Bus bar module and manufacturing method of bus bar module

Abstract

To provide a bus bar module capable of suppressing a decrease in yield of a flexible printed circuit board.SOLUTION: A bus bar module 1 includes a flexible printed circuit board 3 having a trunk line part 30 having a longitudinal direction X and a width direction Y, and a branch part 31 connected to an edge of the trunk line part in the width direction, a bus bar 10 connected to the branch part of the flexible printed circuit board, and a case 4 for housing the flexible printed circuit board and the bus bar. The branch part is cut into a shape having a base end part 32 connected to the trunk line part and a piece part 33 extending in the longitudinal direction from the base end part, and the branch part is connected to the bus bar 10 in a state in which the piece part is deformed so as to extend in the width direction Y.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a bus bar module and a method for manufacturing a bus bar module. [Background technology]

[0002] There are conventional techniques for connecting a flexible printed circuit board and a bus bar. Patent Document 1 discloses a connection structure between a bus bar and a circuit board, in which the bus bar is connected to a flat portion of the circuit board. The flat portion in Patent Document 1 extends in the width direction of the circuit board. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2023-074117 Summary of the Invention [Problem to be solved by the invention]

[0004] In the circuit board of Patent Document 1, if the distance from the trunk line portion of the circuit board to the bus bar is long, the flat portion needs to be long. As a result, the yield rate when manufacturing the circuit board may decrease. It is desirable to be able to suppress the decrease in yield rate of the flexible printed circuit board when the branch portion extends in the width direction between the trunk line portion and the bus bar of the flexible printed circuit board.

[0005] An object of the present invention is to provide a bus bar module that can suppress a decrease in yield of flexible printed circuit boards, and a method for manufacturing the bus bar module. [Means for solving the problem]

[0006] The busbar module of the present invention comprises a flexible printed circuit board having a trunk portion having longitudinal and width directions and branch portions connected to the widthwise edges of the trunk portion, a bus bar connected to the branch portions of the flexible printed circuit board, and a case that houses the flexible printed circuit board and the bus bar, wherein the branch portions are cut into a shape having a base end connected to the trunk portion and a piece portion extending in the longitudinal direction from the base end, and the branch portions are connected to the bus bar in a state where the piece portion is deformed so that it extends in the width direction.

[0007] A method for manufacturing a busbar module according to the present invention includes the steps of: forming a flexible printed circuit board having a trunk portion having longitudinal and width directions and branch portions connected to the widthwise edges of the trunk portion; deforming the branch portions; connecting bus bars to the branch portions; and accommodating the bus bars and the flexible printed circuit board in a case; wherein, in the step of forming the flexible printed circuit board, the branch portions are cut into a shape having a base end portion connected to the trunk portion and a piece portion extending from the base end in the longitudinal direction; and, in the step of deforming the branch portions, the branch portions are deformed so that the piece portion extends in the width direction. [Effects of the Invention]

[0008] In the busbar module according to the present invention, the branch portions of the flexible printed circuit board are cut into a shape having a base end connected to the trunk portion and a piece portion extending longitudinally from the base end, and the branch portions are connected to the busbar in a state in which the piece portion is deformed so as to extend widthwise. The busbar module according to the present invention has the effect of suppressing a decrease in yield of the flexible printed circuit board. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a plan view of a bus bar module according to an embodiment. [Figure 2] FIG. 2 is a perspective view of the bus bar module according to the embodiment. [Figure 3] Figure 3 shows an example of the layout of a flexible printed circuit board that can be manufactured from a single board. [Figure 4] FIG. 4 is a perspective view showing how the bent portion is formed. [Figure 5] FIG. 5 is a plan view showing an example of a jig plate. [Figure 6] FIG. 6 is a diagram showing a flexible printed circuit board placed on a jig plate. [Figure 7] FIG. 7 is a diagram showing a flexible printed circuit board in which a bent portion is formed by a jig plate. [Figure 8] FIG. 8 is a perspective view showing an example of a deformation mode of the branch portion. [Figure 9] FIG. 9 is a plan view showing an example of a modified form of the branch portion. [Figure 10] FIG. 10 is a plan view showing an example of the jig plate. [Figure 11] FIG. 11 is a diagram showing a flexible printed circuit board placed on a jig plate. DETAILED DESCRIPTION OF THE INVENTION

[0010] A busbar module and a method of manufacturing a busbar module according to an embodiment of the present invention will be described in detail below with reference to the drawings. Note that the present invention is not limited to the embodiment. Furthermore, the components in the following embodiments include those that can be easily imagined by a person skilled in the art or that are substantially the same.

