Noise reduction device

Abstract

This invention discloses a noise suppression device that can handle high currents while ensuring the required insulation performance while suppressing an increase in size. [Solution] The noise reduction device 10 comprises an annular magnetic body 16 having an inner hole 18, a first bus bar 12 having connecting portions 20 and 22 at both ends, a second bus bar 14 having connecting portions 24 and 26 at both ends, a first resin part 38 having a cylindrical portion 32 and a first flange portion 36, and a second resin part 44 having a partition wall portion 40 and a second flange portion 42. The intermediate portion 28 of the first bus bar 12 is inserted through the cylindrical portion 32, the cylindrical portion 32 is inserted into the inner hole 18, the first flange portion 36 is positioned between the first end face 64 of the magnetic body 16 and the connecting portion 20, the partition wall portion 40 is inserted into the inner hole 18 while sandwiched between the intermediate portion 30 and the cylindrical portion 32 of the second bus bar 14, and the second flange portion 42 is positioned between the second end face 68 of the magnetic body 16 and the connecting portion 26.

Description

Technical Field

[0001] The present disclosure relates to a noise removal device.

Background Art

[0002] In vehicles that run by motor drive such as electric vehicles and hybrid vehicles, a bus bar, which is an energized member through which a large current flows, is wired. In Patent Document 1, in order to remove noise from such a bus bar, it has been proposed to adopt a noise removal device (filter device) in which an annular magnetic body such as a ferrite core is externally inserted with respect to a pair of bus bars.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in order to cope with the increasing current of in-vehicle devices in recent years, it has been necessary to ensure a large insulation distance between bus bars required for a noise removal device and an insulation distance between end faces on both axial sides of a magnetic body and a connection part between the end faces and other members of a bus bar protruding from the end faces. Therefore, in order to pass a through-hole of a magnetic body while increasing the separation distance between bus bars, it has been necessary to increase the size of the magnetic body itself or increase the protruding dimension of a connection part of a bus bar protruding from an end face of the magnetic body, and the noise removal device has inevitably become larger.

[0005] Therefore, a noise removal device is disclosed that can ensure the required insulation performance while suppressing an increase in size and can cope with an increase in current.

Means for Solving the Problems

[0006] The noise reduction device of the present disclosure comprises: an annular magnetic body having an internal bore; a first busbar extending through the internal bore of the magnetic body and having connecting portions at both ends; a second busbar extending through the internal bore of the magnetic body and having connecting portions at both ends; a first resin part having a cylindrical portion through which the intermediate portion of the first busbar is inserted and a first flange portion extending outward from one opening of the cylindrical portion; and a second resin part having a partition wall portion onto which the intermediate portions of the second busbar are superimposed and a second flange portion extending outward from one end of the partition wall portion, wherein the intermediate portion of the first busbar is inserted through the cylindrical portion of the first resin part, The cylindrical portion of the resin part is inserted into the inner hole of the magnetic material, the first flange portion of the first resin part is positioned between the first end face on one axial side of the magnetic material and the connecting portion positioned on the axial side of the magnetic material, the partition wall portion of the second resin part is sandwiched between the intermediate portion of the second busbar and the cylindrical portion of the first resin part, the partition wall portion is inserted into the inner hole of the magnetic material, and the second flange portion of the second resin part is positioned between the second end face on the other axial side of the magnetic material and the connecting portion positioned on the other axial side of the magnetic material. [Effects of the Invention]

[0007] The noise suppression device of this disclosure provides a noise suppression device that can handle high currents while ensuring the required insulation performance while suppressing an increase in size. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a front perspective view of the noise reduction device according to Embodiment 1. [Figure 2] Figure 2 is a rear perspective view of the noise reduction device shown in Figure 1. [Figure 3] Figure 3 is a plan view of the noise reduction device shown in Figure 1. [Figure 4] Figure 4 is a cross-sectional view taken along line IV-IV in Figure 3. [Figure 5] Figure 5 is a cross-sectional view of the VV section in Figure 3. [Figure 6] Figure 6 is a perspective view showing one step in the assembly process of the noise reduction device shown in Figure 1. [Figure 7] Figure 7 is a perspective view showing one of the assembly steps of the noise reduction device shown in Figure 1, and is a diagram showing the steps that follow from Figure 6. [Figure 8] Figure 8 is a perspective view showing one of the assembly steps of the noise reduction device shown in Figure 1, and is a diagram showing the steps that follow from Figure 7. [Figure 9] Figure 9 is a perspective view showing one step in the assembly process of the noise reduction device shown in Figure 1, and is a diagram showing the process that follows from Figure 8. [Figure 10] Figure 10 is a perspective view of the noise reduction device shown in Figure 1, excluding the magnetic material and the housing case containing the magnetic material. [Figure 11] Figure 11 is a perspective view showing the first resin part and the second resin part, which constitute the noise reduction device shown in Figure 1, superimposed on each other. [Figure 12] Figure 12 is a plan view of the superimposed state of the first resin part and the second resin part shown in Figure 11. [Figure 13] Figure 13 is a perspective view of the first resin part that constitutes the noise reduction device shown in Figure 1. [Figure 14] Figure 14 is a perspective view of the second resin part that constitutes the noise reduction device shown in Figure 1. [Modes for carrying out the invention]

