Manufacturing method for 1-pole terminal block

Abstract

To provide a technique capable of manufacturing plural types of one pole terminal blocks by sharing a metal mold.SOLUTION: A metal mold unit 9 comprises a plurality of metal molds 91, 92, 93, and 94 for constructing a cavity that manufactures a resin part 4 of a one pole terminal block 1A; and a piece 95 that holds a pre-manufactured terminal 2, and is assembled to the metal mold 91. When manufacturing the one pole terminal block 1A, first, the piece 95 is assembled to a concave part 90 of the metal mold 91, and the terminal 2 previously formed, is attached to the piece 95. Also, a collar 3 previously formed is, fitted to a convex part of the metal mold 94. Next, each of the metal molds 91, 92, 93, and 94, is closed and the molten resin is filled to the cavity. Then after a predetermined hardening time was passed, each of the metal molds 91, 92, 93, and 94 is opened, and the one pole terminal block 1A of a finished product is fetched out. The metal mold unit 9 can manufacture plural types of the one pole terminal blocks by replacing the piece 95 with another one.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a terminal block. [Background technology]

[0002] Terminal blocks for connecting wires have a variety of structures, one example of which is shown in Fig. 9 (see Patent Document 1). Terminal block 500 shown in Fig. 9 is fixed to the housing of a traction motor mounted on an automobile, and includes three bus bars 502, two collars 503, and housing 504 that holds them.

[0003] Each bus bar 502 includes a first connection portion 521 and a second connection portion 522. The first connection portion 521 is connected to, for example, a terminal of a traction motor. The second connection portion 522 is connected to, for example, a terminal of an inverter.

[0004] Collar 503 is made of metal and is formed in a cylindrical shape. A bolt for fixing terminal block 500 to the housing of the traction motor is passed through collar 503.

[0005] Housing 504 is made of insulating synthetic resin. Housing 504 is formed by filling a cavity of a mold with molten resin and solidifying the molten resin. Bus bar 502 and collar 503 are set in the cavity of the mold when housing 504 is molded, and are insert-molded into housing 504.

[0006] In addition to the terminal block 500, there are terminal blocks of various shapes to suit the mounting conditions of each vehicle. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Publication No. 2022-52013 Summary of the Invention [Problem to be solved by the invention]

[0008] In order to manufacture the various shapes of terminal blocks described above, it is necessary to create a mold for each product, which poses the problem of increased development time and costs.

[0009] Therefore, an object of the present invention is to provide a technique for manufacturing a plurality of types of single-pole terminal blocks by using a common mold. [Means for solving the problem]

[0010] The present invention is a method for manufacturing a single-pole terminal block having a terminal having a first connection portion formed on one end side and a second connection portion formed on the other end side, and a resin portion that holds the terminal, and is characterized in that a mold unit is used that includes a plurality of molds that form cavities for molding the resin portion, and a piece that holds the pre-molded terminal and is to be incorporated into one of the molds, and the method comprises preparing a plurality of types of terminals and a plurality of types of pieces that hold each terminal, selecting one terminal and one piece from the plurality of types of terminals and the plurality of types of pieces, incorporating the selected piece into the mold, and filling the cavity with molten resin with the one terminal set in the cavity, thereby manufacturing the single-pole terminal block. [Effects of the Invention]

[0011] According to the present invention, a plurality of types of single-pole terminal blocks can be manufactured using a common mold. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a perspective view showing an example of a one-pole terminal block manufactured by a manufacturing method according to one embodiment of the present invention. [Figure 2] 2 is a perspective view of the single-pole terminal block of FIG. 1 as seen from a different angle. [Figure 3] FIG. 10 is a perspective view showing another example of a one-pole terminal block manufactured by a manufacturing method according to one embodiment of the present invention. [Figure 4]FIG. 10 is a perspective view showing yet another example of a one-pole terminal block manufactured by a manufacturing method according to one embodiment of the present invention. [Figure 5] 2 is a schematic diagram of a mold unit for molding a resin portion of the single-pole terminal block of FIG. 1, showing a state in which the mold is closed. FIG. [Figure 6] 6 is a diagram showing a state in which the mold of the mold unit of FIG. 5 is opened. FIG. [Figure 7] 1A and 1B are diagrams showing a terminal block assembly structure in which a one-pole terminal block manufactured by a manufacturing method according to one embodiment of the present invention is attached to an attachment portion, where (a) is a rear view and (b) is a plan view. [Figure 8] 10A and 10B are diagrams showing another terminal block assembly structure in which a one-pole terminal block manufactured by a manufacturing method according to one embodiment of the present invention is attached to an attachment portion, where (a) is a rear view and (b) is a plan view. [Figure 9] FIG. 10 is a perspective view showing a conventional terminal block. DETAILED DESCRIPTION OF THE INVENTION

[0013] A "method for manufacturing a single-pole terminal block" according to one embodiment of the present invention will be described with reference to FIGS.

