Method for manufacturing terminal block and bus bar terminal

Abstract

To provide a terminal block that is capable of reducing noise with a compact configuration.SOLUTION: A terminal block 20 includes a conductive path forming body 30 including bus bar terminals 40A, 40B, and 40C, an annular magnetic core 50, and an insulating base 60. The conductive path forming body includes a first connection portion 32, a second connection portion 34, and an intermediate portion 36 between the first connection portion and the second connection portion. When viewed along an extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion. The magnetic core includes a plurality of split cores 50A and 50B, and the magnetic core surrounds the intermediate portion in a state where the plurality of split cores are arranged to form a ring shape. The insulating base holds the intermediate portion and the magnetic core surrounding the intermediate portion in a state where at least a part of the first connection portion and at least a part of the second connection portion are exposed.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a terminal block and a method for manufacturing a bus bar terminal. [Background technology]

[0002] Patent Document 1 discloses a terminal block including a housing having a resin portion, and a bus bar integrally including an embedded portion embedded in the resin portion and a connection portion protruding outward from the resin portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2017 / 154543 Summary of the Invention [Problem to be solved by the invention]

[0004] There is a demand for terminal blocks that have a compact configuration and that reduce noise.

[0005] Therefore, an object of the present disclosure is to provide a terminal block that is compact in configuration and capable of reducing noise. [Means for solving the problem]

[0006] The terminal block of the present disclosure comprises a conductive path forming body including a bus bar terminal, a ring-shaped magnetic core, and an insulating base that holds the conductive path forming body and the magnetic core, wherein the conductive path forming body includes a first connection portion, a second connection portion, and an intermediate portion between the first connection portion and the second connection portion, and when viewed along the extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion, the magnetic core includes a plurality of split cores, and the magnetic core surrounds the intermediate portion with the plurality of split cores arranged to form a ring, and the insulating base holds the intermediate portion and the magnetic core surrounding the intermediate portion with at least a portion of the first connection portion and at least a portion of the second connection portion exposed.

[0007] In addition, the manufacturing method of a bus bar terminal disclosed herein includes the steps of preparing a cylindrical metal material, pressing an end of the cylindrical metal material into a flat shape, bending the cylindrical metal material, and positioning the end of the cylindrical metal material at a position that is off from an extension of a middle portion of the cylindrical metal material. Effect of the Invention

[0008] According to the present disclosure, it is possible to reduce noise in a terminal block with a compact configuration.

[0009] In addition, a bus bar terminal suitable for the above terminal block can be manufactured. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view showing a terminal block according to the first embodiment. [Diagram 2] FIG. 2 is a front view showing the terminal block. [Diagram 3] FIG. 3 is an exploded perspective view showing the terminal block. [Figure 4] FIG. 4 is an exploded perspective view showing the terminal block. [Diagram 5] FIG. 5 is a cross-sectional view taken along line VV in FIG. [Figure 6]FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. [Figure 7] FIG. 7 is an explanatory diagram showing a manufacturing method of the bus bar terminal. [Figure 8] FIG. 8 is an explanatory diagram showing a manufacturing method of the bus bar terminal. [Figure 9] FIG. 9 is an explanatory diagram showing a manufacturing method of the terminal block. [Figure 10] FIG. 10 is an explanatory diagram showing a manufacturing method of the terminal block. [Figure 11] FIG. 11 is an explanatory diagram showing a manufacturing method of the terminal block. [Figure 12] FIG. 12 is a perspective view showing a terminal block according to a modified example. [Figure 13] FIG. 13 is a perspective view showing the internal structure of the terminal block. [Figure 14] FIG. 14 is a perspective view showing a terminal block according to the second embodiment. [Figure 15] FIG. 15 is a perspective view showing the internal structure of the terminal block. [Figure 16] FIG. 16 is a cross-sectional view taken along line XVI-XVI in FIG. [Figure 17] FIG. 17 is a cross-sectional view taken along line XVII-XVII in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] [Description of the embodiments of the present disclosure] First, the embodiments of the present disclosure will be listed and described.

[0012] The terminal block of the present disclosure is as follows.

[0013] (1) A terminal block comprising: a conductive path forming body including a bus bar terminal; a ring-shaped magnetic material core; and an insulating base that holds the conductive path forming body and the magnetic material core, wherein the conductive path forming body includes a first connection portion, a second connection portion, and an intermediate portion between the first connection portion and the second connection portion, and when viewed along the extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion, the magnetic material core includes a plurality of split cores, and the magnetic material core surrounds the intermediate portion with the plurality of split cores arranged to form a ring, and the insulating base holds the intermediate portion and the magnetic material core surrounding the intermediate portion with at least a portion of the first connection portion and at least a portion of the second connection portion exposed.

[0014] According to this terminal block, the magnetic core includes a plurality of split cores. Therefore, by combining the plurality of split cores around the middle portion that is narrower than the first connection portion and the second connection portion, the middle portion can be surrounded by the magnetic core. By surrounding the middle portion of the conductive path forming body with the annular magnetic core, noise can be reduced. In addition, since the first connection portion or the second connection portion does not need to be inserted into the annular magnetic core, the inner circumference of the magnetic core can be made smaller. This, combined with the magnetic core surrounding the narrowed middle portion, makes it possible to miniaturize the magnetic core.

[0015] (2) In the terminal block of (1), the inner circumference of the magnetic core may be formed into a shape that restricts passage between the first connection portion and the second connection portion, while allowing passage of the intermediate portion.

[0016] This makes it easier to place the magnetic core close to the middle portion, which makes it possible to reduce the size of the magnetic body and improve the noise reduction effect.

[0017] (3) In the terminal block according to (1) or (2), the bus bar terminal may be a pressed part made of a single metal material.

[0018] This allows the bus bar terminal to be easily processed.

[0019] (4) A terminal block according to any one of (1) to (3), wherein the conductive path forming body includes a plurality of the busbar terminals, each of the plurality of busbar terminals includes a first busbar end, a second busbar end, and a busbar intermediate portion between the first busbar end and the second busbar end, the plurality of busbar intermediate portions extend parallel to each other with a gap therebetween, at least one of the plurality of first busbar ends extends in a direction intersecting with the plurality of busbar intermediate portions so that the first connection portion is wider than the intermediate portion, and at least one of the plurality of second busbar ends extends in a direction intersecting with the plurality of busbar intermediate portions so that the second connection portion is wider than the intermediate portion.

[0020] This allows the first busbar end and the second busbar end to be bent relative to the busbar middle portion according to the layout of the mating component to which the busbar terminal is connected. In this case, the first connection portion and the second connection portion may be wider than the middle portion. In such a case, a magnetic core with a small inner circumference can be disposed around the middle portion.

[0021] (5) A terminal block according to any one of (1) to (4), wherein the conductive path forming body includes a cylindrical bus bar terminal as the bus bar terminal, the cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, and the end portion of the cylindrical intermediate portion is curved so that the flat end portion extends in a direction intersecting with the extension direction of the intermediate portion of the cylindrical intermediate portion.

