Lead block and rotary connector device

Abstract

This lead block (70) is provided with a lead block body (71) and a plurality of busbars (72). The plurality of busbars (72) include a plurality of exposed sections (73) that are exposed from the lead block body (71) and correspond respectively to the plurality of busbars (72). The plurality of exposed sections (73) each extend in a longitudinal direction (D4) and are disposed at intervals in an disposition direction (D5) that is orthogonal to the longitudinal direction (D4). The plurality of exposed sections (73) include at least one first exposed section (74). The at least one exposed section (74) includes a first surface (80) and a first additional surface (81) that is disposed on the back side, in the adisposition direction (D5), of the first surface (80). The first surface (80) includes a first cut surface (90) that has an area smaller than the area of the first surface (80). The first additional surface (81) includes a first additional cut surface (91) that has an area smaller than the area of the first additional surface (81).

Description

Technical Field

[0001] The technology disclosed in the present application relates to a lead block and a rotary connector device.

Background Art

[0002] Patent Documents 1 to 4 describe a rotary connector device having a lead block.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0004] Considering the manufacturing cost of the rotary connector device, it is preferable to reduce the manufacturing cost of the lead block.

[0005] The problem of the technology disclosed in the present application is to reduce the manufacturing cost of the lead block.

Means for Solving the Problems

[0006] The lead block according to the first feature includes a lead block body containing an electrically insulating material, and a plurality of busbars partially embedded in the lead block body and containing a conductive material. The plurality of busbars include a plurality of exposed portions that are exposed from the lead block body and correspond to the plurality of busbars respectively. The plurality of exposed portions each extend in the longitudinal direction and are arranged at intervals in the arrangement direction perpendicular to the longitudinal direction. The plurality of exposed portions include at least one first exposed portion. The at least one first exposed portion includes a first surface and a first additional surface arranged on the back side of the first surface in the arrangement direction. The first surface includes a first cut surface having an area smaller than the area of the first surface. The first additional surface includes a first additional cut surface having an area smaller than the area of the first additional surface.

[0007] In the lead block according to the first feature, since the first cut surface having an area smaller than the area of the first surface is arranged on the first surface, and the first additional cut surface having an area smaller than the area of the first additional surface is arranged on the first additional surface, the amount of material cut from the plurality of busbars and discarded during manufacturing can be reduced. Thereby, the manufacturing cost of the lead block can be reduced.

[0008] According to the lead block according to the second feature, in the lead block according to the first feature, the first surface includes a first adjacent surface adjacent to the first cut surface. The first additional surface includes a first additional adjacent surface adjacent to the first additional cut surface. The appearance of the first cut surface is different from the appearance of the first adjacent surface. The appearance of the first additional cut surface is different from the appearance of the first additional adjacent surface.

[0009] In the lead block according to the second feature, the surface finishing process of the first cut surface and the first additional cut surface can be omitted. Thereby, the manufacturing cost of the lead block can be further reduced compared to the case where the surface finishing of the first cut surface and the first additional cut surface is performed.

[0010] According to the lead block according to the third feature, in the lead block according to the second feature, the first cut surface is displaced from the first adjacent surface in the arrangement direction.

[0011] According to the lead block according to the fourth feature, in the lead block according to the second or third feature, the first additional cutting surface is displaced from the first additional adjacent surface in the arrangement direction.

[0012] According to the lead block according to the fifth feature, in the lead block according to any one of the first to fourth features, the first additional cutting surface is disposed on the back side of the first cutting surface in the arrangement direction.

[0013] In the lead block according to the fifth feature, for example, when cutting a connecting bar that connects a plurality of exposed portions from the plurality of exposed portions during manufacturing, deformation of the plurality of exposed portions can be suppressed.

[0014] According to the lead block according to the sixth feature, in the lead block according to any one of the first to fifth features, Longitudinal direction the length of the first cutting surface in Longitudinal direction is shorter than the length of the first surface in Longitudinal direction the length of the first additional cutting surface in Longitudinal direction is shorter than the length of the first additional surface in

[0015] In the lead block according to the sixth feature, compared with the case where the length of the first cutting surface is equal to the length of the first surface and / or the case where the length of the first additional cutting surface is equal to the length of the first additional surface, the amount of material cut off and discarded from the plurality of busbars can be reduced. Thereby, the manufacturing cost of the lead block can be further reduced.

[0016] According to the lead block according to the seventh feature, in the lead block according to any one of the first to sixth features, the plurality of exposed portions include a second exposed portion. The second exposed portion includes a second surface facing at least one first exposed portion in the arrangement direction and a second additional surface disposed on the back side of the second surface in the arrangement direction. The second surface includes a second cutting surface having an area smaller than the area of the second surface.

[0017] In the lead block according to the seventh feature, since the second cut surface having an area smaller than the area of the second surface is disposed on the second surface, the amount of material cut from a plurality of bus bars and discarded during manufacturing can be reduced. Thereby, the manufacturing cost of the lead block can be further reduced.

[0018] According to the lead block according to the eighth feature, in the lead block according to the seventh feature, one of the plurality of bus bars includes a first protrusion protruding in the arrangement direction from the second additional surface of the second exposed portion. The first protrusion is at least partially embedded in the lead block body.

[0019] In the lead block according to the eighth feature, since the first protrusion is at least partially embedded in the lead block body, the connection strength between the second exposed portion and the lead block body can be increased while reducing the manufacturing cost of the lead block. When a connection bar connecting a plurality of exposed portions during manufacturing includes the first protrusion, a part of the connection bar can be used to improve the connection strength, and the effective utilization of the material of the lead block can be promoted while increasing the connection strength between the second exposed portion and the lead block body.

[0020] According to the lead block according to the ninth feature, in the lead block according to the seventh or eighth feature, the plurality of exposed portions include a third exposed portion. The third exposed portion includes a third surface facing at least one of the first exposed portions in the arrangement direction and a third additional surface disposed on the back side of the third surface in the arrangement direction. The third surface includes a third cut surface having an area smaller than the area of the third surface.

[0021] In the lead block according to the ninth feature, since the third cut surface having an area smaller than the area of the third surface is disposed on the third surface, the amount of material cut from a plurality of bus bars and discarded during manufacturing can be reduced. Thereby, the manufacturing cost of the lead block can be further reduced.

[0022] According to the lead block according to the 10th feature, in the lead block according to the 9th feature, one of the plurality of bus bars includes a second protrusion protruding in the arrangement direction from the third additional surface of the third exposed portion. The second protrusion is at least partially embedded in the lead block body.

[0023] In the lead block according to the 10th feature, since the second protrusion is at least partially embedded in the lead block body, it is possible to increase the connection strength between the third exposed portion and the lead block body while reducing the manufacturing cost of the lead block. When the connecting bar connecting the plurality of exposed portions during manufacturing includes the second protrusion, a part of the connecting bar can be used to improve the connection strength, and while increasing the connection strength between the third exposed portion and the lead block body, it is possible to promote the effective use of the material of the lead block.

[0024] According to the lead block according to the 11th feature, in the lead block according to any one of the 1st to 10th features, the plurality of bus bars include at least one first bus bar including at least one first exposed portion. The at least one first bus bar includes a first end portion and a first additional end portion. In the at least one first bus bar, the first cut surface and the first additional cut surface are disposed between the first end portion and the first additional end portion.

[0025] In the lead block according to the 11th feature, by providing the first cut surface and the first additional cut surface at portions other than the first end portion and the first additional end portion, it becomes easier to integrally hold the plurality of bus bars with less material during manufacturing.

[0026] According to the lead block according to the 12th feature, in the lead block according to the 11th feature, the first end portion is exposed from the lead block body. When viewed from the orthogonal direction orthogonal to the longitudinal direction and the arrangement direction, the first additional end portion is disposed inside the contour of the lead block body.

[0027] In the lead block according to the 12th feature, compared with the case where the first additional end is disposed on or outside the contour of the lead block body, contact between the first additional end and other members such as a cable can be suppressed.

[0028] According to the lead block according to the 13th feature, in the lead block according to the 11th or 12th feature, the first additional end is at least partially embedded in the lead block body.

