JP5138471B2 - Electrical parts for vehicles - Google Patents

Description

  The present invention relates to an electrical component to be mounted on a vehicle, and more specifically, a metal terminal portion extending in a direction orthogonal to the surface of the circuit portion is provided at a tip portion of an elongated metal circuit portion. The present invention relates to electrical parts for vehicles.

A vehicle such as an automobile is provided with an electrical junction box for installing a plurality of relays, fuses, and the like and branch-connecting them to a plurality of wire harnesses.
As an electrical component provided in the electrical junction box, a bus bar that is a metal plate is provided to constitute an internal circuit in the electrical junction box.

A conventionally known bus bar is shown in FIG.
The bus bar 10 is made of a metal having a high electrical conductivity such as copper, and has a flat circuit portion 12 and a tab (connecting terminal: claims) raised in a direction orthogonal to the circuit portion 12. Terminal portion in terms of range) 14. The tab 14 is a terminal for electrical connection with other components arranged in the electrical junction box. The tab 14 is connected to a circuit board on which electronic components such as a relay are mounted, a fuse, or a connector for electrical connection to the outside of the electrical junction box (see, for example, Patent Document 1).
The bus bar 10 shown in FIG. 12 is provided with five tabs 14 on the front side and five tabs 14 on the back side. The front and back tabs 14 are electrically connected to each other. An elongated circuit portion 12 is provided for connection.

FIG. 13 shows a state before the above-described bus bar is formed.
The bus bar 10 is formed by punching and bending a metal plate such as copper with a press or the like. In the state punched by the press machine, as shown here, the tab 14 is also integrally formed at the tip of the circuit portion 12.
The tab 14 is configured to be bent from this state so as to rise in a direction perpendicular to the circuit unit 12 at a predetermined location.
In this way, the bus bar 10 having the plurality of tabs 14 is formed from one metal plate.

A case where a plurality of tabs 14 are provided not only in the width direction but also in the length direction of the metal plate will be described with reference to FIGS.
First, a plurality of slits 11 having a predetermined width are formed on one rectangular metal plate 9. A rectangular portion 13 between the slits 11 is configured as a circuit portion 12 or a tab 14. After the slit 11 is formed, an intermediate position 13a in the length direction of the rectangular portion 13 is cut in the width direction.

Next, the rectangular portion 13 is bent at a predetermined position so that the cut intermediate position 13a becomes the respective tip portion, and is raised face to face. Of the rectangular portion 13, the raised portion becomes the tab 14, and the portion that is not raised on the same plane as the metal plate 9 becomes the circuit portion 12.
In this way, it is possible to realize a configuration in which a plurality of tabs 14 aligned in the width direction of the metal plate 9 are provided in two rows in the length direction of the metal plate 9. However, in this state, each circuit portion 12 is configured to be connected by the outer peripheral portion 16 of the metal plate 9, so that in order to form the actual bus bar 10, the metal plate 9 has a desired circuit configuration. It is necessary to cut the outer peripheral portion 16.

When the tabs 14 are provided in a plurality of rows in the length direction of the metal plate 9, in addition to the method described above, the tabs 14 are arranged in the length direction of the metal plate 9 by stacking a plurality of metal plates 9 up and down. Multiple rows can be provided.
Therefore, another method of providing two rows of tabs 14 in the length direction of the metal plate 9 will be described with reference to FIGS.

As described above, a plurality of metal plates 9 provided with a plurality of tabs 14 aligned in the width direction of the metal plate 9 are prepared in advance. In addition, it is necessary to form the tab 14 at a position where the tab 14 of the metal plate 9 disposed above does not overlap with the tab 14 of the metal plate 9 disposed below.
Thus, by stacking the two metal plates 9 on which the tabs 14 and the circuit portions 12 are formed, two rows of tabs 14 are provided in the length direction of the metal plates 9.

Japanese Patent No. 3198966 (Fig. 1 etc.)

