JP4844496B2 - Manufacturing method of conductive material and electric junction box for automobile containing conductive material - Google Patents

Description

  The present invention relates to a method for manufacturing a conductive material and an electrical junction box for an automobile containing the conductive material, and more specifically, to easily manufacture a conductive material in which a tab is protruded and joined to a separate bus bar.

  In an electric junction box mounted on an automobile, bus bars are alternately stacked with insulating plates inside the case, and the bus bars arranged in the same layer are formed by punching a conductive metal plate with a die and continuing to the bus bars. The tab forming portion formed in this manner is bent to provide a tab (terminal portion) protruding from the bus bar forming the circuit pattern portion.

However, when the bus bar integrated with a tab is processed as described above, it is necessary to punch out the conductive metal plate by projecting the tab forming portion laterally from the circuit pattern portion of the bus bar, and the yield of the conductive metal plate is increased. In addition to being worse, the tab forming position is limited, and when a tab cannot be formed, the tab must be formed on the bus bar of another layer, and the bus bar becomes multi-layered.
In addition, even if the circuit pattern is the same, the protruding position of the tab is different. For example, a new die for bus bar punching must be provided each time the circuit design is changed. There is.

For the above problem, the bus bar and the tab are conventionally provided separately and joined,
Japanese Patent Laid-Open No. 2001-359221 (Patent Document 1) and the like.
As shown in FIG. 6, in the bus bar circuit body of Patent Document 1, a tab mounting hole 1a is provided in a bus bar 2 insert-molded in an insulating substrate 1, and the mounting portion 3a of the tab 3 is press-fitted into the tab mounting hole 1a. Then, the crimping portion 3b divided into the fork at the tip of the mounting portion 3a is clamped and fastened, and soldering 4 is applied to the crimping portion 3b as necessary, so that the tab 3 is attached to the bus bar 2. Is increasing.

  However, the bus bar circuit body requires a step of crimping the crimping portion 3b after inserting the mounting portion 3a of the tab 3 into the tab mounting hole 1a, and also a step of soldering if necessary. Therefore, there is a problem that the work process increases and the cost is increased.

JP 2001-359221 A

  This invention is made | formed in view of the said problem, and makes it a subject to fix a tab firmly to a bus bar by a simple method in the electrically conductive material which made the bus bar and the tab separate.

In order to solve the above problems, as a first invention, a bus bar and a tab, which are separately formed from a conductive metal plate, are fixed, and the conductive material integrated with the tab protruding from the bus bar. A manufacturing method comprising:
In the bus bar, a V-groove is cut in the thickness direction from the surface, and a thin portion is left between the lower end of the V-groove and the back surface of the bus bar,
The tab has a rectangular cross section, a connection terminal portion is provided on one end side in the length direction, a bus bar joint portion is provided on the other end side, a protruding end portion is provided in a V shape at the tip, and the angle of the protruding end portion α is smaller than the angle β of the V groove,
The protruding end portion of the bus bar joint portion of the tab is press-fitted into the V groove of the bus bar, and the thin wall portion at the lower end of the V groove is cut by the pressure input to protrude the V-shaped protruding end portion from the lower surface of the bus bar, There is provided a method for producing a conductive material, characterized in that an end face of the cut thin portion and both side faces of a V-groove continuous with the cut end face are pressed and fixed to an outer peripheral face of the tab.

As described above, in the present invention, the protruding end portion of the tab is press-fitted into the V groove provided in the bus bar, and the thin portion at the lower portion of the V groove is cut, and the cut end surfaces and the both end surfaces are continuous. Both side surfaces of the V-groove are pulled in the press-fitting direction of the tab, are plastically deformed and bent by this tensile force, and the cut end surface and both side surfaces of the V-groove are pressed and fixed to the outer peripheral surface of the tab. In this way, the tab can be firmly fixed in a state where it is pierced into the bus bar only by pressing the tab into the V-groove with a pushing force capable of cutting the thin portion of the bus bar.
Therefore, the plastic deformation part of the bus bar is pressed and fixed to the outer peripheral surface of the tab while eliminating the caulking process required in the conventional process of joining the tab and the bus bar, thereby obtaining a connection with high connection reliability. be able to.

