Noise filter and method for manufacturing a noise filter

Abstract

This invention provides a noise filter and a method for manufacturing the same that can improve the mounting density of electronic components. [Solution] The noise filter 500 according to this disclosure comprises an input terminal block 10A, an output terminal block 10B, a relay terminal block 10C, and a base plate 50. The base plate 50 holds the input terminal block 10A, the output terminal block 10B, and the relay terminal block 10C, and the input terminal block 10A, the output terminal block 10B, and the relay terminal block 10C are equipped with terminal fittings 20, and the relay terminal block 10C is composed of the relay terminal block 10C, the input terminal block 10A, and the output terminal block 10B. The relay terminal block 10C has substantially the same shape as the input terminal block 10A and the output terminal block 10B.

Description

Technical Field

[0001] The present disclosure relates to a noise filter and a method for manufacturing the noise filter.

Background Art

[0002] The noise filter disclosed in Patent Document 1 includes a case, a substrate, two terminal fittings, two terminal blocks, a relay terminal, and electronic components. The substrate is disposed on the bottom plate of the case such that the main surface of the substrate and the main surface of the bottom plate of the case are substantially parallel. The two terminal blocks are disposed on the substrate with a predetermined interval therebetween. One and the other of the two terminal fittings are respectively held by one and the other of the two terminal blocks. The relay terminal and the electronic components are disposed between the two terminal fittings on the substrate.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The inventors of the present application have found the following problems. There is a demand for a noise filter in which many electronic components can be mounted with respect to the bottom plate area of the case. In such a noise filter, the relay terminal occupies a certain area inside the case. Therefore, there was room for consideration regarding improvement of the mounting density of electronic components.

[0005] In view of the above problems, an object of the present disclosure is to provide a noise filter capable of improving the mounting density of electronic components and a method for manufacturing the same.

Means for Solving the Problems

[0006] The noise filter according to this disclosure comprises an input terminal block, an output terminal block, a relay terminal block, and a base plate, wherein the base plate holds the input terminal block, the output terminal block, and the relay terminal block, the input terminal block, the output terminal block, and the relay terminal block are equipped with terminal fittings, the relay terminal block, the input terminal block, and the output terminal block are made of a resin material, and the relay terminal block has substantially the same shape as the input terminal block and the output terminal block.

[0007] Furthermore, in the noise filter described above, the input terminal block, the output terminal block, and the relay terminal block each comprise a circuit board and electronic components, wherein the circuit board is positioned between the terminal fittings and the base plate, rising from the base plate, and the electronic components are mounted on the circuit board.

[0008] Furthermore, in the noise filter described above, a cover is further provided attached to the base plate, the input terminal block, the relay terminal block, and the output terminal block are arranged in the arrangement direction on the base plate, the input terminal block and the output terminal block are located at one end and the other end of the base plate in the arrangement direction, respectively, the cover comprises a plate-like portion facing the base plate, a side wall extending from the plate-like portion to the base plate, and an extension piece extending along the side wall from one end or the other end of the plate-like portion in the arrangement direction, the input terminal block or the output terminal block has an edge portion extending toward the side wall, and the edge portion may have a recess that engages with the extension piece.

[0009] Furthermore, in the noise filter described above, a cover is provided attached to the base plate, the input terminal block, the relay terminal block, and the output terminal block are arranged in the direction of arrangement on the base plate, the input terminal block and the output terminal block are located at one end and the other end of the base plate in the direction of arrangement, the cover comprises a plate-like portion facing the base plate and a side wall extending from the plate-like portion to the base plate, the input terminal block, the relay terminal block, and the output terminal block have edges extending toward the side wall, and the plate-like portion or the side wall may have grooves into which the edges are inserted.

[0010] Furthermore, in the noise filter described above, a cover is further provided attached to the base plate, the input terminal block, the relay terminal block, and the output terminal block are arranged in the arrangement direction on the base plate, the input terminal block and the output terminal block are located at one end and the other end of the base plate in the arrangement direction, the cover comprises a plate-like portion facing the base plate and a side wall extending from the plate-like portion to the base plate, the input terminal block, the relay terminal block, and the output terminal block are equipped with a plurality of terminal fittings and further comprise terminal walls separating the plurality of terminal fittings, and the plate-like portion further comprises projections that contact the end of the terminal wall in the arrangement direction.

[0011] In the method for manufacturing a noise filter according to the present disclosure, the noise filter comprises an input terminal block, an output terminal block, a relay terminal block, and a base plate, wherein the input terminal block, the output terminal block, and the relay terminal block each comprise a substrate and electronic components, the electronic components are mounted on the substrate, the substrate and the base plate are fastened together such that the substrate rises from the base plate, and the input terminal block, the relay terminal block, and the output terminal block, which are mounted or capable of mounting terminal fittings, are attached to the base plate so as to cover the substrate.

