Fuse unit
The fuse unit with exposed terminal connections and resin-covered terminals simplifies integration and reduces manufacturing costs by allowing easy adaptation to component changes, while protecting the fuses.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- AUTONETWORKS TECH LTD
- Filing Date
- 2024-12-26
- Publication Date
- 2026-06-25
Smart Images
Figure 0007880036000001 
Figure 0007880036000002 
Figure 0007880036000003
Abstract
Description
Technical Field
[0001] The present disclosure relates to a fuse unit.
Background Art
[0002] High-voltage battery packs used in electric vehicles, hybrid vehicles, etc. usually have a number of battery cells stacked and electrically connected in series or parallel by a wiring module. As such a wiring module, conventionally, a conductor module described in Japanese Patent Application Laid-Open No. 2019-32928 (Patent Document 1 below) is known. The conductor module described in Patent Document 1 includes a wiring material and a plurality of bus bars. The wiring material has a plurality of wirings that electrically connect the bus bar and the battery module monitoring unit, and fuses provided in the middle of the wirings. In Patent Document 1, a flexible printed circuit board (FPC) is exemplified as the wiring material. By using an FPC as the wiring material, fuses can be easily provided on the wiring material by mounting.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] In the conductor module as described above, when the battery cell, bus bar, etc. are changed, it is necessary to separately design and prepare the wiring material. Therefore, it is difficult to reduce the manufacturing cost of the wiring material.
Means for Solving the Problems
[0005] The fuse unit of this disclosure comprises a first terminal electrically connected to a mating member, a second terminal electrically connected directly or indirectly to a wiring member, a resin portion covering a part of the first terminal and a part of the second terminal, and a chip fuse, wherein the resin portion maintains the distance between the first terminal and the second terminal, the first terminal has a first connection portion exposed from the resin portion, the second terminal has a second connection portion exposed from the resin portion, and the chip fuse comprises a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion.
[0006] Furthermore, the manufacturing method of the fuse unit of this disclosure comprises: a terminal forming step of forming a first terminal and a second terminal; a resin part forming step of forming a resin part that covers a part of the first terminal and a part of the second terminal by insert molding, the resin part exposing the outer surface of the first terminal as a first connection part and the outer surface of the second terminal as a second connection part; and a mounting step of mounting the first electrode of a chip fuse having a first electrode and a second electrode to the first connection part and mounting the second electrode to the second connection part. [Effects of the Invention]
[0007] According to this disclosure, it is possible to provide a fuse unit that can reduce manufacturing costs. [Brief explanation of the drawing]
[0008] [Figure 1] Figure 1 is a perspective view of a fuse unit according to Embodiment 1, showing the fuse unit connected to an electric wire. [Figure 2] Figure 2 is a plan view of a fuse unit connected to an electric wire according to Embodiment 1. [Figure 3] Figure 3 is a cross-sectional view of AA in Figure 2. [Figure 4] Figure 4 is a plan view of the first and second terminals according to Embodiment 1. [Figure 5]Figure 5 is a plan view of an intermediate molded body according to Embodiment 1. [Figure 6] Figure 6 is a plan view of the fuse unit according to Embodiment 1. [Figure 7] Figure 7 is a perspective view of a wiring module including a fuse unit according to Embodiment 1. [Figure 8] Figure 8 is a perspective view of a fuse unit according to Embodiment 2, showing the fuse unit connected to an electric wire. [Figure 9] Figure 9 is a cross-sectional view of a fuse unit according to Embodiment 2, and corresponds to Figure 3 of Embodiment 1. [Figure 10] Figure 10 is a perspective view of a fuse unit according to Embodiment 3, showing the fuse unit connected to an electric wire. [Figure 11] Figure 11 is a cross-sectional view of a fuse unit according to Embodiment 3, and corresponds to Figure 3 of Embodiment 1. [Figure 12] Figure 12 is a cross-sectional view of a fuse unit according to Embodiment 4, and corresponds to Figure 3 of Embodiment 1. [Figure 13] Figure 13 is a perspective view of a fuse unit according to Embodiment 5, showing the fuse unit connected to an electric wire. [Figure 14] Figure 14 is a plan view of a fuse unit according to Embodiment 6, showing the fuse unit connected to an electric wire. [Figure 15] Figure 15 is a cross-sectional view of BB in Figure 14. [Figure 16] Figure 16 is a perspective view of a fuse unit according to Embodiment 7, showing the fuse unit connected to an electric wire. [Figure 17] Figure 17 is a plan view of a fuse unit connected to an electric wire according to Embodiment 7. [Figure 18] Figure 18 is a cross-sectional