Wiring component for electrical appliances

Abstract

Wiring component for electrical equipment (1), comprising: a large number of busbars (2); a housing (3) made of resin in which the plurality of busbars (2) are exposed at both ends (2ea, 2eb) and are embedded inside at a distance from each other, and a hollow section (3v) is provided in which an opening is formed through which an intermediate section (2m) of each of the plurality of busbars (2) is exposed; a filling material (5) made of an elastomer, which is filled into the hollow section (3v) and covers an entire circumference of the busbars (2) at least at a boundary section between the intermediate sections (2m) and the housing (3); and a lid element (4) with a lid section (4c) closing the opening and an embedded section (4b) extending from the lid section (4c) towards the filling material (5) and embedded in the filling material (5).

Description

Technical field

[0001] The present application relates to a wiring component for electrical devices. Background of the invention

[0002] To promote the reduction of the number of wiring harnesses for electrical devices, the reduction of cable diameters, and the electrification of mechanically operated parts (power steering, engine intake and exhaust devices) in a passenger car with an internal combustion engine, it is desirable to increase the voltage to a level higher than the nominal voltage of 12 V. If, in this case, a circuit to which the nominal voltage of 12 V and the increased high voltage are applied is provided in a circuit of an electrical junction box for power distribution, the occurrence of a leakage current due to the potential difference is likely.Therefore, a circuit unit with a structure was disclosed in which an insulating resin is filled between a low-voltage busbar and a high-voltage busbar, as well as between high-voltage busbars in which a leakage current may occur, in order to prevent the occurrence of the leakage current (see, for example, patent document 1). Objections Patent document

[0003] Patent document 1: Japanese patent application Disclosure No. 2002-27636 (paragraphs 0015 to 0022, Fig. 1 to Fig. 3) Description of the invention Problem to be solved by the invention

[0004] However, since the metallic busbar and the resin it contains have different coefficients of linear expansion, a tiny gap can form due to displacement caused by a temperature change. Therefore, if the busbar is exposed to the outside environment, there is a possibility that fluid, such as water, seeping through this tiny gap from one end to the other, creating a leakage current at the other end connected to another device.

[0005] The present application discloses a technique for solving the problem described above, wherein one objective of the present application is to achieve a highly reliable wiring component for electrical devices that prevents leakage current. Means to solve the problem

[0006] A wiring component for electrical equipment disclosed in the present application comprises a plurality of busbars, a housing made of resin in which the plurality of busbars are exposed at both ends and embedded at a distance from one another, and in which a hollow section is provided with an opening formed therein through which an intermediate section of each of the plurality of busbars is exposed, as well as a filling material made of an elastomer which is filled into the hollow section and covers an entire circumference of the busbars at least at a boundary section between the intermediate sections and the housing, and a cover element with a cover section closing the opening and an embedded section which extends from the cover section to the filling material and is embedded in the filling material. Advantageous effect of the invention

[0007] With the wiring component for electrical devices disclosed in the present application, it is possible to obtain a very reliable wiring component for electrical devices that prevents leakage current caused by a gap between the busbars and the housing, since at least the boundary section between the intermediate sections of the busbars and the housing is covered with the elastomer. Brief description of the drawings Fig. 1A and Fig. Figure 1B is a perspective view of a wiring component for electrical devices or a perspective view in which part of the component is transparent, according to embodiment 1. Fig. Figure 2 is a perspective view of the wiring component for electrical devices, in which part of it is transparent, according to embodiment 1. Fig. Figure 3 is a top view of the wiring component for electrical devices according to embodiment 1. Fig. 4A and Fig. Figures 4B are each a different cross-sectional view of the wiring component for electrical devices according to embodiment 1. Fig. Figure 5 is a perspective view of a wiring component for electrical devices according to embodiment 2. Fig. Figure 6 is a cross-sectional view of the wiring component for electrical devices according to embodiment 2. Fig. Figure 7 is a perspective view of a cover element of a wiring component for electrical devices according to embodiment 3. Fig. Figure 8 is a cross-sectional view of the wiring component for electrical devices according to embodiment 3. Fig. Figure 9 is a perspective view of a cover element of a wiring component for electrical devices according to embodiment 4. Fig. 10 is a cross-sectional view of the wiring component for electrical devices according to embodiment 4. Fig. Figure 11 is a perspective view of an integrally formed product consisting of busbars and a housing in a wiring component for electrical equipment according to embodiment 5. Fig. Figure 12 is a perspective view of a cover element of a wiring component for electrical devices according to embodiment 6. Fig. 13 is a cross-sectional view of the wiring component for electrical devices according to embodiment 6. Fig. Figure 14 is a perspective view of an integrally formed product consisting of busbars and a housing in a wiring component for electrical equipment according to embodiment 7. Fig. Figure 15 is a perspective view of a cover element of the wiring component for electrical devices according to embodiment 7. Fig. Figure 16 is a cross-sectional view of the wiring component for electrical devices according to embodiment 7. Fig. Figure 17 is a perspective view of an integrally formed product consisting of busbars and a housing in a wiring component for electrical equipment according to embodiment 8. Fig. Figure 18 is a perspective view of a cover element of the wiring component for electrical devices according to embodiment 8; Fig. Figure 19 is a perspective view of an integrally formed product consisting of busbars and a housing in a wiring component for electrical equipment according to embodiment 9. Fig. Figure 20 is a perspective view of a cover element of the wiring component for electrical devices according to embodiment 9. Fig. Figure 21 is a perspective view of the wiring component for electrical devices according to embodiment 9. Fig. Figure 22 is a cross-sectional view of the wiring component for electrical devices according to embodiment 9. Embodiments of the invention, embodiment 1