[0012] Furthermore, in the noise filter manufacturing method described above, the input terminal block, the relay terminal block, and the output terminal block each have guides extending upward from the base plate, and the input terminal block, the relay terminal block, and the output terminal block are mounted on the base plate so as to cover the substrate by engaging the substrate with the guides. [Effects of the Invention]

[0013] This disclosure can improve the mounting density of electronic components. [Brief explanation of the drawing]

[0014] [Figure 1] This is a perspective view showing a noise filter according to an embodiment. [Figure 2] This is a perspective view showing the noise filter according to the embodiment with the cover removed. [Figure 3] This is a perspective view showing a base plate according to an embodiment. [Figure 4] This is a perspective view showing the main parts of a noise filter according to an embodiment. [Figure 5] This is a perspective view of a relay terminal unit according to an embodiment. [Figure 6] This is a perspective view of the relay terminal unit according to the embodiment, taken from a different angle. [Figure 7] This is a perspective view of a relay terminal block according to an embodiment. [Figure 8] This is a perspective view of the relay terminal block according to the embodiment, taken from a different angle. [Figure 9] This is a plan view of a relay terminal block according to an embodiment. [Figure 10] This is a perspective view of the terminal fitting according to the embodiment. [Figure 11] This is a perspective view of the mounting substrate according to the embodiment. [Figure 12] This is a front view of the mounting substrate according to the embodiment. [Figure 13] This is a perspective view of the output terminal unit according to the embodiment. [Figure 14] It is a perspective view of the output-side terminal unit according to the embodiment, seen from another angle. [Figure 15] It is a perspective view of the mounting substrate and the base plate according to the embodiment. [Figure 16] It is a perspective view of the mounting substrate and the base plate according to the embodiment, seen from another angle. [Figure 17] It is a perspective view of the cover according to the embodiment. [Figure 18] It is a bottom view of the cover according to the embodiment. [Figure 19] It is a perspective view of the cover and the output-side terminal block according to the embodiment. [Figure 20] It is a cross-sectional view taken along the arrow XX-XX of FIG. 19. [Figure 21] It is a bottom view of the cover and each terminal block according to the embodiment. [Figure 22] It is a circuit diagram of the noise filter according to the embodiment. [Figure 23] It is a flowchart showing a manufacturing method of the noise filter according to the embodiment. [Figure 24] It is a diagram showing a manufacturing method of the noise filter according to the embodiment.

Embodiments for Carrying Out the Invention

[0015] Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings are simplified as appropriate.

[0016] <Embodiment> The configuration of the noise filter according to the embodiment will be described with reference to FIGS. 1 to 21.

[0017] Naturally, the right-handed XYZ coordinate system shown in Figure 1 and other drawings is for convenience in explaining the positional relationships of the components. Typically, the positive Z-axis is vertically upward, and the XY plane is horizontal, and this is common across drawings. The X-axis direction is the arrangement direction of the input terminal unit 100A, relay terminal unit 100C, and output terminal unit 100B, which will be described later. The Y-axis direction is the width direction of the lead wires 42-47, which will be described later.

[0018] Figure 1 is a perspective view showing a noise filter according to an embodiment. Figure 2 is a perspective view showing the noise filter shown in Figure 1 with the cover removed. As shown in Figures 1 and 2, the noise filter 500 comprises a base plate 50, an input terminal unit 100A, an output terminal unit 100B, a relay terminal unit 100C, coil units 40A and 40B, and a cover 60.

[0019] Figure 3 is a perspective view showing a base plate according to an embodiment. As shown in Figure 3, the base plate 50 is a plate-like body extending in the longitudinal direction. The base plate 50 may be made of a metal material. However, the base plate 50 only needs to have the strength required as a housing, and the material constituting the base plate 50 is not limited to a metal material. The main surface of the base plate 50 is covered with insulating paper 80. The base plate 50 includes fastening parts 53A, 53B, 53C, 56 and protruding pieces 54A, 54B, 54C. The fastening part 53A and the protruding piece 54A are arranged at one end 51 in the longitudinal direction of the base plate 50. The fastening part 53B and the protruding piece 54B are arranged at the other end 52 in the longitudinal direction of the base plate 50. The fastening part 53C and the protruding piece 54C are arranged between the one end 51 and the other end 52. The input-side terminal unit 100A shown in Figure 2 is fastened to the fastening part 53A and supported by the protruding piece 54A. The output terminal unit 100B is fastened to the fastening portion 53B and supported by the protruding piece 54B. The intermediate terminal unit 100C is fastened to the fastening portion 53C and supported by the protruding piece 54C. The protruding piece 54C has a hole that can engage with the engaging portion 18 of the intermediate terminal block 10C of the intermediate terminal unit 100C shown in Figures 5 and 6. Similarly, the protruding piece 54A has a hole that can engage with the engaging portion 18 of the input terminal block 10A of the input terminal unit 100A, which will be described later. The protruding piece 54B also has a hole that can engage with the engaging portion 18 of the output terminal block 10B, which will be described later. The fastening portion 56 may be positioned on the edge of the base plate 50.

[0020] As shown in Figure 2, the base plate 50 holds the input terminal unit 100A, the output terminal unit 100B, the relay terminal unit 100C, and the coil units 40A and 40B. The input terminal unit 100A, coil unit 40A, relay terminal unit 100C, coil unit 40B, and output terminal unit 100B are arranged in this order from one end 51 to the other end 52. In other words, the relay terminal unit 100C is positioned at a distance between the input terminal unit 100A and the output terminal unit 100B. Coil unit 40A is positioned between the input terminal unit 100A and the relay terminal unit 100C. Coil unit 40B is positioned between the relay terminal unit 100C and the output terminal unit 100B. Also, the input terminal unit 100A and the relay terminal unit 100C face each other. The input terminal unit 100A and the output terminal unit 100B are opposite each other with the relay terminal unit 100C in between.

