Lead block and rotary connector device

Abstract

The lead block (70) has a lead block body (71) and a plurality of bus bars (72). The plurality of bus bars (72) includes a plurality of exposed portions (73) that are exposed from the lead block body (71) and respectively correspond to the plurality of bus bars (72). The plurality of exposed portions (73) respectively extend in a long side direction (D4) and are arranged at intervals in an arrangement direction (D5) that is perpendicular to the long side direction (D4). The plurality of exposed portions (73) includes at least one first exposed portion (74). The at least one first exposed portion (74) includes a first surface (80) and a first additional surface (81) that is arranged on a back side of the first surface (80) in the arrangement direction (D5). The first surface (80) includes a first cut surface (90) that has an area smaller than an area of the first surface (80). The first additional surface (81) includes a first additional cut surface (91) that has an area smaller than an area of the first additional surface (81).

Description

Technical Field

[0001] The technology disclosed in this application relates to lead blocks and rotary connector devices. Background Technology

[0002] Patent documents 1 to 4 describe rotary connector devices with lead blocks.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 10-144371

[0006] Patent Document 2: Japanese Patent Application Publication No. 2003-022879

[0007] Patent Document 3: Japanese Patent Application Publication No. 2003-045598

[0008] Patent Document 4: International Publication No. 2018 / 047581 Summary of the Invention

[0009] The problem that the invention aims to solve

[0010] When considering the manufacturing cost of rotary connector devices, it is preferable to reduce the manufacturing cost of lead blocks.

[0011] The technical problem disclosed in this application is to reduce the manufacturing cost of lead blocks.

[0012] Methods for solving problems

[0013] The first feature of the lead block includes: a lead block body containing an electrically insulating material; and a plurality of busbars partially embedded within the lead block body and containing a conductive material. The plurality of busbars includes a plurality of exposed portions protruding from the lead block body and corresponding to each of the plurality of busbars. The plurality of exposed portions extend along a long side direction and are spaced apart in a configuration direction perpendicular to the long side direction. The plurality of exposed portions includes at least one first exposed portion. The at least one first exposed portion includes: a first surface; and a first additional surface disposed on the back side of the first surface in the configuration direction. The first surface includes a first cut surface having an area smaller than the area of ​​the first surface. The first additional surface includes a first additional cut surface having an area smaller than the area of ​​the first additional surface.

[0014] In the lead block with the first feature, a first cutting surface having an area smaller than that of the first surface is disposed on the first surface, and a first additional cutting surface having an area smaller than that of the first additional surface is disposed on the first additional surface. Therefore, during manufacturing, the amount of material discarded from cutting multiple busbars can be reduced. As a result, the manufacturing cost of the lead block can be reduced.

[0015] According to the lead block of the second feature, in the lead block of the first feature, the first surface includes a first adjacent surface adjacent to the first cut surface. The first additional surface includes a first additional adjacent surface adjacent to the first additional cut surface. The appearance of the first cut surface is different from the appearance of the first adjacent surface. The appearance of the first additional cut surface is different from the appearance of the first additional adjacent surface.

[0016] In the lead block with the second feature, the finishing processes for the first cut surface and the first additional cut surface can be omitted. As a result, compared with the case where the finishing processes for the first cut surface and the first additional cut surface are performed, the manufacturing cost of the lead block can be further reduced.

[0017] According to the lead block of the third feature, in the lead block of the second feature, the first cut surface is offset from the first adjacent surface in the configuration direction.

[0018] According to the lead block of the fourth feature, in the lead block of the second or third feature, the first additional cut surface is offset from the first additional adjacent surface in the configuration direction.

[0019] According to the lead block of the fifth feature, in any one of the lead blocks of the first to fourth features, the first additional cut surface is disposed on the back side of the first cut surface in the configuration direction.

[0020] In the lead block of the fifth feature, for example, when the connecting strip connecting multiple exposed parts is cut from the multiple exposed parts during manufacturing, deformation of the multiple exposed parts can be suppressed.

[0021] According to the lead block of feature 6, in any one of the lead blocks of features 1 to 5, the length of the first cut surface in the length direction is shorter than the length of the first surface in the length direction. The length of the first additional cut surface in the length direction is shorter than the length of the first additional surface in the length direction.

[0022] In the lead block of the sixth feature, compared to the case where the length of the first cut surface is equal to the length of the first face and / or the length of the first additional cut surface is equal to the length of the first additional face, the amount of material discarded from cutting multiple busbars can be further reduced. This further reduces the manufacturing cost of the lead block.

[0023] According to the lead block of feature 7, in any one of the lead blocks of features 1 to 6, a plurality of exposed portions include a second exposed portion. The second exposed portion includes: a second surface facing at least one first exposed portion in the configuration direction; and a second additional surface disposed on the back side of the second surface in the configuration direction. The second surface includes a second cut-off surface having an area smaller than the area of ​​the second surface.

[0024] In the lead block of the seventh feature, a second cutting surface with an area smaller than that of the second surface is disposed on the second surface. Therefore, during manufacturing, the amount of material discarded from cutting multiple busbars can be reduced. As a result, the manufacturing cost of the lead block can be further reduced.

[0025] According to the lead block of feature 8, in the lead block of feature 7, one of the plurality of busbars includes a first protrusion projecting from the second additional surface of the second exposed portion along the configuration direction. The first protrusion is at least partially embedded in the lead block body.

[0026] In the lead block of feature 8, the first protrusion is at least partially embedded within the lead block body, thereby reducing the manufacturing cost of the lead block and increasing the connection strength between the second exposed portion and the lead block body. When the connecting strip connecting multiple exposed portions includes the first protrusion during manufacturing, a portion of the connecting strip can be used to improve the connection strength, thereby increasing the connection strength between the second exposed portion and the lead block body and promoting efficient use of the lead block material.

[0027] According to the lead block of feature 9, in the lead block of feature 7 or feature 8, a plurality of exposed portions include a third exposed portion. The third exposed portion includes: a third surface facing at least one first exposed portion in the configuration direction; and a third additional surface disposed on the back side of the third surface in the configuration direction. The third surface includes a third cut surface having an area smaller than the area of ​​the third surface.

[0028] In the lead block of the 9th feature, a third cutting surface with an area smaller than that of the third surface is disposed on the third surface. Therefore, during manufacturing, it is possible to reduce the amount of material discarded from cutting multiple busbars. As a result, the manufacturing cost of the lead block can be further reduced.

[0029] According to the lead block of feature 10, in the lead block of feature 9, one of the plurality of busbars includes a second protrusion that protrudes from the third additional surface of the third exposed portion along the configuration direction. The second protrusion is at least partially embedded in the lead block body.

[0030] In the lead block of the 10th feature, the second protrusion is at least partially embedded in the lead block body, thus reducing the manufacturing cost of the lead block and improving the connection strength between the third exposed portion and the lead block body. When the connecting strip connecting multiple exposed portions includes the second protrusion during manufacturing, a portion of the connecting strip can be used to improve the connection strength, thereby increasing the connection strength between the third exposed portion and the lead block body and promoting the efficient use of the lead block material.

[0031] According to the lead block of feature 11, in any one of the lead blocks of features 1 to 10, the plurality of busbars includes at least one first busbar, which includes at least one first exposed portion. The at least one first busbar includes a first end and a first additional end. In the at least one first busbar, a first cut surface and a first additional cut surface are disposed between the first end and the first additional end.

[0032] In the lead block of the 11th feature, by providing the first cut surface and the first additional cut surface in the portion other than the first end and the first additional end, it is easy to integrally hold multiple busbars with less material during manufacturing.

