Electrical device wiring member

Abstract

The present invention includes: a plurality of bus bars (2); a frame (3) made of resin, which exposes both ends of each of the plurality of bus bars (2) and embeds the bus bars (2) in a state of being spaced apart from each other inside, and has a space portion (3v) in which an opening is formed to expose an intermediate portion (2m) of each of the plurality of bus bars (2); a filling material (5) made of an elastomer, which is filled in the space portion (3v) and covers the entire circumference of the bus bar (2) at least at a boundary portion of the intermediate portion (2m) and the frame (3); and a cover member (4) having a cover portion (4c) that seals the opening and a buried portion (4b) that extends from the cover portion (4c) to the filling material (5) and is embedded in the filling material (5).

Description

Technical Field

[0001] This application relates to a wiring component for electrical equipment. Background Technology

[0002] In internal combustion engine passenger vehicles, in order to reduce the number of wiring harnesses for electrical components, reduce cable diameters, and electrify mechanically operated parts (power steering, engine intake and exhaust systems), it is desirable to achieve voltages higher than the rated voltage of 12V. In this case, when a circuit applying the higher voltage (up to the rated 12V) is installed in the electrical connection box of the power distribution system, leakage current due to potential difference is easily generated. Therefore, a circuit body is disclosed, which is configured to fill insulating resin between the low-voltage system busbar and the high-voltage system busbar, and between the high-voltage system busbars themselves, to prevent leakage current (for example, see Patent Document 1). Existing technical documents Patent documents

[0003] Patent Document 1: Japanese Patent Application Publication No. 2002-27636 (paragraphs 0015-0022, Figures 1-2002) Figure 3 ) Summary of the Invention The technical problem that the invention aims to solve

[0004] However, because the coefficients of linear expansion of the metal busbar and the filling resin are different, tiny gaps can sometimes form due to displacement caused by temperature changes. Therefore, when the busbar is exposed to the outside, liquids such as water that have entered from one end through these tiny gaps can travel to the other end and may cause leakage current at the other end where it is connected to other equipment.

[0005] This application discloses a technology for solving the above-mentioned technical problems, the purpose of which is to obtain a highly reliable electrical equipment wiring component that prevents leakage current. Technical solutions adopted to solve technical problems

[0006] This application discloses an electrical equipment wiring component, characterized in that it comprises: a plurality of busbars; a frame made of resin, the frame being embedded inside with the two ends of each of the plurality of busbars exposed and spaced apart from each other, and having a space portion having an opening for the middle portion of each of the plurality of busbars to be exposed; a filler material made of elastomer, the filler material filling the space portion and covering the entire circumference of the busbars at least at the boundary portion between the middle portion and the frame; and a cover member, the cover member having a cover portion for sealing the opening and an embedded portion extending from the cover portion into the filler material and embedded in the filler material. Invention Effects

[0007] According to the electrical equipment wiring component disclosed in this application, since it is configured to cover at least the boundary portion of the busbar with the frame by using an elastomer, a highly reliable electrical equipment wiring component can be obtained to prevent leakage current caused by the gap between the busbar and the frame. Attached Figure Description

[0008] Figure 1A and Figure 1B These are a perspective view of the electrical equipment wiring components of Embodiment 1 and a perspective view showing a portion of the perspective view. Figure 2 This is a perspective view of a portion of the electrical equipment wiring components of Embodiment 1. Figure 3 This is a top view of the electrical equipment wiring components according to Embodiment 1. Figure 4A and Figure 4B These are cross-sectional views of the electrical equipment wiring components of Embodiment 1, each with a different cut surface. Figure 5 This is a perspective view of the electrical equipment wiring components according to Embodiment 2. Figure 6 This is a cross-sectional view of the electrical equipment wiring component according to Embodiment 2. Figure 7 This is a perspective view of the cover component of the electrical equipment wiring component according to Embodiment 3. Figure 8 This is a cross-sectional view of the electrical equipment wiring component according to Embodiment 3. Figure 9 This is a perspective view of the cover component of the electrical equipment wiring component according to embodiment 4. Figure 10 This is a cross-sectional view of the electrical equipment wiring component according to Embodiment 4. Figure 11 This is a perspective view of the integrally molded busbar and frame of the electrical equipment wiring component according to embodiment 5. Figure 12 This is a perspective view of the cover member of the electrical equipment wiring component according to embodiment 6. Figure 13 This is a cross-sectional view of the electrical equipment wiring component according to Embodiment 6. Figure 14 This is a perspective view of the integrally molded busbar and frame of the electrical equipment wiring component according to embodiment 7. Figure 15 This is a perspective view of the cover member of the electrical equipment wiring component according to embodiment 7. Figure 16 This is a cross-sectional view of the electrical equipment wiring component according to Embodiment 7. Figure 17 This is a perspective view of the integrally molded busbar and frame of the electrical equipment wiring component according to embodiment 8. Figure 18 This is a perspective view of the cover member of the electrical equipment wiring component according to embodiment 8. Figure 19 This is a perspective view of the integrally molded busbar and frame of the electrical equipment wiring component according to embodiment 9. Figure 20 This is a perspective view of the cover member of the electrical equipment wiring component according to embodiment 9. Figure 21 This is a perspective view of the electrical equipment wiring components according to embodiment 9. Figure 22 This is a cross-sectional view of the electrical equipment wiring component according to embodiment 9. Detailed Implementation