[0022] In this case, the cylindrical intermediate portion can be easily bent in any direction, which makes it easy to process the flat end portion so as to extend in any direction.

[0023] (6) A terminal block according to any one of (1) to (5), wherein the conductive path forming body includes a cylindrical bus bar terminal as the bus bar terminal, the cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, the flat end portion is curved in its thickness direction, and the tip portion of the flat end portion extends in a direction intersecting the extension direction of the cylindrical intermediate portion.

[0024] In this case, by processing the direction of the flat end portion relative to the cylindrical intermediate portion in any direction, the flat end portion can be easily processed to extend in any direction.

[0025] (7) A terminal block according to any one of (1) to (6), wherein the conductive path forming body includes a first cylindrical bus bar terminal and a second cylindrical bus bar terminal as the bus bar terminals, each of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, the cylindrical intermediate portions of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal extend in parallel with a gap therebetween, and the end portion or the flat end portion of the cylindrical intermediate portions of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal may be bent at the same position in the extension direction of the multiple cylindrical intermediate portions.

[0026] As a result, the end or flat end of each of the cylindrical intermediate portions of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal is bent at the same position in the extending direction of the plurality of cylindrical intermediate portions, so that the flat end of each of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal is easily arranged at a position suitable for connection to a mating component. This makes it difficult to put a strain on the installation space of the magnetic core. This allows the magnetic core to be large in the extending direction of the plurality of cylindrical intermediate portions.

[0027] (8) In the terminal block according to any one of (1) to (7), the magnetic core may include a magnetic filler material interposed between the plurality of split cores.

[0028] In this case, the magnetic filler present between the multiple split cores suppresses the air gap, thereby improving noise reduction performance.

[0029] Further, a method for manufacturing the bus bar terminal of the present disclosure is as follows.

[0030] (9) A method for manufacturing a bus bar terminal includes preparing a cylindrical metal material, pressing an end of the cylindrical metal material into a flat shape, bending the cylindrical metal material, and positioning the end of the cylindrical metal material at a position that is off the extension of a middle portion of the cylindrical metal material.

[0031] In this way, by pressing the end of the cylindrical metal material into a flat shape, the end formed into a flat shape can be easily connected to the mating part by surface contact. By bending the cylindrical part in any direction or by arbitrarily setting the flat direction relative to the cylindrical part, it is easy to arbitrarily set the extension direction of the flat part of the end relative to the middle part of the cylindrical metal material.

[0032] [Details of the embodiment of the present disclosure] Specific examples of the manufacturing method of the terminal block and bus bar terminal of the present disclosure will be described below with reference to the drawings. Note that the present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims.

[0033] [Embodiment 1] The terminal block 20 according to the first embodiment will be described below. Fig. 1 is a perspective view showing the terminal block 20. Fig. 2 is a front view showing the terminal block 20. In Fig. 2, the housing 11 of the device 10 to which the terminal block 20 is fixed, the connection mating terminals 14 and 15 which are connection mating parts, and the wiring parts 16 and 17 are shown by two-dot chain lines. Figs. 3 and 4 are exploded perspective views showing the terminal block 20. Fig. 5 is a cross-sectional view taken along line VV in Fig. 2, and Fig. 6 is a cross-sectional view taken along line VI-VI in Fig. 2.

[0034] <Overall configuration of the terminal block> The terminal block 20 is attached to a housing 11 of the device 10. The device 10 is, for example, a rotating electric machine or an inverter. The housing 11 is a case that covers the internal components of the device 10. A mounting hole 11h is formed in the housing 11. The terminal block 20 is attached to a portion of the housing 11 surrounding the mounting hole 11h. The terminal block 20 electrically connects electrical components inside the device 10 to electrical components outside the device 10 via the mounting hole 11h.

[0035] For example, the device 10 may be a rotating electric machine, and the terminal block 20 may be used as a component that electrically connects electrical components in the rotating electric machine with an inverter outside the rotating electric machine. In this case, it may be required to remove noise from the drive current passing through the terminal block 20. In particular, when a silicon carbide (SiC) semiconductor is used in the inverter, the noise level may be high. The terminal block 20 includes a magnetic core 50 and is configured to remove noise from the drive current passing through the terminal block 20.

[0036] The terminal block 20 includes a conductive path formation body 30 , a magnetic core 50 , and an insulating base 60 .

[0037] The conductive path forming body 30 is a part that forms a conductive path that connects the inside and outside of the device 10. In this embodiment, the conductive path forming body 30 includes multiple (here, three) bus bar terminals 40A, 40B, and 40C. The conductive path forming body may also be configured to include only one bus bar terminal.

[0038] The conductive path formation body 30 includes a first connection portion 32, a second connection portion 34, and an intermediate portion 36 between the first connection portion 32 and the second connection portion 34. The first connection portion 32 and the second connection portion 34 are portions that are connected to electrical components inside or outside the device 10. The intermediate portion 36 is a portion that electrically connects the first connection portion 32 and the second connection portion 34.

[0039] When the conductive path formation body 30 includes a plurality of bus bar terminals 40A, 40B, 40C, the first connection portion 32 is a portion including a plurality of one-side ends (first bus bar ends 42A, 42B, 42C described later) of the plurality of bus bar terminals 40A, 40B, 40C. Similarly, the second connection portion 34 is a portion including a plurality of other-side ends (second bus bar ends 44A, 44B, 44C described later) of the plurality of bus bar terminals 40A, 40B, 40C, and the intermediate portion 36 is a portion including a plurality of intermediate portions (bus bar intermediate portions 46A, 46B, 46C described later) of the plurality of bus bar terminals 40A, 40B, 40C.

[0040] When viewed along the extending direction A of the intermediate portion 36, the first connecting portion 32 and the second connecting portion 34 are wider than the intermediate portion 36. Therefore, the first connecting portion 32 and the second connecting portion can be easily arranged in a layout suitable for connection with the connection counterpart terminal 14 or the connection counterpart terminal 15. Also, by configuring the intermediate portion 36 to be narrower than the first connecting portion 32 and the second connecting portion 34, the intermediate portion 36 of the conductive path forming body 30 can be easily made smaller.

[0041] The magnetic core 50 is an annular component made of a magnetic material.

[0042] The magnetic core 50 is disposed so as to surround the middle portion 36 of the conductive path forming body 30. This removes noise, particularly high-frequency noise, from the current flowing through the conductive path forming body 30. For example, an inductor is formed by the magnetic core 50 and each of the bus bar terminals 40A, 40B, and 40C constituting the conductive path forming body 30, and the inductor exhibits high impedance with respect to the high-frequency current flowing through the conductive path forming body 30, thereby removing high-frequency noise.