[0009] <Description of Embodiments in this Disclosure> First, embodiments of this disclosure will be listed and described. The noise reduction device of this disclosure is (1) A first resin part having an annular magnetic body having an internal bore, a first busbar extending through the internal bore of the magnetic body and having connecting portions at both ends, a second busbar extending through the internal bore of the magnetic body and having connecting portions at both ends, a cylindrical portion through which the intermediate portion of the first busbar is inserted, and a first flange portion extending outward from one opening of the cylindrical portion, and a second resin part having a partition wall portion into which the intermediate portions of the second busbar are superimposed, and a second flange portion extending outward from one end of the partition wall portion, wherein the intermediate portion of the first busbar is inserted through the cylindrical portion of the first resin part, The cylindrical portion of the first resin part is inserted into the inner hole of the magnetic material, the first flange portion of the first resin part is positioned between the first end face on one axial side of the magnetic material and the connecting portion positioned on the axial side of the magnetic material, the partition wall portion of the second resin part is sandwiched between the intermediate portion of the second busbar and the cylindrical portion of the first resin part, the partition wall portion is inserted into the inner hole of the magnetic material, and the second flange portion of the second resin part is positioned between the second end face on the other axial side of the magnetic material and the connecting portion positioned on the other axial side of the magnetic material.

[0010] In the noise reduction device of this embodiment, the intermediate portion of the first busbar, which penetrates the inner bore of the annular magnetic material, is inserted into the inner bore of the magnetic material while being inserted into the cylindrical portion of the first resin part. Furthermore, the intermediate portion of the second busbar, which penetrates the inner bore of the magnetic material, penetrates the inner bore of the magnetic material while being sandwiched between the partition wall portion of the second resin part and the cylindrical portion of the first resin part. As a result, by combining the first resin part and the second resin part, the insulation distance between the intermediate portions of the first and second busbars and the magnetic material can be reliably secured. Moreover, the first flange portion of the first resin part is positioned between the first end face on one axial side of the magnetic material and the connecting portion located on one axial side of the magnetic material. Similarly, the second flange portion of the second resin part is positioned between the second end face on one axial side of the magnetic material and the connecting portion located on the other axial side of the magnetic material. As a result, the insulation distance between both end faces of the magnetic material and the connecting portions provided at the ends of each busbar can be increased by the first and second flange portions positioned between them. As a result, even if a large current flows through the first and second busbars, it is not necessary to separate the connection points of each busbar from the end faces of the magnetic material as in the conventional structure, and the noise suppression device can be miniaturized. In other words, according to this embodiment, it is possible to ensure the insulation performance required for the noise suppression device while suppressing the increase in size of the noise suppression device.

[0011] (2) In (1) above, it is preferable that the partition wall portion of the second resin part comprises an upper rail portion that protrudes upward from a pair of side edges and fits into the cylindrical portion of the first resin part, and a lower rail portion that protrudes downward from a pair of side edges and covers and fits into the side surface of the intermediate portion of the second bus bar. The upper rail portion and the lower rail portion of the second resin part can hold the first resin part and the second resin part in a fitted state, and furthermore, the partition wall portion can be stably held between the intermediate portion of the second bus bar and the cylindrical portion of the first resin part, and the first / second bus bar and the first / second resin part can be held in a fitted state while stably maintaining the insulation distance of the combination of the first resin part and the second resin part. Moreover, the upper rail portion and the lower rail portion can also serve to reinforce the partition wall portion, which can contribute to further miniaturization.

[0012] (3) In the above (2), it is preferable that at least one of the opposing surfaces of the upper rail portion and the cylindrical portion is provided with an abutting rib that suppresses displacement by abutting against the other opposing surface during fitting. The abutting rib can prevent rattling when the upper rail portion and the cylindrical portion are fitted, and further realize more stable assembly and stable securing of the insulation distance.