[0009] Implementation Method 1 Figure 1A , Figures 1B to 4A , Figure 4B This is a diagram used to explain the configuration of the electrical equipment wiring components in Embodiment 1. Figure 1A This is a 3D view of the electrical equipment wiring components as seen from above. Figure 1B In the context of Figure 1A A perspective view of the frame portion used to represent the state of the cover and generatrix from the same viewpoint. Figure 2 This is a perspective view of the frame portion used to indicate the state of the cover and busbars when observing electrical equipment wiring components from below. Furthermore, Figure 3 It is a top view of the frame portion used to show the state of the busbars of electrical equipment wiring components. Figure 4A Is with Figure 3 The sectional view corresponding to line AA. Figure 4B Is with Figure 3 The sectional view corresponding to the BB line.

[0010] Before describing the configuration of the electrical equipment wiring component 1 in each embodiment of this application, the basic configuration and usage common to general electrical equipment wiring components will be described. The basic configuration is as follows: Figure 1A , Figure 3 As shown, the two ends (ends 2ea and 2eb) of the busbar 2, which is embedded in the frame 3 in the middle, protrude from the frame 3. In addition, for example, when one end (end 2ea) is connected to other equipment or wiring components that require airtightness, the other end (end 2eb) is usually exposed to the outside for use.

[0011] Therefore, water must not penetrate into other connected equipment through electrical wiring components. For example, in harsh environments with repeated rapid temperature changes, when using electrical wiring components with gaps between the busbar and resin as described in the background art, liquid can sometimes seep into the gaps due to the pressure difference between the inside and outside of the component. This infiltrated liquid then becomes a pathway, potentially causing a short circuit between the exposed portions of the busbars to which different voltages are applied. Therefore, electrical wiring components with exposed busbars require a waterproof structure.

[0012] Therefore, in Embodiment 1 of this application, the electrical equipment wiring component 1 is configured such that the entire circumference of the middle portion 2m of the busbar 2, which is integrally embedded in the frame 3, is covered by a filler material 5 made of elastic resin. Specifically, as Figure 1B , Figure 2 and Figure 4B As shown, a space 3v is formed in the frame 3, which exposes both ends (end 2ea, end 2eb) and embeds the middle portion of the busbar 2. The space 3v is open vertically (in the z-direction of the figure) to expose the middle portion 2m of the busbar 2. Furthermore, an elastic filling material 5 is formed by hardening the potting material that fills the space 3v, such as… Figure 4A As shown, the entire circumference of the middle section 2m of busbar 2 is covered.

[0013] For example, busbar 2 is made of conductors with excellent conductivity such as copper (Cu) and aluminum (Al). Two busbars, 2A and 2B, which are subjected to different voltages, are spaced apart and embedded in the frame 3 through insert molding. In the frame 3, in addition to thermoplastic resins such as PPS (Poly Phenylene Sulfide), thermosetting resins can also be used as long as they can be inserted and have strength as the frame 3.

[0014] Furthermore, as an integrally molded product of busbar 2 and frame 3, for the upper and lower open spaces 3v, the lower opening (negative side in the z direction) is sealed by adhesive connector 9, allowing potting material to flow in from the upper opening (positive side in the z direction). The flowing potting material hardens to form a filling material 5 covering the middle portion 2m. Additionally, the electrical equipment wiring component 1 is completed by covering the other opening with a cover member 4, which is partially (embedded portion 4b) embedded in the potting material before it hardens.

[0015] In the electrical equipment wiring component 1 configured as described above, since the resin material constituting the frame 3 and the metal material constituting the busbar 2 have different coefficients of linear expansion, displacement may occur between the frame 3 and the busbar 2 due to temperature changes. At this time, since the frame 3 uses a resin material with rigidity (bending strength, tensile strength) as a frame, it is difficult to track the displacement, and a gap will be generated between it and the busbar 2 as described in the background art.

[0016] In contrast, the potting material used in filler material 5 is an elastic material such as silicone. Therefore, it does not have the rigidity of a frame, but it is more flexible than the resin constituting frame 3, and thus can track the displacement of busbar 2. Therefore, at least in the part covering busbar 2, no gap is generated between it and busbar 2.

[0017] Furthermore, the fit between the space 3v and the frame 3 is excellent. Therefore, even assuming that the gaps between the busbar 2 and the frame 3 are continuously formed between the end 2ea and the space 3v, and between the end 2eb and the space 3v, the gaps are cut off from each other by the filling material 5. Therefore, even if moisture enters the space 3v from the end 2ea, it will not reach the end 2eb, and vice versa.

[0018] Furthermore, as described above, the filler material 5 is superior to the frame 3 in terms of tracking and adhesion, i.e., maintaining a seal. However, since its rigidity is lower than that of the resin material constituting the frame 3, deformation or damage may occur when external force is applied, thus impairing the seal. To address this, a cover member 4 is provided to seal the opening at the top of the space 3v and prevent external force from being applied to the filler material 5.