[0029] In the lead block according to the 13th feature, contact between the first additional end and other members such as a cable can be surely suppressed.

[0030] According to the lead block according to the 14th feature, in the lead block according to any one of the 1st to 13th features, the lead block body includes an opening. The first cut surface and the first additional cut surface are disposed in the opening.

[0031] In the lead block according to the 14th feature, a connecting bar that connects a plurality of exposed portions during manufacturing can be cut from the plurality of connecting portions through the opening.

[0032] The rotary connector device according to the 15th feature includes a stator, a rotor rotatably provided about a rotation axis with respect to the stator, and a lead block according to any one of the 1st to 14th features.

[0033] In the rotary connector device according to the 15th feature, since the manufacturing cost of the lead block can be reduced, the manufacturing cost of the rotary connector device can be reduced.

[0034] The manufacturing method of the lead block according to the 16th feature includes a molding step of embedding a bus bar plate including a plurality of bus bars and a connecting bar that connects a plurality of exposed portions of the plurality of bus bars into the lead block body by insert molding so that the plurality of exposed portions are exposed from the lead block body, and a cutting step of cutting the connecting bar from the plurality of exposed portions.

[0035] In the method for manufacturing a lead block according to the 16th feature, it is possible to reduce the material cut from a plurality of bus bars and discarded. Thereby, the manufacturing cost of the lead block can be reduced.

[0036] The method for manufacturing a lead block according to the 17th feature is the method for manufacturing a lead block according to the 16th feature, and the molding process includes a process of embedding a bus bar plate into the lead block body by insert molding so that at least a part of a plurality of exposed portions and a connecting bar are arranged in the opening of the lead block body.

[0037] In the method for manufacturing a lead block according to the 17th feature, the peripheral portions of a plurality of exposed portions can be held by the lead block body.

[0038] According to the method for manufacturing a lead block according to the 18th feature, in the method for manufacturing a lead block according to the 17th feature, the cutting process includes a process of cutting a connecting bar from a plurality of exposed portions through an opening of the lead block body.

[0039] In the method for manufacturing a lead block according to the 18th feature, the connecting bar can be cut from a plurality of exposed portions while the peripheral portions of the plurality of exposed portions are held by the lead block body. Thereby, the cutting operation is stabilized.

[0040] According to the method for manufacturing a lead block according to the 19th feature, in the method for manufacturing a lead block according to any one of the 16th to 18th features, the molding process includes a process of embedding a bus bar plate into the lead block body by insert molding so that a part of the connecting bar is embedded in the lead block body.

[0041] In the method for manufacturing a lead block according to the 19th feature, the connection strength between a plurality of exposed portions and the lead block body can be increased.

[0042] According to the lead block according to the 20th feature, the manufacturing method of the lead block according to any one of the 16th to 19th features further includes a pressing step of forming a bus bar plate from a plate containing a conductive material by pressing.

[0043] In the manufacturing method of the lead block according to the 20th feature, the remaining portion separated from the bus bar plate by pressing can be reduced.

Advantages of the Invention

[0044] With the technology disclosed in the present application, the manufacturing cost of the lead block can be reduced.

Brief Description of the Drawings

[0045]

Figure 1

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DETAILED DESCRIPTION OF THE INVENTION

[0046] Hereinafter, embodiments will be described with reference to the drawings. In the drawings, the same reference numerals indicate corresponding or identical configurations.

[0047] As shown in FIG. 1, the rotary connector device 1 according to the present embodiment includes a stator 10 and a rotor 20. The stator 10 is configured to be attached to the vehicle body. The rotor 20 is rotatably provided about a rotation axis A1 with respect to the stator 10. The rotor 20 is configured to be fixed to the steering wheel. The rotary connector device 1 includes a first connector 30 and a second connector 40. The first connector 30 is provided on the stator 10. The second connector 40 is provided on the rotor 20.

[0048] The first connector 30 is configured such that the vehicle body side connector is removably attached. The first connector 30 includes a first connector housing portion 31 into which the vehicle body side connector is inserted. The vehicle body side connector is electrically connected to an electric circuit such as a control device. The second connector 40 is configured such that the steering side connector is removably attached. The second connector 40 includes a second connector housing portion 41 into which the steering side connector is inserted. The steering side connector is electrically connected to an electric circuit such as switches of the steering wheel and an airbag device.

[0049] As shown in FIG. 2, the stator 10 and the rotor 20 define a cable accommodation space 50 provided so as to surround the rotation axis A1 between the stator 10 and the rotor 20. For example, the cable accommodation space 50 is annular and extends in the circumferential direction D2 with respect to the rotation axis A1. The rotary connector device 1 includes an electric cable 60. The electric cable 60 electrically connects the first connector 30 to the second connector 40. The electric cable 60 is disposed within the cable accommodation space 50. The electric cable 60 has flexibility and has a flat shape. The electric cable 60 may also be referred to as a flexible flat cable.

[0050] As shown in FIG. 1, the rotary connector device 1 includes a lead block 70. In the present embodiment, the rotary connector device 1 includes a plurality of lead blocks 70. The lead blocks 70A and 70B of the plurality of lead blocks 70 are attached to the stator 10. The lead blocks 70A and 70B are disposed within the first connector housing portion 31. The lead blocks 70C and 70D of the plurality of lead blocks 70 are attached to the rotor 20. The lead blocks 70C and 70D are disposed within the second connector housing portion 41. The first connector 30 includes the lead blocks 70A and 70B. The second connector 40 includes the lead blocks 70C and 70D. However, the total number of the lead blocks 70 is not limited to the present embodiment.

[0051] As shown in FIG. 3, the lead block 70 includes a lead block body 71 and a plurality of bus bars 72. The lead block body 71 contains an electrical insulating material. The plurality of bus bars 72 are partially embedded in the lead block body 71 and contain a conductive material. The electrical insulating material includes, for example, a resin material. The conductive material includes, for example, a metal material such as copper. The plurality of bus bars 72 are electrically insulated from each other by the lead block body 71. The plurality of bus bars 72 are electrically connected to the plurality of wirings included in the electric cable 60 (see FIG. 2), respectively.

[0052] The plurality of bus bars 72 include a plurality of exposed portions 73 that are exposed from the lead block body 71 and correspond to the plurality of bus bars 72, respectively. The bus bar 72 includes the exposed portion 73. The plurality of exposed portions 73 each extend in the longitudinal direction D4 and are arranged at intervals in the arrangement direction D5 orthogonal to the longitudinal direction D4.

[0053] The plurality of exposed portions 73 include at least one first exposed portion 74. In the present embodiment, the plurality of exposed portions 73 include a plurality of first exposed portions 74. However, the total number of the first exposed portions 74 is not limited to the present embodiment.

[0054] The plurality of exposed portions 73 include a second exposed portion 75. The plurality of exposed portions 73 include a third exposed portion 76. At least one first exposed portion 74 is arranged between the second exposed portion 75 and the third exposed portion 76 in the arrangement direction D5. The plurality of first exposed portions 74 are arranged between the second exposed portion 75 and the third exposed portion 76 in the arrangement direction D5. The plurality of first exposed portions 74, the second exposed portion 75, and the third exposed portion 76 are arranged at intervals in the arrangement direction D5.

[0055] The plurality of bus bars 72 includes at least one first bus bar 77 that includes at least one first exposed portion 74. The at least one first bus bar 77 includes a first end 77A and a first additional end 77B. In this embodiment, the plurality of bus bars 72 includes a plurality of first bus bars 77 that include a plurality of first exposed portions 74. The plurality of bus bars 72 includes a first end 77A and a first additional end 77B. However, the total number of the first bus bars 77 is not limited to this embodiment.

[0056] The plurality of bus bars 72 includes a second bus bar 78 that includes a second exposed portion 75. The plurality of bus bars 72 includes a third bus bar 79 that includes a third exposed portion 76. The second bus bar 78 includes a second end 78A and a second additional end 78B. The third bus bar 79 includes a third end 79A and a third additional end 79B. At least one of the second bus bar 78 and the third bus bar 79 may be omitted from the plurality of bus bars 72.