[0021] In this embodiment, the input terminal unit 100A and the output terminal unit 100B have the same configuration. Figure 4 is a perspective view showing the main parts of the noise filter according to this embodiment. As shown in Figure 4, the input terminal unit 100A includes a male screw 70, a terminal fitting 20, an input terminal block 10A, and a mounting board 30A. The output terminal unit 100B includes a male screw 70, a terminal fitting 20, an output terminal block 10B, and a mounting board 30B. In this embodiment, the input terminal unit 100A and the output terminal unit 100B each include three sets of male screws 70 and terminal fittings 20.

[0022] Figures 5 and 6 are perspective views of a relay terminal unit according to an embodiment. As shown in Figures 5 and 6, the relay terminal unit 100C comprises terminal fittings 20, a relay terminal block 10C, and a mounting board 30C. In this embodiment, the relay terminal unit 100C is equipped with three terminal fittings 20. The relay terminal block 10C is mounted on three terminal fittings 20.

[0023] The intermediate terminal block 10C has the same configuration as the input terminal block 10A and the output terminal block 10B. Specifically, the intermediate terminal block 10C has substantially the same shape as the input terminal block 10A and the output terminal block 10B. Therefore, the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C can be manufactured using the same mold. The input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C are preferably molded by injection molding. The intermediate terminal block 10C, the input terminal block 10A, and the output terminal block 10B are made of resin material. The resin material is, for example, thermoplastic resin, thermosetting resin, etc. The resin material constituting the intermediate terminal block 10C, the resin material constituting the input terminal block 10A, and the resin material constituting the output terminal block 10B may be of different types or of the same type. If the intermediate terminal block 10C is made of the same type of resin material as the input terminal block 10A and the output terminal block 10B, then the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C can be manufactured using the same type of resin material. This makes it possible to reduce the manufacturing costs of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C.

[0024] Figures 7 and 8 are perspective views of a relay terminal block according to an embodiment. Figure 9 is a plan view of the relay terminal block shown in Figures 7 and 8. As shown in Figures 7 to 9, the relay terminal block 10C comprises a main body 11, edge portions 12b and 12c, guides 14b and 14c, a terminal fitting holding portion 16, and an engaging portion 18.

[0025] The main body 11 is a wall extending in a U-shape (squared C-shaped) cross-section in the vertical direction (here, the Z-axis direction). In this embodiment, the main body 11 comprises a central part 11a and side parts 11b and 11c. The side part 11b extends from one end of the central part 11a in the width direction in the direction of arrangement (here, the X-axis direction). The side part 11c extends from the other end of the central part 11a in the width direction in the direction of arrangement.

[0026] Guides 14b and 14c are provided at the ends of the side portions 11b and 11c of the main body 11, respectively, on the lower vertical side (in this case, the negative Z-axis direction). Guides 14b and 14c extend in the vertical direction (in this case, the Z-axis direction). In this embodiment, guides 14b and 14c are grooves that extend in a substantially straight line. The engaging portion 18 is provided at the end of the main body 11 on the lower vertical side (in this case, the negative Z-axis direction). In this embodiment, the engaging portion 18 is a substantially rectangular prism that protrudes from the main body 11 in the direction of arrangement.

[0027] The terminal fitting holder portion 16 is provided at the end of the main body 11 in the vertical upper direction (here, in the positive Z-axis direction). Multiple terminal fitting holder portions 16 are provided so as to be aligned in the width direction (here, in the Y-axis direction). Terminal walls 15 separate the multiple terminal fitting holder portions 16 from each other. In this embodiment, two terminal walls 15 separate three terminal fitting holder portions 16 from each other. As shown in Figure 9, the terminal fitting holder portion 16 has holes 16A and 16B. Hole 16B is located near the center of the terminal fitting holder portion 16. Hole 16A is located around hole 16B.

[0028] The edges 12b and 12c extend from the sides 11b and 11c of the main body 11 in the width direction (here, the Y-axis direction), respectively. Specifically, the edge 12b includes a recess 13b and a fastening portion 17b. The recess 13b is located on the vertically upper side of the edge 12b. The fastening portion 17b is located at the vertically lower end of the edge 12b. Similarly, the edge 12c includes a recess 13c and a fastening portion 17c. The recess 13c is located on the vertically upper side of the edge 12c. The fastening portion 17c is located at the vertically lower end of the edge 12c. The recesses 13b and 13c are recessed in the direction of arrangement. The fastening portions 17b and 17c may have openings that widen from the vertically lower side to the vertically upper side.