[0019] The cover member 4 is made of resin with the same rigidity as the frame 3. An embedded portion 4b is provided at the front end of the columnar portion 4j extending from the cover portion 4c (which seals the opening) towards the filler material 5. This embedded portion 4b is embedded within the filler material 5 and extends in a direction perpendicular to the extension direction (z) (y-direction). When the potting material hardens to form the filler material 5, the embedded portion 4b provides an anchoring effect relative to the installation / removal direction (z-direction) of the cover member 4, preventing the cover member 4 from falling off. Furthermore, the cover member 4 has a structure in which the middle portions of the four sides of the cover portion 4c are flattened to provide ribs 4cp, which can be pre-fixed relative to the opening of the space portion 3v of the frame 3. Therefore, even before the potting material hardens and the cover member 4 has provided an anchoring effect, the cover member 4 will not easily fall off.

[0020] Therefore, even under conditions of high-intensity vibration, impact, or high-pressure car washing, where a large external force is applied to the cover member 4, it can prevent the cover member 4 from falling off and exposing the filling material 5. Furthermore, regarding the opening at the bottom of the space 3v, to prevent external forces from being applied towards the filling material 5, it can be sealed by a receiving member 9 having the same rigidity as the frame 3 or the cover member 4. In this case, a portion corresponding to the embedded part 4b that provides an anchoring effect in the filling material 5, similar to the cover member 4, can also be provided in the receiving member 9.

[0021] However, for example, if the ASSY (ASSemblY: assembly) is assembled and the structure is such that external forces cannot be applied to the filler material 5 through the opening below by other components, it is not necessarily necessary to have a receiving element 9. In this case, in order to use it only during the filling of the potting material, the receiving element 9 can also be made of a material such as adhesive tape that can be peeled off after the potting material hardens to form the filler material 5.

[0022] Furthermore, in the electrical equipment wiring component 1 of this application, an open space 3v is formed at the top and bottom during the integral molding stage. Therefore, it can be integrally molded using only the upper and lower molds without using a sliding mold, thus offering the advantage of low mold costs.

[0023] Implementation Method 2 In this second embodiment, a structure that is superior to the case illustrated in embodiment 1 in preventing the cap member from falling off will be described, in the state before the potting material hardens into the filling material. Figure 5 and Figure 6 This is used to describe the structure of the electrical equipment wiring component in Embodiment 2. Figure 5 This is a 3D view of the electrical equipment wiring components as seen from above. Figure 6 Is with Figure 5 The sectional view corresponding to the CC line.

[0024] Furthermore, in the electrical equipment wiring component of this embodiment, the same structure as in Embodiment 1 can be used for the structure other than preventing the cover member from falling off. Descriptions of the same parts are omitted, and references are made to the structure used in Embodiment 1. Figure 4B .

[0025] In the electrical equipment wiring component 1 of this embodiment 2, such as Figure 5 and Figure 6As shown, a snap-fit ​​protrusion 4cf is provided at the middle portion of the two opposite sides of the cover portion 4c, and a recess 3a is provided on the upper part of the outer side 3fx of the enclosing space portion 3v of the frame 3, which engages with the snap-fit ​​protrusion 4cf. In other words, the snap-fit ​​protrusion 4cf and the recess 3a function as a snap-fit ​​mechanism, which restricts the movement of the cover member 4 in the direction of disassembly from the frame 3. The assembly sequence is the same as that of Embodiment 1. After the busbar 2 is molded using the resin constituting the frame 3, the receiving member 9 is glued to the frame 3, and the cover member 4 is installed before the potting material hardens.

[0026] After the potting material hardens to form the filler material 5, the embedded part 4b provides an anchoring effect, preventing the cover member 4 from falling off. Unlike embodiment 1, when the anchoring effect is not present, pre-fixation is achieved using a snap-fit ​​connection between the protrusion 4cf and the recess 3a. Therefore, the fixing force with the frame 3 is greater compared to pre-fixation via the rib 4cp. For example, considering the installation environment of the cover member 4, this is a useful structure for situations where a firm pre-fixation is required before the potting material hardens.

[0027] Implementation Method 3 In Embodiment 3, the shape of the embedded part of the cover member is improved for the electrical equipment wiring component of Embodiment 1 or 2. Figure 7 and Figure 8 This is used to describe the structure of the electrical equipment wiring component in Embodiment 3. Figure 7 This is a three-dimensional view of the cover structure from above. Figure 8 Is with Figure 4A The corresponding sectional view.

[0028] Furthermore, in the electrical equipment wiring component of this embodiment 3, for structures other than the shape of the embedded part, the same structure as in embodiment 1 or embodiment 2 can be applied. For the same parts, the description is omitted, and the structure used in embodiment 1 is referenced. Figure 1A , Figure 1B , Figure 2 as well as Figure 3 .

[0029] In the electrical equipment wiring component 1 of this embodiment 3, such as Figure 7 and Figure 8 As shown, the cross-sectional shape of the embedded portion 4b of the cover member 4 is approximately prismatic, that is, it is inclined relative to the direction of travel toward the filling material 5. More specifically, it has an inclined surface whose area widens toward the front end away from the cover portion 4c in a direction perpendicular to the direction extending from the cover portion 4c, and an inclined surface whose area narrows toward the front end from the widened portion.