[0057] The first end 77A is exposed from the lead block body 71. The first bus bar 77 includes a first pin terminal 77C that is exposed from the lead block body 71. The first pin terminal 77C protrudes from the lead block body 71 in the longitudinal direction D4. The first pin terminal 77C includes the first end 77A. When viewed from the orthogonal direction D6 that is orthogonal to the longitudinal direction D4 and the arrangement direction D5, the first end 77A is disposed outside the contour 71A of the lead block body 71.

[0058] On the other hand, when viewed from the orthogonal direction D6 that is orthogonal to the longitudinal direction D4 and the arrangement direction D5, the first additional end 77B is disposed inside the contour of the lead block body 71. The first additional end 77B is at least partially embedded in the lead block body 71. In this embodiment, the first additional end 77B is partially embedded in the lead block body 71, but a part of the surface of the first additional end 77B is exposed from the lead block body 71. However, the entire first additional end 77B may be embedded in the lead block body 71.

[0059] As shown in FIG. 4, at least one first exposed portion 74 includes a first surface 80 and a first additional surface 81. The first additional surface 81 is disposed on the back side of the first surface 80 in the arrangement direction D5. Each of the plurality of first exposed portions 74 includes the first surface 80 and the first additional surface 81.

[0060] The second exposed portion 75 includes a second surface 83 and a second additional surface 84. The second surface 83 faces at least one first exposed portion 74 in the arrangement direction D5. The second additional surface 84 is disposed on the back side of the second surface 83 in the arrangement direction D5.

[0061] The third exposed portion 76 includes a third surface 85 and a third additional surface 86. The third surface 85 faces at least one first exposed portion 74 in the arrangement direction D5. The third additional surface 86 is disposed on the back side of the third surface 85 in the arrangement direction D5.

[0062] One of the plurality of bus bars 72 includes a first protrusion 87 that protrudes in the arrangement direction D5 from the second additional surface 84 of the second exposed portion 75. The second bus bar 78 includes the first protrusion 87. The first protrusion 87 is at least partially embedded in the lead block body 71. In the present embodiment, the first protrusion 87 is partially embedded in the lead block body 71. However, the entire first protrusion 87 may be embedded in the lead block body 71. Also, the first protrusion 87 may be omitted from the plurality of bus bars 72.

[0063] One of the plurality of bus bars 72 includes a second protrusion 88 that protrudes in the arrangement direction D5 from the third additional surface 86 of the third exposed portion 76. The third bus bar 79 includes the second protrusion 88. The second protrusion 88 is at least partially embedded in the lead block body 71. In the present embodiment, the second protrusion 88 is partially embedded in the lead block body 71. However, the entire second protrusion 88 may be embedded in the lead block body 71. Also, the second protrusion 88 may be omitted from the plurality of bus bars 72.

[0064] The lead block body 71 includes an opening 71B. The plurality of exposed portions 73 are at least partially disposed within the opening 71B when viewed in the orthogonal direction D6. The plurality of first exposed portions 74, second exposed portions 75, and third exposed portions 76 are at least partially disposed within the opening 71B when viewed in the orthogonal direction D6.

[0065] As shown in FIG. 5, the first surface 80 includes a first cut surface 90 having an area smaller than the area of the first surface 80. The first cut surface 90 is disposed within the opening 71B. The length L11 of the first cut surface 90 in the longitudinal direction D4 is shorter than the length L12 of the first surface 80 in the longitudinal direction D4. The first surface 80 includes a first adjacent surface 80A adjacent to the first cut surface 90. The first surface 80 includes a first adjacent surface 80B adjacent to the first cut surface 90. The appearance of the first cut surface 90 is different from the appearance of the first adjacent surface 80A. The appearance of the first cut surface 90 is different from the appearance of the first adjacent surface 80B. The appearance of the first adjacent surface 80A is the same as the appearance of the first adjacent surface 80B.

[0066] As will be described later, the first cut surface 90 is a surface formed when the connecting bar 104 (see FIGS. 9 to 11) is cut from the plurality of first exposed portions 74 during the manufacture of the lead block 70. The first adjacent surfaces 80A and 80B are surfaces formed by, for example, press working (e.g., shearing), whereas the first cut surface 90 is a surface formed in a process different from the first adjacent surfaces 80A and 80B and after the first adjacent surfaces 80A and 80B. The first cut surface 90 is a surface formed by, for example, press working (e.g., shearing) in the same manner as the first adjacent surfaces 80A and 80B.

[0067] As shown in FIG. 12, the first adjacent surface 80A includes a shear plane 80C and a fracture plane 80D. The fracture plane 80D is adjacent to the shear plane 80C in the orthogonal direction D6. The shear plane 80C is a plane formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The fracture plane 80D is a plane formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the shear plane 80C is different from the appearance of the fracture plane 80D.

[0068] Similarly, the first adjacent surface 80B includes a shear plane 80E and a fracture plane 80F. The fracture plane 80F is adjacent to the shear plane 80E in the orthogonal direction D6. The shear plane 80E is a plane formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The fracture plane 80F is a plane formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the shear plane 80E is different from the appearance of the fracture plane 80F.

[0069] The first cutting plane 90 includes a first shear plane 90A and a first fracture plane 90B. The first fracture plane 90B is adjacent to the first shear plane 90A in the orthogonal direction D6. The first shear plane 90A is a plane formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The first fracture plane 90B is a plane formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the first shear plane 90A is different from the appearance of the first fracture plane 90B.

[0070] As shown in FIG. 12, the length of the first shear plane 90A in the orthogonal direction D6 is different from the lengths of the shear planes 80C and 80E in the orthogonal direction D6. The length of the first fracture plane 90B in the orthogonal direction D6 is different from the lengths of the fracture planes 80D and 80F in the orthogonal direction D6. Therefore, the appearance of the first cut surface 90 is different from the appearances of the first adjacent surfaces 80A and 80B. Note that the first cut surface 90 may be a surface that has been surface-finished after the connecting bar 104 has been cut from the plurality of first exposed portions 74. Similarly, the first adjacent surfaces 80A and 80B may be surfaces that have been surface-finished. When the first cut surface 90 is surface-finished, the first shear plane 90A and the first fracture plane 90B are at least partially replaced by the finished surface. When the first adjacent surface 80A is surface-finished, the shear plane 80C and the fracture plane 80D are at least partially replaced by the finished surface. When the first adjacent surface 80B is surface-finished, the shear plane 80E and the fracture plane 80F are at least partially replaced by the finished surface. Therefore, there may be a case where the appearance of the first cut surface 90 is the same as the appearances of the first adjacent surfaces 80A and 80B.

[0071] As shown in FIG. 6, the first additional surface 81 includes a first additional cut surface 91 having an area smaller than the area of the first additional surface 81. The first additional cut surface 91 is disposed within the opening 71B. The length L13 of the first additional cut surface 91 in the longitudinal direction D4 is shorter than the length L14 of the first additional surface 81 in the longitudinal direction D4. The first additional surface 81 includes a first additional adjacent surface 81A adjacent to the first additional cut surface 91. The first additional surface 81 includes a first additional adjacent surface 81B adjacent to the first additional cut surface 91. The appearance of the first additional cut surface 91 is different from the appearance of the first additional adjacent surface 81A. The appearance of the first additional cut surface 91 is different from the appearance of the first additional adjacent surface 81B. The appearance of the first additional adjacent surface 81A is the same as the appearance of the first additional adjacent surface 81B.

[0072] The first additional cut surface 91 is disposed on the back side of the first cut surface 90 (see FIG. 5) in the arrangement direction D5. The first additional cut surface 91 is disposed at the same position as the first cut surface 90 (see FIG. 5) in the longitudinal direction D4. However, the first additional cut surface 91 may not be disposed on the back side of the first cut surface 90 (see FIG. 5) in the arrangement direction D5. The first additional cut surface 91 may be displaced from the first cut surface 90 (see FIG. 5) in the longitudinal direction D4.

