WO2018066273A1

WO2018066273A1 - Method for manufacturing busbar resin molded article

Info

Publication number: WO2018066273A1
Application number: PCT/JP2017/031107
Authority: WO
Inventors: 邦弘岩田; 寛栗山
Original assignee: 豊田鉄工株式会社
Priority date: 2016-10-03
Filing date: 2017-08-30
Publication date: 2018-04-12
Also published as: JP6619317B2; JP2018058237A

Abstract

A method for manufacturing a busbar resin molded article is provided with: a busbar manufacturing step of manufacturing a busbar coupled body in which a plurality of busbars are coupled together via a coupling part, by metal powder injection molding using metal powder as material; an arrangement step of arranging the busbar coupled body with respect to a resin-molding mold; a resin molding step of closing the mold and injecting and filling synthetic resin material into the mold with the busbar coupled body arranged in the mold; and a segmentation step, with respect to the busbar coupled body that has been integrated with the synthetic resin material by means of the resin molding step, of segmenting the coupled part so that the plurality of busbars are insulated from each other.

Description

Manufacturing method of bus bar resin molded product

The present invention relates to a method for manufacturing a bus bar resin molded product.

The bus bar resin molded product is obtained by integrating a bus bar used as a wiring material with a synthetic resin material by resin injection molding. As a bus bar resin molded product, for example, a joint connector described in Patent Document 1 is known.

In the joint connector described in Patent Document 1, a plurality of bus bars insulated from each other are integrated through a synthetic resin material by resin injection molding. The specific manufacturing method first includes manufacturing a bus bar base material. The bus bar base material is obtained by connecting a plurality of bus bars that are insulated from each other through a connecting portion when the joint connector is completed. This bus bar base material is integrated with a synthetic resin material by resin injection molding. Then, the bus bar base material is divided into a plurality of bus bars insulated from each other by breaking the connecting portion. Thereby, a joint connector in which a plurality of bus bars insulated from each other are integrated via the synthetic resin material is completed.

JP 2000-331750 A

The joint connector described in Patent Document 1 has a plurality of bus bars made of flat tab pieces. The plurality of bus bars are arranged in parallel. The bus bar base material in this case has one connection part which makes strip | belt shape, and the several tab piece which protrudes in a cantilever form from the side edge of a connection part. A plurality of tab pieces are arranged in parallel. It can be said that the bus bar base material has a simple configuration that can be grasped two-dimensionally. The bus bar base material having such a simple configuration is manufactured by using a relatively simple processing method among metal material processing methods such as press processing.

On the other hand, when a plurality of bus bars are arranged three-dimensionally, which must be grasped three-dimensionally, a bus bar base material formed by connecting a plurality of bus bars is manufactured by a simple processing method such as pressing. Difficult to do. In this case, a plurality of bus bars must be manufactured individually. Then, when integrating a plurality of individually manufactured bus bars with a synthetic resin material by resin injection molding, a plurality of individually manufactured bus bars are sequentially arranged in the mold used for the resin injection molding. There is a concern that the number of work man-hours will increase.

An object of the present invention is to provide a method of manufacturing a bus bar resin molded product in which an increase in work man-hours is suppressed regardless of the arrangement of a plurality of bus bars.

A method of manufacturing a bus bar resin molded product according to a first aspect that achieves the above object is a method of manufacturing a bus bar resin molded product by integrating a plurality of bus bars that are insulated from each other through a synthetic resin material by resin injection molding. It is. This method includes a bus bar manufacturing process for manufacturing a bus bar connecting body in which a plurality of bus bars are connected through a connecting portion by metal powder injection molding using metal powder as a material, and a bus bar for a resin molding die. An arrangement process for arranging the coupling body, a resin molding process for injecting and filling a synthetic resin material into the mold with the bus bar coupling body arranged in a mold for resin molding, and a resin molding process Then, about the bus-bar coupling body after being integrated with the synthetic resin material, a dividing step of dividing the connecting portion is provided so that the plurality of bus bars are insulated from each other.

A method for manufacturing a bus bar resin molded product according to a second aspect that achieves the above object is to manufacture a bus bar assembly in which a plurality of bus bars are connected via a connecting portion by metal powder injection molding using metal powder as a material. A bus bar manufacturing process, an arrangement process of arranging the bus bar coupling body in a mold for resin molding, and a state in which the bus bar coupling body is arranged in a mold for resin molding, and clamping and synthetic resin in the mold A resin molding step of injecting and filling the material, and the resin molding step is configured to insulate the plurality of bus bars from each other by using the injection pressure of the synthetic resin material generated when the synthetic resin material is injected and filled. In addition, a dividing step of dividing the connecting portion is included.

