JP5971592B2 - Power supply device and vehicle headlamp using the same - Google Patents

Description

  The present invention relates to a power supply device and a vehicle headlamp using the same.

  In recent years, as HID lamps for automobiles are generalized, demands for miniaturization and weight reduction of power supply devices for HID lamps have become stricter, and recently, LED lamps for automobiles are becoming widespread. There are similar requirements for power supply devices for lamps.

  As a power supply device for an HID lamp, there is one disclosed in Patent Document 1, and this power supply device is provided with a case made of die-casting consisting of a case body and a flange, and a vehicle body battery connected to the case body. A power connector and an output connector provided on the flange surface are provided. The output connector is electrically connected to the socket portion to which the HID lamp is mounted by a bulb line, and the bulb line is covered with a shield mesh. In such a power supply device, as a method of suppressing unnecessary radiation noise, it is common to screw a part of the shield mesh to the flange surface.

JP 2003-203517 A

  By the way, in recent years, the demand for weight reduction of automobile parts is very strict, the weight reduction in units of one screw is required, and the ground connection for suppressing unnecessary radiation noise is also required to be reviewed. In response to such demands, it has been studied to provide a ground terminal integrally with the flange in accordance with the fact that the flange is made into a sheet metal for weight reduction.

  However, in this case, if the ground terminal is formed by cutting and raising a part of the flange, a hole is formed in the flange, and it is necessary to make the size of the hole as small as possible from the viewpoint of unnecessary radiation noise. Further, from the viewpoint of weight reduction, it is necessary to use a single screw for fixing the flange, but even in this case, it is necessary to secure the tensile strength of the ground terminal to some extent.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a power supply device that secures the tensile strength of the ground terminal while reducing the weight, and a vehicle headlamp using the power supply device. There is.

A power supply device according to the present invention includes a power conversion unit that converts power supplied from a power source into desired power and supplies the power to a load, a mounting board on which at least circuit components constituting the power conversion unit are mounted, and a conductive material And a case in which at least the mounting board is accommodated, and an output connector mounted on the mounting board and electrically connected to the output end of the power conversion unit. Case, a cover attached to the body so as to close the box-shaped body with one side open, the opening of the ball di. The cover has one insertion hole provided near the outer edge of the cover and through which a fixing screw for fixing the cover to the body is inserted, and a ground terminal provided on the insertion hole side from the center of the cover. The ground terminal is configured such that a fitting terminal provided on a connection cable for connecting to an external circuit is detachably fitted.

In this power supply device, the cover has a lead-out hole for leading the output connector to the external ground terminal, consist sites projecting from the open end edge of the guide Deana are preferred.

  Moreover, in this power supply device, it is preferable that the cover is provided with a convex portion between the insertion hole and the ground terminal so as to surround the ground terminal.

  The vehicle headlamp of the present invention includes the power supply device described above.

  Since the cover and body are fastened with a single fixing screw, the weight can be reduced compared to when fastening with multiple fixing screws, and the ground terminal is placed from the center of the cover to the insertion hole side. Therefore, the tensile strength of the ground terminal can be ensured.

It is a disassembled perspective view which shows an example of the power supply device of this embodiment. The same as above, (a) is an overall perspective view, (b) is a top view. The cover used for the above is shown, (a) is an overall perspective view, (b) is an enlarged view of a main part thereof. It is a top view which can abbreviate | omit a part of connection cable connected same as the above. An example of the headlamp for vehicles using the same is shown, (a) is a schematic block diagram, (b) is typical sectional drawing.

  Below, embodiment of the power supply device 2 and the headlamp 3 for vehicles is described with reference to FIGS. In the following description, the ab direction in FIG. 1 is defined as the vertical direction, the cd direction is defined as the front-rear direction, and the ef direction is defined as the left-right direction unless otherwise specified.

  As shown in FIG. 1, the power supply device 2 of the present embodiment includes a case 21, a mounting substrate 24, an input connector 25, and an output connector 26.