[0073] As will be described later, the first additional cut surface 91 is a surface formed when the connecting bar 104 (see FIGS. 9 to 11) is cut from a plurality of first exposed portions 74 during the manufacture of the lead block 70. The first additional adjacent surfaces 81A and 81B are surfaces formed by, for example, press working (e.g., shearing), whereas the first additional cut surface 91 is a surface formed in a process different from the first additional adjacent surfaces 81A and 81B and after the first additional adjacent surfaces 81A and 81B. The first additional cut surface 91 is a surface formed by, for example, press working (e.g., shearing) in the same manner as the first additional adjacent surfaces 81A and 81B.

[0074] As shown in FIG. 13, the first additional adjacent surface 81A includes an additional shear surface 81C and an additional fracture surface 81D. The additional fracture surface 81D is adjacent to the additional shear surface 81C in the orthogonal direction D6. The additional shear surface 81C is a surface formed when the material is sheared by a punch and a die during shearing, and includes a plurality of ribs extending in one direction (e.g., the orthogonal direction D6). The additional fracture surface 81D is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the additional shear surface 81C is different from the appearance of the additional fracture surface 81D.

[0075] Similarly, the first additional adjacent surface 81B includes an additional shear surface 81E and an additional fracture surface 81F. The additional fracture surface 81F is adjacent to the additional shear surface 81E in the orthogonal direction D6. The additional shear surface 81E is a surface formed by shearing a material with a punch and a die during a shearing process, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The additional fracture surface 81F is a surface formed by fracturing after a part of the material is sheared with a punch and a die during a shearing process, and includes fine irregularities. Therefore, the appearance of the additional shear surface 81E is different from the appearance of the additional fracture surface 81F.

[0076] The first additional cutting surface 91 includes a first additional shear surface 91A and a first additional fracture surface 91B. The first additional fracture surface 91B is adjacent to the first additional shear surface 91A in the orthogonal direction D6. The first additional shear surface 91A is a surface formed by shearing a material with a punch and a die during a shearing process, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The first additional fracture surface 91B is a surface formed by fracturing after a part of the material is sheared with a punch and a die during a shearing process, and includes fine irregularities. Therefore, the appearance of the first additional shear surface 91A is different from the appearance of the first additional fracture surface 91B.

[0077] As shown in FIG. 13, the length of the first additional cut surface 91A in the orthogonal direction D6 is different from the lengths of the additional cut surfaces 81C and 81E in the orthogonal direction D6. The length of the first additional fracture surface 91B in the orthogonal direction D6 is different from the lengths of the additional fracture surfaces 81D and 81F in the orthogonal direction D6. Therefore, the appearance of the first additional cut surface 91 is different from the appearances of the first additional adjacent surfaces 81A and 81B. Note that the first additional cut surface 91 may be a surface that has been surface-finished after the connecting bar 104 has been cut from the plurality of first exposed portions 74. Similarly, the first additional adjacent surfaces 81A and 81B may be surfaces that have been surface-finished. When the first additional cut surface 91 is surface-finished, the first additional cut surface 91A and the first additional fracture surface 91B are at least partially replaced by the finished surface. When the first additional adjacent surface 81A is surface-finished, the additional cut surface 81C and the additional fracture surface 81D are at least partially replaced by the finished surface. When the first additional adjacent surface 81B is surface-finished, the additional cut surface 81E and the additional fracture surface 81F are at least partially replaced by the finished surface. Therefore, the appearance of the first additional cut surface 91 may be the same as the appearances of the first additional adjacent surfaces 81A and 81B in some cases.

[0078] As shown in FIG. 5, the second surface 83 includes a second cut surface 93 having an area smaller than the area of the second surface 83. The second cut surface 93 is disposed within the opening 71B. The length L21 of the second cut surface 93 in the longitudinal direction D4 is shorter than the length L22 of the second surface 83 in the longitudinal direction D4. The second surface 83 includes second adjacent surfaces 83A and 83B adjacent to the second cut surface 93. The appearance of the second cut surface 93 is different from the appearances of the second adjacent surfaces 83A and 83B, respectively. The appearance of the second adjacent surface 83A is the same as the appearance of the second adjacent surface 83B.

[0079] As will be described later, the second cut surface 93 is a surface formed when the connecting bar 104 (see FIGS. 9 to 11) is cut from a plurality of first exposed portions 74 during the manufacture of the lead block 70. The second adjacent surfaces 83A and 83B are surfaces formed by, for example, press working (e.g., shearing), whereas the second cut surface 93 is a surface formed in a process different from the second adjacent surfaces 83A and 83B and after the second adjacent surfaces 83A and 83B. The second cut surface 93 is a surface formed by, for example, press working (e.g., shearing) in the same manner as the second adjacent surfaces 83A and 83B.

[0080] As shown in FIG. 14, the second adjacent surface 83A includes a shear surface 83C and a fracture surface 83D. The fracture surface 83D is adjacent to the shear surface 83C in the orthogonal direction D6. The shear surface 83C is a surface formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (e.g., the orthogonal direction D6). The fracture surface 83D is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the shear surface 83C is different from the appearance of the fracture surface 83D.

[0081] Similarly, the second adjacent surface 83B includes a shear surface 83E and a fracture surface 83F. The fracture surface 83F is adjacent to the shear surface 83E in the orthogonal direction D6. The shear surface 83E is a surface formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (e.g., the orthogonal direction D6). The fracture surface 83F is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the shear surface 83E is different from the appearance of the fracture surface 83F.

[0082] The second cut surface 93 includes a second shear surface 93A and a second fracture surface 93B. The second fracture surface 93B is adjacent to the second shear surface 93A in the orthogonal direction D6. The second shear surface 93A is a surface formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The second fracture surface 93B is a surface formed by fracture after a part of the material is sheared with a punch and a die during shearing, and includes fine unevenness. Therefore, the appearance of the second shear surface 93A is different from the appearance of the second fracture surface 93B.

[0083] As shown in FIG. 14, the length of the second shear surface 93A in the orthogonal direction D6 is different from the lengths of the shear surfaces 83C and 83E in the orthogonal direction D6. The length of the second fracture surface 93B in the orthogonal direction D6 is different from the lengths of the fracture surfaces 83D and 83F in the orthogonal direction D6. Therefore, the appearance of the second cut surface 93 is different from the appearances of the second adjacent surfaces 83A and 83B. Note that the second cut surface 93 may be a surface on which a surface finish is applied after the connecting bar 104 is cut from the plurality of first exposed portions 74. Similarly, the second adjacent surfaces 83A and 83B may be surfaces on which a surface finish is applied. When a surface finish is applied to the second cut surface 93, the second shear surface 93A and the second fracture surface 93B are at least partially replaced by the finished surface. When a surface finish is applied to the second adjacent surface 83A, the shear surface 83C and the fracture surface 83D are at least partially replaced by the finished surface. When a surface finish is applied to the second adjacent surface 83B, the shear surface 83E and the fracture surface 83F are at least partially replaced by the finished surface. Therefore, there may be a case where the appearance of the second cut surface 93 is the same as the appearances of the second adjacent surfaces 83A and 83B.

[0084] As shown in FIG. 6, the third surface 85 includes a third cut surface 95 having an area smaller than the area of the third surface 85. The third cut surface 95 is disposed within the opening 71B. The length L31 of the third cut surface 95 in the longitudinal direction D4 is shorter than the length L32 of the third surface 85 in the longitudinal direction D4. The third surface 85 includes third adjacent surfaces 85A and 85B adjacent to the third cut surface 95. The appearance of the third cut surface 95 is different from the appearances of the third adjacent surfaces 85A and 85B respectively. The appearance of the third adjacent surface 85A is the same as the appearance of the third adjacent surface 85B.

[0085] As will be described later, the third cut surface 95 is a surface formed when the connecting bar 104 (see FIGS. 9 to 11) is cut from the plurality of first exposed portions 74 during the manufacture of the lead block 70. The third adjacent surfaces 85A and 85B are surfaces formed by, for example, press working (e.g., shearing), whereas the third cut surface 95 is a surface formed in a process different from the third adjacent surfaces 85A and 85B and after the third adjacent surfaces 85A and 85B. The third cut surface 95 is a surface formed by, for example, press working (e.g., shearing) in the same manner as the third adjacent surfaces 85A and 85B.

