Bus bar module and method for manufacturing bus bar module

Abstract

Provided is a bus bar module capable of suppressing a reduction in the yield of a flexible printed circuit board. A bus bar module (1) is provided with: a flexible printed circuit board (3) having a main line section (30) having a longitudinal direction (X) and a width direction (Y), and a branch section (31) connected to an edge of the main line section in the width direction; a bus bar (10) connected to the branch portion of the flexible printed circuit board; and a case (4) that accommodates the flexible printed circuit board and the bus bar, the branch portion being cut into a shape having a base end portion (32) connected to the trunk line portion and a sheet portion (33) extending in the longitudinal direction from the base end portion, and the branch portion being connected to the bus bar (10) in a state where the sheet portion is deformed to extend in the width direction (Y).

Description

Technical Field

[0001] This invention relates to busbar modules and methods for manufacturing busbar modules. Background Technology

[0002] Previously, there were techniques for connecting flexible printed circuit boards (PCBs) to busbars. Patent Document 1 discloses a connection structure between a busbar and a PCB where the busbar is connected to a flat portion of the PCB. The flat portion of Patent Document 1 extends along the width direction of the PCB.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2023-074117 Summary of the Invention

[0006] The technical problem that the invention aims to solve

[0007] In the circuit board of Patent Document 1, when the distance from the trunk portion to the busbar of the circuit board is long, it is necessary to extend the flat plate portion. As a result, the yield rate of the circuit board is sometimes reduced. When the branch portion is extended in the width direction between the trunk portion and the busbar of the flexible printed circuit board, it is desirable to suppress the reduction in the yield rate of the flexible printed circuit board.

[0008] The purpose of this invention is to provide a busbar module that can suppress the decrease in yield of flexible printed circuit boards and a method for manufacturing the busbar module.

[0009] Technical means for solving problems

[0010] The busbar module of the present invention is characterized by comprising: a flexible printed circuit board having a trunk portion and a branch portion, the trunk portion having a length direction and a width direction, the branch portion being connected to the edge of the trunk portion in the width direction; a busbar being connected to the branch portion of the flexible printed circuit board; and a housing housing accommodating the flexible printed circuit board and the busbar, wherein the branch portion is cut into a shape having a base end portion and a sheet portion, the base end portion being connected to the trunk portion, the sheet portion extending from the base end portion along the length direction, and the branch portion being connected to the busbar module in a state where the sheet portion is deformed to extend along the width direction.

[0011] The manufacturing method of the busbar module according to the present invention is characterized by comprising: a step of forming a flexible printed circuit board having a trunk portion and a branch portion, the trunk portion having a length direction and a width direction, and the branch portion being connected to the edge of the trunk portion in the width direction; a step of deforming the branch portion; a step of connecting the busbar to the branch portion; and a step of housing the busbar and the flexible printed circuit board in a housing, wherein in the step of forming the flexible printed circuit board, the branch portion is cut into a shape having a base end portion and a sheet portion, the base end portion being connected to the trunk portion, and the sheet portion extending from the base end portion along the length direction; and in the step of deforming the branch portion, the branch portion is deformed such that the sheet portion extends along the width direction.

[0012] Invention Effects

[0013] In the busbar module of the present invention, the branch portion of the flexible printed circuit board is cut into a shape having a base end portion connected to the trunk portion and a sheet portion extending from the base end portion along the length direction. The branch portion is connected to the busbar in a state where the sheet portion is deformed to extend along the width direction. The busbar module according to the present invention has the effect of suppressing the reduction in the yield of the flexible printed circuit board. Attached Figure Description

[0014] Figure 1 This is a plan view of the busbar module involved in the embodiment.

[0015] Figure 2 This is a perspective view of the busbar module involved in the embodiment.

[0016] Figure 3 This is an example of a configuration of a flexible printed circuit board that can be manufactured from a single substrate.

[0017] Figure 4 It is a three-dimensional diagram showing the formation of the bend.

[0018] Figure 5 This is a plan view showing an example of a jig plate.

[0019] Figure 6 This is a diagram showing a flexible printed circuit board mounted on a fixture plate.

[0020] Figure 7 This diagram shows a flexible printed circuit board with a bent portion formed by a fixture plate.

[0021] Figure 8 This is a three-dimensional diagram illustrating an example of how a branch can be deformed.

[0022] Figure 9 This is a plan view showing an example of how a branch can be deformed.

[0023] Figure 10 This is a plan view showing an example of a jig board.

[0024] Figure 11 This is a diagram showing a flexible printed circuit board mounted on a fixture plate.