The perspective view which shows schematic structure of the bus-bar resin molded product of 1st Embodiment. The perspective view which shows schematic structure of a bus bar in the bus bar resin molded product. The figure explaining the manufacturing process of the bus-bar resin molded product. The perspective view which shows schematic structure of a bus-bar coupling body in the bus-bar resin molded product. The perspective view which shows the aspect of a conveyance process in the manufacturing process of the bus-bar resin molded product. FIG. 4 is a cross-sectional view showing an arrangement process in the manufacturing process of the bus bar resin molded product, particularly a cross-sectional view taken along line VI-VI in FIG. 3. The perspective view which shows the aspect of a parting process in the manufacturing process of the bus-bar resin molded product. The perspective view which shows schematic structure of a bus bar in the bus-bar resin molded product of 2nd Embodiment. The figure explaining the manufacturing process of the bus-bar resin molded product. The perspective view which shows schematic structure of a bus-bar coupling body in the bus-bar resin molded product. FIG. 10 is a cross-sectional view showing an aspect of an arrangement process in the manufacturing process of the bus bar resin molded product, particularly a cross-sectional view taken along the line XI-XI in FIG. 9. Sectional drawing which shows the aspect of the resin molding process in the manufacturing process of the bus-bar resin molded product. Sectional drawing which shows the aspect of a bus-bar manufacturing process in the manufacturing process of the bus-bar resin molded product of a modification. Sectional drawing which shows schematic structure of a bus bar in the bus-bar resin molded product of a modification. The perspective view which shows schematic structure of a bus-bar coupling body in the bus-bar resin molded product of a modification.

(First embodiment)
Hereinafter, 1st Embodiment of the manufacturing method of a bus-bar resin molded product is described.
As shown in FIG. 1, the bus bar resin molded product 1 includes a plurality (two in this embodiment) of

bus bars

2 and 3 made of a conductive metal material such as copper used as a wiring material. The bus bar resin molded product 1 is obtained by integrating

bus bars

2 and 3 via a resin coating portion 4 made of a synthetic resin material. The

bus bars

2 and 3 are integrated in a state of being insulated from each other by the resin coating portion 4. The

first terminals

2a and 3a that are part of the

bus bars

2 and 3 protrude from the resin coating portion 4 and are configured to be electrically connected to, for example, an electrode of the DC power supply V. Also, the

second terminals

2b and 3b, which are part of the

bus bars

2 and 3, protrude from the resin coating portion 4 and are configured to be electrically connected to, for example, the electrodes of the inverter Inv. Thus, the bus bar resin molded product 1 functions as a conductor through the

bus bars

2 and 3.

Specifically, as shown in FIGS. 1 and 2, the

bus bars

2 and 3 are both L-shaped, and are provided with rectangular parallelepiped

main body portions

20 and 30 having long sides and short sides, respectively. In the following description, the longitudinal direction of the

main body portions

20 and 30 is defined as “extending direction”, the short direction of the

main body portions

20 and 30 is defined as “width direction”, and the longitudinal direction of the

main body portions

20 and 30 and The direction orthogonal to the short direction is defined as the “thickness direction”. In this case, it can be said that the

main body portions

20 and 30 have a thin plate shape in which the length in the thickness direction is smaller than the length in the width direction.

The

main body portions

20 and 30 are arranged side by side so that surfaces parallel to each other in the thickness direction face each other. That is, the

main body portions

20 and 30 are not arranged so that the longitudinal direction and the short direction are parallel to the direction in which they are arranged, but are arranged so that the longitudinal direction and the short direction are orthogonal to each other. . As a result, the

bus bars

2 and 3 are not arranged so as to be two-dimensionally graspable with respect to the resin coating portion 4, but are arranged in a three-dimensional manner that must be grasped three-dimensionally with respect to the resin coating portion 4. Has been.

1st terminal

2a, 3a and

2nd terminal

2b, 3b are provided in the edge part of the extension direction of the main-

body parts

20 and 30, respectively. The

first terminals

2 a and 3 a are portions extending from one end of the long side in the width direction of the

main body portions

20 and 30 at one end portion of the

main body portions

20 and 30. The

first terminals

2 a and 3 a have a thin plate shape having a thickness in the extending direction of the

main body portions

20 and 30 and having a width in the thickness direction of the

main body portions

20 and 30, respectively. The

second terminals

2b and 3b are ends of the

main body portions

20 and 30 opposite to the

first terminals

2a and 3a.

The

main body portions

20 and 30 are respectively provided with a plurality of (two in this embodiment)

column portions

21 and 31 extending in the width direction. The

column portions

21 and 31 bulge in the thickness direction of the

main body portions

20 and 30, respectively, and have a columnar shape extending in the width direction of the

main body portions

20 and 30. The tips of the

column portions

21 and 31 protrude in the width direction from both sides of the long sides of the

main body portions

20 and 30. The two

column portions

21 and 31 are provided in the

main body portions

20 and 30 with predetermined intervals in the extending direction, respectively. In this embodiment, the column parts 21 and 31 (especially the front-end | tip) are an example of a metal mold | positioning part.

Between the bus bar 2 and the bus bar 3, projecting

pieces

22, 32 projecting toward the mutually opposing

column parts

21, 31 are respectively provided on the

column parts

21 and 31 that oppose each other. The protruding

pieces

22 and 32 are provided in the middle of the

main body portions

20 and 30 in the

column portions

21 and 31 in the width direction. The protruding

pieces

22 and 32 facing each other are divided in the manufacturing process of the bus bar resin molded product 1, and a connecting portion 51 (described later in FIG. 4) that connects the bus bar 2 and the bus bar 3 before the dividing. Part of). Note that part of the ends of the

column parts

21 and 31 and part of the ends of the protruding

pieces

22 and 32 protrude from the resin coating part 4, respectively.