[0008] Fig. 1A, Fig. 1B to Fig. 4A and Fig. Section 4B serves to describe a design of a wiring component for electrical devices according to embodiment 1. Fig. 1A is a perspective view of the wiring component for electrical devices seen from above. Fig. 1B is a perspective view of a housing in through view to show the condition of a cover element and busbars from the same viewpoint as Fig. to show 1A, and Fig. Figure 2 is a perspective view of the enclosure in a see-through view to show the condition of the cover element and busbars when the wiring component for electrical equipment is viewed from below. Furthermore, Fig. 3. A top view of the housing in a see-through view to show the condition of the busbars of the wiring component for electrical equipment. Fig. 4A is a cross-sectional view drawn from a line AA. Fig. 3 corresponds to, and Fig. 4B is a cross-sectional view formed by a line BB. Fig. 3 corresponds.

[0009] Before describing the design of the wiring component 1 for electrical devices according to each embodiment of the present application, a basic design and an application mode that are common for a conventional wiring component for electrical devices will be described. The basic design consists of the fact that, as in Fig. 1A and Fig. Figure 3 shows that both ends (end section 2ea, end section 2eb) of a busbar 2, whose intermediate section is embedded in the housing 3, protrude from the housing 3. In many cases, for example, in a state where one end (end section 2ea) is connected to another device requiring a hermetic seal or to a wiring component, the other end (end section 2eb) is exposed to the external environment.

[0010] Therefore, it should not be possible for water to penetrate another device connected via the electrical wiring component 1. For example, if the electrical wiring component, which has a gap between the busbar and resin as described in the prior art, is used in a harsh environment with repeated rapid temperature changes, a pressure differential will develop between the inside and outside of the component, allowing liquid to enter the gap. The ingress of liquid could then create a path and cause a short circuit between exposed sections of the busbars carrying different voltages. Therefore, a watertight design is required for the electrical wiring component where the busbars are exposed externally.

[0011] Therefore, the wiring component 1 for electrical devices according to embodiment 1 of the present application is designed such that the entire circumference of intermediate sections 2m of the busbars 2, which are embedded in a housing 3 by integral molding, is covered with a filler material 5 made of an elastomeric resin. More precisely, as in Fig. 1B, Fig. 2 and Fig. As shown in Figure 4B, a hollow section 3v is formed in the housing 3, in which the intermediate sections of the busbars 2 are embedded with their two ends (end section 2ea and end section 2eb) exposed. This hollow section 3v is open in the vertical direction (z-direction in the figures) and in which the intermediate sections 2m of the busbars 2 are exposed. The entire circumference of the intermediate sections 2m of the busbars 2 is covered with the elastic filler material 5, which is formed by the curing of a potting material poured into the hollow section 3v, as shown in Figure 4B. Fig. 4A shown.

[0012] For example, a busbar 2 is formed from a conductor with excellent electrical conductivity, such as Cu and Al, and a total of two busbars, namely a busbar 2A and a busbar 2B, to which different voltages are applied, are embedded at a distance by overmolding in the housing 3. For the housing 3, in addition to a thermoplastic resin such as polyphenylene sulfide (PPS), a thermosetting resin can also be used, as long as the injection molding process can be carried out and the resin has the strength required for the housing 3.

[0013] Then, in the integrally formed product consisting of busbars 2 and housing 3, a lower opening (negative side in the z-direction) of the vertically open hollow section 3v is closed by attaching a support element 9, and the potting compound is poured in from an upper opening (positive side in the z-direction). As the poured potting compound hardens, the filler material 5 forms, covering the intermediate sections 2m. Furthermore, before the potting compound hardens, a cover element 4 is positioned to close the other opening, so that a section (an embedded section 4b) is embedded in the potting compound, thus completing the wiring component 1 for electrical devices.

[0014] Since the resin material forming the housing 3 and the metal material forming the busbars 2 have different coefficients of linear expansion, a displacement occurs between the housing 3 and the busbars 2 in the wiring component 1 for electrical devices, which is designed as described above, due to temperature changes. Because the housing 3 uses a resin material with a certain stiffness (flexural strength, tensile strength), it is difficult to track this displacement, and as described in the prior art, a gap forms between the housing 3 and the busbars 2.

[0015] However, since elastomeric resin, such as silicone rubber, is used as the potting material for the filler material 5, the potting material does not have the rigidity of the housing, but rather a flexibility compared to the resin that forms the housing 3, so that the potting material can follow the displacement of the busbars 2. For this reason, at least in the section covering the busbars 2, no gap forms between the busbars 2 and the potting material.

[0016] Furthermore, the adhesion between the housing 3 and the potting compound is also good in the hollow section 3v. Therefore, even if gaps continuously form between a busbar 2 and the housing 3 between the end section 2ea and the hollow section 3v, and between the end section 2eb and the hollow section 3v, these gaps are interrupted by the filling material 5. Thus, even if water penetrates from the end section 2ea into the hollow section 3v, the water does not reach the end section 2eb, and vice versa.

