great merit in that a configuration suitable for mounting such a semiconductor component can be obtained.
- the connecting portions 20a, 22a, 24a of the electrical parts 20, 22, 24 are inserted into the hole portion 17 and brought into pressure contact with the electric wires 12 exposed on the inner surface of the hole portion 17, so that the connecting portions 20a, 22a are connected. , 24a and the electric wire 12 can be coupled, so that it is not necessary to separately provide a structure for pressurizing when the coupling is performed, and therefore, the coupling operation can be easily performed.
- the part connected to the electrical components 20, 22, 24 of the electric wire 12 is exposed to the outside of the wiring body module 14 by the wire pressing member 56, when mounting the electrical components 20, 22, 24, Laser light can be easily irradiated to the contact portions between the connecting portions 20a, 22a, 24a of the electrical components 20, 22, 24 and the electric wires 12, and the connecting operation thereof can be easily performed.
- the positioning pin 46 can be positioned at other positions. An extra stand may be provided. In this case, the positioning pins 46 may be provided in an appropriately scattered manner.
- FIG. 12 shows a case where the positioning pins 46 are arranged in a plurality of rows and columns as an example. In this case, the electric wire 12 is aligned along the predetermined wiring pattern while positioning using at least one selected from the plurality of positioning pins 46 in accordance with the initially assumed circuit wiring pattern. (See the electric wire 12 shown by a solid line in FIG. 12).
- the electric wire is positioned using at least one selected from the plurality of positioning pins 46 according to the changed wiring pattern. 12 can be wired along the changed predetermined wiring pattern (see the electric wire 12 indicated by a two-dot chain line in FIG. 12). Thereby, it can respond to a change of a wiring pattern more flexibly.
- the positioning pin 46 may be attached or detached according to the change of the wiring pattern. As shown in FIG. 13, the positioning pins 46 are detachably inserted into and fixed to the respective through holes 43 formed in the lower mold 40. Similarly to the above, each through-hole 43 is positioned at a position where the electric wire 12 can be positioned along the wiring pattern assumed in design (and, if necessary, a position where the electric components 20, 22, 24 are mounted). In addition, extra portions are formed at other positions. And the said positioning pin 46 is attached to the position (position where the electrical components 20, 22, and 24 are mounted as needed) which can position the electric wire 12 along the wiring pattern assumed on design. A hole filling pin 48 is fitted into the unnecessary through hole 43.
- the hole-filling pin 48 has a configuration in which a portion protruding from the lower mold surface 42 of the positioning pin 46 is deleted. By inserting the hole-filling pin 48 into the through-hole 43, the unnecessary through-holes are provided. The hole 43 is filled, and the lower mold surface 42 is flush with that portion.
- the positioning pin 46 is erected at a position necessary for positioning the electric wire 12 wired in a predetermined wiring pattern, and the excess positioning pin 46 is deleted.
- the electric wire 12 can be positioned and held. 14 and 15, the positioning pin 46 is indicated by a solid line, and the hole-filling pin 48 is indicated by a two-dot chain line.
- the positioning pin 46 and the filling pin 48 are inserted / removed according to the changed wiring pattern. Accordingly, for example, as shown in FIG. 15, the positioning pins 46 are erected at positions necessary for positioning the electric wires 12 wired with the changed predetermined wiring pattern, and the extra positioning pins 46 are installed. The electric wire 12 can be positioned and held in the deleted mode.
- the above is applicable not only when the wiring pattern is changed, but also when the mounting positions, types, additions, etc. of the electrical components 20, 22, 24 are changed.
- the positioning pin 46 or the through-hole 43 is an extra place for mounting the electrical parts 20, 22, 24 at a place where the electrical parts 20, 22, 24 are expected to be additionally mounted. May be. Further, other portions may be provided extra for changing the wiring pattern.
- the wire pressing member 56 may be provided in addition to the necessary portion as described above, or may be configured to be attached and detached according to the wiring pattern.
- the size, shape, etc. of the positioning pin 46 and the through-hole 43 may all be substantially the same, and are also used for mounting the electric parts 20, 22, 24 and those for just positioning the electric wire 12. It may be different from what is provided.
- the size and shape of the portion of the positioning pin 46 that protrudes from the lower mold surface 42 is the connecting portion of the electrical components 20, 22, 24. It is good to set it as the structure according to the magnitude
- FIG. 16 is a view showing a modification for exposing the portion of the electric wire 12 to the outside of the wiring body module 14.
- the member 58 may be formed.
