JP2001286028A - Method of manufacturing large-sized bus bar - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a large-size bys bar having dimensions larger than the dimensions of a mold for blanking. SOLUTION: A plurality of bus bars 11 and 12 counterposed to each other on the same plane so as to form a large-sized bus bar 10. Each bus bar 11 and 12 is provided with many connecting ends 13 and 14 on opposing sides, and they are connected electrically with each other through cables (d). Thus, a large-sized bus bar including a large dimension of bus bar circuit is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a large bus bar, and more particularly, to a method for manufacturing a large bus bar having a size exceeding a die size for punching a bus bar.

[0002]

2. Description of the Related Art Various kinds of electric components are mounted on automobiles and the like. Various types of electric components are used as relay portions for connecting these electric components and the like, or for forming circuits including relays and fuses. An electrical junction box is used. In general, an electric connection box often includes a bus bar formed by punching a conductive metal plate into a required shape as an internal circuit.

FIG. 10 shows a conventional electric junction box 1 which forms a hollow housing from an upper case 2 and a lower case 3 and has a connector 2 for connecting connectors for various external circuits on an upper surface 2a of the upper case 2. An accommodating portion 2b, a fuse accommodating portion 2c for mounting a fuse, and the like are provided. Further, a bus bar 4 constituting an internal circuit is accommodated inside the electric connection box 1.

As shown in FIG. 11, the bus bar 4 is formed by punching a generally rectangular conductive metal plate P with a press machine (not shown) equipped with a die for punching into a required shape. At the same time, the end portion punched out in a male tab shape is erected by bending or the like to form the bus bar 4 having the tab portion 4a.

[0005]

As described above, since the bus bar is punched into a required shape by a press equipped with a die for punching, the size of the bus bar that can be formed is determined by mounting the die. There is a problem that the size of the press is limited. For example, as shown in FIG.
When the conductive metal plate P is punched out to form a bus bar of the above dimensions, these dimensions X and Y exceed the maximum dimension (shown by a two-dot chain line in the figure) of the mold K that can be mounted on the press. If so, the conductive metal plate cannot be punched out, and there is a problem that such a large bus bar cannot be physically formed by a conventional method.

[0006] When it is impossible to form a large bus bar as described above, the design of the electric connection box is redone again, and the internal circuit of the electric connection box is multi-layered, or some of the relay boxes and the like are partially used. The size of the non-punchable bus bar is reduced so as to fall within a punchable range by, for example, incorporating a function of a bus bar. Therefore, if the formation of large busbars becomes impossible, the design department and the like will be forced to review and reexamine the entire electric circuit, and the time required for these reviews will be a factor that delays the start-up of production. It could be. In addition, with the recent electronic control of various functions of automobiles, the number of internal circuits required for the electric junction box is also increasing, and it is increasingly difficult to prevent the bus bar from increasing in size. .

[0007] The present invention has been made in view of the above problems, and using a press machine of a size conventionally used,
It is an object of the present invention to manufacture a large busbar having a size exceeding the size of a die for punching.

[0008]

SUMMARY OF THE INVENTION In order to solve the above problems, the present invention provides a large bus bar in which a plurality of bus bars are arranged on the same plane to face each other, and each of the bus bars has at least a mutual bus bar. The present invention provides a method for manufacturing a large bus bar in which a large number of connection ends are provided on the sides facing each other, and the connection ends of the bus bars facing each other are electrically connected to each other to form a bus bar circuit.

As described above, when a plurality of bus bars are combined, it is possible to form a large bus bar exceeding the size of a mold. By keeping the dimensions of each bus bar combined above within the dimensions of the die for punching, each bus bar can always be formed, and by combining each bus bar within these dimensions, it is possible to make a large-sized large bus bar. . Further, by connecting the connection ends of the combination portions, which are opposing portions of the bus bars, to each other, a bus bar circuit corresponding to the size of the large bus bar can be formed. The number of busbars to be combined is not particularly limited as long as it is two or more, and the number of busbars matching the required size of the large busbar is combined.