[0017] It is noted that, as described above, the filler material 5 is superior to the housing 3 in terms of flexibility and adhesion, i.e., its function in maintaining the seal, but has lower stiffness than the resin material from which the housing 3 is formed. Therefore, when an external force is applied, there is a possibility of deformation, spalling, or similar damage occurring, thus compromising the seal. The cover element 4 is designed to close the opening of the upper part of the hollow section 3v and prevent any external force from being exerted on the filler material 5.

[0018] The cover element 4 is formed from resin with the same stiffness as the housing 3. At the distal end of a column-shaped section 4j, extending from the opening-closing cover section 4c towards the filler material 5, an embedded section 4b is provided. This section is embedded in the filler material 5 and extends in the direction (y-direction) perpendicular to the extension direction (z-direction). When the potting compound has cured to form the filler material 5, the embedded section 4b exhibits an anchoring effect with respect to the attachment / removal direction (z-direction) of the cover element 4 and has a structure capable of preventing the cover element 4 from coming loose.Furthermore, the cover element 4 is provided with crimp ribs 4cp on intermediate sections on four sides of the cover section 4c and has a structure that can be temporarily fixed in relation to the opening of the hollow section 3v of the housing 3. Therefore, the cover element 4 itself is not easily detachable even in a state where the anchoring effect of the cover element 4 is not present before the potting material has hardened.

[0019] This prevents the cover element 4 from coming loose and the filler element 5 from being exposed, even when a large external force is exerted on it in an environment with strong vibrations, shocks, or in high-pressure car washes. To prevent an external force from acting on the filler material 5, the lower opening of the hollow section 3v can be closed by the support element 9, which has the same stiffness as the housing 3 or the cover element 4. In this case, the support element 9 can also be provided with a section corresponding to the embedded section 4b, which, like the cover element 4, provides an anchoring effect in the filler material 5.

[0020] However, the support element 9 need not necessarily be designed in such a way that another element, in an assembled state as a subassembly (arrangement), exerts an external force on the filler material 5 via the lower opening. In this case, the support element 9 can, for example, be formed from a strip material, so that the support element 9 is only used for the period of time required to fill the potting compound and is then removed after the potting compound has cured and the filler material 5 has formed.

[0021] Furthermore, in the wiring component 1 for electrical devices of the present application, the upwardly and downwardly open hollow section 3v is formed in the integrally formed product stage. This makes it possible to carry out the integral forming with only one upper and one lower mold, without using a slide mechanism, which offers the advantage of reducing the mold effort. Design 2

[0022] According to embodiment 2, a design is described which prevents the detachment of the cover element in a state prior to the hardening of the potting material as filler material even better than the case described in embodiment 1. Fig. 5 and Fig. Figure 6 shows diagrams describing the design of a wiring component for electrical devices according to embodiment 2. Fig. Figure 5 is a perspective view of the wiring component for electrical devices from above, and Fig. 6 is a cross-sectional view corresponding to a line CC from Fig. 5.

[0023] It should be noted that the wiring component for electrical devices according to embodiment 2 can be designed the same way as in embodiment 1, with the exception of preventing the cover element from detaching, whereby the description of the same section is omitted and referred to as belonging to embodiment 1. Fig. 4B is referred to.

[0024] In the wiring component 1 for electrical devices according to embodiment 2, as in Fig. 5 and Fig. As shown in Figure 6, snap-fit ​​projections 4cf are provided on intermediate sections between two opposite sides of the cover section 4c, and recessed sections 3a, which engage with the snap-fit ​​projections 4cf, are provided on upper sections of an outer side surface 3fx that surrounds the hollow section 3v of the housing 3. In other words, the snap-fit ​​projections 4cf and the recessed sections 3a act as a snap-fit ​​mechanism to form a snap connection that controls the movement of the cover element 4 in the direction in which the cover element 4 is detached from the housing 3. The assembly sequence is the same as in embodiment 1. After the busbars 2 are overmolded with the resin from which the housing 3 is formed, the support element 9 is attached to the housing 3, and the cover element 4 is attached before the potting compound has cured.

[0025] After the potting compound has cured and the filler material 5 has formed, the embedded section 4b exhibits an anchoring effect, preventing the cover element 4 from detaching. The present embodiment differs from embodiment 1 in that, during periods when the anchoring effect is not present, temporary fastening is achieved using the snap-fit ​​connection between the snap-fit ​​projections 4cf and the recessed sections 3a, resulting in a greater fastening force on the housing 3 than in the case of temporary fastening by the ribs 4cp. This design is particularly useful when a secure temporary fastening is required before the potting compound has cured, considering the fastening environment of the cover element 4. embodiment 3

[0026] According to embodiment 3, a shape of the embedded section of the cover element is defined, unlike the wiring component for electrical devices according to embodiment 1 or embodiment 2. Fig. 7 and Fig. Figure 8 shows diagrams describing the design of a wiring component for electrical devices according to embodiment 3. Fig. Figure 7 is a perspective view of a lid element seen from above, and Fig. Figure 8 is a cross-sectional view accordingly Fig. 4A.