[0011] [Embodiment] An embodiment will be described with reference to FIGS. 1 to 11. The embodiment relates to a busbar module and a manufacturing method of the busbar module. FIG. 1 is a plan view of the busbar module according to the embodiment. FIG. 2 is a perspective view of the busbar module according to the embodiment. FIG. 3 is an example of an arrangement of flexible printed circuit boards that can be manufactured from a single board. FIG. 4 is a perspective view showing how bent portions are formed. FIG. 5 is a plan view showing an example of a jig plate. FIG. 6 is a diagram showing the flexible printed circuit board placed on the jig plate. FIG. 7 is a diagram showing the flexible printed circuit board with bent portions formed by the jig plate. FIG. 8 is a perspective view showing an example of a deformation mode of the branch portion. FIG. 9 is a plan view showing an example of a deformation mode of the branch portion. FIG. 10 is a plan view showing an example of a jig plate. FIG. 11 is a diagram showing the flexible printed circuit board placed on the jig plate.

[0012] As shown in FIG. 1, the busbar module 1 of this embodiment includes a flexible printed circuit board 3, a busbar 10, and a case 4. The flexible printed circuit board 3 includes a base film, a coverlay, and a conductive layer. The base film and the coverlay are flexible insulating resin layers. The conductive layer is sandwiched between the base film and the coverlay for protection. The conductive layer is, for example, a conductive metal foil and includes a plurality of circuit patterns 5.

[0013] The flexible printed circuit board 3 has a trunk portion 30 and branch portions 31. The trunk portion 30 has a longitudinal direction X and a width direction Y. The multiple circuit patterns 5 extend in the longitudinal direction X in the trunk portion 30 and are arranged side by side in the width direction Y. The branch portions 31 are portions that are connected to the busbars 10. The branch portions 31 are connected to edges of the trunk portion 30 in the width direction Y.

[0014] FIG. 2 shows an enlarged view of a branch portion 31 connected to the busbar 10. In the busbar module 1 of this embodiment, the branch portion 31 is connected to the busbar 10 in a deformed state. More specifically, the branch portion 31 of this embodiment has a base end portion 32 and a piece portion 33. The base end portion 32 is a portion connected to the trunk portion 30. The piece portion 33 is connected to the trunk portion 30 via the base end portion 32. As shown in FIG. 3, the branch portion 31 is cut from the substrate 200 so that the piece portion 33 extends from the base end portion 32 in the longitudinal direction X. In other words, when the flexible printed circuit board 3 is formed, the piece portion 33 extends from the base end portion 32 in the longitudinal direction X.

[0015] 2, a connecting portion 34 is provided at the tip of the piece portion 33. A contact portion to be connected to the bus bar 10 is arranged in the connecting portion 34. A chip fuse 6 is mounted on the connecting portion 34. The bus bar 10 is connected to the circuit pattern 5 via the chip fuse 6.

[0016] The branch portion 31 is connected to the busbar 10 in a state in which the piece portion 33 is deformed to extend in the width direction Y. The branch portion 31 in FIG. 2 has a bent portion 35. The bent portion 35 is bent so that the piece portion 33 extends in the width direction Y. By deforming the branch portion 31, it is possible to make the branch portion 31 extend in the width direction Y to the busbar 10.

[0017] According to the busbar module 1 of this embodiment, by reducing the width Wd of the flexible printed circuit board 3 during manufacturing, it is possible to improve manufacturing efficiency and reduce manufacturing costs. For example, by reducing the width Wd of the flexible printed circuit board 3, the number of flexible printed circuit boards 3 that can be formed from the substrate 200 increases, as will be described below. For example, by reducing the width Wd, the efficiency of the process of mounting components such as the chip fuse 6 on the flexible printed circuit board 3 improves.

[0018] 3 shows an example of an arrangement of flexible printed circuit boards 3 that can be manufactured from one substrate 200. In the example of FIG. 3, four flexible printed circuit boards 3 are formed from one substrate 200. As shown in FIG. 3, in the flexible printed circuit board 3 of this embodiment, the branch portions 31 are cut so that the pieces 33 extend in the longitudinal direction X. This makes it possible to minimize the outermost shape 210 of one flexible printed circuit board 3 on the substrate 200. More specifically, it is possible to shorten the width Wd of the outermost shape 210.