[0025] Explanation of reference numerals in the attached figures

[0026] 1: Busbar Module

[0027] 3: Flexible printed circuit board

[0028] 4: Casing

[0029] 5: Circuit diagram 6: Chip fuse

[0030] 10: Busbar

[0031] 30: Main section, 31: Branch section, 32: Base end, 33: Plate section, 34: Connecting section

[0032] 35: Bending section

[0033] 40: Main body, 41: Wiring, 43: Holding part

[0034] 200: Substrate

[0035] 300: Jig plate, 310: Main body, 320: Support part, 330: Hinge

[0036] 340: Rotating plate, 350: Rotating shaft

[0037] FL: Broken line

[0038] X: Length direction, Y: Width direction Detailed Implementation

[0039] Hereinafter, a busbar module and a method for manufacturing a busbar module according to embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to this embodiment. Furthermore, the constituent elements in the following embodiments include elements readily conceived by those skilled in the art or substantially the same elements.

[0040] [Example]

[0041] Reference Figures 1 to 11 The following describes an embodiment. This embodiment relates to a busbar module and a method for manufacturing the busbar module. Figure 1 This is a plan view of the busbar module involved in the embodiment. Figure 2 This is a perspective view of the busbar module involved in the embodiment. Figure 3 This is an example of a configuration of a flexible printed circuit board that can be manufactured from a single substrate. Figure 4It is a three-dimensional diagram showing a situation where a bend is formed. Figure 5 This is a plan view showing an example of a jig plate. Figure 6 This is a diagram showing a flexible printed circuit board mounted on a fixture plate. Figure 7 This diagram illustrates a flexible printed circuit board with bent sections formed using a fixture plate. Figure 8 This is a three-dimensional diagram illustrating an example of how a branch can be deformed. Figure 9 This is a plan view illustrating examples of how branches can be deformed. Figure 10 This is a plan view showing an example of a jig plate. Figure 11 This is a diagram showing a flexible printed circuit board mounted on a fixture plate.

[0042] like Figure 1 As shown, the busbar module 1 of this embodiment includes a flexible printed circuit board 3, a busbar 10, and a housing 4. The flexible printed circuit board 3 has a base film, a cover layer, and a conductive layer. The base film and the cover layer are flexible, insulating resin layers. The conductive layer is protected by being sandwiched between the base film and the cover layer. The conductive layer is, for example, a conductive metal foil having multiple circuit patterns 5.

[0043] The flexible printed circuit board 3 has a trunk section 30 and a branch section 31. The trunk section 30 has a length direction X and a width direction Y. Multiple circuit patterns 5 extend along the length direction X and are arranged along the width direction Y in the trunk section 30. The branch section 31 is the part that connects to the bus bar 10. The branch section 31 is connected to the edge of the trunk section 30 in the width direction Y.

[0044] Figure 2 An enlarged view of the branch portion 31 connected to the busbar 10 is shown. In the busbar module 1 of this embodiment, the branch portion 31 is connected to the busbar 10 in a deformed state. More specifically, the branch portion 31 of this embodiment has a base end portion 32 and a plate portion 33. The base end portion 32 is the portion connected to the trunk portion 30. The plate portion 33 is connected to the trunk portion 30 via the base end portion 32. Figure 3 As shown, the branch portion 31 is cut from the substrate 200 in such a way that the sheet portion 33 extends from the base end portion 32 along the length direction X. In other words, when forming the flexible printed substrate 3, the sheet portion 33 extends from the base end portion 32 along the length direction X.

[0045] like Figure 2 As shown, a connecting portion 34 is provided at the end of the chip portion 33. A contact portion for connecting to the busbar 10 is disposed on the connecting portion 34. A chip fuse 6 is mounted on the connecting portion 34. The busbar 10 is connected to the circuit pattern 5 via the chip fuse 6.

[0046] The branch 31 is connected to the busbar 10 in a state where the plate 33 is deformed and extends in the width direction Y. Figure 2The branch portion 31 has a bent portion 35. The bent portion 35 bends the sheet portion 33 in such a way that it extends in the width direction Y. By deforming the branch portion 31, it is possible to extend the branch portion 31 into the busbar 10 in the width direction Y.

[0047] According to the busbar module 1 of this embodiment, by suppressing the width Wd of the flexible printed circuit board 3 during manufacturing, manufacturing efficiency can be improved and manufacturing costs reduced. For example, by reducing the width Wd of the flexible printed circuit board 3, the number of flexible printed circuit boards 3 formed from the substrate 200 can be increased, as will be explained below. For example, by reducing the width Wd, the efficiency of the process of mounting components such as the chip fuse 6 onto the flexible printed circuit board 3 is improved.