  When the tab 14 is formed by cutting and raising from the metal plate 9 as in the prior art, since the cut and raised portion is required, the metal plate 9 needs to be at least larger than the length of the portion that becomes the tab 14 in advance. It is. In addition, the portion after being cut and raised becomes a space portion that does not need to be used, and there is a problem that materials are actually required even for unnecessary portions, and raw material costs are wasted.

Further, when the two rows of tabs 14 are formed by cutting and raising, as shown in FIG. 14, even if they are formed so as to face each other in one metal plate 9, the distance between them is too large. Therefore, there is a problem that it is impossible to cope with the pitch between the tabs facing each other.
Furthermore, in the case where two metal plates are stacked to form the tabs 14 in two rows, two metal plates are required, which increases the cost.

  In the conventional manufacturing method as described above, the tabs 14 are cut and raised using a large press device. However, it is possible to cope with the narrow pitch of the tabs 14 and the miniaturization of the bus bar 10 as a whole. There was a problem that it was not possible.

  Accordingly, the present invention is made to solve the above-described problems, and an object of the present invention is to provide an electric component for a vehicle that can be provided at a low cost without wasting raw materials and can be miniaturized. is there.

According to the vehicle electrical component of the present invention, in the vehicle electrical component disposed in the vehicle, a metal elongated thin plate-like circuit portion constituting the electric circuit, and the circuit portion surface from the tip portion of the circuit portion. A metal terminal portion extending in a direction perpendicular to the circuit portion, wherein the circuit portion and the terminal portion are configured separately, and a base portion of the terminal portion is inserted into the circuit portion. An insertion hole is formed, and after the terminal portion is inserted into the insertion hole, the periphery of the insertion hole is caulked, and the outer peripheral surface of the portion inserted into the insertion hole of the terminal portion is subjected to caulking. A concave portion is formed so that the inner wall surface of the insertion hole is deformed and enters, and by caulking, the circumference of the insertion hole of the circuit portion is tapered so that the thickness of the circuit portion gradually decreases from the insertion hole toward the outside. As the surface goes outward, the It is characterized by being formed over a plurality of stages so as path angle becomes smaller.
By adopting this configuration, an electrical component can be manufactured by joining a prefabricated terminal part to a circuit part, so material is wasted compared to the case of cutting and raising to form a terminal part. And can contribute to cost reduction. In addition, since it can be manufactured without using a large press device, it is possible to achieve a narrow pitch of the terminal portions and a reduction in the size of the entire electrical component.
Further, the terminal portion is firmly joined to the circuit portion by caulking to constitute an electric circuit.
Further, since the recess is formed, the inner wall surface of the insertion hole and the outer peripheral surface of the terminal portion are firmly joined by caulking to constitute an electric circuit.
In addition, as described above, the taper surface by caulking presses the meat around the insertion hole in the circuit portion in the direction of the terminal portion in the insertion hole, so that strong bonding can be performed, but if the taper angle is made too steep, the circuit portion is There is also a possibility that the thickness becomes very thin and the predetermined strength cannot be maintained. Therefore, the taper angle is increased near the periphery of the insertion hole so that more meat is pressed in the direction of the insertion hole, and the taper angle is decreased outside the periphery of the insertion hole so that the circuit portion is not too thin. While avoiding this, it is possible to press the meat somewhat toward the insertion hole. For this reason, the strength of the circuit portion itself can be maintained by pressing as much meat as possible in the direction of the insertion hole and strengthening the joining so as not to become too thin.