- the projecting member 58 is formed by forming the base end portion of the portion of the positioning pin 46 that projects from the lower mold surface 42 to have a larger diameter than the distal end side portion.
- the resin molded portion 16 is recessed at the portion of the positioning pin 46 trace, and the electric wire 12 is partially exposed at the back portion of the recessed portion 16a, and is thus exposed to the outside of the wiring body module 14.
- the connection parts 20a, 22a, 24a of the electric components 20, 22, 24 and the electric wire 12 can be easily coupled.
- wiring members such as other jumper wires may be used in combination.
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Abstract
Description
図1及び図2は電気回路装置10の概略構成を示す斜視図である。この電気回路装置10は、自動車等において、接続配線間の規格(電線種等)相違の吸収、接続配線同士をコネクタ中継により相互接続する際のコネクタ中継基地、ヒューズ及びリレー、半導体素子等の実装電気部品の搭載基地等としての機能を担うものであり、いわゆる、電気接続箱、ジャンクションブロック、リレーボックス、ヒューズボックス、電装ユニット等として用いられるものである。この電気回路装置10は、配線体モジュール14と、電気部品20、22、24とを備えている。配線体モジュール14は、後述する下金型40内で所定パターンに布線された電線12(図1及び図2では図示省略、図10参照)と、当該電線12を埋設した状態で所定形状に金型成型(いわゆるモールド成型)された樹脂成形部分16とを有している。電気部品20、22、24は、本電気回路装置10の回路に接続される部品であり、上記電線12に電気的に接続されて配線体モジュール14に実装されている。ここでは、電気部品20、22、24として、配線体モジュール14の一の側部(ここでは短辺側の一側部)に実装される複数の第1コネクタ端子部20と、配線体モジュール14の他の側部(ここでは長辺側の一側部)に実装される第2コネクタ端子部22と、配線体モジュール14の略中央よりの部分に実装される電力用半導体素子等の素子部品24とを想定している。勿論、電気部品20、22、24としては、その他の各種電気部品、例えば、リレー、ヒューズ、その他の制御用半導体素子、コンデンサ、抵抗等であってもよい。
図3は電気回路装置10の製造方法を示すフローチャートである。この電気回路装置10の製造方法は、下金型40内に電線12を布線する工程(布線工程)と、金型40、50内に樹脂を流し込んで固化することで配線体モジュール14を製造する工程(流込固化工程)と、配線体モジュール14に電気部品20、22、24を実装する工程(電気部品実装工程)とを備えている。
位置決めピン46は、設計上想定される布線パターンに沿って電線12を位置決めできる位置(必要に応じて、電気部品20、22、24が実装される位置)に加えて、他の位置にも余分に立設されていてもよい。この場合、位置決めピン46は適宜散在する態様で設ければよい。図12は、一例として位置決めピン46を縦横複数列に配列した場合を示している。この場合、当初想定される回路の布線パターンに応じて、当該複数の位置決めピン46のなかから選択された少なくとも一つを利用して位置決めしつつ、電線12を当該所定の布線パターンに沿って布線することができる(図12において実線で示す電線12参照)。そして、設計変更等により布線パターンが変った場合には、当該変更された布線パターンに応じて、複数の位置決めピン46のなかから選択された少なくとも一つを利用して位置決めしつつ、電線12を当該変更された所定の布線パターンに沿って布線することができる(図12において2点鎖線で示す電線12参照)。これにより、布線パターンの変更に対してより柔軟に対応することができる。
Claims (14)
- 金型内に電線を布線する工程と、
前記金型内に流動化した樹脂を流し込んで固化することで、前記電線が前記樹脂に埋設された配線体モジュールを製造する工程と、
前記配線体モジュールに電気部品を実装する工程と、
を備えた電気回路装置の製造方法。 - 請求項1記載の電気回路装置の製造方法であって、
前記金型内に電線を布線する工程では、
金型内に位置決めピンを立設し、前記電線を前記位置決めピンで位置決めしつつ布線する、電気回路装置の製造方法。 - 請求項2記載の電気回路装置の製造方法であって、
前記位置決めピンは前記金型内に形成された穴に着脱自在に立設される、電気回路装置の製造方法。 - 請求項2記載の電気回路装置の製造方法であって、
前記位置決めピンは、前記電気部品が実装される位置に立設され、
前記配線体モジュールに電気部品を実装する工程では、
前記位置決めピン跡として前記配線体モジュールに形成された孔部に前記電気部品の接続部を挿入して前記電線に電気的に接続することで、前記電気部品を実装する、電気回路装置の製造方法。 - 請求項4記載の電気回路装置の製造方法であって、