[0043] The magnetic core 50 surrounds the intermediate portion 36 while being insulated from the intermediate portion 36. Since the intermediate portion 36 is disposed on the inner periphery of the magnetic core 50, the inner periphery is formed in a shape that allows the intermediate portion 36 to pass through. It is preferable that the inner periphery of the magnetic core 50 has a shape that allows it to approach the outer periphery of the intermediate portion 36 under the condition that insulation with respect to the intermediate portion 36 is maintained. This is because the distance between the intermediate portion 36 and the magnetic core 50 can be reduced, and even a small magnetic core 50 can easily increase impedance. In addition, by reducing the inner periphery of the magnetic core 50, the magnetic core 50 can be made smaller, which contributes to the miniaturization and cost reduction of the terminal block 20.

[0044] As described above, the first connecting portion 32 and the second connecting portion 34 are wider than the intermediate portion 36. If the inner periphery of the magnetic core is set to a size that allows the first connecting portion 32 and the second connecting portion 34 to pass through, the gap between the inner periphery of the magnetic core and the intermediate portion 36 will be large when the magnetic core covers the intermediate portion 36. This may result in a smaller impedance due to the magnetic core. If the increased gap is compensated for by increasing the magnetic path cross-sectional area of ​​the magnetic core, the magnetic core may become larger. In addition, the magnetic core may become larger by the amount that the inner periphery of the magnetic core is enlarged. If the magnetic core becomes larger, the terminal block may become larger, which may also increase costs.

[0045] Therefore, the inner periphery of the magnetic core 50 is made small enough to restrict passage between the first connection portion 32 and the second connection portion 34. The inner periphery of the magnetic core 50 is made as small as possible within a range that maintains insulation with respect to the intermediate portion 36. For example, the inner periphery of the magnetic core 50 may be made small enough to maintain a minimum gap of about 1 mm to 10 mm from the outer periphery of the intermediate portion 36.

[0046] Also, the magnetic core 50 includes a plurality of split cores 50A, 50B. For example, the annular magnetic core 50 is split into two. The magnetic core 50 may be split into two symmetrically or asymmetrically. The magnetic core may be split into three or more parts. In this embodiment, the magnetic core 50 has a track shape in which semi-annular parts are connected to both ends of a pair of parallel parts. The magnetic core 50 is split into two symmetrically along a splitting plane perpendicular to the long side direction.

[0047] Each of the split cores 50A and 50B is made of a magnetic material. For example, the split cores 50A and 50B may be made of ferrite, may be made of laminated electromagnetic steel sheets, or may be made of dust material.

[0048] The split cores 50A, 50B are arranged with their end faces facing each other to form a ring shape, and the magnetic core 50 surrounds the intermediate portion 36. In this case, the first connection portion 32 and the second connection portion 34 do not need to pass through the magnetic core 50, so the inner peripheral portion of the magnetic core 50 can be made smaller so as to approach the shape of the outer peripheral portion of the intermediate portion 36, regardless of the spreading shapes of the first connection portion 32 and the second connection portion 34.

[0049] A magnetic filler 52 may be interposed between the multiple split cores 50A and 50B. The magnetic filler 52 is a magnetic material that is softer than the split cores 50A and 50B, and fills the gaps between the split cores 50A and 50B. The magnetic filler 52 is, for example, a magnetic sheet. The magnetic sheet is, for example, a sheet including a base material such as resin or rubber and a magnetic powder such as ferrite dispersed in the base material. The magnetic filler 52 may be a magnetic adhesive. The magnetic adhesive is an adhesive including a base material such as resin or rubber and a magnetic powder such as ferrite dispersed in the base material. The magnetic filler 52 may be a filler including a magnetic sheet and a magnetic adhesive in combination.

[0050] The magnetic filler 52 is interposed between the end faces of the multiple split cores 50A, 50B, thereby reducing the air gap in the magnetic path around the intermediate portion 36. For example, when the end faces of the multiple split cores 50A, 50B are non-parallel, the magnetic filler 52 can fill the gap between the non-parallel end faces and adhere closely to the end faces. Also, when there are fine irregularities on the end faces of the multiple split cores 50A, 50B, the magnetic filler 52 can fill the irregularities and adhere closely to the end faces. This reduces the magnetic resistance of the magnetic core 50, improving the noise reduction effect.

[0051] The insulating base 60 is a portion that holds the conductive path forming body 30 and the magnetic core 50. The insulating base 60 keeps the bus bar terminals 40A, 40B, and 40C of the conductive path forming body 30 in a constant positional relationship in an insulated state. The insulating base 60 also keeps the magnetic core 50 in a constant positional relationship surrounding the bus bar terminals 40A, 40B, and 40C in a state insulated from the bus bar terminals 40A, 40B, and 40C. The insulating base 60 holds the intermediate portion 36 and the magnetic core 50 surrounding the intermediate portion 36 in a state in which at least a part of the first connection portion 32 and at least a part of the second connection portion 34 are exposed.

[0052] The insulating base 60 may be, for example, a part molded from resin using one or both of the conductive path forming body 30 and the magnetic core 50 as insert parts. The insulating base 60 may be, for example, a part molded from resin separately from the conductive path forming body 30 and the magnetic core 50.

[0053] In this embodiment, the insulating base 60 includes a first resin portion 62 and a second resin portion 66 .

[0054] The first resin portion 62 is a portion molded from resin using the conductive path formation body 30 as an insert portion. The first resin portion 62 keeps the multiple bus bar terminals 40A, 40B, 40C in a constant positional relationship while being insulated from each other. The first resin portion 62 also covers the periphery of the intermediate portion 36, separating the intermediate portion 36 from the magnetic core 50 so as to insulate them from each other.

[0055] More specifically, the first resin portion 62 includes a fixing plate portion 63 , a body portion 64 , and a holding protrusion portion 65 .

[0056] The fixing plate portion 63 is formed in a plate shape that is larger than the mounting hole 11h. A fixing hole 63h is formed in the fixing plate portion 63. The fixing plate portion 63 can cover the outer surface of the housing 11 around the mounting hole 11h. In this state, the terminal block 20 is fixed to the housing 11 by screwing a screw into the housing 11 through the fixing hole 63h.

[0057] The body 64 protrudes from the fixed plate 63. When the fixed plate 63 is attached to the housing 11, the body 64 is disposed in the mounting hole 11h. The intermediate portion 36 of the conductive path forming body 30 is located in the body 64. The conductive path forming body 30 penetrates the fixed plate 63, and the first connection portion 32 is exposed on the surface of the fixed plate 63 opposite to the body 64. In this embodiment, the first connection portion 32 includes a plurality of first bus bar ends 42A, 42B, 42C, and the plurality of first bus bar ends 42A, 42B, 42C are electrically connected to the connection counterpart terminal 14. The connection counterpart terminal 14 is, for example, a plate-shaped bus bar terminal extending from an inverter. The first bus bar ends 42A, 42B, 42C may have screw insertion holes formed therein and be fixed to the connection counterpart terminal 14 by screws.

