Fuse unit

Abstract

A fuse unit includes: a bus bar including a plurality of fusible parts interposed between a power supply side terminal and a plurality of load side terminals; and an insulating resin portion formed by insert molding using the bus bar as an insert component. The insulating resin portion includes: first and second resin portions respectively arranged at peripheries on the sides of the power supply side terminal and the load side terminals with respect to the fusible parts; and a plurality of coupling portions coupling the first resin portion and the second resin portion in a position outside each of the fusible parts. Each of the coupling portions is formed such that a reinforcement portion having a lower heat shrinkage rate than the insulating resin portion and having a higher strength than the insulating resin portion is an insert component. The reinforcement portion is provided using the bus bar.

Claims

1. A fuse unit comprising: a bus bar that includes a plurality of fusible parts extending from a power supply side terminal to a plurality of load side terminals; and an insulating resin portion that is formed by insert molding using the bus bar as an insert component, wherein the insulating resin portion includes: a first resin portion that is arranged at a periphery on a side of the power supply side terminal with respect to the fusible parts; a second resin portion that is arranged at a periphery on a side of the load side terminals with respect to the fusible parts; and a plurality of coupling portions that couple the first resin portion and the second resin portion at positions outside each of the fusible parts, each of the coupling portions is formed such that a reinforcement portion having a lower heat shrinkage rate than the insulating resin portion and having a higher strength than the insulating resin portion is an insert component such that there is a plurality of the reinforcement portions, each of the reinforcement portions is arranged apart from the fusible parts such that each of the fusible parts does not extend via any of the reinforcement portions from the power supply side terminal, the reinforcement portions are arranged along the fusible parts, and the reinforcement portions extend beyond middles of the fusible parts from the power supply side terminal toward the load side terminals.

2. The fuse unit of claim 1, wherein each of the reinforcement portions has the same width as each of the coupling portions, and side end surfaces on both sides of each of the reinforcement portions are flush with side end surfaces on both sides of each of the coupling portions.

3. The fuse unit of claim 1, wherein each of the reinforcement portions overlaps with the load side terminals adjacent each other, viewed from a width direction thereof.

4. The fuse unit of claim 1, wherein the reinforcement portions extend from the power supply side terminal at positions different from positions at which the fusible parts extend from the power supply side terminal [such that each of the fusible parts does not extend from any of the reinforcement portions].

5. The fuse unit according to claim 1, wherein the fusible parts and the reinforcement portions are alternatingly provided.

6. The fuse unit according to claim 1, wherein the reinforcement portions extending from the power supply side terminal toward the load side terminal in a direction has the same length in the extending direction.

7. The fuse unit according to claim 1, wherein a dimension of heat shrinkage of a part of the coupling portion of the insulating resin portion in which the reinforcement portion is provided is smaller than a dimension of heat shrinkage of a part of the coupling portion of the insulating resin portion in which the reinforcement portion is not provided.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front view of a conventional fuse unit.

(2) FIG. 2 is a perspective view of a conventional bus bar.

(3) FIG. 3A is a front view of a conventional coupling portion.

(4) FIG. 3B is a cross-sectional view taken along line A3-A3 of FIG. 3A.

(5) FIG. 3C is a cross-sectional view taken along line B3-B3 of FIG. 3A.

(6) FIG. 3D is a cross-sectional view illustrating a shrinkage state of the conventional coupling portion after resin molding.

(7) FIG. 4 is a perspective view of a fuse unit according to an embodiment of the present invention.

(8) FIG. 5 is a front view of a fuse unit according to the embodiment of the present invention.

(9) FIG. 6 is a perspective view of a bus bar according to the embodiment of the present invention.

(10) FIG. 7 is a front view of the bus bar according to the embodiment of the present invention.

(11) FIG. 8 is an enlarged view of a portion M of FIG. 5.

(12) FIG. 9A is a front view of a coupling portion according to the embodiment of the present invention.

(13) FIG. 9B is a cross-sectional view taken along line A1-A1 of FIG. 9A.

(14) FIG. 9C is a cross-sectional view taken along line B1-B1 of FIG. 9A.

(15) FIG. 9D is a cross-sectional view illustrating a shrinkage state of the coupling portion according to the embodiment of the present invention after resin molding.

(16) FIG. 10A is a front view of a coupling portion according to a variation of the embodiment of the present invention.

(17) FIG. 10B is a cross-sectional view taken along line A2-A2 of FIG. 10A.

(18) FIG. 10C is a cross-sectional view taken along line B2-B2 of FIG. 10A.

(19) FIG. 10D is a cross-sectional view illustrating a shrinkage state of the coupling portion according to variation of the embodiment of the present invention after resin molding.