The connection ends are formed in a parallel arrangement, and the distance between the adjacent connection ends of one bus bar is at least the same as the distance between the connection ends of the other bus bar facing the connection end, and both connection ends are formed. Are placed in an opposing positional relationship, these opposing connection ends are overlapped, the overlapped portion is joined by welding, and the connection ends are electrically connected. In this way, by forming the connection ends at the same interval, when the bus bars are arranged to face each other, the positions of the connection ends always coincide with each other, so that the connection ends necessary to form the required bus bar circuit are formed. A bus bar circuit can be easily formed by welding together.

The conductive connection between the connection ends is performed with a conductive material interposed. For example, using a short pin having female tabs at both ends or an electric wire having female terminals connected to both ends, the distal end is inserted and connected to the respective connection ends formed in a male tab shape. As described above, when the electric wire to which the short pins and the female terminals are connected is used as the conductive material, if the connection end of each bus bar is formed in a male tub shape, the female portion of the short pin or the female terminal end can be replaced. A required bus bar circuit can be easily formed simply by inserting and connecting the connection ends of the bus bars opposite to each other.

Further, it is also preferable that the conductive connection between the connection ends is performed by press-connecting to the respective connection ends, each of which has a cut-off end formed with a press-contact blade, using an electric wire or a conductive plate piece. is there. In this manner, if the press-contact blade is formed at the connection end of each bus bar, a large-sized bus bar circuit can be easily formed by press-connect using an electric wire or a plate piece as a conductive material.

The above-mentioned electric wire is characterized in that connection ends having a relative positional relationship are connected to each other, or connection ends having a non-matching positional relationship are connected to each other. When an electric wire is used as the conductive material, the electric wire has flexibility, so that a desired shape such as a linear shape or a curved shape can be deformed. Therefore, when the above-described characteristics of the electric wires are used, even when the connection ends of the bus bars facing each other are conductively connected, the connection ends of the relative positional relationship are connected to each other, and the connected electric wires are in a parallel state. A connection form is also possible, and a connection form in which the connected wires are connected in a non-parallel state or in an intersecting cross state by connecting the connection ends having an unrelated positional relationship is also possible. As described above, when the electric wire is used as the conductive material, the degree of freedom of the connection form is increased, and various forms of bus bar circuits can be formed.

The connection end is bent upright and formed in an L-shape. When the connection ends are formed in an L-shape as described above, a short pin, an electric wire, a metal piece, or the like, which is a conductive material, can be inserted into each connection end from above or press-connected, and a bus bar circuit can be more easily formed.

[0015]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a large bus bar 10 assembled by the method for manufacturing a large bus bar according to the first embodiment.
Is shown. The large bus bar 10 includes the first bus bar 11
The second bus bar 12 and the second bus bar 12 are formed so as to be opposed to each other on the same plane, and the connecting ends 13 and 14 are electrically connected to each other.

The large bus bar 10 has a vertical dimension of X and a horizontal dimension of Y. As shown in FIG.
Has a size exceeding the upper limit (shown by a two-dot chain line in the figure) of a mold size that can be mounted on a press machine (not shown) used for punching. On the other hand, the first bus bar 11 has a vertical dimension of L
1. The lateral dimension is Y, and is set to a size that can be accommodated in the mold dimensions. The second bus bar 12 has a vertical dimension of L2 and a horizontal dimension of Y, and is sized to fit within the above-described mold dimensions. In addition, the vertical dimensions L1, L of the first and second busbars 11, 12 are described.
2 is set so as to be the same as the vertical dimension X of the large bus bar 10.

First, the method of forming the large bus bar 10 using the first and second bus bars 11 and 12 is as follows. First, a bus bar configuration having a vertical dimension X and a horizontal dimension Y required for the large bus bar is examined. A first bus bar punching die and a second bus bar punching die are prepared in a form divided into L2 and forming a connection end described later at a portion to be a divided side. The first and second bus bar punching dies have dimensions that can be mounted on a press machine.