In the

main body parts

20 and 30, work

auxiliary parts

23 and 33 are provided between the

first terminals

2 a and 3 a and the

pillar parts

21 and 31 of the

pillar parts

21 and 31 that are close to the

first terminals

2 a and 3 a. Is provided. The work

auxiliary parts

23 and 33 are provided at one end of the long sides of the

main body parts

20 and 30. The

work assistants

23 and 33 have bottomed

cylindrical holes

23a and 33a and plate-like

gripping pieces

23b and 33b, respectively. The

hole portions

23 a and 33 a have openings in the width direction of the

main body portions

20 and 30. The gripping

pieces

23 b and 33 b extend in the thickness direction of the

main body portions

20 and 30. The work

auxiliary parts

23 and 33 are respectively covered with the resin coating part 4. In the present embodiment, the

holes

23a and 33a (work auxiliary parts 23 and 33) are examples of gripping positioning parts, and the

grip pieces

23b and 33b (work auxiliary parts 23 and 33) are examples of gripping parts.

Hereinafter, the manufacturing method of the bus bar resin molded product 1 will be described.
As shown in FIG. 3, this manufacturing method mainly includes five processes, that is, a bus bar manufacturing process, a transport process, an arrangement process, a resin molding process, and a dividing process.

In the bus bar manufacturing process, the bus bar 2 and the bus bar 3 are manufactured by metal powder injection molding (MIM: Metal Injection Molding) using metal powder including copper powder.

As shown in a simplified manner in FIG. 3, in the bus bar manufacturing process, the metal material 130, which is a metal powder dissolved in the MIM mold 100 (core 110 and cavity 120), is injected and filled, and the bus bar 2 and the bus bar 3. Are integrally injection-molded. The metal material 130 is injected and filled into the MIM mold 100 from, for example, an injection port (so-called gate) 140 provided at one location inside the MIM mold 100. The injection port 140 is connected to a passage (so-called runner or sprue) 150 provided in the core 110. This passage is connected to a portion where an injection machine 160 for injecting the metal material 130 is disposed.

Thereafter, an integrated product in which the bus bar 2 and the bus bar 3 are integrated is taken out from the MIM mold 100 by injection molding, whereby the bus bar connector 50 is completed. In addition, after taking out the bus-bar coupling body 50 from the MIM mold 100, the metal material 130 is hardened through an arbitrary process such as a sintering process (not shown).

As shown in FIG. 4, the bus bar connector 50 includes

first terminals

2a and 3a,

second terminals

2b and 3b,

main body portions

20 and 30, two

pillar portions

21 and 31, work auxiliary portions 23 and 33 ( The bus bar 2 and the bus bar 3 having the

hole portions

23a and 33a and the

gripping pieces

23b and 33b) are integrated. In this case, the bus bar 2 and the bus bar 3 are connected via a plurality of (two in this embodiment) connecting portions 51 formed by connecting the protruding

pieces

22 and 32 facing each other. In the present embodiment, the connecting portion 51 has a prismatic shape.

The connecting portion 51 is provided with a plurality of (two in the present embodiment) notches 52 at predetermined intervals in the longitudinal direction. The notch 52 is notched in a U shape on the side where the

first terminals

2a and 3a of the

bus bars

2 and 3 extend. Thus, the

bus bars

2 and 3 are connected to each other through the connecting portions 51 a that are the projecting

pieces

22 and 32 that face each other and are located between the two notches 52. In the connecting part 51, the part of the notch 52 is a weak part having weaker strength than the other parts by the amount of the part of the connecting part 51 cut out.

As shown in FIG. 3 in a simplified manner, in the transport process after the bus bar manufacturing process, the bus bar connecting body 50 taken out from the MIM mold 100 in the bus bar manufacturing process is gripped by the transport robot 200, and the subsequent resin molding process. It is conveyed to the resin molding die 300 (core 310 and cavity 320) used in the above.

As shown in FIG. 5, the transport robot 200 has

arms

220 and 230 that hold the bus bar connector 50 from both sides of the

bus bars

2 and 3 in the thickness direction. The arm 220 grips from the outside of the bus bar 2 when gripping the bus bar connector 50. The arm 230 grips from the outside of the bus bar 3 when gripping the bus bar connector 50. The

arms

220 and 230 have rod-like positioning pins 221 and 231 extending with respect to the bus bar connector 50, respectively. The

arms

220 and 230 have engaging

hooks

222 and 232 having hooks at the ends. The

arms

220 and 230 move with respect to the bus bar connector 50 so as to approach the

bus bars

2 and 3 from the direction in which the

first terminals

2a and 3a extend (above the paper surface), respectively. , 33 is engaged.

In this case, as shown in an enlarged view in FIG. 5, the tip of the positioning pin 221 is inserted into the hole 23 a of the work assistant 23. Further, the front end of the engagement hook 222 is engaged with the gripping piece 23b of the work assisting portion 23 from the opposite side (downward on the paper surface) to the direction in which the first terminal 2a extends. The same applies to the positioning pin 231 and the engagement hook 232, and the distal end of the positioning pin 231 is inserted into the hole 33 a of the work auxiliary portion 33, and the distal end of the engagement hook 232 is held by the work auxiliary portion 33. It is engaged with the piece 33b. Thereby, the

arms

220 and 230 of the transfer robot 200 can be positioned with respect to the bus bar connector 50 and can hold the bus bar connector 50.