DESCRIPTION OF EMBODIMENTS

(20) An embodiment of the present invention will be described below with reference to accompanying drawings.

Embodiment

(21) FIGS. 4 to 9D show an embodiment of the present invention. As shown in FIGS. 4 and 5, a fuse unit 1 is designed to be mounted on a vehicle, and is directly attached to a so-called battery (not shown). The fuse unit 1 includes: a bus bar 2 that is formed with a conductive metal plate; and an insulating resin portion 10 that is arranged so as to cover an appropriate area on the periphery of the bus bar 2.

(22) As shown in detail in FIGS. 6 and 7, the bus bar 2 is formed by bending the conductive metal plate having a predetermined shape. The bus bar 2 includes: a conductive plate portion 4 having a power supply side terminal 3; a plurality of load side terminals 5a and 5b; a plurality of fusible parts 6 that is interposed between the conductive plate portion 4 and each of the load side terminals 5a and 5b; and a plurality of reinforcement portions 7 that is arranged between the adjacent fusible parts 6. FIGS. 6 and 7 show the form of the bus bar 2 before insert molding; the adjacent load side terminals 5a and 5b are coupled by joint portions 8.

(23) The power supply side terminal 3 has a bolt insertion hole 3a. A battery post and the mating terminal (not shown) such as a battery connection terminal are connected to the power supply side terminal 3 using the bolt insertion hole 3a by fastening with a bolt and a nut.

(24) The conductive plate portion 4 is bent substantially at a right angle in the intermediate position. Thus, the fuse unit 1 is arranged along both the upper surface and the side surface of the battery (not shown).

(25) The load side terminals 5a and 5b are arranged a distance apart from each other side by side. The two in the center position of the load side terminals 5a and 5b have the form of a tab terminal; the two on both outsides have the form of a fastening terminal. In each of the load side terminals 5a having the form of a tab terminal, a connector housing portion 12a is provided by insert-molding the insulating resin portion 10. The mating terminal (not shown) on the load side is connected with a connector to each of the load side terminals 5a having the form of a tab terminal. The load side terminals 5b having the form of a fastening terminal have bolt insertion holes 15. In the load side terminals 5b having the form of a fastening terminal, fixing bolts 9 are provided by insert-molding the insulating resin portion 10 using the bolt insertion holes 15. The mating terminals (not shown) on the load side are connected to the load side terminals 5b by fastening nuts.

(26) As shown in detail in FIGS. 8 and 9D, each of the reinforcement portions 7 is provided to extend from the conductive plate portion 4 toward the load side terminals 5a and 5b. The reinforcement portions 7 are not coupled to the load side terminals 5a and 5b. The reinforcement portions 7 are arranged in positions corresponding to coupling portions 13b to 13d of the insulating resin portion 10, respectively; the reinforcement portions 7 are used as insert components when the insulating resin portion 10 are insert-molded. Each of the reinforcement portions 7 has a lower heat shrinkage rate than the insulating resin portion 10, and has a higher strength than the insulating resin portion 10. The reinforcement portions 7 are set such that they have smaller widths than the coupling portions 13b to 13d. Thus, the side end surfaces of the reinforcement portions 7 are positioned D (indicated in FIG. 9C) inwardly from the side end surfaces of the coupling portions 13b to 13d.

(27) The fusible parts 6 are arranged a distance apart from each other side by side. Each of the fusible parts 6 has a smaller width than each of the load side terminals 5a and 5b, and is bent in a crank shape. The width dimension of each of the fusible parts 6 is set based on the individual rated current and voltage values. The three fusible parts 6 are provided with crimp portions 6a. A low-melting point metal (for example, tin) 6b is fixed to each of the crimp portions 6a by crimping.

(28) As shown in FIGS. 4 and 5, the insulating resin portion 10 includes: a first resin portion 11 that is arranged at the periphery of the conductive plate portion 4 including the power supply side terminal 3; a second resin portion 12 that is arranged at the periphery of the load side terminals 5a and 5b; and a plurality of coupling portions 13a to 13e that couples the first resin portion 11 and the second resin portion 12 in positions outside the fusible parts 6.

(29) In the second resin portion 12, a connector housing portion 12a is provided around the load side terminals 5a having the form of a tab terminal.

(30) A window portion 14 through which each of the fusible parts 6 is exposed is individually provided between the adjacent coupling portions 13a to 13e. Thus, it is possible to visually check whether or not each of the fusible parts 6 is melted down. As shown in FIGS. 9A to 9D, in the coupling portions 13b to 13d excluding the both ends thereof, the reinforcement portions 7 of the bus bar 2 are individually incorporated. In other words, the three coupling portions 13b to 13d have a double structure composed of the reinforcement portion 7 and the resin material.

