Circuit components and electrical junction boxes

Abstract

To provide a circuit structure that can prevent movement and deformation of control terminals in molding a resin-made holding member.SOLUTION: A circuit structure comprises: a plurality of electronic components; a plurality of control terminals electrically connected with the plurality of electronic components; and a holding member that has insulating properties and holds the plurality of control terminals. The control terminals are insertion articles that are integral with the resin-made holding member. The control terminal has, in part thereof, an exposed face that is exposed from the holding member, a contact face that is a surface on the opposite side of the exposed face and in contact with the holding member, a first side face that is located between the exposed face and the contact face, and a second side face that is located between the exposed face and the contact face. A first space part is formed on the lateral side of the first side face, and a second space part is formed on the lateral side of the second side face.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a circuit structure and an electrical connection box.

Background Art

[0002] Patent Document 1 discloses a circuit structure including a control board, a plurality of switching elements that operate based on signals from the control board, and a bus bar that constitutes a power circuit. The switching elements are connected to the bus bar by solder.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As a component of the power circuit, the circuit structure further includes a plurality of control terminals in addition to the bus bar. The control terminals are electrically connected to electronic components such as switching elements, and signals from the control board are transmitted to the electronic components through the control terminals. The circuit structure further includes a holding member having insulation and holding the control terminals. The holding member is made of a resin having thermoplasticity and is formed by injection molding. The control terminals may be installed as insert parts in the injection mold, and the holding member may be formed. FIG. 9 is a cross-sectional view showing a part of an injection mold 90 and a control terminal 91.

[0005] By making surface contact between a portion of the control terminal 91 and the mold 90, the control terminal 91 can be positioned relative to the mold 90. However, during injection molding, the injection pressure of the molten resin 99 causes some of the resin 99 to flow between the mold 90 and the control terminal 91, potentially causing the control terminal 91 to tilt or deform within the mold 90, as shown in Figure 9. This could lead to the control terminal 91 coming into contact with another conductor 92, such as a busbar integrated with the holding member 95, potentially causing a short circuit.

[0006] Therefore, the object of this disclosure is to provide a circuit configuration that can suppress movement or deformation of control terminals during the molding of a resin-based holding member. [Means for solving the problem]

[0007] A circuit configuration according to one aspect of the present disclosure comprises a plurality of electronic components, a plurality of control terminals electrically connected to the plurality of electronic components, and a retaining member having insulating properties and holding the plurality of control terminals, wherein the control terminals are insert parts that are integral with the retaining member, which is made of resin, and the control terminals have, in part, an exposed surface that is exposed from the retaining member, a contact surface on the opposite side of the exposed surface that is in contact with the retaining member, a first side surface located between the exposed surface and the contact surface, and a second side surface located between the exposed surface and the contact surface, wherein a first space is formed on the side of the first side surface, and a second space is formed on the side of the second side surface.

[0008] An electrical junction box according to one aspect of the present disclosure comprises the circuit component and a cover that covers the circuit component. [Effects of the Invention]

[0009] According to this disclosure, when molding a resin-based retaining member, it is possible to suppress the movement or deformation of the control terminals due to the injection pressure of the molten resin. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a perspective view of an electrical junction box equipped with the circuit configuration according to this embodiment. [Figure 2] Figure 2 is a perspective view of the circuit configuration, seen from the opposite side compared to Figure 1. [Figure 3] Figure 3 is an exploded view of the circuit configuration with the control board removed. [Figure 4] Figure 4 is a cross-sectional view showing the control terminals and a portion of the retaining member. [Figure 5] Figure 5 is a perspective view showing the control terminals and a portion of the retaining member. [Figure 6] Figure 6 is a cross-sectional view taken along the line V in Figure 5. [Figure 7] Figure 7 is a cross-sectional view showing a part of the mold used to form a resin-based retaining member. [Figure 8] Figure 8 is a cross-sectional view showing the process of molding a retaining member with control terminals as insert parts. [Figure 9] Figure 9 is a cross-sectional view showing a portion of the injection molding die and control terminals. [Modes for carrying out the invention]

[0011] <Summary of the embodiments of this disclosure> The embodiments of this disclosure are outlined below. (1) The circuit configuration of this embodiment comprises a plurality of electronic components, a plurality of control terminals electrically connected to the plurality of electronic components, and a retaining member having insulating properties and holding the plurality of control terminals, wherein the control terminals are insert parts that are integrated with the retaining member, which is made of resin, and the control terminals have, in part, an exposed surface that is exposed from the retaining member, a contact surface on the opposite side of the exposed surface that is in contact with the retaining member, a first side surface located between the exposed surface and the contact surface, and a second side surface located between the exposed surface and the contact surface, wherein a first space is formed on the side of the first side surface, and a second space is formed on the side of the second side surface.