  The case 21 includes a body 23 made of aluminum die casting and a cover 22 formed by press working. The body 23 has a body main body 231 formed in a flat circular box shape whose one surface (upper surface in FIG. 1) is open, and a plurality (three in this embodiment) are provided on the outer surface of the body main body 231. A mounting portion 232 is integrally provided. Each mounting portion 232 is provided with an insertion hole 232a through which a fixing screw (not shown) for fixing the body 23 to a housing 34 of the vehicle headlamp 3 described later is inserted. Further, a connector mounting portion 233 for mounting the input connector 25 is integrally provided on the outer surface of the body main body 231. The connector mounting portion 233 passes through an elliptical opening 233a that is long in the left-right direction. It is connected to the internal space of the main body 231. In the connector mounting portion 233, screw holes 233b into which mounting screws 29 for mounting the input connector 25 are screwed are provided on both the left and right sides of the opening 233a. Further, a boss portion 234 having a screw hole into which a fixing screw 28 for fixing the cover 22 to the body 23 is screwed is provided in the front end portion inside the body main body 231.

  The cover 22 has a circular cover body 221 formed of, for example, a stainless steel plate having a thickness of 0.5 mm so as to fit within the opening of the body 23, and a fixing screw 28 is provided at the front end edge of the cover body 221. An insertion hole 221a through which is inserted is provided. Further, a rectangular lead-out hole 221 b that is formed slightly larger than the outer shape of the output connector 26 is provided in a portion near the center of the cover main body 221. Here, in this embodiment, as shown in FIG. 3B, when forming the lead-out hole 221b, pressing is performed in such a manner that a part of the lead-out hole 221b is left in a rectangular plate shape. The ground terminal 221c is formed by bending the part upward. As described above, by forming the ground terminal 221c by using a part of the member that is normally punched and discarded, the material efficiency can be improved and the cost can be reduced. Further, in the cover main body 221, a convex portion 221d formed in a U-shape is provided between the insertion hole 221a and the ground terminal 221c so as to surround the front side and the left and right sides of the ground terminal 221c. Is formed by projecting a part of the cover body 221 upward.

  Here, since a pressing force is applied to the cover 22 when a fitting terminal 45 (see FIG. 4) described later is fitted to the ground terminal 221c, and a pulling force is applied when the cover terminal 22 is pulled out, the fixing screw 28 is used as a fulcrum. There is a possibility that the force is dispersed throughout the cover 22 and the cover 22 is deformed. However, as in this example, by providing the convex portion 221d so as to surround the ground terminal 221c, it is possible to withstand the load applied when the ground terminal 221c is fitted and pulled out, and as a result, the plastic deformation of the cover 22 is suppressed. Can do. Therefore, the deformation resistance strength can be ensured while reducing the thickness of the cover 22 as compared with the case without the convex portion 221c.

  The mounting board 24 includes a printed board 241 formed in a circular shape, and a circuit component 242 is mounted on the upper surface of the printed board 241. Here, in this embodiment, what constitutes a power converter (for example, an inverter or the like) that converts at least the power supplied from the DC power supply 1 (see FIG. 5) into desired power is mounted as the circuit component 242. The printed circuit board 241 is also mounted with an output connector 26 that is electrically connected to the output end of the power converter. Further, at the rear end portion of the printed circuit board 241, an insertion hole 241a through which a fixing screw (not shown) for fixing the printed circuit board 241 to the body 23 is inserted, and a connection terminal provided in the input connector 25 described later. A plurality of (four in this embodiment) through-holes 241b through which 27 is inserted are provided. In addition, a groove 241 c for allowing the boss 234 provided on the body 23 to escape is provided at the front end of the printed circuit board 241.

  The input connector 25 has a connector main body 251 formed in an elliptical cylinder shape that is long in the left-right direction, and an attachment portion 252 for attaching the input connector 25 to the body 23 is integrally formed at the front end portion of the connector main body 251. Is provided. Insertion holes 252a through which attachment screws 29 for attaching the input connector 25 to the body 23 are inserted are respectively provided on the left and right sides of the connector main body 251 in the attachment portion 252. In addition, a plurality of (four in this embodiment) contact pins (four in this embodiment) are integrally provided in the cylinder of the connector main body 251, each of which is integrally provided with connection terminals 27 to be plugged into through holes 241 b provided in the printed circuit board 241. (Not shown) are arranged side by side in the left-right direction.

