JPH11220823A - Busbar structure of electrical junction box - Google Patents

Abstract

PROBLEM TO BE SOLVED: To positivaly prevent the short circuit due to the jumper wire of a busbar being accommodated in an electrical connection box. SOLUTION: In busber structure that is accommodated in an electrical connection box and where specific patterns are electrically connected by a jumper wire, the jumper wire is constituted by a covering electric wire 10, and both conductor terminal parts 11a and 11b where the covering is peeled from both terminals of the covering electric wire 10 are welded to specific pattern parts 7e and 7f by laser. As a result, the covering electric wire that becomes the jumper wire may not have to be molded integrally with a busbar as before, mold for forming the busbar can be miniaturized and hence mold costs can be reduced, and at the same time the yield of a metal plate for forming the busbar can be improved, thus reducing the costs of the electrical connection box.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bus bar structure housed in an electric junction box, and more particularly to a bus bar structure capable of reliably preventing a short circuit of a circuit due to a jumper wire.

[0002]

2. Description of the Related Art An electrical junction box used for branch connection of a wire harness for automobiles to various electric components is designed such that branch connection points are concentrated in one place and wiring is rationally and economically connected. With the increase in the density of wire harnesses, various types have been developed according to vehicle types or applications.

As shown in FIG. 6, a bus bar 7A is formed from a hoop material 6 by a press die as shown in FIG.
To 7C, and each of the bus bars 7A to 7C
The tab terminals 7a and 7b are cut and raised from the pattern portion in the vertical direction, and insulating plates 8A to 8C are interposed between the bus bars 7A to 7C, respectively. And a lower case 9B.

[0004] Of the above bus bars 7 (A to C), FIG.
Taking one bus bar 7 as an example as shown in FIG. 1B, there is a bus bar 7 provided with a separate bus bar component 7 ′ serving as a jumper wire straddling the pattern portion of the bus bar 7.

[0005] This separate busbar part 7 'is usually
As shown in FIG. 5 (a), the busbar 7
The bus bar 7 is integrally formed via a bridge cut portion 7d, and cut (cut) by the bridge cut portion 7d when the bus bar 7 is assembled to the insulating plates 8 (A to C). So that it is assembled to the bus bar 7.

[0006]

However, since the bus bar component 7 'which becomes a jumper wire is integrally formed with the bus bar 7, the bus bar forming die becomes large and the die cost becomes high. The yield of the metal plate for use becomes poor and the electric junction box becomes expensive.

Further, since the bus bar component 7 'serving as a jumper wire is a vertical bus bar, the bus bar component 7' may be deformed or buckled when housed in a case of an electric junction box.

When the bus bar component 7 'buckles, there is a risk of short-circuiting with other circuits.

The present invention is most suitable for a busbar housed in an electric junction box, and more particularly, to provide a busbar structure of an electric junction box capable of reliably preventing a short circuit of a circuit due to a jumper wire.

[0010]

In order to solve the above-mentioned problems, the present invention provides a bus bar structure which is housed in an electric connection box and electrically connects predetermined pattern portions to each other by jumper wires. The present invention provides a bus bar structure of an electric junction box, wherein a wire is formed of a covered electric wire, and both ends of the two core wires, whose coatings are peeled off from both ends of the covered electric wire, are welded to predetermined patterns of the bus bar, respectively. Things.

According to the present invention, a covered electric wire having an insulating outer peripheral surface is adopted as a jumper wire, and the ends of the core wires, the coatings of both ends of which are peeled off, are welded to predetermined pattern portions of the bus bar, respectively.

According to a second aspect of the present invention, insertion holes for inserting both ends of the core wire of the covered electric wire are formed in predetermined pattern portions of the bus bar, and the ends of the core wires inserted into the insertion holes are inserted. The inner edge of the hole can be laser welded.

Further, flat surfaces are respectively formed on the outer peripheral surfaces of both ends of the core wire of the insulated wire, and the flat surfaces of the ends of the two core wires are formed into predetermined pattern portions of the bus bar. The ends of the core wires can be laser-welded to the upper surface of the pattern portion by respectively applying them to the upper surfaces of the two.

[0014]

Embodiments of the present invention will be described below in detail with reference to the drawings. Note that the same components and operations as those of the prior art are denoted by the same reference numerals, and detailed description thereof will be omitted.

FIGS. 1 and 2 show the bus bar structure according to the first embodiment, in which adjacent pattern portions 7e and 7f of the bus bar 7 are provided.
Are formed with insertion holes 7g and 7h, respectively. The pattern portions 7e and 7f do not necessarily have to be adjacent to each other, and may be far apart with another pattern portion therebetween.

A sheathed wire 10 serving as a jumper wire is provided, and the sheaths 10a are peeled off from both ends of the sheathed wire 10 to expose both ends of the core wires 11a and 11b to a predetermined length. The core wire of the covered electric wire 10 may be a single wire or a stranded wire.

The coated electric wire 10 is bent in an inverted U-shape so that both ends of the core wires 11a and 11b coincide with the intervals between the insertion holes 7g and 7h of the adjacent pattern portions 7e and 7f. The core ends 11a and 11b are inserted into the insertion holes 7g and 7h of the pattern portions 7e and 7f, respectively.

Thereafter, the laser beam LB is applied to the ends of the core wires 11a and 11b inserted into the insertion holes 7g and 7h and the inner edges of the insertion holes 7g and 7h, and laser welding is performed.