According to the vehicle electrical component of the present invention, in the vehicle electrical component disposed in the vehicle, a metal elongated thin plate-like circuit portion constituting the electric circuit, and the circuit portion surface from the tip portion of the circuit portion. A metal terminal portion extending in a direction perpendicular to the circuit portion, wherein the circuit portion and the terminal portion are configured separately, and a base portion of the terminal portion is inserted into the circuit portion. An insertion hole is formed, and after the terminal portion is inserted into the insertion hole, the periphery of the insertion hole is caulked, and the outer peripheral surface of the portion inserted into the insertion hole of the terminal portion is subjected to caulking. The inner wall surface of the insertion hole is deformed to form a convex portion that is sandwiched by the deformed inner wall surface of the insertion hole.By caulking, the circumference of the insertion hole of the circuit portion is gradually increased from the insertion hole toward the outside. The taper surface that is thin is going outward. It is characterized by being formed over a plurality of steps as the taper angle becomes smaller with respect to the circuit unit surface I.
By adopting this configuration, an electrical component can be manufactured by joining a prefabricated terminal part to a circuit part, so material is wasted compared to the case of cutting and raising to form a terminal part. And can contribute to cost reduction. In addition, since it can be manufactured without using a large press device, it is possible to achieve a narrow pitch of the terminal portions and a reduction in the size of the entire electrical component.
Further, the terminal portion is firmly joined to the circuit portion by caulking to constitute an electric circuit.
Further, since the convex portion is formed, the inner wall surface of the insertion hole and the outer peripheral surface of the terminal portion are firmly joined by caulking to constitute an electric circuit.
In addition, as described above, the taper surface by caulking presses the meat around the insertion hole in the circuit portion in the direction of the terminal portion in the insertion hole, so that strong bonding can be performed, but if the taper angle is made too steep, the circuit portion is There is also a possibility that the thickness becomes very thin and the predetermined strength cannot be maintained. Therefore, the taper angle is increased near the periphery of the insertion hole so that more meat is pressed in the direction of the insertion hole, and the taper angle is decreased outside the periphery of the insertion hole so that the circuit portion is not too thin. While avoiding this, it is possible to press the meat somewhat toward the insertion hole. For this reason, the strength of the circuit portion itself can be maintained by pressing as much meat as possible in the direction of the insertion hole and strengthening the joining so as not to become too thin.

  As the taper surface, a first taper surface having a taper angle of 60 degrees with respect to the circuit portion surface, and a second taper angle with respect to the circuit portion surface of 10 degrees outside the first taper surface. It may be characterized by comprising a tapered surface.

  The circuit portions may be provided in two rows so as to face each other at a predetermined interval.

  According to the electrical component for a vehicle according to the present invention, the raw material can be saved, so that it can be provided at a low cost. In addition, it is possible to reduce the pitch between terminals and to reduce the size.

DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of an electrical component for a vehicle according to the present invention will be described.
As an electric component for a vehicle of the present invention, a bus bar provided on a power distribution board for branching / connecting an electric system in an electric connection box will be described as an embodiment.
FIG. 1 shows an exploded perspective view of the bus bar, and FIG. 2 shows a side view of the bus bar.
As described in the prior art, the bus bar 50 is made of a metal having high electrical conductivity such as copper, and has a flat circuit portion 52 and a tab (in a direction perpendicular to the circuit portion 52) ( Terminal portion) 54 in the claims.

The circuit portion 52 and the tab 54 constituting the bus bar 50 are formed as separate bodies, and the bus bar 50 is configured by joining the tab 54 to the circuit portion 52.
The joining is realized by forming an insertion hole 55 at a predetermined position of the tip of the circuit part 52, inserting the base part 54 a of the tab 54 into the insertion hole 55, and caulking the circuit part 52 and the tab 54. .

The shape of the tab 54 will be described with reference to FIG.
The tab 54 is a columnar member having a circular cross section or a quadrangular cross section, and has a sharp tip. Further, a flange portion 56 formed so as to protrude outward is formed at a predetermined position on the base 54 a side of the tab 54. The bottom surface of the flange portion 56 is provided at a position so as to contact the surface of the circuit portion 52 when the base portion 54a is inserted into the insertion hole 55 of the circuit portion 52. The flange portion 56 has a role of positioning at the time of insertion. doing.

A concave portion 58 is formed on the outer peripheral surface of the base portion 54 a that is a portion to be inserted into the insertion hole 55 of the circuit portion 52 of the tab 54. The recess 58 shown in FIG. 3 is a groove or a recess formed in a V-shaped cross section, and is formed in a circumference of about one-fourth with respect to the outer periphery of the base portion 54a along the length direction. Yes.
In addition, this recessed part 58 is not limited to what was shown in FIG. 3, It may be formed in the whole outer peripheral surface of the base 54a, and the number is not limited to two. Further, the shape of the groove is not limited to the V shape, and may be a circular arc shape or a square shape.