[0033] According to the lead block of feature 12, in the lead block of feature 11, the first end protrudes from the lead block body. When viewed from a vertical direction perpendicular to the long side direction and the arrangement direction, the first additional end is positioned inside the outline of the lead block body.

[0034] In the lead block of the 12th feature, compared with the case where the first additional end is disposed on the outline of the lead block body or disposed at a position outside the outline of the lead block body, it is possible to suppress the first additional end from contacting other components such as cables.

[0035] According to the lead block of feature 13, in the lead block of feature 11 or feature 12, the first additional end is at least partially embedded in the lead block body.

[0036] In the lead block of feature 13, contact between the first additional end and other components such as cables can be reliably prevented.

[0037] According to feature 14, in any one of features 1 to 13, the lead block body includes an opening. A first cut surface and a first additional cut surface are disposed within the opening.

[0038] In the lead block of feature 14, during manufacturing, the connecting strip connecting multiple exposed portions can be cut from the multiple connecting portions through openings.

[0039] The rotary connector device of feature 15 has: a stator; a rotating body configured to rotate about a rotation axis relative to the stator; and any one of features 1 to 14.

[0040] In the rotary connector device of feature 15, the manufacturing cost of the lead block can be reduced, thereby reducing the manufacturing cost of the rotary connector device.

[0041] The manufacturing method of the lead block of feature 16 includes the following steps: a molding step in which a busbar plate comprising multiple busbars and connecting strips that connect multiple exposed portions of the multiple busbars to each other is embedded in the lead block body by insert forming in such a way that multiple exposed portions are exposed from the lead block body; and a cutting step in which the connecting strips are cut from the multiple exposed portions.

[0042] In the manufacturing method of the lead block of feature 16, the amount of material discarded from cutting multiple busbars can be reduced. This reduces the manufacturing cost of the lead block.

[0043] Regarding the manufacturing method of the lead block of feature 17, in the manufacturing method of the lead block of feature 16, the molding process includes the following step: embedding the busbar plate into the lead block body by insert forming such that at least a portion of the connecting strip and a plurality of exposed portions are disposed in the opening of the lead block body.

[0044] In the manufacturing method of the lead block of feature 17, the peripheral portions of multiple exposed portions can be retained by the lead block body.

[0045] According to the manufacturing method of the lead block according to feature 18, in the manufacturing method of the lead block according to feature 17, the cutting process includes the following step: cutting the connecting strip from multiple exposed portions through the opening of the lead block body.

[0046] In the manufacturing method of the lead block of feature 18, the connecting strip can be cut from the multiple exposed portions while the peripheral portions of the multiple exposed portions are held by the lead block body. This ensures a stable cutting operation.

[0047] According to the manufacturing method of the lead block according to feature 19, in the manufacturing method of any one of features 16 to 18, the molding process includes the following process: embedding the busbar plate into the lead block body by insert forming in such a way that a part of the connecting strip is embedded into the lead block body.

[0048] In the manufacturing method of the lead block of feature 19, the connection strength between the multiple exposed portions and the lead block body can be improved.

[0049] According to the lead block of feature 20, the manufacturing method of any one of the lead blocks of features 16 to 19 further includes the following stamping process: forming a busbar plate from a plate containing conductive material by stamping.

[0050] In the manufacturing method of the lead block of feature 20, the remaining portion cut off from the busbar can be reduced by stamping.

[0051] Invention Effects

[0052] The technology disclosed in this application can reduce the manufacturing cost of lead blocks. Attached Figure Description

[0053] Figure 1 This is a plan view of the rotary connector device according to this embodiment.

[0054] Figure 2 yes Figure 1 A cross-sectional view of the rotary connector assembly shown.

[0055] Figure 3 yes Figure 1 Side view of the lead block of the rotary connector assembly shown.

[0056] Figure 4 yes Figure 3 A partial side view of the lead block shown.

[0057] Figure 5 yes Figure 3 A partial 3D view of the lead block shown.

[0058] Figure 6 yes Figure 3 A partial 3D view of the lead block shown.

[0059] Figure 7 yes Figure 4 A cross-sectional view of the lead block in line VII-VII.

[0060] Figure 8 It is shown Figure 3 The flowchart shows the manufacturing method of the lead block.

[0061] Figure 9 It is shown Figure 3 The diagram shows a plan view of the stamping process of the lead block.

[0062] Figure 10 It is shown Figure 3 The diagram shows a plan view of the molding process for the lead block.

[0063] Figure 11 It is shown Figure 3 The diagram shows the cutting process of the lead block and the plan view of the carrier cutting process.

[0064] Figure 12 It is shown Figure 3 A diagram showing the surface condition of the first face of the lead block.

[0065] Figure 13 It is shown Figure 3 A diagram showing the surface condition of the first additional surface of the lead block.

[0066] Figure 14 It is shown Figure 3 A diagram showing the surface condition of the second side of the lead block.

[0067] Figure 15 It is shown Figure 3 A diagram showing the surface condition of the third side of the lead block.

[0068] Figure 16 This is a diagram showing the surface condition of the first surface of the lead block in the modified example.

[0069] Figure 17 This is a diagram showing the surface state of the first surface of the lead block in the modified example.

[0070] Figure 18 The positional relationship between the first cut surface and the first adjacent surface of the lead block in the modified example is shown, as well as the positional relationship between the first additional cut surface and the first additional adjacent surface.

[0071] Figure 19 The positional relationship between the first cut surface and the first adjacent surface of the lead block in the modified example is shown, as well as the positional relationship between the first additional cut surface and the first additional adjacent surface. Detailed Implementation

[0072] Hereinafter, the embodiments will be described with reference to the accompanying drawings. The same reference numerals in the drawings indicate corresponding or identical structures.

[0073] like Figure 1 As shown, the rotary connector device 1 of this embodiment includes a stator 10 and a rotating body 20. The stator 10 is configured to be mounted on a vehicle body. The rotating body 20 is configured to be rotatable relative to the stator 10 about a rotation axis A1. The rotating body 20 is configured to be fixed to a steering wheel. The rotary connector device 1 includes a first connector 30 and a second connector 40. The first connector 30 is provided on the stator 10. The second connector 40 is provided on the rotating body 20.

[0074] The first connector 30 is configured for detachable installation of the vehicle-side connector. The first connector 30 includes a first connector housing 31 into which the vehicle-side connector is inserted. The vehicle-side connector is electrically connected to electrical circuits such as control devices. The second connector 40 is configured for detachable installation of the steering-side connector. The second connector 40 includes a second connector housing 41 into which the steering-side connector is inserted. The steering-side connector is electrically connected to electrical circuits such as steering wheel switches and airbag devices.

[0075] like Figure 2 As shown, the stator 10 and the rotating body 20 define a cable storage space 50 between them, arranged in a manner surrounding the rotation axis A1. For example, the cable storage space 50 is annular and extends circumferentially D2 relative to the rotation axis A1. The rotary connector assembly 1 has a cable 60. The cable 60 electrically connects the first connector 30 to the second connector 40. The cable 60 is disposed within the cable storage space 50. The cable 60 is flexible and has a flat shape. The cable 60 may also be referred to as a flexible flat cable.

[0076] like Figure 1 As shown, the rotary connector device 1 has lead blocks 70. In this embodiment, the rotary connector device 1 has a plurality of lead blocks 70. Lead blocks 70A and 70B of the plurality of lead blocks 70 are mounted on the stator 10. Lead blocks 70A and 70B are disposed within the first connector receiving portion 31. Lead blocks 70C and 70D of the plurality of lead blocks 70 are mounted on the rotating body 20. Lead blocks 70C and 70D are disposed within the second connector receiving portion 41. The first connector 30 includes lead blocks 70A and 70B. The second connector 40 includes lead blocks 70C and 70D. However, the total number of lead blocks 70 is not limited to this embodiment.