[0048] Figure 3 An example configuration of a flexible printed circuit board 3 that can be manufactured from a single substrate 200 is shown. Figure 3 In this example, four flexible printed circuit boards 3 are formed from one substrate 200. For example... Figure 3 As shown, in the flexible printed circuit board 3 of this embodiment, the branch portion 31 is cut such that the sheet portion 33 extends along the length direction X. This minimizes the outermost shape 210 of one flexible printed circuit board 3 in the substrate 200. More specifically, the width Wd of the outermost shape 210 can be shortened.

[0049] As a comparative example with respect to the flexible printed circuit board 3 of this embodiment, a flexible printed circuit board extending from the trunk section 30 in the width direction Y is studied. In the flexible printed circuit board of the comparative example, the value of the width Wd is determined according to the distance from the trunk section 30 to the busbar 10. Therefore, when the distance from the trunk section 30 to the busbar 10 is long, the width Wd of the outermost shape 210 becomes larger. As a result, the number of flexible printed circuit boards that can sometimes be formed from a single substrate 200 is reduced.

[0050] In contrast, in the busbar module 1 of this embodiment, the width Wd of the outermost shape 210 of the flexible printed circuit board 3 can be minimized. For example, the width Wd of the outermost shape 210 can be set to the same size regardless of the distance from the trunk section 30 to the busbar 10.

[0051] Figure 4 The diagram shows a flexible printed circuit board 3 with a bent portion 35 formed at the branch 31. The bent portion 35 is formed, for example, at the root of the sheet portion 33 near the base end 32. In the bent portion 35, the sheet portion 33 is bent along a fold line FL. The fold line FL is inclined with respect to the length direction X and the width direction Y. The inclination angle of the fold line FL with respect to the width direction Y is, for example, 45°. The sheet portion 33 is bent, for example, with the mounting surface 33a as the inside. The mounting surface 33a is the surface on which the chip fuse 6 is mounted. The contact portion connected to the busbar 10 is exposed at the mounting surface 33a.

[0052] The process of deforming branch 31 can be carried out by manual operation by the operator or by using a jig. Figure 5 An example of a jig plate 300 used in a bending process is shown. The jig plate 300 has: a main body 310 having a mounting surface 310a; and a support portion 320 rotatable relative to the main body 310. The support portion 320 is connected to the main body 310 via a hinge 330. The hinge 330 has a rotation axis along the mounting surface 310a. The support portion 320 rotates while supporting the sheet portion 33 of the flexible printed circuit board 3.

[0053] Figure 6 A flexible printed circuit board 3 is shown placed on a fixture plate 300. The flexible printed circuit board 3 is disposed on the fixture plate 300 such that the trunk portion 30 is placed on the mounting surface 310a of the main body 310 and the sheet portion 33 is placed on the support portion 320. The support portion 320 supports the sheet portion 33 while rotating, and a bending portion 35 is formed on the sheet portion 33. Figure 7 A flexible printed circuit board 3 with a bent portion 35 is shown using a jig plate 300.

[0054] Furthermore, the connecting portion 34 can be connected to the busbar 10 before or after the bending process. When the connecting portion 34 is connected to the busbar 10 before the bending process, the support portion 320 can also be configured to support both the sheet portion 33 and the busbar 10.

[0055] The manufacturing method of the busbar module 1 involved in this embodiment includes a forming process, a deformation process, a connecting process, and a housing process. The forming process is the process of forming the flexible printed circuit board 3.

[0056] In the forming process, a flexible printed circuit board 3 having a trunk portion 30 and a branch portion 31 is formed. The trunk portion 30 has a length direction X and a width direction Y, and the branch portion 31 is connected to the edge of the trunk portion 30 in the width direction Y. The forming process is performed, for example, by an apparatus that cuts the flexible printed circuit board 3 from the substrate 200. This apparatus, for example, uses a die to punch the flexible printed circuit board 3. In the forming process, the branch portion 31 is cut into a base end portion 32 connected to the trunk portion 30 and a sheet portion 33 extending from the base end portion 32 in the length direction X. Furthermore, after the forming process, a mounting process is performed to install components such as a chip fuse 6 onto the flexible printed circuit board 3.

[0057] In the deformation process, the branch portion 31 of the flexible printed circuit board 3 is deformed. In the deformation process, the branch portion 31 is deformed such that the sheet portion 33 extends along the width direction Y. The deformation process can be performed manually by an operator or using a fixture such as a jig plate 300. For example, the deformation process is a bending process that forms a bent portion 35 in the branch portion 31.