view of the CC shown in Figure 17. [Figure 19]FIG. 19 is a view showing a state in which the third terminal is inserted into the cavity in the C-C cross section of FIG. 17. [Figure 20] FIG. 20 is a view showing a state in which the third terminal is inserted into the cavity and the retainer is in the temporary locking position in the C-C cross section of FIG. 17. [Figure 21] FIG. 21 is a side view of a fuse unit connected to an electric wire according to Embodiment 7. [Figure 22] FIG. 22 is a D-D cross-sectional view of FIG. 21, in which the second terminal, the third terminal, and the electric wire are omitted. [Figure 23] FIG. 23 is a side view of a fuse unit excluding the third terminal according to Embodiment 7, showing a state in which the retainer is in the temporary locking position. [Figure 24] FIG. 24 is an E-E cross-sectional view of FIG. 23. [Figure 25] FIG. 25 is a plan view of the first terminal, the second terminal, and the resin part according to Embodiment 7. [Figure 26] FIG. 26 is an F-F cross-sectional perspective view of FIG. 25. [Figure 27] FIG. 27 is a G-G cross-sectional view of FIG. 25. [Figure 28] FIG. 28 is a plan view of the first terminal and the second terminal according to Embodiment 7. [Figure 29] FIG. 29 is a perspective view of a fuse unit according to a modified example of Embodiment 1, showing a state in which the fuse unit is connected to an electric wire. [Figure 30] FIG. 30 is a perspective view of a fuse unit according to another embodiment, showing a state in which the fuse unit is connected to a flexible substrate.
Embodiments for Carrying Out the Invention
[0009] [Description of Embodiments of the Present Disclosure] First, the embodiments of the present disclosure will be listed and described. [1] The fuse unit of the present disclosure comprises a first terminal electrically connected to a mating member, a second terminal electrically connected directly or indirectly to a wiring member, a resin portion covering a part of the first terminal and a part of the second terminal, and a chip fuse, wherein the resin portion maintains a distance between the first terminal and the second terminal, the first terminal has a first connection portion exposed from the resin portion, the second terminal has a second connection portion exposed from the resin portion, and the chip fuse comprises a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion.
[0010] This configuration allows for easy inclusion of chip fuses in the fuse unit during implementation. Furthermore, even if mating components or wiring components are changed, the fuse unit may not need to be redesigned, thus reducing the manufacturing cost of the fuse unit.
[0011] [2] In the above [1], it is preferable that the resin portion has a portion that protrudes from the first connection portion and the second connection portion and comprises a peripheral wall portion arranged around the chip fuse.
[0012] With this configuration, the surrounding wall can protect the chip fuse.
[0013] [3] In the above [2], it is preferable that the peripheral wall surrounds the first connecting portion and the second connecting portion.
[0014] With this configuration, the peripheral wall prevents foreign matter from coming into contact with the chip fuse, thus preventing stress from being generated at the connection between the first connection part and the first electrode, and at the connection between the second connection part and the second electrode.
[0015] [4] Any one of the fuse units from [1] to [3] above is the same as Chip fuse It is preferable to further provide a cover member that covers the object.
[0016] With this configuration, the presence of a cover member prevents condensation from adhering to the chip fuse. Therefore, it is possible to prevent a short circuit between the first electrode and the second electrode via condensation.
[0017] [5] Preferably, any one of the fuse units described in [1] to [4] above further comprises a third terminal to which the wiring member is connected, the second terminal comprises a first terminal connection portion connected to the third terminal, and the third terminal comprises a second terminal connection portion connected to the first terminal connection portion by mating.
[0018] This configuration makes it easier to connect the wiring component to the second terminal.
[0019] [6] Preferably, the fuse unit described in [5] above further comprises a retainer that is assembled to the resin part and holds the third terminal.
[0020] With this configuration, the third terminal can be held in place by the resin part, making it easier to determine the position of the third terminal relative to the resin part.
[0021] [7] In any one of the above [1] to [6], it is preferable that the first terminal or the second terminal has a notch recessed from the outer edge, and the notch defines the first connection portion or the second connection portion.
[0022] With this configuration, the notch defines the first or second connection point, allowing the size of the first or second connection point to be appropriately adjusted, and enabling control of heat dissipation from the first or second connection point when mounting the chip fuse.
