JP3820339B2

JP3820339B2 - Laminated wiring board assembly and manufacturing method thereof

Info

Publication number: JP3820339B2
Application number: JP2000140717A
Authority: JP
Inventors: 浩梅田; 洋行村越
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 2000-05-12
Filing date: 2000-05-12
Publication date: 2006-09-13
Anticipated expiration: 2020-05-12
Also published as: JP2001327042A

Description

【０００１】
【発明の属する技術分野】
本発明は、複数のブスバーと複数の電線とがマトリックス的に配索された一対の配線板を上下二層に重ねて成り、電気接続箱等に収容される積層配線板組立体及びその製造方法に関する。
【０００２】
【従来の技術】
この種の積層配線板組立体として、図１１〜図１３に示すものがある。この積層配線板組立体１は、図１２に示すように、幅方向に複数のブスバー４を所定間隔毎にインサート成形して成る一対の絶縁基板２，３を所定距離隔てて略一平面上に並列に配置し、この一対の絶縁基板２，３間に複数の電線５を掛け渡すように布線して該一対の絶縁基板２，３の各表面２ａ，３ａ上に該複数の電線５を各ブスバー４と略直交する長手方向にそれぞれ直線的に配索し、次に、一対の絶縁基板２，３間の複数の電線５の各渡し部６を図１２中矢印Ｘ方向に折り曲げて該一対の絶縁基板２，３の各裏面２ｂ，３ｂ同士を重ね合わせることにより組み立てられるようになっている。
【０００３】
また、電線５の布線時に、図１３に示すように、一対の絶縁基板２，３より露出した所定位置のブスバー４の露出部４ａと該ブスバー４の露出部４ａにクロスするように配索された所定位置の電線５の一部５ａは、抵抗溶接用の一対の電極７，８間に挾まれて接合されるようになっている。
【０００４】
尚、この積層配線板組立体１に関する類似技術は、特願平１０−３０８４２４号等に開示されている。
【０００５】
【発明が解決しようとする課題】
しかしながら、前記従来の積層配線板組立体１では、電線５として絶縁被覆のない裸電線を用い、一対の絶縁基板２，３間の複数の電線５の渡し部６が折り曲げられてＵ字状に屈曲した状態で一対の絶縁基板２，３の隣接する各端部２ｃ，３ｃより外側に突出しているため、隣接する各電線５，５の渡し部６，６がショートしたり、リークするおそれがあった。
【０００６】
尚、一対の絶縁基板２，３の隣接する各端部２ｃ，３ｃから屈曲状態で突出する複数の電線５の渡し部６の突出量を可及的に小さくして隣接する各電線５，５の渡し部６，６間のショート等を防ぐために、一対の絶縁基板２，３の組立時にその隣接する各端部２ｃ，３ｃを突き合わせた状態で各電線５の渡し部６を折り曲げようとすると、この渡し部６の折り曲げ時に該渡し部６が伸びて電線５に余分なテンションがかかってしまい、このテンションの発生によりブスバー４の露出部４ａと電線５の一部５ａとの接合状態が不安定になるおそれがある。
【０００７】
そこで、本発明は、前記した課題を解決すべくなされたものであり、電線に余分なテンションを与えずに該電線を簡単に折り曲げることができ、かつ、電線間のショートやリークを確実に防止することができる積層配線板組立体及びその製造方法を提供することを目的とする。
【０００８】
【課題を解決するための手段】
請求項１の発明は、略一平面上に並設された一対の配線板間に複数の電線を掛け渡すように布線して該一対の配線板の各表面に該複数の電線をそれぞれ配索し、この一対の配線板間の前記複数の電線の各渡し部を折り曲げて該一対の配線板の各裏面同士を重ね合わせて成る積層配線板組立体において、前記各配線板として複数のブスバーを絶縁基板にインサート成形して成るブスバー配線板を用い、この一対のブスバー配線板の突き合わされる各端部の裏面側の角部分にアール部をそれぞれ形成すると共に、該各端部の表面側から裏面側にかけて前記複数の電線の各渡し部を収容する電線収容部をそれぞれ形成し、かつこれら各電線収容部の両側に絶縁リブをそれぞれ一体突出形成し、前記一対のブスバー配線板の隣接する各端部同士を突き合わせた状態から前記各絶縁基板より露出した前記各ブスバーの露出部と前記各電線の接続部とを溶接により接合した後で、前記各渡し部を折り曲げる際に前記各アール部同士を当接自在にしたことを特徴とする。
【００１１】
この積層配線板組立体では、一対のブスバー配線板の隣接する各端部を突き合わせた状態で複数の電線の渡し部を折り曲げる際に、各渡し部が電線収容部に収容されながらその伸びが抑えられて折り曲げられるため、各電線の渡し部に余分なテンションが発生することがなく、ブスバーの露出部と電線の接続部との接合部分に負荷がかかることがない。これにより、ブスバーの露出部と電線の接続部との接合状態が安定し、ブスバーと電線の接続不良の発生が確実に防止される。特に、複数の電線の渡し部が収容される各電線収容部の両側の絶縁リブにより隣接する各電線の渡し部間の沿面距離が十分に確保され、各電線の渡し部間のショート及びリークがより確実に防止される。
【００１４】
請求項２の発明は、一対の配線板を略一平面上に並列に配置し、この一対の配線板間に複数の電線を掛け渡すように布線して該一対の配線板の各表面に該複数の電線をそれぞれ配索し、次に、前記一対の配線板間の前記複数の電線の各渡し部を折り曲げて該一対の配線板の各裏面同士を重ね合わせて成る積層配線板組立体の製造方法において、前記各配線板として複数のブスバーを絶縁基板にインサート成形して成るブスバー配線板を用い、この一対のブスバー配線板の隣接する各端部を突き合わせた状態で該一対のブスバー配線板の表面に前記複数の電線を配索した後で、前記各絶縁基板より露出した前記各ブスバーの露出部と前記各電線の接続部とを溶接により接合し、次に、前記一対のブスバー配線板の各端部の裏面側の角部分に形成された各アール部同士を当接させながら前記複数の電線の各渡し部を折り曲げて該一対のブスバー配線板の各裏面同士を重ね合わせると共に、該各端部の表面側から裏面側にかけて形成された各電線収容部に前記各渡し部をそれぞれ収容したことを特徴とする。