[0030] In this case, the assembly sequence is the same as that in Embodiment 1. After the busbar 2 is insert-molded using the resin constituting the frame 3, the receiving member 9 is glued to the frame 3, and the cover member 4 is installed before the filler material 5 (encapsulating material) hardens. When the embedded part 4b enters the filler material 5, the filler material 5 easily winds around along the inclination of the embedded part 4b, thus reducing the possibility of air being drawn into the interior of the filler material 5. For example, in a configuration with relative to Figure 4A In the case where the direction of travel is perpendicular to the plane shown, when the embedded part 4b enters into the filling material 5, air enters before the filling material 5 wraps around the embedded part 4b. When the potting material hardens, air bubbles will be generated inside, which may become a leakage path.

[0031] In particular, in structures with a small amount of filler material 5, if air bubbles enter the interior of the filler material 5 when the cover member 4 is installed, the proportion of air bubbles in the filler material 5 increases, thus increasing the possibility of randomly generating leakage paths. Therefore, the advantages of this structure are greater. Furthermore, in the assembly process of the cover member 4, it is necessary to speed up the installation of the cover member 4 to minimize the installation time. In fast assembly processes, air bubbles can easily get mixed in before the filler material 5 wraps around the embedded portion 4b. Therefore, a structure in which the embedded portion 4b is inclined relative to the direction of travel is effective. In particular, by setting the cross-sectional shape to a rhombus shape, having an inclined surface whose area narrows from the expanded area towards the cover portion 4c, the peeling of the filler material 5 wrapped around the embedded portion 4b can be further suppressed.

[0032] After the potting material hardens to form the filling material 5, the embedded part 4b provides an anchoring effect for the filling material 5, which can prevent the cover component 4 from falling off.

[0033] Implementation Method 4 In this embodiment 4, since the amount of filler material used is reduced compared to the electrical equipment wiring components in embodiments 1 to 3, the volume of the embedded part of the cover member is increased. Figure 9 and Figure 10 This is used to describe the structure of the electrical equipment wiring component in Embodiment 4. Figure 9 This is a three-dimensional view of the cover structure from above. Figure 10 Is with Figure 4A The corresponding sectional view.

[0034] Furthermore, in the electrical equipment wiring component of this embodiment 4, the same structure as in embodiments 1 to 3 can be applied to structures other than the shape of the embedded part. For the same parts, the description is omitted, and the structure used in embodiment 1 is referenced. Figure 1A , Figure 1B , Figure 2 as well as Figure 3 .

[0035] In the electrical equipment wiring component 1 of this embodiment 4, such as Figure 9 and Figure 10 As shown, compared with the embedded part 4b in Embodiments 1 to 3, the volume of the embedded part 4b of the cover member 4 is increased, eliminating the difference from the columnar part 4j. The assembly sequence is the same as that in Embodiment 1. After the busbar 2 is molded with the resin constituting the frame 3, the receiving part 9 is pasted to the frame 3, and the cover member 4 is installed before the potting material hardens.

[0036] In Embodiment 4, the volume of the portion inserted into the filler material 5 of the cover member 4 (including the embedded portion 4b corresponding to the columnar portion 4j in Embodiment 1) is increased. In this case, the amount of filler material 5 is small, but the amount of filler material 5 can be reduced as long as it meets the purpose of waterproofing and insulation performance between busbars of different voltages. Therefore, the volume of the embedded portion 4b can be increased before the above-mentioned filler amount is reached, thus reducing the amount of filler material 5. Generally speaking, the potting material constituting the filler material 5 is more expensive than the resin material constituting the frame 3, etc. Therefore, with this structure, the material cost is cheaper than in Embodiments 1 to 3.

[0037] Implementation Method 5 In this embodiment 5, a through hole is provided in the middle part of the busbar to facilitate the winding of the filler material. Figure 11 The diagram used to describe the structure of the electrical equipment wiring component of Embodiment 5 is a perspective view of the integrally molded busbar and frame from above.

[0038] Furthermore, in the electrical equipment wiring component of this embodiment 5, for structures other than the shape of the busbar, the same structure as in embodiments 1 to 4 can be applied. For the same parts, the description is omitted, and for the relationship between the embedded part and the filling material, the method used in embodiment 1 is referenced. Figure 4A , Figure 4B .

[0039] In the electrical equipment wiring component 1 of this embodiment 5, such as Figure 11 As shown, a through hole 2h is provided on the surface opposite the opening in the middle part 2m of the busbar 2, which should be covered by the filling material 5. The assembly sequence is the same as that in Embodiment 1. After the busbar 2 is molded with the resin that constitutes the frame 3, the receiving part 9 is pasted to the frame 3, and the cover member 4 is installed before the potting material hardens.

[0040] Sufficient time is required to fill the space 3v with the filler material 5 without introducing air bubbles. However, it is difficult to completely eliminate air bubbles generated inside the filler material 5 simply by injecting potting material into the atmosphere. Therefore, in embodiment 5, a through hole 2h is formed in the middle part 2m of the busbar 2 that is exposed into the space 3v.