Moreover, since the angle α of the protruding end portion of the bus bar joint portion of the tab is smaller than the angle β of the V groove of the bus bar, the protruding end portion can be smoothly inserted into the V groove. It is easy to press-fit, and it can be surely cut by applying a pressing force to the thin part on the bottom side of the V-groove of the bus bar, and both sides of the V-groove bent in the cutting direction at the time of cutting are The surface can be securely pressed.
The angle α of the protruding end of the tab is preferably 45 to 90 degrees, and the angle β of the V groove of the bus bar determined by the thickness of the bus bar and the width of the V groove is preferably 50 to 165 degrees.
The width of the bus bar joint portion that is continuous with the inclined surface of the protruding end portion of the tab is preferably 0.64 to 5.6 mm, and is equal to or larger than the width on the opening side of the V groove of the bus bar facing the width. By setting the width of the bus bar joint portion of the tab to be equal to or larger than the width of the bus bar on the opening side of the V groove, the protruding end portion of the tab is press-fitted into the V groove and the tab can be firmly fixed to the bus bar.

  As described above, in the present invention, since the bus bar and the tab are joined separately and the tab is erected from the bus bar, the tab can be erected only by providing the V-groove at the required position of the bus bar. Therefore, when the bus bar and the tab are integrally punched from the conductive metal plate as in the prior art, the tab formation position is limited, but in the present invention, the tab can be erected at an arbitrary position of the bus bar. The number of bus bar layers can be reduced, and the electrical junction box that accommodates the bus bars can be downsized. Furthermore, even if the position of the tab is changed, it is not necessary to start a new die for bus bar punching and bending, and the die cost can be reduced. In addition, the tab itself can be used for other bus bars.

Sectional area of the V groove of the bus bar 0.1～1.3Mm ² is preferred. The thickness of the bus bar is preferably 0.5 mm to 0.9 mm, and the thickness of the thin portion between the lower end point of the V groove and the other end surface of the bus bar is preferably 0.1 mm to 0.2 mm.

  The size of the thin portion of the bus bar below the lower end point of the V-groove of the bus bar is 0.1 mm to 0.2 mm as described above. When the dimension is larger than 0.2 mm, it is cut at the protruding end of the tab. This is because it is difficult to cut the thin portion and the protruding end portion of the tab may be deformed. On the other hand, the thickness of the thin portion is 0.1 mm or more, and it is difficult to form the V-groove leaving the thin portion with a thickness of less than 0.1 mm, and the plastic deformation force at the time of cutting becomes weak. This is because the force that firmly presses the V-groove continuous with the cut end surface against the outer peripheral surface of the tab is weakened.

Furthermore, as a second invention, a conductive material is mounted on an insulating plate inside an electrical junction box mounted on an automobile,
The conductive material is a conductive material in which bus bars and tabs formed separately from the conductive metal plate manufactured by the manufacturing method described above are integrated,
For a vehicle containing a conductive material, wherein a V-shaped protruding end portion of the tab protruding from the lower surface of the bus bar is fitted in a positioning V groove provided in an insulating plate on which the bus bar is placed. An electrical junction box is provided.

  As described above, the bus bar can be positioned on the insulating plate by fitting the protruding end portion of the tab protruding from the lower surface of the bus bar into the positioning V groove provided on the insulating plate on which the bus bar is disposed. In addition, since the tab can be erected from an arbitrary position of the bus bar, the number of bus bar layers can be reduced, and the electrical connection box can be made thinner.

As described above, according to the method for manufacturing a conductive material of the first invention, the tab is press-fitted into the V-groove of the bus bar, and the thin wall portion of the bus bar below the V-groove is cut, so that the cut end face and the cut end face are obtained. Both side surfaces of the V-groove that is continuous with the outer peripheral surface of the tab can be pressed and fixed. Therefore, since the tab and the bus bar are pressed and fixed only by the pressing pressure into the V-groove, the conventional caulking work and soldering work that are required can be eliminated, and the separate bus bar and the tab can be easily and securely attached. Can be joined.
Further, by making it separate from the bus bar, the tab can be erected only by forming a V-groove at an arbitrary position of the bus bar. Therefore, it is not necessary to start a new bus bar punching die even if the tab position is changed, and the design can be easily changed without incurring costs. In addition, the tab itself can be used for other bus bars.

In the electrical junction box of the second invention, the V-shaped protruding end portion of the tab protruding from the lower surface of the bus bar is fitted into the positioning V-groove provided in the insulating plate on which the bus bar is mounted. Can be easily positioned on the insulating plate.
Furthermore, in the electrical connection box for automobiles, since there are a large number of tabs protruding from the bus bar and connected to the terminals of the external circuit and connecting to the relay terminals inside the electrical connection box, the tabs can be widely used. The electric junction box can be manufactured at low cost.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 4 show a first embodiment of the present invention.

  As shown in FIG. 1, a conductive material 10 of the present invention includes a bus bar 11 formed by punching a conductive metal plate into a circuit pattern, and a tab punched from a conductive metal plate separately from the bus bar 11. 13 and are integrated.

