Safety connection unit with articulated section

Abstract

Safety connection unit including: a busbar (30); a hinge section (38) provided at a center of the busbar (30) and comprising a band plate section (33) and bending sections (31, 32) at both side edges of the band plate section (33); and two locking connection bodies (10, 20) which are integrally provided on both sides of the joint section (38) and are formed by attaching two resin housings (11, 21) made of insulating resin to plate sections forming respective locking circuits by a casting process, wherein a required part is exposed, characterized by the fact that the two bodies (10, 20) are arranged to be pivoted towards each other in a U-shape in plan view during a bending process at the bending sections (31, 32), in order to subsequently be arranged at a distance which corresponds to the width of the strip plate section (33), Individually for the resin housings (11, 21) at positions remote from the joint section (38) engagement units (130, 140) are provided which are designed to maintain the U-shape in plan view, and two or more pairs of a recessed guide (111) and a protruding guide (121) are provided near the joint section (38) along both side edges of the band plate section (33) on opposite surfaces of the two resin housings, wherein the recessed and protruding guides (111, 121) are opposite each other, and each pair of guides (111, 121) is arranged to engage with each other to guide the two resin housings (11, 21) into suitable positions during bending, wherein the pairs of guides (121) are each arranged with intervals between them.

Description

BACKGROUND OF THE INVENTION 1. Field of the invention

[0001] The present invention relates to a fuse connection unit that is directly attached to a vehicle battery and supplies power to each load through multiple fuses (a fuse section). Specifically, the present invention relates to a fuse connection unit that is manufactured in a flat form by a press-fit resin housing process in which a busbar is attached to a mold, the busbar comprising a section forming a fuse circuit, and is then bent into a stereoscopic block shape according to a mold for mounting to the battery or the like. 2. Description of the state of the art

[0002] The safety connection units described in patent publications 1 and 2 are known as such a type of safety connection unit.

[0003] The safety connection unit described in patent publication 1 includes a bendable hinge section 533 in the center of a busbar 530, as shown in Fig. Figure 1 shows plate sections (not shown) forming fuse circuits, provided on both sides of the hinge section 533 for connection to it. Resin bodies 511 and 521 are formed on the two plate sections forming fuse circuits, with the required portion exposed to the outside, thus forming two bodies 510 and 520 that constitute fuse connections. After forming, the two bodies 510 and 520 are pivoted approximately 90° into an L-shaped position on the hinge section 533. Reference numeral 536 in the drawing designates a fuse section.

[0004] The locking connection unit described in patent publication 2 comprises a hinged section in the center of a busbar, wherein the hinged section includes bending sections on both lateral edges of a strip plate section. On both sides of the hinged section, two plate sections forming locking circuits are integrally formed for connection to it. These two plate sections forming locking circuits are arranged parallel to each other with a spacing equal to the width of the strip plate inserted between them when pivoted in the same direction at the bending sections. Two resin housings made of insulating resin are attached to the individual plate sections forming locking circuits by a press-fit process, exposing a required portion and thus forming two bodies that constitute locking connections.The two bodies are then pivoted in the same direction at the bending sections. In a top view, the two bodies and the hinge section form a U-shape. The two resin housings are secured by U-shaped engagement units. Patent Publication 1: Published Japanese patent publication no. 2001-297683 Patent Publication 2: Published Japanese Patent Publication No. 2004-186006

[0005] Furthermore, EP 1 255 271 A2 discloses a locking unit in which only one locking arm is provided. The locking arm must be designed to engage in a wall section with a recess. A similar arrangement is shown in DE 10 2007 036 646 A1. SUMMARY OF THE INVENTION

[0006] In each of the previously described conventional locking connection units, the positional relationship between the two bodies is determined by pivoting the two bodies at the joint section formed on the busbar. Accordingly, the positional relationship between the two bodies can vary considerably depending on the bending method at the joint section. Due to these variations in the positional relationship between the two bodies, the unit may not be able to connect to the other connector because the cable length of the other connector is insufficient, unnecessary stress exerted on the connection section may cause deformation of the unit, or it may lead to a deterioration of the watertightness or cable detachment of the other connector.