[0077] like Figure 3 As shown, the lead block 70 has a lead block body 71 and a plurality of busbars 72. The lead block body 71 contains an electrically insulating material. The plurality of busbars 72 are partially embedded in the lead block body 71 and contain a conductive material. The electrically insulating material includes, for example, a resin material. The conductive material includes, for example, a metallic material such as copper. The plurality of busbars 72 are electrically insulated from each other through the lead block body 71. The plurality of busbars 72 are connected to the cable 60 (see reference 60). Figure 2 The multiple wirings contained herein are electrically connected.

[0078] The multiple busbars 72 include multiple exposed portions 73 that protrude from the lead block body 71 and correspond to each of the multiple busbars 72. The busbars 72 include exposed portions 73. The multiple exposed portions 73 extend along the long side direction D4 and are spaced apart in the arrangement direction D5 perpendicular to the long side direction D4.

[0079] The plurality of exposed portions 73 include at least one first exposed portion 74. In this embodiment, the plurality of exposed portions 73 include a plurality of first exposed portions 74. However, the total number of first exposed portions 74 is not limited to this embodiment.

[0080] Multiple exposed portions 73 include a second exposed portion 75. Multiple exposed portions 73 include a third exposed portion 76. At least one first exposed portion 74 is disposed between the second exposed portion 75 and the third exposed portion 76 in the configuration direction D5. Multiple first exposed portions 74 are disposed between the second exposed portion 75 and the third exposed portion 76 in the configuration direction D5. Multiple first exposed portions 74, second exposed portions 75, and third exposed portions 76 are disposed at intervals in the configuration direction D5.

[0081] The plurality of busbars 72 include at least one first busbar 77, which includes at least one first exposed portion 74. The at least one first busbar 77 includes a first end 77A and a first additional end 77B. In this embodiment, the plurality of busbars 72 include a plurality of first busbars 77, which include a plurality of first exposed portions 74. The plurality of busbars 72 include a first end 77A and a first additional end 77B. However, the total number of first busbars 77 is not limited to this embodiment.

[0082] The plurality of busbars 72 includes a second busbar 78, which includes a second exposed portion 75. The plurality of busbars 72 includes a third busbar 79, which includes a third exposed portion 76. The second busbar 78 includes a second end 78A and a second additional end 78B. The third busbar 79 includes a third end 79A and a third additional end 79B. At least one of the second busbar 78 and the third busbar 79 may also be omitted from the plurality of busbars 72.

[0083] The first end portion 77A protrudes from the lead block body 71. The first busbar 77 includes a first pin terminal 77C protruding from the lead block body 71. The first pin terminal 77C protrudes from the lead block body 71 along the long side direction D4. The first pin terminal 77C includes the first end portion 77A. When viewed from a vertical direction D6, which is perpendicular to both the long side direction D4 and the arrangement direction D5, the first end portion 77A is positioned outside the outline 71A of the lead block body 71.

[0084] On the other hand, when viewed from a vertical direction D6, which is perpendicular to both the long side direction D4 and the arrangement direction D5, the first additional end 77B is positioned inside the outline of the lead block body 71. The first additional end 77B is at least partially embedded within the lead block body 71. In this embodiment, the first additional end 77B is partially embedded within the lead block body 71, but a portion of the surface of the first additional end 77B protrudes from the lead block body 71. However, the first additional end 77B may also be entirely embedded within the lead block body 71.

[0085] like Figure 4 As shown, at least one first exposed portion 74 includes a first surface 80 and a first additional surface 81. The first additional surface 81 is disposed on the back side of the first surface 80 in the configuration direction D5. A plurality of first exposed portions 74 each include a first surface 80 and a first additional surface 81.

[0086] The second exposed portion 75 includes a second surface 83 and a second additional surface 84. The second surface 83 faces at least one of the first exposed portions 74 in the configuration direction D5. The second additional surface 84 is disposed on the back side of the second surface 83 in the configuration direction D5.

[0087] The third exposed portion 76 includes a third surface 85 and a third additional surface 86. The third surface 85 faces at least one first exposed portion 74 in the configuration direction D5. The third additional surface 86 is disposed on the back side of the third surface 85 in the configuration direction D5.

[0088] One of the multiple busbars 72 includes a first protrusion 87 projecting from the second additional surface 84 of the second exposed portion 75 along the arrangement direction D5. A second busbar 78 includes the first protrusion 87. The first protrusion 87 is at least partially embedded within the lead block body 71. In this embodiment, the first protrusion 87 is partially embedded within the lead block body 71. However, the first protrusion 87 may also be entirely embedded within the lead block body 71. Furthermore, the first protrusion 87 may be omitted from the multiple busbars 72.

[0089] One of the multiple busbars 72 includes a second protrusion 88 projecting from the third additional surface 86 of the third exposed portion 76 along the arrangement direction D5. The third busbar 79 includes the second protrusion 88. The second protrusion 88 is at least partially embedded within the lead block body 71. In this embodiment, the second protrusion 88 is partially embedded within the lead block body 71. However, the second protrusion 88 may also be entirely embedded within the lead block body 71. Furthermore, the second protrusion 88 may be omitted from the multiple busbars 72.

[0090] The lead block body 71 includes an opening 71B. A plurality of exposed portions 73 are at least partially disposed within the opening 71B when viewed from the vertical direction D6. A plurality of first exposed portions 74, second exposed portions 75 and third exposed portions 76 are at least partially disposed within the opening 71B when viewed from the vertical direction D6.

[0091] like Figure 5 As shown, the first surface 80 includes a first cut surface 90, which has an area smaller than that of the first surface 80. The first cut surface 90 is disposed within the opening 71B. The length L11 of the first cut surface 90 in the long side direction D4 is shorter than the length L12 of the first surface 80 in the long side direction D4. The first surface 80 includes a first adjacent surface 80A adjacent to the first cut surface 90. The first surface 80 includes a first adjacent surface 80B adjacent to the first cut surface 90. The appearance of the first cut surface 90 is different from that of the first adjacent surface 80A. The appearance of the first cut surface 90 is different from that of the first adjacent surface 80B. The appearance of the first adjacent surface 80A is the same as that of the first adjacent surface 80B.

[0092] As will be described later, the first cut surface 90 is formed when the connecting strip 104 (see reference) is manufactured during the production of the lead block 70. Figures 9-11 The first cut surface 90 is a surface formed when cut from multiple first exposed portions 74. The first adjacent surfaces 80A and 80B are formed, for example, by stamping (e.g., shearing), while the first cut surface 90 is formed after the first adjacent surfaces 80A and 80B by a different process than that of the first adjacent surfaces 80A and 80B. The first cut surface 90 is, for example, a surface formed by stamping (e.g., shearing) in the same manner as the first adjacent surfaces 80A and 80B.

[0093] like Figure 12 As shown, the first adjacent surface 80A includes a shear surface 80C and a fracture surface 80D. The fracture surface 80D is adjacent to the shear surface 80C in the vertical direction D6. The shear surface 80C is a surface formed by shearing material by a punch and die during a shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The fracture surface 80D is a surface formed by fracture after a portion of the material has been sheared by a punch and die during a shearing process, and includes fine irregularities. Therefore, the appearance of the shear surface 80C is different from that of the fracture surface 80D.

[0094] Similarly, the first adjacent surface 80B includes a shear surface 80E and a fracture surface 80F. The fracture surface 80F is adjacent to the shear surface 80E in the vertical direction D6. The shear surface 80E is the surface formed by the punch and die shearing the material during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The fracture surface 80F is the surface formed by the material fracturing after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the shear surface 80E is different from that of the fracture surface 80F.