Next, these first and second busbar dies are mounted on a press machine, and a conductive plate is punched out.
It is punched into a shape that matches the shape of the double bus bar. At this time, as shown in FIG. 3A, the ends of the main portions 11a and 12a of the band-shaped bus bar serving as the connection end are connected to the tip 13
a, 14a are punched out so as to be cut out, and the press-contact blade 13b,
14b. The connection end 1 is bent upward and stands up in an L-shape from the main body portions 11a and 12a.
3 and 14 are formed.

The first and second bus bars 11 and 12 thus formed are arranged on the same plane such that the sides on which the connection ends 13 and 14 are provided face each other. Then, as shown in FIG. 3 (B), one end side d-1 of the electric wire d as a conductive material is connected to the connection end 13 of the first bus bar 11.
The other end side d-2 is press-connected to the connection end 14 of the second bus bar 12 via the press-contact blades 13b and 14b to achieve conduction.

The large-sized large bus bar 10 shown in FIG. 1 is formed by performing the pressure contact connection by the electric wire d to the connection ends 13 and 14 necessary for forming the bus bar circuit. In this embodiment, the two bus bars 11 and 12
Although a larger bus bar is formed, if the required size of the larger bus bar is further larger, two or more bus bars may be combined to form a larger bus bar. In this case as well, a large number of connection ends are formed on opposite sides where each bus bar is arranged, and these connection ends are electrically connected to form a bus bar circuit.

The wires d are connected to the connection ends 13 and 14 in a relative positional relationship, and the wires d are connected in parallel. In response to the addition of a circuit or the like, as shown in FIG. 4, the large-sized bus bar 10 'may be formed by connecting the connection ends having no relative positional relationship. For example,
The connection end 13-2 'of the first bus bar 11' and the connection end 14-3 'of the second bus bar 12' are located on the sides facing each other, but the connection ends 13-2 'and 14 −
3 'is not opposite. However, since the electric wire d, which is a conductive material, has flexibility, the electric wire d is appropriately bent and connected to the connection end 13-.
2 ′ and the connection end 14-3 ′ are electrically connected.

Also, the second busbar is used for the connection end 13-4 'of the first busbar 11' which is not located on the opposite side by using the wire d 'which is longer than the other wires d. By connecting to the connection end 14-4 'of 12', it is possible to form various bus bar circuits.

Further, the connection ends located on the opposite sides of each bus bar need not necessarily be erected in an L-shape.
As shown in the figure, the connection ends 13 ", 14" extending in the same direction from the bus bar bodies 11a ", 12a" are connected to each other by the electric wire d bent in an inverted U-shape via the press-contact blades 13b ", 14b". The connection may be made conductive.

In addition, as shown in FIG. 6A, as the conductive material, a plate piece H made of a conductive material other than the electric wire is used.
May be used. The plate material H is formed in a long plate shape using a conductive metal, a conductive resin, or the like, and connects the connection end 13 of the first bus bar 11 and the connection end 14 of the second bus bar 12 similarly to the electric wire. , Are pressed into contact with the respective press-contact blades 13b and 14b to conduct electricity. Further, as shown in FIG. 6B, the connection ends 13 ″, 1
Also for 4 ″, conductive connection is possible by using a plate piece H ′ having a dimension shorter than the longitudinal dimension of the above-mentioned plate piece H.

FIG. 7A shows a connection state between the bus bars in the method for manufacturing a large bus bar according to the second embodiment. The large busbar of the second embodiment is also formed by combining a plurality of busbars as in the first embodiment, but the second embodiment is different from the first embodiment in the connection form between the busbars. . That is, the connection ends 53 and 54 of the first bus bar 51 and the second bus bar 52 are
3a and 54a are formed in a male tab shape, and the main body 51 is formed.
a, 52a to be bent upward to form an L-shape.