[0007] In the conventional fuse link unit described above, the positional relationship between the two bodies depends on the joint section. Consequently, the overall strength of the fuse link unit can depend on the strength of the joint section. If the fuse link unit mounted on a vehicle is subjected to vibration, stress and material fatigue are concentrated at the joint section, causing damage. Furthermore, applying an external force concentrates a significant stress at the joint section. Therefore, the busbar plate thickness itself must be considerable, and the fuse link unit cannot be used for low-current fuses.

[0008] In view of the circumstances described above, an objective of the present invention is to provide a locking connection unit in which the positional relationship between the two bodies can be suitably maintained; engagement units that secure the bodies can be easily brought into engagement with each other and a stress concentrated at the joint section is reduced for an increase in overall strength.

[0009] The present invention is defined in independent claim 1. Preferred embodiments are defined in the dependent claims.

[0010] A fuse connection unit according to a first aspect comprises: a busbar; a hinge section provided at a center of the busbar and comprising bending sections on both lateral edges of a strip plate section; and two fuse-connection forming bodies integrally provided on both sides of the hinge section for connection to two strip plate sections forming fuse circuits, and formed by attaching two resin housings consisting of insulating resin to the respective strip plate sections forming fuse circuits by a press-fit method, wherein a required part is exposed and the two bodies are arranged parallel with a distance equal to the width of the strip plate after being pivoted in the same direction at the bending sections.The two bodies are pivoted at the bending sections in the same direction into a U-shape in plan view, and the U-shape in plan view is maintained by engagement units, each individually provided for the resin housings at positions remote from the joint section. Furthermore, at least one pair of recessed and protruding guides is provided near the joint section on opposite surfaces of the two resin housings, the recessed and protruding guides being opposite each other when the two bodies are pivoted and engaging each other when the two bodies are pivoted to guide the two resin housings into suitable positions.

[0011] In the safety connection unit according to the first aspect, several pairs of recessed and protruding guides can be provided, wherein the pairs of recessed and protruding guides are arranged at intervals along both side edges of the strip plate section.

[0012] Furthermore, the recessed and protruding guides can each include an inner lower surface and an upper surface that abut each other when the two bodies are fully pivoted. At this point, the locking connection unit can include engagement units that secure the two bodies. These engagement units are disengaged and separated from each other when the inner lower surface of the recessed guide and the upper surface of the protruding guide are abutting each other, and engaged when the bodies are bent.

[0013] Furthermore, the locking connection unit can include: a guide chamfer on an inner side surface of the recessed guide and / or an outer side surface of the protruding guide. The guide chamfer is brought into sliding contact with the recessed or protruding guide when the recessed and protruding guides begin to engage with each other, and then guides them into a suitable position.

[0014] According to the locking mechanism of the first aspect, the recessed and protruding guides are positioned close to the joint section. During the process of bringing the two bodies into alignment, they are secured, their positions constrained by the action of the recessed and protruding guides. Consequently, the two bodies are fixed in suitable positions without any special user intervention once the bending is complete. The engagement points of the two bodies are reliably engaged with each other. This eliminates variations in the positional relationship between the two bodies, and, for example, the locking mechanism can be easily attached to the other joint.This eliminates the possibility of the connector separating due to insufficient cable length, deformation of the unit due to unnecessary stress exerted on the connection sections, deterioration of water resistance, or cable detachment from the other connector. Furthermore, a portion of the external force is absorbed by the section near the joint where the recessed and protruding guides engage. This reduces the stress concentration at the joint. Consequently, the possibility of damage to the joint is significantly reduced when an external force, including vibration, acts on the locking connector. The overall strength of the locking connector is thus increased, and the product strength is less affected by the joint.The busbar itself can therefore be made thin, so that the fuse connection unit can be used for low-voltage fuses.

[0015] Furthermore, multiple pairs of recessed and protruding guides are provided along the bending sections. In this case, the bodies are guided into a predetermined positional relationship as the bending process progresses, even if the degree of bending differs between the upper and lower ends of each bending section. The two bodies are thus secured in suitable positions.