[0058] The retaining protrusion 65 protrudes outward from the end of the body 64 opposite the fixed plate 63. In this embodiment, the retaining protrusion 65 protrudes in an annular shape from the periphery of the end of the body 64. The magnetic core 50 is disposed between the fixed plate 63 and the retaining protrusion 65 in a state in which the magnetic core 50 surrounds the body 64. This allows the magnetic core 50 to be held in a fixed position relative to the body 64.

[0059] The second resin part 66 is formed in a holder shape surrounding the outer periphery, upper side and lower side of the magnetic core 50. In this embodiment, the second resin part 66 is divided into two divided holder parts 66A and 66B. One side edge of the divided holder parts 66A and 66B is connected by a thin hinge 67a so as to be openable and closable. A locking protrusion 66Bp is formed on the other side edge of the divided holder part 66A, and a locking piece 66Ap extends from the other side edge of the divided holder part 66B. By closing the opened divided holder parts 66A and 66B, the magnetic core 50 can be placed inside the divided holder parts 66A and 66B. With the magnetic core 50 covered by the split holder parts 66A, 66B, the split holder parts 66A, 66B are kept in a closed state by engaging the locking protrusion 66Bp on the other side edge of the split holder part 66A with the locking hole formed in the locking piece 66Ap on the other side edge of the split holder part 66B.

[0060] The conductive path forming body 30 penetrates the body 64, and the second connection portion 34 protrudes below the body 64. In this embodiment, the second connection portion 34 includes a plurality of second bus bar ends 44A, 44B, 44C, and the plurality of second bus bar ends 44A, 44B, 44C are electrically connected to the connection counterpart terminals 15, respectively. The connection counterpart terminals 15 are, for example, plate-shaped bus bar terminals extending from an electrical component in the device 10. The second bus bar ends 44A, 44B, 44C may have screw insertion holes formed therein and may be fixed to the connection counterpart terminals 15 by screw fastening.

[0061] An annular seal 22 may be disposed on the surface of the fixing plate portion 63 facing the housing 11. The annular seal 22 is an annular elastic part located around the mounting hole 11h. The annular seal 22 is interposed in a compressed state between the fixing plate portion 63 and the housing 11, thereby sealing off liquid around the mounting hole 11h.

[0062] A relay connector 24 may be held on the fixed plate portion 63. The relay connector 24 is a connector that relays and connects the wiring component 16 inside the device 10 and the wiring component 17 outside the device 10. For example, the relay connector 24 has a configuration that allows connection to both the connector on the wiring component 16 side and the connector on the wiring component 17 side outside the device 10, and the circuit of the wiring component 16 and the circuit of the wiring component 17 are electrically connected via a relay terminal in the relay connector 24.

[0063] The fixing plate portion 63 may be molded by using the relay connector 24 as an insert portion. It is not essential that the terminal block 20 includes the relay connector 24.

[0064] <About the conductive path formation body> The conductive path forming body 30 will be described in more detail. The conductive path forming body 30 includes a plurality of bus bar terminals 40A, 40B, and 40C. Each of the plurality of bus bar terminals 40A, 40B, and 40C is preferably an integral body of a conductive material, and is not a component in which a plurality of components are combined by insertion connection. For example, each of the plurality of bus bar terminals 40A, 40B, and 40C may be a press-processed component of a single metal material. If each of the plurality of bus bar terminals 40A, 40B, and 40C is a press-processed component of a single metal material, it is not necessary to form a spring structure or a contact structure for insertion connection, which makes it possible to reduce costs. In addition, heat generation at the contact portion is suppressed.

[0065] Each of the bus bar terminals 40A, 40B, 40C includes a first bus bar end portion 42A, 42B, 42C, a second bus bar end portion 44A, 44B, 44C, and a bus bar intermediate portion 46A, 46B, 46C. The bus bar intermediate portion 46A, 46B, 46C is located between the first bus bar end portion 42A, 42B, 42C and the second bus bar end portion 44A, 44B, 44C. The bus bar terminal 40A and the bus bar terminal 40C may have mirror symmetry with respect to a plane passing through the central axis of the bus bar terminal 40B. The first bus bar ends 42A, 42B, 42C and the second bus bar ends 44A, 44B, 44C extend relative to the bus bar intermediate portions 46A, 46B, 46C in a direction intersecting with the extension direction A of the bus bar intermediate portions 46A, 46B, 46C.

[0066] The plurality of bus bar intermediate portions 46A, 46B, 46C extend parallel to one another at intervals. In this embodiment, the plurality of bus bar intermediate portions 46A, 46B, 46C are arranged in a line in this order at intervals. The intervals are set to a size according to a desired insulation distance.

[0067] At least one of the multiple first bus bar end portions 42A, 42B, 42C extends in a direction intersecting the multiple bus bar intermediate portions 46A, 46B, 46C so that the first connection portion 32 extends wider than the intermediate portion .

[0068] In addition, at least one of the multiple second bus bar end portions 44A, 44B, 44C extends in a direction intersecting the multiple bus bar intermediate portions 46A, 46B, 46C so that the second connection portion 34 extends wider than the intermediate portion 36.

[0069] Here, the extent of the first connecting portion 32, the second connecting portion 34, and the intermediate portion 36 may be the extent when viewed along the extending direction A of the intermediate portion 36. Moreover, the extent is the range over which each of the first connecting portion 32, the second connecting portion 34, or the intermediate portion 36 extends. For example, the size of the extent may be evaluated by the area of ​​a convex hull (see Q1 and Q2 in FIG. 5 and Q1 and Q3 in FIG. 6) that can include each of the first connecting portion 32, the second connecting portion 34, or the intermediate portion 36 when viewed along the extending direction A of the intermediate portion 36.

[0070] The extent of the extension of the first connecting portion 32, the second connecting portion 34 and the intermediate portion 36 may be evaluated by the area of ​​a circumscribing circle that can encompass each component part of the first connecting portion 32, the second connecting portion 34 or the intermediate portion 36 when viewed along the extension direction A of the intermediate portion 36.

[0071] In the present embodiment, the first connection portion 32 is a portion that widens at the end relative to the intermediate portion 36, and includes a portion that protrudes upward from the insulating base 60. The first connection portion 32 includes first bus bar ends 42A, 42B, 42C.

[0072] The first bus bar ends 42A, 42B, 42C are bent in a direction intersecting the bus bar intermediate portions 46A, 46B, 46C, here, in a direction perpendicular to the bus bar intermediate portions 46A, 46B, 46C. The first bus bar end 42A is bent toward one side of the direction in which the bus bar intermediate portions 46A, 46B, 46C are arranged. The first bus bar end 42C is bent in the opposite direction to the first bus bar end 42A. The first bus bar end 42B is bent in a direction perpendicular to the direction in which the bus bar intermediate portions 46A, 46B, 46C are arranged.