As described above, the coated electric wire 10 having an insulating outer peripheral surface is adopted as a jumper wire,
Laser-welding the core ends 11a and 11b at both ends to the predetermined pattern portions 7e and 7g of the bus bar 7 does not require the insulated wire 10 to be the jumper wire to be integrally formed with the bus bar as in the related art. In addition, the size of the busbar molding die is reduced and the mold cost is reduced, the yield of the busbar molding metal plate is improved, and the electric connection box is also inexpensive. In addition, the insulated wire 10 can be an existing one and only the coatings at both ends are peeled off, so that the cost of parts is also reduced.

In addition, a part of the insulated wire 10 serving as a jumper wire is oriented vertically, and there is no problem even if the wire is deformed or buckled when housed in the case of the electric connection box, and the outer peripheral surface has insulation. Therefore, even if buckling occurs, there is no danger of short-circuiting with other circuits. These greatly increase the degree of freedom in circuit design using jumper wires.

Further, the core wire ends 11a,
11b is the insertion hole 7 of the pattern portions 7e and 7g of the bus bar 7.
Since the insulated wire 10 is positioned by inserting it into g and 7h, the jumper position can be set accurately, and laser welding can be performed accurately.

FIGS. 3 and 4 show a bus bar structure according to a second embodiment, in which a covered electric wire 10 serving as a jumper wire is provided.
The sheath 10a is peeled off from both ends of the insulated wire 10 to expose both ends of the core wires 11a and 11b with a predetermined length, and a flat notch is formed in one of the outer peripheral surfaces of the ends of the core wires 11a and 11b. The surfaces 11c are respectively formed. In addition, as shown in FIG.
Surface 11c squashed flat on both outer peripheral surfaces of a and 11b
May be formed respectively, and this coated electric wire 10
Is bent in an inverted U-shape so that both core ends 11a and 11b coincide with the interval between the adjacent pattern parts 7e and 7f, and then the flat surfaces 11a of the two core ends 11a and 11b are bent.
c is applied to the upper surfaces of the pattern portions 7e and 7f, respectively.

Thereafter, the laser beam LB is applied to the core ends 11a and 11b applied to the pattern parts 7e and 7f, and the core ends 11a and 11b are applied to the pattern parts 7e and 7b.
Laser welding on the upper surface of f.

In the second embodiment, the same operation and effect as those in the first embodiment can be obtained.

In the case of the above laser welding, the laser beam LB is compared with resistance welding, arc welding, ultrasonic welding and the like.
Is non-contact, the insulated wire 10 which becomes a jumper wire can be reliably welded with only a simple jig, and the mass productivity is good because the welding seconds per location are short.

Among various types of laser welding, YAG laser welding is non-contact, has a small heat affected layer,
It has low power consumption, is small in size, can be easily used for three-dimensional welding due to the use of optical fibers, and can divide a beam into multiple parts for simultaneous multipoint welding.
It is optimal because the automation is easy and the production cost is significantly reduced.

[0027]

As is clear from the above description, according to the present invention, a coated electric wire having an insulating outer peripheral surface is adopted as a jumper wire, and the ends of the core wire obtained by peeling off the coating at both ends of the coated electric wire are used as busbars. By welding to the predetermined pattern portions, it is not necessary to integrally form the insulated wire serving as a jumper wire into the bus bar as in the conventional case, so that the bus bar forming mold is reduced in size and the mold cost is reduced. At the same time, the yield of the busbar forming metal plate is improved, and the electric connection box is also inexpensive. As the above-mentioned covered electric wire, an existing one can be used and only the coating on both ends is peeled off, so that the cost of parts is also reduced.

In addition, a part of the insulated wire serving as a jumper wire is oriented vertically, so that there is no problem even if it is deformed or buckled when housed in the case of the electric connection box, and the outer peripheral surface has insulation. Therefore, even if buckling occurs, there is no possibility of short-circuiting with another circuit.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a bus bar structure according to a first embodiment of the present invention.

FIG. 2 is an assembled sectional view of the bus bar structure of the first embodiment.

FIG. 3 is an exploded perspective view of a bus bar structure according to a second embodiment.

FIG. 4A is an assembled cross-sectional view of a bus bar structure according to a second embodiment, and FIGS. 4B and 4C are front cross-sectional views of core wire ends.

FIG. 5 is a perspective view of a conventional bus bar structure, in which (a) is a perspective view of a bus bar integrally formed with a bus bar component serving as a jumper wire, and (b) is a perspective view of a bus bar to which the bus bar component is assembled.

FIG. 6 is an exploded perspective view of a conventional bus bar processing and assembling procedure.

[Description of Signs] 7 Busbar 7e, 7f Pattern portion 7g, 7h Insertion hole 10 Insulated wire 11a, 11b Core end LB Laser beam

Claims (3)

[Claims] 1. A busbar structure which is housed in an electric connection box and has predetermined pattern portions electrically connected to each other by a jumper wire, wherein the jumper wire is constituted by a covered electric wire and covered from both ends of the covered electric wire. A bus bar structure of an electric junction box, wherein both ends of the core wire, from which the above-mentioned pieces are peeled off, are welded to predetermined pattern portions of the bus bar, respectively. 2. An insertion hole for inserting both ends of the core wire of the covered electric wire is formed in predetermined pattern portions of the bus bar, and the end of the core wire inserted into the insertion hole is formed on an inner edge of the insertion hole. The bus bar structure of the electric junction box according to claim 1, which is laser-welded. 3. A flat surface is formed on each of outer peripheral surfaces of both core wire ends of the covered electric wire, and the flat surfaces of both core wire ends are respectively applied to upper surfaces of predetermined pattern portions of the bus bar. 2. The bus bar structure of an electric junction box according to claim 1, wherein the end of the core wire is laser-welded to the upper surface of the pattern portion.