【００１７】
この積層配線板組立体の製造方法では、一対のブスバー配線板の隣接する各端部同士を突き合わせた状態でそれらの絶縁基板より露出した各ブスバーの露出部と各電線の接続部とを溶接により接合し、その後で各端部の裏面側の角部分に形成された各アール部同士を当接させながら各電線の渡し部を折り曲げながら各電線収容部に収容したので、ブスバーと電線の接続不良がない高品質の積層配線板組立体が簡単かつ短時間で大量に組み立てられる。即ち、複数の電線の各渡し部を折り曲げるだけの作業により、各電線間のショートやリークがない高品質の積層配線板組立体が簡単かつ短時間で大量に組み立てられる。
【００１８】
【発明の実施の形態】
以下、本発明の一実施形態を図面に基づいて説明する。
【００１９】
図１は本発明の一実施形態の積層配線板組立体の要部を示す拡大断面図、図２は同組立体の組立前の状態を示す斜視図、図３は同組立体の組立後の状態を示す平面図、図４は同組立体の組立後の状態を裏側から見た斜視図、図５は同組立体に用いられるブスバー配線板のブスバーと電線の接合状態を示す部分横断面図、図６は同ブスバーと電線の接合状態を示す部分縦断面図、図７は同ブスバーと電線の接合状態を示す部分平面図、図８は同ブスバーと電線の接合状態を示す部分底面図、図９（ａ）〜図９（ｅ）は同組立体の組立過程を順を追って示す部分断面図、図１０は同組立体を収容する電気接続箱の分解斜視図である。
【００２０】
図１０に示すように、積層配線板組立体２０は、電気接続箱１０の外形を成す合成樹脂製で箱形の上，下ケース１１，１２内に収容されている。即ち、上，下ケース１１，１２内に積層配線板組立体２０を中心にその上下に対称になるように複数のブスバー１４の端子１４ａ，１４ｂを突設させたブスバー配線板１５，１６と複数の電線１７を布線した布線シート１８，１９をそれぞれ配置することにより収容してある。尚、上，下ケース１１，１２にはコネクタ装着部１３Ａ，１３Ｂ等を一体突出形成してある。
【００２１】
図２に示すように、積層配線板組立体２０は、隣接する各端部２１ｃ，２２ｃ同士を突き合わせて略一平面上に並列に配置された一対のブスバー配線板（配線板）２１，２２と、この一対のブスバー配線板２１，２２間に掛け渡すように布線されて該一対のブスバー配線板２１，２２の各表面２１ａ，２２ａにそれぞれ配索された複数の電線３７とを備えている。この複数の電線３７として絶縁被覆のない裸電線が用いられている。
【００２２】
各ブスバー配線板２１，２２は絶縁基板２３，２４の幅方向に複数のブスバー２５，２６を直線的かつ並列にインサート成形して成り、各ブスバー２５，２６の両端には上向きのタブ端子（端子）２５ａ，２５ａ、２６ａ，２６ａをともに同一高さに起立させている。さらに、各絶縁基板２３，２４の表面の各ブスバー２５，２６と略直交する方向には断面凹溝状の電線収容部２７，２８をそれぞれ一体形成してある。この各電線収容部２７，２８は絶縁基板２３，２４の表面からその隣接する各端部の表面側から裏面側にかけて形成されていて、各端部側の各電線収容部２７，２８の両側には絶縁リブ２９，３０をそれぞれ一体突出形成してある。さらに、各電線収容部２７，２８の相対向する内面にはストッパとしての一対の突起２７ａ，２７ａ、２８ａ，２８ａを所定間隔毎に一体突出形成してあり、各電線収容部２７，２８に収容される電線３７が相対向する各一対の突起２７ａ，２７ａ、２８ａ，２８ａ間で挾持されるようにその収容状態が保持されるようになっている。
【００２３】
また、一対のブスバー配線板２１，２２の突き合わされる各端部２１ｃ，２２ｃの裏面側の角部分、即ち、各絶縁基板２３，２４の隣接する各端部に一体突出形成された各絶縁リブ２９，３０の下側には略円弧面状のアール部３１，３２をそれぞれ形成してあり、この隣接する各アール部３１，３２同士は一対の絶縁基板２３，２４間に掛け渡された複数の電線３７の渡し部３７ａを折り曲げて該一対の絶縁基板２３，２４を上下に重ね合わせる際に当接自在になっている。
【００２４】
さらに、所定のブスバー２５，２６の一部は各絶縁基板２３，２４から露出している。即ち、図５〜図８に示すように、各絶縁基板２３，２４の各ブスバー２５，２６の一部は露出部２５ｂ，２６ｂとなって表裏面側に露出しており、その周りには該各ブスバー２５，２６の露出部２５ｂ，２６ｂと各電線３７の接続部３７ｂとを挾んで接合させる抵抗溶接用の一対の電極３８，３９の径より大径の接続用孔３３，３４を形成してある。この接続用孔３３，３４は矩形に形成されていて、該矩形の接続用孔３３，３４の各辺の略中央に各ブスバー２５，２６の露出部２５ｂ，２６ｂと各電線３７の接続部３７ａが位置するようにそれぞれ配置されている。これにより、各接続用孔３３，３４内において各ブスバー２５，２６の露出部２５ｂ，２６ｂと電線３７の接続部３７ｂとが略直交するようにそれぞれ配索され、かつ、各ブスバー２５，２６の露出部２５ｂ，２６ｂは完全に露出されるようになっている。尚、図５に示すように、電線収容部２７，２８と接続用孔３３，３４の境部分には円弧状に湾曲した曲面部２７ｂ，２８ｂをそれぞれ形成してあり、該各曲面部２７ｂ，２７ｂ、２８ｂ，２８ｂに電線３７が隙間なく当接するようになっている。
【００２５】
さらに、図２，図４に示すように、組立完了時に裏側に位置する絶縁基板２４に配索される各ブスバー２６及び電線３７は該絶縁基板２４の略中央を避けてそれぞれ配索されている。そして、この絶縁基板２４の各ブスバー２６及び各電線３７がそれぞれ配索されていない箇所である略中央部には肉抜きとしての略矩形の孔３５を形成してある。
【００２６】