[0012] In the circuit configuration of this embodiment, the control terminal is an insert that is integrated with a resin-made retaining member. During the molding of the retaining member, molten resin is filled near the control terminal. A portion of the contact surface of the control terminal comes into contact with the retaining member, and a portion of it becomes integrated with the retaining member. The exposed portion of the control terminal is formed by contact with the molding die. In this mold, protrusions are provided on both sides of a portion of the control terminal, so that after molding, a first space is formed on the side of the first side surface and a second space is formed on the side of the second side surface. By providing protrusions on both sides of a portion of the control terminal in this way, molten resin is less likely to penetrate between the exposed surface and the mold. Therefore, during the molding of the holding member, it is possible to suppress the movement or deformation of the control terminal due to the injection pressure of the molten resin.

[0013] (2) Preferably, the retaining member has a thick portion that contacts the contact surface, a first thin film made of resin that covers the first side surface, and a second thin film made of resin that covers the second side surface, wherein the side surface of the first thin film is exposed in the first space, and the side surface of the second thin film is exposed in the second space. With this configuration, the control terminal is joined to the resin retaining member not only at the contact surface but also on the first and second sides, making it difficult for the control terminal to detach from the retaining member.

[0014] For molding the retaining member, a pair of the aforementioned protrusions are provided in the mold, with a portion of the control terminal interposed between them. Manufacturing tolerances are possible in the first dimension between the pair of protrusions and the second dimension between the first and second sides of the control terminal. It is preferable to set the first dimension slightly larger than the second dimension in order to interpose a portion of the control terminal between the pair of protrusions. This creates a minute gap between the protrusions and the control terminal, into which molten resin may flow. However, the minute gap is thin, making it difficult for molten resin to enter. Therefore, it is difficult for the resin to penetrate between the mold and the control terminal through the minute gap. The molten resin that does enter the minute gap hardens to form the first thin film portion and the second thin film portion.

[0015] (3) Preferably, the circuit component further includes a control board that outputs a signal to the electronic component through the control terminal. The control terminal includes a first terminal body portion connected to the control board, a pad portion that is electrically connected to the first terminal body portion and is provided along the holding member and serves as a part having the exposed surface and the contact surface, and a second terminal body portion that is electrically connected to the pad portion and the electronic component. According to this configuration, before connecting the control board to the first terminal body portion of the control terminal, by bringing the probe of a tester for electrical inspection into contact with each pad portion, it becomes possible to perform electrical inspection on each of the plurality of electronic components. In the pad portion, since the surface on the opposite side of the exposed surface (contact surface) contacts the holding member, deformation of the pad portion is prevented even when the probe of the tester contacts the exposed surface.

[0016] (4) Preferably, the pad portion is provided to extend from the base portion of the first terminal body portion, and the holding member has a first embedded portion that embeds the boundary region between the first terminal body portion and the pad portion among the control terminals. In this case, it becomes possible to prevent the first terminal body portion from lifting from the holding member by the embedded portion.

[0017] (5) Preferably, the pad portion is provided to extend from the base portion of the second terminal body portion, and the holding member has a second embedded portion that embeds the boundary region between the pad portion and the second terminal body portion. The second embedded portion has a resin surface that constitutes the same surface as the exposed surface of the pad portion. In this case, since the exposed surface of the pad portion and the resin surface of the second embedded portion are the same surface, molding by a mold is easy in the portion of the holding member that covers the space between the pad portion and the second terminal body portion. Also, the configuration of the mold is simplified.

[0018] (6) Preferably, the second terminal body portion has a terminal surface that is exposed from the holding member and is connected to the electronic component, and a second exposed surface that is on the opposite side of the terminal surface and is exposed from the holding member. When the retaining member is made of resin and is formed by injection molding using a mold, the metal member that will become the second terminal body can be positioned by partially contacting it with the mold. However, by contacting the mold from both sides so as to sandwich that part, the terminal surface and the second exposed surface are formed. By contacting the mold from both sides in this way, the positioning accuracy of the second terminal body, especially the terminal surface, is improved. As a result, connection failures between the terminal surface and electronic components are suppressed.

[0019] (7) The electrical junction box of this embodiment comprises a circuit component described in any one of (1) to (6) above, and a cover that covers the circuit component. According to the electrical connection box of this embodiment, when molding the resin-based retaining member, it is possible to suppress the movement or deformation of the control terminals due to the injection pressure of the molten resin.

[0020] <Details of the embodiments of this disclosure> The embodiments of this disclosure will be described in detail below with reference to the drawings. At least some of the embodiments described below may be combined in any way.

[0021] [Regarding the electrical junction box 10] Figure 1 is a perspective view of an electrical junction box 10 equipped with a circuit component 11 according to this embodiment. The electrical junction box 10 can be mounted on various devices, but the electrical junction box 10 of this embodiment is mounted on an automobile. Specifically, the electrical junction box 10 is interposed in the middle of a wiring path connecting a first in-vehicle device (not shown) and a second in-vehicle device. The electrical junction box 10 comprises a circuit component 11 and a cover 12 that covers the circuit component 11. The cover 12 is made of metal, for example (aluminum or aluminum alloy), and has a heat dissipation function to release the heat generated in the circuit component 11. The electrical junction box 10 may further include other units attached to the circuit component 11 on the opposite side of the cover 12, although these are not shown.