[0016] The distance between the two bodies can be appropriately determined by the inner lower surface of the recessed guide and the upper surface of the protruding guide abutting each other. The band plate section of the joint is not unnecessarily deformed. Furthermore, the engagement units provided for the two bodies are brought into engagement by causing the inner lower surface of the recessed guide and the upper surface of the protruding guide to abut each other, and then the bodies are further flexed. Accordingly, it is possible to achieve a rattle-free engagement by utilizing the elasticity of the bodies. This can improve the vibration resistance of the fuse connection unit attached to a battery and prevent abnormal noise from it.Furthermore, there is no need to strictly define the fitting tolerance of the engagement units, thus reducing the manufacturing costs of a mold. Additionally, the pairs of recessed and protruding guides are arranged vertically along the bending sections. The distance between the two bodies is appropriately controlled at each vertical position of the recessed and protruding guides. This increases machinability when engaging the engagement units. Moreover, when the engagement units are in engagement, the point where the recessed and protruding guides abut each other acts as an axis of rotation, exerting tension on the joint section. This prevents deformation of the strip plate section.

[0017] Even if the bending angles vary at the bending sections between the upper and lower ends of the two bodies, the bending positions are corrected by the guide chamfers of the recessed and protruding guides, which are brought into sliding contact with each other. The bodies can therefore ultimately be guided into the appropriate positions, and the engagement units of the two bodies can be properly aligned. The two bodies are then securely locked in place. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1A and Fig. Figure 1B shows a front view and a top view of a conventional example. Fig. Figure 2 is a perspective view illustrating a locking connection unit of an embodiment of the present invention, which is half-bent in a bending process. Fig. 3A to 3C are top views illustrating successive intermediate positions of the locking connection unit between the unbent and bent states during the bending process. Fig. 4D to 4E are top views, which are shown in Fig. The position shown in 3C during the bending process illustrates the following intermediate positions of the locking connection unit. Fig. Figure 5 is a perspective view illustrating the locking connection unit after the bending process is complete. Fig. Figure 6 is a top view of the same. Fig. Figure 7 is a front view of the same. Fig. Figure 8 is a right-hand view of the same. Fig. 9 is along a line 9-9 of the Fig. 7. Cross-sectional view taken. Fig. 10 is along a line 10-10 of the Fig. 7. Cross-sectional view taken. Fig. Figure 11 is a top view that schematically illustrates a relationship between a joint section, a recessed guide, a protruding guide and engagement units in the locking connection unit of the embodiment. Fig. 12A and Fig. Figures 12B are a front view and a right-side view of the same. Fig. Figure 13 is a top view that schematically illustrates a force relationship when an inner lower surface of the recessed guide rests against the upper surface of the protruding guide in the embodiment. Fig. Figure 14 is a top view illustrating the sliding of the tip of the protruding guide on a guide slope of the inner side surface of the recessed guide to provide a guiding operation. DESCRIPTION OF THE PREFERRED EXECUTION FORM

[0018] The following is a description of an embodiment of the present invention with reference to the drawings.

[0019] One in Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9 to Fig. 10 The fuse connection unit shown includes: a busbar 30; resin housings 11 and 21 attached to a required part of the busbar 30 by a press-fit procedure; and a resin cover covering an exposed part of the busbar 30 (not shown).

[0020] The busbar 30 is manufactured by pressing a conductive metal plate. A hinged section 38, incorporating bending sections 31 and 32 on both lateral edges of a strip plate section 33, is provided at the center of the busbar 30. Two plate sections (not shown) forming safety circuits are integrally provided on both sides of the hinged section 38 for connection to it. These two safety circuit plate sections are pivoted in the same direction at the bending sections 31 and 32 during a bending operation to be arranged parallel at a distance equal to the width of the strip plate section 33.

[0021] At an upper end of one of the plate sections forming the fuse circuits, a battery connection section 35, used for direct attachment to the battery, and a generator connection section 34, connected to a generator, are provided by bending rectangular widened pieces in opposite directions. The connection sections 35 and 34 are provided with an opening or a notch through which a bolt is inserted.