[0019] As a comparative example of the flexible printed circuit board 3 of this embodiment, a flexible printed circuit board in which the entire branch portion extends from the trunk portion 30 in the width direction Y will be considered. In the flexible printed circuit board of the comparative example, the value of the width Wd is determined depending on the distance from the trunk portion 30 to the bus bar 10. Therefore, if the distance from the trunk portion 30 to the bus bar 10 is long, the width Wd of the outermost shape 210 becomes large. As a result, the number of flexible printed circuit boards that can be formed from one substrate 200 may be reduced.

[0020] In contrast, in the busbar module 1 of this embodiment, it is possible to minimize the width Wd of the outermost shape 210 of the flexible printed circuit board 3. For example, it is possible to make the width Wd of the outermost shape 210 the same regardless of the distance from the trunk line portion 30 to the busbar 10.

[0021] FIG. 4 shows the flexible printed circuit board 3 when a bent portion 35 is formed in the branch portion 31. The bent portion 35 is formed, for example, at the base portion of the piece portion 33 close to the base end portion 32. At the bent portion 35, the piece portion 33 is bent along a fold line FL. The fold line FL is inclined with respect to the longitudinal direction X and the width direction Y. The inclination angle of the fold line FL with respect to the width direction Y is, for example, 45°. The piece portion 33 is bent, for example, with the mounting surface 33a facing inward. The mounting surface 33a is the surface on which the chip fuse 6 is mounted. The contact portion connected to the busbar 10 is exposed on the mounting surface 33a.

[0022] The step of deforming the branch portion 31 may be performed manually by an operator, or may be performed using a jig. Figure 5 shows an example of a jig plate 300 used in the bending step. The jig plate 300 has a main body 310 having a mounting surface 310a, and a support portion 320 that is rotatable relative to the main body 310. The support portion 320 is connected to the main body 310 via a hinge 330. The hinge 330 has a rotation axis that is aligned with the mounting surface 310a. The support portion 320 rotates while supporting the side portion 33 of the flexible printed circuit board 3.

[0023] Fig. 6 shows a flexible printed circuit board 3 placed on a jig plate 300. The flexible printed circuit board 3 is set on the jig plate 300 with the backbone 30 placed on the placement surface 310a of the main body 310 and the piece 33 placed on the support portion 320. The support portion 320 rotates while supporting the piece 33, forming a bent portion 35 in the piece 33. Fig. 7 shows the flexible printed circuit board 3 with the bent portion 35 formed using the jig plate 300.

[0024] The connecting portion 34 may be connected to the bus bar 10 before the bending process, or may be connected to the bus bar 10 after the bending process. When the connecting portion 34 is connected to the bus bar 10 before the bending process, the supporting portion 320 may be formed so as to be able to support the piece portion 33 and the bus bar 10.

[0025] The manufacturing method of the busbar module 1 according to this embodiment includes a forming step, a deforming step, a connecting step, and an accommodating step. The forming step is a step of forming the flexible printed circuit board 3.

[0026] In the forming process, a flexible printed circuit board 3 is formed, which has a trunk portion 30 having a longitudinal direction X and a width direction Y, and branch portions 31 connected to edges of the trunk portion 30 in the width direction Y. The forming process is performed, for example, by an apparatus that cuts the flexible printed circuit board 3 from the substrate 200. This apparatus, for example, punches out the flexible printed circuit board 3 using a mold. In the forming process, the branch portions 31 are cut so as to have base ends 32 connected to the trunk portion 30 and piece portions 33 extending from the base ends 32 in the longitudinal direction X. After the forming process, a mounting process is performed in which components such as chip fuses 6 are mounted on the flexible printed circuit board 3.

[0027] In the deformation process, the branch portions 31 of the flexible printed circuit board 3 are deformed. In the deformation process, the branch portions 31 are deformed so that the pieces 33 extend in the width direction Y. The deformation process may be performed manually by an operator or may be performed using a jig such as a jig plate 300. The deformation process is, for example, a bending process in which bent portions 35 are formed in the branch portions 31.

[0028] In the connecting step, the bus bar 10 is connected to the branch portion 31. The bus bar 10 is connected to a contact portion arranged on the connection portion 34 of the branch portion 31 by welding, soldering, or the like.

[0029] In the accommodation step, the bus bar 10 and the flexible printed circuit board 3 are accommodated in the case 4. As shown in FIG. 1 , the case 4 has a main body 40 that accommodates the bus bar 10 and the flexible printed circuit board 3. The main body 40 is molded from, for example, an insulating synthetic resin. The main body 40 has a wiring path 41 and a plurality of holding portions 43.