[0027] The wiring component for electrical devices according to embodiment 3 can be designed the same way as in embodiment 1 or embodiment 2, except for the shape of the embedded section, the description of which is omitted and refers to the section belonging to embodiment 1. Fig. 1A, Fig. 1B, Fig. 2 and Fig. 3 is referred to.

[0028] In the case of wiring component 1 for electrical devices according to embodiment 3, as shown in Fig. 7 and Fig. As shown in Figure 8, the cross-sectional shape of the embedded section 4b of the cover element 4 is rhombus-shaped: that is, it is inclined with respect to the insertion direction towards the filling material 5. More precisely, the embedded section 4b is provided with an inclined surface such that, towards the distal end and away from the cover section 4c, a surface is extended in the direction perpendicular to the extension direction from the cover section 4c, and with an inclined surface such that, towards the distal end, a surface is narrowed with respect to the fully extended surface.

[0029] In this case, too, the assembly sequence is the same as in embodiment 1. After the busbars 2 are overmolded with the resin from which the housing 3 is formed, the support element 9 is attached to the housing 3, and the cover element 4 is fitted before the filler material 5 (potting compound) has cured. When the embedded section 4b enters the filler material 5, the filler material 5 can easily flow around it along the inclination of the embedded section 4b, thus reducing the possibility of air entering the filler material 5. For example, if a surface runs perpendicular to the insertion direction, as in Fig. As shown in Figure 4A, when the embedded section 4b enters the filler material 5, air enters before the filler material 5 surrounds the embedded section 4b, and when the potting compound has cured, air bubbles inside become connected, which can cause a leak path.

[0030] Particularly in a setup where the fill quantity of the fill material 5 is low, if air bubbles penetrate the interior of the fill material 5 when the cover element 4 is attached, the ratio of air bubbles to the fill quantity of the fill material 5 increases, thus increasing the likelihood of a leak path being created. This enhances the advantage of the present design. Furthermore, if the assembly time of the cover element 4 is to be minimized, it is necessary to increase the assembly speed of the cover element 4 during the assembly process. In the case of an assembly process where the assembly speed is high, because air bubbles are likely to be mixed before the fill material 5 circulates around the embedded section 4b, the setup with the embedded section 4b inclined relative to the insertion direction is effective.In particular, because the cross-sectional shape is rhombic, the embedded section 4b has an inclined surface, so that the area is narrowed from the fully extended section to the cover section 4c, which further prevents the filler material 5, which surrounds the embedded section 4b, from detaching.

[0031] After the potting compound has cured to form the filler material 5, the embedded section 4b has an anchoring effect for the filler material 5 to prevent the cover element 4 from coming loose. Design 4

[0032] In embodiment 4, the volume of the embedded section of the lid element is increased in order to reduce the amount of filler material used, in contrast to the wiring component for electrical devices according to embodiments 1 to 3. Fig. 9 and Fig. Figure 10 are diagrams describing the design of a wiring component for electrical devices according to embodiment 4. Fig. Figure 9 is a perspective view of a lid element seen from above, and Fig. 10 is a cross-sectional view accordingly Fig. 4A.

[0033] It should be noted that the wiring component for electrical devices according to embodiment 4 can have the same design as in embodiments 1 to 3, with the exception of the shape of the embedded section, whereby the description of the same sections is omitted and referred to as belonging to embodiment 1. Fig. 1A, Fig. 1B, Fig. 2 and Fig. 3 is referred to.

[0034] In the case of wiring component 1 for electrical devices according to embodiment 4, as shown in Fig. 9 and Fig. As shown in Figure 10, the volume of the embedded section 4b of the cover element 4 is larger than that of the embedded sections 4b of embodiments 1 to 3, and the columnar section 4j does not differ from the embedded sections 4b. The assembly sequence is the same as in embodiment 1. After the busbars 2 have been overmolded using the resin from which the housing 3 is formed, the support element 9 is attached to the housing 3, and the cover element 4 is attached before the potting compound has cured.

[0035] According to embodiment 4, a structure is provided in which the volume of the section of the cover element 4 inserted into the filler material 5 (the embedded section 4b including the section corresponding to the columnar section 4j in embodiment 1) is increased. Although the fill quantity of the filler material 5 is reduced in this case, it can be further reduced as long as the quantity of filler material 5 is sufficient to fulfill the waterproof function, which is the purpose of the filler material 5, and the insulating performance between busbars with different voltages. Therefore, the fill quantity of the filler material 5 can be reduced by increasing the size of the embedded part 4b until the fill quantity reaches the quantity described above. In general, the material costs of the potting compound from which the filler material 5 is formed are higher than those of the resin material from which the housing 3 and the like are formed.Therefore, according to the present interpretation, the material costs are lower than those of embodiment 1 to embodiment 3. Design 5

[0036] According to embodiment 5, a through-hole is provided in an intermediate section of a busbar, so that the through-hole facilitates the circulation of the filling material. Fig. Figure 11 is a perspective view of an integrally shaped product consisting of busbars and the housing in top view to describe a design of a wiring component for electrical devices according to embodiment 5.