以上実施形態の積層配線板組立体２０を組み立てる場合には、まず、図２及び図９（ａ）に示すように、一対のブスバー配線板２１，２２を隣接する各端部２１ｃ，２２ｃ同士を突き合わせた状態で略一平面上に並列に配置し、この一対のブスバー配線板２１，２２間に複数の電線３７を掛け渡すように布線して該一対のブスバー配線板２１，２２の各表面２１ａ，２２ａに直線的に連なるように形成された各電線収容部２７，２８に電線３７をそれぞれ収容する。この際、各電線収容部２７，２８に収容される電線３７は相対向する各一対の突起２７ａ，２７ａ，２８ａ，２７ａ間でそれぞれ挾持される。また、一方のブスバー配線板２１の電線収容部２７のみに収容されて、他方のブスバー配線板２２の表面２２ａには配索されない電線３７もあるが、全ての電線３７は各電線収容部２７，２８に完全に収容されるので、各ブスバー配線板２１，２２の各表面２１ａ，２２ａより突出することがない。
【００２７】
次に、図５〜図８に示すように、一対のブスバー配線板２１，２２の隣接する各端部２１ｃ，２２ｃ同士を突き合わせた状態で該一対のブスバー配線板２１，２２を成す各絶縁基板２３，２４より一部が露出した各ブスバー２５，２６の露出部２５ｂ，２６ｂと各電線３７の接続部３７ｂとを抵抗溶接用の一対の電極３８，３９を介して接合する。これにより、各電線収容部２７，２８内に電線３７は確実に保持され、図２に示すように、各端部２１ｃ，２２ｃが突き合われた一対のブスバー配線板２１，２２は略平板状になる。
【００２８】
この状態から、図９（ｂ）〜図９（ｄ）に示すように、一対のブスバー配線板２１，２２間に位置する各電線３７の渡し部３７ａを折り曲げる。この際に、一対のブスバー配線板２１，２２の突き合わされた各端部２１ｃ，２２ｃの裏面２１ｂ，２２ｂ側の角部分、即ち、各絶縁リブ２９，３０の下側の円弧面状の各アール部３１，３２同士が当接しながら各電線３７の渡し部３７ａがヒンジとなって他方のブスバー配線板２２を一方のブスバー配線板２１に対して反転させることができると共に、図９（ａ）〜図９（ｅ）に示すように、一対のブスバー配線板２１，２２の各裏面２１ｂ，２２ｂ同士が重ね合わされるまで各電線３７の渡し部３７ａが各端部２１ｃ，２２ｃの表面側から裏面側にかけて形成された各電線収容部２７，２８に収容されながら折り曲げられるため、各電線３７の渡し部３７ａを折り曲げる際に、該各電線３７の渡し部３７ａの伸びが抑えられて各電線３７に余分なテンションが発生することがなく、また、各ブスバー２５，２６の露出部２５ｂ，２６ｂと各電線３７の接続部３７ｂとの接合部分に負荷がかかることがない。これにより、各電線３７と各電線収容部２７，２８内の各一対の突起２７ａ，２７ａ、２８ａ，２８ａとの保持状態が外れることがなく、また、各ブスバー２５，２６の露出部２５ｂ，２６ｂと各電線３７の接続部３７ｂとの接合状態を安定させることができ、ブスバー２５，２６と電線３７の接続不良の発生を確実に防ぐことができる。
【００２９】
そして、図１，図４，図９（ｅ）に示すように、一対のブスバー配線板２１，２２間の各電線３７の渡し部３７ａを略１８０度折り曲げて該一対のブスバー配線板２１，２２の各裏面２１ｂ，２２ｂ同士を重ね合わせることで積層配線板組立体２０の組立が完成する。この際、各電線３７のＵ字状に折り曲げられた渡し部３７ａは、突き合わされた各端部２１ｃ，２２ｃの各電線収容部２７，２８内に完全に収容される。また、各電線３７の隣接するＵ字状に折り曲げられた渡し部３７ａは各端部２１ｃ，２２ｃ側の各電線収容部２７，２８の両側に突設された各絶縁リブ２９，２９，３０，３０により沿面距離が十分に確保される。これらにより、各電線３７のＵ字状に折り曲げられて隣接する各渡し部３７ａ，３７ａ間のショート及びリークを確実に防止することができる。
【００３０】
このように、一対のブスバー配線板２１，２２の隣接する各端部２１ｃ，２２ｃを突き合わせた状態で、該各端部２１ｃ，２２ｃの各アール部３１，３２同士を当接させながら複数の電線３７の各渡し部３７ａを折り曲げて一対のブスバー配線板２１，２２を上下に折り畳むだけの作業により、各電線３７，３７間のショートやリークがない高品質の積層配線板組立体２０を簡単かつ短時間で大量に組み立てることができる。特に、一対のブスバー配線板２１，２２の隣接する各端部２１ｃ，２２ｃ同士を突き合わせた状態でその各絶縁基板２３，２４より露出した各ブスバー２５，２６の露出部２５ｂ，２６ｂと各電線３７の接続部３７ｂとを抵抗溶接により接合し、その後で、各電線３７の渡し部３７ａを折り曲げながら各電線収容部２７，２８に完全に収容するようにしたので、ブスバー２５，２６と電線３７の接続不良がない高品質の積層配線板組立体２０を簡単かつ短時間で大量に組み立てることができる。
【００３１】
尚、前記実施形態によれば、裏面側のブスバー配線板にのみ反り防止用の肉抜き孔を形成したが、表面側のブスバー配線板にも反り防止用の肉抜き孔を形成しても良い。また、肉抜き形成は貫通しない穴状でも良いことは勿論である。さらに、抵抗溶接用の電極が挿入されるブスバーの露出部と電線の接続部の接続用孔は方形に限らず円形や楕円形等でも良いことは勿論である。
【００３３】
【発明の効果】
以上説明したように、請求項１の発明の積層配線板組立体によれば、配線板として複数のブスバーを絶縁基板にインサート成形して成るブスバー配線板を用い、一対のブスバー配線板の隣接する各端部同士を突き合わせた状態から絶縁基板より露出した各ブスバーの露出部と各電線の接続部とを溶接により接合した後で、各電線の渡し部を折り曲げ自在にしたので、一対のブスバー配線板の隣接する各端部を突き合わせた状態で複数の電線の渡し部を折り曲げる際に、各渡し部が電線収容部に収容されながらその伸びが抑えられて折り曲げられるため、各電線の渡し部に余分なテンションが発生することがなく、ブスバーの露出部と電線の接続部との接合部分に負荷がかかることがない。これにより、ブスバーの露出部と電線の接続部との接合状態を安定させることができ、ブスバーと電線の接続不良の発生を確実に防ぐことができる。特に、各電線の渡し部が収容される電線収容部の両側に絶縁リブをそれぞれ一体突出形成したので、各絶縁リブにより隣接する各電線の渡し部間の沿面距離を十分に確保することができ、各電線の渡し部間のショート及びリークをより確実に防止することができる。
【００３６】