[0023] [8] In the above [7], it is preferable that the resin portion has grooves that are recessed relative to the first and second connecting portions, the inner surface constituting the grooves is connected to the first and second connecting portions, and a part of the grooves is located inside the notches.
[0024] With this configuration, when forming the resin part, it is possible to suppress the movement of molten resin through the notch to the outer surface of the first and second connection parts. This makes it possible to suppress the generation of burrs on the first and second connection parts.
[0025] [9] A method for manufacturing a fuse unit according to the present disclosure includes: a terminal forming step of forming a first terminal and a second terminal; a resin part forming step of forming a resin part by insert molding that covers a part of the first terminal and a part of the second terminal, the resin part exposing the outer surface of the first terminal as a first connection part and the outer surface of the second terminal as a second connection part; and a mounting step of mounting the first electrode of a chip fuse having a first electrode and a second electrode to the first connection part and the second electrode to the second connection part.
[0026] According to this method of manufacturing a fuse unit, by forming a resin part that exposes the first and second connection parts during the resin part forming process, the chip fuse can be easily incorporated into the fuse unit during the mounting process. Furthermore, even if the mating components to which the first and second terminals are connected are changed, it may not be necessary to redesign the fuse unit, thus reducing the manufacturing cost of the fuse unit.
[0027] [Details of the embodiments of this disclosure] Embodiments of the present disclosure are described below. This disclosure is not limited to these examples, but is indicated by the claims, and all modifications within the meaning and scope of the claims are intended to be included. In the drawings, some parts of the configuration may be exaggerated or simplified for illustrative purposes. Also, the dimensional ratios of the parts may differ in the drawings. In this specification, “orthogonal” and “parallel” include not only strictly orthogonal or parallel, but also approximately orthogonal or parallel to the extent that they produce the function and effect of the present embodiment.
[0028] Each drawing shows three mutually perpendicular directions, designated as the first direction D1, the second direction D2, and the third direction D3. That is, the first direction D1 and the second direction D2 are mutually perpendicular, the first direction D1 and the third direction D3 are mutually perpendicular, and the second direction D2 and the third direction D3 are mutually perpendicular. By indicating arrows on both sides of the solid lines that show each direction, the direction indicated by the arrow on the side without a symbol is understood to be the same as the direction indicated by the arrow on the side without a symbol.
[0029] <Embodiment 1> (Fuse unit 10) Embodiment 1 of this disclosure will be described with reference to Figures 1 to 7. As shown in Figures 1 to 3, the fuse unit 10 of this embodiment includes a first terminal 20, a second terminal 30, a resin part 40, and a chip fuse 50. Note that for multiple identical components, reference numerals may be assigned to only some of the components, while the reference numerals for other components may be omitted.
[0030] (1st terminal 20) The first terminal 20 is made of a conductive metal. As shown in Figure 4, the first terminal 20 has a rectangular plate-shaped portion 21 and a through hole 22 that penetrates the plate-shaped portion 21. The through hole 22 is located near the end in the extension direction of the plate-shaped portion 21. The plate-shaped portion 21 has two recesses 21A at both ends in the width direction of the plate-shaped portion 21 (a direction perpendicular to both the extension direction and the thickness direction of the plate-shaped portion 21). The recesses 21A are formed recessed from the edge in the width direction of the plate-shaped portion 21. The plate-shaped portion 21 is equipped with a mating member connection portion 23 that is electrically connected to a mating member. The mating member is, for example, a busbar 60 (see Figure 7). The connection between the mating member connection portion 23 and the mating member is made, for example, by welding or soldering.
[0031] (2nd terminal 30) The second terminal 30 is made of a conductive metal. The metal constituting the second terminal 30 may be different from the metal constituting the first terminal 20. As shown in Figure 4, the second terminal 30 comprises a rectangular plate-shaped portion 31, a through hole 32 penetrating the plate-shaped portion 31, and a barrel portion 33. The barrel portion 33 is formed in conjunction with the plate-shaped portion 31 in the extension direction of the second terminal 30. The plate-shaped portion 31 has two recesses 31A at both ends in the width direction of the second terminal 30 (a direction perpendicular to both the extension direction of the second terminal 30 and the thickness direction of the plate-shaped portion 31). The recesses 31A are formed recessed from the edge in the width direction of the second terminal 30.