On the other hand, as the conductive material for connection, an electric wire d "having female terminals 60-1 and 60-2 connected to both ends is used.
One of the female terminals 60-1 of the electric wire d ″ is inserted and connected to the connection end 53 of the first bus bar 51, and the other female terminal 60-2 is inserted and connected to the connection end 54 of the second bus bar 52 to establish conduction. FIG. 7B shows a connection state when the connection ends 53 ′ and 54 ′ are not bent upright. In this case, the electric wire d ″ is used. Are electrically connected. Note that other modes, configurations, and the like other than those described above are the same as those of the first embodiment.

FIGS. 8A and 8B show a modification of the second embodiment, in which short pins 70 and 7 are used as conductive materials.
This is the case where 0 'is used. Short pin 70, 70 '
Are formed of conductive metal or conductive resin, etc., and the short pins 70 have an inverted U-shape,
0-1 and 70-2, while the short pin 7
0 ′ is a linear shape and female tab portions 70-1 ′ and 2 ′ at both ends.
Is provided. The inverted U-shaped short pin 70 connects the connection end 53 erected in the L-shape to the connection end 54 so as to conduct, and the linear short pin 70 ′ is not bent and erected. 'And the connection end 54'.

FIG. 9A shows a connection state between the bus bars in the method for manufacturing a large bus bar according to the third embodiment. The large busbar of the third embodiment is also formed by combining a plurality of busbars, but the conductive connection part is different from the first and second embodiments. That is, the connection ends 83-1 to 83-1 of the first bus bar 81 and the second bus bar 82, respectively.
3, 84-1 to 3-4 are not particularly formed in a tab shape or the like, and are in a state of being cut off. However, the connection ends 83-1 to 83-1 and the connection ends 84-1 to 83-1 are formed at the same interval in a parallel arrangement so as to face each other.

For example, in FIG.
1, 2, and 3 are connected to the connection ends 84-1, 2, and 3, respectively, so that at least the interval K1 between the connection ends 83-1 and 83-2, the connection ends 84-1 and 84-2 Interval K
3 are set to the same size, similarly, the interval K2 between the connection end 83-2 and the connection end 83-3, the connection end 84-2 and the connection end 8
The distance K4 from 4-3 is also set to the same size so that when these connection ends are overlapped, the position of each connection end matches. Note that all the intervals K1 to K4 may be set to the same size in order to enable all types of busbars to be interconnected and to increase the versatility of each busbar. Further, if all the intervals are set to the same size, it is possible to easily oppose a circuit change or the like. For example, in FIG. 9A, even if the connection end 84-2 of the second bus bar 82 is deleted by a circuit change, the connection end 83-1, the connection end 84-1 and the connection end 83-
3 and the connection end 84-3 can be easily connected because their positions match.

In the state where the connection ends are overlapped in this way, the connection ends are connected by various weldings such as spot welding, resistance welding, ultrasonic welding and the like, and the first and second bus bars 81, 8 are connected.
2 to form a bus bar circuit of a large bus bar. In addition to the welding, the respective connection ends may be electrically connected using a conductive adhesive.

FIG. 9B shows a modification of the third embodiment, in which the connection ends 84 'of the second bus bars 82' are perpendicular to the connection ends 83-1 to 8-3 of the first bus bar 81. This is the case when it is formed. Also in this case, one connection end 84 ′
Are connected to each other by welding or the like to form a required bus bar circuit. Therefore, if the conductive connection between the connection ends is performed by various kinds of welding or the like, various connection forms are possible, and it is possible to form a bus bar circuit other than a form in which the connection ends of the bus bars to be connected protrude at the same interval in a parallel arrangement. Become. Note that the connection modes of the first, second, and third embodiments described above can be applied independently, and can also be applied by appropriately mixing them.