[0029] Figure 10 is a perspective view of a terminal fitting according to an embodiment. As shown in Figures 5 and 10, the terminal fitting 20 is held in the terminal fitting holding part 16. The terminal fitting 20 only needs to be able to electrically connect to each of the lead wires 42 to 47 shown in Figure 2, and is not limited to its shape. The terminal fitting 20 according to this embodiment comprises a main body 21 and crimping pieces 22 and 23. The terminal fitting 20 may further comprise a boss 24 and insertion pieces 26 to 28. The main body 21 is a plate-like body extending in a horizontal plane (here, the XY plane). The terminal fitting 20 may be formed by processing a single plate-like body, or the main body 21, crimping pieces 22 and 23, boss 24, and insertion pieces 26 to 28 may be integrally molded. The crimping pieces 22 and 23 are rod-like bodies protruding from the main body 21, which may be bent to crimp each of the lead wires 42 to 47 described later. Crimping pieces 22 and 23 crimp each lead wire 42 to 47, electrically connecting the lead wires 42 to 47 to the multiple terminal fittings 20. Furthermore, the terminal fittings 20 may be soldered to each lead wire 42 to 47, thereby strengthening the electrical connection between the lead wires 42 to 47 and the multiple terminal fittings 20. The boss 24 is a substantially cylindrical body that protrudes vertically downward. The boss 24 is preferably inserted and fitted into the hole 16B of the terminal fitting holding part 16. The main body 21 has a hole 25, which connects to the inner space of the boss 24. The insertion pieces 26 to 28 are each inserted into multiple holes 16A of the terminal fitting holding part 16. The terminal fitting 20 may have at least one of the boss 24 and insertion pieces 26 to 28, one or more of them. Also, the terminal fitting 20 does not necessarily need to have a boss 24. Furthermore, the terminal fitting 20 does not necessarily need to have insertion pieces 26-28. Also, the crimping pieces 22 and 23 are preferably provided near the center in the arrangement direction of the main body 21 (here, in the X-axis direction). In addition, the terminal fitting 20 may further include another crimping piece in addition to the crimping pieces 22 and 23. It is preferable that the crimping pieces 22 and 23 are provided at one end in the arrangement direction of the main body 21, and the other crimping piece is provided at the other end in the arrangement direction of the main body 21.

[0030] In this embodiment, the mounting board 30C has the same configuration as mounting boards 30A and 30B. Figure 11 is a perspective view of the mounting board according to the embodiment. Figure 12 is a front view of the mounting board shown in Figure 11. As shown in Figures 11 and 12, the mounting board 30C comprises a board 31, an electronic component 32, a resistor 33, and a conductor 34. The board 31 mounts the electronic component 32 and the resistor 33. The board 31 has a predetermined printed wiring pattern. An example of the printed wiring pattern will be described later. The electronic component 32 is, for example, a capacitor. The three conductors 34 shown in Figure 12 connect the board 31 to the three terminal fittings 20 shown in Figures 5 and 6. The electronic component 32 and the resistor 33 are electrically connected via the board 31. The coil units 40A and 40B, the electronic component 32, and the resistor 33 are electrically connected to each other via the terminal fittings 20, the printed wiring pattern on the board 31, and the conductors 34.

[0031] Figures 13 and 14 are perspective views of the output terminal unit according to the embodiment. As shown in Figures 13 and 14, in this embodiment, the output terminal unit 100B has the same configuration as the intermediate terminal unit 100C, except that it is equipped with a male screw 70. The male screw 70 is, for example, a screw with a washer. The male screw 70 is inserted into the hole 25 of the main body 21 of the terminal fitting 20 shown in Figure 10. The male screw 70 and the terminal fitting 20 are fastened together while a connecting wire (not shown) is sandwiched between them. Then, the terminal fitting 20 can electrically connect to an external device (not shown) via the connecting wire. The external device is, for example, a power supply.

[0032] Figures 15 and 16 are perspective views of the mounting substrate and base plate according to the embodiment. As shown in Figures 15 and 16, the substrate 31 of mounting substrate 30A is fastened to the fastening portion 53A using male screws 71 and supported by the protruding piece 54A. Similarly, the substrate 31 of mounting substrate 30B is fastened to the fastening portion 53B using male screws 71 and supported by the protruding piece 54B. The substrate 31 of mounting substrate 30C is fastened to the fastening portion 53C using male screws 71 and supported by the protruding piece 54C. Each substrate 31 of mounting substrates 30A, 30B, and 30C is positioned to rise from the base plate 50. Furthermore, each substrate 31 of mounting substrates 30A, 30B, and 30C is positioned between the terminal fitting 20 shown in Figure 4 and the base plate 50. In other words, the main surface of each substrate 31 extends in a direction intersecting the main surface of the base plate 50. For example, the main surface of each substrate 31 may extend in a direction substantially perpendicular to the main surface of the base plate 50.

[0033] As shown in Figure 2, the coil unit 40A comprises a ring core 41A and lead wires 42, 43, and 44. The lead wires 42 to 44 are wound around the ring core 41A. As shown in Figures 2 and 4, one end of each lead wire 42 to 44 is electrically connected to three terminal fittings 20 of the input terminal unit 100A. The other ends of each lead wire 42 to 44 are electrically connected to three terminal fittings 20 of the relay terminal unit 100C. In this embodiment, the lead wires 42 to 44 comprise a conductor and an insulating coating. The insulating coating covers at least a portion of the conductor, for example, the portion of the conductor that spans conductors of different phases. Phase-to-phase insulation can be achieved in the coil unit 40A. The insulating coating may cover substantially the entire conductor. The coil unit 40A is positioned inside the coil holding portion 48A on the base plate 50. The coil holding portion 48A is a cylindrical body extending around the ring core 41A. The coil unit 40A is preferably bonded and fixed to the insulating paper 80 and the base plate 50 via a silicone resin. The silicone resin preferably has heat dissipation properties. The silicone resin may be formed, for example, by solidifying a silicone adhesive. The heat generated by the coil unit 40A can be dissipated by being transferred to the base plate 50 via the silicone resin and the insulating paper 80.