[0032] The barrel portion 33 comprises a core wire crimping portion 33A and an insulating coating crimping portion 33B (an example of a fixing portion). The core wire crimping portion 33A is positioned between the plate-shaped portion 31 and the insulating coating crimping portion 33B in the direction of extension of the second terminal 30. As shown in Figure 3, the core wire crimping portion 33A is crimped to the core wire of the electric wire 70 (an example of a wiring member). The core wire crimping portion 33A electrically connects the second terminal 30 to the electric wire 70. The insulating coating crimping portion 33B is crimped to the insulating coating of the electric wire 70. The insulating coating crimping portion 33B can fix the electric wire 70 to the second terminal 30. The insulating coating crimping portion 33B suppresses the transmission of tensile stress to the core wire crimping portion 33A, for example, when tensile stress is applied to the electric wire 70. This makes it easier to maintain the electrical connection between the electric wire 70 and the second terminal 30.
[0033] (Resin part 40) The resin part 40 is made of an insulating synthetic resin. As shown in Figures 1 to 3, the resin part 40 is positioned between the first terminal 20 and the second terminal 30, covering a portion of the first terminal 20 and a portion of the second terminal 30. As will be described later, the resin part 40 is integrally formed with the first terminal 20 and the second terminal 30 by insert molding. As shown in Figures 2 and 3, during insert molding, the molten resin, which is the raw material for the resin part 40, fills the inside of the through holes 22, 32 and recesses 21A, 31A, thereby holding the first terminal 20 and the second terminal 30 with respect to the resin part 40. The resin part 40 positions the first terminal 20 and the second terminal 30 so that they do not directly contact each other. The first terminal 20 and the second terminal 30 are spaced apart in the first direction D1. The first terminal 20 is positioned such that the extension direction of the plate-like portion 21 of the first terminal 20 is the first direction D1. The second terminal 30 is positioned such that its extension direction is the first direction D1.
[0034] (Mounting surface 41) As shown in Figure 3, the resin portion 40 is formed having a mounting surface 41. The mounting surface 41 is located between the first terminal 20 and the second terminal 30. The mounting surface 41 is the surface on which the chip fuse 50 is mounted. The mounting surface 41 is perpendicular to the second direction D2 (hereinafter described as the vertical direction). The second direction D2 coincides with the thickness direction of the plate-like portions 21 and 31.
[0035] (First connection section 24) A first connecting portion 24, which is part of the outer surface of the plate-like portion 21, is exposed from the mounting surface 41. The first connecting portion 24 is exposed from the resin portion 40 next to the mounting surface 41. The first connecting portion 24 is located at the end of the first terminal 20 closer to the second terminal 30 in the first direction D1. The first connecting portion 24 is flush with the mounting surface 41. In other words, the first connecting portion 24 is parallel to the mounting surface 41 and is located at the same position as the mounting surface 41 in the second direction D2. The first connecting portion 24 is continuous with the mounting surface 41 in the first direction D1. Here, "flush" means a state in which two parallel surfaces are smoothly connected without any steps, but in this specification, in addition to the state of being flush, it also includes a state that is substantially perceived as being flush. A state that is considered to be substantially flush with the surface refers to a state in which, for example, a minute step appears between the mounting surface 41 and the first connecting portion 24 due to the effects of manufacturing tolerances or thermal expansion, or a state in which the mounting surface 41 and the first connecting portion 24 slightly intersect and are not strictly parallel to each other.
[0036] (Second connection section 34) A second connecting portion 34, which is part of the outer surface of the plate-like portion 31, is exposed from the mounting surface 41. The second connecting portion 34 is exposed from the resin portion 40 next to the mounting surface 41. The second connecting portion 34 is located at the end of the second terminal 30 closer to the first terminal 20 in the first direction D1. The second connecting portion 34 is positioned flush with the mounting surface 41.
[0037] (Peripheral wall part 42) As shown in Figure 1, the resin portion 40 includes a peripheral wall portion 42 that protrudes beyond the first connection portion 24 and the second connection portion 34. The peripheral wall portion 42 protrudes, for example, along a direction perpendicular to the first connection portion 24 and the second connection portion 34. The peripheral wall portion 42 also extends, for example, from the mounting surface 41 to one side (upwards) in the second direction D2. The peripheral wall portion 42 is arranged to surround the chip fuse 50 in a direction perpendicular to the second direction D2. The peripheral wall portion 42 is positioned so as not to contact the chip fuse 50. As shown in Figure 3, the height of the peripheral wall portion 42 from the mounting surface 41 (dimension in the second direction D2) is greater than the height of the chip fuse 50.