[0022] One of the plate sections forming the fuse circuit includes several fuse elements 36 and a load connection section (not shown). The other plate section forming a fuse circuit also includes fuse elements 36 and a load connection section.

[0023] The upper and lower edges of the rectangular strip plate section 33, with a predetermined width, are bent in one thickness direction to form flanges 33a with a length equal to the overall width of the strip plate section 33. The flanges 33a at the upper and lower edges protrude slightly but serve as ribs, increasing the bending stiffness of the strip plate section 33.

[0024] Resin housings 11 and 21, made of insulating resin, are attached to the two plate sections forming the safety circuits on both sides of the joint section 38 by a press-fit process, with a required portion exposed. The plate sections forming the safety circuits and the resin housings 11 and 21 thus form two bodies 10 and 20, which constitute the safety connections.

[0025] At the free ends of these bodies 10 and 20, two pairs of engaging sections (engagement units) 140 and engaged sections (engagement units) 130 are provided, which engage with each other to fix the gap between the free ends. These pairs are arranged vertically with spacing.

[0026] The two resin housings 11 and 21 are positioned opposite each other when the two bodies 10 and 20 are pivoted. Pairs of recessed guides 111 and protruding guides 121 are arranged vertically at intervals along the two side edges of the band plate section 33 on the opposite surfaces of the two resin housings 11 and 21 in surrounding areas 110 and 120 of the hinge section 38. These recessed and protruding guides 111 and 121 engage with each other when the two bodies are pivoted. The two housings 11 and 21 are thus guided into suitable positions.

[0027] At the lower ends of the resin housings 11 and 21, connecting piece receiving sections 12 and 22 are formed. The load connection connection sections are arranged within the connecting piece receiving sections 12 and 22. A connecting piece suitable for detachable attachment to the other connecting piece is thus formed.

[0028] Next, a description of an example is given that has a structure developed from the embodiment.

[0029] As in Fig. 11 and Fig. As shown in Figure 13, an inner lower surface 111b and an upper surface 112b are formed on the recessed and protruding guides 111 and 121, respectively. This inner lower surface 111b and this upper surface 121b are in contact with each other when the bending process of the bodies 10 and 20 is complete.

[0030] As in Fig. As shown in Figure 14, guide ramps 111a and 121a are provided on an inner side surface of the recessed guide 111 and an outer side surface of the protruding guide 121, respectively. The guide ramps 111a and 121a come into sliding contact with each other when the recessed and protruding guides 111 and 121 begin to engage with each other, and then guide each other into suitable positions.

[0031] If the recessed and protruding guides 111 and 121 are designed to have a circular cross-section, the guide chamfers 111a and 121a should have tapered surfaces. Furthermore, in the example shown in the drawing, the guide chamfers 111a and 121a are provided for both the inner side surface of the recessed guide 111 and the outer side surface of the protruding guide 121. However, the guide chamfers should only be located at least on either the inner side surface of the recessed guide 111 or the outer side surface of the protruding guide 121.

[0032] Next, a description of the manufacturing process for this safety connection unit will be given.

[0033] First, the hinge section 38 is positioned essentially in the center of a flat metal plate. The plate sections forming the safety circuits are pressed onto both sides of the hinge section 38. The busbar 30 is thus manufactured. Next, the resin housings 11 and 21 are integrally formed with the plate sections forming the safety circuits on both sides of the hinge section 38 of the busbar 30 by an injection molding process using a resin. The bodies 10 and 20 are thus formed.

[0034] Next, we will illustrate Fig. 3A to 3C and Fig. 4D and Fig. 4E successively performs the bending process of bodies 10 and 20. The two bodies 10 and 20 are pivoted at the bending sections 31 and 32 of the two side edges of the hinge section 38 so that they lie parallel and offer a U-shaped top view. The engaging and engaged sections 140 and 130 provided at the free ends of bodies 10 and 20 are as shown in Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9 to Fig. Figure 10 shows and confirms this. The exposed part of busbar 30 is then covered with a cover (not shown). The fuse connection unit is thus complete.