[0034] The coil unit 40B comprises a ring core 41B and lead wires 45, 46, and 47. The lead wires 45 to 47 are wound around the ring core 41B. One end of each lead wire 45 to 47 is electrically connected to three terminal fittings 20 of the relay terminal unit 100C. The other ends of each lead wire 45 to 47 are electrically connected to three terminal fittings 20 of the output terminal unit 100B. In this embodiment, the lead wires 45 to 47 may have the same configuration as the lead wires 42 to 44. The lead wires 42 to 47 may also comprise a conductor and an insulating coating that covers substantially the entire conductor. The coil unit 40B is positioned inside the coil holding portion 48B on the base plate 50. The coil holding portion 48B is a cylindrical body extending along the circumference of the ring core 41B. The coil unit 40B may be bonded and fixed to the insulating paper 80 and the base plate 50 via silicone resin. The silicone resin may be formed, for example, by solidifying a silicone adhesive. The heat generated by the coil unit 40B can be dissipated by transferring it to the base plate 50 via the silicone resin and insulating paper 80.

[0035] The three terminal fittings 20 of the relay terminal unit 100C relay the electrical connections between lead wire 42 and lead wire 45, between lead wire 43 and lead wire 46, and between lead wire 44 and lead wire 47, respectively.

[0036] Figure 17 is a perspective view of a cover according to an embodiment. As shown in Figure 17, the cover 60 comprises a plate-like portion 61 and side walls 62 and 63. The plate-like portion 61 may be provided with ventilation holes 61a for allowing air to enter and exit the inside of the cover 60. The plate-like portion 61 may be provided with recesses 61b that are recessed downward in the vertical direction (here, in the negative Z-axis direction). The plate-like portion 61 has a main surface 61A and a main surface 61B. The main surface 61A faces upward in the vertical direction. The main surface 61B faces the base plate 50 shown in Figure 3. The side walls 62 and 63 extend from the plate-like portion 61 to the base plate 50, respectively. Specifically, the side walls 62 and 63 extend from one end and the other end of the plate-like portion 61 in the width direction (here, in the Y-axis direction), respectively, to the base plate 50. The side walls 62 and 63 face each other. The plate-like portion 61 and the side walls 62 and 63 are preferably plate-like bodies bent in a squared C-shaped cross-section. The side walls 62 and 63 are provided with fastening portions 68. The fastening portions 68, the fastening portions 17b and 17c shown in Figures 5-9, 13, and 14, and the fastening portion 56 shown in Figures 1-3 are fastened together using male screws 72.

[0037] Figure 18 is a bottom view of the cover according to the embodiment. As shown in Figure 18, the plate-like portion 61 comprises extension pieces 64A, 64B, 65A, 65B, grooves 66A, 66B, 66C, and protrusions 67A, 67B, 67C.

[0038] As shown in Figures 17 and 18, the extension piece 64B extends from the other end 612 along the side wall 62 in the direction of arrangement of the plate-like portion 61 (in this case, the X-axis direction). The extension piece 65B extends from the other end 612 along the side wall 63. The extension piece 64A extends from one end 611 along the side wall 62 in the direction of arrangement of the plate-like portion 61. The extension piece 65A extends from one end 611 along the side wall 63.

[0039] Grooves 66A, 66B, and 66C are provided on the main surface 61B of the plate-shaped portion 61. Grooves 66A, 66B, and 66C are provided on various parts of the main surface 61B so as to be inserted into the respective edges 12b and 12c of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C. Specifically, grooves 66A and 66B may be provided at one end 611 and the other end 612 of the main surface 61B, respectively. Groove 66C may be provided between the one end 611 and the other end 612. More specifically, the two grooves 66A are adjacent to the extension pieces 64A and 65A, respectively. The two grooves 66B are adjacent to the extension pieces 64B and 65B, respectively. The grooves 66A, 66B, and 66C have a shape into which the respective edges 12b and 12c of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C can be inserted. On the main surface 61B, the grooves 66A, 66B, and 66C extend in a direction intersecting the arrangement direction, for example, in a direction perpendicular to the arrangement direction.

[0040] The protrusions 67A, 67B, and 67C are provided on the main surface 61B of the plate-like portion 61. The protrusions 67A, 67B, and 67C project vertically downward from the main surface 61B (in this case, in the negative Z-axis direction). The protrusions 67A, 67B, and 67C are provided on various parts of the main surface 61B so as to contact the terminal walls 15 of the input terminal block 10A, output terminal block 10B, and relay terminal block 10C in the direction of arrangement (in this case, in the X-axis direction). Specifically, the protrusions 67A and 67B may be provided at one end 611 and the other end 612 of the main surface 61B, respectively. The protrusion 67C may be provided between the one end 611 and the other end 612. More specifically, two protrusions 67A are provided side by side in the width direction at one end 611. Two protrusions 67B are provided side by side in the width direction at the other end 612. Four protrusions 67C are provided in parallel in the width direction between one end 611 and the other end 612.