[0013] (4) In any one of the above (1) to (3), it is preferable that the second flange portion of the second resin part has positioning protrusions that protrude from the partition wall portion toward the second bus bar side and are arranged on both sides in the plate width direction of the middle portion of the second bus bar. The displacement of the middle portion of the second bus bar in the plate width direction with respect to the partition wall portion of the second resin part can be suppressed, the middle portion of the second bus bar can be positioned in the plate width direction with respect to the partition wall portion, and the insulation distance between the second end surface of the magnetic body and the connection portion on the other axial side can also be increased, and further improvement of the insulation performance can be achieved.

[0014] <Details of Embodiments of the Present Disclosure> A specific example of the noise removing device of the present disclosure will be described below with reference to the drawings. It should be noted that the present disclosure is not limited to these examples, and is defined by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0015] <Embodiment 1> Hereinafter, the noise reduction device 10 of Embodiment 1 of this disclosure will be described with reference to Figures 1 to 14. This noise reduction device 10 is installed inside an electrical junction box in a vehicle such as an electric vehicle or a hybrid vehicle, and removes noise in the first busbar 12 and second busbar 14 that connect electrical components inside the electrical junction box. Specifically, the noise reduction device 10 comprises an annular magnetic body 16 made of ferrite or the like, and a first busbar 12 and a second busbar 14 inserted into an inner hole 18 of the magnetic body 16. The magnetic body 16, such as ferrite, functions as a low-pass filter to remove high-frequency components (noise) of the current flowing through the first busbar 12 and the second busbar 14. The noise reduction device 10 can be positioned in any orientation, but in the following description, "up" refers to the upper part in Figure 4, "down" refers to the lower part in Figure 4, "left" refers to the upper part in Figure 3, "right" refers to the lower part in Figure 3, "front" refers to the left in Figure 3, and "rear" refers to the right in Figure 3. Furthermore, in the case of multiple identical components, reference numerals may be assigned to only some of the components, while the reference numerals are omitted for the others.

[0016] <Noise reduction device 10> As described above, the noise reduction device 10 comprises a magnetic body 16 having an internal bore 18, and a first busbar 12 and a second busbar 14 extending through the internal bore 18 of the magnetic body 16. Both the first busbar 12 and the second busbar 14 extend in the front-rear direction as a whole, and both ends of these first busbar 12 and second busbar 14 are connected to electrical components in an electrical junction box. Specifically, the first busbar 12 has a first front connection part 20 as a connection part at its front end and a first rear connection part 22 as a connection part at its rear end. The second busbar 14 has a second front connection part 24 as a connection part at its front end and a second rear connection part 26 as a connection part at its rear end. In the first busbar 12, the section between the first front connection part 20 and the first rear connection part 22 in the front-rear direction is the first intermediate part 28. In the second busbar 14, the area between the second front connection 24 and the second rear connection 26 in the front-rear direction is the second intermediate section 30, which serves as an intermediate section.

[0017] The noise reduction device 10 includes a first resin part 38 having a cylindrical portion 32 through which the intermediate portion (first intermediate portion 28) of the first busbar 12 is inserted, and a first flange portion 36 extending outward from a front opening 34, which is one opening of the cylindrical portion 32. The noise reduction device 10 also includes a second resin part 44 having a partition wall portion 40 into which the intermediate portions (second intermediate portion 30) of the second busbar 14 are superimposed, and a second flange portion 42 extending outward from a rear end, which is one end of the partition wall portion 40.

[0018] <1st Bus Bar 12> As shown in Figures 8 and 10, the first busbar 12 is a member that extends in the front-rear direction as a whole, and is made of a metal with excellent conductivity such as copper (including copper alloys) or aluminum (including aluminum alloys). As described above, the front end of the first busbar 12 is the first front connection part 20, the rear end is the first rear connection part 22, and the space between the first front connection part 20 and the first rear connection part 22 in the front-rear direction is the first intermediate part 28.

[0019] In Embodiment 1, the positions of the first front connecting portion 20 and the first rear connecting portion 22 are different in the left-right direction, and the portion extending rearward from the first front connecting portion 20 and the portion extending forward from the first rear connecting portion 22 are connected by a connecting portion 46 that widens in a direction perpendicular to the front-rear direction and curves in an arc shape. In other words, the front end of the portion extending forward from the left end, which is one end of the connecting portion 46 in the circumferential direction, is the first front connecting portion 20, and the portion extending rearward from the right end, which is the other end of the connecting portion 46 in the circumferential direction, is the first rear connecting portion 22. As a result, the first front connecting portion 20 is located to the left of the first rear connecting portion 22. The connecting portion 46 is located in the rear portion of the first busbar 12, and a first straight portion 48 extending straight in the front-rear direction is provided between the left end of the connecting portion 46 and the first front connecting portion 20 in the front-rear direction. In other words, the first intermediate section 28 is composed of a connecting section 46 and a first straight section 48. In the first busbar 12, the first front connecting section 20 and the first rear connecting section 22 are formed with bolt insertion holes 50 through which bolts (not shown) are inserted for bolt fastening to electrical components (or busbars extending from electrical components, etc.).