Subsequently, as shown in a simplified manner in FIG. 3, in the arrangement step after the conveyance step, the bus bar connector 50 conveyed in the conveyance step is arranged in the resin molding die 300 (core 310 and cavity 320). . In this case, the bus bar coupling body 50 is arranged with respect to the resin molding die 300, whereby the

integrated bus bars

2 and 3 are collectively arranged with respect to the resin molding die 300.

As shown in FIG. 6, the core 310 and the cavity 320 of the resin molding die 300 have

mold portions

311 and 321 which are internal spaces provided by cutting out the inside. The

mold parts

311 and 321 have opening

parts

312 and 322 that open between the mold part 311 and the mold part 321 so as to face each other. In the

mold portions

311 and 321, the

bottom portions

313 and 323 respectively facing the opening

portions

312 and 322 have a plurality of portions (in this embodiment, positions for positioning the bus bar connector 50 with respect to the core 310 and the cavity 320). 4) positioning recesses 314, 324, which are the same number as the total of the

column portions

21, 31, are provided. The positioning recesses 314 and 324 are recessed at the

bottoms

313 and 323 on the side opposite to the

openings

312 and 322, so that the ends of the

column parts

21 and 31 provided on the

bus bars

2 and 3 can be fitted. Is set.

In this case, in the core 310 of the resin molding die 300, the front ends of the

column portions

21 and 31 of the

bus bars

2 and 3, the front ends on the side where the

first terminals

2 a and 3 a extend are the positioning recesses 314 of the bottom portion 313. Each is fitted. Similarly, in the cavity 320, of the ends of the

column portions

21 and 31 of the

bus bars

2 and 3, the ends opposite to the side where the

first terminals

2 a and 3 a extend are fitted into the positioning recesses 324 of the bottom portion 323, respectively. Accordingly, the bus bar connector 50 is disposed in the resin molding die 300 in a state of being positioned with respect to the core 310 and the cavity 320, respectively.

In addition, the bus bar connector 50 is disposed in the resin molding die 300 so that the connecting portion 51a including the notch 52 among the connecting portions 51 of the bus bar connector 50 is brought into contact with the core 310 and the cavity 320, respectively. Is done. Thus, the synthetic resin material 330 is configured not to be injected and filled around the connecting portion 51 a including the notch 52 of the connecting portion 51. That is, the connecting portion 51 a including the notch 52 is configured to be exposed without being covered by the resin coating portion 4.

Subsequently, as shown in a simplified manner in FIG. 3, in the resin molding step after the arranging step, the bus bar connecting body 50 is placed in the resin molding die 300 and the mold is clamped to perform the resin molding die. 300 (core 310 and cavity 320) is melt-filled with the synthetic resin material 330, and the resin coating portion 4 is injection-molded onto the bus bar connector 50. For example, a synthetic resin material 330 is injected and filled into the resin molding die 300 from, for example, an injection port 340 provided at one location inside the resin molding die 300. The injection port 340 is connected to a passage (so-called runner or sprue) 350 provided in the core 310. This passage is connected to a portion where an injection machine 360 for injecting the synthetic resin material 330 is disposed.

Thereafter, an integrated product in which the resin coating portion 4 is integrated with the bus bar connector 50 is taken out of the resin molding die 300 by injection molding, thereby completing the bus bar connector resin molded product 1 ′. In the bus bar connector resin molded product 1 ′, the

bus bars

2 and 3 are electrically connected via the connecting portion 51.

Subsequently, as shown in a simplified manner in FIG. 3, in the dividing step after the resin molding step, the bus bar connector 50 of the bus bar connector resin molded product 1 ′ taken out from the resin molding die 300 in the resin molding step. The connecting portion 51 is cut by the cutting device 400.

As shown in FIG. 7, the cutting device 400 has a breaking portion 410 that divides the connecting portion 51 of the bus bar connector 50. When the breaking portion 410 divides the connecting portion 51, for example, a force acts on the connecting portion 51a, in particular, from the side where the

first terminals

2a and 3a of the

bus bars

2 and 3 extend (above the paper surface). Let In this case, in the connecting portion 51, the two notches 52 that are weak portions are broken, and the connecting portions 51a that are portions between the two notches 52 are cut off, that is, cut, and the protruding

pieces

22 and 32 are cut. Divided to leave only. As a result, the

bus bars

2 and 3 are separated from each other so as to be insulated from each other by the resin coating portion 4 while being released from the electrically connected state via the connecting portion 51.

Then, as shown in a simplified manner in FIG. 3, after the dividing step, the bus bar resin molded product 1 is completed in which the

bus bars

2 and 3 are integrated with the resin coating portion 4 being insulated from each other.
According to the present embodiment described above, the following operations and effects are achieved.

(1) When the bus bar resin molded product 1 is manufactured, the bus bar connector 50 is first manufactured by metal powder injection molding. In this case, the bus bar connector 50 can be manufactured regardless of how the

bus bars

2 and 3 insulated from each other are arranged with respect to the resin coating portion 4. Even when the

bus bars

2 and 3 are three-dimensionally arranged with respect to the resin coating portion 4 as in the present embodiment, the bus bars can be obtained by using metal powder injection molding. The coupling body 50 can be manufactured suitably. Thereby, in the arrangement step, the

bus bars

2 and 3 can be collectively arranged in the resin molding die 300 by arranging the bus bar connector 50 in the resin molding die 300. Therefore, an increase in work man-hours can be suppressed regardless of the arrangement of the

bus bars

2 and 3.