[0041] Figure 19 is a perspective view of the cover and output terminal block according to the embodiment. Figure 20 is a cross-sectional view taken along the line XX-XX in Figure 19. As shown in Figures 19 and 20, the edge 12b of the output terminal block 10B extends toward the side wall 62. The recess 13b of the edge 12b of the output terminal block 10B engages with the extension piece 64B. Similarly, the edge 12c of the output terminal block 10B extends toward the side wall 63. The recess 13c of the edge 12c of the output terminal block 10B engages with the extension piece 65B. Also, the edge 12c of the input terminal block 10A extends toward the side wall 62. The recess 13c of the edge 12c of the input terminal block 10A engages with the extension piece 64A. The edge 12b of the input terminal block 10A extends toward the side wall 63. The recess 13b on the edge 12b of the input terminal block 10A engages with the extension piece 65A.

[0042] Figure 21 is a bottom view of the cover and each terminal block according to the embodiment. As shown in Figure 21, the edges 12b and 12c of the input terminal block 10A are inserted into the groove 66A. The edges 12b and 12c of the output terminal block 10B are inserted into the groove 66B. The edges 12b and 12c of the intermediate terminal block 10C are inserted into the groove 66C. This prevents the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C from moving in the direction of arrangement (in this case, the X-axis direction).

[0043] Furthermore, the protrusions 67A, 67B, and 67C contact the terminal walls 15 of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C. This prevents the input terminal block 10A and the output terminal block 10B from moving toward the intermediate terminal block 10C. It also prevents the intermediate terminal block 10C from moving toward the input terminal block 10A and from moving toward the output terminal block 10B.

[0044] Based on the above, the noise filter 500's configuration allows the intermediate terminal block 10C, input terminal block 10A, and output terminal block 10B to be made of resin material. Furthermore, the intermediate terminal block 10C has substantially the same shape as the input terminal block 10A and the output terminal block 10B. Therefore, the intermediate terminal block 10C, like the input terminal block 10A and the output terminal block 10B, can hold circuit boards and electronic components. The noise filter 500 can hold stacked electronic components. Consequently, the mounting density of electronic components can be improved. Therefore, the noise filter 500 can mount many electronic components relative to the area of ​​the main surface of the base plate 50.

[0045] Furthermore, in this embodiment, the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C are each positioned between the terminal fittings 20 and the base plate 50, rising from the base plate 50. The electronic components 32 are mounted on the circuit boards 31. Therefore, the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C can hold more electronic components 32, thereby increasing the mounting density of electronic components.

[0046] Furthermore, in this embodiment, the recesses 13b and 13c of the output terminal block 10B engage with the extension pieces 64B and 65B, respectively. The recesses 13b and 13c of the input terminal block 10A engage with the extension pieces 65A and 64A, respectively. In addition, the edges 12b and 12c of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C are inserted into grooves 66A, 66B, and 66C, respectively. The projections 67A, 67B, and 67C also contact the terminal walls 15 of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C. These features prevent the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C from moving in the direction of arrangement. As a result, the positions of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C can be firmly fixed to the cover 60. As a result, the durability of the noise filter 500 can be increased. For example, the noise filter 500 may have a tall cover 60, an input terminal block 10A, an output terminal block 10B, and an intermediate terminal block 10C to increase the mounting density of electronic components. Even in such cases, since the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C are securely fixed to the cover 60, the noise filter 500 can withstand external stresses such as shocks and vibrations.

[0047] (circuit) As described above, the electronic components 32, resistors 33, and coil units 40A and 40B of the input terminal block 10A, output terminal block 10B, and intermediate terminal block 10C are electrically connected via conductors 34, terminal fittings 20, and printed wiring patterns on each circuit board 31. Thus, they form an electrical circuit. An example of this formed electrical circuit is shown in Figure 22. Figure 22 is a circuit diagram of the noise filter 500 shown in Figure 1. The capacitors Cx1 to Cx3 and resistors R1 to R3 shown in Figure 22 correspond to the electronic components 32 and resistors 33 of the mounting board 30A shown in Figure 16. Similarly, the capacitors Cx4 to Cx6 and resistors R4 to R6 shown in Figure 22 correspond to the electronic components 32 and resistors 33 of the mounting board 30B shown in Figure 16. Similarly, the capacitors Cx7 to Cx9 and resistors R7 to R9 shown in Figure 22 correspond to the electronic components 32 and resistors 33 of the mounting board 30C shown in Figure 16. The inductors L1 and L2 shown in Figure 22 correspond to the coil units 40A and 40B shown in Figure 2.

[0048] <Manufacturing method> Next, an example of a method for manufacturing the noise filter 500 will be described with reference to Figures 1, 2, 4, 11, 12, 15, 16, 23, and 24. Figure 23 is a flowchart showing a method for manufacturing a noise filter according to an embodiment. Figure 24 is a diagram showing a method for manufacturing a noise filter according to an embodiment.

[0049] As shown in Figures 11 and 12, the mounting board 30C is assembled by mounting the electronic components 32, resistors 33, and wires 34 onto the substrate 31 (step ST1). The electronic components 32 and other components may be electrically connected to the substrate 31 using soldering as appropriate. The mounting boards 30A and 30B are assembled in the same manner.