[0073] The intermediate portion 36 includes bus bar intermediate portions 46A, 46B, and 46C, and the convex hull Q1 of the intermediate portion 36 is the area surrounded by the outer edges of the outer bus bar intermediate portions 46A, 46C in the direction in which the bus bar intermediate portions 46A, 46B, and 46C are arranged (see FIG. 5).

[0074] The convex hull Q2 of the first connection portion 32 is an area surrounded by a convex polygon connecting the corners of the tips of the first bus bar ends 42A, 42B, 42C. The corners of the tips of the first bus bar ends 42A, 42B, 42C are located at positions away from the outside of the bus bar intermediate portions 46A, 46B, 46C, and therefore the convex hull Q2 is larger than the convex hull Q1. Thus, the first connection portion 32 extends wider than the intermediate portion 36.

[0075] Further, the second connection portion 34 is a portion that widens on the end side relative to the intermediate portion 36, and includes a portion that protrudes downward from the insulating base 60. The second connection portion 34 includes second bus bar ends 44A, 44B, 44C.

[0076] The second bus bar ends 44A, 44C are bent in a direction intersecting the bus bar intermediate portions 46A, 46B, 46C, here, in a direction intersecting at 45 degrees. The second bus bar end 44A is bent obliquely toward one side of the direction in which the bus bar intermediate portions 46A, 46B, 46C are arranged. The second bus bar end 44C is bent in the opposite direction to the second bus bar end 44A. The second bus bar end 44B extends straight without being bent relative to the bus bar intermediate portion 46B.

[0077] The convex hull Q3 of the second connection portion 34 is a range that surrounds the corners of the tips of the second bus bar ends 44A, 44C and the outer edges of the base end portions of the second bus bar ends 44A, 44B, 44C that extend from the insulating base 60 (see FIG. 6). The corners of the tips of the second bus bar ends 44A, 44C are located at positions away from the bus bar intermediate portions 46A, 46B, 46C on the outer side, and the base end portions of the second bus bar ends 44A, 44B, 44C that extend from the insulating base 60 are also located in a range similar to that of the bus bar intermediate portions 46A, 46B, 46C. Therefore, the convex hull Q3 is larger than the convex hull Q1. Therefore, the second connection portion 34 is wider than the intermediate portion 36.

[0078] In the present embodiment, the bus bar terminals 40A, 40B, 40C are cylindrical bus bar terminals that include flat end portions and cylindrical intermediate portions that are closer to a cylinder than the flat end portions.

[0079] The cylindrical intermediate portion being closer to a cylinder than the flattened end portion means that the cross-sectional shape (cross section in a direction perpendicular to the extending direction A) of the cylindrical intermediate portion is closer to a circle than the cross-sectional shape of the flattened end portion. The flattened end portion is flatter than the cylindrical intermediate portion. The degree of flatness may be evaluated as the ratio of the short side dimension in the direction perpendicular to the longest direction to the longitudinal dimension in the longest direction of the cross-sectional shape of the flattened end portion or the cylindrical intermediate portion. A smaller ratio of the short side dimension to the longitudinal dimension may be evaluated as being flatter. A degree of flatness closer to 1 may be evaluated as being closer to a circle.

[0080] In this embodiment, the bus bar intermediate portions 46A, 46B, 46C excluding the portions close to the first bus bar ends 42A, 42B, 42C and the portions close to the base ends of the second bus bar ends 44A, 44B, 44C are cylindrical intermediate portions having a circular cross section. The first bus bar ends 42A, 42B, 42C are flat ends having a rectangular plate shape. The portions close to the tip ends of the second bus bar ends 44A, 44B, 44C are also flat ends having a rectangular plate shape.

[0081] At the second bus bar end 44A, 44C side of the bus bar terminals 40A, 40C, the end of the cylindrical middle portion, i.e., the base end of the second bus bar end 44A, 44C, is bent, so that the second bus bar end 44A, 44C as a flat end extends in a direction intersecting with the bus bar middle portion 46A, 46C including the middle portion of the cylindrical middle portion. Since the end of the cylindrical middle portion has a circular cross section, it is easy to bend in various directions relative to the bus bar middle portion 46A, 46C. Therefore, the second bus bar end 44A, 44C can be easily bent in different directions from each other.

[0082] At the side of first bus bar end 42A, 42B, 42C of bus bar terminals 40A, 40B, 40C, the flat end is bent in its thickness direction, and first bus bar end 42A, 42B, 42C, which is the tip of the flat end, extends in a direction intersecting the extension direction of the cylindrical intermediate portion.

[0083] For example, by pressing the cylindrical intermediate portion in a desired direction, the flattening direction of the flattened end portion relative to the cylindrical intermediate portion can be processed in a desired direction. By setting the flattening direction of the flattened end portion in a desired bending direction, the bending direction of the flattened end portion can be easily set in a desired direction.

[0084] The above will be described more specifically using a manufacturing method for the bus bar terminal 40A as an example.

[0085] First, a cylindrical metal material 90 is prepared as shown in Fig. 7. The cylindrical metal material 90 is a metal material in the shape of a round bar. The cylindrical metal material 90 may be made of copper, a copper alloy, aluminum, an aluminum alloy, or the like.

[0086] Then, the ends of the cylindrical metal material 90 are pressed into a flattened shape. By arbitrarily setting the pressing direction for the middle part of the cylindrical metal material 90, the flattening directions of both ends of the cylindrical metal material 90 can be arbitrarily made different from each other. For example, the flattening directions of both ends of the cylindrical metal material 90 can be set to positions shifted by 90 degrees around the central axis of the cylindrical metal material 90.

[0087] As shown in FIG. 8, a cylindrical metal material 90 has flattened ends 92, 94 at both ends, with a cylindrical middle portion 96 therebetween.

[0088] Then, by bending the base end of the flat end 92 in its thickness direction, the tip end of the flat end 92 extends in a direction intersecting the cylindrical intermediate portion 96. As a result, a first busbar end 42A extending in a direction intersecting the busbar intermediate portion 46A can be formed above the busbar intermediate portion 46A where the base end of the flat end 92 is connected to the upper end of the cylindrical intermediate portion 96.

[0089] Since the flat end 92 is formed by pressing the cylindrical metal material 90 flat, the flat direction of the flat end 92 can be easily adjusted by adjusting the pressing direction during processing. By forming the flat end 92 so as to be flat in the direction to be bent, the first busbar end 42A can be easily processed to extend in any direction. For example, in the busbar terminal 40C, the first busbar end 42C can be easily bent in the opposite direction to the first busbar end 42A. Also, for example, in the busbar terminal 40B, by making the flat direction of the flat end different, the first busbar end 42B can be easily bent in a direction different from the first busbar ends 42A and 42C. A hole for screw fixing is formed in the first busbar end 42A as necessary.