[0086] As shown in FIG. 15, the third adjacent surface 85A includes a shear surface 85C and a fracture surface 85D. The fracture surface 85D is adjacent to the shear surface 85C in the orthogonal direction D6. The shear surface 85C is a surface formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in one direction (e.g., the orthogonal direction D6). The fracture surface 85D is a surface formed by fracturing after a part of the material is sheared with a punch and a die during shearing, and includes fine irregularities. Therefore, the appearance of the shear surface 85C is different from the appearance of the fracture surface 85D.

[0087] Similarly, the third adjacent surface 85B includes a shearing surface 85E and a fracture surface 85F. The fracture surface 85F is adjacent to the shearing surface 85E in the orthogonal direction D6. The shearing surface 85E is a surface formed by shearing a material with a punch and a die during shearing processing, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The fracture surface 85F is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing processing, and includes fine irregularities. Therefore, the appearance of the shearing surface 85E is different from the appearance of the fracture surface 85F.

[0088] The third cut surface 95 includes a third shearing surface 95A and a third fracture surface 95B. The third fracture surface 95B is adjacent to the third shearing surface 95A in the orthogonal direction D6. The third shearing surface 95A is a surface formed by shearing a material with a punch and a die during shearing processing, and includes a plurality of ribs extending in one direction (for example, the orthogonal direction D6). The third fracture surface 95B is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing processing, and includes fine irregularities. Therefore, the appearance of the third shearing surface 95A is different from the appearance of the third fracture surface 95B.

[0089] As shown in FIG. 15, the length of the third shearing surface 95A in the orthogonal direction D6 is different from the lengths of the shearing surfaces 85C and 85E in the orthogonal direction D6. The length of the third fracture surface 95B in the orthogonal direction D6 is different from the lengths of the fracture surfaces 85D and 85F in the orthogonal direction D6. Therefore, the appearance of the third cut surface 95 is different from the appearances of the third adjacent surfaces 85A and 85B. Note that the third cut surface 95 may be a surface on which a surface finish is applied after the connecting bar 104 is cut from the plurality of first exposed portions 74. Similarly, the third adjacent surfaces 85A and 85BIt may be a surface with a surface finish. When the third cut surface 95 has a surface finish, the third shear surface 95A and the third fracture surface 95B are at least partially replaced by the finished surface. When the third adjacent surface 85A has a surface finish, the shear surface 85C and the fracture surface 85D are at least partially replaced by the finished surface. When the third adjacent surface 85B has a surface finish, the shear surface 85E and the fracture surface 85F are at least partially replaced by the finished surface. Therefore, the appearance of the third cut surface 95 may be the same as the appearance of the third adjacent surfaces 85A and 85B.

[0090] As shown in FIG. 3, in at least one first bus bar 77, the first exposed portion 74 is disposed between the first end portion 77A and the first additional end portion 77B. In at least one first bus bar 77, the first cut surface 90 and the first additional cut surface 91 are disposed between the first end portion 77A and the first additional end portion 77B. In the second bus bar 78, the second cut surface 93 is disposed between the second end portion 78A and the second additional end portion 78B. In the third bus bar 79, the third cut surface 95 is disposed between the third end portion 79A and the third additional end portion 79B.

[0091] As shown in FIG. 6, the first protrusion 87 includes a second additional cut surface 97. The second additional cut surface 97 is an end surface of the first protrusion 87 and is exposed from the lead block body 71. As will be described later, the second additional cut surface 97 is a surface formed when the connecting bar 104 (see FIGS. 9 to 11) is cut from the first protrusion 87 during the manufacture of the lead block 70.

[0092] As shown in FIG. 5, the second protrusion 88 includes a third additional cut surface 98. The third additional cut surface 98 is an end surface of the second protrusion 88 and is exposed from the lead block body 71. As will be described later, the third additional cut surface 98 is a surface formed when the connecting bar 104 (see FIGS. 9 to 11) is cut from the second protrusion 88 during the manufacture of the lead block 70.

[0093] The plurality of exposed portions 73 each include a plurality of cable mounting surfaces 73A. The cable mounting surfaces 73A are arranged to face the orthogonal direction D6. The plurality of cable mounting surfaces 73A face the electrical cable 60 (see FIG. 2) in a state where the electrical cable 60 is connected to the plurality of bus bars 72.

[0094] As shown in FIG. 6, the plurality of exposed portions 73 each include a plurality of back surfaces 73B. The back surfaces 73B are arranged on the back side of the cable mounting surfaces 73A in the orthogonal direction D6. The back surfaces 73B are arranged to face the orthogonal direction D6.

[0095] As shown in FIG. 7, the plurality of exposed portions 73 each include a plurality of convex portions 73C. The convex portions 73C protrude from the cable mounting surfaces 73A in the orthogonal direction D6. The plurality of convex portions 73C are each electrically connected to a plurality of wirings included in the electrical cable 60 (see FIG. 2). For example, the plurality of convex portions 73C are connected to the plurality of wirings included in the electrical cable 60 (see FIG. 2) by a connection method such as ultrasonic bonding or resistance welding.

[0096] The plurality of exposed portions 73 each include a plurality of concave portions 73D. The concave portions 73D are arranged on the back surfaces 73B of the plurality of exposed portions 73. The concave portions 73D are arranged on the back side of the convex portions 73C in the orthogonal direction D6. The convex portions 73C and the concave portions 73D are formed, for example, by press working. At least one of the convex portions 73C and the concave portions 73D may be omitted from the exposed portion 73.

[0097] A method for manufacturing the lead block 70 will be described with reference to FIGS. 8 to 11.

[0098] As shown in FIGS. 8 and 9, the manufacturing method of the lead block 70 includes a pressing step S1 of forming the bus bar plate 102 from the plate 100 containing the conductive material by pressing. As shown in FIG. 9, the bus bar plate 102 includes a plurality of bus bars 72, a connecting bar 104 that connects a plurality of exposed portions 73 of the plurality of bus bars 72 to each other, and a carrier 106 that connects the plurality of bus bars 72 to each other. The plurality of first end portions 77A, second end portions 78A, and third end portions 79A are connected to the carrier 106.

[0099] As shown in FIGS. 8 and 10, the manufacturing method of the lead block 70 includes a molding step S2 of embedding a bus bar plate 102 including a plurality of bus bars 72 and a connecting bar 104 that connects a plurality of exposed portions 73 of the plurality of bus bars 72 to each other into the lead block main body 71 by insert molding so that the plurality of exposed portions 73 are exposed from the lead block main body 71.

[0100] The molding step S2 includes a step S21 of embedding the bus bar plate 102 into the lead block main body 71 by insert molding so that at least a part of the plurality of exposed portions 73 and the connecting bar 104 are disposed in the opening 71B of the lead block main body 71. The molding step S2 includes a step S22 of embedding the bus bar plate 102 into the lead block main body 71 by insert molding so that a part of the connecting bar 104 is embedded in the lead block main body 71. Steps S21 and S22 are usually executed by one insert molding, but may be executed by separate insert moldings. Also, one of steps S21 and step S22 may be omitted from the molding step S2.

[0101] As shown in FIGS. 8 and 11, the manufacturing method of the lead block 70 includes a cutting step S3 of cutting the connecting bar 104 from the plurality of exposed portions 73. The cutting step S3 includes a step S31 of cutting the connecting bar 104 from the plurality of exposed portions 73 through the opening 71B of the lead block main body 71. For example, in the cutting step S3, the connecting bar 104 is cut from the plurality of exposed portions 73 by pressing.

[0102] As shown in FIG. 11, the connecting bar 104 includes a plurality of first connecting portions 104A, a second connecting portion 104B, and a third connecting portion 104C. When the plurality of first connecting portions 104A are cut from the plurality of exposed portions 73, a plurality of first cut surfaces 90 (see FIG. 5), a plurality of first additional cut surfaces 91 (see FIG. 6), a second cut surface 93 (see FIG. 5), and a third cut surface 95 (see FIG. 6) are formed. When the second connecting portion 104B is cut from the first protruding portion 87, a second additional cut surface 97 (see FIG. 6) is formed. When the third connecting portion 104C is cut from the second protruding portion 88, a third additional cut surface 98 (see FIG. 5) is formed.