[0022] [Regarding circuit component 11] Figure 2 is a perspective view of the circuit assembly 11 as seen from the opposite side of Figure 1. Figure 2 shows the state with the cover 12 removed. In Figures 1 and 2, the circuit assembly 11 comprises a plurality of electronic components 15, a plurality of control terminals 16, a single holding member 14, and a single control board 13. Figure 3 is an exploded view of the circuit assembly 11 with the control board 13 removed. The circuit assembly 11 further comprises a plurality of conductive plates 17. The power circuit of the circuit assembly 11 is formed by the plurality of conductive plates 17 and the plurality of control terminals 16.

[0023] In this embodiment, the circuit configuration 11 comprises three (three) conductive plates 17 (see Figure 1) and eight control terminals 16 (see Figure 3). The number of control terminals 16 and electronic components 15 are equal, and each control terminal 16 is connected to one electronic component 15 in a one-to-one relationship. The number of conductive plates 17, control terminals 16, electronic components 15, and control board 13 is arbitrary and can be changed.

[0024] The electronic component 15 is a semiconductor relay, such as a field-effect transistor (FET). In the following description, we will describe the case where the electronic component 15 is a field-effect transistor, and the field-effect transistor will be referred to as "FET". The FET 15 has multiple terminals. As shown in the enlarged view of Figure 1, the FET 15 has multiple terminals, namely a source terminal (first terminal) 15a, a gate terminal (second terminal) 15b, and a drain terminal (third terminal) 15c. Each terminal is mechanically and electrically connected to a conductive plate 17 or a control terminal 16 by solder or the like.

[0025] The conductive plate 17 is manufactured by press-forming a metal plate into a predetermined shape. The conductive plate 17 is a metal plate and is also called a busbar. Preferably, the conductive plate 17 is made of copper, such as pure copper or a copper alloy. The entire conductive plate 17 is a conductor, and no wiring patterns like those found on typical printed circuit boards are formed on the conductive plate 17. As shown in Figure 1, the circuit configuration 11 has a first conductive plate 17-1, a second conductive plate 17-2, and a third conductive plate 17-3.

[0026] The control terminal 16 is manufactured by press-forming a metal wire into a predetermined shape. The control terminal 16 is a metal terminal. Preferably, the control terminal 16 is made of copper, such as pure copper or a copper alloy. Figure 4 is a cross-sectional view showing the control terminal 16 and a part of the retaining member 14. The control terminal 16 has a bent shape and has a first terminal body portion 31, a pad portion 33, and a second terminal body portion 32. Details of each part of the control terminal 16 will be described later.

[0027] In Figure 2, the control board 13 is a substantially rectangular insulating substrate, and its first surface 13a has a control circuit section 27. The control circuit section 27 has the function of outputting a signal to the FET 15 through the control terminal 16. The FET 15 operates based on this signal. The control circuit section 27 has an integrated circuit including a switching element and a diode as second electronic components for making the FET 15 function. The control circuit section 27 includes a wiring pattern 29 for electrically connecting the second electronic components to the control terminal 16.

[0028] A through-hole 18 is formed in the control board 13, through which a portion of the control terminal 16 passes (see Figure 3). By filling the through-hole 18 with a conductive material, the control circuit unit 27 and a portion of the first terminal body 31 of the control terminal 16 are mechanically and electrically connected. Before the control board 13 is connected to the control terminal 16 (see Figure 3), the multiple control terminals 16 are not electrically connected to each other (non-energized).

[0029] The retaining member 14 is made of thermoplastic resin and is molded by injection molding. In this embodiment, as will be explained later, the retaining member 14 is manufactured by insert molding, in which the control terminal 16 and the conductive plate 17 are placed in an injection molding die 60 (see Figure 7). As a result, a portion of the control terminal 16 and a portion of the conductive plate 17 are embedded in the retaining member 14, and the control terminal 16, conductive plate 17, and retaining member 14 are integrated. The control terminal 16 and the conductive plate 17 are insert parts that become integrated with the resin retaining member 14.

[0030] The retaining member 14 is made of, for example, PPS (polyphenylene sulfide), PBT (polybutylene terephthalate), nylon, PP (polypropylene), or PE (polyethylene), and has insulating properties. The retaining member 14 holds eight control terminals 16 and three conductive plates 17, and functions as a case for the circuit assembly 11. As shown in Figure 3, the retaining member 14 has a housing space 30 that opens towards the control board 13. The first terminal body portion 31 and the pad portion 33 of the control terminal 16 are provided in the housing space 30. The control board 13 is attached to the first terminal body portion 31 so as to close the housing space 30.