By providing the recess 58, the caulking is performed more firmly.
That is, after inserting the base portion 54a of the tab 54 into the insertion hole 55 and then caulking the periphery of the insertion hole 55, the meat of the circuit portion 52 moves toward the insertion hole 55, and the inner wall surface of the insertion hole 55 becomes the base portion 54a. It is pressed against the outer peripheral surface. At this time, by deforming the inner wall surface of the insertion hole 55 so as to enter the recess 58, the base portion 54a and the circuit portion 52 are firmly joined to form an electric circuit.

Next, FIG. 4 shows a bottom view of the circuit portion after the tab joint, FIG. 5 shows a sectional view of the joint portion, and FIG. 6 shows an enlarged view of the joint portion of FIG.
After caulking is performed around the insertion hole 55 of the circuit portion 52, a tapered surface 60 is formed such that the circuit portion 52 becomes thinner from the periphery of the insertion hole 55 toward the outside. The tapered surface 60 is formed by using a caulking tool (described later) having a tapered surface.
In this way, by caulking with a caulking tool having a tapered surface, the meat of the circuit portion 52 moves from the periphery of the insertion hole 55 toward the insertion hole 55, and the tab 54 inserted into the insertion hole 55. Since the base 54a is tightened, strong caulking can be performed.

The taper surface is provided such that the taper angle decreases in a plurality of stages with respect to the surface of the circuit portion 52 as it goes outward from the insertion hole 55. In the present embodiment, the taper surface 60 is composed of a first taper surface 60a and a second taper surface 60b, and the taper angle of the first taper surface 60a in the vicinity of the periphery of the insertion hole 55 is formed at 60 degrees. The taper angle of the second taper surface 60b located outside the first taper surface 60a is 10 degrees, and the entire taper surface 60 is formed in two stages.
Since the first taper surface 60a has a large taper angle, more meat can be pressed toward the insertion hole 55, and the second taper surface 60b has a small taper angle so that the circuit portion 52 is not so thin. The meat is pressed in the direction of the insertion hole 55.

In the present embodiment, the tapered surface 60 has a flat surface and is formed in a pyramid shape as a whole so as to surround the four sides around the insertion hole 55. However, the surface of the tapered surface 60 is It may be formed in a curved surface and formed in a conical shape as a whole.
The tapered surface 60 shown here is formed at a predetermined interval from the outer edge of the insertion hole 55. That is, the periphery of the insertion hole 55 is a portion that is not pressed by the caulking tool, and is formed so as to be flush with other portions.

A method for manufacturing a bus bar using a caulking tool will be described with reference to FIGS.
First, the circuit part 52 is formed by punching a metal plate (not shown) such as copper. An insertion hole 55 is formed at the tip of the circuit portion 52. Such punching and punching of the insertion hole 55 can be performed using a normal press machine.

  The tab 54 is manufactured separately from the metal plate that forms the circuit portion 52. The tab 54 is also manufactured by punching a metal plate (not shown) such as copper into a predetermined shape. The processing of the tab 54 can also be performed using a normal press machine.

  Then, the base portion 54 a of the tab 54 is inserted into the insertion hole 55 of the circuit portion 52. After the insertion, the circuit portion 52 and the base portion 54a of the tab 54 are caulked using the caulking tool 62. Caulking is performed on the back surface side of the circuit portion 52 (the side on which the connection side of the tab 54 does not protrude).

The caulking tool 62 has a circular shape or a quadrangular shape in plan view, and a tapered surface 64 is formed on the side in contact with the back surface side of the circuit portion 52 so that the diameter gradually increases downward.
In the center of the caulking tool 62, a relief hole 65 is formed for allowing the base portion 54a of the tab 54 protruding to the back surface side of the circuit portion 52 to enter and escape. The diameter of the escape hole 65 is larger than the diameter of the base portion 54a, so that pressing by a caulking tool is not performed in the vicinity of the base portion 54a.