[0014] 1 and 2, a single-pole terminal block 1A is a component used to connect wires together. This single-pole terminal block 1A includes a single-pole terminal 2 having a first connection portion 21 formed on one end and a second connection portion 22 formed on the other end, a collar 3, and a resin portion 4 that holds the terminal 2 and the collar 3.

[0015] The first connecting portion 21 is formed in a semi-cylindrical shape obtained by dividing a cylinder into two by a plane passing through the center axis of the cylinder, and is provided with a bolt insertion hole 23 .

[0016] The second connecting portion 22 is formed in a cylindrical shape and has a female thread portion 24. The female thread portion 24 is composed of a hole recessed from the other end of the terminal 2 and a spiral thread cut on the inner circumferential surface of the hole.

[0017] The collar 3 is made of metal and is formed in a cylindrical shape. A bolt is passed through the collar 3 to fix the single-pole terminal block 1A to the mounting portion.

[0018] 5 and 6, the resin part 4 is made of insulating synthetic resin and includes a cylindrical terminal holding part 42 and a plate-like collar holding part 43 connected to the outer peripheral surface of the terminal holding part 42. The outer peripheral surface of the terminal holding part 42 is formed with an annular packing mounting groove 44 for mounting an annular packing.

[0019] The terminal 2 is insert-molded into the resin part 4, with the first connection part 21 protruding from one end face of the terminal holding part 42, the second connection part 22 protruding from the other end face of the terminal holding part 42, and the central part being embedded in the terminal holding part 42.

[0020] The collar 3 is insert-molded into the resin part 4. The outer peripheral surface of the collar 3 is covered with a collar holding part 43. The central axis of the collar 3 is parallel to the central axis of the second connecting part 22.

[0021] The mold unit 9 includes a plurality of molds 91, 92, 93, and 94 that form cavities for molding the resin portion 4, and a piece 95 that holds a pre-molded terminal 2 and is fitted into a recess 90 of the mold 91. The piece 95 is formed in a rectangular shape and includes a recess for positioning the first connecting portion 21. The mold 94, which is arranged opposite the mold 91, includes a recess for positioning the second connecting portion 22 and a protrusion for holding a pre-molded collar 3.

[0022] The single-pole terminal block 1A is manufactured by the following method. First, a piece 95 is fitted into the recess 90 of a mold 91, and a pre-formed terminal 2 is attached to the piece 95. A pre-formed collar 3 is attached to the protrusion of the mold 94. Next, the molds 91, 92, 93, and 94 are closed as shown in FIG. 5. By closing the molds 91, 92, 93, and 94 in this manner, a cavity is formed, into which the terminal 2 and collar 3 are set. Next, the cavity is filled with molten resin. After a predetermined curing time has passed, the molds 91, 92, 93, and 94 are opened, and the completed single-pole terminal block 1A is removed.

[0023] The die unit 9 described above can manufacture the single-pole terminal block 1B shown in FIG. 3, the single-pole terminal block 1C shown in FIG. 4, and the like, by replacing the piece 95 with another one.

[0024] The single-pole terminal block 1B has a different configuration from the single-pole terminal block 1A in the orientation of the first connection portion 21 relative to the collar 3, i.e., the orientation of the bolt insertion hole 23, but otherwise has the same configuration as the single-pole terminal block 1A. The terminal 2 of the single-pole terminal block 1B and the terminal 2 of the single-pole terminal block 1A are the same part, and the specifications are changed by rotating the orientation by 90 degrees using a bridge when setting them in the mold unit 9.

[0025] The single-pole terminal block 1C has the same configuration as the single-pole terminal block 1A, except that a terminal 102 is used instead of the terminal 2. The first connection portion 121 of the terminal 102 is longer than the first connection portion 21 of the terminal 2, and the position of the bolt insertion hole 23 differs from that of the single-pole terminal block 1A.

[0026] When manufacturing the single-pole terminal block 1B, the above-mentioned mold unit 9 is used, a piece corresponding to the terminal 2 of the single-pole terminal block 1B is inserted into the recess 90 of the mold 91, the terminal 2 is attached to this piece, and then the single-pole terminal block 1B is manufactured using the same procedure as when manufacturing the single-pole terminal block 1A.

[0027] When manufacturing the single-pole terminal block 1C, the above-mentioned mold unit 9 is used, a piece corresponding to the terminal 102 of the single-pole terminal block 1C is inserted into the recess 90 of the mold 91, the terminal 102 is attached to this piece, and then the single-pole terminal block 1C is manufactured using the same procedure as when manufacturing the single-pole terminal block 1A.