[0031] The holding member 14 has a plate-shaped central base portion 19 and a frame portion 20 surrounding it. As shown in Figure 1, the main body portion 22 of the conductive plate 17 on which the FET 15 is mounted is provided on the base portion 19. The main body portions 22 of the three conductive plates 17 are arranged in a planar manner on the base portion 19 without overlapping. The three conductive plates 17 are provided separately and are in a non-contact state. The three conductive plates 17 and the control terminal 16 are provided separately and are in a non-contact state.

[0032] In this embodiment (see Figure 1), the source terminal 15a of the FET 15 is connected to the third conductive plate 17-3 located in the center. The drain terminal 15c of the FET 15 is connected to either the first conductive plate 17-1 or the second conductive plate 17-2. As shown in the enlarged view of Figure 1, a through-hole 28 is provided in the central third conductive plate 17-3, and a part of the second terminal body 32 of the control terminal 16 is exposed through the hole 28. The gate terminal 15b of the FET 15 is connected to the part of the second terminal body 32 exposed through the hole 28. As a result, the gate terminal 15b of the FET 15 and the control terminal 16 are electrically connected.

[0033] Mounting holes 39 for fixing the cover 12 are provided in the frame portion 20. The end 21A of the first conductive plate 17-1 and the end 21B of the second conductive plate 17-2 protrude outward from the frame portion 20. Cables and the like (not shown) are connected to these ends 21A and 21B.

[0034] [Regarding control terminal 16] Figure 5 is a perspective view showing a control terminal 16 and a part of the retaining member 14. As described above, the control terminal 16 has a bent shape and has a first terminal body portion 31, a pad portion 33, and a second terminal body portion 32. In this embodiment, the first terminal body portion 31, the pad portion 33, and the second terminal body portion 32 are formed by bending the same metal member. That is, the first terminal body portion 31 is made of a part of a long, narrow plate-shaped metal member, the pad portion 33 is made of the other part of the metal member, and the second terminal body portion 32 is made of a part of the metal member that is different from the aforementioned part and the other part.

[0035] The first terminal body portion 31, the pad portion 33, and the second terminal body portion 32 each have a rectangular shape in cross-section (see Figure 6). Figure 6 is a cross-sectional view taken along the V arrow in Figure 5. As shown in Figure 5, the first terminal body portion 31 has a straight shape. The first terminal body portion 31 and the pad portion 33 are bent at a right angle. The pad portion 33 extends from the base portion 31a of the first terminal body portion 31 and has a straight shape. The second terminal body portion 32 and the pad portion 33 are bent at a right angle. The pad portion 33 extends from the base portion 32a of the second terminal body portion 32 and has a straight shape. The second terminal body portion 32 has a U shape.

[0036] [First terminal body part 31] The first terminal body 31 is connected to the control board 13 (see Figures 2 and 3). The tip of the first terminal body 31 is inserted through the through hole 18 of the control board 13 and is electrically connected to the wiring pattern 29 provided on the control board 13. As described above, the control circuit unit 27 of the control board 13 outputs a signal to the FET 15 through the control terminal 16. The signal is output from the control board 13 to the first terminal body 31. This signal is then supplied from the first terminal body 31 to the gate terminal 15b of the FET 15 through the pad unit 33 and the second terminal body 32 (see Figure 5).

[0037] The first terminal body portion 31 has an elongated plate shape. The first terminal body portion 31 protrudes from the first embedded portion 23, which is part of the retaining member 14. The portion of the first terminal body portion 31 that protrudes from the first embedded portion 23 is exposed as a whole. In other words, as shown in Figure 5, the first terminal body portion 31 has a first surface 41 on one side in its thickness direction that is exposed from the retaining member 14, and a second surface 42 on the opposite side of the first surface 41 that is also exposed from the retaining member 14. Furthermore, the side surfaces 43 on both sides located between the first surface 41 and the second surface 42 are also exposed surfaces. Before the control board 13 is connected, the first terminal body portion 31 is in the form of a cantilever beam extending from the first embedded portion 23.

[0038] [Pad section 33] The pad portion 33 extends from the base portion 31a of the first terminal body portion 31 and is integral with the first terminal body portion 31 and electrically connected to it. The pad portion 33 has an elongated plate shape. As shown in Figure 5, the pad portion 33 is provided along the retaining member 14 and is exposed from a part of the retaining member 14. The pad portion 33 is provided along the thickened portion 50 of the retaining member 14.

[0039] As shown in Figures 4 and 5, the pad portion 33 has a first exposed surface 34 that is exposed from the retaining member 14 and a contact surface 35 on the opposite side of the first exposed surface 34. The first exposed surface 34 has an elongated shape. Specifically, for example, the first exposed surface 34 is an elongated rectangle and has a first side 34a and a second side 34b that is more than twice as long as the first side 34a. The contact surface 35 is in contact with the retaining member 14 throughout its entirety and is a non-exposed surface that is not exposed from the retaining member 14. As described above, the retaining member 14 is manufactured by insert molding, which is performed by installing the control terminal 16 in an injection molding die 60 (see Figure 7). Therefore, the pad portion 33 is joined to a part of the retaining member 14 at the contact surface 35.