前記位置決めピン跡として前記配線体モジュールに形成された孔部は、前記電気部品の接続部が前記孔部に挿入された状態で、前記孔部の内面に露出する前記電線と前記接続部とが加圧接触可能な態様に形成され、
前記配線体モジュールに電気部品を実装する工程では、前記電気部品の接続部を前記孔部に挿入して前記接続部を前記孔部の内面に露出する前記電線に加圧接触させた状態で、前記接続部と前記電線とを結合する、電気回路装置の製造方法。 - 請求項1記載の電気回路装置の製造方法であって、
前記配線体モジュールを製造する工程では、
前記電線のうち前記電気部品に接続される部分を前記配線体モジュールの外部に露出させるように前記電線を押える電線押え部材、又は、前記電線のうち前記電気部品に接続される部分を前記配線体モジュールの外部に露出させるように前記金型の金型面から突出した突出部材により、前記電線のうち前記電気部品に接続される部分を前記配線体モジュールの外部に露出させる、電気回路装置の製造方法。 - 金型内で所定パターンに布線された電線と、所定パターンに布線された前記電線を埋設した状態で所定形態に成型された樹脂成形部分とを有する配線体モジュールと、
前記配線体モジュールに実装された電気部品と、
を備えた電気回路装置。 - 請求項7記載の電気回路装置であって、
前記樹脂成形部分に、前記電線を所定パターンに位置決め保持するための位置決めピンを配設可能な孔部が形成されている、電気回路装置。 - 請求項8記載の電気回路装置であって、
前記位置決めピンを配設可能な孔部に前記電気部品の接続部を挿入して前記電線に電気的に接続することで、前記電気部品が実装された、電気回路装置。 - 請求項9記載の電気回路装置であって、
前記位置決めピンを配設可能な前記孔部は、前記電気部品の接続部が前記孔部に挿入された状態で、前記孔部の内面に露出する前記電線と前記接続部とが加圧接触可能な態様に形成され、前記電気部品の接続部を前記孔部に挿入して前記接続部を前記孔部の内面に露出する前記電線に加圧接触させた状態で、前記接続部と前記電線とが結合された、電気回路装置。 - 請求項7記載の電気回路装置であって、
前記樹脂成形部分に、前記電線のうち前記電気部品に接続される部分を前記配線体モジュールの外部に露出させるように前記電線を押える電線押え部材、又は、前記電線のうち前記電気部品に接続される部分を前記配線体モジュールの外部に露出させるように前記金型の金型面から突出した突出部材を配設可能な凹部が形成された、電気回路装置。 - 電気回路装置を製造するための金型装置であって、
第1金型面を有する第1金型と、
前記第1金型面との間で樹脂成形可能な第2金型面を有する第2金型と、
を備え、
前記第1金型面及び前記第2金型面のうちの少なくとも一方に、布線された電線を位置決め可能な位置決めピンが立設された、金型装置。 - 請求項12記載の金型装置であって、
前記位置決めピンは前記金型内に形成された穴に着脱自在に立設される、金型装置。 - 請求項12記載の金型装置であって、
前記第1金型面及び前記第2金型面のうちの少なくとも一方に、前記電線のうち前記電気部品に接続される部分を樹脂成形部分の外部に露出させるように前記電線を押える電線押え部材、又は、前記電線のうち前記電気部品に接続される部分を前記配線体モジュールの外部に露出させるように前記第1金型面又は前記第2金型面から突出した突出部材をさらに備えた、金型装置。
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US12/864,670 US20100307820A1 (en) | 2008-01-29 | 2008-07-23 | Electrical circuit device, method for manufacturing the same, and metallic mold |
CN200880125801.3A CN101933207B (zh) | 2008-01-29 | 2008-07-23 | 电路装置及其制造方法和金属模具装置 |
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JP2008017482A JP5088559B2 (ja) | 2008-01-29 | 2008-01-29 | 電気回路装置の製造方法及び電気回路装置、金型装置 |
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JPH0830529B2 (ja) * | 1986-02-18 | 1996-03-27 | 富士重工業株式会社 | 無段変速機の制御装置 |
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- 2008-01-29 JP JP2008017482A patent/JP5088559B2/ja not_active Expired - Fee Related
- 2008-07-23 CN CN200880125801.3A patent/CN101933207B/zh not_active Expired - Fee Related
- 2008-07-23 WO PCT/JP2008/063190 patent/WO2009096055A1/ja active Application Filing
- 2008-07-23 US US12/864,670 patent/US20100307820A1/en not_active Abandoned
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