[0058] In the connection process, the busbar 10 is connected to the branch section 31. The busbar 10 is connected to the contact portion of the connection section 34 disposed in the branch section 31 by welding, soldering or the like.

[0059] During the housing process, the busbar 10 and the flexible printed circuit board 3 are housed within the housing 4. For example... Figure 1 As shown, the housing 4 has a body 40 that houses the busbar 10 and the flexible printed circuit board 3. The body 40 is molded, for example, from an insulating synthetic resin. The body 40 has wiring 41 and a plurality of retaining portions 43.

[0060] The wiring 41 houses the flexible printed circuit board 3. The wiring 41 may also be formed as a groove-shaped passage. For example, the wiring 41 may also have a main passage that houses the trunk section 30 and a branch passage that houses the branch section 31.

[0061] The retaining portion 43 receives and holds the busbar 10. A plurality of retaining portions 43 are adjacent to the fabric line 41 in the width direction Y and are arranged along the fabric line 41 in the length direction X. The retaining portion 43 is formed in a frame shape and has a protrusion for locking the busbar 10.

[0062] The housing process includes a busbar housing process in which the busbar 10 is housed in the holding part 43 and a substrate housing process in which the flexible printed circuit board 3 is housed in the wiring 41. The busbar housing process and the substrate housing process can be performed simultaneously or at different times. For example, the substrate housing process can be performed after the busbar housing process is completed, or the busbar housing process can be performed after the substrate housing process is completed.

[0063] Furthermore, the order of the deformation process, the connection process, and the housing process is arbitrary. For example, the deformation process that deforms the branch 31 can be performed before or after the connection process. For example, the flexible printed circuit board 3 with the bent portion 35 can be housed in the housing 4 that houses the busbar 10. In this case, the connection portion 34 of the flexible printed circuit board 3 can be connected to the busbar 10 housed in the holding portion 43.

[0064] Furthermore, the deformation of the branch portion 31 in the deformation process can be different from the deformation that forms the bent portion 35. For example, as Figure 8 and Figure 9As shown, the deformation of the branch portion 31 can also be a deformation that causes the plate portion 33 to rotate relative to the main line portion 30. This deformation is achieved by deforming the base end portion 32, thereby causing the plate portion 33 to rotate relative to the main line portion 30. In this case, the direction of rotation is along the rotation direction of the plane including the main line portion 30. The plate portion 33 rotates relative to the main line portion 30 with the base end portion 32 as the center. The base end portion 32 is elastically deformed in a way that elongates the inner edge 32a.

[0065] In the deformed branch 31, such as Figure 9 As shown, the sheet portion 33 extends in the width direction Y. Figure 8 and Figure 9 The deformation process shown can be performed manually by the operator or using a jig. Figure 10 An example of a jig plate 300 used in a rotation process that rotates the piece 33 is shown. Figure 10 The fixture plate 300 includes: a main body 310 having a mounting surface 310a; and a rotating plate 340 rotatable relative to the main body 310. The rotating plate 340 rotates about a rotation axis 350. The axis of the rotation axis 350 is orthogonal to the mounting surface 310a. The rotating plate 340 is capable of rotating along the mounting surface 310a about the rotation axis 350. A limiter may also be provided on the main body 310 to restrict the range of rotation of the rotating plate 340.

[0066] Figure 11 A flexible printed circuit board 3 is shown placed on a fixture plate 300. The flexible printed circuit board 3 is disposed on the fixture plate 300 such that the trunk portion 30 is placed on the mounting surface 310a of the main body 310 and the sheet portion 33 is placed on a rotating plate 340. The rotating plate 340 may also have a holding mechanism for holding the sheet portion 33. The rotating plate 340 supports the sheet portion 33 while rotating as shown by arrow AR1, causing the sheet portion 33 to rotate relative to the trunk portion 30. Thus, as... Figure 9 As shown, the shape of the branch 31 becomes the shape of the plate 33 extending along the width direction Y.

[0067] The connecting part 34 can be connected to the busbar 10 before the rotation process, or it can be connected to the busbar 10 after the rotation process. When the connecting part 34 is connected to the busbar 10 before the rotation process, the rotating plate 340 can also be configured to hold the plate 33 and the busbar 10.