[0041] When potting material is injected into the integrally molded part formed by attaching the receiving part 9 to the bottom of the space 3v, the potting material gradually fills in from the bottom of the space 3v, allowing air bubbles attempting to accumulate on the lower surface of the busbar 2 to escape through the through-hole 2h. Therefore, a structure is created where air bubbles are difficult to accumulate inside the filling material 5 formed by the hardening of the potting material. Furthermore, the through-hole 2h can be used for positioning the busbar 2 during insert molding, ensuring that the opening of the through-hole 2h on the busbar 2 is not exposed to the outside after the potting material is filled.

[0042] When inserting busbars into the frame using resin, the positioning of the busbars is crucial. If the mold pin is inserted further into the through-hole during molding, the portion of the busbar with the through-hole will be exposed after molding. If used in this state, conductive substances such as salt will accumulate in the electrical wiring component, potentially causing a short circuit. Therefore, sometimes a process of filling the exposed portion with adhesive is required. However, in the structure of the electrical wiring component 1 of this embodiment 5, the portion exposed from the frame 3 with the through-hole 2h is covered by the filling material 5, thus the through-hole 2h used for positioning the busbar 2 is not exposed. Therefore, it has the advantage of eliminating the need for an additional adhesive coating process.

[0043] Implementation Method 6 In this embodiment 6, since the exposed area of ​​the filling material is reduced compared to the electrical equipment wiring components of embodiments 1 to 5, a cover plate covering the upper surface of the filling material is provided on the cover member. Figure 12 and Figure 13 This is used to describe the structure of the electrical equipment wiring component in Embodiment 6. Figure 12 This is a perspective view of the cover component from below. Figure 13 Is with Figure 4A The corresponding sectional view.

[0044] Furthermore, in the electrical equipment wiring component of this embodiment 6, the same structure as in embodiments 1 to 5 can be applied to the structure other than the cover plate of the cover member. For the same parts, the description is omitted, and the structure used in embodiment 1 is referenced. Figure 1A , Figure 1B , Figure 2 as well as Figure 3 .

[0045] In the electrical equipment wiring component 1 of this embodiment 6, such as Figure 12 and Figure 13 As shown, a cover plate 4t is provided at the midpoint between the embedded portion 4b of the columnar portion 4j of the cover member 4 and the cover portion 4c, covering the upper surface of the filling material 5. With this structure, even if harmful substances that adversely affect the filling material 5 intrude through the gap between the cover member 4 and the upper opening of the space portion 3v, the area of ​​the upper panel in contact with the harmful substances is reduced because the upper surface of the filling material 5 is covered by the cover plate 4t. Furthermore, by aligning the shape of the cover plate 4t in the xy plane with the inner circumferential surface of the space portion 3v, the entire upper panel of the filling material 5 can be covered by the cover plate 4t.

[0046] Implementation Method 7 In this embodiment 7, a structure in which a labyrinth structure is formed between the cover member and the frame in order to enhance the isolation between the filling material and the outside will be described. Figures 14-16 This is used to describe the structure of the electrical equipment wiring component in Embodiment 7. Figure 14 This is a three-dimensional view of the integrally molded product, showing the busbar and frame from above. Figure 15 This is a three-dimensional view of the cover component from the bottom side. Figure 16 Is with Figure 4A The corresponding sectional view.

[0047] Furthermore, in the electrical equipment wiring component of this embodiment 7, for structures other than the labyrinth structure of the cover member and the frame, the same structure as in embodiments 1 to 6 can be applied. For the same parts, the description is omitted, and the structure used in embodiment 1 is referenced. Figure 1A , Figure 1B , Figure 2 as well as Figure 3 .

[0048] In the electrical equipment wiring component 1 of this embodiment 7, such as Figure 14 As shown, a groove 3d recessed in the z-direction is formed throughout the entire circumference of the inner edge of the upper opening of the space portion 3v in the frame 3, and a ridge 3r protruding in the z-direction is formed throughout the entire circumference of the inner side of the groove 3d in the xy plane. Correspondingly, as Figure 15 As shown, a ridge 4r corresponding to the groove 3d is provided all around the outer edge of the opposite surface 4ff of the cover portion 4c of the cover member 4 facing the space portion 3v, and a groove 4d corresponding to the ridge 3r is formed all around the inner side of the ridge 4r.

[0049] Therefore, when the cover component 4 is placed over the frame 3, as... Figure 16As shown, the ridge 3r is embedded into the groove 4d, and the ridge 4r is embedded into the groove 3d, forming a labyrinth structure that isolates the space 3v from the outside. In other words, the groove 4d, ridge 3r, groove 3d, and ridge 4r are combined to function as a labyrinth sealing mechanism. By forming a labyrinth structure, even when the electrical wiring component 1 is located externally, it is possible to prevent liquids such as salt water and water from intruding through the gap between the cover member 4 and the frame 3.

[0050] Implementation Method 8 In this embodiment 8, the structure for fixing the cover member to the frame by means of a threaded structure will be described. Figure 17 and Figure 18 This is used to describe the structure of the electrical equipment wiring component in Embodiment 8. Figure 17 This is a three-dimensional view of the integrally molded product, showing the busbar and frame from above. Figure 18 This is a three-dimensional view of the cover component viewed from below.

[0051] Furthermore, in the electrical equipment wiring component of this embodiment 8, for structures other than those used to fix the cover member to the frame, the same configuration as in embodiments 1, 3 to 7 can be applied. For the same structures, the description is omitted, and the relationship between the busbar, the embedded part, and the filling material is referenced from that used in embodiment 1. Figure 4A , Figure 4B .