[0035] The recessed and protruding guides 111 and 121 are located near the joint section 38, and the bodies 10 and 20 are pivoted at the bending sections 31 and 32 on the two lateral edges of the joint section 38. The bodies 10 and 20 begin to pivot at the bending sections 31 and 32 and are positioned opposite each other. During this process, the bodies 10 and 20 are pivoted, their positions being constrained by the guiding action of the recessed and protruding guides 111 and 112.

[0036] Accordingly, bodies 10 and 20 are fixed in suitable positions without any special attention from the user once the bending is complete. The engaging section 140 and the engaged section 130 are reliably engaged with each other. This eliminates variations in the positional relationship between bodies 10 and 20. It is therefore possible to easily attach the locking connection unit to the other connector. This eliminates the possibility of the connector separating due to insufficient cable length, deformation of the unit due to unnecessary stress exerted on the connection sections, a deterioration of the watertight seal, or cable detachment from the other connector.

[0037] Furthermore, a portion of the external force is absorbed by the section near the joint section 38, where the recessed and protruding guides 111 and 121 engage. This reduces the stress concentration at the joint section 38. Consequently, the possibility of damage to the joint section 38 when an external force, including vibration, acts on the fuse link assembly is significantly reduced. The overall strength of the fuse link assembly is thus increased, and the product strength is less affected by the joint section 38. As a result, the busbar 30 itself can be made thin, making the fuse link assembly suitable for low-voltage fuses.

[0038] Furthermore, the pairs of recessed and protruding guides 111 and 121 are provided vertically at intervals along the bending sections 31 and 32. The bodies 10 and 20 are thus guided in such a way that they maintain a predetermined positional relationship as the bending progresses, even if the degree of bending differs between the upper and lower ends of each of the bending sections 31 and 32. The two bodies 10 and 20 are secured in suitable positions.

[0039] As in Fig. 11 and Fig. As shown in Figure 13, the inner lower surface 111b and the upper surface 121b, which abut each other when the two bodies 10 and 20 are fully pivoted into the closed positions, are secured in the recessed and projecting guides 111 and 121, respectively. In this case, the inner lower surface 111b of the recessed guide 111 and the upper surface 121b of the projecting guide 121 each abut each other. Accordingly, the distance between the two bodies 10 and 20 can be suitably determined. Furthermore, the band plate section 33 of the joint section 38 is not unnecessarily deformed.

[0040] The relative positional relationship between the two engaging sections 140 and engaged sections 130, which secure the two bodies 10 and 20, is such that the engaging and engaged sections 140 and 130 are unlocked and moved away from each other when the inner lower surface 111b of the recessed guide 111 and the upper surface 121b of the protruding guide 121 are in contact and are allowed to engage with each other by bending the bodies 10 and 20. This can provide a rattle-free engagement.

[0041] Specifically, t1 (a distance at the joint section 38) and t2 (a distance at the recessed and protruding guides 111 and 121) are set such that the distance at the side of the free end, when the engaging and engaged sections 140 and 130 are not engaged, is slightly larger than the distance t3, when the engaging and engaged sections 140 and 130 are in engagement. The engaging and engaged sections 140 and 130 are therefore brought into engagement by causing the inner lower surface 111b of the recessed guide 111 and the upper surface 121b of the protruding guide 121 to bear against each other, and then by further bending the bodies 10 and 20. Accordingly, it is possible to achieve engagement without rattling by utilizing the elasticity of the bodies 10 and 20.This can improve the resistance to vibration of the fuse connection unit attached to a battery and prevent abnormal noise from it. Furthermore, in such a case, there is no need to strictly define the fit tolerance of the engagement units (engaging and engaged sections 140 and 130), thereby reducing the manufacturing costs of a mold.

[0042] Furthermore, the pairs of recessed and protruding guides 111 and 121 are arranged along the bending sections 31 and 32 in the vertical direction. In this case, by adjusting the size of the previously described distance t2 (the distance between the recessed and protruding guides 111 and 121), the distance t3 between the two bodies 10 and 20 at their free ends is appropriately controlled at each vertical position of the recessed and protruding guides 111 and 121, as shown in Fig. Figure 12 shows that this increases the machinability when engaging the engagement units (engaging and engaged sections 140 and 130).