[0020] <2nd Bus Bar 14> As shown in Figure 6, the second busbar 14 is a member that extends in the front-rear direction as a whole and is made of the same metal as the first busbar 12. As described above, the front end of the second busbar 14 is the second front connecting portion 24, and the rear end is the second rear connecting portion 26, and the space between the second front connecting portion 24 and the second rear connecting portion 26 in the front-rear direction is the second intermediate portion 30.

[0021] In Embodiment 1, the positions of the second front connecting portion 24 and the second rear connecting portion 26 are different in the vertical direction, and the portion extending forward from the second front connecting portion 24 and the second rear connecting portion 26 are connected by a vertical portion 52 that extends in the vertical direction. In other words, the portion extending forward from the lower end of the vertical portion 52 is the second front connecting portion 24, and the rear end of the portion extending backward from the upper end of the vertical portion 52 is the second rear connecting portion 26. As a result, the second front connecting portion 24 is located below the second rear connecting portion 26. The vertical portion 52 is provided in the front portion of the second busbar 14, and a second straight portion 54 that extends straight in the front-rear direction is provided between the upper end of the vertical portion 52 and the second rear connecting portion 26 in the front-rear direction. That is, the second intermediate portion 30 is composed of the vertical portion 52 and the second straight portion 54. In the second busbar 14, the second front connecting portion 24 and the second rear connecting portion 26 are formed with bolt insertion holes 56 through which bolts (not shown) are inserted for bolt fastening to electrical components (or busbars extending from electrical components, etc.).

[0022] <Magnetic material 16> The magnetic material 16 is an annular member made of, for example, ferrite (particularly Mn-Zn ferrite) or nanocrystalline soft magnetic material, and as shown in Figure 5, its cross-section has an overall shape that is approximately oval, with the left-right dimension being larger than the vertical dimension. An internal hole 18 is formed in the central part of the magnetic material 16, penetrating in the front-to-back direction, and this internal hole 18 has a horizontally elongated shape, with the left-to-right dimension being larger than the vertical dimension. In Embodiment 1, the internal hole 18 has an approximately oval cross-section and is formed with a constant cross-sectional shape over the entire length of the magnetic material 16 in the front-to-back direction.

[0023] The magnetic material 16 is housed in an insulating housing case 58, and the outer and inner surfaces of the magnetic material 16 are covered by the housing case 58. Specifically, the housing case 58 comprises an outer cylindrical portion 60 having a substantially oval or elliptical cross-section that covers the outer circumferential surface of the magnetic material 16, and an inner cylindrical portion 62 having a substantially rounded rectangular cross-section that covers the inner circumferential surface of the magnetic material 16. The housing case 58 also comprises a front wall portion 66 that covers the front end surface 64, which is the first end surface in one axial direction of the magnetic material 16, and a rear wall portion 70 that covers the rear end surface 68, which is the second end surface in the other axial direction of the magnetic material 16. The outer cylindrical portion 60 and the inner cylindrical portion 62 are connected by the annular front wall portion 66 and the rear wall portion 70, respectively. A central hole 72 is formed by the inner hole of the inner cylindrical portion 62, which penetrates the central part of the housing case 58 in the front-to-back direction. The central hole 72 has a horizontally elongated, substantially oval cross-section, similar to the inner hole 18 of the magnetic material 16. Furthermore, in Embodiment 1, leg portions 74 protruding outward in the left-right direction are integrally formed on the outer cylindrical portion 60 of the housing case 58. Each leg portion 74 has a bolt insertion hole 76 through which a bolt (not shown) is inserted for, for example, fixing the noise suppression device 10 inside the electrical connection box.

[0024] The housing case 58, having the shape described above, can be formed as an integrally molded product that includes the magnetic material 16 by, for example, molding the housing case 58 with the magnetic material 16 set inside the molding cavity of the housing case 58 during the molding process. Alternatively, the housing case 58 may be composed of multiple members, and the housing case 58 having the magnetic material 16 inside may be formed by assembling the multiple members with the magnetic material 16 housed inside.

[0025] <First resin part 38> As described above, the first resin part 38 comprises a cylindrical portion 32 extending in the front-rear direction and a first flange portion 36 extending outward from the front opening 34 of the cylindrical portion 32. The cylindrical portion 32 has a substantially rectangular cross-section and is formed to a size through which the first straight portion 48 of the first busbar 12 can be inserted. In Embodiment 1, as shown in Figures 6 and 13, the first flange portion 36 is an annular portion that extends continuously around the entire circumference in the circumferential direction.

