Busbar module and method for manufacturing a busbar module

Abstract

A busbar module (1) comprises: a flexible printed circuit board (3) with a main section (30) having a longitudinal direction (X) and a width direction (Y), and a branch section (31) connected to an edge of the main section in the width direction; a busbar (10) connected to the branch section of the flexible printed circuit board; and a housing (4) that accommodates the flexible printed circuit board and the busbar. The branch section is cut into a shape having: a base end (32) connected to the main section; and a section (33) extending longitudinally from the base end. The branch section is connected to the busbar (10) in a state where the section is deformed so that it extends in the width direction (Y).

Description

BACKGROUND OF THE INVENTION 1. Field of the invention

[0001] The present invention relates to a busbar module and a method for manufacturing a busbar module. 2. Description of the related prior art

[0002] There is a conventional technique for connecting a flexible printed circuit board (PCB) and a busbar. JP 2023-074 117 A discloses a connection structure between a busbar and a PCB in which the busbar is connected to a flat, plate-like section of the PCB. The flat, plate-like section of JP 2023-074 117 A extends in the width direction of the PCB.

[0003] If the distance between the main section of the printed circuit board (PCB) and the busbar is large in JP 2023-074 117 A, the flat, plate-like section must be long. This can lead to a decrease in PCB manufacturing yield. It is desirable to mitigate this yield decrease in the flexible PCB by extending the branch section between the main section and the busbar in the width direction. SUMMARY OF THE INVENTION

[0004] One object of the present invention is to provide a busbar module and a method for manufacturing a busbar module which can suppress the deterioration of the yield in a flexible printed circuit board.

[0005] To achieve the above-mentioned objective, a busbar module according to one aspect of the present invention comprises a flexible printed circuit board with a main section having a longitudinal and a width direction, and a branch section connected to an edge of the main section in the width direction; a busbar connected to the branch section of the flexible printed circuit board; and a housing accommodating the flexible printed circuit board and the busbar, wherein the branch section is cut into a shape having a base end connected to the main section and a section extending from the base end in the longitudinal direction, and the branch section is connected to the busbar in a state in which the section is deformed so that it extends in the width direction.

[0006] To achieve the above-mentioned objective, a method for manufacturing a busbar module according to another aspect of the present invention comprises a step of forming a flexible printed circuit board with a main section having a longitudinal and a transverse direction and a branch section connected to an edge of the main section in the transverse direction; a step of deforming the branch section; a step of connecting a busbar to the branch section;and a step of housing the busbar and the flexible printed circuit board in a housing, wherein the step of forming the flexible printed circuit board comprises cutting the branch section into a shape having a base end connected to the main section and a piece section extending longitudinally from the base end, and the step of deforming the branch section comprises deforming the branch section to enable the piece section to extend in the width direction.

[0007] The above-mentioned and other tasks, features, advantages and the technical and industrial significance of this invention will be better understood by reading the following detailed description of the currently preferred embodiments of the invention when considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a top view of a busbar module according to one embodiment; Fig. Figure 2 is a perspective view of the busbar module according to the embodiment; Fig. Figure 3 is an example of an arrangement of a flexible printed circuit board that can be manufactured from a substrate; Fig. Figure 4 is a perspective view illustrating a state in which a curved section is formed; Fig. Figure 5 is a top view illustrating an example of a chipboard; Fig. Figure 6 is a view illustrating a flexible printed circuit board placed on a clamping board; Fig. Figure 7 is a view illustrating a flexible printed circuit board in which a curved section is formed by a clamping plate; Fig. Figure 8 is a perspective view illustrating an example of a deformation mode of a branch section; Fig. Figure 9 is a top view illustrating an example of a deformation mode of the branch section; Fig. Figure 10 is a top view illustrating an example of the chipboard; and Fig. Figure 11 is a view showing a flexible printed circuit board placed on the clamping board. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0008] A busbar module and a manufacturing method for a busbar module according to one embodiment of the present invention are described in detail below with reference to the drawings. Note that the present invention is not limited by this embodiment. Furthermore, the components in the following embodiment include those that are readily apparent to those skilled in the art or are substantially identical. embodiment