[0052] In the electrical equipment wiring component 1 of this embodiment 8, such as Figure 17 As shown, the at least open portion of the space 3v of the frame 3 is formed into a cylindrical shape in the xy plane, and a female thread 3fs is formed on the inner circumferential surface of the upper opening. Correspondingly, as... Figure 18 As shown, the cover member 4 also forms the cover portion 4c into a circle, and forms a male thread 4cms corresponding to the female thread 3fs on the outer peripheral surface.

[0053] Therefore, when the cover member 4 covers the frame 3, it is inserted while rotating along the threads and fixed by the threaded structure, resulting in a greater fixing force compared to the case of simple (flattened) pre-fixation via the ribs 4cp. Furthermore, the installed state of the cover member 4 is easier to visually confirm compared to pre-fixation using the ribs 4cp. For example, if the direction of the load applied to the cover member 4 is tilted from the vertical direction (z-direction) due to pre-fixation using the ribs 4cp, it is conceivable that the ribs 4cp may not be flattened, leading to the cover member 4 being installed without exerting the expected fixing force.

[0054] Even under these conditions, the cover member 4 is positioned at a specified height relative to the frame 3, and there is a possibility of mistakenly believing that the installation of the cover member 4 has been completed. On the other hand, with the threaded structure of the cover member 4, the installation method is easy and eliminates the aforementioned concerns. Furthermore, in the case of the threaded structure, the cover member 4 can be disassembled, and even if the installation of the cover member 4 fails, it can be repeatedly installed and removed as long as the potting material has hardened.

[0055] Implementation Method 9 In the above embodiments, an example of providing a space that gathers and exposes the middle portions of multiple busbars will be described. In this embodiment 9, an example of providing multiple spaces separated by partitions to expose the middle portions of each busbar will be described. Figures 19-22 This is used to describe the structure of the electrical equipment wiring component in Embodiment 9. Figure 19 This is a three-dimensional view of the integrally molded product, showing the busbar and frame from above. Figure 20 This is a perspective view of the cover component from below. Figure 21 A three-dimensional view of the electrical equipment wiring components from above. Additionally, Figure 22 Is with Figure 21 The sectional view corresponding to the DD line.

[0056] Furthermore, in the electrical equipment wiring component of this embodiment 9, for structures other than those in which the space portion is set separately for each busbar, the same structure as in embodiments 1 to 8 can be used. For the same parts, the description is omitted.

[0057] In the electrical equipment wiring component 1 of this embodiment 9, such as Figure 19 As shown, the middle section 2m of busbars 2A and 2B is separated by a partition wall 3p, and separately exposed spaces 3vA and 3vB are provided respectively. Furthermore, as... Figure 20 As shown, in the cover component 4, columnar parts 4jA and 4jB are provided in the cover part 4c that centrally seals the two spatial parts 3vA and 3vB. The columnar parts 4jA and 4jB extend relative to the spatial parts 3vA and 3vB respectively, and embedded parts 4bA and 4bB are formed at their respective front ends.

[0058] The assembly sequence is the same as in the embodiments described above. After the busbar 2 is molded with the resin constituting the frame 3, the receiving member 9 is attached to the frame 3. However, the potting material as the filler material 5 (filler materials 5A, 5B) is divided into two separate spaces 3vA and 3vB for potting. After the potting material is injected into the spaces 3vA and 3vB respectively, the cover member 4 is installed before the filler material 5 hardens.

[0059] When the potting material hardens to form filler material 5, such as Figure 21 and Figure 22 As shown, the embedded parts 4bA and 4bB are respectively designed to provide an anchoring effect relative to the installation / removal direction (z-direction) of the cover member 4 and to prevent the cover member 4 from falling off. In addition, the spatial distance and creepage distance between the busbars 2A and 2B can be ensured in advance by the partition wall 3p. Therefore, even if there is a deviation in the filling of the filling material 5, the insulation between the two can be well ensured.

[0060] Furthermore, although this example shows an instance where the embedded part 4b is provided in multiple spaces 3v, it is not limited to this. For example, any one space 3v may be provided for a cover part 4c. Also, although an example shows a case where multiple spaces 3v are sealed together, it is not limited to this; a cover member 4 may be provided in each space 3v.

[0061] Furthermore, this application describes various exemplary embodiments and examples, but the various features, methods, and functions described in one or more embodiments are not limited to specific embodiments and can be applied to embodiments individually or in various combinations. Therefore, numerous modifications not illustrated are contemplated within the scope of the technology disclosed in this application. For example, these include modifications, additions, or omissions of at least one constituent element, as well as extraction of at least one constituent element and combination with constituent elements disclosed in other embodiments.

[0062] For example, while examples of using PPS in the frame 3, copper in the busbar 2, and silicone in the filler material 5 are shown, this is not a limitation. For example, other thermosetting or thermoplastic elastomers can be used as filler material 5, as long as they meet the requirements of fit and trackability; any material that is referred to as a "resilient polymer" is suitable.