[0037] The wiring component for electrical devices according to embodiment 5 can be designed the same way as in embodiments 1 to 4, with the exception of the shape of the busbars, whereby the description of the same sections is omitted and those belonging to embodiment 1 are omitted. Fig. 4A and Fig. 4B can be used to describe the relationship between the embedded section and the filler material.

[0038] In the case of wiring component 1 for electrical devices according to embodiment 5, as shown in Fig. As shown in Figure 11, the through-hole 2h, which extends in the vertical direction (z), is provided on a surface of the busbar 2 facing the opening in the intermediate section 2m, which is to be covered with the filler material 5. The assembly sequence is the same as in embodiment 1. That is, after the busbars 2 have been overmolded using the resin from which the housing 3 is formed, the support element 9 is attached to the housing 3, and the cover element 4 is attached before the potting material has cured.

[0039] Since it is desirable to fill space 3v with the filler material 5 without trapping air bubbles, sufficient time is required to fill space 3v with the filler material 5. However, it is difficult to completely remove the air bubbles generated within the filler material 5 to the atmosphere simply by injecting the potting compound. Therefore, in embodiment 5, the through-hole 2h, which runs vertically through the busbar 2, is formed in the intermediate section 2m of the busbar 2, which is exposed in the hollow section 3v.

[0040] When the potting compound is injected into the integrally molded product, where the support element 9 is attached to the bottom of the hollow section 3v, the potting compound is gradually poured in from the bottom of the hollow section 3v, and air bubbles that accumulate on the lower surface of the busbar 2 can be released from the through-hole 2h. This results in a structure in which air bubbles are less likely to accumulate within the filler material 5 formed by the curing of the potting compound. Furthermore, the through-hole 2h can be used to position the busbar 2 during overmolding, and the through-hole 2h of the busbar 2 is not exposed to the outside after the potting compound has been poured in.

[0041] When busbars are overmolded using the same resin as the housing, their positioning is critical. If a mold pin remains inserted in the through-hole during casting, the section of the busbar where the through-hole is formed will be exposed after casting. At this stage, a conductive substance such as salt can deposit on the electrical wiring component, potentially causing a short circuit. Therefore, in some cases, it is necessary to fill the exposed section with an adhesive.However, in the construction of the wiring component 1 for electrical devices according to embodiment 5, the through-hole 2h, which is used for positioning the busbar 2, is not exposed, since the section exposed by the housing 3 in which the through-hole 2h is formed is to be covered with the filler material 5. This has the advantage that an additional application of adhesive is not required. Design 6

[0042] According to embodiment 6, a cover plate covering the upper surface of the filler material is provided on the lid element to reduce the exposed area of ​​the filler material, unlike the wiring component 1 for electrical devices according to embodiments up to embodiment 5. Fig. 12 and Fig. Figure 13 are diagrams describing a design of a wiring component for electrical devices according to embodiment 6. Fig. Figure 12 is a perspective view of a lid element seen from below, and Fig. Figure 13 is a cross-sectional view accordingly Fig. 4A.

[0043] The wiring component for electrical devices according to embodiment 6 can be designed the same way as in embodiments 1 to 5, with the exception of the cover plate of the lid element, whereby the description of the same sections is omitted and referred to those belonging to embodiment 1. Fig. 1A, Fig. 1B, Fig. 2 and Fig. 3 is referred to.

[0044] In the case of wiring component 1 for electrical devices according to embodiment 6, as shown in Fig. 12 and Fig. As shown in Figure 13, a cover plate 4t, which covers an upper surface of the fill material 5, is provided in an intermediate section in the columnar section 4j of the cover element 4 between the embedded section 4b and the cover section 4c. In this configuration, even if a harmful substance that adversely affects the fill material 5 penetrates through a gap between the cover element 4 and the upper opening of the hollow section 3v, the upper surface of the fill material 5 is covered by the cover plate 4t, thereby reducing the area of ​​the upper surface that comes into contact with the harmful substance. Furthermore, the entire upper surface of the fill material 5 can be covered by the cover plate 4t by adapting the outer shape of the cover plate 4t in the xy-plane to the inner circumferential surface of the hollow section 3v. Model 7

[0045] In embodiment 7, a design is described in which a labyrinth structure is formed between the lid element and the housing to reinforce the insulation between the filling material and the outside. Fig. 14 to Fig. Figure 16 are diagrams describing a design of a wiring component for electrical devices according to embodiment 7. Fig. Figure 14 is a perspective view of an integrally formed product consisting of busbars and a housing, seen from above. Fig. Figure 15 is a perspective view of a lid element seen from below, and Fig. Figure 16 is a cross-sectional view accordingly Fig. 4A.

[0046] It should be noted that the wiring component for electrical devices according to embodiment 7 can use the same design as in embodiments 1 to 6, with the exception of the labyrinthine structure between the cover element and the housing, whereby the description of identical sections is omitted and referred to those belonging to embodiment 1. Fig. 1A, Fig. 1B, Fig. 2 and Fig. 3 is referred to.