[0040] As shown in Figure 6, the pad portion 33 has a first exposed surface 34 and a contact surface 35, as well as a first side surface 36 and a second side surface 37. The first side surface 36 is the surface located between the first exposed surface 34 and the contact surface 35. The second side surface 37 is the surface opposite to the first side surface 36 and is located between the first exposed surface 34 and the contact surface 35.

[0041] In this embodiment, the first side surface 36 is covered by a first thin film portion 51 made of resin, and the second side surface 37 is covered by a second thin film portion 52 made of resin. The first thin film portion 51 and the second thin film portion 52 are each part of the retaining member 14. The first thin film portion 51 and the second thin film portion 52 are each film-like resin portions and are thin compared to the thick portion 50 that the contact surface 35 is in contact with. A first space portion K1 is formed on the side of the first side surface 36 covered by the first thin film portion 51. A second space portion K2 is formed on the side of the second side surface 37 covered by the second thin film portion 52.

[0042] The side surface 51a of the first thin film portion 51 is exposed in the first space K1. The side surface 52a of the second thin film portion 52 is exposed in the second space K2. The retaining member 14 has a first protrusion 57 that rises from the thick portion 50. The first protrusion 57 and the pad portion 33 are provided separately. The space formed between the first protrusion 57 and the pad portion 33 (first thin portion 51) is the first space K1. The retaining member 14 has a second protrusion 58 that rises from the thick portion 50. The second protrusion 58 and the pad portion 33 are provided separately. The space formed between the second protrusion 58 and the pad portion 33 (second thin portion 52) is the second space K2.

[0043] [Second terminal body part 32] As shown in Figure 5, the second terminal body portion 32 is provided in a continuous manner with the pad portion 33. The second terminal body portion 32 has a shape (U-shape) formed by bending a long, narrow plate. The base portion 32a of the second terminal body portion 32 is connected to the pad portion 33, and the second terminal body portion 32 is electrically connected to the pad portion 33. The second terminal body portion 32 has a first piece portion 46 that is continuous with the pad portion 33, a second piece portion 47 that is spaced apart from and parallel to the first piece portion 46, and an intermediate piece portion 48 that connects the first piece portion 46 and the second piece portion 47. The second piece portion 47 is exposed from the retaining member 14, and the intermediate piece portion 48 has a surface that is exposed from the retaining member 14.

[0044] The gate terminal 15b of the FET 15 is connected to the intermediate piece 48 by solder or the like. This connects the second terminal body 32 to the FET 15 both mechanically and electrically. The second terminal body 32 has a terminal surface 45 exposed from the retaining member 14 on its intermediate piece 48, and a second exposed surface 44 on the opposite side of the terminal surface 45, also exposed from the retaining member 14. The FET 15 (gate terminal 15b) is connected to the terminal surface 45.

[0045] [Regarding the retaining member 14] Figure 7 is a cross-sectional view showing a part of the mold 60 used to mold the resin-made retaining member 14. The portion of the mold 60 shown in Figure 7 provides the cross-sectional structure of the circuit component 11 shown in Figure 6. In the circuit component 11 of this embodiment, the control terminals 16 and the conductive plate 17 are insert parts that are integrated with the resin-made retaining member 14. During the molding of the retaining member 14, molten resin is filled into the cavity 60a formed in the mold 60. The molten resin is also filled near the control terminals 16. As a result of this molding, the contact surface 35 of the pad portion 33 of the control terminal 16 comes into contact with the retaining member 14 (see Figure 6), and the pad portion 33 becomes integrated with the retaining member 14. In the cavity 60a, molten resin is also filled near the conductive plate 17. As a result, the conductive plate 17 comes into contact with the retaining member 14 (see Figure 6), and becomes integrated with the retaining member 14.

[0046] As shown in Figure 7, the exposed surface 34 of the pad portion 33 is in contact with the mold 60 during molding and is formed when it is separated from the mold 60 during demolding. In the mold 60, protrusions 61, 61 are provided on both sides of the pad portion 33. These protrusions 61, 61 form a first space K1 on the side of the first side surface 36 of the pad portion 33 and a second space K2 on the side of the second side surface 37 after molding (see Figure 6). The protrusions 61 constitute a part of the mold 60.

[0047] The cross-sectional shapes of the first space K1 and the second space K2 coincide with the cross-sectional shapes of the protrusions 61, 61. In this way, by providing the protrusions 61 on both sides of the pad portion 33 in the mold 60, it becomes difficult for the molten resin to penetrate between the exposed surface 34 and the mold 60. In other words, when the molten resin flows and fills the cavity 60a, the protrusions 61 function as a barrier that hides the pad portion 33, making it difficult for the resin flow to affect the pad portion 33.