(31) As shown in detail in FIG. 8, the three coupling portions 13b to 13d couple an area L between the lower end surface of the first resin portion 11 and the upper end surface of the second resin portion 12. Here, the lower end side of the coupling portions 13b to 13d is provided such that a dimension L1 from the upper end surface of the second resin portion 12 is a limit and is inserted into the second resin portion 12.

(32) A method of manufacturing the fuse unit 1 will now be described briefly. First, as shown in FIGS. 6 and 7, the bus bar 2 having a predetermined shape is produced by punching a conductive metal material.

(33) Then, the low-melting point metal 6b is fixed by crimping to each of the fusible parts 6 of the bus bar 2. Then, each of the joint portions 8 of the bus bar 2 is cut.

(34) Then, the bus bar 2 and the fixing bolts 9 are set within a mold (not shown) for resin molding, and insert molding is performed using the bus bar 2 and the fixing bolts 9 as insert components. Thus, an appropriate area on the outside of the bus bar 2 is covered, and the insulating resin portion 10 having the window portions 14 through which the fusible parts 6 are exposed is formed. In this way, the manufacturing of the fuse unit 1 shown in FIGS. 4 and 5 is completed.

(35) As described above, in the fuse unit 1, the coupling portions 13a to 13e that couple the first resin portion 11 and the second resin portion 12 in positions outside the fusible parts 6 are included, the coupling portions 13b to 13d have a lower heat shrinkage rate than the insulating resin portion 10 and the reinforcement portions 7 having a higher strength than the insulating resin portion 10 are formed as insert components. As described above, since the coupling portions 13b to 13d are formed with the reinforcement portions 7 that are made of a low heat shrinkage material and the resin material, the amount of heat shrinkage produced after the resin molding in the coupling portions 13b to 13d is reduced. Specifically, if the heat shrinkage dimension of the coupling portion in the conventional example is a dimension d (shown in FIG. 3D), the heat shrinkage dimension is a dimension d1 (d1<d, shown in FIG. 9D) that is smaller than the dimension d. Moreover, since the coupling portions 13b to 13d are formed with the reinforcement portions 7 having a high mechanical strength and the resin material, as compared with the case where only the resin material is used, the mechanical strength is increased. Consequently, the stress concentration of the fusible parts 6 resulting from the heat shrinkage produced after the resin molding is minimized, and the mechanical strength of the coupling portions 13b to 13d is also enhanced.

(36) Since the reinforcement portions 7 are provided using the bus bar 2, a special member for the reinforcement portions 7 is not needed, and thus it is possible to decrease the cost.

(37) (Variation)

(38) A variation of the embodiment will now be described. This variation differs in only the configuration of a reinforcement portion 7A from the embodiment. Specifically, although, as shown in FIGS. 10A to 10D, the reinforcement portion 7A is formed with the bus bar 2, its width dimension is set equal to the width of the coupling portion 13b. Therefore, the side end surfaces of the reinforcement portion 7A on both sides are flush with the side end surface of the coupling portion 13b.

(39) The other configuration is the same as the embodiment, and hence its description will not be repeated. In FIGS. 10A to 10D, for the sake of clarity, the same constituent parts are identified with the same symbols.

(40) As in the embodiment, in the variation, the stress concentration of the fusible parts 6 resulting from the heat shrinkage produced after the resin molding is minimized, and the mechanical strength of the coupling portion 13b (not shown) is also enhanced.

(41) Since the reinforcement portion 7A has the same width as the coupling portion 13b, as shown in FIG. 10D, the amount of heat shrinkage d2 (d2<d1) produced after the resin molding in the coupling portion 13b is lower than that in the embodiment. Thus, it is possible to further reduce the stress concentration of the fusible parts 6 resulting from the heat shrinkage produced after the resin molding.

(42) (Others)

(43) Although, in the embodiment, the reinforcement portions 7 and 7A are provided using the bus bar 2, they may be naturally provided using a member other than the bus bar 2, as long as the member has a lower heat shrinkage rate than the insulating resin portion 10, and has a higher strength than the insulating resin portion.

(44) Although, in the embodiment, the reinforcement portions 7 and 7A are provided only within the coupling portions 13b to 13d, which are positioned between the adjacent fusible parts 6, they may be provided within the coupling portions 13a and 13e, which are positioned on both ends.

REFERENCE SIGNS LIST

(45) 1: fuse unit 2: bus bar 3: power supply side terminal 5a and 5b: load side terminal 6: fusible part 7 and 7A: reinforcement portion 10: insulating resin portion 11: first resin portion 12: second resin portion