請求項２の発明の積層配線板組立体の製造方法によれば、一対のブスバー配線板の隣接する各端部同士を突き合わせた状態でそれらの絶縁基板より露出した各ブスバーの露出部と各電線の接続部とを溶接により接合し、その後で各端部の裏面側の角部分に形成された各アール部同士を当接させながら複数の電線の渡し部を折り曲げながら各電線収容部に収容するようにしたので、ブスバーと電線の接続不良がない高品質の積層配線板組立体を簡単かつ短時間で大量に組み立てることができる。即ち、複数の電線の各渡し部を折り曲げるだけの作業により、各電線間のショートやリークがない高品質の積層配線板組立体を簡単かつ短時間で大量に組み立てることができる。
【図面の簡単な説明】
【図１】本発明の一実施形態の積層配線板組立体の要部を示す拡大断面図である。
【図２】上記積層配線板組立体の組立前の状態を示す斜視図である。
【図３】上記積層配線板組立体の組立後の状態を示す平面図である。
【図４】上記積層配線板組立体の組立後の状態を裏側から見た斜視図である。
【図５】上記積層配線板組立体に用いられるブスバー配線板のブスバーと電線の接合状態を示す部分横断面図である。
【図６】上記ブスバー配線板のブスバーと電線の接合状態を示す部分縦断面図である。
【図７】上記ブスバー配線板のブスバーと電線の接合状態を示す部分平面図である。
【図８】上記ブスバー配線板のブスバーと電線の接合状態を示す部分底面図である。
【図９】（ａ）〜（ｅ）は上記積層配線板組立体の組立過程を順を追って示す部分断面図である。
【図１０】上記積層配線板組立体を収容する電気接続箱の分解斜視図である。
【図１１】従来の積層配線板組立体の斜視図である。
【図１２】上記従来の積層配線板組立体の組立前の状態を示す斜視図である。
【図１３】上記従来の積層配線板組立体に用いられるブスバー配線板のブスバーと電線の接合状態を示す部分横断面図である。
【符号の説明】
２０積層配線板組立体
２１，２２一対のブスバー配線板（配線板）
２１ａ，２２ａ表面
２１ｂ，２２ｂ裏面
２１ｃ，２２ｃ端部
２３，２４絶縁基板
２５，２６ブスバー
２５ｂ，２６ｂ露出部
２７，２８電線収容部
２９，３０絶縁リブ
３１，３２アール部
３７電線
３７ａ渡し部
３７ｂ接続部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a laminated wiring board assembly in which a pair of wiring boards in which a plurality of bus bars and a plurality of electric wires are arranged in a matrix are stacked in two upper and lower layers and accommodated in an electrical junction box or the like, and a method for manufacturing the same About.
[0002]
[Prior art]
As this type of laminated wiring board assembly, there are those shown in FIGS. As shown in FIG. 12, this laminated wiring board assembly 1 has a pair of insulating substrates 2 and 3 formed by insert-molding a plurality of bus bars 4 in the width direction at predetermined intervals on a substantially flat surface. The plurality of electric wires 5 are arranged in parallel and arranged so that a plurality of electric wires 5 are spanned between the pair of insulating substrates 2 and 3, and the plurality of electric wires 5 are placed on the respective surfaces 2 a and 3 a of the pair of insulating substrates 2 and 3. Each bus bar 4 is linearly routed in a longitudinal direction substantially orthogonal to each bus bar 4, and then each connecting portion 6 of the plurality of electric wires 5 between the pair of insulating substrates 2 and 3 is bent in the direction of arrow X in FIG. The rear surfaces 2b and 3b of the pair of insulating substrates 2 and 3 are assembled by overlapping each other.
[0003]
Further, as shown in FIG. 13, when the electric wire 5 is wired, it is arranged so as to cross the exposed portion 4 a of the bus bar 4 exposed from the pair of insulating substrates 2 and 3 and the exposed portion 4 a of the bus bar 4. A part 5a of the electric wire 5 at a predetermined position is sandwiched and joined between a pair of electrodes 7 and 8 for resistance welding.