[0009] One embodiment is described with reference to the Fig. Described in sections 1 to 11. The present embodiment relates to a busbar module and a manufacturing method for a busbar module. Fig. Figure 1 is a top view of a busbar module according to the embodiment. Fig. Figure 2 is a perspective view of the busbar according to the embodiment. Fig. Figure 3 is a perspective view of an arrangement example of a flexible printed circuit board that can be manufactured from a substrate. Fig. Figure 4 is a perspective view illustrating a state in which a curved section is formed. Fig. Figure 5 is a top view illustrating an example of a chipboard. Fig. Figure 6 is a view showing a flexible printed circuit board placed on the clamping board. Fig. Figure 7 is a view showing a flexible printed circuit board in which a curved section is formed by the clamping plate. Fig. Figure 8 is a perspective view showing an example of a deformation mode of a branch section. Fig. Figure 9 is a top view showing an example of a deformation mode of the branch section. Fig. Figure 10 is a top view illustrating an example of the chipboard. Fig. Figure 11 is a view illustrating a flexible printed circuit board placed on the clamping board.

[0010] As in Fig. As shown in Figure 1, a busbar module 1 of the present embodiment comprises a flexible printed circuit board 3, a busbar 10, and a housing 4. The flexible printed circuit board 3 comprises 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 embedded between and protected by the base film and the cover layer. The conductive layer is a conductive metal foil and, for example, has a plurality of circuit patterns 5.

[0011] The flexible printed circuit board 3 comprises a main section 30 and a branch section 31. The main section 30 has a longitudinal direction X and a lateral direction Y. The plurality of circuit patterns 5 extend in the longitudinal direction X and are each arranged in the lateral direction Y within the main section 30. The branch section 31 is a section connected to the busbar 10. The branch section 31 is connected to an edge of the main section 30 in the lateral direction Y.

[0012] Fig. Figure 2 is an enlarged view of the branch section 31 connected to the busbar 10. In the busbar module 1 of the present embodiment, the branch section 31, which is in a deformed state, is connected to the busbar 10. More precisely, the branch section 31 of the present embodiment has a base end 32 and a section 33. The base end 32 is a section that is connected to the main section 30. The section 33 is connected to the main section 30 via the base end 32. As shown in Figure 2, the branch section 31 is connected to the main section 30 via the base end 32. Fig. As shown in Figure 3, the branch section 31 is cut out of the substrate 200, so that the piece section 33 extends from the base 32 in the longitudinal direction X. In other words, when the flexible printed circuit board 3 is formed, the piece section 33 extends from the base 32 in the longitudinal direction X.

[0013] As in Fig. As shown in Figure 2, a connecting section 34 is provided at one end of the component section 33. The connecting section 34 has a contact section that is to be connected to the busbar 10. A chip fuse 6 is provided, which is mounted on the connecting section 34. The busbar 10 is connected to the circuit pattern 5 via the chip fuse 6.

[0014] Branch section 31 is connected to busbar 10 in a state in which section 33 is deformed so that it extends in the width direction Y. Branch section 31 in Fig. Section 2 comprises a curved section 35. The curved section 35 is bent such that the section 33 can extend in the width direction Y. By deforming the branch section 31, the branch section 31 can be extended in the width direction Y to the busbar 10.

[0015] According to the busbar module 1 of the present embodiment, reducing the width Wd of the flexible printed circuit board 3 during manufacturing enables improved manufacturing efficiency and a reduction in manufacturing costs. For example, reducing the width Wd of the flexible printed circuit board 3 results in an increased number of flexible printed circuit boards 3 that can be formed from the substrate 200 as described below. For example, the reduced width Wd improves the efficiency of the step of attaching components such as the chip fuse 6 to the flexible printed circuit board 3.

[0016] Fig. Figure 3 shows an example arrangement of the flexible printed circuit board 3, which can be manufactured from a substrate 200. In the example of Fig. 3 Four flexible printed circuit boards 3 are formed from a substrate 200. As in Fig. As shown in Figure 3, in the flexible printed circuit board 3 of the present embodiment, the branch section 31 is cut such that the section 33 can extend in the longitudinal direction X. This makes it possible to minimize the outermost shape 210 of a flexible printed circuit board 3 in the substrate 200. More precisely, the width Wd of the outermost shape 210 can be reduced.

[0017] As a comparative example with respect to the flexible printed circuit board 3 of the present embodiment, a flexible printed circuit board is examined in which the entire branch section extends in the width direction Y from the main section 30. In the flexible printed circuit board of the comparative example, the value of the width Wd is determined according to the distance from the main section 30 to the busbar 10. Therefore, the width Wd of the outermost form 210 would increase if the distance between the main section 30 and the busbar 10 is large. Consequently, the number of flexible printed circuit boards that can be formed from a substrate 200 would decrease in some cases.