(2) Further, in the bus bar manufacturing process of the present embodiment, by adopting metal powder injection molding, the connecting part 51 is notched so that the connecting part 51 has a shape and arrangement that can be easily cut in the subsequent cutting process. 52 is provided, and the connecting portion 51 is exposed from the resin coating portion 4. The bus bar coupling body 50 which comprises the connection part 51 which is easy to be divided can be manufactured. Therefore, a function for assisting the dividing operation of the connecting portion 51 regardless of the arrangement of the

bus bars

2 and 3 can be added to the bus bar connector 50 by the bus bar manufacturing process.

(3) As shown in FIG. 7, the bus bar connector 50 after the resin molding step is integrated with the resin coating portion 4 in a state where the connecting portion 51 a is exposed from the resin coating portion 4. In the dividing step of the present embodiment, the connecting portion 51 is divided by cutting off the connecting portion 51 a of the connecting portion 51.

According to the present embodiment, in the dividing step, it is only necessary to divide the connecting portion 51a which is a portion exposed from the resin coating portion 4 in the connecting portion 51, and it is easy for an operator or a working device to confirm the portion to be divided. Become. Therefore, the function for assisting the dividing operation of the connecting portion 51 can be added to the bus bar connector 50 by the bus bar manufacturing process.

(4) Also, as shown in FIG. 6, when the bus bar connector 50 is placed in the resin molding die 300 in the placement step, the bus bars 2, 3 are placed in the positioning recesses 314, 324 of the core 310 and the cavity 320. The bus bar connector 50 is positioned with respect to the resin molding die 300 by fitting the tips of the

column parts

21 and 31 respectively.

That is, in the bus bar manufacturing process of the present embodiment, the

column parts

21 and 31 are formed by adopting metal powder injection molding so that the bus bar connector 50 can be easily placed in the resin molding die 300 in the subsequent placement process. The bus-bar coupling body 50 which comprised this can be manufactured. Therefore, the function for assisting the arrangement | work which arrange | positions the bus-bar coupling body 50 to the resin mold 300 can be added to the bus-bar coupling body 50 by a bus-bar manufacturing process.

(5) As shown in FIG. 3 and FIG. 5, in the method for manufacturing the bus bar resin molded product 1 of the present embodiment, the bus bar connector 50 is placed between the bus bar manufacturing process and the arranging process. It includes a transport process for transporting to the top. In this case, the bus bar connector 50 is gripped by the transport robot 200 via the

work assistants

23 and 33.

That is, in the bus bar manufacturing process of the present embodiment, by adopting metal powder injection molding, work is performed so that the transport robot 200 can easily transport the bus bar connector 50 to the resin molding die 300 in the subsequent transport process. The bus-bar coupling body 50 which comprised the auxiliary | assistant parts 23 and 33 (

hole part

23a, 33a and holding

piece

23b, 33b) can be manufactured. Therefore, even when the transport process is included, a function for assisting the transport operation of the transport robot 200 that transports the bus bar connector 50 to the resin molding die 300 is added to the bus bar connector 50 by the bus bar manufacturing process. can do.

(Second Embodiment)
Next, 2nd Embodiment of the manufacturing method of a bus-bar resin molded product is described. In addition, the same code | symbol is attached | subjected to the same structure as embodiment already demonstrated, and the duplicate description is abbreviate | omitted.

First, the configuration of the

bus bars

2 and 3 of this embodiment will be described.
As shown in FIG. 8, in the bus bar 2, the pillar portion 21 is provided with a protruding piece 24 that protrudes toward the pillar portion 31 of the opposing bus bar 3. On the other hand, in the bus bar 3, the column portion 31 is provided with a bent portion 34 that protrudes toward the column portion 21 of the opposite bus bar 2 and bends on the opposite side to the side on which the first terminal 3 a extends. ing. The bent portion 34 is provided with a large surface portion 35 having a surface 35a whose surface area is set larger than that of other portions. The large surface portion 35 has a disk shape, and is configured such that the surface area of the surface 35 a is larger in the extending direction of the main body portion 30 than other portions. The protruding piece 24 and the bent portion 34 are provided in the middle of the

main body portions

20 and 30 in the width direction of the

column portions

21 and 31. Note that the protruding piece 24 and the bent portion 34 facing each other are divided in the manufacturing process of the bus bar resin molded product 1, and a connecting portion 53 (described later) that connects the bus bar 2 and the bus bar 3 before the cutting. (Shown in FIG. 10). The protruding piece 24 and the bent portion 34 are entirely covered with the resin coating portion 4. In the present embodiment, the large surface portion 35 is an example of a pressure receiving portion, and the surface 35a is an example of a pressure receiving surface.

Hereinafter, the manufacturing method of the bus-bar resin molded product 1 of this embodiment is demonstrated.
As shown in FIG. 9, this manufacturing method mainly includes four processes, that is, a bus bar manufacturing process, a transport process, an arrangement process, and a resin molding process. And the manufacturing method of this embodiment differs in the point from which the resin molding process serves as a parting process with respect to the said 1st Embodiment including a parting process after a resin molding process.