  As shown in FIG. 2, a V-groove 11a is provided at a required position of the bus bar 11 in the thickness direction from the surface 11e toward the lower surface 11f. The V-shaped groove 11a is provided with a pair of opposed rectangular inclined surfaces 11b and 11c of a tab and has a V-shaped cross section.

In the present embodiment, the thickness of the bus bar 11 is 0.64 mm, and the distance L between the lower end point P1 of the inclined surfaces 11b and 11c and the lower surface 11f of the bus bar 11 is 0.1 mm. The angle β formed by the inclined surfaces 11b and 11c is 60 degrees, the width d1 of the opening of the V groove 11a is 0.64 mm, and the cross-sectional area S1 is 0.17 mm ² .

  As shown in FIG. 3 (A), the tab 13 is made of an elongated plate having a rectangular cross section, one end side in the length direction (upper end in the figure) is a connection terminal portion 13a, and the other end side is a bus bar joint portion. 13b, and a protruding end portion 13e is provided in a V shape at the tip. The upper outer peripheral surface continuing to the protruding end portion 13e is a pressure contact surface 13h that is pressed by the bus bar 11 when the protruding end portion 13e is press-fitted into the V groove 11a.

In the present embodiment, as shown in FIG. 3B, the V-shaped protruding end 13e has an angle α formed by the inclined surfaces 13f and 13g on both sides of 45 degrees, which is larger than the angle β of the V groove of the bus bar 11. It is small. The width d2 of the projecting end 13e corresponding to the width d1 of the opening of the V groove 11a is 0.64 mm, which is the same as the width d1 of the V groove 11a, and the sectional area S2 is 0.247 mm ² .

The bus bar 11 and the tab 13 are joined and integrated as shown in FIG. That is, first, as shown in FIG. 4 (A), the inclined surfaces 13f and 13g of the protruding end portion 13e of the tab 13 are aligned with the inclined surfaces 11b and 11c of the V groove 11a of the bus bar 11, and the tab 13 is aligned with the V groove 11a. The protruding end 13e is inserted. At that time, since the angle β of the V-groove 11a is larger than the angle α of the protruding end 13e, it can be inserted without requiring a pushing force.
As shown in FIG. 4 (B), the tip P2 of the protruding end 13e of the tab 13 is made to coincide with the lower end point P1 of the V-groove 11a of the bus bar 11, and in this state, the tab 13 is pushed in at a stroke and the protruding end 13e Cutting is performed from the lower end point P1 of the V groove 11a of the bus bar 11 toward the bus bar lower surface 11f by the pressure input of the tip P2, and the protruding end 13e of the tab 13 is press-fitted into the V groove 11a of the bus bar 11. In that case, since the thickness of the lower part of a V-groove is 0.1 mm, a big pushing force is not required.

  As shown in FIG. 4C, when the tab 13 is pushed in until the protruding end 13e protrudes from the lower surface 11f of the bus bar 11, both sides 11d of the cut surface at the lower end of the V groove 11a are curved downward by the protruding end 13e. In addition, the inclined surfaces 11b and 11c of the continuous V-groove 11a are pulled downward, and the cut end surface 11d of the bus bar 11 is cut on the upper pressure contact surface 13h continuous with the protruding end 13e of the tab 13. And both side inclined surfaces 11b and 11c of the V-groove are in pressure contact.

  As described above, the cut end surface 11d of the bus bar 11 and the both side surfaces of the continuous V groove 11a are in pressure contact with the protruding end portion 13e and the press contact surface 13h of the continuous upper tab 13, which is conventionally required. In addition, it is not necessary to crimp the tab 13 after inserting it into the bus bar 11. That is, the bus bar joint portion 13b of the tab 13 can be fixed to the V groove 11a of the bus bar 11 only by pushing. In the fixed state, the protruding end 13e of the tab 13 penetrates the V groove 11a of the bus bar 11 and protrudes from the bus bar lower surface 11f.

According to the manufacturing method of the conductive material 10 in which the tab 13 protrudes from the bus bar 11 described above, the bus bar 11 and the tab 13 are separated from each other. Therefore, the bus bar 11 is not limited to the position where the tab 13 is erected. The degree of freedom of the circuit pattern can be increased. Furthermore, when the circuit pattern is the same and the position of the tab 13 is different (for example, when the connection position with the connector is changed), it is only necessary to change the position of the V-groove formed on the bus bar. Since it is not necessary to provide it, the mold cost can be reduced, and the tab 13 can be used for different bus bars 11, and versatility can be improved.
Further, since caulking, solder connection, or the like is not required and the tabs can be joined simply by pushing them into the bus bar, the joining work is simplified, and the manufacturing cost can be reduced in this respect as well.