[0030] The wiring path 41 accommodates the flexible printed circuit board 3. The wiring path 41 may be formed as a groove-like passage. The wiring path 41 may have, for example, a main passage that accommodates the trunk portion 30 and branch passages that accommodate the branch portions 31.

[0031] The holding portion 43 accommodates and holds the bus bar 10. The holding portions 43 are adjacent to the wiring path 41 in the width direction Y and are arranged in the longitudinal direction X along the wiring path 41. The holding portion 43 is formed in a frame shape and has a protrusion that locks the bus bar 10.

[0032] The accommodating step includes a busbar accommodating step of accommodating the busbar 10 in the holding portion 43, and a board accommodating step of accommodating the flexible printed circuit board 3 in the wiring path 41. The busbar accommodating step and the board accommodating step may be performed simultaneously or at different times. For example, the board accommodating step may be performed after the busbar accommodating step is completed, or the busbar accommodating step may be performed after the board accommodating step is completed.

[0033] The order of the deformation step, connection step, and accommodation step is arbitrary. For example, the deformation step of deforming the branch portion 31 may be performed before or after the connection step. For example, a flexible printed circuit board 3 having a bent portion 35 formed therein may be accommodated in a case 4 accommodating a bus bar 10. In this case, the connection portion 34 of the flexible printed circuit board 3 may be connected to the bus bar 10 accommodated in the holding portion 43.

[0034] The deformation of the branch portion 31 in the deformation step may be different from the deformation that forms the bent portion 35. For example, the deformation of the branch portion 31 may be a deformation that rotates the piece portion 33 relative to the trunk portion 30, as shown in FIGS. 8 and 9. This deformation rotates the piece portion 33 relative to the trunk portion 30 by deforming the base end portion 32. The direction of the relative rotation at this time is along a plane including the trunk portion 30. The piece portion 33 rotates relative to the trunk portion 30 around the base end portion 32. The base end portion 32 elastically deforms so as to elongate the inner side 32a.

[0035] As shown in FIG. 9 , in the deformed branch portion 31, the piece 33 extends in the width direction Y. The deformation steps shown in FIGS. 8 and 9 may be performed manually by an operator or using a jig. FIG. 10 shows an example of a jig plate 300 used in the rotation step of rotating the piece 33. The jig plate 300 in FIG. 10 includes a main body 310 having a mounting surface 310a and a rotating plate 340 that is rotatable relative to the main body 310. The rotating plate 340 rotates around a rotation shaft 350. The axis of the rotation shaft 350 is perpendicular to the mounting surface 310a. The rotating plate 340 can rotate along the mounting surface 310a around the rotation shaft 350. The main body 310 may be provided with a stopper that limits the rotatable range of the rotating plate 340.

[0036] 11 shows the flexible printed circuit board 3 placed on the jig plate 300. The flexible printed circuit board 3 is set on the jig plate 300 with the trunk portion 30 placed on the placement surface 310a of the main body 310 and the piece portion 33 placed on the rotating plate 340. The rotating plate 340 may have a holding mechanism for holding the piece portion 33. The rotating plate 340 rotates as shown by the arrow AR1 while supporting the piece portion 33, causing the piece portion 33 to rotate relative to the trunk portion 30. As a result, the branch portion 31 is shaped such that the piece portion 33 extends in the width direction Y, as shown in FIG.

[0037] The connecting portion 34 may be connected to the bus bar 10 before the rotating step, or may be connected to the bus bar 10 after the rotating step. When the connecting portion 34 is connected to the bus bar 10 before the rotating step, the rotating plate 340 may be configured to be able to hold the piece portion 33 and the bus bar 10.

[0038] The jig plate 300 used in the rotation step is preferably configured to reduce damage to the circuit pattern 5 caused by deformation of the branch portion 31. For example, the position of the rotation axis 350 of the jig plate 300 may be set so as to reduce the amount of expansion and contraction of the circuit pattern 5 when the piece portion 33 is rotated. As an example, when the flexible printed circuit board 3 is placed on the jig plate 300 as shown in FIG. 11 , the rotation axis 350 may be positioned so that the axis of the rotation axis 350 intersects with the circuit pattern 5 of the branch portion 31.