[0095] The first cutting surface 90 includes a first shear surface 90A and a first fracture surface 90B. The first fracture surface 90B is adjacent to the first shear surface 90A in the vertical direction D6. The first shear surface 90A is a surface formed by shearing material by a punch and die during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The first fracture surface 90B is a surface formed by fracture after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the first shear surface 90A is different from that of the first fracture surface 90B.

[0096] like Figure 12 As shown, the length of the first shear surface 90A in the vertical direction D6 is different from the lengths of the shear surfaces 80C and 80E in the vertical direction D6. The length of the first fracture surface 90B in the vertical direction D6 is different from the lengths of the fracture surfaces 80D and 80F in the vertical direction D6. Therefore, the appearance of the first cut surface 90 is different from the appearance of the first adjacent surfaces 80A and 80B. In addition, the first cut surface 90 may also be a surface that has been finished after the connecting strip 104 is cut from the plurality of first exposed portions 74. Similarly, the first adjacent surfaces 80A and 80B may also be surfaces that have been finished. When the first cut surface 90 is finished, the first shear surface 90A and the first fracture surface 90B are at least partially replaced with finished surfaces. When the first adjacent surface 80A is finished, the shear surface 80C and the fracture surface 80D are at least partially replaced with finished surfaces. When the first adjacent surface 80B is finished, the shear surface 80E and the fracture surface 80F are at least partially replaced by the finished surfaces. Therefore, it is also possible for the appearance of the first cut surface 90 to be the same as that of the first adjacent surfaces 80A and 80B.

[0097] like Figure 6As shown, the first additional surface 81 includes a first additional cut surface 91, which has an area smaller than that of the first additional surface 81. The first additional cut surface 91 is disposed within the opening 71B. The length L13 of the first additional cut surface 91 in the long side direction D4 is shorter than the length L14 of the first additional surface 81 in the long side direction D4. The first additional surface 81 includes a first additional adjacent surface 81A adjacent to the first additional cut surface 91. The first additional surface 81 includes a first additional adjacent surface 81B adjacent to the first additional cut surface 91. The appearance of the first additional cut surface 91 is different from that of the first additional adjacent surface 81A. The appearance of the first additional cut surface 91 is different from that of the first additional adjacent surface 81B. The appearance of the first additional adjacent surface 81A is the same as that of the first additional adjacent surface 81B.

[0098] The first additional cutting surface 91 is positioned in the configuration direction D5 at the first cutting surface 90 (see reference). Figure 5 The first additional cut surface 91 is disposed on the back side of the first cut surface 90 (refer to the long side direction D4). Figure 5 The same position. However, the first additional cut surface 91 may also not be configured in the configuration direction D5 at the first cut surface 90 (see reference). Figure 5 The back side of the first additional cut surface 91 can also be on the long side direction D4, adjacent to the first cut surface 90 (see reference). Figure 5 )stagger.

[0099] As will be described later, the first additional cut surface 91 is formed when the connecting strip 104 (see reference) is manufactured during the production of the lead block 70. Figures 9-11 The first additional adjacent surfaces 81A and 81B are formed when cut from multiple first exposed portions 74. The first additional adjacent surfaces 81A and 81B are formed, for example, by stamping (e.g., shearing). In contrast, the first additional cut surface 91 is formed after the first additional adjacent surfaces 81A and 81B by a different process than that of the first additional adjacent surfaces 81A and 81B. The first additional cut surface 91 is, for example, formed by stamping (e.g., shearing) in the same manner as the first additional adjacent surfaces 81A and 81B.

[0100] like Figure 13 As shown, the first additional adjacent surface 81A includes an additional shear surface 81C and an additional fracture surface 81D. The additional fracture surface 81D is adjacent to the additional shear surface 81C in the vertical direction D6. The additional shear surface 81C is a surface formed by shearing material by a punch and die during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The additional fracture surface 81D is a surface formed by fracture after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the additional shear surface 81C is different from that of the additional fracture surface 81D.

[0101] Similarly, the first additional adjacent surface 81B includes an additional shear surface 81E and an additional fracture surface 81F. The additional fracture surface 81F is adjacent to the additional shear surface 81E in the vertical direction D6. The additional shear surface 81E is a surface formed by shearing material by a punch and die during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The additional fracture surface 81F is a surface formed by fracture after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the additional shear surface 81E is different from that of the additional fracture surface 81F.

[0102] The first additional cutting surface 91 includes a first additional shear surface 91A and a first additional fracture surface 91B. The first additional fracture surface 91B is adjacent to the first additional shear surface 91A in the vertical direction D6. The first additional shear surface 91A is a surface formed by shearing material by a punch and die during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The first additional fracture surface 91B is a surface formed by fracture after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the first additional shear surface 91A is different from that of the first additional fracture surface 91B.

[0103] like Figure 13 As shown, the length of the first additional shear surface 91A in the vertical direction D6 is different from the lengths of the additional shear surfaces 81C and 81E in the vertical direction D6. The length of the first additional fracture surface 91B in the vertical direction D6 is different from the lengths of the additional fracture surfaces 81D and 81F in the vertical direction D6. Therefore, the appearance of the first additional cut surface 91 is different from the appearance of the first additional adjacent surfaces 81A and 81B. In addition, the first additional cut surface 91 may also be a surface that has been finished after the connecting strip 104 has been cut from the plurality of first exposed portions 74. Similarly, the first additional adjacent surfaces 81A and 81B may also be surfaces that have been finished. When the first additional cut surface 91 has been finished, the first additional shear surface 91A and the first additional fracture surface 91B are at least partially replaced with finished surfaces. When the first additional adjacent surface 81A has been finished, the additional shear surface 81C and the additional fracture surface 81D are at least partially replaced with finished surfaces. When the first additional adjacent surface 81B is finished, the additional shear surface 81E and the additional fracture surface 81F are at least partially replaced by finished surfaces. Therefore, it is also possible for the appearance of the first additional cut surface 91 to be the same as that of the first additional adjacent surfaces 81A and 81B.

[0104] like Figure 5As shown, the second surface 83 includes a second cut surface 93, which has an area smaller than that of the second surface 83. The second cut surface 93 is disposed within the opening 71B. The length L21 of the second cut surface 93 in the long side direction D4 is shorter than the length L22 of the second surface 83 in the long side direction D4. The second surface 83 includes second adjacent surfaces 83A and 83B adjacent to the second cut surface 93. The appearance of the second cut surface 93 is different from that of the second adjacent surfaces 83A and 83B. The appearance of the second adjacent surface 83A is the same as that of the second adjacent surface 83B.

[0105] As will be described later, the second cut surface 93 is formed when the connecting strip 104 (see reference) is manufactured during the production of the lead block 70. Figures 9-11 The second adjacent surfaces 83A and 83B are formed when cut from multiple first exposed portions 74. The second adjacent surfaces 83A and 83B are formed, for example, by stamping (e.g., shearing). In contrast, the second cut surface 93 is formed after the second adjacent surfaces 83A and 83B by a different process than that of the second adjacent surfaces 83A and 83B. The second cut surface 93 is, for example, formed by stamping (e.g., shearing) in the same manner as the second adjacent surfaces 83A and 83B.

[0106] like Figure 14 As shown, the second adjacent surface 83A includes a shear surface 83C and a fracture surface 83D. The fracture surface 83D is adjacent to the shear surface 83C in the vertical direction D6. The shear surface 83C is a surface formed by shearing material by a punch and die during a shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The fracture surface 83D is a surface formed by fracture after a portion of the material has been sheared by a punch and die during a shearing process, and includes fine irregularities. Therefore, the appearance of the shear surface 83C is different from that of the fracture surface 83D.