  Next, an assembly procedure of the power supply device 2 will be described. First, the operator attaches the input connector 25 to the body 23 using the attachment screw 29. At this time, the connection terminal 27 provided on the input connector 25 is disposed inside the body main body 231 through the opening 233 a provided in the connector mounting portion 233 of the body 23. Next, the operator stores the mounting board 24 in the body 23 in a state where the boss portion 234 provided in the body 23 and the position of the groove 241c provided in the mounting board 24 are aligned, and a fixing screw (not shown). The mounting substrate 24 is fixed to the body 23 using At this time, each connection terminal 27 of the input connector 25 is inserted into the corresponding through hole 241b of the mounting board 24, and each connection terminal 27 is mechanically and electrically connected to the mounting board 24 using solder. . The operator attaches the cover 22 to the body 23 so as to close the opening of the body 23, and then fixes the cover 22 to the body 23 using the fixing screw 28. At this time, the output connector 26 mounted on the mounting substrate 24 is exposed to the outside through the lead-out hole 221 b provided in the cover 22. The power supply device 2 is assembled according to the above procedure.

  Here, FIGS. 2A and 2B show a state where the power supply device 2 is assembled. In the present embodiment, as shown in FIG. When viewed from the upper side (the direction in which the cover 22 is assembled), the fixing screw 28 inserted into the insertion hole 221a provided in the cover 22, the ground terminal 221c, the output connector 26, and the input connector 25 are linearly connected. Has been placed. In the present embodiment, the cover 22 and the body 23 are fastened with a single fixing screw 28, and the weight can be reduced as compared with the case of fastening with a plurality of fixing screws. Furthermore, in this embodiment, as shown in FIG. 1, a ground terminal 221c is provided on the side of the insertion hole 221a from the center of the cover 22, and the tensile strength of the ground terminal 221c is increased depending on the distance between the ground terminal 221c and the insertion hole 221a. For example, it can be set to about 10 kgf. Thereby, it is possible to suppress the plastic deformation of the cover 22 when the ground terminal 221c is pulled. Further, in the state where the cover 22 is assembled to the body 23, the opening portion of the lead-out hole 221b can be reduced by the output connector 26, so that unnecessary radiation noise can be suppressed.

  By the way, in the case 21 as described above, when the cover 22 is screwed to the body 23, it is necessary to provide the boss 234 on the body main body 231, but this boss 234 is arranged near the outer edge of the body main body 231. Otherwise, the printed board 241 must be provided with a hole through which the boss 234 is inserted. Since the mounting area of the printed circuit board 241 is reduced by the holes and the arrangement of the circuit components 242 and the wiring patterns is restricted, the boss portion 234 is provided near the outer edge (front end edge) of the body main body 231 in this embodiment. ing.

  Here, FIG. 4 is an example of a connection cable 4 for connecting between the power supply device 2 and an igniter 32 described later. The connection cable 4 has a rectangular box-shaped connector 44 connected to the output connector 26 mounted on the mounting substrate 24, and one end of an electric wire 41 is connected to the connector 44. The end is connected to the igniter 32. These electric wires 41 are covered with a cylindrical shield mesh wire 43 made of a conductive metal, and a ground wire 42 is connected to an end of the shield mesh wire 43. Further, a fitting terminal 45 fitted to the ground terminal 221c is connected to the tip of the ground wire 42. When the operator connects the connector 44 to the output connector 26 and fits the fitting terminal 45 to the ground terminal 221c, the mounting board 24 and the igniter 32 are electrically connected. Thus, in this embodiment, the connector 44 connected to the output connector 26 and the fitting terminal 45 fitted to the ground terminal 221c are provided separately.

  Next, a vehicle headlamp 3 using the above-described power supply device 2 will be described with reference to FIG.