As shown in FIGS. 9 and 10, in the bus bar manufacturing process of the present embodiment, the

first terminals

2 a and 3 a, the

second terminals

2 b and 3 b, the

main body portions

20 and 30, the two column portions 21 (the protruding pieces 24). ), 31 (bent portion 34) and bus bar 2 and bus bar 3 each having work

auxiliary portions

23, 33 are manufactured by metal injection molding. In this case, the bus bar 2 and the bus bar 3 are connected via a plurality of (two in this embodiment) connecting portions 53 formed by connecting the protruding pieces 24 and the bent portions 34 facing each other. In the present embodiment, the connecting portion 53 has a shape in which a prism extends so as to face the disk-shaped portion (large surface portion 35).

Further, as shown in an enlarged view in FIG. 10, the connecting portion 53 is provided with a plurality of (two in this embodiment)

notches

54 and 55 at predetermined intervals in the longitudinal direction. The notch 54 is provided between the column portion 21 and the large surface portion 35 of the bus bar 2, and is notched in a U shape on the side where the first terminal 2 a of the bus bar 2 extends. The notch 55 is provided between the pillar portion 31 and the large surface portion 35 of the bus bar 3, and is notched in a U shape on the side opposite to the side where the first terminal 3 a of the bus bar 2 extends. In the connecting portion 53, the portions of the

notches

54 and 55 are fragile portions having weaker strength than the other portions by the amount of the notch of the connecting portion 53.

Further, as shown in FIG. 11, in the arrangement step after the conveying step, the resin molding die 300 has a space between the column portion 21 and the large surface portion 35 of the bus bar 2 in the connecting portion 53 of the bus bar connecting body 50. The bus bar coupling body 50 is disposed so that the portion between the pillar portion 31 and the large surface portion 35 of the bus bar 3 is in contact with the cavity 320. Thereby, the site | part which each contact | abuts to the cavity 320 among the connection parts 53 can fix the connection part 53 at a later resin molding process.

As shown in FIGS. 9 and 11, the core 310 of the resin molding die 300 is provided with injection ports 340 at two locations, and the surface 35 a of the large surface portion 35 of the connecting portion 53 is formed at the injection port 340. Bus bar coupling bodies 50 are arranged so as to face each other. In this case, the cutouts 54 of the connecting portion 53 respectively face the injection port 340 on the cutout side.

Further, as shown in FIG. 11, the resin filling portion 325 in which the synthetic resin material 330 is injected and filled in the cavity 320 of the resin molding die 300 between the portions in contact with the connecting portion 53 of the bus bar connector 50. Is provided. Accordingly, the bus bar connector 50 is disposed in the resin molding die 300 so that the opposite side of the surface 35 a of the large surface portion 35 of the connecting portion 53 faces the resin filling portion 325. In this case, the cutout 55 of the connecting portion 53 faces the resin filling portion 325 on the cutout side.

As shown in FIG. 12, in the resin molding process after the arrangement process of the present embodiment, when the synthetic resin material 330 dissolved in the

mold parts

311 and 321 is injected and filled through the injection port 340, the synthetic resin is filled in the resin filling part 325. While the material 330 is injected and filled, the injection pressure of the synthetic resin material 330 acts on the surface 35 a of the large surface portion 35 of the connecting portion 53. In this case, the connecting portion 53 is a fragile portion, and the notch 54 notched in the surface facing the injection port 340 is broken by the injection pressure, and the fragile portion is formed on the surface facing the resin filling portion 325. It is bent by the injection pressure toward the resin filling part 325 around the notch 55 that is notched. That is, the connecting portion 53 is divided from the notch 54 into the protruding piece 24 and the bent portion 34. As a result, the

bus bars

2 and 3 are separated from each other so as to be insulated from each other by the resin coating portion 4 while being released from the electrically connected state via the connecting portion 53. In addition, the protruding piece 24 and the bent portion 34 are covered with the resin coating portion 4 by the synthetic resin material 330 injected and filled in the resin filling portion 325 in a divided state. Thus, the resin molding process of the present embodiment also serves as a cutting process for cutting the

bus bars

2 and 3. That is, the resin molding process includes a dividing process of dividing the

bus bars

2 and 3.

Thus, as shown in a simplified manner in FIG. 9, after the resin molding step, the bus bar resin molded product 1 is completed in which the

bus bars

2 and 3 are integrated with each other by the resin coating portion 4.

According to the present embodiment described above, the following functions and effects can be obtained in addition to the functions and effects (1), (3) to (5) of the first embodiment.
(6) In the bus bar manufacturing process of the present embodiment, by adopting metal powder injection molding, the large surface portion 35 is formed on the connecting portion 53 so that the connecting portion 53 is easily cut and formed in the subsequent cutting step. In addition to being provided,

notches

54 and 55 are provided in the connecting portion 53. The bus bar coupling body 50 which comprises the connection part 53 which is easy to be divided can be manufactured. Therefore, a function for assisting the dividing operation of the connecting portion 53 regardless of the arrangement of the

bus bars

2 and 3 can be added to the bus bar connecting body 50 by the bus bar manufacturing process.