[0107] Similarly, the second adjacent surface 83B includes a shear surface 83E and a fracture surface 83F. The fracture surface 83F is adjacent to the shear surface 83E in the vertical direction D6. The shear surface 83E is the surface formed by the punch and die shearing the material during a shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The fracture surface 83F is the surface formed by the material fracturing after a portion of it has been sheared by the punch and die during a shearing process, and includes fine irregularities. Therefore, the appearance of the shear surface 83E differs from that of the fracture surface 83F.

[0108] The second cut surface 93 includes a second shear surface 93A and a second fracture surface 93B. The second fracture surface 93B is adjacent to the second shear surface 93A in the vertical direction D6. The second shear surface 93A is a surface formed by shearing material by a punch and die during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The second fracture surface 93B is a surface formed by fracture after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the second shear surface 93A is different from that of the second fracture surface 93B.

[0109] like Figure 14 As shown, the length of the second shear surface 93A in the vertical direction D6 is different from the lengths of the shear surfaces 83C and 83E in the vertical direction D6. The length of the second fracture surface 93B in the vertical direction D6 is different from the lengths of the fracture surfaces 83D and 83F in the vertical direction D6. Therefore, the appearance of the second cut surface 93 is different from the appearance of the second adjacent surfaces 83A and 83B. In addition, the second cut surface 93 may also be a surface that has been finished after the connecting strip 104 is cut from the plurality of first exposed portions 74. Similarly, the second adjacent surfaces 83A and 83B may also be surfaces that have been finished. When the second cut surface 93 has been finished, the second shear surface 93A and the second fracture surface 93B are at least partially replaced with finished surfaces. When the second adjacent surface 83A has been finished, the shear surface 83C and the fracture surface 83D are at least partially replaced with finished surfaces. When the second adjacent surface 83B is finished, the shear surface 83E and the fracture surface 83F are at least partially replaced by the finished surfaces. Therefore, it is also possible for the appearance of the second cut surface 93 to be the same as that of the second adjacent surfaces 83A and 83B.

[0110] like Figure 6 As shown, the third surface 85 includes a third cut surface 95, which has an area smaller than that of the third surface 85. The third cut surface 95 is disposed within the opening 71B. The length L31 of the third cut surface 95 in the long side direction D4 is shorter than the length L32 of the third surface 85 in the long side direction D4. The third surface 85 includes third adjacent surfaces 85A and 85B adjacent to the third cut surface 95. The appearance of the third cut surface 95 is different from the appearance of each of the third adjacent surfaces 85A and 85B. The appearance of the third adjacent surface 85A is the same as that of the third adjacent surface 85B.

[0111] As will be described later, the third cut surface 95 is formed when the connecting strip 104 (see reference) is manufactured during the production of the lead block 70. Figures 9-11The third adjacent surfaces 85A and 85B are formed when cut from multiple first exposed portions 74. The third adjacent surfaces 85A and 85B are formed, for example, by stamping (e.g., shearing). In contrast, the third cut surface 95 is formed after the third adjacent surfaces 85A and 85B by a different process than that of the third adjacent surfaces 85A and 85B. The third cut surface 95 is, for example, formed by stamping (e.g., shearing) in the same way as the third adjacent surfaces 85A and 85B.

[0112] like Figure 15 As shown, the third adjacent surface 85A includes a shear surface 85C and a fracture surface 85D. The fracture surface 85D is adjacent to the shear surface 85C in the vertical direction D6. The shear surface 85C is a surface formed by shearing material by a punch and die during a shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The fracture surface 85D is a surface formed by fracture after a portion of the material has been sheared by a punch and die during a shearing process, and includes fine irregularities. Therefore, the appearance of the shear surface 85C is different from that of the fracture surface 85D.

[0113] Similarly, the third adjacent surface 85B includes a shear surface 85E and a fracture surface 85F. The fracture surface 85F is adjacent to the shear surface 85E in the vertical direction D6. The shear surface 85E is the surface formed by the punch and die shearing the material during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The fracture surface 85F is the surface formed by the material fracturing after the punch and die have sheared a portion of the material during the shearing process, and includes fine irregularities. Therefore, the appearance of the shear surface 85E is different from that of the fracture surface 85F.

[0114] The third cut surface 95 includes a third shear surface 95A and a third fracture surface 95B. The third fracture surface 95B is adjacent to the third shear surface 95A in the vertical direction D6. The third shear surface 95A is a surface formed by shearing material by a punch and die during the shearing process, and includes multiple ribs extending in one direction (e.g., the vertical direction D6). The third fracture surface 95B is a surface formed by fracture after a portion of the material has been sheared by the punch and die during the shearing process, and includes fine irregularities. Therefore, the appearance of the third shear surface 95A is different from that of the third fracture surface 95B.

[0115] like Figure 15As shown, the length of the third shear surface 95A in the vertical direction D6 is different from the lengths of the shear surfaces 85C and 85E in the vertical direction D6. The length of the third fracture surface 95B in the vertical direction D6 is different from the lengths of the fracture surfaces 85D and 85F in the vertical direction D6. Therefore, the appearance of the third cut surface 95 is different from the appearance of the third adjacent surfaces 85A and 85B. In addition, the third cut surface 95 may also be a surface that has been finished after the connecting strip 104 is cut from the plurality of first exposed portions 74. Similarly, the third adjacent surfaces 85A and 85B may also be surfaces that have been finished. When the third cut surface 95 has been finished, the third shear surface 95A and the third fracture surface 95B are at least partially replaced with finished surfaces. When the third adjacent surface 85A has been finished, the shear surface 85C and the fracture surface 85D are at least partially replaced with finished surfaces. When the third adjacent surface 85B is finished, the shear surface 85E and the fracture surface 85F are at least partially replaced by finished surfaces. Therefore, there are also cases where the appearance of the third cut surface 95 is the same as that of the third adjacent surfaces 85A and 85B.

[0116] like Figure 3 As shown, in at least one first busbar 77, a first exposed portion 74 is disposed between a first end 77A and a first additional end 77B. In at least one first busbar 77, a first cut surface 90 and a first additional cut surface 91 are disposed between the first end 77A and the first additional end 77B. In the second busbar 78, a second cut surface 93 is disposed between the second end 78A and the second additional end 78B. In the third busbar 79, a third cut surface 95 is disposed between the third end 79A and the third additional end 79B.

[0117] like Figure 6 As shown, the first protrusion 87 includes a second additional cut surface 97. The second additional cut surface 97 is the end face of the first protrusion 87, protruding from the lead block body 71. As will be described later, the second additional cut surface 97 is formed when the connecting strip 104 (see reference 104) is manufactured in the lead block 70. Figures 9-11 The surface formed when cut from the first protrusion 87.

[0118] like Figure 5 As shown, the second protrusion 88 includes a third additional cut surface 98. The third additional cut surface 98 is the end face of the second protrusion 88, protruding from the lead block body 71. As described later, the third additional cut surface 98 is formed when the connecting strip 104 (see reference 104) is manufactured in the lead block 70. Figures 9-11 The surface formed when cut from the second protrusion 88.

[0119] Multiple exposed portions 73 each include multiple cable mounting surfaces 73A. The cable mounting surfaces 73A are configured to face the vertical direction D6. The multiple cable mounting surfaces 73A are located at the cable 60 (refer to...). Figure 2 When connected to multiple busbars 72, it is opposite to the cable 60.

[0120] like Figure 6 As shown, each of the multiple exposed portions 73 includes a multiple back face 73B. The back face 73B is disposed on the back side of the cable mounting surface 73A in the vertical direction D6. The back face 73B is configured to face the vertical direction D6.