[0047] In the wiring component 1 for electrical devices according to embodiment 7, as shown in Fig. As shown in Figure 14, a groove section 3d, recessed in the z-direction, is formed over the entire circumference of the inner edge section of the upper opening of the hollow section 3v in the housing 3, and a web section 3r, projecting in the z-direction, is formed over the entire circumference on the inside of the groove section 3d in the xy-plane. Accordingly, in the cover element 4, as shown in Fig. Figure 15 shows a web section 4r corresponding to the groove section 3d, provided on the outer edge section of a surface 4ff of the cover section 4c opposite the hollow section 3v over the entire circumference, and a groove section 4d corresponding to the web section 3r is formed within the web section 4r over the entire circumference.

[0048] Accordingly, when the cover element 4 is placed on the housing 3, as shown in Fig. As shown in Figure 16, the web section 3r is fitted into the groove section 4d, and the web section 4r is fitted into the groove section 3d, forming a labyrinth seal structure and insulating the hollow section 3v from the outside. That is, the groove section 4d, the web section 3r, the groove section 3d, and the web section 4r are combined to function as a labyrinth seal mechanism. By forming the labyrinth seal structure, it is possible to prevent liquids, such as salt water or water, from penetrating from a gap between the cover element 4 and the housing 3 when the wiring component 1 for electrical equipment is installed outdoors. Design 8

[0049] According to embodiment 8, a design is described in which the cover element and the housing are fastened via a threaded structure. Fig. 17 and Fig. Figure 18 are diagrams describing a design of a wiring component for electrical devices according to embodiment 8. Fig. Figure 17 is a perspective view of an integrally formed product consisting of busbars and a housing, seen from above, and Fig. Figure 18 is a perspective view of a lid element seen from below.

[0050] The wiring component for electrical devices according to embodiment 8 can be designed in the same way as in embodiment 1, embodiment 3 to embodiment 7, with the exception of the assembly for attaching the cover element and the housing to each other, whereby the description of identical sections is omitted and the relationship between the busbars, the embedded section and the filling material is referred to as that belonging to embodiment 1. Fig. 4A and Fig. 4B is referred to.

[0051] In the case of wiring component 1 for electrical devices according to embodiment 8, as shown in Fig. As shown in Figure 17, at least the opening of the hollow section 3v of the housing 3 is formed in a circular cylindrical shape in the xy-plane, and an internal thread 3fs is formed on the inner circumferential surface of the upper opening. Accordingly, in the Fig. In the lid element 4 shown in Figure 18, the lid section 4c is circularly formed, and an external thread 4cms corresponding to the internal thread 3fs is formed on the outer circumferential surface.

[0052] This means that when the cover element 4 is placed onto the housing 3, the cover element 4 is inserted while being rotated along the thread and tightened by the threaded structure, resulting in a greater tightening force than if the cover element 4 were temporarily fixed simply by the (squashed) ribs 4cp. Furthermore, the fastening status of the cover element 4 can be easily visually determined compared to temporary fastening with the ribs 4cp. For example, if the direction of the load exerted on the cover element 4 is inclined from the vertical direction (z-direction) when temporarily fastened with the ribs 4cp, there may be a situation where the cover element 4 is fastened with an unquashed rib 4cp, and the expected tightening force is not exerted.

[0053] Even in such a case, the cover element 4 is positioned at a specific height relative to the housing 3, and there is a possibility that it will be incorrectly recognized as being fastened. In contrast, the fastening method for the cover element 4 using the threaded structure is simple, and the aforementioned concerns can be eliminated. Furthermore, the cover element 4 can be loosened with the threaded structure, and even if the fastening of the cover element 4 fails, it can be repeatedly fastened and loosened before the potting compound has cured. Design 9

[0054] In each of the embodiments described above, an example was described in which the hollow section is provided for the collective exposure of the intermediate sections of a plurality of busbars. Embodiment 9 describes an example in which several hollow sections, separated by a partition, are provided to expose individual intermediate sections of the busbars. Fig. 19 to Fig. Figure 22 are diagrams describing a design of a wiring component for electrical devices according to embodiment 9. Fig. Figure 19 is a perspective view of an integrally formed product consisting of busbars and a housing, seen from above. Fig. Figure 20 is a perspective view of a lid element seen from below, and Fig. Figure 21 is a perspective view of the wiring component for electrical devices seen from above. Fig. 22 is a cross-sectional view along a line DD from Fig. 21.

[0055] It should be noted that the wiring component for electrical devices according to embodiment 9 can use the same design as in embodiments 1 to 8, which differs from the design in which the hollow section is individually provided according to each busbar, with the description of the same section being omitted.

[0056] In the case of wiring component 1 for electrical devices according to embodiment 9, as shown in Fig. As shown in Figure 19, the intermediate sections 2m of the busbars 2A and 2B are divided by a partition 3p, and hollow sections 3vA and 3vB are provided to expose the busbars 2A and 2B individually, respectively. Fig. As shown in Figure 20, the lid element 4 is provided with column-shaped sections 4jA and 4jB, which extend to the hollow sections 3vA and 3vB respectively, and in which the embedded sections 4bA and 4bB are formed at the respective distal ends in the lid section 4c, which jointly closes the two hollow sections 3vA and 3vB.

[0057] The assembly sequence is the same as in the embodiments described above, and after the busbars 2 have been overmolded using the resin that forms the housing 3, the support element 9 is attached to the housing 3. However, the potting compound (filler 5A and 5B) serving as filler material 5 is potted separately in each of the hollow sections 3vA and 3vB. After the potting compound has been injected into each of the hollow sections 3vA and 3vB, the cover element 4 is fitted before the potting compound has cured as filler material 5.