[0063] Furthermore, in this example, although an example is shown where the middle portion 2m, disposed in the space 3v, is connected to the boundary portion of the frame 3 and covered by the filling material 5, it is not necessarily limited to this from the viewpoint of preventing the intrusion of moisture through the gap created between the ends 2ea and 2eb. If it is only necessary to cut off the leakage path between the busbars 2A and 2B in the space 3v, it would be sufficient, for example, to form a partition wall 3p extending along the xz plane in the frame 3 and separating the busbars 2A and 2B within the space 3v, as in Embodiment 9. In this case, it is not necessary to further cover the middle portion of the middle portion 2m with the filling material 5; as long as the boundary portion of the middle portion 2m and the frame 3 is covered throughout the entire circumference, both the cutting off of the leakage path and the prevention of moisture intrusion through the gap between the frame 3 and the busbars 2 can be achieved.

[0064] Furthermore, regarding the material constituting the frame 3, it is not limited to thermoplastic resin as long as it is a material in which the busbar 2 is embedded and has rigidity as a frame; thermosetting resin can also be used. Additionally, although an example is shown where the space portion 3v is open at both the top and bottom, and can be formed using only upper and lower molds, it is not limited to this; as long as the filler material 5 can be filled, it can also be open on only one side. Furthermore, for the busbar 2, not only aluminum can be used, but any conductive material with excellent conductivity can be used, and the number is not limited to two.

[0065] As described above, the electrical equipment wiring component 1 according to this application is configured to include: a plurality of busbars 2; a frame 3 made of resin, the frame 3 exposing the two ends (end 2ea, end 2eb) of each of the plurality of busbars 2 and embedding them inside in a mutually spaced manner, and having a space portion 3v, the space portion 3v forming an opening for exposing the middle portion 2m of each of the plurality of busbars 2; a filler material 5 made of elastomer, the filler material 5 filling the space portion 3v and covering the entire circumference of the busbars 2 at least at the boundary between the middle portion 2m and the frame 3; and a cover member 4, the cover member 4 having a cover portion 4c that seals the opening and an embedding portion 4b extending from the cover portion 4c toward the filler material 5 and embedded in the filler material 5. Therefore, leakage current caused by the gap between the busbar 2 and the resin constituting the frame 3 can be prevented, thus obtaining a highly reliable electrical wiring component 1. At this time, since the opening is sealed by the cover 4c, the fit between the busbar 2 and the frame 3 is excellent, as is the tracking ability relative to displacement, while protecting the poorly rigid filler material 5 from external forces, thereby maintaining the aforementioned fit.

[0066] If the space portion 3v is configured to have a second opening on the opposite side of the opening blocked by the cover portion 4c, it can be formed by upper and lower molds without using a sliding mold.

[0067] The frame 3 is an integrally molded product with multiple busbars 2, so it can be easily manufactured, especially when there is a second opening, it can be manufactured more simply by using only upper and lower molds.

[0068] If the embedded part 4b is configured to have a portion that is widened toward the front end away from the cover part 4c in a direction perpendicular to the direction (z direction) extending from the cover part 4c, then after the filling material 5 hardens, it can prevent detachment by means of the anchoring effect.

[0069] At this time, if the structure is configured with an inclined surface that widens from the front end and narrows as it moves further away from the cover portion 4c, it can suppress the entrainment of air bubbles toward the filler material 5 when the cover member 4 is installed. In addition, if it has an inclined surface that narrows from the widened portion toward the cover portion 4c, it can further suppress the peeling of the filler material 5 that wraps around the embedded portion 4b.

[0070] If the structure is configured such that a through hole 2h is formed on the surface opposite to the opening in the middle part 2m, then air bubbles can escape as the filling material 5 is filled.

[0071] If the filling material is configured to cover the entire circumference of the 2m middle section and the 5th layer, leakage current between the busbars 2 can be reliably prevented even if multiple busbars 2 are arranged without separation in the space section 3v.

[0072] If a ridge 4r protruding in the thickness direction and a groove 4d recessed in the thickness direction are formed all around the outer edge of the opposite side 4ff of the cover 4c facing the opening, and a second groove (groove 3d) and a second ridge (ridge 3r) that respectively fit into the ridge 4r and the groove 4d are formed on the inner edge of the opening of the frame 3, a labyrinth structure can be formed, which can reliably prevent moisture from entering through the gap between the cover 4c and the opening.

[0073] If the cover member 4 and the frame 3 are configured with a snap-fit ​​mechanism that restricts the movement of the cover member 4 from the frame 3 when the cover part 4c seals the opening, the cover member 4 can be prevented from falling off the frame 3 before the potting material hardens.

[0074] Alternatively, the cover member 4 can be configured such that a male thread 4ms is formed on the outer peripheral surface of the cover 4c, and a female thread 3fs corresponding to the male thread 4ms is formed on the inner peripheral surface of the opening of the frame 3, which can also prevent the cover member 4 from falling off the frame 3 before the potting material hardens. (Symbol Explanation)

[0075] 1. Electrical equipment wiring components; 2. Busbars; 2ea, 2eb ends; 2h through holes; 2m intermediate parts; 3. Frames; 3a recesses (hook-and-loop fastening mechanism); 3d slots (maze mechanism); 3fs female threads; 3p partitions; 3r ridges (maze mechanism); 3v space parts; 4. Cover components; 4b embedded parts; 4c cover parts; 4cf hook-and-loop fastening protrusions (hook-and-loop fastening mechanism); 4cms male threads; 4cp ribs; 4d slots (maze mechanism); 4j columnar parts; 4r ridges (maze mechanism); 4t covering plates; 5. Filling materials.