[0026] As shown in Figures 11 and 12, when the first resin part 38 is assembled with the second resin part 44, the cylindrical part 32 is positioned between the left-right sides of a pair of upper rail sections 84, 84 provided on the second resin part 44, and the inner surface 88 of each upper rail section 84 and the left-right outer surface 78 of the cylindrical part 32 are opposing surfaces in the left-right direction. At the front ends of both left-right outer surfaces 78 of the cylindrical part 32, contact ribs 80 are formed, which protrude outward in the left-right direction and abut against the inner surface 88 of each upper rail section 84 when assembled with the second resin part 44, thereby suppressing the relative displacement of the first resin part 38 and the second resin part 44 in the left-right direction. The rear surface of each contact rib 80 is an inclined surface 82 that slopes inward in the left-right direction as it moves towards the rear, so that each upper rail section 84 can be easily guided outward in the left-right direction of each contact rib 80 when assembled with the second resin part 44.

[0027] In Embodiment 1, when the first resin part 38 and the second resin part 44 are assembled, there is a slight gap between each contact rib 80 and the inner surface 88 of each upper rail portion 84 in the left-right direction. However, these contact ribs 80 and the inner surface 88 of each upper rail portion 84 may be in zero-touch contact or in a pressure-contact state. That is, when assembling the second resin part 44, which will be described later, each contact rib 80 may be press-fitted into each upper rail portion 84. This effectively prevents rattling and unintended detachment between the first resin part 38 and the second resin part 44.

[0028] As will be described later, when the first resin part 38 is assembled to the housing case 58, the first intermediate portion 28 (particularly the first straight portion 48) of the first busbar 12 is inserted through the cylindrical portion 32 of the first resin part 38, and the cylindrical portion 32 is inserted into the inner hole 18 of the magnetic material 16 (the central hole 72 of the housing case 58). In addition, the first flange portion 36 of the first resin part 38 is positioned between the front end surface 64 (the front wall portion 66 of the housing case 58), which is the first end face of the magnetic material 16, and the connecting portion (first front connecting portion 20) located on one axial side (forward) of the magnetic material 16.

[0029] <Second resin part 44> As described above, the second resin part 44 comprises a partition wall portion 40 extending in the front-rear direction and a second flange portion 42 extending outward from the rear end of the partition wall portion 40. In Embodiment 1, as shown in Figures 2 and 14, the second flange portion 42 is generally rectangular and flat, having a larger left-right dimension than the partition wall portion 40, protruding from the partition wall portion 40 on both sides in the left-right direction, and extending upward from the partition wall portion 40.

[0030] Furthermore, upper rail sections 84 are provided on both left and right edges of the bulkhead section 40, projecting upward and fitting into the cylindrical section 32 when assembled with the first resin part 38. In addition, lower rail sections 86 are provided on both left and right edges of the bulkhead section 40, projecting downward and fitting to cover both left and right sides of the second intermediate section 30 (particularly the second straight section 54) when assembled with the second busbar 14. Each of these upper rail sections 84 and lower rail sections 86 is formed over substantially the entire length (front-to-back direction) of the bulkhead section 40. The inner surfaces 88 and 90 of each upper rail section 84 and each lower rail section 86 extend substantially straight in the front-to-back direction, and the opposing dimensions between left and right sides of each upper rail section 84 and each lower rail section 86 are kept constant over substantially the entire length of the bulkhead section 40. When the partition wall portion 40 of the second resin part 44 is inserted through the central hole 72 of the housing case 58, the space enclosed by the lower portion of the inner cylindrical portion 62, the partition wall portion 40, and each lower rail portion 86 has a substantially rectangular cross-section and is formed to a size that allows the second straight portion 54 of the second busbar 14 to be inserted. On the other hand, the outer surfaces of the partition wall portion 40, each upper rail portion 84, and each lower rail portion 86 are smoothly continuous and are curved surfaces 92 that curve in a substantially arc shape so as to follow the left and right sides of the inner surface of the central hole 72 when the second resin part 44 is inserted through the central hole 72 of the housing case 58.

[0031] Furthermore, positioning protrusions 94 are provided at both ends of the second flange portion 42 in the left-right direction, projecting downward from the partition wall portion 40 towards the second busbar 14, and positioned on both sides in the plate width direction (left-right direction) of the second intermediate portion 30 (particularly the second straight portion 54) of the second busbar 14. By providing these positioning protrusions 94, when assembling the second busbar 14 and the second resin part 44, the second intermediate portion 30 (second straight portion 54) can be easily guided to the left-right central portion of the second resin part 44.