[0050] Next, as shown in Figures 15 and 16, the mounting substrates 30A, 30B, and 30C are placed on the base plate 50 (step ST2). Specifically, each substrate 31 of mounting substrates 30A, 30B, and 30C is supported by the protruding pieces 54A, 54B, and 54C, respectively. The substrate 31 of mounting substrate 30A is fastened to the fastening portion 53A using a male screw 71. Similarly, the substrate 31 of mounting substrate 30B is fastened to the fastening portion 53B using a male screw 71. The substrate 31 of mounting substrate 30C is also fastened to the fastening portion 53C using a male screw 71. Each substrate 31 is positioned so as to rise from the base plate 50.

[0051] Next, as shown in Figure 4, the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C are attached to the base plate 50 (step ST3). Specifically, as shown in Figure 24, the guides 14b and 14c of the intermediate terminal block 10C are engaged with the substrate 31, and the intermediate terminal block 10C is fitted onto the substrate 31. The engaging portion 18 of the intermediate terminal block 10C is engaged with the hole in the protruding piece 54C of the base plate 50. Similarly, the guides 14b and 14c of the input terminal block 10A are engaged with the substrate 31, and the input terminal block 10A is fitted onto the substrate 31. The engaging portion 18 of the input terminal block 10A is engaged with the hole in the protruding piece 54A of the base plate 50. Also, the guides 14b and 14c of the output terminal block 10B are engaged with the substrate 31, and the output terminal block 10B is fitted onto the substrate 31. The engaging portion 18 of the output terminal block 10B engages with the hole in the protruding piece 54B of the base plate 50. As a result, the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C cover the respective boards 31 of the mounting boards 30A, 30B, and 30C.

[0052] Next, the multiple terminal fittings 20 are mounted on the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C, respectively (step ST4). Specifically, the boss 24 of each terminal fitting 20 is inserted into the hole 16B of each terminal fitting holder 16. In addition, the insertion pieces 26 to 28 are inserted into multiple holes 16A of the terminal fitting holder 16. Each terminal fitting 20 is then held in place by the terminal fitting holder 16 of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C.

[0053] Next, as shown in Figure 2, the coil units 40A and 40B are attached to the base plate 50 (step ST5). Specifically, the coil holder 48A is placed on the base plate 50 between the input terminal unit 100A and the intermediate terminal unit 100C. The coil holder 48B is placed on the base plate 50 between the intermediate terminal unit 100C and the output terminal unit 100B. Silicone adhesive is placed inside the coil holders 48A and 48B. Coil unit 40A is placed inside the coil holder 48A, and coil unit 40B is placed inside the coil holder 48B. The silicone adhesive hardens, and silicone resin is formed. The coil units 40A and 40B are bonded and fixed to the insulating paper 80 and the base plate 50 via the silicone resin. One end of each lead wire 42-44 is electrically connected to the three terminal fittings 20 of the input terminal unit 100A. The other ends of lead wires 42-44 are electrically connected to the three terminal fittings 20 of the relay terminal unit 100C. Similarly, one end of lead wires 45-47 is electrically connected to the three terminal fittings 20 of the relay terminal unit 100C. The other ends of lead wires 45-47 are electrically connected to the three terminal fittings 20 of the output terminal unit 100B. Also, the three conductors 34 of the input terminal unit 100A are electrically connected to the three terminal fittings 20 of the input terminal unit 100A. Similarly, the three conductors 34 of the output terminal unit 100B are electrically connected to the three terminal fittings 20 of the output terminal unit 100B. Similarly, the three conductors 34 of the relay terminal unit 100C are electrically connected to the three terminal fittings 20 of the relay terminal unit 100C.

[0054] Finally, the cover 60 is attached to the base plate 50 (step ST6). Specifically, as shown in Figures 1 and 2, the cover 60 is placed over the input terminal block 10A, the output terminal block 10B, the intermediate terminal block 10C, and the coil units 40A and 40B. The fastening parts 17b and 17c of the input terminal block 10A, the output terminal block 10B, and the intermediate terminal block 10C (see Figure 19, etc.), the fastening parts 56 of the base plate 50, and the fastening parts 68 of the cover 60 (see Figure 17) are fastened together using male screws 72.

[0055] Based on the above, a noise filter 500 can be manufactured.

[0056] The order in which steps ST1 to ST5 described above are performed may be changed as appropriate. For example, step ST4 may be performed before step ST3. Also, step ST5 may be performed before step ST4.

[0057] It should be noted that the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. Furthermore, the present invention may be implemented by combining the above embodiments or examples thereof as appropriate.

[0058] For example, in this embodiment, the guides 14b and 14c are grooves extending in a substantially straight line, but they only need to have a shape that can engage with the substrate 31, and may be, for example, plate-like bodies extending in a substantially straight line.

[0059] Furthermore, in this embodiment, the plate-like portion 61 is provided with grooves 66A, 66B, and 66C, but the side walls 62 and 63 may also be provided with grooves 66A, 66B, and 66C.