[0090] Moreover, by bending the end of the cylindrical intermediate portion 96, the flat end portion 94 extends in a direction intersecting with the intermediate portion of the cylindrical intermediate portion 96. As a result, the second busbar end portion 44A is formed in which the flat end portion 94 is connected to the lower end portion of the cylindrical intermediate portion 96. Since the bending point is set at the end portion of the cylindrical intermediate portion 96, the bending direction can be set arbitrarily. Therefore, in the busbar terminal 40C, the second busbar end portion 44C can be easily bent in the opposite direction to the second busbar end portion 44A. A hole for screw fixing is formed in the second busbar end portion 44A as necessary.

[0091] In this manner, the cylindrical metal material 90 can be bent so that the end portion of the cylindrical metal material 90 can be easily positioned at a position that is not on the extension of the middle portion of the cylindrical metal material 90.

[0092] It should be noted that either the process of flattening the end portion of the columnar metal material 90 or the process of bending the columnar metal material 90 may be performed first.

[0093] As shown in Figs. 3 and 4, if cylindrical bus bar terminals are used as the bus bar terminals 40A, 40B, 40C, it is easy to arbitrarily set the bending directions of the first bus bar ends 42A, 42B, 42C and the second bus bar ends 44A, 44B, 44C.

[0094] This makes it easy to align the bending points of the bus bar intermediate portions 46A, 46B, 46C in the extension direction A to the same position, while aligning the first bus bar ends 42A, 42B, 42C to the same position in the same direction, and aligning the second bus bar ends 44A, 44B, 44C to the same position.

[0095] For example, focus on the first bus bar ends 42A, 42B, 42C. The bent points 42V on the first bus bar ends 42A, 42B, 42C sides are aligned at the same position in the extension direction A of the bus bar intermediate portions 46A, 46B, 46C. The first bus bar ends 42A, 42B, 42C are located at the same position in the same direction. Note that the bent points 42V being at the same position and the first bus bar ends 42A, 42B, 42C being at the same position include cases where they are the same within a tolerance range, for example, cases where they are the same within a range of ±5 mm.

[0096] In this case, any one of the first bus bar ends 42A, 42B, 42C can be considered to be an example of a first cylindrical bus bar terminal, and any other one can be considered to be an example of a second cylindrical bus bar terminal.

[0097] Also, for example, attention is given to the second bus bar ends 44A, 44B, 44C. The bent portions 44V on the second bus bar ends 44A, 44C side are aligned at the same position in the extending direction A of the bus bar intermediate portions 46A, 46B, 46C. They are located at the same position as the second bus bar ends 44A, 44C in the same direction. The second bus bar end 44B is shifted from the second bus bar ends 44A, 44C in the above direction depending on the position of the connection mating terminal 15.

[0098] In this case, one of the second bus bar ends 44A, 44C can be considered to be an example of a first cylindrical bus bar terminal, and the other can be considered to be an example of a second cylindrical bus bar terminal.

[0099] <Terminal block manufacturing method> An example of a manufacturing method for the terminal block 20 will be described.

[0100] As shown in Fig. 9, a plurality of bus bar terminals 40A, 40B, 40C are assembled. The assembly is performed by arranging bus bar intermediate portions 46A, 46B, 46C in a parallel state with a gap between them. The assembly and arrangement of the plurality of bus bar terminals 40A, 40B, 40C may be performed, for example, by setting the bus bar terminals 40A, 40B, 40C in a die 98 for molding the first resin portion 62. The relay connector 24 may be set in the die 98.

[0101] Then, molten resin is supplied into the die 98, with the bus bar middle portions 46A, 46B, and 46C of the bus bar terminals 40A, 40B, and 40C serving as insert portions. As a result, the first resin portion 62 is molded with the bus bar middle portions 46A, 46B, and 46C disposed therein.

[0102] 10, the bus bar terminals 40A, 40B, 40C and the first resin portion 62 are removed from the mold 98. In this state, the first bus bar ends 42A, 42B, 42C are exposed from the fixing plate portion 63, and the second bus bar ends 44A, 44B, 44C are exposed downward from the body portion 64. Between the fixing plate portion 63 and the retaining projection 65, the bus bar intermediate portions 46A, 46B, 46C are covered by the body portion 64. A space in which the magnetic core 50 can be disposed is formed on the outer periphery of the body portion 64 between the fixing plate portion 63 and the retaining projection 65.

[0103] 11, split cores 50A, 50B move from both outsides of body portion 64 toward body portion 64. Split cores 50A, 50B combine to form an annular shape with their end faces facing each other. At this time, magnetic filler 52 is disposed between the end faces of split cores 50A, 50B.

[0104] Thereafter, the second resin part 66 is set around the magnetic core 50 so as to cover the outer periphery of the magnetic core 50. This keeps the split cores 50A and 50B in a combined state. In addition, the magnetic core 50 is protected and insulated from the surroundings.

[0105] <Effects, etc.> According to the terminal block 20 configured as above, the magnetic core 50 includes a plurality of split cores 50A, 50B. Therefore, by combining the plurality of split cores 50A, 50B around the middle portion 36, which is smaller in width than the first connecting portion 32 and the second connecting portion 34, the middle portion 36 can be surrounded by the magnetic core 50. By surrounding the middle portion 36 of the conductive path forming body 30 with the annular magnetic core 50, noise can be reduced. In addition, since the first connecting portion 32 or the second connecting portion 34 does not need to be inserted into the annular magnetic core 50, the inner circumference of the magnetic core 50 can be made smaller. This allows the magnetic core 50 to be made smaller. In addition, the distance between the magnetic core 50 and the middle portion 36 can be reduced, improving the noise reduction effect.

[0106] By forming the inner circumferential portion of the magnetic core 50 into a shape that restricts passage between the first connecting portion 32 and the second connecting portion 34 and allows passage of the intermediate portion 36, it becomes easier to bring the magnetic core 50 close to the intermediate portion 36. This makes it possible to reduce the size of the magnetic core 50 and improve the noise reduction effect.

[0107] Furthermore, by forming bus bar terminals 40A, 40B, 40C as press-formed components made of a single metal material, they can be processed more easily than when the bus bar terminals are formed as combined components made of a plurality of parts.

[0108] In addition, the conductive path forming body 30 includes a plurality of bus bar terminals 40A, 40B, 40C, the plurality of bus bar intermediate portions 46A, 46B, 46C extending parallel to one another at intervals, at least one of the plurality of first bus bar ends 42A, 42B, 42C extending in a direction intersecting the plurality of bus bar intermediate portions 46A, 46B, 46C so that the first connection portion 32 is wider than the intermediate portion 36, and at least one of the plurality of second bus bar ends 44A, 44B, 44C extending in a direction intersecting the plurality of bus bar intermediate portions 46A, 46B, 46C so that the second connection portion 34 is wider than the intermediate portion 36. Therefore, the first bus bar ends 42A, 42B, 42C and the second bus bar ends 44A, 44B, 44C can be appropriately bent and arranged with respect to the bus bar middle portions 46A, 46B, 46C according to the layout of the connection counterpart terminals 14, 15. In this case, the first connection portion 32 and the second connection portion 34 may be wider than the middle portion 36. In such a case, the magnetic core 50 with a small inner circumference can be arranged around the middle portion 36.