[0048] Therefore, during the molding of the retaining member 14, it is possible to suppress the movement or deformation of the control terminal 16, including the pad portion 33, in the cavity 60a due to the injection pressure of the molten resin. As a result, it is possible to prevent the control terminal 16 (pad portion 33) and the conductive plate 17 from coming into contact (short-circuiting).

[0049] As shown in Figure 6, after molding, the retaining member 14 has a thick resin portion 50 that contacts the contact surface 35 of the pad portion 33, a first thin resin portion 51 that covers the first side surface 36, and a second thin resin portion 52 that covers the second side surface 37. The first thin resin portion 51 and the second thin resin portion 52 are sufficiently thin compared to the thick resin portion 50. The side surface 51a of the first thin resin portion 51 is exposed in the first space K1. The side surface 52a of the second thin resin portion 52 is exposed in the second space K2. The pad portion 33 is joined to the retaining member 14 not only at the contact surface 35, but also at the first side surface 36 and the second side surface 37. As a result, the control terminal 16, including the pad portion 33, is difficult to detach from the retaining member 14.

[0050] As described above (see Figure 7), a pair of protrusions 61, 61 are provided in the mold 60 for molding the holding member 14. A part of the control terminal 16 (pad portion 33) is interposed between these protrusions 61, 61. Manufacturing tolerances are possible in the first dimension L1 between the pair of protrusions 61, and in the second dimension L2 between the first side surface 36 and the second side surface 37 of the control terminal 16. It is preferable to set the first dimension L1 slightly larger than the second dimension L2 in order to interpose the pad portion 33 between the pair of protrusions 61, 61. In this case, a minute gap e is formed between the protrusions 61 and the pad portion 33. Molten resin may flow into this minute gap e.

[0051] However, the minute gap e is thin, making it difficult for molten resin to enter it. Therefore, it is difficult for molten resin to penetrate between the mold 60 and the first exposed surface 34 of the pad portion 33 through the minute gap e. When the molten resin that has managed to enter the minute gap e hardens, the hardened portion becomes the first thin film portion 51 and the second thin film portion 52.

[0052] The gap size of the minute gap e is preferably set to a value that makes it difficult for molten resin to enter. As a result, the corner (edge) 38 formed between the first exposed surface 34 and the first side surface 36 (or second side surface 37) in the pad portion 33 is exposed. It is preferable that the corner 38 is not covered by the first thin film portion 51 or the second thin film portion 52. With respect to the thick portion 50, the first thin film portion 51 and the second thin film portion 52 are lower than the first exposed surface 34.

[0053] As shown in Figures 4 and 5, the entire first bent portion 25 between the first terminal body 31 and the pad portion 33 is embedded by a first embedded portion 23 made of resin. The first embedded portion 23 is part of the retaining member 14. In other words, the retaining member 14 has a first embedded portion 23 that embeds the first boundary region J1 between the first terminal body 31 and the pad portion 33 of the control terminal 16. Part of the pad portion 33 and most of the first terminal body 31 are exposed from the retaining member 14, but the first embedded portion 23 makes it possible to prevent the first terminal body 31 from lifting up from the retaining member 14.

[0054] The second bend portion 26 between the second terminal body portion 32 and the pad portion 33 is embedded by a second embedded portion 24 made of resin. The second embedded portion 24 is another part of the retaining member 14. In other words, the retaining member 14 has a second embedded portion 24 that embeds the second boundary region J2 between the pad portion 33 and the second terminal body portion 32 of the control terminal 16. The second embedded portion 24 makes it possible to prevent the second terminal body portion 32 and the pad portion 33 from lifting up from the retaining member 14.

[0055] With respect to the direction perpendicular to the longitudinal direction of the pad portion 33, as described above (see Figure 6), the first space portion K1 and the second space portion K2 are formed on both sides of the pad portion 33 via the first thin film portion 51 and the second thin film portion 52. In other words, the retaining member 14 is missing on both sides of the pad portion 33. In contrast, as shown in Figure 5, with respect to the longitudinal direction of the pad portion 33, the side of the pad portion 33 facing the first terminal body portion 31 is provided with a first embedded portion 23, which is embedded with resin. With respect to the longitudinal direction of the pad portion 33, the side of the pad portion 33 facing the second terminal body portion 32 is provided with a second embedded portion 24, which is embedded with resin.

[0056] The second bent portion 26 between the pad portion 33 and the second terminal body portion 32 is embedded in the second embedded portion 24. The second embedded portion 24 has a resin surface 54 that is on the same plane as the first exposed surface 34 of the pad portion 33. Since the first exposed surface 34 of the pad portion 33 and the resin surface 54 of the second embedded portion 24 are on the same plane, the portion of the holding member 14 that covers the area between the pad portion 33 and the second terminal body portion 32 (base portion 32a) can be easily molded using the mold 60 (see Figure 8). In addition, the structure of the mold 60 is simplified.

[0057] Both sides of the intermediate piece 48, which is part of the second terminal body 32, are exposed from the holding member 14. In other words, the second terminal body 32 has a terminal surface 45 on the intermediate piece 48 that is exposed from the holding member 14 and connected to the FET 15, and a second exposed surface 44 on the opposite side of the terminal surface 45 that is also exposed from the holding member 14.