[0032] As will be described later, when the second resin part 44 is assembled into the housing case 58, the partition wall portion 40 of the second resin part 44 is sandwiched between the second intermediate portion 30 (particularly the second straight portion 54) of the second busbar 14 and the cylindrical portion 32 of the first resin part 38, and the partition wall portion 40 is inserted into the inner hole 18 of the magnetic material 16 (the central hole 72 of the housing case 58). In addition, the second flange portion 42 of the second resin part 44 is positioned between the rear end surface 68 (the rear wall portion 70 of the housing case 58), which is the second end surface of the magnetic material 16, and the connecting portion (second rear connecting portion 26) located on the other axial side (rear) of the magnetic material 16.

[0033] <Assembly method for noise reduction device 10> The following describes a specific example of how to assemble the noise reduction device 10, with particular reference to Figures 6 to 9. However, the assembly method of the noise reduction device 10 is not limited to the description below.

[0034] First, as shown in Figure 6, the first resin part 38 is brought closer from above the second busbar 14, and as shown in Figure 7, the cylindrical part 32 is superimposed on the second straight part 54 of the second intermediate part 30. At this time, the first flange part 36 is located in front of the vertical part 52 of the second busbar 14, and the contact between the first flange part 36 and the vertical part 52 suppresses the forward displacement of the first resin part 38 relative to the second busbar 14.

[0035] Subsequently, the cylindrical portion 32 and the second straight portion 54, which are stacked vertically, are brought closer from the front to the central hole 72 of the housing case 58 containing the magnetic material 16, and as shown in Figure 8, these cylindrical portion 32 and the second straight portion 54 are inserted into the central hole 72. The insertion of these cylindrical portion 32 and the second straight portion 54 into the central hole 72 is restricted by the vertical portion 52 of the second busbar 14 contacting the front wall portion 66 of the housing case 58. Next, the first busbar 12 is brought closer from the rear to the housing case 58, to which the first resin part 38 and the second busbar 14 are assembled as described above, and the first straight portion 48 of the first intermediate portion 28 is inserted through the rear opening of the cylindrical portion 32.

[0036] As a result, as shown in Figure 9, the first front connecting portion 20, which is the front end of the first straight portion 48, protrudes further forward than the first flange portion 36. Also, since the first rear connecting portion 22 is located to the right of the first front connecting portion 20 by the connecting portion 46, in the state shown in Figure 9, the first rear connecting portion 22 and the second rear connecting portion 26 are positioned side by side in the left-right direction. Note that the forward insertion of the first busbar 12 into the housing case 58 is limited by the connecting portion 46 of the first busbar 12 contacting the rear wall portion 70 of the housing case 58. Subsequently, the second resin part 44 is brought closer from the rear of the first busbar 12, and the partition portion 40 of the second resin part 44 is inserted into the central hole 72 of the housing case 58.

[0037] At that time, as shown in Figures 5 and 10, the partition wall portion 40 is inserted between the cylindrical portion 32 and the second straight portion 54 in the vertical direction. As a result, the cylindrical portion 32 through which the first straight portion 48 is inserted is inserted into the space surrounded by the upper portion of the inner cylindrical portion 62, the partition wall portion 40 and each upper rail portion 84, and the second straight portion 54 is inserted into the space surrounded by the lower portion of the inner cylindrical portion 62, the partition wall portion 40 and each lower rail portion 86. In particular, the inclined surfaces 82 of each contact rib 80 provided on the left and right outer surface of the cylindrical portion 32 guide each upper rail portion 84 outward in the left and right direction of each contact rib 80. Furthermore, forward insertion of the second resin part 44 into the housing case 58 is limited, for example, by the rear end of the cylindrical portion 32 contacting the second flange portion 42. In particular, the second flange portion 42 is provided with positioning protrusions 94 that project downward, and the second straight portion 54 is positioned between the positioning protrusions 94 in the left-right direction. Therefore, when the second resin part 44 is assembled into the housing case 58, the right-side positioning protrusion 94 is positioned between the first rear connection portion 22 and the second rear connection portion 26 in the left-right direction. In this way, the noise reduction device 10 is completed.

[0038] In the noise reduction device 10 manufactured in this manner, the second front connection portion 24 is provided via the vertical portion 52 and is located relatively far below the first front connection portion 20. The area around the first front connection portion 20 is surrounded by the first flange portion 36 of the first resin part 38. On the other hand, although the first rear connection portion 22 and the second rear connection portion 26 are located relatively close to each other, a positioning projection 94 is provided between them, projecting downward from the second flange portion 42. Such a noise reduction device 10 can be attached, for example, inside an electrical connection box in a vehicle by bolts (not shown) inserted through each leg portion 74. Furthermore, the first front connection portion 20 and the first rear connection portion 22 of the first busbar 12, and the second front connection portion 24 and the second rear connection portion 26 of the second busbar 14 are connected to electrical components (or busbars extending from electrical components, etc.) inside the electrical junction box, thereby electrically connecting the electrical components inside the electrical junction box to the first busbar 12 and the second busbar 14 in the noise reduction device 10. When current flows through the first busbar 12 and the second busbar 14, noise in the current is removed by the magnetic material 16 provided around the first busbar 12 (first straight portion 48) and the second busbar 14 (second straight portion 54).