[0103] As shown in FIGS. 8 and 11, the manufacturing method of the lead block 70 includes a carrier cutting step S4 of cutting the carrier 106 from the plurality of bus bars 72. For example, by pressing, the carrier 106 is cut from the plurality of bus bars 72. Thus, the lead block 70 is manufactured. When the bus bar plate 102 does not include the carrier 106, the carrier cutting step S4 may be omitted. Also, the cutting step S3 and the carrier cutting step S4 may be executed simultaneously as one step, or may be executed at different timings as separate steps.

[0104] The features of the lead block 70 according to this embodiment are as follows. (1) The lead block 70 includes a lead block main body 71 containing an electrical insulating material, and a plurality of bus bars 72 partially embedded in the lead block main body 71 and containing a conductive material. The plurality of bus bars 72 include a plurality of exposed portions 73 exposed from the lead block main body 71 and corresponding to the plurality of bus bars 72 respectively. The plurality of exposed portions 73 each extend in the longitudinal direction D4 and are arranged at intervals in the arrangement direction D5 orthogonal to the longitudinal direction D4. The plurality of exposed portions 73 include at least one first exposed portion 74. The at least one first exposed portion 74 includes a first surface 80 and a first additional surface 81 arranged on the back side of the first surface 80 in the arrangement direction D5. The first surface 80 includes a first cut surface 90 having an area smaller than the area of the first surface 80. The first additional surface 81 includes a first additional cut surface 91 having an area smaller than the area of the first additional surface 81.

[0105] In the lead block 70, since the first cut surface 90 having an area smaller than the area of the first surface 80 is arranged on the first surface 80 and the first additional cut surface 91 having an area smaller than the area of the first additional surface 81 is arranged on the first additional surface 81, the amount of material cut from the plurality of bus bars 72 and discarded during manufacturing can be reduced. Thereby, the manufacturing cost of the lead block 70 can be reduced. (2) The first surface 80 includes a first adjacent surface 80A adjacent to the first cut surface 90. The first additional surface 81 includes a first additional adjacent surface 81A adjacent to the first additional cut surface 91. The appearance of the first cut surface 90 is different from the appearance of the first adjacent surface 80A. The appearance of the first additional cut surface 91 is different from the appearance of the first additional adjacent surface 81A. Therefore, the surface finishing process of the first cut surface 90 and the first additional cut surface 91 can be omitted. Thereby, the manufacturing cost of the lead block 70 can be further reduced compared to the case where the surface finishing of the first cut surface 90 and the first additional cut surface 91 is performed. (3) The first additional cut surface 91 is arranged on the back side of the first cut surface 90 in the arrangement direction D5. Thereby, for example, when cutting a connecting bar connecting the plurality of exposed portions 73 from the plurality of exposed portions 73 during manufacturing, deformation of the plurality of exposed portions 73 can be suppressed. (4) Longitudinal direction D4 The length of the first cut surface 90 inLongitudinal direction D4 is shorter than the length of the first surface 80 in Longitudinal direction D4 The length of the first additional cutting surface 91 in Longitudinal direction D4 is shorter than the length of the first additional surface 81 in . Thus, compared with the case where the length of the first cutting surface 90 is equal to the length of the first surface 80 and / or the length of the first additional cutting surface 91 is equal to the length of the first additional surface 81, the amount of material cut off from the plurality of bus bars 72 and discarded can be reduced. Thereby, the manufacturing cost of the lead block 70 can be further reduced. (5) The plurality of exposed portions 73 includes a second exposed portion 75. The second exposed portion 75 includes a second surface 83 facing at least one first exposed portion 74 in the arrangement direction D5, and a second additional surface 84 arranged on the back side of the second surface 83 in the arrangement direction D5. The second surface 83 includes a second cutting surface 93 having an area smaller than the area of the second surface 83. Since the second cutting surface 93 having an area smaller than the area of the second surface 83 is arranged on the second surface 83, the amount of material cut off from the plurality of bus bars 72 and discarded during manufacturing can be reduced. Thereby, the manufacturing cost of the lead block 70 can be further reduced. (6) One of the plurality of bus bars 72 includes a first protruding portion 87 protruding in the arrangement direction D5 from the second additional surface 84 of the second exposed portion 75. The first protruding portion 87 is at least partially embedded in the lead block body 71. Thereby, while reducing the manufacturing cost of the lead block 70, the connection strength between the second exposed portion 75 and the lead block body 71 can be increased. When the connecting bar connecting the plurality of exposed portions 73 during manufacturing includes the first protruding portion 87, a part of the connecting bar can be used for improving the connection strength, and while increasing the connection strength between the second exposed portion 75 and the lead block body 71, the effective utilization of the material of the lead block 70 can be promoted. (7) The plurality of exposed portions 73 includes a third exposed portion 76. The third exposed portion 76 includes a third surface 85 facing at least one first exposed portion 74 in the arrangement direction D5, and a third additional surface 86 arranged on the back side of the third surface 85 in the arrangement direction D5. The third surface 85 includes a third cut surface 95 having an area smaller than the area of the third surface 85. Since the third cut surface 95 having an area smaller than the area of the third surface 85 is arranged on the third surface 85, the amount of material cut from the plurality of bus bars 72 and discarded during manufacturing can be reduced. Thereby, the manufacturing cost of the lead block 70 can be further reduced. (8) It includes a second protruding portion 88 protruding in the arrangement direction D5 from the third additional surface 86 of the third exposed portion 76. The second protruding portion 88 is at least partially embedded in the lead block body 71. Thereby, while reducing the manufacturing cost of the lead block 70, the connection strength between the third exposed portion 76 and the lead block body 71 can be increased. When the connecting bar connecting the plurality of exposed portions 73 during manufacturing includes the second protruding portion 88, a part of the connecting bar can be used for improving the connection strength, and while increasing the connection strength between the third exposed portion 76 and the lead block body 71, the effective utilization of the material of the lead block 70 can be promoted. (9) The plurality of bus bars 72 includes at least one first bus bar 77 including at least one first exposed portion 74. The at least one first bus bar 77 includes a first end portion 77A and a first additional end portion 77B. In the at least one first bus bar 77, the first cut surface 90 and the first additional cut surface 91 are arranged between the first end portion 77A and the first additional end portion 77B. By providing the first cut surface 90 and the first additional cut surface 91 at portions other than the first end portion 77A and the first additional end portion 77B, it becomes easier to integrally hold the plurality of bus bars 72 with less material during manufacturing. (10) The first end portion 77A is exposed from the lead block body 71. When viewed from the orthogonal direction D6 that is orthogonal to the longitudinal direction D4 and the arrangement direction D5, the first additional end portion 77B is disposed inside the contour of the lead block body 71. Thereby, compared with the case where the first additional end portion 77B is disposed on the contour of the lead block body 71 or outside the contour of the lead block body 71, it is possible to suppress the first additional end portion 77B from contacting other members such as a cable. (11) The first additional end portion 77B is at least partially embedded in the lead block body 71. Thereby, it is possible to surely suppress the first additional end portion 77B from contacting other members such as a cable. (12) The lead block body 71 includes an opening. The first cut surface 90 and the first additional cut surface 91 are disposed in the opening. Thereby, at the time of manufacture, a connecting bar that connects a plurality of exposed portions 73 can be cut from a plurality of connecting portions through the opening. (13) The rotary connector device 1 includes a stator 10, a rotating body 20 provided rotatably about a rotation axis A1 with respect to the stator 10, and a lead block 70. Since the manufacturing cost of the lead block 70 can be reduced, the manufacturing cost of the rotary connector device 1 can be reduced. (14) The manufacturing method of the lead block 70 includes a molding step S2 of embedding a bus bar plate 102 including a plurality of bus bars 72 and a connecting bar 104 that connects a plurality of exposed portions 73 of the plurality of bus bars 72 to each other into the lead block body 71 by insert molding so that the plurality of exposed portions 73 are exposed from the lead block body 71, and a cutting step S3 of cutting the connecting bar 104 from the plurality of exposed portions 73. In this manufacturing method, it is possible to reduce the amount of material cut from the plurality of bus bars 72 and discarded. Thereby, the manufacturing cost of the lead block 70 can be reduced. (15) The molding step S2 includes a step S21 of embedding the bus bar plate 102 into the lead block body 71 by insert molding such that at least a part of the plurality of exposed portions 73 and the connecting bar are disposed in the opening of the lead block body 71. Thereby, the peripheral portions of the plurality of exposed portions 73 can be held by the lead block body 71. (16) The cutting step S3 includes a step S31 of cutting the connecting bar 104 from a plurality of exposed portions 73 through the opening 71B of the lead block body 71. Thereby, the connecting bar can be cut from the plurality of exposed portions 73 while the peripheral portions of the plurality of exposed portions 73 are held by the lead block body 71. Thereby, the cutting operation is stabilized. (17) The molding step S2 includes a step of embedding the bus bar plate 102 into the lead block body 71 by insert molding so that a part of the connecting bar 104 is embedded in the lead block body 71. Thereby, the connection strength between the plurality of exposed portions 73 and the lead block body 71 can be increased. (18) The method for manufacturing the lead block 70 further includes a pressing step S1 of forming the bus bar plate 102 from the plate 100 containing a conductive material by pressing. The remaining portion separated from the bus bar plate 102 by pressing can be reduced.