Further, as described above, the tapered surface 64 is provided so that the taper angle becomes smaller in a plurality of stages with respect to the surface of the circuit portion 52 as it goes outward from the escape hole 65. In the present embodiment, the taper surface 64 is composed of a first taper surface 64a and a second taper surface 64b, and the taper angle of the first taper surface 64a in the vicinity of the periphery of the escape hole 65 is 60 degrees. The taper angle of the second taper surface 64b located outside the first taper surface 64a is 10 degrees, and the entire taper surface 60 is formed in two stages.
The taper surface 64 of the caulking tool 62 of the present embodiment has a flat surface and is formed so as to surround four surrounding surfaces with the escape hole 65 as the center.

When the caulking tool 62 is brought into contact with the back surface side of the circuit portion 52 and pressed against the circuit portion 52, the meat of the circuit portion 52 is inserted into the insertion hole as shown by the arrow in FIG. It moves in the direction of the base 54a in 55, and the base 54a is tightened from the periphery.
Further, as the meat of the circuit portion 52 moves toward the insertion hole 55, the meat on the inner wall surface of the insertion hole 55 enters the recess 58 of the base portion 54a. For this reason, caulking is performed firmly.

Next, the bus bar 50 in which the tabs 54 are formed in two rows will be described with reference to FIG.
In this configuration, the front ends of the circuit unit 52 are arranged to face each other with a narrow predetermined interval A, the tabs 54 are provided at the respective front end portions, and the tabs 54 are arranged in two rows at a narrow interval. It is possible.

First, a plurality of circuit parts 52 are formed by punching a substantially square-shaped metal plate 51 in plan view so that a predetermined interval is formed in the width direction and the tip portions are opposed to each other with an interval A therebetween. .
Then, an insertion hole 55 is drilled at the tip of each circuit portion 52, and a separately manufactured tab 54 is inserted into each insertion hole 55.
After the tabs 54 are inserted into the respective insertion holes 55, the caulking tool 62 is brought into contact with the back side of each circuit portion 52 to perform caulking.
Thus, by providing the circuit portion 52 and the tab 54 separately, it is possible to manufacture an electric circuit in which the tabs are arranged in two rows at a narrow interval without being stacked.

In the embodiment described above, the concave portion 58 is formed in the base portion 54a. However, as shown in FIG. 11, it is also preferable that the base 54a is provided with a convex portion 66 protruding in the radial direction.
The convex portions 66 are mountain-shaped with a V-shaped cross section, and are formed in a circumference of about one-fourth with respect to the outer periphery of the base portion 54a, two in the length direction.

After inserting the tab 54 in which the convex portion 66 is formed in the base portion 54 a into the insertion hole 55, the caulking tool 62 is brought into contact with the back surface side of the circuit portion 52 and pressed against the circuit portion 52. By the taper surface 64, the flesh of the circuit portion 52 moves toward the base 54a in the insertion hole 55, and the base 54a is tightened from the periphery.
Then, when the flesh of the circuit portion 52 moves toward the insertion hole 55, the flesh of the inner wall surface of the insertion hole 55 enters the periphery of the convex portion 66 of the base portion 54a, and the convex portion 66 is the flesh of the inner wall surface of the insertion hole 55. It will be in a state of being pinched. Thus, even if it is a case where the convex part 66 is provided in the base 54a, it crimps firmly.

  In addition, as this convex part 66, it is not limited to what was shown in FIG. 11, It may be formed in the whole outer peripheral surface of the base 54a, and the number is not limited to two. Further, the cross-sectional shape of the convex portion is not limited to the V shape, and may be a circular arc shape or a quadrangular cross section.

In the embodiment described above, only the bus bar has been described as the embodiment of the electric component for a vehicle of the present invention.
However, the vehicle electrical component of the present invention is not limited to the bus bar in the electrical junction box, and can be used for various electrical components such as a connector terminal for connecting wire cables. .