[0121] like Figure 7 As shown, the plurality of exposed portions 73 each include a plurality of protrusions 73C. The protrusions 73C protrude from the cable mounting surface 73A in the vertical direction D6. The plurality of protrusions 73C are connected to the cable 60 (see reference). Figure 2 The multiple wirings contained herein are electrically connected. For example, multiple protrusions 73C are connected to cable 60 (see reference). Figure 2 The multiple wirings contained herein are connected by connection methods such as ultrasonic bonding and resistance welding.

[0122] Each of the plurality of exposed portions 73 includes a plurality of recesses 73D. The recesses 73D are disposed on the back surface 73B of the plurality of exposed portions 73. The recesses 73D are disposed on the back side of the protrusions 73C in the vertical direction D6. The protrusions 73C and the recesses 73D are formed, for example, by stamping. At least one of the protrusions 73C and the recesses 73D may also be omitted from the exposed portions 73.

[0123] Reference Figures 8-11 The manufacturing method of lead block 70 is described.

[0124] like Figure 8 and Figure 9 As shown, the manufacturing method of the lead block 70 includes the following stamping process S1: a busbar plate 102 is formed from a plate 100 containing conductive material by stamping. For example... Figure 9 As shown, the busbar plate 102 includes: a plurality of busbars 72; a connecting strip 104 that connects the plurality of exposed portions 73 of the plurality of busbars 72 to each other; and a carrier 106 that connects the plurality of busbars 72 to each other. A plurality of first ends 77A, second ends 78A and third ends 79A are connected to the carrier 106.

[0125] like Figure 8 and Figure 10 As shown, the manufacturing method of the lead block 70 includes the following molding process S2: a busbar plate 102 comprising a plurality of busbars 72 and a connecting bar 104 that connects the plurality of exposed portions 73 of the plurality of busbars 72 to each other is embedded in the lead block body 71 by insert forming in such a way that the plurality of exposed portions 73 are exposed from the lead block body 71.

[0126] The molding process S2 includes the following step S21: embedding the busbar plate 102 into the lead block body 71 by insert forming, such that at least a portion of the connecting strip 104 and a plurality of exposed portions 73 are disposed within the opening 71B of the lead block body 71. The molding process S2 includes the following step S22: embedding the busbar plate 102 into the lead block body 71 by insert forming, such that a portion of the connecting strip 104 is embedded within the lead block body 71. Steps S21 and S22 are typically performed by insert forming in one step, but can also be performed by insert forming separately. Furthermore, one of steps S21 and S22 can be omitted from the molding process S2.

[0127] like Figure 8 and Figure 11 As shown, the manufacturing method of the lead block 70 includes a cutting step S3 in which the connecting strip 104 is cut from the plurality of exposed portions 73. The cutting step S3 includes a step S31 in which the connecting strip 104 is cut from the plurality of exposed portions 73 through the opening 71B of the lead block body 71. For example, in the cutting step S3, the connecting strip 104 is cut from the plurality of exposed portions 73 by stamping.

[0128] like Figure 11 As shown, the connecting strip 104 includes a plurality of first connecting portions 104A, second connecting portions 104B, and third connecting portions 104C. When the plurality of first connecting portions 104A are cut from the plurality of exposed portions 73, a plurality of first cut surfaces 90 are formed (see reference). Figure 5 Multiple first additional cut surfaces 91 (refer to) Figure 6 ), second section 93 (refer to) Figure 5 ) and the third cut surface 95 (refer to) Figure 6 When the second connecting portion 104B is cut off from the first protrusion 87, a second additional cut surface 97 is formed (see reference). Figure 6 When the third connecting portion 104C is cut off from the second protrusion 88, a third additional cutting surface 98 is formed (see reference). Figure 5 ).

[0129] like Figure 8 and Figure 11 As shown, the manufacturing method of the lead block 70 includes a carrier cutting step S4: cutting the carrier 106 from multiple busbars 72. For example, the carrier 106 is cut from multiple busbars 72 by stamping. This manufactures the lead block 70. Alternatively, if the busbar plate 102 does not contain the carrier 106, the carrier cutting step S4 can be omitted. Furthermore, the cutting step S3 and the carrier cutting step S4 can be performed simultaneously as a single step, or they can be performed at different times as other steps.

[0130] The features of the lead block 70 in this embodiment are as follows.

[0131] (1) The lead block 70 includes: a lead block body 71 containing an electrically insulating material; and a plurality of busbars 72 partially embedded in the lead block body 71 and containing a conductive material. The plurality of busbars 72 includes a plurality of exposed portions 73 protruding from the lead block body 71 and corresponding to each of the plurality of busbars 72. The plurality of exposed portions 73 extend along a long side direction D4 and are spaced apart in a configuration direction D5 perpendicular to the long side direction D4. The plurality of exposed portions 73 includes at least one first exposed portion 74. The at least one first exposed portion 74 includes: a first surface 80; and a first additional surface 81 disposed on the back side of the first surface 80 in the configuration direction D5. The first surface 80 includes a first cut surface 90 having an area smaller than that of the first surface 80. The first additional surface 81 includes a first additional cut surface 91, which has an area smaller than that of the first additional surface 81.

[0132] In the lead block 70, a first cutting surface 90 having an area smaller than that of the first surface 80 is disposed on the first surface 80, and a first additional cutting surface 91 having an area smaller than that of the first additional surface 81 is disposed on the first additional surface 81. Therefore, during manufacturing, the amount of material discarded from cutting multiple busbars 72 can be reduced. As a result, the manufacturing cost of the lead block 70 can be reduced.

[0133] (2) The first surface 80 includes a first adjacent surface 80A adjacent to the first cut surface 90. The first additional surface 81 includes a first additional adjacent surface 81A adjacent to the first additional cut surface 91. The appearance of the first cut surface 90 is different from that of the first adjacent surface 80A. The appearance of the first additional cut surface 91 is different from that of the first additional adjacent surface 81A. Therefore, the finishing process of the first cut surface 90 and the first additional cut surface 91 can be omitted. As a result, compared with the case where the first cut surface 90 and the first additional cut surface 91 are finished, the manufacturing cost of the lead block 70 can be further reduced.

[0134] (3) The first additional cutting surface 91 is disposed on the back side of the first cutting surface 90 in the arrangement direction D5. Thus, for example, when the connecting strip connecting the plurality of exposed portions 73 is cut from the plurality of exposed portions 73 during manufacturing, deformation of the plurality of exposed portions 73 can be suppressed.

[0135] (4) The length of the first cut surface 90 in the length direction D4 is shorter than the length of the first surface 80 in the length direction D4. The length of the first additional cut surface 91 in the length direction D4 is shorter than the length of the first additional surface 81 in the length direction D4. Therefore, compared with the case where the lengths of the first cut surface 90 and the first surface 80 are equal and / or the lengths of the first additional cut surface 91 and the first additional surface 81 are equal, the amount of material discarded from cutting multiple busbars 72 can be further reduced. Therefore, the manufacturing cost of the lead block 70 can be further reduced.

[0136] (5) The plurality of exposed portions 73 includes a second exposed portion 75. The second exposed portion 75 includes: a second surface 83 facing at least one first exposed portion 74 in the configuration direction D5; and a second additional surface 84 disposed on the back side of the second surface 83 in the configuration direction D5. The second surface 83 includes a second cut surface 93 having an area smaller than that of the second surface 83. The second cut surface 93 having an area smaller than that of the second surface 83 is disposed on the second surface 83, thus reducing the amount of material discarded when cut from the plurality of busbars 72 during manufacturing. As a result, the manufacturing cost of the lead block 70 can be further reduced.