[0004]
A similar technique relating to the laminated wiring board assembly 1 is disclosed in Japanese Patent Application No. 10-308424.
[0005]
[Problems to be solved by the invention]
However, in the conventional laminated wiring board assembly 1, a bare wire without an insulation coating is used as the wire 5, and the transfer portions 6 of the plurality of wires 5 between the pair of insulating substrates 2 and 3 are bent into a U shape. In the bent state, the pair of insulating substrates 2 and 3 protrude outward from the adjacent end portions 2c and 3c, so there is a possibility that the passing portions 6 and 6 of the adjacent electric wires 5 and 5 are short-circuited or leaked. there were.
[0006]
The adjacent wires 5, 5 are made adjacent to the pair of insulating substrates 2, 3 by making the protruding amount of the connecting portions 6 of the plurality of wires 5 protruding in a bent state from the adjacent ends 2 c, 3 c as small as possible. In order to prevent a short circuit between the transfer portions 6 and 6, when the pair of insulating substrates 2 and 3 are assembled, the transfer portions 6 of the electric wires 5 are bent with the adjacent end portions 2c and 3c abutting each other. When the transfer portion 6 is bent, the transfer portion 6 is extended and an excessive tension is applied to the electric wire 5. Due to the generation of the tension, the connection state between the exposed portion 4 a of the bus bar 4 and the part 5 a of the electric wire 5 is not good. May become stable.
[0007]
Therefore, the present invention has been made to solve the above-described problems, and can easily bend the wire without applying extra tension to the wire, and reliably prevent short-circuiting or leakage between the wires. It is an object of the present invention to provide a laminated wiring board assembly and a method for manufacturing the same.
[0008]
[Means for Solving the Problems]
According to the first aspect of the present invention, a plurality of electric wires are wired between a pair of wiring boards arranged substantially on one plane, and the plurality of electric wires are respectively arranged on the respective surfaces of the pair of wiring boards. and search, in the plurality of laminated wiring board assembly of superposed each back surface between the pair of wiring board by bending the respective passes of the wire of the pair of wiring plates, the plurality as the respective wiring boards busbar A bus bar wiring board formed by insert molding on an insulating substrate is used, and a rounded portion is formed at each corner on the back side of each end of the pair of bus bar wiring boards to be abutted, and the front side of each end. An electric wire accommodating portion for accommodating each of the plurality of electric wire passing portions from the rear surface to the rear surface side, and insulating ribs are integrally formed on both sides of each electric wire accommodating portion , and the pair of bus bar wiring boards are adjacent to each other. Butt each end Wherein the Align was state exposed from the respective insulating substrate and the exposed portion of the bus bar and connection of the wires after bonding by welding, freely abutting the respective rounded portions when folding the respective passing portions It is characterized by that.
[0011]
In this laminated wiring board assembly, when bending a plurality of electric wire passing portions in a state in which adjacent ends of a pair of bus bar wiring boards are abutted with each other, the extending portions are suppressed while being accommodated in the electric wire accommodating portion. Therefore, no extra tension is generated at the connecting portion of each electric wire, and no load is applied to the joint portion between the exposed portion of the bus bar and the connecting portion of the electric wire. Thereby, the joining state of the exposed portion of the bus bar and the connecting portion of the electric wire is stabilized, and the occurrence of poor connection between the bus bar and the electric wire is reliably prevented. In particular, the insulation ribs on both sides of each wire accommodating portion in which a plurality of wire passing portions are accommodated ensure a sufficient creepage distance between adjacent wire passing portions, and shorts and leaks between the wire passing portions are prevented. More reliably prevented.
[0014]
According to the invention of claim 2 , a pair of wiring boards are arranged in parallel on a substantially flat surface, and a plurality of electric wires are arranged between the pair of wiring boards so as to be arranged on each surface of the pair of wiring boards. A laminated wiring board assembly in which the plurality of electric wires are respectively routed, and then the respective wiring portions of the plurality of electric wires between the pair of wiring boards are bent and the back surfaces of the pair of wiring boards are overlapped with each other. In this manufacturing method, a bus bar wiring board formed by insert-molding a plurality of bus bars on an insulating substrate is used as each wiring board, and the pair of bus bar wirings in a state where the adjacent ends of the pair of bus bar wiring boards are abutted with each other. After arranging the plurality of electric wires on the surface of the plate, the exposed portions of the bus bars exposed from the insulating substrates and the connecting portions of the electric wires are joined by welding, and then the pair of bus bars Formed at the corners on the back side of each end of the wiring board With superposed each back surface between the pair of bus bar wiring board by bending the respective passing portions of the plurality of electric wires while abutting the respective rounded portions which are formed toward the back side from the front surface side of the respective end Further, each of the passing portions is accommodated in each of the electric wire accommodating portions.
[0017]
In this method of manufacturing a laminated wiring board assembly, the exposed portions of the bus bars exposed from the insulating substrates and the connection portions of the electric wires are welded together while the adjacent ends of the pair of bus bar wiring boards are in contact with each other. Bonding and then connecting each wire part while bending each rounded part formed at the corners on the back side of each end while bending each wire accommodating part, poor connection between busbar and wire High-quality laminated wiring board assemblies without any problems can be assembled in large quantities in a short time. That is, a high-quality laminated wiring board assembly free from short-circuits or leaks between the electric wires can be easily assembled in a large amount of time by simply bending each transfer portion of the plurality of electric wires.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
[0019]
FIG. 1 is an enlarged cross-sectional view showing a main part of a laminated wiring board assembly according to an embodiment of the present invention, FIG. 2 is a perspective view showing a state before the assembly of the assembly, and FIG. FIG. 4 is a perspective view of the assembled state as seen from the back side, and FIG. 5 is a partial cross-sectional view showing a joined state of the bus bar and the electric wire of the bus bar wiring board used in the assembly. FIG. 6 is a partial longitudinal sectional view showing the joined state of the bus bar and the electric wire, FIG. 7 is a partial plan view showing the joined state of the bus bar and the electric wire, and FIG. 8 is a partial bottom view showing the joined state of the bus bar and the electric wire. FIG. 9A to FIG. 9E are partial cross-sectional views showing the assembly process of the assembly step by step, and FIG. 10 is an exploded perspective view of an electrical junction box that accommodates the assembly.