[0109] In addition, bus bar terminals 40A, 40C are cylindrical bus bar terminals, and the lower end of a cylindrical middle portion 96 is bent, and the flat end portion 94 extends in a direction intersecting with the extending direction A of the middle portion of the cylindrical middle portion 96. The cylindrical middle portion 96 is easier to bend in any direction than when it is in the shape of a thin elongated plate. This makes it easier to process the flat end portion 94 to extend in any direction.

[0110] Moreover, bus bar terminals 40A, 40B, 40C are cylindrical bus bar terminals, and flat end portions 92 are bent in their thickness direction, with the tips of the flat end portions 92 extending in a direction intersecting with the extension direction A of the cylindrical intermediate portion 96. For this reason, by processing the direction of the flat end portions 92 relative to the cylindrical intermediate portion 96 in any direction, it is easy to process the flat end portions 92 to extend in any direction.

[0111] In addition, the bus bar terminals 40A, 40B, and 40C are cylindrical bus bar terminals, and the ends of the cylindrical intermediate portions are bent to form the bent portion 44V, or the flat ends are bent to form the bent portion 42V. This makes it difficult to put a strain on the installation space of the magnetic core 50, compared to a case where the bus bar terminals are bent at different positions at each end. In other words, it is easy to set the length of the linearly extending bus bar intermediate portions 46A, 46B, and 46C to be large. This allows the magnetic core 50 to be large in the extending direction A of the multiple cylindrical intermediate portions 96, i.e., the intermediate portion 36. If the height of the magnetic core 50 can be increased, the outer peripheral shape of the magnetic core 50 can be made smaller.

[0112] Furthermore, if magnetic filler 52 is interposed between multiple split cores 50A, 50B, noise reduction performance can be improved.

[0113] According to the manufacturing method of the bus bar terminal 40A, a cylindrical metal material 90 is prepared, the ends of the cylindrical metal material 90 are pressed into a flat shape to form flat ends 92, 94, and the cylindrical metal material 90 is bent to dispose the ends of the cylindrical metal material 90 at positions that are off the extension of the middle part of the cylindrical metal material. By pressing the ends of the cylindrical metal material 90 into a flat shape, the ends formed into a flat shape can be easily connected to the mating terminals 14, 15 by surface contact. By bending the cylindrical part of the cylindrical metal material 90 in any direction or by arbitrarily setting the flat direction relative to the cylindrical part, the extension direction of the flat part of the end relative to the middle part of the cylindrical metal material can be easily set in any direction. Therefore, it is easy to set the extent of the intermediate portion 36 to be smaller than the extent of the first connecting portion 32 and the second connecting portion 34, while still providing a large space between the first connecting portion 32 and the second connecting portion 34 to install the magnetic core 50.

[0114] In the above-described first embodiment, an example has been described in which the terminal block 20 includes three bus bar terminals 40A, 40B, and 40C. The number of bus bar terminals included in the terminal block is arbitrary.

[0115] 12 and 13, a terminal block 120 according to a modified example includes two bus bar terminals 40A, 40C. That is, the terminal block 120 is configured such that the intermediate bus bar terminal 40B in the above-described terminal block 20 is omitted, and the terminal block 120 is made smaller in size in the width direction. Furthermore, the relay connector 24 is also omitted in the terminal block 120.

[0116] In this modification, the first bus bar ends 42A, 42C of the two bus bar terminals 40A, 40C are also bent relative to the bus bar middle portions 46A, 46C. Therefore, the first connection portion 132 of the conductive path formation body 130 including the two bus bar terminals 40A, 40C is wider than the middle portion 136. In addition, the second bus bar ends 44A, 44C of the two bus bar terminals 40A, 40C are bent relative to the bus bar middle portions 46A, 46C. Therefore, the second connection portion 134 of the conductive path formation body 130 is wider than the middle portion 136.

[0117] As in the first embodiment, by forming the magnetic core 50 into a divided configuration, it is possible to reduce noise and make the magnetic core smaller.

[0118] The terminal block may include only one bus bar terminal. For example, the terminal block may include only bus bar terminal 40A. Even in this case, the first connection portion including first bus bar end 42A and the second connection portion including second bus bar end 44A can each be made wider than the middle portion including bus bar middle portion 46A, and by using a divided magnetic core, it is possible to reduce noise and make the magnetic core smaller.

[0119] [Embodiment 2] A terminal block 220 according to the second embodiment will be described. Fig. 14 is a perspective view showing the terminal block 220 according to the second embodiment. Fig. 15 is a perspective view showing bus bar terminals 240A, 240B, 240C and magnetic core 250 of the terminal block. Fig. 16 is a cross-sectional view taken along line XVI-XVI in Fig. 15, and Fig. 17 is a cross-sectional view taken along line XVII-XVII in Fig. 15. Note that the second embodiment will be described mainly with respect to the differences from the first embodiment.

[0120] The terminal block 220 includes a conductive path formation body 230 , a magnetic core 250 , and an insulating base 260 .

[0121] The conductive path formation body 230 includes a plurality of bus bar terminals 240A, 240B, and 240C. The main difference between the terminal block 220 and the terminal block 20 is the configuration related to the bus bar terminals 240A, 240B, and 240C.

[0122] That is, while the bus bar terminals 40A, 40B, and 40C of the first embodiment are formed by processing a cylindrical metal material, the bus bar terminals 240A, 240B, and 240C of the second embodiment are formed by bending a thin and long metal plate material. The metal plate material is made of, for example, copper, a copper alloy, aluminum, an aluminum alloy, or the like.

[0123] A long, thin metal plate is easier to bend in its thickness direction than in its width direction. Therefore, by configuring as follows, the first connection portion 232 and the second connection portion 234 of the conductive path formation body 230 are made wider than the middle portion 236.

[0124] That is, bus bar intermediate portions 246A, 246B, and 246C of bus bar terminals 240A, 240B, and 240C are arranged in parallel with a gap therebetween. Bus bar intermediate portions 246A, 246B, and 246C are arranged to overlap each other in the same region in the thickness direction.

[0125] That is, the first bus bar ends 242A, 242B, 242C at the upper ends of the bus bar terminals 240A, 240B, 240C are bent in the thickness direction, for example at a right angle. The base ends of the first bus bar ends 242A, 242B, 242C are arranged in parallel with a gap between them in the vertical direction. The end of the first bus bar end 242A is formed into an L-shape and is arranged at a position spaced apart on one side outward from the first bus bar end 242B. The end of the first bus bar end 242C is formed into an opposite L-shape and is arranged at a position spaced apart on the other side outward from the first bus bar end 242B.

[0126] In order to align the ends of the first bus bar ends 242A, 242B, 242C at the same position in the extension direction A of the bus bar intermediate portions 246A, 246B, 246C, a step portion is provided at the first bus bar ends 242B, 242C.