  While the present invention has been described in detail with reference to a preferred embodiment, the present invention is not limited to this embodiment, and it goes without saying that many modifications can be made without departing from the spirit of the invention. .

It is a disassembled perspective view of the bus bar which is position embodiment of the electrical component for vehicles of this invention. It is a side view of a bus bar. (A) It is a side view of a tab. (B) It is a front view of a tab. (C) It is a bottom view of a tab. It is a bottom view of the junction part of the circuit part and tab of a bus bar. It is sectional drawing of the junction part of the circuit part and tab of a bus bar. It is an enlarged view of the junction part shown in FIG. It is explanatory drawing which shows the place which makes a crimping tool approach the back surface side of a circuit part. It is explanatory drawing which shows the place which makes a crimping tool contact | abuts on the back surface side of a circuit part, and is pressed. It is explanatory drawing which shows the place where crimping was completed. It is a bottom view of the bus bar in which tabs are arranged in two rows. It is an enlarged view of a junction part which shows the example which provided the convex part in the base of a tab. It is a perspective view which shows the conventional bus bar. It is a perspective view which shows the state before the tab start-up of the conventional bus bar. It is explanatory drawing which shows the manufacturing process in the case of providing the conventional tab in 2 rows. It is explanatory drawing which shows the place which raised the tab in the continuation of the manufacturing process shown in FIG. It is explanatory drawing which shows the other manufacturing process at the time of providing the conventional tab in 2 rows. It is explanatory drawing which shows the place which accumulated the metal plate in the continuation of the manufacturing process shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 50 Bus bar 51 Metal plate 52 Circuit part 54 Tab 54a Base 55 Insertion hole 56 Flange part 58 Concave part 60 Tapered surface 62 Caulking tool 64 Tapered surface 65 Escape hole 66 Convex part

Claims (4)

In the electric parts for vehicles arranged in the vehicle,
An elongated flat plate-shaped circuit made of metal that constitutes an electric circuit,
A metal terminal portion extending in a direction orthogonal to the circuit portion surface from the tip portion of the circuit portion;
The circuit portion and the terminal portion are configured separately.
The circuit portion is formed with an insertion hole for inserting the base portion of the terminal portion, and after the terminal portion is inserted into the insertion hole, the periphery of the insertion hole is caulked ,
On the outer peripheral surface of the portion to be inserted into the insertion hole of the terminal portion, a recess is formed such that the inner wall surface of the insertion hole is deformed and entered during caulking,
By caulking, the taper surface around the insertion hole of the circuit part gradually becomes thinner as it goes outward from the insertion hole, and the taper angle with respect to the circuit part surface as it goes outward An electrical component for a vehicle, wherein the electrical component is formed in a plurality of stages so as to be small . In the electric parts for vehicles arranged in the vehicle,
An elongated flat plate-shaped circuit made of metal that constitutes an electric circuit,
A metal terminal portion extending in a direction orthogonal to the circuit portion surface from the tip portion of the circuit portion;
The circuit portion and the terminal portion are configured separately.
The circuit portion is formed with an insertion hole for inserting the base portion of the terminal portion, and after the terminal portion is inserted into the insertion hole, the periphery of the insertion hole is caulked ,
On the outer peripheral surface of the portion to be inserted into the insertion hole of the terminal portion, a convex portion is formed so as to be sandwiched between the insertion hole inner wall surface deformed by deformation of the insertion hole inner wall surface during caulking,
By caulking, the taper surface around the insertion hole of the circuit part gradually becomes thinner as it goes outward from the insertion hole, and the taper angle with respect to the circuit part surface as it goes outward An electrical component for a vehicle, wherein the electrical component is formed in a plurality of stages so as to be small .   As the taper surface, a first taper surface having a taper angle of 60 degrees with respect to the circuit portion surface, and a second taper angle with respect to the circuit portion surface of 10 degrees outside the first taper surface. The vehicular electrical component according to claim 1, wherein the vehicular electrical component is a tapered surface.   4. The vehicular electrical component according to claim 1, wherein the circuit units are provided in two rows so as to face each other at a predetermined interval. 5. .