[0058] Once the potting compound has cured to form the filler material 5, as shown in Fig. 21 and Fig. As shown in Figure 22, each of the embedded sections 4bA and 4bB exhibits an anchoring effect in the fastening / loosening direction (z-direction) of the cover element 4 and has a structure capable of preventing the cover element 4 from coming loose. Furthermore, since the air and creepage distance between the busbars 2A and 2B can be ensured in advance by the partition 3p, the insulation between the busbars 2A and 2B can be reliably ensured even if the fill state of the fill material 5 changes.

[0059] It should be noted that the present example describes an instance where the embedded section 4b is provided for each of the multiple hollow sections 3v, although this is not a restriction. For example, it may be provided for each of the hollow sections 3v with respect to a cover section 4c. Furthermore, an example has been described where the multiple hollow sections 3v are closed together, although this is not a restriction, and the cover element 4 may be provided for each of the hollow sections 3v.

[0060] Although various exemplary embodiments and examples are described in the present application, various features, aspects, and functions described in one or more embodiments are not necessarily associated with an application of the content disclosed in a particular embodiment and may be applicable to any embodiment, either alone or in their various combinations. Accordingly, countless variants are conceivable within the scope of the technology disclosed herein, which are not illustrated. These include, for example, the case in which at least one component is modified, added, or omitted, and the case in which at least one component is removed and combined with a component disclosed in another embodiment.

[0061] An example was described in which PPS is used for the housing 3, copper for the busbars 2, and silicone rubber for the filler material 5, but this is not a limitation. For example, another thermosetting elastomer or a thermoplastic elastomer can also be used as filler material 5, as long as it exhibits good adhesion and flexibility; any so-called elastic polymer material is applicable.

[0062] In this example, the entire intermediate section 2m arranged in the hollow section 3v is covered with the filling material 5, which extends continuously to the boundary section with the housing 3. However, this is not necessarily a limitation with regard to preventing the ingress of water through a gap formed between the end section 2ea and the end section 2eb. To block only the leakage path between busbar 2A and busbar 2B in the hollow section 3v, as in embodiment 9, for example, it is sufficient to form the partition 3p, which extends in the direction of the xz-plane in the housing 3 and divides the space between busbar 2A and busbar 2B in the hollow section 3v.In this case, it is not necessary to cover the further intermediate section of the intermediate section 2m with the filling material 5, and if the boundary section between the intermediate section 2m and the housing 3 is covered over its entire circumference, both the blocking of the leak path and the prevention of water ingress through the gaps between the housing 3 and the busbars 2 can be achieved.

[0063] Furthermore, the material from which the housing 3 is formed is not limited to thermoplastic resin, and a thermosetting resin can also be used, provided it is a material in which the busbars 2 are embedded and which possesses the rigidity of the housing. An example has also been described in which the hollow section 3v is open to the top and bottom, so that molding can be carried out using only the upper and lower molds, although this is not a limitation, and only one side can be open as long as the filler material 5 can be inserted. In addition to aluminum, any conductor with excellent conductivity can be applied to the busbars 2, and the number of busbars 2 is not limited to two.

[0064] As described above, the wiring component 1 for electrical devices according to the present application is designed to comprise: a plurality of busbars 2, a resin housing 3 in which the plurality of busbars 2 are exposed at both ends (end section 2ea, end section 2eb) and embedded at a distance from each other, and which has a hollow section 3v in which an opening is formed through which an intermediate section 2m of each of the plurality of busbars 2 is exposed, a filler material 5 of an elastomer which is filled into the hollow section 3v and covers an entire circumference of the busbars 2 at least at a boundary section between the intermediate sections 2m and the housing 3, and a cover element 4 with a cover section 4c which closes the opening, and an embedded section 4b.which extends from the cover section 4c to the filler material 5 and is embedded in the filler material 5. This prevents leakage current caused by the gap between the busbars 2 and the resin forming the housing 3, thus ensuring the high reliability of the wiring component 1 for electrical devices. Since the opening is closed by the cover section 4c, the filler material 5, which exhibits excellent adhesion between the busbars 2 and the housing 3 and good compliance with displacements, but lower stiffness, is protected from external forces and its adhesion is maintained.

[0065] If the hollow section 3v is designed to have a second opening on the opposite side from the opening to be closed by the lid section 4c, it is possible to form the part using an upper and a lower mold without using a slide tool.

[0066] Since the housing 3 is an integrally formed product with the plurality of busbars 2, the housing 3 can be easily manufactured, and in particular, if the housing 3 has the second opening, the housing 3 can be more easily manufactured using only an upper and a lower mold.

[0067] If the embedded section 4b is designed such that the section with the surface extends in a direction (xy direction) perpendicular to a direction (z direction) in which the embedded section extends from the cover section 4c towards a distal end of the embedded section and away from the cover section 4c, it can be prevented that the cover element detaches due to the anchoring effect after the filler material 5 has cured.