Claims

1. A wiring component for electrical equipment, characterized in that, include: Multiple busbars; A frame made of resin, wherein the two ends of each of the plurality of busbars are exposed and embedded inside in a spaced manner, and having a space portion having an opening for the middle portion of each of the plurality of busbars to be exposed. A filling material made of an elastomer that is superior to the resin constituting the frame in terms of tracking and fit, and has lower rigidity than the resin constituting the frame, fills the space, covering the entire circumference of the busbar at least at the boundary between the middle portion and the frame, and cutting off the gap between the middle portion and the frame. as well as A cover member having a cover portion that seals the opening and an embedded portion extending from the cover portion into the filler material and embedded in the filler material, the space portion having a second opening on the opposite side of the opening sealed by the cover portion.

2. The electrical equipment wiring component as described in claim 1, characterized in that, The frame is an integrally molded product with the plurality of busbars.

3. The electrical equipment wiring component as described in claim 1, characterized in that, The embedded portion has a portion whose area is widened toward the front end away from the cover portion in a direction perpendicular to the direction extending from the cover portion.

4. The electrical equipment wiring component as described in claim 2, characterized in that, The embedded portion has a portion whose area is widened toward the front end away from the cover portion in a direction perpendicular to the direction extending from the cover portion.

5. The electrical equipment wiring component as described in claim 3, characterized in that, An inclined surface is formed, which extends from the widened portion of the area toward the front end and narrows as it moves further away from the cover.

6. The electrical equipment wiring component as described in claim 4, characterized in that, An inclined surface is formed, which extends from the widened portion of the area toward the front end and narrows as it moves further away from the cover.

7. The electrical equipment wiring component as described in any one of claims 1 to 6, characterized in that, A through hole is formed on the surface of the middle part opposite to the opening.

8. The electrical equipment wiring component as described in any one of claims 1 to 6, characterized in that, The filling material covers the entire circumference of the middle section.

9. The electrical equipment wiring component as described in claim 7, characterized in that, The filling material covers the entire circumference of the middle section.

10. The electrical equipment wiring component as claimed in any one of claims 1 to 6 and 9, characterized in that, The outer edge of the cover portion facing the opening is formed with ridges protruding in the thickness direction and grooves recessed in the thickness direction throughout the entire circumference. A second groove and a second ridge are formed on the inner edge of the opening of the frame, which respectively engage with the ridge and the groove.

11. The electrical equipment wiring component as described in claim 7, characterized in that, The outer edge of the cover portion facing the opening is formed with ridges protruding in the thickness direction and grooves recessed in the thickness direction throughout the entire circumference. A second groove and a second ridge are formed on the inner edge of the opening of the frame, which respectively engage with the ridge and the groove.

12. The electrical equipment wiring component as described in claim 8, characterized in that, The outer edge of the cover portion facing the opening is formed with ridges protruding in the thickness direction and grooves recessed in the thickness direction throughout the entire circumference. A second groove and a second ridge are formed on the inner edge of the opening of the frame, which respectively engage with the ridge and the groove.

13. The electrical equipment wiring component as claimed in any one of claims 1 to 6, 9, 11, and 12, characterized in that, The cover member and the frame are provided with a snap-fit ​​mechanism, which is used to form a snap-fit ​​engagement that restricts the movement of the cover member in the direction of detachment from the frame when the cover seals the opening.

14. The electrical equipment wiring component as described in claim 7, characterized in that, The cover member and the frame are provided with a snap-fit ​​mechanism, which is used to form a snap-fit ​​engagement that restricts the movement of the cover member in the direction of detachment from the frame when the cover seals the opening.

15. The electrical equipment wiring component as described in claim 8, characterized in that, The cover member and the frame are provided with a snap-fit ​​mechanism, which is used to form a snap-fit ​​engagement that restricts the movement of the cover member in the direction of detachment from the frame when the cover seals the opening.

16. The electrical equipment wiring component as described in claim 10, characterized in that, The cover member and the frame are provided with a snap-fit ​​mechanism, which is used to form a snap-fit ​​engagement that restricts the movement of the cover member in the direction of detachment from the frame when the cover seals the opening.

17. The electrical equipment wiring component as claimed in any one of claims 1 to 6, 9, 11, and 12, characterized in that, A male thread is formed on the outer peripheral surface of the cover, and a female thread corresponding to the male thread is formed on the inner peripheral surface of the opening of the frame.

18. The electrical equipment wiring component as described in claim 7, characterized in that, A male thread is formed on the outer peripheral surface of the cover, and a female thread corresponding to the male thread is formed on the inner peripheral surface of the opening of the frame.

19. The electrical equipment wiring component as described in claim 8, characterized in that, A male thread is formed on the outer peripheral surface of the cover, and a female thread corresponding to the male thread is formed on the inner peripheral surface of the opening of the frame.

20. The electrical equipment wiring component as described in claim 10, characterized in that, A male thread is formed on the outer peripheral surface of the cover, and a female thread corresponding to the male thread is formed on the inner peripheral surface of the opening of the frame.

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