[0018] In contrast, the busbar module 1 of the present embodiment can minimize the width Wd of the outermost shape 210 of the flexible printed circuit board 3. For example, the width Wd of the outermost shape 210 can be shaped such that it has a uniform size regardless of the distance from the main section 30 to the busbar 10.

[0019] Fig. Figure 4 shows the flexible printed circuit board 3 when the bent section 35 is formed in the branch section 31. The bent section 35 is formed, for example, at a root section of the component section 33 near the end of the base 32. In the bent section 35, the component section 33 is bent along a fold line FL. The fold line FL is inclined with respect to the longitudinal direction X and the lateral direction Y. The inclination angle of the fold line FL with respect to the lateral direction Y is, for example, 45°. The component section 33 is bent, for example, with an inwardly facing mounting surface 33a. The mounting surface 33a is a surface on which the chip fuse 6 is mounted. The contact section connected to the busbar 10 is exposed at the mounting surface 33a.

[0020] The step of deforming the branch section 31 can be carried out manually by an operator or using a clamping device. Fig. Figure 5 shows an example of a clamping plate 300 used in the bending step. The 300 comprises: a main body 310 with a placement surface 310a; and a support 320, which is pivotable relative to the main body 310. The support 320 is connected to the main body 310 via a hinge 330. The hinge 330 has a pivot shaft along the placement surface 310a. The support 320 rotates while supporting the section 33 of the flexible printed circuit board 3.

[0021] Fig. Figure 6 shows the flexible printed circuit board 3, which is placed on the clamping plate 300. The flexible printed circuit board 3 is arranged on the clamping plate 300 such that the main section 30 is to be placed on the placement surface 310a of the main body 310 and the component section 33 is to be placed on the support 320. The support 320 pivots while supporting the component section 33 and forms the curved section 35 in the component section 33. Fig. Figure 7 shows the flexible printed circuit board 3 in which the curved section 35 is formed using the clamping plate 300.

[0022] The connecting section 34 can be connected to the busbar 10 before the bending step or after the bending step. If the connecting section 34 is connected to the busbar 10 before the bending step, the support 320 can be shaped to support the section 33 and the busbar 10.

[0023] The method for manufacturing the busbar module 1 according to the present embodiment comprises a forming step, a deformation step, a joining step, and an adjustment step. The forming step is a step of shaping the flexible printed circuit board 3.

[0024] The forming step shapes the flexible printed circuit board 3, which comprises: the main section 30 with the longitudinal direction X and the width direction Y; and the branch section 31, which is connected to the edge of the main section 30 in the width direction Y. The forming step is performed, for example, by a device that cuts the flexible printed circuit board 3 from the substrate 200. This device, for example, performs a die-cutting operation to cut out the flexible printed circuit board 3. In the forming step, the branch section 31 is cut such that the base end 32 is connected to the main section 30 and the branch section 31 extends from the base end 32 in the longitudinal direction X. The step performed after the forming step is an assembly step in which components, such as the chip fuse 6, are mounted onto the flexible printed circuit board 3.

[0025] The deformation step deforms the branch section 31 of the flexible printed circuit board 3. During the deformation step, the branch section 31 is deformed so that the section 33 can extend in the width direction Y. The deformation step can be performed manually by an operator or using a device such as the fixture plate 300. For example, the deformation step is a bending step to form the bent section 35 on the branch section 31.

[0026] The connecting step connects the busbar 10 to the branch section 31. The busbar 10 is connected to the contact section, which is arranged in the connecting section 34 of the branch section 31, using a method such as welding and soldering.

[0027] The intake step takes the busbar 10 and the flexible circuit board 3 into the housing 4. As shown in Fig. As shown in Figure 1, the housing 4 comprises a main body 40, which accommodates the busbar 10 and the flexible printed circuit board 3. The main body 40 is, for example, made of an insulating synthetic resin. The main body 40 includes a routing path 41 and a plurality of holders 43.

[0028] The routing path 41 accommodates the flexible printed circuit board 3. The routing path 41 can be configured as a slot-like passage. The routing path 41 can, for example, include a main passage that accommodates the main section 30 and a secondary passage that accommodates the secondary section 31.