[0127] As a result, a convex hull R2 surrounding the first bus bar end portions 242A, 242B, 242C is larger than a convex hull R1 surrounding the bus bar middle portions 246A, 246B, 246C (see FIG. 17).

[0128] Also, the second bus bar ends 244A, 244B, 244C at the lower ends of the bus bar terminals 240A, 240B, 240C are bent in the thickness direction, for example, at a right angle. The base ends of the second bus bar ends 244A, 244B, 244C are arranged in parallel with a gap between them in the vertical direction. The second bus bar end 244A and the second bus bar end 244C are formed in a shape that extends outward on both sides of the second bus bar end 244B. The portions extending from the side edges of the extending portions are bent so as to extend along the extending direction A of the bus bar intermediate portions 246A, 246C. Also, the tip end of the second bus bar end 244B is bent so as to extend along the extending direction A of the bus bar intermediate portion 246B. As a result, the ends of the second bus bar ends 244A, 244B, 244C extend in parallel with a gap therebetween along the extension direction A of the bus bar intermediate portions 246A, 246B, 246C.

[0129] As a result, a convex hull R3 surrounding the second bus bar end portions 244A, 244B, 244C is larger than a convex hull R1 surrounding the bus bar middle portions 246A, 246B, 246C (see FIG. 16).

[0130] The insulating base 260 holds the bus bar intermediate portions 246A, 246B, 246C, the base ends of the first bus bar ends 242A, 242B, 242C, and the base ends of the second bus bar ends 244A, 244B, 244C in fixed positions while insulating them from each other.

[0131] Further, the magnetic core 250 has split cores 250A and 250B surrounding the bus bar middle portions 246A, 246B, and 246C, similarly to the first embodiment. The insulating base 260 also maintains the state in which the split cores 250A and 250B surround the bus bar middle portions 246A, 246B, and 246C.

[0132] According to the terminal block 220 of the second embodiment, the magnetic core 250 includes a plurality of split cores 250A, 250B. Therefore, as in the first embodiment, by combining a plurality of split cores 250A, 250B, the magnetic core 250 can surround the middle portion 236, thereby reducing noise. In addition, since the first connecting portion 232 or the second connecting portion 234 does not need to be inserted into the annular magnetic core 250, the inner circumference of the magnetic core 250 can be made smaller. This allows the magnetic core 250 to be made smaller.

[0133] Other than the effects achieved by the cylindrical bus bar terminal, the same effects as those of the first embodiment can be achieved.

[0134] The configurations described in the above embodiment and modifications can be combined as appropriate as long as they are not mutually inconsistent.

[0135] For example, a cylindrical bus bar terminal and a plate-shaped bus bar terminal may be used in combination in the same terminal block. [Explanation of symbols]

[0136] 10 equipment 11. Cabinet 11h Mounting hole 14, 15 Connection terminal 16, 17 Wiring parts 20, 120, 220 terminal block 22 Annular seal 24 Relay connector 30, 130, 230 Conductive path forming body 32, 132, 232 First connection part 34, 134, 234 Second connection part 36, 136, 236 Middle 40A, 40B, 40C, 240A, 240B, 240C Busbar terminals 42A, 42B, 42C, 242A, 242B, 242C First bus bar end 42V Bending point 44A, 44B, 44C, 244A, 244B, 244C Second bus bar end 44V Bending point 46A, 46B, 46C, 246A, 246B, 246C Busbar center section 50, 250 Magnetic core 50A, 50B, 250A, 250B split core 52 Magnetic filler 60, 260 Insulation base 62 First resin part 63 Fixed plate part 63h Fixing hole 64 Torso 65 Holding protrusion 66 Second Resin Part 66A, 66B Separate holder section 66Ap locking piece 66Bp Locking protrusion 67a Thin hinge 90 Cylindrical metal material 92, 94 flat end 96 Cylindrical middle section 98 Mold Q1, Q2, Q3, R1, R2, R3 convex hull

Claims

1. A conductive path formation body including a bus bar terminal; An annular magnetic core; an insulating base for holding the conductive path formation body and the magnetic core; Equipped with the conductive path formation includes a first connection portion, a second connection portion, and an intermediate portion between the first connection portion and the second connection portion, When viewed along an extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion, The magnetic core includes a plurality of split cores, The split cores are arranged to form a ring shape, and the magnetic core surrounds the intermediate portion. A terminal block, wherein the insulating base holds the intermediate portion and the magnetic core surrounding the intermediate portion, with at least a portion of the first connection portion and at least a portion of the second connection portion exposed.

2. 2. The terminal block according to claim 1, A terminal block, wherein an inner peripheral portion of the magnetic core is formed into a shape that restricts passage between the first connection portion and the second connection portion, and allows passage of the intermediate portion.

3. The terminal block according to claim 1 or 2, The bus bar terminal is a press-formed part made of a single metal material.

4. The terminal block according to claim 1 or 2, The conductive path formation body includes a plurality of the bus bar terminals, Each of the plurality of bus bar terminals includes a first bus bar end portion, a second bus bar end portion, and a bus bar intermediate portion between the first bus bar end portion and the second bus bar end portion, The plurality of bus bar intermediate portions extend parallel to one another at intervals, at least one of the plurality of first bus bar end portions extends in a direction intersecting the plurality of bus bar intermediate portions such that the first connection portion is wider than the intermediate portions; at least one of the plurality of second bus bar end portions extends in a direction intersecting the plurality of bus bar intermediate portions such that the second connection portion extends wider than the intermediate portion.

5. The terminal block according to claim 1 or 2, The conductive path formation includes a cylindrical bus bar terminal as the bus bar terminal, The cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, A terminal block, wherein an end of the cylindrical intermediate portion is bent and the flat end portion extends in a direction intersecting with an extension direction of the intermediate portion of the cylindrical intermediate portion.

6. The terminal block according to claim 1 or 2, The conductive path formation includes a cylindrical bus bar terminal as the bus bar terminal, The cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, The flat end portion is bent in its thickness direction, and a tip portion of the flat end portion extends in a direction intersecting with the extending direction of the cylindrical intermediate portion.

7. The terminal block according to claim 1 or 2, the conductive path formation includes a first cylindrical bus bar terminal and a second cylindrical bus bar terminal as the bus bar terminal, Each of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, the cylindrical intermediate portions of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal extend in parallel with each other at an interval; A terminal block, wherein an end or a flat end of the cylindrical intermediate portion of each of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal is bent at the same position in an extension direction of the multiple cylindrical intermediate portions.

8. The terminal block according to claim 1 or 2, The magnetic core includes a magnetic filler interposed between the plurality of split cores.

9. A method for manufacturing a bus bar terminal, comprising: A cylindrical metal material is prepared. The end of the cylindrical metal material is pressed into a flat shape, A method for manufacturing a bus bar terminal, comprising bending the cylindrical metal material and positioning an end of the cylindrical metal material at a position that is off the extension of a middle portion of the cylindrical metal material.

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