  The vehicle headlamp 3 according to this embodiment includes the above-described power supply device 2, an igniter 32 that generates a high-frequency start pulse from the voltage supplied from the power supply device 2, an HID lamp 31, and the HID lamp 31 are detachable. And a lamp socket 33 to be mounted. A DC 12 V DC power source 1 (battery) is connected to the input end of the power supply device 2 via a switch S1. The HID lamp 31, the igniter 32, and the lamp socket 33 are housed in a housing 34 that is formed in a box shape whose one surface (the left surface in FIG. 5B) is open, and further surrounds the HID lamp 31. A reflecting mirror 37 is attached.

  Further, the power supply device 2 is fixed to the lower surface of the housing 34 using a fixing screw (not shown), and the connection cable 4 connects the power supply device 2 and the igniter 32. In addition, a translucent cover 35 is attached to one surface of the housing 34, and the light emitted from the HID lamp 31 and the light reflected by the reflecting mirror 37 are transmitted through the translucent cover 35 and irradiated to the outside. . A cap 36 that is removed when the lamp is replaced is attached to the other side of the housing 34 (the right side in FIG. 5B).

  When the user turns on the switch S <b> 1, the vehicle headlight 3 is supplied with DC 12 V from the DC power supply 1 to the power supply device 2, and the power supply device 2 boosts the DC 12 V and supplies it to the igniter 32. When the boosted voltage is supplied from the power supply device 2, the igniter 32 supplies a high voltage of 25 kV to the HID lamp 31 via the lamp socket 33 and causes the HID lamp 31 to break down. Then, after generating an arc in the HID lamp 31, when the power supply device 2 supplies a predetermined lighting power to the HID lamp 31, the HID lamp 31 is lit with a predetermined illuminance. Here, although unnecessary radiation noise is generated when the HID lamp 31 is lit, the igniter 32 and the casing (case 21) of the power supply device 2 are connected by the ground wire 42, and unnecessary radiation noise is dropped from the ground wire 42 to the ground. Therefore, propagation of unnecessary radiation noise to the atmosphere can be suppressed.

  According to the vehicle headlamp 3, by using the power supply device 2 described above, it is possible to provide the vehicle headlamp 3 that secures the tensile strength of the ground terminal 221c while reducing the weight.

  Note that the positional relationship between the insertion hole 221a and the ground terminal 221c of this embodiment is merely an example, and the ground terminal 221c only needs to be disposed on the insertion hole 221a side from the center of the cover 22, and is not limited to this embodiment. In the present embodiment, the ground terminal 221c is provided integrally with the lead-out hole 221b. However, if the ground terminal 221c is provided in the vicinity of the insertion hole 221a, the ground terminal 221c may be provided separately from the lead-out hole 221b. Furthermore, in this embodiment, since the standard thickness of the ground terminal 221c is 0.5 mm, a stainless steel plate having a thickness of 0.5 mm is used. For example, a plate having a thickness of 0.5 mm or more is used. Also good. In this case, crushing may be performed by pressing so that the plate thickness of the ground terminal becomes 0.5 mm.

2 Power supply device 21 Case 22 Cover 23 Body 24 Mounting board 26 Output connector 28 Fixing screw 221a Insertion hole 221c Ground terminal 242 Circuit component

Claims (4)

A power conversion unit that converts power supplied from the power source into desired power and supplies the load to the load; and
A mounting substrate on which circuit components constituting at least the power converter are mounted;
A case made of a conductive material and containing at least the mounting substrate;
An output connector mounted on the mounting substrate and electrically connected to the output end of the power converter;
The case consists of a cover attached to the body so as to close the box-shaped body with one side open, the opening of the pre-Symbol body,
The cover is provided near the outer edge of the cover and has one insertion hole through which a fixing screw for fixing the cover to the body is inserted; and a ground terminal provided on the insertion hole side from the center of the cover; have,
The ground terminal is configured such that a fitting terminal provided on a connection cable connecting between the ground terminal and an external circuit is detachably fitted . The cover has a lead-out hole for leading the output connector to the outside,
The ground terminal, a power supply device according to claim 1, characterized in that it consists of parts that projects from the open end edge of the front Symbol outlet hole.   The power supply device according to claim 1, wherein the cover is provided with a convex portion between the insertion hole and the ground terminal so as to surround the ground terminal.   A vehicle headlamp comprising the power supply device according to claim 1.

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