[0058] Figure 8 is a cross-sectional view showing the molding of the retaining member 14 with the control terminal 16 as an insert. Figure 8 shows the second terminal body portion 32 and its surrounding area of ​​the control terminal 16 together with the mold 60. As described above, the retaining member 14 is made of resin and is molded by injection molding using the mold 60. The metal member that will become the second terminal body portion 32 can be positioned by partially contacting the mold 60. As shown in Figure 8, the mold 60 is made to contact a part 32b of the second terminal body portion 32 by sandwiching it from both sides. The terminal surface 45 and the second exposed surface 44 are formed on the portion of the second terminal body portion 32 that is in contact with the mold 60.

[0059] By bringing the first portion 60b and the second portion 60c of the mold 60 into contact with a portion 32b of the second terminal body 32 from both sides, the positioning accuracy of the second terminal body 32, particularly the terminal surface 45, is improved. As a result, poor connections between the terminal surface 45 and the FET 15 (gate terminal 15b) are suppressed.

[0060] [Regarding the electrical testing of electronic component (FET) 15] During the manufacturing process of the circuit component 11, an electrical test is performed to confirm that there are no connection problems with the FET 15. In the case of the circuit component 11 of this embodiment, as shown in Figure 3, each pad portion 33 of the control terminal 16 is housed in the housing space 30 of the holding member 14, but each pad portion 33 is exposed to the outside before the control board 13 is connected to the control terminal 16. Therefore, before connecting the control board 13 to the control terminal 16, an electrical test of each of the multiple FETs 15 is performed by touching the probe of a tester (not shown) to each pad portion 33.

[0061] To this end, the control terminal 16 has a pad portion 33 and a second terminal body portion 32 which is electrically connected to the pad portion 33 and the FET 15. The pad portion 33 is provided along a resin retaining member 14 and is exposed from a part of the retaining member 14. By contacting the probe of a tester to each pad portion 33, it is possible to perform electrical testing on each of the multiple FETs 15. Therefore, it is not necessary to provide a test circuit component 99 (see Figure 9) on the control board 13 as in the conventional method. The omission of the test circuit component 99 makes it possible to reduce the cost of the circuit configuration 11 and to miniaturize the control board 13.

[0062] In this embodiment, the first terminal body 31 (see Figure 4) has a first surface 41 exposed from the holding member 14 and a second surface 42 opposite to the first surface 41, which is also exposed from the holding member 14. The first terminal body 31 is a thin, elongated plate, and both the first surface 41 and the second surface 42 are exposed from the holding member 14. Therefore, if the probe of a tester is brought into contact with the first surface 41 or the second surface 42, the first terminal body 31 may deform. If the first terminal body 31 is deformed, a problem may occur in the connection with the control board 13.

[0063] In contrast, the pad portion 33 has a first exposed surface 34 that is partially exposed from the holding member 14, and a contact surface 35 that is opposite to the first exposed surface 34 and is in contact with the holding member 14. Since the surface opposite to the first exposed surface 34 (the contact surface 35) of the pad portion 33 is in contact with the holding member 14, even if the probe of the tester is brought into contact with the first exposed surface 34, the force caused by that contact is supported by the holding member 14, and deformation of the pad portion 33 is prevented.

[0064] To prevent the tester probe from interfering with the first terminal body 31, the probe should be brought into contact with the target region Q (see Figure 5) of the first exposed surface 34 of the pad portion 33 that is away from the first terminal body 31. The first exposed surface 34 of the pad portion 33 has an elongated shape that includes not only the target region Q but also a portion of that target region Q. For example, the first exposed surface 34 of the pad portion 33 has a second side 34b that is more than three times longer than the first side 34a.

[0065] This is because the retaining member 14 is made of resin and, as explained in Figure 7, is formed by injection molding using a mold 60, and a part of the metal member that will become the pad portion 33 is brought into contact with the mold 60, with the contact portion becoming the first exposed surface 34. In other words, when the metal member is brought into contact with the mold 60, the longer the contact portion, the more stably the metal member is positioned. Thus, by setting the first exposed surface 34 of the pad portion 33 to an elongated shape, the contact area of ​​the metal member with respect to the mold 60 increases, the metal member becomes more stable, and the occurrence of defective products is suppressed.

[0066] [Other components] In this embodiment, with respect to the control terminal 16, the first terminal body portion 31, the pad portion 33, and the second terminal body portion 32 are formed by bending the same metal member. Therefore, joining the first terminal body portion 31, the pad portion 33, and the second terminal body portion 32 is unnecessary. However, one or all of the first terminal body portion 31, the pad portion 33, and the second terminal body portion 32 may be separate members, and the control terminal 16 may be configured to join these parts together, for example, by welding.