[0029] The holder 43 receives and holds the busbar 10. The multiple holders 43 border the routing path 41 in the width direction Y and are each arranged in the length direction X along the routing path 41. The holder 43 is designed in the form of a frame and has a projection that locks the busbar 10 in place.

[0030] The pick-up step comprises: a busbar pick-up step to pick up the busbar 10 in the holder 43; and a circuit board pick-up step to pick up the flexible printed circuit board 3 in the routing path 41. The busbar pick-up step and the circuit board pick-up step can be performed simultaneously or at different times. For example, the circuit board placement step can be performed after completion of the busbar placement step, or the busbar placement step can be performed after completion of the circuit board placement step.

[0031] The sequence of the deformation step, the connection step, and the assembly step can be arbitrarily defined. For example, the deformation step of the branch section 31 can be performed before or after the connection step. For example, the flexible printed circuit board 3, in which the bent section 35 is formed, can be housed in the enclosure 4, which contains the busbar 10. In this case, the connection section 34 of the flexible printed circuit board 3 can be connected to the busbar 10 housed in the holder 43.

[0032] The deformation of the branch section 31 in the deformation step can be a different deformation than the deformation to form the bent section 35. For example, as in the Fig. 8 and Fig. As shown in Figure 9, the branch section 31 is deformed by rotating the section 33 relative to the main section 30. This deformation is one in which the base end 32 is deformed to rotate the section 33 relative to the main section 30. The direction of rotation at this point is a direction of rotation along a plane containing the main section 30. The section 33 rotates around the base 32 relative to the main section 30. The base 32 is elastically deformed, so that an inner surface 32a extends.

[0033] In branch section 31, section 33 extends after the deformation, as shown in Fig. 9 shown, in the latitude direction Y. The one in the Fig. 8 and Fig. The deformation step shown in step 9 can be performed manually by an operator or using a clamping device. Fig. Figure 10 shows an example of the clamping device plate 300, which is used in a turning step to rotate the workpiece section 33. The clamping plate 300 in Fig. 10 comprises: a main body 310 with a placement surface 310a; and a rotary plate 340, which is rotatable with respect to the main body 310. The rotary plate 340 rotates about a rotating shaft 350. The axis of the rotating shaft 350 is orthogonal to the placement surface 310a. The rotary plate 340 can rotate along the placement surface 310a about the rotating shaft 350 as its center of rotation. The main body 310 may have a stop to limit the rotation range of the rotary plate 340.

[0034] Fig. Figure 11 shows the flexible printed circuit board 3, which is placed on the clamping plate 300. The flexible printed circuit board 3 is arranged on the clamping plate 300 such that the main section 30 is located on the placement surface 310a of the main body 310 and the branch section 33 is located on the rotating plate 340. The rotating plate 340 may have a holding mechanism that holds the branch section 33. The rotating plate 340 rotates, as indicated by arrow AR1, while supporting the branch section 33 so that the branch section 33 can rotate relative to the main section 30. This allows the branch section 31 to assume a shape in which the branch section 33 extends in the width direction Y, as shown in Fig. 9 shown.

[0035] The connecting section 34 can be connected to the busbar 10 before or after the rotation step. In the case where the connecting section 34 is connected to the busbar 10 before the rotation step, the rotary plate 340 can be designed to hold the component section 33 and the busbar 10.

[0036] The clamping plate 300 used in the rotary step is preferably configured to reduce the stress on the circuit pattern 5 due to the deformation of the branch section 31. For example, the position of the rotary shaft 350 of the clamping plate 300 can be adjusted to reduce the extent of expansion and contraction of the circuit pattern 5 when the section 33 is rotated. As, for example, in Fig.As shown in Figure 11, the rotary shaft 350 can be arranged in a state in which the flexible printed circuit board 3 is placed on the clamping plate 300 such that the axis of rotation of the rotary shaft 350 intersects the circuit pattern 5 of the branch section 31.

[0037] As described above, the busbar module 1 of the present embodiment comprises the flexible printed circuit board 3, the busbar 10, and the housing 4. The flexible printed circuit board 3 comprises: the main section 30 with longitudinal direction X and width direction Y; and the branch section 31, which is connected to the edge of the main section 30 in the width direction Y. The busbar 10 is connected to the branch section 31 of the flexible printed circuit board 3. The housing 4 accommodates the flexible printed circuit board 3 and the busbar 10.