[0068] If the embedded section 4b is designed such that the section with the area extending towards the distal end forms an inclined surface, narrowing the area with increasing distance from the cover section 4c, it is possible to prevent the inclusion of air bubbles in the filling material 5 when the cover element 4 is attached. Furthermore, if an inclined surface is designed such that it narrows the area from the fully extended surface of the section towards the cover section 4c, it is possible to further prevent the separation of the filling material 5 surrounding the embedded section 4b.

[0069] If the through-hole 2h is formed on the surface of the intermediate section 2m facing the opening, the air bubbles can escape as the filling material 5 is progressively poured in.

[0070] If the filling material 5 is designed to cover the entire circumference over the entire length of the intermediate sections 2m, the leakage current between the busbars 2 can be reliably prevented even if the multiple busbars 2 are arranged without a partition in the hollow section 3v.

[0071] If the projecting web section 4r and the recessed groove section 4d are formed over the entire circumference of the outer edge section of the surface 4ff of the cover section 4c facing the opening, and a second groove section (groove section 3d) and a second web section (web section 3r), which are to be adapted to the web section 4r and the groove section 4d respectively, are formed in the inner edge section of the opening of the housing 3, the labyrinthine structure can be formed to reliably prevent water from entering through the gap between the cover section 4c and the opening.

[0072] If the cover element 4 and the housing 3 are provided with the snap-fit ​​mechanism to form the snap connection which controls the movement of the cover element 4 towards removal from the housing 3 when the cover section 4c closes the opening, the cover element 4 can be prevented from detaching from the housing 3 even before the potting material has cured.

[0073] Alternatively, if the external thread 4cms is formed on the outer circumferential surface of the cover section 4c and the corresponding internal thread 3fs is formed on the inner circumferential surface of the opening of the housing 3, it can also be prevented that the cover element 4 detaches from the housing 3 before the potting material has hardened. Reference symbol list

[0074] 1: Wiring component for electrical devices, 2: Busbar, 2ea, 2eb: End section, 2h: Through hole, 2m: Intermediate section, 3: Housing, 3a: Recessed section (snap-fit ​​mechanism), 3d: Grooved section (maze mechanism), 3fs: Internal thread, 3p: Partition, 3r: Web section (maze mechanism), 3v: Hollow section, 4: Cover element, 4b: Embedded section, 4c: Cover section, 4cf: Snap-fit ​​projection (snap-fit ​​mechanism), 4cms: External thread, 4cp: Rib, 4d: Grooved section (maze mechanism), 4j: Columnar section, 4r: Web section (maze mechanism), 4t: Cover plate, 5: Filler material

Claims

[1] Wiring component for electrical equipment (1), comprising: a large number of busbars (2); a housing (3) made of resin in which the plurality of busbars (2) are exposed at both ends (2ea, 2eb) and are embedded inside at a distance from each other, and a hollow section (3v) is provided in which an opening is formed through which an intermediate section (2m) of each of the plurality of busbars (2) is exposed; a filling material (5) made of an elastomer, which is filled into the hollow section (3v) and covers an entire circumference of the busbars (2) at least at a boundary section between the intermediate sections (2m) and the housing (3); and a lid element (4) with a lid section (4c) closing the opening and an embedded section (4b) extending from the lid section (4c) towards the filling material (5) and embedded in the filling material (5). [2] Wiring component for electrical devices (1) according to claim 1, wherein the hollow section (3v) is provided with a second opening on an opposite side of the opening, which is to be closed with the cover section (4c). [3] Wiring component for electrical equipment (1) according to claim 1 or 2, wherein the housing (3) is a product integrally formed with the plurality of busbars (2). [4] Wiring component for electrical devices (1) according to one of claims 1 to 3, wherein the embedded section (4b) has a section whose surface is extended in a direction perpendicular to a direction in which the embedded section extends from the cover section (4c) towards a distal end of the embedded section and away from the cover section (4c). [5] Wiring component for electrical devices (1) according to claim 4, wherein an inclined surface is formed such that from the section where the area is widened to the distal end of the embedded section (4b) the area narrows with increasing distance from the cover section (4c). [6] Wiring component for electrical devices (1) according to one of claims 1 to 5, wherein a through hole (2h) is provided on a surface facing the opening in the intermediate section (2m). [7] Wiring component for electrical devices (1) according to any one of claims 1 to 6, wherein the filling material (5) covers the entire circumference of the intermediate section (2m) over the entire length of the intermediate section (2m). [8] Wiring component for electrical devices (1) according to any one of claims 1 to 7, wherein a projecting web section (4r) in the thickness direction and a groove section (4d) recessed in the thickness direction are formed over the entire circumference of an outer edge section of a surface (4ff) of the cover section (4c) facing the opening, and a second groove section (3d) and a second web section (3r), which are adapted to the web section (4r) and the groove section (4d) respectively, are formed in an inner edge section of the opening of the housing (3). [9] Wiring component for electrical devices (1) according to any one of claims 1 to 8, wherein the cover element (4) and the housing (3) are provided with a snap-fit ​​mechanism to form a snap connection which controls the movement of the cover element (4) in the direction of removal from the housing (3) when the cover section (4c) closes the opening. [10] Wiring component for electrical devices (1) according to any one of claims 1 to 8, wherein an external thread (4cms) is formed on an outer circumference of the cover section (4c) and an internal thread (3fs) corresponding to the external thread (4cms) is formed on an inner circumference of the opening in the housing (3).

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