[0137] (6) One of the multiple busbars 72 includes a first protrusion 87 that protrudes from the second additional surface 84 of the second exposed portion 75 along the arrangement direction D5. The first protrusion 87 is at least partially embedded in the lead block body 71. This reduces the manufacturing cost of the lead block 70 and increases the connection strength between the second exposed portion 75 and the lead block body 71. When the connecting strip connecting the multiple exposed portions 73 includes the first protrusion 87 during manufacturing, a portion of the connecting strip can be used to improve the connection strength, thereby increasing the connection strength between the second exposed portion 75 and the lead block body 71 and promoting efficient use of the material of the lead block 70.

[0138] (7) The plurality of exposed portions 73 includes a third exposed portion 76. The third exposed portion 76 includes: a third surface 85 facing at least one first exposed portion 74 in the configuration direction D5; and a third additional surface 86 disposed on the back side of the third surface 85 in the configuration direction D5. The third surface 85 includes a third cut surface 95 having an area smaller than that of the third surface 85. The third cut surface 95 having an area smaller than that of the third surface 85 is disposed on the third surface 85, thus reducing the amount of material discarded when cut from the plurality of busbars 72 during manufacturing. As a result, the manufacturing cost of the lead block 70 can be further reduced.

[0139] (8) The third exposed portion 76 includes a second protrusion 88 protruding from the third additional surface 86 along the arrangement direction D5. The second protrusion 88 is at least partially embedded in the lead block body 71. As a result, the manufacturing cost of the lead block 70 can be reduced and the connection strength between the third exposed portion 76 and the lead block body 71 can be improved. When the connecting strip connecting the multiple exposed portions 73 includes the second protrusion 88 during manufacturing, a portion of the connecting strip can be used to improve the connection strength, thereby improving the connection strength between the third exposed portion 76 and the lead block body 71 and promoting the efficient use of the material of the lead block 70.

[0140] (9) The plurality of busbars 72 includes at least one first busbar 77, which includes at least one first exposed portion 74. The at least one first busbar 77 includes a first end 77A and a first additional end 77B. In the at least one first busbar 77, a first cut surface 90 and a first additional cut surface 91 are disposed between the first end 77A and the first additional end 77B. By providing the first cut surface 90 and the first additional cut surface 91 at portions other than the first end 77A and the first additional end 77B, the plurality of busbars 72 can be easily integrally held with less material during manufacturing.

[0141] (10) The first end 77A protrudes from the lead block body 71. When viewed from a vertical direction D6, which is perpendicular to the long side direction D4 and the arrangement direction D5, the first additional end 77B is positioned inside the outline of the lead block body 71. Therefore, compared to the case where the first additional end 77B is positioned on the outline of the lead block body 71 or outside the outline of the lead block body 71, it is possible to suppress contact between the first additional end 77B and other components such as cables.

[0142] (11) The first additional end 77B is at least partially embedded in the lead block body 71. As a result, contact between the first additional end 77B and other components such as cables can be reliably prevented.

[0143] (12) The lead block body 71 includes an opening. A first cutting surface 90 and a first additional cutting surface 91 are disposed within the opening. Thus, during manufacturing, the connecting strip connecting the plurality of exposed portions 73 can be cut from the plurality of connecting portions through the opening.

[0144] (13) The rotary connector device 1 includes: a stator 10; a rotating body 20 configured to rotate about a rotation axis A1 relative to the stator 10; and a lead block 70. Since the manufacturing cost of the lead block 70 can be reduced, the manufacturing cost of the rotary connector device 1 can be reduced.

[0145] (14) The manufacturing method of the lead block 70 includes: a molding step S2, in which a busbar plate 102 comprising a plurality of busbars 72 and a connecting strip 104 that connects the plurality of exposed portions 73 of the plurality of busbars 72 to each other is embedded into the lead block body 71 by insert forming such that the plurality of exposed portions 73 are exposed from the lead block body 71; and a cutting step S3, in which the connecting strip 104 is cut from the plurality of exposed portions 73. In this manufacturing method, the amount of material discarded from cutting the plurality of busbars 72 can be reduced. As a result, the manufacturing cost of the lead block 70 can be reduced.

[0146] (15) The molding process S2 includes the following process S21: the busbar plate 102 is embedded into the lead block body 71 by insert forming such that at least a portion of the connecting strip and a plurality of exposed portions 73 are disposed in the opening of the lead block body 71. As a result, the peripheral portions of the plurality of exposed portions 73 can be held by the lead block body 71.

[0147] (16) The cutting process S3 includes the following process S31: the connecting strip 104 is cut from the plurality of exposed portions 73 through the opening 71B of the lead block body 71. As a result, the connecting strip can be cut from the plurality of exposed portions 73 while the periphery of the plurality of exposed portions 73 is held by the lead block body 71. As a result, the cutting operation is stable.

[0148] (17) The molding process S2 includes the following steps: the busbar plate 102 is embedded into the lead block body 71 by insert forming in such a way that a portion of the connecting strip 104 is embedded into the lead block body 71. As a result, the connection strength between the plurality of exposed portions 73 and the lead block body 71 can be improved.

[0149] (18) The manufacturing method of the lead block 70 also includes the following stamping process S1: a busbar plate 102 is formed from a plate 100 containing conductive material by stamping. The stamping process can reduce the remaining portion cut off from the busbar plate 102.

[0150] like Figure 12 As shown, in this embodiment, the length of the first shear surface 90A in the vertical direction D6 is longer than the lengths of the shear surfaces 80C and 80E in the vertical direction D6. However, as... Figure 16 As shown, the length of the first shear surface 90A in the vertical direction D6 can also be shorter than the lengths of the shear surfaces 80C and 80E in the vertical direction D6. Furthermore, the length of the first shear surface 90A in the vertical direction D6 can also be equal to the lengths of the shear surfaces 80C and 80E in the vertical direction D6. The above dimensional relationships can be applied to the dimensional relationships between the first additional shear surface 91A and the additional shear surfaces 81C and 81E, the second shear surface 93A and the shear surfaces 83C and 83E, and the third shear surface 95A and the shear surfaces 85C and 85E.

[0151] like Figure 12 As shown, in this embodiment, the first shear surface 90A and shear surfaces 80C and 80E are positioned closer to the cable mounting surface 73A than the first fracture surface 90B and fracture surfaces 80D and 80F. However, as Figure 17 As shown, the first fracture surface 90B can also be configured near the cable mounting surface 73A.

[0152] like Figures 4-6 As shown, in this embodiment, the first cutting surface 90 is arranged on the same plane as the first adjacent surfaces 80A and 80B in the arrangement direction D5. However, as... Figure 18 and Figure 19 As shown, the first cut surface 90 may not be arranged on the same plane as the first adjacent surfaces 80A and 80B. The first additional cut surface 91 may also not be arranged on the same plane as the first additional adjacent surfaces 81A and 81B. The first cut surface 90 may also be offset from the first adjacent surfaces 80A and 80B in the arrangement direction D5. The first additional cut surface 91 may also be offset from the first additional adjacent surfaces 81A and 81B in the arrangement direction D5. The positional relationship between the second cut surface 93 and the second adjacent surfaces 83A and 83B in the arrangement direction D5 is similar. The positional relationship between the third cut surface 95 and the third adjacent surfaces 85A and 85B in the arrangement direction D5 is also similar.

[0153] In this embodiment and the above-described variations, the material is cut by stamping (specifically, shearing), but other cutting methods may also be applied.

[0154] Furthermore, in this application, "having" and its derivatives are non-restrictive terms describing the existence of a constituent element, and do not exclude the existence of other constituent elements not described. This also applies to "possessing," "containing," and their derivatives.

[0155] In this application, ordinal numbers such as "first" and "second" are merely terms used to identify the structure and do not have any other meaning (such as a specific order). For example, the existence of "first element" does not imply the existence of "second element," and conversely, the existence of "second element" does not imply the existence of "first element."