[0020]
As shown in FIG. 10, the laminated wiring board assembly 20 is made of a synthetic resin that forms the outer shape of the electrical connection box 10 and is accommodated in the upper and lower cases 11 and 12 of the box shape. That is, a plurality of bus bar wiring boards 15, 16 in which terminals 14a, 14b of a plurality of bus bars 14 are provided so as to be symmetrical in the upper and lower cases around the laminated wiring board assembly 20 in the upper and lower cases 11, 12. The wiring sheets 18 and 19 in which the electric wires 17 are wired are accommodated by arranging them. The upper and lower cases 11 and 12 are integrally formed with connector mounting portions 13A and 13B.
[0021]
As shown in FIG. 2, the laminated wiring board assembly 20 includes a pair of bus bar wiring boards (wiring boards) 21 and 22 that are arranged in parallel on one plane with the adjacent end portions 21 c and 22 c abutting each other. And a plurality of electric wires 37 wired so as to be spanned between the pair of bus bar wiring boards 21 and 22 and routed on the respective surfaces 21a and 22a of the pair of bus bar wiring boards 21 and 22, respectively. . As the plurality of electric wires 37, bare electric wires having no insulation coating are used.
[0022]
Each bus bar wiring board 21, 22 is formed by insert-molding a plurality of bus bars 25, 26 linearly and in parallel in the width direction of the insulating substrates 23, 24. ) 25a, 25a, 26a and 26a are all erected at the same height. Furthermore, electric wire accommodating portions 27 and 28 having a concave groove section are integrally formed in a direction substantially orthogonal to the bus bars 25 and 26 on the surfaces of the insulating substrates 23 and 24, respectively. The electric wire receiving portions 27 and 28 are formed from the surface of the insulating substrates 23 and 24 from the front surface side to the back surface side of the adjacent end portions on both sides of the electric wire receiving portions 27 and 28 on the end portion side. Insulating ribs 29 and 30 are integrally formed. Furthermore, a pair of protrusions 27a, 27a, 28a, 28a as stoppers are integrally formed at predetermined intervals on the opposing inner surfaces of the electric wire accommodating portions 27, 28, and are accommodated in the electric wire accommodating portions 27, 28, respectively. The accommodation state is maintained so that the electric wire 37 to be held is held between the pair of protrusions 27a, 27a, 28a, 28a facing each other.
[0023]
Insulating ribs formed integrally and projecting at the corners on the back side of the end portions 21c and 22c with which the pair of bus bar wiring boards 21 and 22 are abutted, that is, adjacent end portions of the insulating substrates 23 and 24, respectively. 29 and 30 are respectively formed with arcuate portions 31 and 32 having a substantially arcuate surface shape, and each of the adjacent round portions 31 and 32 is a plurality of spanned between a pair of insulating substrates 23 and 24. The connecting portion 37a of the electric wire 37 is bent so that the pair of insulating substrates 23 and 24 can be brought into contact with each other when they are stacked one above the other.
[0024]
Furthermore, some of the predetermined bus bars 25 and 26 are exposed from the insulating substrates 23 and 24. That is, as shown in FIG. 5 to FIG. 8, a part of each bus bar 25, 26 of each insulating substrate 23, 24 is exposed to the front and back sides as exposed portions 25 b, 26 b, Connection holes 33 and 34 having a diameter larger than the diameter of the pair of electrodes 38 and 39 for resistance welding for sandwiching and joining the exposed portions 25b and 26b of the bus bars 25 and 26 and the connection portions 37b of the electric wires 37 are formed. It is. The connection holes 33 and 34 are formed in a rectangular shape, and the exposed portions 25b and 26b of the bus bars 25 and 26 and the connection portions 37a of the electric wires 37 are provided at substantially the center of each side of the rectangular connection holes 33 and 34. Are arranged so as to be positioned. As a result, the exposed portions 25b and 26b of the bus bars 25 and 26 and the connection portions 37b of the electric wires 37 are routed so as to be substantially orthogonal to each other in the connection holes 33 and 34, and the bus bars 25 and 26 The exposed portions 25b and 26b are completely exposed. As shown in FIG. 5, curved portions 27b and 28b that are curved in an arc shape are formed at the boundary portions between the wire receiving portions 27 and 28 and the connection holes 33 and 34, respectively. The electric wire 37 comes into contact with 27b, 28b, 28b without a gap.
[0025]
Further, as shown in FIGS. 2 and 4, the bus bars 26 and the electric wires 37 that are routed on the insulating substrate 24 located on the back side when the assembly is completed are routed so as to avoid the approximate center of the insulating substrate 24. . In addition, a substantially rectangular hole 35 is formed in the insulating substrate 24 at a substantially central portion where the bus bars 26 and the electric wires 37 are not routed.