Further, since the angle α of the protruding end portion 13e of the tab 13 is smaller than the angle β of the V groove 11a of the bus bar 11, the protruding end portion 13e of the tab 13 can be smoothly inserted into the V groove 11a of the bus bar 11. it can. And since the front-end | tip P2 of the V-shaped protrusion end part 13e of the tab 13 can be correctly aligned with the front-end | tip P1 of the V groove 11a of the bus bar 11, the bus bar 11 can be easily cut | disconnected by pushing the tab 13 at a stretch.
Further, by making the width d2 of the bus bar joint portion 13b of the tab 13 the same as the width d1 of the opening side of the V groove 11a of the bus bar 11 into which the protruding end portion 13e of the tab 13 is inserted, the protrusion of the tab 13 into the V groove 11a. The end 13e is press-fitted and the tab 13 can be firmly fixed to the bus bar 11.

  5 (A) and 5 (B) show a second embodiment in which the conductive material 10 is used as an internal circuit of an electric junction box mounted on an automobile.

The conductive material 10 and the insulating plate 12 are alternately stacked and accommodated in the case 20 of the electrical junction box. The bus bar 11 of the conductive material 10 is fixed on the insulating plate 12 as a flat bus bar to form an internal circuit of the electrical junction box.
The fixed tab 13 joined to the bus bar 11 is positioned by fitting a V-shaped protruding end 13e protruding from the V-groove 11a of the bus bar 11 into a positioning V-groove 12a formed in advance on the lower insulating plate 12. In the lower portion of the connector housing portion 21 provided in the case 20.
The connection terminal portion 13 a at the upper end of the tab 13 is protruded into the connector housing portion 21 and is connected to the terminal in the connector C of the electric wire terminal that fits into the connector housing portion 21.

As described above, when the conductive material 10 of the present invention is used for the electrical junction box, the tab 13 protruding from the bus bar 11 is easily provided at a position corresponding to the position of the connector housing portion provided in the case. Can do. Also, not only for connection with connectors, but also when connecting bus bars arranged in other layers via relay terminals, tabs and relay terminals can be placed at any position, so the space in the electrical connection box is effective. The electrical connection box can be miniaturized accordingly.
Further, when the V-shaped protruding end portion of the tab protruding from the bus bar is fitted and fixed in a V-shaped groove provided on the insulating plate, the work of caulking and fixing the bus bar and the insulating plate can be eliminated.

It is a disassembled perspective view of the bus bar and tab which form the electrically conductive material of 1st Embodiment of this invention. It is sectional drawing of the said bus-bar. (A) is a perspective view of the said tab, (B) is a front view of the bus-bar junction part of (A). (A)-(C) are drawings which show the joining process of a bus-bar and a tab. A 2nd embodiment is shown, (A) is a schematic sectional view of an electric junction box, and (B) is an important section enlarged view. It is a figure which shows a prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Conductive material 11 Bus bar 11a V groove 11f Lower surface 12 Insulation board 12a Positioning V groove 13 Tab 13a Connection terminal part 13b Bus bar junction part 13e Protrusion end part alpha Protrusion end part angle V V groove angle S1 V groove cross-sectional area S2 Protrusion End cross-sectional area

Claims (2)

A method for producing a conductive material integrated with a bus bar and a tab formed separately from a conductive metal plate, with the tab protruding from the bus bar,
In the bus bar, a V-groove is cut in the thickness direction from the surface, and a thin portion is left between the lower end of the V-groove and the back surface of the bus bar,
The tab has a rectangular cross section, a connection terminal portion is provided on one end side in the length direction, a bus bar joint portion is provided on the other end side, a protruding end portion is provided in a V shape at the tip, and the angle of the protruding end portion α is smaller than the angle β of the V groove,
The protruding end portion of the bus bar joint portion of the tab is press-fitted into the V groove of the bus bar, and the thin wall portion at the lower end of the V groove is cut by the pressure input to protrude the V-shaped protruding end portion from the lower surface of the bus bar, A method for producing a conductive material, characterized in that an end face of the cut thin portion and both side faces of a V-groove continuous with the cut end face are pressed and fixed to an outer peripheral face of the tab. Conductive material is mounted on an insulating plate inside the electrical junction box mounted on the automobile,
The conductive material is a conductive material in which a bus bar and a tab formed separately from the conductive metal plate manufactured by the manufacturing method according to claim 1 are integrated,
For a vehicle containing a conductive material, wherein a V-shaped protruding end portion of the tab protruding from the lower surface of the bus bar is fitted in a positioning V groove provided in an insulating plate on which the bus bar is placed. Electrical junction box.

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