[0043] Furthermore, when the engaging and engaged sections 140 and 130 are brought into engagement, the point where the recessed and protruding guides 111 and 121 abut each other serves as an axis of rotation. Accordingly, a compressive force B is exerted on the recessed and protruding guides 111 and 121, but a tension A is exerted on the band plate section 33 of the joint section 38. This prevents deformation of the band plate section 33.

[0044] Furthermore, as in Fig.As shown in Figure 14, the tip of the protruding guide 121 and the guide chamfer 111a of the recessed guide 111 are brought into sliding contact with each other, even if the bending angles at the bending sections 31 and 32 vary between the upper and lower ends of the two bodies. This allows the bending positions of the bodies to be corrected. The bodies 10 and 20 can therefore ultimately be guided into the appropriate positions, and the engagement units (the engaging and engaged sections 140 and 130) can be appropriately aligned. The two bodies 10 and 20 are then appropriately locked in place.

[0045] If the fuse connection unit is mounted on the battery, first connect the battery connection section 35 to a starter cable terminal (not shown) and a battery connection terminal (not shown). The battery connection terminal is connected to an electrode rod (not shown) of the battery. The fuse connection unit is thus mounted directly to the battery. The generator connection section 34 is connected to a generator terminal (not shown). Finally, connect the connectors (the portions of connector receptacle sections 12 and 22) to the other connector (not shown), thus completing the wiring.

[0046] Through such a connection, power from the battery or generator is distributed to each load via fuses in each plate section forming a fuse circuit. When the battery becomes low, it is supplied with power from the generator and recharged. If a predetermined amount of current or more flows through one of the fuses 36 due to a short circuit or similar event, the fuse 36 heats up and melts, thus preventing an accident caused by an excess current.

Claims

A fuse connection unit comprising: a busbar (30); a hinge section (38) provided at a center of the busbar (30) and comprising a strip plate section (33) and bending sections (31, 32) on both side edges of the strip plate section (33); and two fuse connection-forming bodies (10, 20) integrally provided on both sides of the hinge section (38) and formed by attaching two resin housings (11, 21) made of insulating resin to the respective fuse-connecting plate sections by an injection molding process, wherein a required part is exposed, characterized in that the two bodies (10, 20) are arranged to be pivoted towards each other in a U-shape in plan view during a bending operation at the bending sections (31, 32), in order to subsequently be arranged at a distance corresponding to the width of the strip plate section (33), individually for the resin housings (11, 21).21) at positions remote from the joint section (38) engagement units (130, 140) are provided which are configured to maintain the U-shape in plan view, and two or more pairs of a recessed guide (111) and a protruding guide (121) are provided near the joint section (38) along both side edges of the strip plate section (33) on opposite surfaces of the two resin housings, wherein the recessed and protruding guides (111, 121) are opposite each other, and each pair of guides (111, 121) is configured to engage with each other to guide the two resin housings (11, 21) into suitable positions during bending, the pairs of guides (121) being spaced apart from each other. A locking connection unit according to claim 1, wherein the recessed guide (111) comprises an inner recessed surface (111b), the protruding guide (121) comprises a protruding surface (121b), and the recessed surface (111b) and the protruding surface (121b) are arranged to be in contact with each other when the bending process of the two bodies (10, 20) is completed. A locking connection unit according to claim 2, wherein the engagement units (130, 140) are arranged to be disengaged and separated from each other when the inner recessed surface (111b) and the protruding surface (121b) are in contact and the bodies (10, 20) are not further bent, and the engagement units (130, 140) are arranged to engage with each other when the bodies (10, 20) are further bent after they have already been in contact with the inner recessed surface (111b) and the protruding surface (121b). A locking connection unit according to one of the preceding claims, in which a guide ramp (111a) is provided on an inner side surface of the recessed guide (111) and / or a guide ramp (121a) is provided on an outer side surface of the protruding guide (121), and the guide ramp (111a, 121a) is arranged to be brought into sliding contact with the recessed guide (111) or the protruding guide (121) when the guides (111, 121) begin to engage with each other, in order to then guide them into a suitable position.

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