[0026]
When assembling the laminated wiring board assembly 20 of the above embodiment, first, as shown in FIG. 2 and FIG. 9A, the ends 21c and 22c adjacent to each other between the pair of bus bar wiring boards 21 and 22 are connected. Each of the surfaces of the pair of bus bar wiring boards 21, 22 is arranged in parallel on a substantially flat surface in a state of being butted and arranged so that a plurality of electric wires 37 are spanned between the pair of bus bar wiring boards 21, 22. The electric wires 37 are accommodated in the electric wire accommodating portions 27 and 28 formed so as to be linearly connected to 21a and 22a, respectively. At this time, the electric wires 37 accommodated in the electric wire accommodating portions 27 and 28 are respectively held between the pair of protrusions 27a, 27a, 28a and 27a facing each other. Further, there is an electric wire 37 that is accommodated only in the electric wire accommodating portion 27 of one bus bar wiring board 21 and is not routed on the surface 22a of the other bus bar wiring board 22, but all electric wires 37 are connected to the electric wire accommodating portions 27, 28, the bus bar wiring boards 21 and 22 do not protrude from the front surfaces 21a and 22a.
[0027]
Next, as shown in FIG. 5 to FIG. 8, each insulating substrate forming the pair of bus bar wiring boards 21, 22 in a state where the adjacent end portions 21 c, 22 c of the pair of bus bar wiring boards 21, 22 face each other. The exposed portions 25b, 26b of the bus bars 25, 26 partially exposed from 23, 24 are joined to the connection portions 37b of the electric wires 37 via a pair of electrodes 38, 39 for resistance welding. Thereby, the electric wire 37 is reliably hold | maintained in each electric wire accommodating part 27 and 28, and as shown in FIG. 2, a pair of bus bar wiring boards 21 and 22 with which each edge part 21c and 22c was faced are substantially flat plate shape. become.
[0028]
From this state, as shown in FIG. 9B to FIG. 9D, the transfer portion 37 a of each electric wire 37 positioned between the pair of bus bar wiring boards 21 and 22 is bent. At this time, the corners on the back surfaces 21b and 22b of the end portions 21c and 22c with which the pair of bus bar wiring boards 21 and 22 are abutted, that is, the arc-shaped rounded surfaces on the lower side of the insulating ribs 29 and 30, respectively. While the portions 31 and 32 are in contact with each other, the transfer portion 37a of each electric wire 37 serves as a hinge, so that the other bus bar wiring board 22 can be reversed with respect to the one bus bar wiring board 21, and FIGS. As shown in FIG.9 (e), until the back surfaces 21b and 22b of a pair of bus bar wiring boards 21 and 22 are piled up, the transfer part 37a of each electric wire 37 is the back surface side from the surface side of each end part 21c and 22c. Therefore, when the transfer portion 37a of each electric wire 37 is bent, the extension of the transfer portion 37a of each electric wire 37 is suppressed and each electric wire 37 is bent. Without extra tension occurs, also, never load is applied to the joint portion between the connecting part 37b of the exposed portion 25b, 26b and the wires 37 of the respective bus bars 25, 26. As a result, the holding state between each wire 37 and each pair of protrusions 27a, 27a, 28a, 28a in each wire housing portion 27, 28 is not removed, and the exposed portions 25b, 26b of each bus bar 25, 26 are not removed. And the connection state 37b of each electric wire 37 can be stabilized, and the occurrence of poor connection between the bus bars 25, 26 and the electric wire 37 can be reliably prevented.
[0029]
Then, as shown in FIGS. 1, 4 and 9E, the connecting portions 37a of the electric wires 37 between the pair of bus bar wiring boards 21 and 22 are bent by approximately 180 degrees, and the pair of bus bar wiring boards 21 and 22 are provided. Assembling of the laminated wiring board assembly 20 is completed by superimposing the back surfaces 21b and 22b of each other. At this time, the transfer portion 37a bent in the U shape of each electric wire 37 is completely accommodated in each electric wire accommodating portion 27, 28 of each end portion 21c, 22c that is abutted. Further, the connecting portions 37a bent in the U-shape adjacent to the respective electric wires 37 are respectively provided with the respective insulating ribs 29, 29, 30, protruding from both sides of the respective electric wire accommodating portions 27, 28 on the end portions 21c, 22c side. 30 ensures a sufficient creepage distance. Accordingly, it is possible to reliably prevent a short circuit and a leak between the adjacent transfer portions 37a and 37a that are bent in a U-shape of each electric wire 37.
[0030]
In this way, a plurality of electric wires are brought into contact with the rounded portions 31 and 32 of the end portions 21c and 22c in a state where the adjacent end portions 21c and 22c of the pair of bus bar wiring boards 21 and 22 are abutted with each other. The high-quality laminated wiring board assembly 20 without any short circuit or leakage between the electric wires 37 and 37 can be easily and simply obtained by bending each of the transfer portions 37a of 37 and folding the pair of bus bar wiring boards 21 and 22 up and down. Can be assembled in large quantities in a short time. In particular, the exposed portions 25b and 26b of the bus bars 25 and 26 exposed from the insulating substrates 23 and 24 and the electric wires 37 in a state where the adjacent end portions 21c and 22c of the pair of bus bar wiring boards 21 and 22 face each other. The connecting portions 37b are joined together by resistance welding, and then the connecting portions 37a of the electric wires 37 are completely accommodated in the electric wire accommodating portions 27 and 28 while being bent, so that the bus bars 25 and 26 and the electric wires 37 are connected. A high-quality laminated wiring board assembly 20 with no connection failure can be assembled in a large amount easily and in a short time.
[0031]
In addition, according to the said embodiment, the thickness reduction hole for warpage prevention was formed only in the bus bar wiring board on the back surface side, but the thickness reduction hole for warpage prevention may be formed also in the surface side bus bar wiring board. . Needless to say, the hole forming may be a hole that does not penetrate. Furthermore, it goes without saying that the connection hole between the exposed portion of the bus bar into which the electrode for resistance welding is inserted and the connection portion of the electric wire is not limited to a square shape but may be a circular shape or an oval shape.