[0039] In the noise reduction device 10 of Embodiment 1, which has the structure described above, a first flange portion 36 is provided between the first front connection portion 20 and the first end face (front end face 64) of the magnetic material 16, thereby ensuring a creepage distance and improving insulation. As a result of this improved insulation, it is not necessary to position the first front connection portion 20 at a large distance from the front end face 64 of the magnetic material 16, and the amount of forward protrusion of the first front connection portion 20 from the first flange portion 36 can be made relatively small. Similarly, a second flange portion 42 is provided between the second rear connection portion 26 and the second end face (rear end face 68) of the magnetic material 16, and by ensuring a creepage distance, insulation is improved. As a result, the amount of rearward protrusion of the second rear connection portion 26 from the second flange portion 42 can be made relatively small, and the noise reduction device 10 can be made smaller. Furthermore, by making the first flange portion 36 annular and providing a positioning projection 94 between the first rear connection portion 22 and the second rear connection portion 26, the creepage distance between the first front connection portion 20 and the second front connection portion 24, and the creepage distance between the first rear connection portion 22 and the second rear connection portion 26 can also be secured, thereby improving the insulation between them.

[0040] The partition wall portion 40 of the second resin part 44 has upper rail portions 84 projecting upward from both left and right edges, and lower rail portions 86 projecting downward from each edge. When assembling the noise reduction device 10, the first straight portion 48 of the first busbar 12 is inserted into the cylindrical portion 32 of the first resin part 38, and this cylindrical portion 32 is then housed in the space surrounded by the upper portion of the inner cylindrical portion 62, the partition wall portion 40, and the upper rail portions 84. Similarly, the second straight portion 54 of the second busbar 14 is housed in the space surrounded by the lower portion of the inner cylindrical portion 62, the partition wall portion 40, and the lower rail portions 86. In other words, although the first straight portion 48 of the first busbar 12 and the second straight portion 54 of the second busbar 14, which are inserted into the inner hole 18 of the magnetic material 16, are located relatively close to each other, they are separated by the cylindrical portion 32 and the partition wall portion 40, resulting in good insulation. In particular, since the surrounding portions of the first straight section 48 and the second straight section 54 are covered with a resin material around their entire circumference, the insulation between them can be more stably achieved.

[0041] The cylindrical portion 32 is provided with contact ribs 80 that protrude outward in the left-right direction on both outer surfaces 78 in the left-right direction. Each contact rib 80 abuts against the inner surface 88 of each upper rail portion 84, thereby suppressing relative displacement (rattling) between the cylindrical portion 32 (first resin part 38) and each upper rail portion 84 (second resin part 44). By suppressing rattle between the first resin part 38 and the second resin part 44, it is possible to prevent the first resin part 38 and the second resin part 44 from unintentionally falling out of the housing case 58 in the noise reduction device 10.

[0042] The second flange portion 42 of the second resin part 44 has positioning protrusions 94 that project downward at both ends in the left-right direction, and the second intermediate portion 30 (second straight portion 54) of the second busbar 14 is positioned between these positioning protrusions 94 in the left-right direction. Therefore, in addition to the lower rail portions 86, the positioning protrusions 94 can also suppress the left-right displacement between the second busbar 14 and the second resin part 44. In particular, since the right-side positioning protrusion 94 is positioned between the first rear connection portion 22 and the second rear connection portion 26 in the left-right direction, insulation between them can also be ensured.

[0043] <Variation> While Embodiment 1 has been described in detail above as a specific example of the present disclosure, the present disclosure is not limited by this specific description. Modifications, improvements, etc., to the extent that they can achieve the objectives of the present disclosure are included in the present disclosure. For example, the following modifications of the embodiments are also included in the technical scope of the present disclosure.