[0068] The fixture plate 300 used in the rotation process is preferably configured to reduce the load on the circuit pattern 5 caused by deformation of the branch 31. For example, the position of the rotation axis 350 of the fixture plate 300 can also be set to reduce the amount of expansion and contraction of the circuit pattern 5 when the plate 33 is rotated. As an example, such as Figure 11As shown, with the flexible printed circuit board 3 placed on the fixture board 300, the rotation axis 350 can also be configured such that the axis of the rotation axis 350 intersects the circuit pattern 5 of the branch 31.

[0069] As described above, the busbar module 1 of this embodiment includes a flexible printed circuit board 3, a busbar 10, and a housing 4. The flexible printed circuit board 3 has a trunk portion 30 having a length direction X and a width direction Y; and a branch portion 31 connected to the edge of the trunk portion 30 in the width direction Y. The busbar 10 is connected to the branch portion 31 of the flexible printed circuit board 3. The housing 4 houses the flexible printed circuit board 3 and the busbar 10.

[0070] The branch portion 31 is cut into a base end portion 32 connected to the trunk portion 30 and a sheet portion 33 extending from the base end portion 32 along the length direction X. The branch portion 31 is connected to the busbar 10 in a state where the sheet portion 33 is deformed to extend in the width direction Y. According to the busbar module 1 of this embodiment, in the structure in which the branch portion 31 extends in the width direction Y between the trunk portion 30 and the busbar 10, the reduction in yield of the flexible printed circuit board 3 formed from the substrate 200 can be suppressed.

[0071] The deformed branch 31, for example, has a sheet portion 33 bent into a bent portion 35 extending in the width direction Y. The position and shape of the bent portion 35 can be adjusted according to the relative position of the trunk portion 30 and the busbar 10. That is, the busbar module 1 of this embodiment can connect the branch 31 to various configurations of the busbar 10 without changing the design of the flexible printed circuit board 3.

[0072] The branch section 31 can also be connected to the busbar 10 in a state where the plate section 33 rotates relative to the main line section 30 by deforming the base end section 32.

[0073] The manufacturing method of the busbar module 1 according to this embodiment includes the forming process, deformation process, connecting process, and housing process described above. In the forming process, the branch portion 31 is cut into a shape having a base end portion 32 connected to the trunk portion 30 and a sheet portion 33 extending from the base end portion 32 along the length direction X. In the deformation process, the branch portion 31 is deformed so that the sheet portion 33 extends along the width direction Y. According to the manufacturing method of the busbar module 1 according to this embodiment, the yield in the forming process can be improved, and the branch portion 31 extends along the width direction Y between the trunk portion 30 and the busbar 10.

[0074] Furthermore, the deformation method of the branch portion 31 based on the deformation process is not limited to the method exemplified in this embodiment. A flexible printed circuit board 3 may also have branch portions 31 that are deformed into different shapes. For example, it is also possible that some of the multiple branch portions 31 of the flexible printed circuit board 3 are deformed in a manner that includes a bending portion 35, while other branch portions 31 are deformed in a manner that causes the sheet portion 33 to rotate relative to the trunk portion 30.

[0075] The contents disclosed in the above embodiments can be appropriately combined to perform the tasks.

Claims

1. A busbar module, characterized in that, have: A flexible printed circuit board, the flexible printed circuit board having a trunk portion and a branch portion, the trunk portion having a length direction and a width direction, and the branch portion being connected to the edge of the trunk portion in the width direction; A busbar, the busbar being connected to the branch portion of the flexible printed circuit board; as well as Housing, the housing housing the flexible printed circuit board and the busbar, The branch is cut into a shape having a base end and a plate portion, the base end being connected to the trunk portion, and the plate portion extending from the base end along the length direction. The branch is connected to the busbar module when the plate is deformed to extend along the width direction.

2. The busbar module according to claim 1, characterized in that, The branch includes a bent portion, which is bent such that the sheet extends along the width direction.

3. The busbar module according to claim 1, characterized in that, The branch is connected to the busbar in a state in which the plate is rotated relative to the trunk section by deforming the base end.

4. A method for manufacturing a busbar module, characterized in that, include: A process for forming a flexible printed circuit board, wherein the flexible printed circuit board has a trunk section and a branch section, the trunk section has a length direction and a width direction, and the branch section is connected to the edge of the trunk section in the width direction; The process of deforming the branch; The process of connecting the busbar to the branch section; as well as The process of housing the busbar and the flexible printed circuit board in the housing. In the process of forming the flexible printed circuit board, the branch portion is cut into a shape having a base end and a sheet portion, the base end being connected to the trunk portion, and the sheet portion extending from the base end along the length direction. In the process of deforming the branch, the branch is deformed such that the piece extends along the width direction.

Images