[0038] The branch section 31 is cut such that the base 32 is connected to the main section 30 and the section 33 extends from the base 32 in the longitudinal direction X. The branch section 31 is connected to the busbar 10, with the section 33 being deformed to extend in the lateral direction Y. The busbar module 1 of the present embodiment has a configuration in which the branch section 31 extends in the lateral direction Y between the main section 30 and the busbar 10, thereby suppressing a deterioration in the yield during the formation of the flexible printed circuit board 3 from the substrate 200.

[0039] After deformation, the branch section 31 has, for example, the bent section 35 in which the segment 33 is bent so that it extends in the width direction Y. The position and shape of the bent section 35 can be adapted according to the relative position between the main section 30 and the busbar 10. The busbar module 1 of the present embodiment can connect the branch sections 31 to the busbars 10 in different arrangements without changing the design of the flexible printed circuit board 3.

[0040] The branch section 31 can be connected to the busbar 10 if the section 33 is rotated relative to the main section 30 by deforming the base end 32.

[0041] The method for manufacturing the busbar 1 according to the present embodiment comprises the forming step, the deformation step, the joining step, and the adjustment step described above. In the forming step, the branch section 31 is cut into a shape in which the base end 32 is connected to the main section 30 and the section 33 extends from the base end 32 in the longitudinal direction X. In the deformation step, the branch section 31 is deformed so that the section 33 can extend in the lateral direction Y. According to the method for manufacturing the busbar module 1 according to the present embodiment, it is possible to extend the branch section 31 in the lateral direction Y between the main section 30 and the busbar 10, while improving the yield in the forming step.

[0042] The type of deformation of the branch section 31 by the deformation step is not limited to the type illustrated in the present embodiment. A flexible printed circuit board 3 can have branch sections 31, each of which is deformed into different shapes. For example, in the plurality of branch sections 31 of the flexible printed circuit board 3, some of the branch sections 31 can be deformed such that they have the bent section 35, and the other branch sections 31 can be deformed such that they rotate the section 33 relative to the main section 30.

[0043] The contents disclosed in the above embodiment can be implemented in a suitable combination.

[0044] In the busbar module according to the present embodiment, the branch section of the flexible printed circuit board is cut into a shape comprising: a base connected to the main section; and a section extending longitudinally from the base, with the branch section connected to the busbar in such a way that the section is deformed to extend in the width direction. According to the busbar module of the present embodiment, it is possible to achieve an effect of suppressing the degradation of the efficiency in the flexible printed circuit board. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2023 - 074 117 A [0002, 0003]

Claims

[1] A busbar module (1) comprising: a flexible printed circuit board (3) with a main section (30) having a longitudinal direction (X) and a width direction (Y), and a branch section (31) connected to an edge of the main section (30) in the width direction (Y); a busbar (10) connected to the branching section (31) of the flexible printed circuit board (3); and a housing (4) that accommodates the flexible printed circuit board (3) and the busbar (10), wherein the branch section (31) is cut into a shape which has a base end (32) connected to the main section (30) and a section (33) extending from the base end (32) in the longitudinal direction (X), and the branch section (31) is connected to the busbar (10) in a state in which the section (33) is deformed so that it extends in the width direction (Y). [2] The busbar module (1) according to claim 1, wherein the branch section (31) comprises a curved section (35) which is bent such that the section (33) can extend in the width direction (Y). [3] The busbar module (1) according to claim 1, wherein the branch section (31) is connected to the busbar (10) in a state in which the section (33) is rotated relative to the main section (30) by deforming the base end (32). [4] A method for manufacturing a busbar module (1), wherein the method comprises: a step of forming a flexible printed circuit board (3) with a main section (30) having a longitudinal direction (X) and a width direction (Y), and a branch section (31) connected to an edge of the main section (30) in the width direction (Y); a step of deforming the branch section (31); a step of connecting a busbar (10) to the branch section (31); and a step of housing the busbar (10) and the flexible printed circuit board (3) in a housing (4), wherein the step of forming the flexible printed circuit board (3) includes cutting the branch section (31) into a shape with a base end (32) connected to the main section (30) and a piece section (31) extending from the base end (32) in the longitudinal direction (X), and The step of deforming the branch section (31) includes deforming the branch section (30) to allow the section (31) to extend in the width direction (Y).

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