[0028] In this way, in this example, by sharing the molds 91, 92, 93, and 94 and changing the pieces and insert parts, it is possible to manufacture a plurality of types of single-pole terminal blocks 1A, 1B, and 1C.

[0029] The single-pole terminal block obtained by the above-described manufacturing method is attached to a mounting portion as shown in, for example, FIGS.

[0030] 7(a) and 7(b) shows a terminal block assembly structure 7 in which three 1-pole terminal blocks 1A, 1D, and 1E with different specifications are attached to an attachment portion 8. The 1-pole terminal blocks 1A, 1D, and 1E use the same terminals 2 and collars 3, and have the same configuration except that the orientation of the bolt insertion holes 23 relative to the collars 3 is different. All of these are manufactured using the same molds 91, 92, 93, and 94 described above.

[0031] Mounting portion 8 is the housing of an inverter mounted on an automobile. Mounting portion 8 is formed with three insertion holes 82 through which terminal holding portions 42 of single-pole terminal blocks 1A, 1D, and 1E are inserted, and three bolt insertion holes 83 through which bolts that have passed through collars 3 of single-pole terminal blocks 1A, 1D, and 1E are passed.

[0032] Each of the single-pole terminal blocks 1A, 1D, and 1E is inserted into the corresponding insertion hole 82, a bolt is inserted into each collar 3 and each bolt insertion hole 83, and a nut is screwed onto the bolt, thereby fixing each of the single-pole terminal blocks 1A, 1D, and 1E to the mounting portion 8. In addition, the space between the insertion hole 82 and the terminal holding portion 42 is sealed by a packing attached to the packing mounting groove 44 of each of the single-pole terminal blocks 1A, 1D, and 1E.

[0033] 7(b), the first connection portions 21 of the single-pole terminal blocks 1A, 1D, 1E are positioned on one side of the mounting portion 8, i.e., inside the housing. The first connection portions 21 are overlapped with the terminals of the inverter and are fastened together by a bolt inserted into the bolt insertion hole 23 and a nut threaded onto the bolt.

[0034] 7(b), the second connection portions 22 of the single-pole terminal blocks 1A, 1D, and 1E are positioned on the other side of the mounting portion 8, i.e., on the outside of the housing. Round terminals connected to the ends of electric wires are placed over these second connection portions 22, and the second connection portions 22 are fastened together with the round terminals by bolts threaded into the female thread portions 24.

[0035] Such a terminal block assembly structure 7 uses unconnected single-pole terminal blocks 1A, 1D, and 1E, and can therefore flexibly accommodate changes in the position of the bolt insertion hole 83 in the mounting portion 8, changes in the pitch between the terminals 2, changes in the number of poles of the terminals 2, etc.

[0036] 8(a) and 8(b) shows a terminal block assembly structure 107 in which four 1-pole terminal blocks 1D of the same configuration are attached to an attachment portion 108. Like the terminal block assembly structure 7, this terminal block assembly structure 107 uses unconnected 1-pole terminal blocks 1D, and therefore can flexibly accommodate changes in the position of the bolt insertion holes in the attachment portion 108, changes in the pitch between the terminals 2, changes in the number of poles of the terminals 2, etc.

[0037] The above-described embodiment merely shows a typical form of the present invention, and the present invention is not limited to this embodiment. In other words, the present invention can be implemented with various modifications within the scope of the gist of the present invention. As long as such modifications still include the configuration of the present invention, they are of course included in the scope of the present invention. [Explanation of symbols]

[0038] 1A,1B,1C,1D,1E 1 pole terminal block 2,102 terminals 3 colors 4 Resin part 9 Mold Unit 91, 92, 93, 94 Molds 95 pieces

Claims

1. A method for manufacturing a one-pole terminal block including a terminal having a first connection portion formed on one end side and a second connection portion formed on the other end side, and a resin portion that holds the terminal, a mold unit including a plurality of molds each forming a cavity for molding the resin portion, and a piece for holding the terminal molded in advance and being incorporated into one of the molds; A plurality of types of terminals and a plurality of types of pieces for holding the respective terminals are prepared, One terminal and one piece are selected from a plurality of types of terminals and a plurality of types of pieces, the selected piece is incorporated into the mold, and the cavity is filled with molten resin with the one terminal set in the cavity, thereby manufacturing the one-pole terminal block. A method for manufacturing a one-pole terminal block.

2. The first connection portion has a bolt insertion hole, and the positions or orientations of the bolt insertion holes of the plurality of types of terminals are different from each other.

2. The method for manufacturing a one-pole terminal block according to claim 1.

3. the one-pole terminal block includes a cylindrical collar held by the resin portion, The terminal and the collar are set in the cavity, and the cavity is filled with molten resin to manufacture the one-pole terminal block.

2. The method for manufacturing a one-pole terminal block according to claim 1.

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