[0060] Furthermore, the noise filter 500 is a second-order filter. The order of the noise filter 500 can be changed by changing the number of relay terminal units 100C provided by the noise filter 500. For example, if the noise filter 500 does not have any relay terminal units 100C, the noise filter 500 can be used as a first-order filter. Also, if the noise filter 500 has two relay terminal units 100C, the noise filter 500 can be used as a third-order filter. As described above, the input terminal block 10A, the output terminal block 10B, and the relay terminal block 10C can be manufactured using the same mold and the same resin material. Therefore, even when changing the order of the noise filter 500, the manufacturing cost of the relay terminal block 10C can be reduced. The relay terminal unit 100C may also be equipped with a male screw 70, similar to the input terminal unit 100A and the output terminal unit 100B. The male screw 70 is inserted into the hole 25 of the body 21 of each terminal fitting 20 in the relay terminal unit 100C. The male screw 70 and the terminal fitting 20 are fastened together such that the male screw 70 and the terminal fitting 20 sandwich the lead wires 42-47. This allows each terminal fitting 20 in the relay terminal unit 100C to be electrically connected to the lead wires 42-47. [Explanation of Symbols]

[0061] 500 Noise Filter 100A Input Terminal Unit 100B Output Terminal Unit 100C Intermediate Terminal Unit 10A Input Terminal Block 10B Output terminal block 10C Intermediate Terminal Block 11 Main unit 11a Central part 11b, 11c Side 12b, 12c edges 13b, 13c recess 14b, 14c Guide 15 Terminal wall 16 Terminal fitting retaining part 16A, 16B hole 17b, 17c Fastening section 18 Engaging part 20 Terminal fittings 21 Main unit 22, 23 Crimping pieces 24 Boss 25 holes 26-28 Insertion piece 30A, 30B, 30C mounted circuit board 31 circuit boards 32 Electronic Components 33 Resistor 34 Conductor 40A, 40B coil unit 41A, 41B Ring Core 43-47 Lead wires 48A, 48B Coil holding section 50 base plate 51 One end 52 Other end 53A, 53B, 53C fastening section 54A, 54B, 54C protruding piece 56 Fastening part 60 Cover 61 Plate-like part 611 One end 612 Other end 62, 63 side wall 64A, 64B, 65A, 65B extension piece 66A, 66B, 66C groove 67A, 67B, 67C protrusions 70-72 Male screw Cx1~Cx9 Capacitors R1~R9 resistor L1, L2 Inductors

Claims

1. Input terminal block and Output terminal block and Intermediate terminal block and Equipped with a base plate, The base plate holds the input terminal block, the output terminal block, and the relay terminal block. The input terminal block, the output terminal block, and the relay terminal block are equipped with terminal fittings. The relay terminal block, the input terminal block, and the output terminal block are made of resin material. The relay terminal block has substantially the same shape as the input terminal block and the output terminal block. Noise filter.

2. The input terminal block, the output terminal block, and the relay terminal block each comprise a circuit board and electronic components. The substrate is positioned between the terminal fitting and the base plate, so as to rise from the base plate. The aforementioned electronic component is mounted on the substrate, The noise filter according to claim 1.

3. The base plate further comprises a cover attached to the base plate, The input terminal block, the relay terminal block, and the output terminal block are arranged in the direction of arrangement on the base plate. The input terminal block and the output terminal block are respectively located at one end and the other end of the base plate in the arrangement direction. The cover comprises a plate-like portion facing the base plate, a side wall extending from the plate-like portion to the base plate, and an extended piece extending along the side wall from one end or the other end of the plate-like portion in the direction of arrangement. The input terminal block or the output terminal block is provided with an edge that extends toward the side wall, The edge portion is provided with a recess that interlocks with the extension piece. The noise filter according to claim 1 or 2.

4. The base plate further comprises a cover attached to the base plate, The input terminal block, the relay terminal block, and the output terminal block are arranged in the direction of arrangement on the base plate. The input terminal block and the output terminal block are respectively located at one end and the other end of the base plate in the arrangement direction. The cover comprises a plate-shaped portion facing the base plate and a side wall extending from the plate-shaped portion to the base plate. The input terminal block, the relay terminal block, and the output terminal block are provided with edges that extend toward the side wall. The plate-like portion or the side wall is provided with a groove into which the edge portion is inserted. The noise filter according to claim 1 or 2.

5. The base plate further comprises a cover attached to the base plate, The input terminal block, the relay terminal block, and the output terminal block are arranged in the direction of arrangement on the base plate. The input terminal block and the output terminal block are respectively located at one end and the other end of the base plate in the arrangement direction. The cover comprises a plate-like portion facing the base plate and a side wall extending from the plate-like portion to the base plate. The input terminal block, the relay terminal block, and the output terminal block are equipped with multiple terminal fittings and further comprise terminal walls that separate the multiple terminal fittings from each other. The plate-like portion further comprises a projection that contacts the end of the terminal wall in the direction of arrangement. The noise filter according to claim 1 or 2.

6. A method for manufacturing a noise filter, The noise filter comprises an input terminal block, an output terminal block, an intermediate terminal block, and a base plate. The input terminal block, the output terminal block, and the relay terminal block each comprise a circuit board and electronic components. The aforementioned electronic components are mounted on the substrate, The substrate and the base plate are fastened together such that the substrate rises from the base plate. The input terminal block, the relay terminal block, and the output terminal block, which are mounted or capable of mounting terminal fittings, are attached to the base plate so as to cover the aforementioned substrate. A method for manufacturing a noise filter.

7. The input terminal block, the relay terminal block, and the output terminal block each have guides that extend upward from the base plate. By engaging the substrate and the guide, the input terminal block, the intermediate terminal block, and the output terminal block are mounted on the base plate so as to cover the substrate. The method for manufacturing a noise filter according to claim 6.

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