[0156] Furthermore, the terms "parallel," "perpendicular," and "consistent" in this disclosure should not be interpreted strictly, but rather include the meanings of "substantially parallel," "substantially perpendicular," and "substantially consistent," respectively. Additionally, the interpretations of other configurations are also not to be interpreted strictly.

[0157] Furthermore, the expression "at least one of A and B" in this disclosure includes, for example, (1) only A, (2) only B, and (3) both A and B. The expression "at least one of A, B, and C" includes, for example, (1) only A, (2) only B, (3) only C, (4) A and B, (5) B and C, (6) A and C, and (7) all three of A, B, and C. In this disclosure, the expression "at least one of A and B" is not interpreted as "at least one of A and at least one of B".

[0158] Based on the above disclosure, it is clear that various modifications and alterations can be made to this invention. Therefore, without departing from the spirit of this invention, this invention can also be implemented using methods different from the specific disclosures in this application.

[0159] Label Explanation

[0160] 1: Rotary connector assembly; 10: Stator; 20: Rotating body; 70: Lead block; 71: Lead block body; 71A: Profile; 71B: Opening; 72: Busbar; 73: Exposed portion; 74: First exposed portion; 75: Second exposed portion; 76: Third exposed portion; 77: First busbar; 77A: First end; 77B: First additional end; 78: Second busbar; 79: Third busbar; 80: First surface; 80A: First adjacent surface; 80B: First adjacent surface; 81: First additional surface; 81A: First additional adjacent surface; 81B: First additional adjacent surface; 83: Second surface; 84: Second additional surface; 85: Third surface; 86: Third additional surface; 87: First protrusion; 88: Second protrusion; 90: First cut surface; 91: First additional cut surface; 93: Second cut surface; 95: Third cut surface; 97: Second additional cut surface; 98: Third additional cut surface; 100: Plate; 102: Busbar plate; 104: Connecting bar; A1: Rotation axis; D4: Long side direction; D5: Configuration direction; D6: Vertical direction; S1: Stamping process; S2: Molding process; S3: Cutting process; S4: Carrier cutting process.

Claims

1. A lead block, comprising: The lead block body contains electrically insulating material; and Multiple busbars are partially embedded within the lead block body and contain conductive material. The plurality of busbars includes a plurality of exposed portions that protrude from the lead block body and correspond to the plurality of busbars respectively. The plurality of exposed portions extend along the long side direction and are spaced apart in a configuration direction perpendicular to the long side direction. The plurality of exposed portions includes at least one first exposed portion. The at least one first exposed portion includes: Page 1; and The first additional surface is disposed on the back side of the first surface in the configuration direction. The first surface includes a first cut surface, which has an area smaller than the area of ​​the first surface. The first additional surface includes a first additional cutting surface, which has an area smaller than that of the first additional surface.

2. The lead block according to claim 1, wherein, The first surface includes a first adjacent surface that is adjacent to the first cut surface. The first additional surface includes a first additional adjacent surface that is adjacent to the first additional cutting surface. The appearance of the first cut surface is different from the appearance of the first adjacent surface. The appearance of the first additional cut surface is different from the appearance of the first additional adjacent surface.

3. The lead block according to claim 2, wherein, The first cut surface is offset from the first adjacent surface in the configuration direction.

4. The lead block according to claim 2 or 3, wherein, The first additional cutting surface is offset from the first additional adjacent surface in the configuration direction.

5. The lead block according to claim 1, wherein, The first additional cutting surface is disposed on the back side of the first cutting surface in the configuration direction.

6. The lead block according to claim 1, wherein, The length of the first cut surface in the long side direction is shorter than the length of the first surface in the long side direction. The length of the first additional cut surface in the long side direction is shorter than the length of the first additional surface in the long side direction.

7. The lead block according to claim 1, wherein, The plurality of exposed portions includes a second exposed portion. The second exposed portion includes: The second surface, which faces the at least one first exposed portion in the configuration direction; and A second additional surface is disposed on the back side of the second surface in the configuration direction. The second surface includes a second cut surface, which has an area smaller than the area of ​​the second surface.

8. The lead block according to claim 7, wherein, One of the plurality of busbars includes a first protrusion that protrudes from the second additional surface of the second exposed portion along the configuration direction. The first protrusion is at least partially embedded within the lead block body.

9. The lead block according to claim 7 or 8, wherein, The plurality of exposed portions includes a third exposed portion. The third exposed portion includes: The third surface, which faces the at least one first exposed portion in the configuration direction; and A third additional surface is disposed on the back side of the third surface in the configuration direction. The third surface includes a third cut surface, which has an area smaller than the area of ​​the third surface.

10. The lead block according to claim 9, wherein, One of the plurality of busbars includes a second protrusion that protrudes from the third additional surface of the third exposed portion along the configuration direction. The second protrusion is at least partially embedded within the lead block body.

11. The lead block according to claim 1, wherein, The plurality of busbars includes at least one first busbar, which includes the at least one first exposed portion. The at least one first busbar includes a first end and a first additional end. In the at least one first busbar, the first cut surface and the first additional cut surface are disposed between the first end and the first additional end.

12. The lead block according to claim 11, wherein, The first end protrudes from the lead block body. When viewed from a vertical direction perpendicular to both the long side direction and the configuration direction, the first additional end is positioned inside the outline of the lead block body.

13. The lead block according to claim 11 or 12, wherein, The first additional end is at least partially embedded within the lead block body.

14. The lead block according to claim 1, wherein, The lead block body includes an opening. The first cutting surface and the first additional cutting surface are disposed within the opening.

15. A rotary connector device, comprising: stator; A rotating body configured to rotate about a rotation axis relative to the stator; and The lead block according to claim 1.

16. A method for manufacturing a lead block, the lead block having: The lead block body contains electrically insulating material; and Multiple busbars are partially embedded within the lead block body and contain conductive material. The plurality of busbars includes a plurality of exposed portions that protrude from the lead block body and correspond to the plurality of busbars respectively. The plurality of exposed portions extend along the long side direction and are spaced apart in a configuration direction perpendicular to the long side direction. The plurality of exposed portions includes at least one first exposed portion. The at least one first exposed portion includes: Page 1; and The first additional surface is disposed on the back side of the first surface in the configuration direction. The first surface includes a first cut surface, which has an area smaller than the area of ​​the first surface. The first additional surface includes a first additional cutting surface, which has an area smaller than the area of ​​the first additional surface, wherein, The manufacturing method of this lead block includes the following steps: In the molding process, a busbar plate comprising multiple busbars and connecting strips that connect multiple exposed portions of the multiple busbars to each other is embedded into the lead block body by insert forming, with the multiple exposed portions exposed from the lead block body. as well as The cutting process involves cutting the connecting strip from the plurality of exposed portions.

17. The method for manufacturing a lead block according to claim 16, wherein, The molding process includes the following steps: embedding the busbar plate into the lead block body by insert forming in such a way that at least a portion of the connecting strip and the plurality of exposed portions are disposed within the opening of the lead block body.

18. The method for manufacturing a lead block according to claim 17, wherein, The cutting process includes the following steps: cutting the connecting strip from the plurality of exposed portions through the opening in the lead block body.

19. The method for manufacturing a lead block according to any one of claims 16 to 18, wherein, The molding process includes the following steps: embedding the busbar plate into the lead block body by means of embedding a portion of the connecting strip into the lead block body through insert forming.

20. The method for manufacturing a lead block according to claim 16, wherein, The manufacturing method of the lead block also includes the following stamping process: the busbar plate is formed from a plate containing conductive material by stamping.

Images