[0106] As shown in FIG. 12, in the present embodiment, the length of the first shear plane 90A in the orthogonal direction D6 is the length of the shear plane 80C and 80E longer than that of Long . However, as shown in FIG. 16, the length of the first shear plane 90A in the orthogonal direction D6 may be 80E longer than the lengths of the shear plane 80C and Short . Further, the length of the first shear plane 90A in the orthogonal direction D6 may be equal to the lengths of the shear planes 80C and 80E in the orthogonal direction D6. The above dimensional relationship can be applied to the dimensional relationships of the first additional shear plane 91A, the additional shear planes 81C and 81E, the second shear plane 93A, the shear planes 83C and 83E, and the third shear plane 95A, the shear planes 85C and 85E.

[0107] As shown in FIG. 12, in the present embodiment, the first shearing plane 90A and the shearing planes 80C and 80E are arranged closer to the cable mounting surface 73A than the first breaking plane 90B and the breaking planes 80D and 80F. However, as shown in FIG. 17, the first breaking plane 90B may be arranged closer to the cable mounting surface 73A.

[0108] As shown in FIGS. 4 to 6, in the present embodiment, the first cutting plane 90 is arranged on the same plane as the first adjacent planes 80A and 80B in the arrangement direction D5. However, as shown in FIGS. 18 and 19, the first cutting plane 90 may not be arranged on the same plane as the first adjacent planes 80A and 80B. The first additional cutting plane 91 may not be arranged on the same plane as the first additional adjacent planes 81A and 81B. The first cutting plane 90 may be displaced from the first adjacent planes 80A and 80B in the arrangement direction D5. The first additional cutting plane 91 may be displaced from the first additional adjacent planes 81A and 81B in the arrangement direction D5. The same applies to the positional relationship in the arrangement direction D5 between the second cutting plane 93 and the second adjacent planes 83A and 83B. The same applies to the positional relationship in the arrangement direction D5 between the third cutting plane 95 and the third adjacent planes 85A and 85B.

[0109] In the present embodiment and the above-described modification, the material is cut by pressing (specifically, shearing), but other cutting methods can also be applied.

[0110] In the present application, "comprise" and its derivatives are non-limiting terms for explaining the existence of components and do not exclude the existence of other components not described. This also applies to "have", "include" and their derivatives.

[0111] In the present application, ordinal numbers such as "first" and "second" are merely terms for identifying the configuration and do not have other meanings (for example, a specific order, etc.). For example, the existence of a "second element" is not implicitly meant just because there is a "first element", nor is the existence of a "first element" implicitly meant just because there is a "second element".

[0112] In addition, the expressions "parallel", "orthogonal", and "coincident" in the present disclosure should not be strictly interpreted, but rather include the meanings of "substantially parallel", "substantially orthogonal", and "substantially coincident", respectively. Also, expressions regarding other arrangements are not to be strictly interpreted.

[0113] In addition, the expression "at least one of A and B" in the present disclosure includes, for example, any of (1) only A, (2) only B, and (3) both A and B. The expression "at least one of A, B, and C" includes, for example, any of (1) only A, (2) only B, (3) only C, (4) A and B, (5) B and C, (6) A and C, and (7) all of A, B, and C. In the present disclosure, the expression "at least one of A and B" is not interpreted as "at least one of A and at least one of B".

[0114] Considering the above disclosure content, it is obvious that various changes and modifications to the present invention are possible. Therefore, the present invention may be implemented in a manner different from the specific disclosure content of this application without departing from the spirit of the present invention.

Explanation of Reference Numerals

[0115] 1: Rotating Connector Device 10: Stator 20: Rotating Body 70: Lead Block 71: Lead Block Body 71A: Contour 71B: Opening 72: Busbar 73: Exposed Portion 74: First Exposed Portion 75: Second Exposed Portion 76: Third Exposed Portion 77: First Busbar 77A: First End 77B: First Additional End 78: Second Busbar 79: Third Busbar 80: First surface 80A: First adjacent surface 80B: First adjacent surface 81: First additional surface 81A: First additional adjacent surface 81B: First additional adjacent surface 83: Second surface 84: Second additional surface 85: Third surface 86: Third additional surface 87: First protrusion 88: Second protrusion 90: First cutting surface 91: First additional cutting surface 93: Second cutting surface 95: Third cutting surface 97: Second additional cutting surface 98: Third additional cutting surface 100: Plate 102: Bus bar plate 104: Connecting bar A1: Axis of rotation D4: Longitudinal direction D5: Arrangement direction D6: Orthogonal direction S1: Press working process S2: Molding process S3: Cutting process S4: Carrier cutting process

Claims

1. A lead block body including an electrical insulating material, and a plurality of bus bars partially embedded in the lead block body and including a conductive material, wherein the plurality of bus bars include a plurality of exposed portions exposed from the lead block body and corresponding to the plurality of bus bars respectively, wherein the plurality of exposed portions each extend in a longitudinal direction and are arranged at intervals in an arrangement direction orthogonal to the longitudinal direction, wherein the plurality of exposed portions include at least one first exposed portion, wherein the at least one first exposed portion includes a first surface and a first additional surface arranged on the back side of the first surface in the arrangement direction, wherein the first surface includes a first cut surface having an area smaller than the area of the first surface, wherein the first additional surface includes a first additional cut surface having an area smaller than the area of the first additional surface, wherein the plurality of exposed portions each include a plurality of cable attachment surfaces, wherein the plurality of cable attachment surfaces are arranged so as to face an orthogonal direction orthogonal to the longitudinal direction and the arrangement direction, wherein the plurality of cable attachment surfaces face the electrical cable in a state where the electrical cable is connected to the plurality of bus bars, wherein the plurality of exposed portions each include a plurality of convex portions, wherein the plurality of convex portions project from the plurality of cable attachment surfaces in the orthogonal direction so as to be electrically connected to a plurality of wirings included in the electrical cable respectively, wherein the plurality of exposed portions each include a plurality of back surfaces, wherein the plurality of back surfaces are arranged on the back side of the plurality of cable attachment surfaces in the orthogonal direction, wherein the plurality of exposed portions each include a plurality of concave portions, wherein the plurality of concave portions are respectively arranged on the plurality of back surfaces and on the back side of each of the plurality of convex portions, wherein the convex portion provided on the at least one first exposed portion among the plurality of convex portions is arranged between the first cut surface and the first additional cut surface in the arrangement direction when viewed from the orthogonal direction, wherein the concave portion provided on the at least one first exposed portion among the plurality of concave portions is arranged between the first cut surface and the first additional cut surface in the arrangement direction when viewed from the orthogonal direction, wherein the first cut surface includes a first shearing surface and a first fracture surface, wherein the first fracture surface is adjacent to the first shearing surface in the orthogonal direction, wherein the first shearing surface is a surface formed by shearing a material with a punch and a die during shearing processing and includes a plurality of ribs extending in the orthogonal direction, The first fracture surface is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. The first additional cutting surface includes a first additional shearing surface and a first additional fracture surface. The first additional fracture surface is adjacent to the first additional shearing surface in the orthogonal direction. The first additional shearing surface is a surface formed by shearing the material by a punch and a die during shearing, and includes a plurality of ribs extending in the orthogonal direction. The first additional fracture surface is a surface formed by fracture after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. When viewed from the arrangement direction, the first shearing surface is arranged closer to the convex portion provided on the at least one first exposed portion among the plurality of convex portions than the first fracture surface in the orthogonal direction. When viewed from the arrangement direction, the first additional shearing surface is arranged closer to the convex portion provided on the at least one first exposed portion among the plurality of convex portions than the first additional fracture surface in the orthogonal direction. Lead block.