(7) Further, according to the present embodiment, since the dividing process can be completed while the resin molding process is performed, it is not necessary for the operator or the work device to perform the dividing operation. Therefore, the resin molding process and the cutting process can be combined, and the total number of processes can be reduced.

(8) As shown in FIG. 10, the bus bar manufacturing process of the present embodiment has the large surface portion 35 configured to have a larger surface area than the other portions in the connecting portion 53 of the bus bar connector 50. Manufacturing the bus bar connector 50.

Further, as shown in FIG. 11, in the arrangement step of the present embodiment, the arrangement is performed so that the surface 35 a of the large surface portion 35 of the connecting portion 53 of the bus bar connecting body 50 faces the injection port 340 of the synthetic resin material 330. Including that.

According to the present embodiment, the injection pressure can be suitably applied to the connecting portion 53 through the large surface portion 35 in the resin molding step, that is, the dividing step. Therefore, the connection part 53 is divided appropriately.

In addition, each said embodiment can also be implemented with the following forms.
As shown in FIG. 13, the core 110 of the MIM mold 100 used in the bus bar manufacturing process of the first embodiment is irradiated with a metal material 130 injected and filled into the MIM mold 100. Two outlets 140 may be provided. In this case, inside the MIM mold 100, the two injection ports 140 are configured so that one by one communicates with the portions 20 ′ and 30 ′ corresponding to the

main body portions

20 and 30 of the

bus bars

2 and 3. .

In the bus bar manufacturing process of this modification, the metal material 130 dissolved in the MIM mold 100 is injected and filled through the injection port 140. The metal material 130 injected and filled from the two injection ports 140 passes through the portions 21 ′ and 31 ′ corresponding to the main body portions 20 and 30 (column portions 21 and 31) of the

bus bars

2 and 3, respectively. Each of the portions 51 ′ corresponding to is filled.

In this case, the metal material 130 filled through the portion 21 'corresponding to the main body portion 20 (column portion 21) of the bus bar 2 and the portion 31' corresponding to the main portion 30 (column portion 31) of the bus bar 3 are passed. The welded metal material 130 joins at a portion corresponding to the connecting portion 51 to form a weld line (weld line) L. The part where the weld line L is formed becomes a fragile part in the connecting part 51 (bus bar connector 50).

In such a modified example, when the connecting portion 51 is divided, even if the notch 52 is not provided, the portion where the weld line L that is a fragile portion is formed breaks. That is, as in the first embodiment, in the bus bar manufacturing process, by adopting metal powder injection molding, it has a portion where a weld line L that is easily divided when the subsequent connecting portion 51 is divided is formed. The bus bar connector 50 can be manufactured. The same applies to the second embodiment. For example, in the case of the second embodiment, the weld line L is set so as to be formed in a portion corresponding to the notch 54 of the connecting portion 53 instead of being provided with the notch 54.

As shown in FIG. 14, in the first embodiment, the bus bar connector 50 is a sintering process after being taken out from the MIM mold 100, and a part of the connecting part 51 transmits heat such as ceramic. You may make it cover with the difficult heat insulating material 500. FIG. In this case, in the part covered with the heat insulating material 500, it becomes difficult for heat to pass in the sintering process, and the solidification of the metal material 130 is prevented. The part where the solidification of the metal material 130 is hindered becomes a fragile part in the connecting part 51 (bus bar connector 50).

In such a modified example, when the connecting portion 51 is divided, even if the notch 52 is not provided, the portion where the solidification of the metal material 130 which is a fragile portion is hindered is broken. That is, the sintering step after the bus bar manufacturing step includes forming a portion that prevents the solidification of the metal material 130 that is easily divided when the subsequent connecting portion 51 is divided. In the sintering step after the bus bar manufacturing step, the bus bar connector 50 can be manufactured so as to have a part that prevents the solidification of the metal material 130 that is easily divided when the subsequent connecting portion 51 is divided. The same applies to the second embodiment. For example, in the first embodiment, the heat insulating material 500 is attached to a portion corresponding to the notch 52 of the connecting portion 51 instead of the notch 52 being provided.

As shown in FIG. 15, in the first embodiment, the position where the connecting portion 51 is provided may be appropriately changed as long as the

bus bars

2 and 3 can be connected. For example, as shown in FIG. 15A, the connecting portion 51 may be provided at a position where the

first terminals

2a and 3a of the

bus bars

2 and 3 are connected to each other. Moreover, as shown by (B) in the figure, the connecting portion 51 may be provided at a position where the

second terminals

2b and 3b of the

bus bars

2 and 3 are connected to each other. Moreover, as shown by (C), (D), and (E) in the same figure, the connection part 51 is the position which connects the edge part of the long side of the main-

body parts

20 and 30 of the

bus bars

2 and 3 mutually. It may be provided. In addition, in the same figure, the example of (E) is effective when avoiding between the main-

body parts

20 and 30 of the

bus bars

2 and 3. FIG. In this way, in the bus bar manufacturing process, the connecting portion 51 can be provided at a desired position by employing metal powder injection molding. The same applies to the second embodiment.

-In the said 1st Embodiment, the notch 52 should just be a shape and arrangement | positioning which are easy to cut | disconnect the connection part 51 at a division | segmentation process, and the structure should be provided alternately with respect to the width direction of the main-

body parts

20 and 30. Or the position to be provided may be changed. The same applies to the second embodiment.