[0032]

As is clear from the above description, by using the method for manufacturing a large bus bar according to the present invention, it is possible to form a large bus bar having a dimension which could not be formed conventionally. Accordingly, it is possible to cope with an increase in the bus bar circuit by increasing the size of the bus bar, and it is also possible to eliminate the work of reviewing the electric circuit to avoid the large bus bar. In the present invention, since a large bus bar is formed by combining a plurality of bus bars having punchable dimensions, the upper limit of the formed dimensions of the bus bar can be eliminated logically.

Furthermore, since various forms can be applied to the conductive connection of each bus bar by using electric wires or the like, which is a conductive material, it is possible to adopt an optimum connection state that meets the conditions. Furthermore, even if the bus bar circuit is changed or added after the design, etc.,
It can be easily handled by changing the connection of each conductive material.

[Brief description of the drawings]

FIG. 1 is a perspective view of a large busbar formed by a manufacturing method according to a first embodiment of the present invention.

FIG. 2 is a schematic view showing dimensions of a large bus bar and each bus bar.

FIG. 3 (A) is a schematic view of a connection end forming state, and FIG.
Is a schematic diagram of the connection status.

FIG. 4 is a perspective view of a large bus bar showing a modification of the connection form of electric wires.

FIG. 5 is a schematic diagram illustrating a connection state of connection ends according to a modified example.

FIGS. 6A and 6B are schematic diagrams showing a connection mode using a plate piece as a conductive material.

FIGS. 7A and 7B are schematic views of a connection mode in a manufacturing method according to a second embodiment.

FIGS. 8A and 8B are schematic diagrams of a connection form according to a modification of the second embodiment.

FIG. 9A is a schematic diagram of a connection mode in a manufacturing method according to a third embodiment, and FIG. 9B is a schematic diagram of a connection mode according to a modification of the third embodiment.

FIG. 10 is an exploded perspective view of a conventional electric junction box.

FIG. 11 is a schematic view showing a procedure for forming a bus bar.

FIG. 12 is a schematic view showing a conventional problem.

[Explanation of symbols]

 10, 10 'Large bus bar 11, 11' First bus bar 12, 12 'Second bus bar 13, 14 Connection end 13b, 14b Pressure contact blade 70, 70' Short pin d, d ', d "Electric wire H, H' Plate piece

Continuing from the front page (72) Inventor Yuki Saito 1-14 Nishisuehirocho, Yokkaichi-shi, Mie Sumitomo Wiring Systems, Ltd. (72) Inventor Norifumi Kobayashi 1-14 Nishisuehirocho, Yokkaichi-shi, Mie F-term (reference) 5G361 BA04 BB01

Claims (6)

[Claims] 1. A large bus bar is formed by arranging a plurality of bus bars on the same plane to face each other, and each of the bus bars is provided with a large number of connection ends on at least sides of the bus bars facing each other. A method for manufacturing a large busbar in which busbar circuits are formed by electrically connecting connection ends of busbars. 2. The connection ends are formed in a parallel arrangement, and the distance between adjacent connection ends of one bus bar is at least the same as the distance between connection ends of the other bus bar facing the connection end, and both connection ends are formed. 2. The connection end according to claim 1, wherein the connection ends are placed in a relative positional relationship, the connection ends facing each other are overlapped, the overlapped portion is joined by welding, and the connection ends are electrically connected. Manufacturing method for large busbars. 3. The conductive connection between the connection ends is performed by inserting and connecting the short ends of the female tabs at both ends or an electric wire having the female terminals connected at both ends to the respective connection ends having the ends formed in a male tab shape. The method for manufacturing a large bus bar according to claim 1, wherein the method is performed. 4. The conductive connection between the connection ends is performed by using an electric wire or a conductive plate to press-connect to the connection ends each having a press-contact blade formed by cutting off the end. The method for manufacturing a large-sized bus bar according to claim 1. 5. The large-sized bus bar according to claim 3, wherein the electric wires connect connection ends having a positional relationship facing each other or connect connection ends having a positional relationship not facing each other. Manufacturing method. 6. The method for manufacturing a large bus bar according to claim 3, wherein the connection end is bent and erected to form an L-shape.