[0067] As shown in Figure 4, the pad portion 33 is provided along the retaining member 14, and its contact surface 35 is in contact with the retaining member 14 over its entire length. In other configurations, a portion of the contact surface 35 may be exposed from the retaining member 14. Although the first exposed surface 34 of the pad portion 33 has been described as being elongated and rectangular, it may also be of other shapes, such as circular or oval.

[0068] In this embodiment (see Figure 6), the first side surface 36 of the pad portion 33 is covered by a first thin film portion 51 made of resin, and the second side surface 37 is covered by a second thin film portion 52 made of resin. As a modification, one or both of the first thin film portion 51 and the second thin film portion 52 may be omitted. The first space K1 and the second space K2, which are formed on the sides of the first side surface 36 and the second side surface 37 of the pad portion 33, may have shapes other than those shown in the figure (cross-sectional shape).

[0069] The electronic component 15 (first electronic component 15) may be a component other than a field-effect transistor, such as a mechanical relay. Even in this case, the electronic component 15 and the control board 13 are electrically connected in the completed state of the circuit configuration 11, and a signal is supplied from the control board 13 to the electronic component 15 through the control terminal 16, causing the electronic component 15 to operate. Note that electrical testing is performed before connecting the control board 13.

[0070] The embodiments described above are illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims rather than by the embodiments, and includes all modifications within the scope equivalent to the configurations described in the claims. [Explanation of symbols]

[0071] 10. Electrical junction box 11 Circuit structure 12 Covers 13 Control board 13a Front page 14 Retaining member 15 Electronic Components 15a Source terminal 15c drain terminal 15b Gate terminal 16 Control terminals 17 Conductive plate 17-1 First conductive plate 17-2 Second conductive plate 17-3 Third conductive plate 18 through holes 19 Base section 20 Frame section 21A end 21B End 22 Main body 23 First buried section 24 Second buried section 25 First bending section 26 Second bending section 27 Control circuit section 28 holes 29 Wiring Patterns 30 Containment space 31 First terminal body 31a base 32 Second terminal main body 32a base 32b part 33 Pad section 34 First exposed surface 34a First side 34b Second side 35 Contact surface 36 First aspect 37 Second aspect 38 corners 39 mounting holes 41 Front page 42 Second side 43 Side view 44 Second exposed surface 45 Terminal surface 46 First piece 47 Second piece 50 Thick part 51 First thin film part 51a side 52 Second thin film part 52a Side view 54 Resin surface 57 First protrusion 58 Second protrusion 60 molds 60a Cavity 60b First part 60c second part 61 Protrusion J1 First boundary area J2 Second boundary area K1 First space K2 Second space L1 First dimension L2 Second dimension

Claims

1. A conductive plate, a plurality of electronic components mounted on the main body of the conductive plate, a plurality of control terminals electrically connected to the plurality of electronic components, a holding member having insulating properties and holding the plurality of control terminals and the conductive plate, and a control board that outputs signals to the electronic components through the control terminals, The control terminal and the conductive plate are insert parts that are integrated with the holding member, which is made of resin. The aforementioned control terminal has, in part, The exposed surface exposed from the holding member, The surface opposite to the exposed surface and the contact surface that contacts the retaining member, It has, The aforementioned control terminal is The first terminal body is connected to the control board, The first terminal body is electrically connected to the first terminal body and is provided along the retaining member, and the pad portion, which is a part of the first terminal body, has the exposed surface and the contact surface, The pad portion and the second terminal body portion which is electrically connected to the electronic component, It has, The aforementioned retaining member is Of the control terminals, the first embedded portion is embedded in the first bent portion between the first terminal body and the pad portion, Of the control terminals, a second embedded portion is provided for embedding the second bent portion between the pad portion and the second terminal body portion, A thickened portion is provided between the first embedded portion and the second embedded portion and contacts the contact surface of the pad portion, It has, The main body of the conductive plate on which the electronic components are mounted is located on the side that sandwiches the thickened portion between itself and the pad portion. circuit construct.

2. The aforementioned control terminal is A first side surface located between the exposed surface and the contact surface, It has a second surface located between the exposed surface and the contact surface, A first space is formed on the side of the first side surface, and a second space is formed on the side of the second side surface. The circuit configuration according to claim 1.

3. The retaining member has a thick portion that contacts the contact surface, a first thin film portion made of resin that covers the first side surface, and a second thin film portion made of resin that covers the second side surface. The side surface of the first thin film portion is exposed in the first space portion. The side surface of the second thin film portion is exposed in the second space portion. The circuit configuration according to claim 2.

4. The second embedded portion has a resin surface that forms the same surface as the exposed surface of the pad portion. The circuit configuration according to any one of claims 1 to 3.

5. The second terminal body has a terminal surface exposed from the holding member and connected to the electronic component, and a second exposed surface on the opposite side of the terminal surface that is also exposed from the holding member. The circuit configuration according to any one of claims 1 to 3.

6. The circuit configuration described in claim 1, An electrical connection box comprising a cover that covers the aforementioned circuit components.

Images