[0044] (1) In the above embodiment, the first straight portion 48 of the first busbar 12 is covered by the cylindrical portion 32 of the first resin part 38, while the second straight portion 54 of the second busbar 14 is simply inserted into the space surrounded by the lower portion of the inner cylindrical portion 62, the partition wall portion 40, and each lower rail portion 86. However, the embodiment is not limited to this. For example, a cylindrical portion may be provided on the second resin part side, and the second straight portion of the second busbar may be inserted into the cylindrical portion, while the first straight portion of the first busbar may be simply inserted into the space surrounded by the upper portion of the inner cylindrical portion, the partition wall portion, and each upper rail portion. Alternatively, cylindrical portions may be provided on both the first resin part and the second resin part, and both the first straight portion and the second straight portion may be inserted into the cylindrical portion.

[0045] (2) In the above embodiment, each abutment rib 80 was provided on both the left and right outer surfaces 78 of the cylindrical portion 32, but the abutment ribs may be provided on the inner surface of the upper rail portion, which is the opposing surface, instead of, or in addition to, the left and right outer surfaces of the cylindrical portion.

[0046] (3) The extension directions of the first busbar 12 and the second busbar 14 in the above embodiment are merely illustrative and not limiting, and can be arbitrarily set according to, for example, the arrangement of electrical components in the electrical junction box. In the above embodiment, the second busbar 14 is provided with a vertical portion 52, and the first front connection portion 20 and the second front connection portion 24 are separated by a relatively large distance in the vertical direction. However, for example, the first front connection portion and the second front connection portion may be brought closer together than in the embodiment described above, in which case the projection dimension of the first flange portion toward the outer circumference may be increased to ensure creepage distance.

[0047] (4) In the above embodiment, the noise reduction device 10 is described as being installed inside the electrical junction box in the vehicle, but this is merely an example, and the noise reduction device according to the present disclosure can be installed in an appropriate location inside the vehicle. [Explanation of Symbols]

[0048] 10. Noise reduction device 12 First Bus Bar 14. Second bus bar 16 Magnetic material 18 Inner bore 20 First forward connection section (connection section) 22 First rear connection section (connection section) 24. Second forward connection section (connection section) 26. Second rear connection section (connection section) 28. First Intermediate Section (Intermediate Section) 30. Second Intermediate Section (Intermediate Section) 32 Cylindrical part 34 Front opening (one of the openings) 36 First flange section 38. First resin part 40 Bulkhead 42 Second flange section 44. Second resin part 46 Connecting part 48. First Straight Section 50 bolt insertion holes 52 Vertical section 54. Second Straight Section 56 Bolt insertion holes 58 storage cases 60 Outer cylinder part 62 Inner cylinder part 64 Front end surface (first end surface) 66 Front wall 68 Rear end surface (second end surface) 70 Rear wall 72 Central hole 74 Legs 76 Bolt insertion holes 78 Lateral outer surface (opposing surface) 80 Contact Ribs 82 Slope 84 Upper rail section 86 Lower rail section 88 (Inner surface of the upper rail section) (opposing surface) 90 (Inner surface of the lower rail section) 92 Curved surface 94 Positioning projection

Claims

1. An annular magnetic material having an internal pore, A first busbar extending through the inner hole of the magnetic material and having connecting portions at both ends, A second busbar extending through the inner hole of the magnetic material and having connecting portions at both ends, A first resin part having a cylindrical portion through which the intermediate portion of the first busbar is inserted, and a first flange portion extending outward from one opening of the cylindrical portion, The second resin part comprises a partition wall portion into which the intermediate portions of the second busbar overlap, and a second flange portion extending outward from one end of the partition wall portion. With the intermediate portion of the first busbar inserted through the cylindrical portion of the first resin part, the cylindrical portion of the first resin part is inserted into the inner hole of the magnetic material, and the first flange portion of the first resin part is positioned between the first end face on one axial side of the magnetic material and the connecting portion located on the axial side of the magnetic material. The partition wall portion of the second resin part is sandwiched between the intermediate portion of the second busbar and the cylindrical portion of the first resin part, with the partition wall portion inserted into the inner hole of the magnetic material, and the second flange portion of the second resin part is positioned between the second end face on the other axial side of the magnetic material and the connecting portion located on the other axial side of the magnetic material. Noise reduction device.

2. The noise reduction device according to claim 1, wherein the partition wall portion of the second resin part comprises an upper rail portion that protrudes upward from a pair of side edges and fits into the cylindrical portion of the first resin part, and a lower rail portion that protrudes downward from a pair of side edges and covers and fits into the side surface of the intermediate portion of the second busbar.

3. The noise reduction device according to claim 2, wherein at least one of the opposing surfaces of the upper rail portion and the cylindrical portion is provided with a contact rib that abuts against the other opposing surface when fitted together to suppress displacement.

4. The noise reduction device according to claim 1 or claim 2, wherein the second flange portion of the second resin part has positioning projections that protrude from the partition wall portion toward the second busbar and are arranged on both sides in the plate width direction of the intermediate portion of the second busbar.

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