[0039] As described above, the busbar module 1 of this embodiment includes the flexible printed circuit board 3, the busbar 10, and the case 4. The flexible printed circuit board 3 includes the trunk portion 30 having the longitudinal direction X and the width direction Y, and the branch portions 31 connected to the edges of the trunk portion 30 in the width direction Y. The busbar 10 is connected to the branch portions 31 of the flexible printed circuit board 3. The case 4 houses the flexible printed circuit board 3 and the busbar 10.

[0040] The branch portions 31 are cut to have base ends 32 connected to the trunk portions 30 and pieces 33 extending from the base ends 32 in the longitudinal direction X. The branch portions 31 are connected to the busbar 10 in a deformed state such that the pieces 33 extend in the width direction Y. According to the busbar module 1 of this embodiment, in a configuration in which the branch portions 31 extend in the width direction Y between the trunk portions 30 and the busbar 10, a decrease in the yield of forming the flexible printed circuit board 3 from the substrate 200 can be suppressed.

[0041] The deformed branch portion 31 has, for example, a bent portion 35 formed by bending the piece portion 33 so that it extends in the width direction Y. The position and shape of the bent portion 35 can be adjusted depending on the relative positions of the trunk portion 30 and the busbar 10. In other words, the busbar module 1 of this embodiment can connect the branch portion 31 to busbars 10 in various arrangements without requiring a design change of the flexible printed circuit board 3.

[0042] Branch portion 31 may be connected to busbar 10 in a state where base end portion 32 is deformed to rotate piece portion 33 relative to trunk portion 30 .

[0043] The manufacturing method of the busbar module 1 according to this embodiment includes the above-described forming step, deformation step, connection step, and accommodation step. In the forming step, the branch portion 31 is cut into a shape having a base end portion 32 connected to the trunk portion 30 and a piece portion 33 extending from the base end portion 32 in the longitudinal direction X. In the deformation step, the branch portion 31 is deformed so that the piece portion 33 extends in the width direction Y. The manufacturing method of the busbar module 1 according to this embodiment makes it possible to extend the branch portion 31 in the width direction Y between the trunk portion 30 and the busbar 10 while improving the yield in the forming step.

[0044] The manner in which the branch portions 31 are deformed in the deformation process is not limited to the manner exemplified in this embodiment. One flexible printed circuit board 3 may have branch portions 31 deformed into different shapes. For example, among the multiple branch portions 31 of the flexible printed circuit board 3, some branch portions 31 may be deformed to have bent portions 35, and other branch portions 31 may be deformed to rotate the pieces 33 relative to the trunk portion 30.

[0045] The contents disclosed in the above embodiments can be implemented in appropriate combinations. [Explanation of symbols]

[0046] 1: Busbar module 3: Flexible printed circuit board 4: Case 5: Circuit pattern, 6: Chip fuse 10: Bus bar 30: trunk portion, 31: branch portion, 32: base end portion, 33: one portion, 34: connection portion 35: Bending part 40: Main body, 41: Wiring path, 43: Retaining portion 200: Substrate 300: Jig plate, 310: Main body, 320: Support part, 330: Hinge 340: Rotating plate, 350: Rotating shaft FL: Fold line X: Longitudinal direction, Y: Width direction

Claims

1. a flexible printed circuit board having a trunk portion having a longitudinal direction and a width direction, and branch portions connected to edges of the trunk portion in the width direction; a bus bar connected to the branch portion of the flexible printed circuit board; a case that accommodates the flexible printed circuit board and the bus bar; Equipped with the branch portion is cut into a shape having a base end portion connected to the trunk portion and a piece portion extending in the longitudinal direction from the base end portion, The branch portion is connected to the bus bar in a state in which the piece portion is deformed so as to extend in the width direction. A busbar module characterized by:

2. The branch portion has a bent portion where the piece portion is bent so as to extend in the width direction. The busbar module according to claim 1 .

3. The branch portion is connected to the bus bar in a state in which the base end portion is deformed to rotate the one portion relative to the trunk portion. The busbar module according to claim 1 .

4. forming a flexible printed circuit board having a trunk portion having a longitudinal direction and a width direction, and branch portions connected to edges of the trunk portion in the width direction; deforming the branch portion; connecting a bus bar to the branch portion; a step of housing the bus bar and the flexible printed circuit board in a case; Including, In the step of forming the flexible printed circuit board, the branch portion is cut into a shape having a base end portion connected to the trunk portion and a piece portion extending in the longitudinal direction from the base end portion, In the step of deforming the branch portion, the branch portion is deformed so that the piece portion extends in the width direction. A method for manufacturing a busbar module comprising:

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