In the second embodiment, the configuration of the connecting portion 53 may be arbitrarily changed as long as the injection pressure is applied during the resin molding process. The large surface portion 35 may have a square plate shape, or the large surface portion 35 may not be provided.

In the above-described embodiments, the configuration of the

work auxiliary units

23 and 33 may be arbitrarily changed as long as the transport robot 200 is configured to be able to grip the bus bar connector 50. The

holes

23a and 33a may be omitted and only the

gripping pieces

23b and 33b may be used, or only one of the

work auxiliary units

23 and 33 may be used.

In each embodiment described above, the operator may transport the bus bar connector 50 in the transporting process. In this case, the

work auxiliary units

23 and 33 may not be provided. Alternatively, the transporting process itself may be omitted, and the placing process may be performed on the resin molding die 300 placed on the spot after the bus bar manufacturing process.

In the above embodiments, the configuration of the

column portions

21 and 31 may be arbitrarily changed as long as the bus bar connector 50 can be positioned with respect to the resin molding die 300. You may leave the center part of the

pillar parts

21 and 31 leaving only the front-end | tip of the

pillar parts

21 and 31. FIG. The

column portions

21 and 31 may be provided only in any one of the

main body portions

20 and 30 in the width direction.

In each of the above embodiments, in the arranging step, the bus bar connector 50 can be positioned with respect to the resin molding die 300 using, for example, a portion where the connecting

portions

51 and 53 contact the resin molding die 300. If it exists, the

column parts

21 and 31 may not be provided.

As in each of the above embodiments, in the bus bar manufacturing process, by adopting metal powder injection molding, even the bus bar coupling body 50 in which three or four or more bus bars are integrated is preferably manufactured. be able to. In addition, when adopting metal powder injection molding, the degree of freedom of arrangement of the plurality of bus bars is increased, and the plurality of bus bars are irregularly arranged, or the plurality of bus bars are included in different shapes. be able to.

The modifications may be applied in combination with each other. For example, the embodiment of the bus bar connector 50 in which three bus bars are integrated and the configuration of the other modifications are applied in combination with each other. May be.

Claims

In a manufacturing method of a bus bar resin molded product in which a plurality of bus bars that are insulated from each other are integrated through a synthetic resin material by resin injection molding,
A bus bar manufacturing process for manufacturing a bus bar connected body in which the plurality of bus bars are connected via a connecting portion by metal powder injection molding using metal powder as a material,
An arrangement step of arranging the bus bar connector with respect to a mold for resin molding;
A resin molding step in which the bus bar connector is placed in the mold, and the mold is clamped and a synthetic resin material is injected and filled into the mold.
A bus bar resin molded product comprising: a dividing step of dividing the connecting portion so that the plurality of bus bars are insulated from each other with respect to the bus bar connecting body integrated with the synthetic resin material through the resin forming step. Production method.
The arranging step includes arranging at least a part of the connecting portion in the bus bar connecting body so as to contact the mold.
The bus bar connector that has undergone the resin molding step is integrated with the synthetic resin material in a state where the part of the bus bar connector is exposed from the synthetic resin material,
The method of manufacturing a bus bar resin molded product according to claim 1, wherein the dividing step includes dividing the part of the connecting portion exposed from the synthetic resin material.
A bus bar resin molded product manufacturing method in which a plurality of bus bars that are insulated from each other are integrated via a synthetic resin material by resin injection molding,
A bus bar manufacturing process for manufacturing a bus bar connected body in which the plurality of bus bars are connected via a connecting portion by metal powder injection molding using metal powder as a material,
An arrangement step of arranging the bus bar connector in a mold for resin molding;
A resin molding step in which the bus bar connector is placed in the mold and the mold is clamped and a synthetic resin material is injected and filled into the mold.
The resin molding step uses the injection pressure of the synthetic resin material generated when the synthetic resin material is injected and filled, and the dividing step of dividing the connecting portion so that the plurality of bus bars are insulated from each other Of manufacturing a bus bar resin molded article including
In the bus bar manufacturing process, a pressure receiving portion, which is a portion of the connecting portion of the bus bar connecting body that is configured to have a larger surface area of the pressure receiving surface that receives the injection pressure than other portions, is formed in the connecting portion. Including
The said arrangement | positioning process is a manufacturing method of the bus-bar resin molded product of Claim 3 arrange | positioned so that the said pressure receiving surface of the said pressure receiving part of the said connection part may oppose the injection port of the said synthetic resin material.
The said bus-bar manufacturing process includes forming the metal mold positioning part which is a site | part for positioning with respect to the said metal mold | die in the said arrangement | positioning process, when arrange | positioning the said bus-bar coupling body in the said metal mold | die. The method for producing a bus bar resin molded product according to any one of claims 1 to 4.
Via the bus bar manufacturing process, prior to the transition to the placement process, further comprising a transport process in which the transport robot grips the bus bar connector and transports it to the mold,
The bus bar manufacturing process includes:
Forming a gripping positioning part which is a part for positioning with respect to the bus bar connector when the transport robot grips the bus bar connector;
The bus bar resin molded product manufacturing method according to claim 4, further comprising: forming a grip part that is a part for the transport robot to grip the bus bar connector.