[0033]
【The invention's effect】
As described above , according to the laminated wiring board assembly of the first aspect of the present invention, the bus bar wiring board formed by insert-molding a plurality of bus bars on the insulating substrate is used as the wiring board, and the pair of bus bar wiring boards are adjacent to each other. Since the exposed part of each bus bar exposed from the insulating substrate and the connecting part of each electric wire are joined by welding after the ends are butted together, the connecting part of each electric wire is made foldable, so a pair of bus bar wires When bending a plurality of wire passing portions with the adjacent end portions of the plates abutting each other, since each passing portion is accommodated in the wire accommodating portion and its extension is suppressed, it is bent. No excessive tension is generated, and no load is applied to the joint between the exposed portion of the bus bar and the connecting portion of the electric wire. Thereby, the joining state of the exposed part of the bus bar and the connecting part of the electric wire can be stabilized, and the occurrence of poor connection between the bus bar and the electric wire can be reliably prevented. In particular, since the insulating ribs are integrally formed on both sides of the electric wire accommodating portion where the electric wire passing portions are accommodated, the creeping distance between adjacent electric wire passing portions can be sufficiently secured by the insulating ribs. Further, it is possible to more reliably prevent a short circuit and a leak between the transfer portions of each electric wire.
[0036]
According to the method for manufacturing a laminated wiring board assembly of the invention of claim 2 , the exposed portions of the bus bars and the electric wires exposed from the insulating substrates in a state where the adjacent end portions of the pair of bus bar wiring boards are in contact with each other. Are connected to each other by welding, and then accommodated in each electric wire accommodating portion while bending each of the rounded portions formed at the corners on the back surface side of each end while bending a plurality of electric wire passing portions. As a result, a high-quality laminated wiring board assembly free from poor connection between the bus bars and the electric wires can be assembled easily and in large quantities in a short time. That is, a high-quality laminated wiring board assembly free from short-circuits or leaks between the electric wires can be assembled in a large amount easily and in a short time by simply bending each transfer portion of the plurality of electric wires.
[Brief description of the drawings]
FIG. 1 is an enlarged cross-sectional view showing a main part of a laminated wiring board assembly according to an embodiment of the present invention.
FIG. 2 is a perspective view showing a state before the laminated wiring board assembly is assembled.
FIG. 3 is a plan view showing a state after the laminated wiring board assembly is assembled.
FIG. 4 is a perspective view of a state after assembly of the laminated wiring board assembly as viewed from the back side.
FIG. 5 is a partial cross-sectional view showing a joined state between a bus bar and a wire of a bus bar wiring board used in the laminated wiring board assembly.
FIG. 6 is a partial longitudinal sectional view showing a joined state of the bus bar and the electric wire of the bus bar wiring board.
FIG. 7 is a partial plan view showing a joined state of the bus bar and the electric wire of the bus bar wiring board.
FIG. 8 is a partial bottom view showing a joined state of the bus bar and the electric wire of the bus bar wiring board.
FIGS. 9A to 9E are partial cross-sectional views showing the assembly process of the laminated wiring board assembly in order. FIG.
FIG. 10 is an exploded perspective view of an electrical junction box that houses the laminated wiring board assembly.
FIG. 11 is a perspective view of a conventional laminated wiring board assembly.
FIG. 12 is a perspective view showing a state before assembly of the conventional multilayer wiring board assembly.
FIG. 13 is a partial cross-sectional view showing a joined state between a bus bar and a wire of a bus bar wiring board used in the conventional laminated wiring board assembly.
[Explanation of symbols]
20 Laminated wiring board assemblies 21, 22 A pair of bus bar wiring boards (wiring boards)
21a, 22a Front surface 21b, 22b Back surface 21c, 22c End portion 23, 24 Insulating substrate 25, 26 Bus bar 25b, 26b Exposed portion 27, 28 Wire receiving portion 29, 30 Insulating rib 31, 32 R portion 37 Electric wire 37a Delivery portion 37b Connection Part

Claims

The plurality of wires are routed between a pair of wiring boards arranged in parallel on substantially one plane, and the plurality of wires are routed on each surface of the pair of wiring boards. In the laminated wiring board assembly formed by folding each of the plurality of electric wires between the boards and overlapping each back surface of the pair of wiring boards,
As each wiring board, a bus bar wiring board formed by insert-molding a plurality of bus bars on an insulating substrate is used, and a rounded portion is formed at each corner on the back side of each end of the pair of bus bar wiring boards to be abutted. , Each of the end portions is formed from the front surface side to the back surface side to accommodate each of the plurality of electric wire accommodating portions, and the insulating ribs are integrally formed on both sides of each of the electric wire accommodating portions, After joining the exposed portions of the bus bars exposed from the insulating substrates and the connecting portions of the electric wires from a state in which adjacent ends of the pair of bus bar wiring boards are butted together, the connecting portions are connected to each other. A laminated wiring board assembly, wherein the rounded portions are made to contact each other when the wire is bent.

A pair of wiring boards are arranged in parallel on a substantially flat surface, and a plurality of wires are routed between the pair of wiring boards, and the plurality of wires are respectively arranged on the surfaces of the pair of wiring boards. Next, in the method of manufacturing a laminated wiring board assembly formed by folding each of the plurality of electric wires between the pair of wiring boards and overlapping each back surface of the pair of wiring boards,
As each wiring board, a bus bar wiring board formed by insert-molding a plurality of bus bars on an insulating substrate is used, and the adjacent ends of the pair of bus bar wiring boards are in contact with each other on the surface of the pair of bus bar wiring boards. After routing a plurality of electric wires, the exposed portions of the bus bars exposed from the insulating substrates and the connection portions of the electric wires are joined by welding, and then each end of the pair of bus bar wiring boards And bending each transfer portion of the plurality of electric wires while bringing the rounded portions formed at the corners on the back side of the portion into contact with each other, and overlapping the back surfaces of the pair of bus bar wiring boards with each end portion. A method of manufacturing a laminated wiring board assembly, wherein each of the passing portions is accommodated in each of the electric wire accommodating portions formed from the front surface side to the back surface side.