2. The first surface includes a first adjacent surface adjacent to the first cutting surface. The first additional surface includes a first additional adjacent surface adjacent to the first additional cutting surface. The appearance of the first cutting surface is different from the appearance of the first adjacent surface. The appearance of the first additional cutting surface is different from the appearance of the first additional adjacent surface. The lead block according to claim 1.

3. The first cutting surface is displaced from the first adjacent surface in the arrangement direction. The lead block according to claim 2.

4. The first additional cutting surface is displaced from the first additional adjacent surface in the arrangement direction. The lead block according to claim 2 or 3.

5. The first additional cutting surface is arranged on the back side of the first cutting surface in the arrangement direction. The lead block according to any one of claims 1 to 4.

6. The length of the first cutting surface in the longitudinal direction is shorter than the length of the first surface in the longitudinal direction. The length of the first additional cutting surface in the longitudinal direction is shorter than the length of the first additional surface in the longitudinal direction. The lead block according to any one of claims 1 to 5.

7. The plurality of exposed portions includes a second exposed portion. The second exposed portion includes a second surface facing the at least one first exposed portion in the arrangement direction, and a second additional surface disposed on the back side of the second surface in the arrangement direction. The second surface includes a second cut surface having an area smaller than the area of the second surface. The lead block according to any one of claims 1 to 6.

8. One of the plurality of bus bars includes a first protruding portion protruding in the arrangement direction from the second additional surface of the second exposed portion. The first protruding portion is at least partially embedded in the lead block body. The lead block according to claim 7.

9. The plurality of exposed portions includes a third exposed portion. The third exposed portion includes a third surface facing the at least one first exposed portion in the arrangement direction, and a third additional surface disposed on the back side of the third surface in the arrangement direction. The third surface includes a third cut surface having an area smaller than the area of the third surface. The lead block according to claim 7 or 8.

10. One of the plurality of bus bars includes a second protruding portion protruding in the arrangement direction from the third additional surface of the third exposed portion. The second protruding portion is at least partially embedded in the lead block body. The lead block according to claim 9.

11. The plurality of bus bars includes at least one first bus bar including the at least one first exposed portion. The at least one first bus bar includes a first end portion and a first additional end portion. In the at least one first bus bar, the first cut surface and the first additional cut surface are disposed between the first end portion and the first additional end portion. The lead block according to any one of claims 1 to 10.

12. The first end portion is exposed from the lead block body. When viewed from the orthogonal direction orthogonal to the longitudinal direction and the arrangement direction, the first additional end portion is disposed inside the contour of the lead block body. The lead block according to claim 11.

13. The first additional end portion is at least partially embedded in the lead block body. The lead block according to claim 11 or 12.

14. The lead block body includes an opening. The first cut surface and the first additional cut surface are disposed in the opening. The lead block according to any one of claims 1 to 13.

15. The length of the first shear plane in the orthogonal direction is longer than the length of the first fracture plane in the orthogonal direction, The length of the first additional shear plane in the orthogonal direction is longer than the length of the first additional fracture plane in the orthogonal direction, The lead block according to any one of claims 1 to 14.

16. A stator, A rotating body rotatably provided around a rotation axis with respect to the stator, The lead block according to any one of claims 1 to 15, A rotary connector device comprising:

17. A molding step of embedding a bus bar plate including a plurality of bus bars and a connecting bar for connecting a plurality of exposed portions of the plurality of bus bars to each other into the lead block body by insert molding so that the plurality of exposed portions are exposed from the lead block body, A cutting step of cutting the connecting bar from the plurality of exposed portions, The plurality of exposed portions each extend in the longitudinal direction and are arranged at intervals in an arrangement direction orthogonal to the longitudinal direction, The plurality of exposed portions include at least one first exposed portion, The at least one first exposed portion includes a first surface and a first additional surface arranged on the back side of the first surface in the arrangement direction, In the cutting step, a first cutting surface having an area smaller than the area of the first surface is formed on the first surface, and a first additional cutting surface having an area smaller than the area of the first additional surface is formed on the first additional surface, The plurality of exposed portions each include a plurality of cable attachment surfaces, The plurality of cable attachment surfaces are arranged so as to face an orthogonal direction orthogonal to the longitudinal direction and the arrangement direction, The plurality of cable attachment surfaces face the electric cable in a state where the electric cable is connected to the plurality of bus bars, The plurality of exposed portions each include a plurality of convex portions, The plurality of convex portions protrude from the plurality of cable attachment surfaces in the orthogonal direction so as to be electrically connected to a plurality of wirings included in the electric cable, respectively, The plurality of exposed portions each include a plurality of back surfaces, The plurality of back surfaces are arranged on the back side of the plurality of cable attachment surfaces in the orthogonal direction, The plurality of exposed portions each include a plurality of concave portions, The plurality of concave portions are respectively arranged on the plurality of back surfaces and on the back side of each of the plurality of convex portions, Of the plurality of convex portions, the convex portion provided on the at least one first exposed portion is disposed between the first cut surface and the first additional cut surface in the arrangement direction when viewed from the orthogonal direction. Of the plurality of concave portions, the concave portion provided on the at least one first exposed portion is disposed between the first cut surface and the first additional cut surface in the arrangement direction when viewed from the orthogonal direction. The first cut surface includes a first shear surface and a first fracture surface. The first fracture surface is adjacent to the first shear surface in the orthogonal direction. The first shear surface is a surface formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in the orthogonal direction. The first fracture surface is a surface formed by breaking after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. The first additional cut surface includes a first additional shear surface and a first additional fracture surface. The first additional fracture surface is adjacent to the first additional shear surface in the orthogonal direction. The first additional shear surface is a surface formed by shearing a material with a punch and a die during shearing, and includes a plurality of ribs extending in the orthogonal direction. The first additional fracture surface is a surface formed by breaking after a part of the material is sheared by a punch and a die during shearing, and includes fine irregularities. When viewed from the arrangement direction, the first shear surface is disposed closer to the convex portion provided on the at least one first exposed portion of the plurality of convex portions than the first fracture surface in the orthogonal direction. When viewed from the arrangement direction, the first additional shear surface is disposed closer to the convex portion provided on the at least one first exposed portion of the plurality of convex portions than the first additional fracture surface in the orthogonal direction. Method for manufacturing a lead block.

18. The molding step includes a step of embedding the bus bar plate into the lead block body by insert molding such that the plurality of exposed portions and at least a part of the connecting bar are disposed in the opening of the lead block body. The method for manufacturing a lead block according to claim 17.

19. The cutting step includes a step of cutting the connecting bar from the plurality of exposed portions through the opening of the lead block body. The method for manufacturing a lead block according to claim 18.

20. The molding process includes a process of embedding the bus bar plate into the lead block body by insert molding so that a part of the connecting bar is embedded in the lead block body. The method for manufacturing a lead block according to any one of claims 17 to 19.

21. Further comprising a pressing process of forming the bus bar plate from a plate containing a conductive material by pressing. The method for manufacturing a lead block according to any one of claims 17 to 20.

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