[0038] (50-chip fuse) As shown in Figure 1, the chip fuse 50 comprises a first electrode 51 and a second electrode 52. When a large current flows and the chip fuse 50 melts, the first electrode 51 and the second electrode 52 are electrically insulated. The chip fuse 50 is mounted on a mounting surface 41. The first electrode 51 is positioned on a first connection part 24, and the second electrode 52 is positioned on a second connection part 34. The first electrode 51 and the first connection part 24 are connected by soldering. The second electrode 52 and the second connection part 34 are connected by soldering. In other words, the chip fuse 50 is mounted on an intermediate molded body 43 (see Figure 5) which consists of a first terminal 20, a second terminal 30, and a resin part 40. Therefore, the chip fuse 50 can be easily incorporated into the fuse unit 10 by the mounting process (see Figure 6).
[0039] The fuse unit 10 is a component for mounting the chip fuse 50 without using flexible printed circuit boards (FPCs). Specifically, the first terminal 20, the second terminal 30, and the resin part 40 form a first connection part 24 and a second connection part 34 on which the chip fuse 50 can be mounted. Therefore, the manufacturing cost of the fuse unit 10 can be easily reduced.
[0040] (Wiring module 1) The fuse unit 10 of this embodiment can be used, for example, in an energy storage module mounted in a vehicle such as an electric vehicle or a hybrid vehicle. The energy storage module comprises a plurality of energy storage elements (not shown) and a wiring module 1 attached to the plurality of energy storage elements. As shown in Figure 7, the wiring module 1 comprises the fuse unit 10, a bus bar 60 connected to the mating member connection portion 23 of the first terminal 20, and an electric wire 70 connected to the barrel portion 33 of the second terminal 30. The bus bar 60 is connected to the electrode terminals of the plurality of energy storage elements. The electric wire 70 is connected to an ECU (Electronic Control Unit) or the like via a connector (not shown). The electric wire 70 functions as a voltage detection line.
[0041] The wiring module 1, which includes the fuse unit 10, is equipped with an electric wire 70 instead of an FPC as a voltage sensing line. Therefore, the wiring module 1 can be manufactured at a lower cost compared to a wiring module in which an FPC is used as a voltage sensing line.
[0042] (Manufacturing method for fuse unit 10) The above describes the configuration of the fuse unit 10, and below, an example of a manufacturing method for the fuse unit 10 will be explained. First, the first terminal 20 and the second terminal 30 are formed by press-forming a metal sheet (terminal formation process, see Figure 4).
[0043] Next, insert molding of the resin part 40 is performed using a portion of the first terminal 20 and a portion of the second terminal 30 as insert portions (resin part forming process). The first terminal 20 and the second terminal 30 are placed in the mold, and molten resin, which will be the raw material for the resin part 40, is filled into the mold. At this time, the first terminal 20 and the second terminal 30 are positioned so that they do not come into direct contact with each other. In addition, the first connection portion 24 and the second connection portion 34 adjacent to the mounting surface 41 are exposed from the resin part 40, and the first connection portion 24 and the second connection portion 34 are flush with the mounting surface 41, so that the first connection portion 24 and the second connection portion 34 are flush with the mounting surface 41. Once the resin has hardened, the mold is removed, and an intermediate molded body 43 is obtained (see Figure 5).
[0044] The chip fuse 50 is placed on the mounting surface 41 of the intermediate molded body 43, and the first electrode 51 is mounted on the first connection part 24, and the second electrode 52 is mounted on the second connection part 34 (mounting process, see Figure 6). With this, the manufacturing of the fuse unit 10 is completed.
[0045] (Effects of Embodiment 1) (1-1) The fuse unit 10 of the present disclosure comprises a first terminal 20 electrically connected to a mating member (bus bar 60), a second terminal 30 electrically connected directly or indirectly to a wiring member (electric wire 70), a resin part 40 covering a part of the first terminal 20 and a part of the second terminal 30, and a chip fuse 50, wherein the resin part 40 maintains the distance between the first terminal 20 and the second terminal 30, the first terminal 20 has a first connection part 24 exposed from the resin part 40, the second terminal 30 has a second connection part 34 exposed from the resin part 40, and the chip fuse 50 comprises a first electrode 51 mounted on the first connection part 24 and a second electrode 52 mounted on the second connection part 34.
[0046] With this configuration, the chip fuse 50 can be easily incorporated into the fuse unit 10 through implementation. Furthermore, even if the mating component or wiring component is changed, it may not be necessary to redesign the fuse unit 10, thus reducing the manufacturing cost of the fuse unit 10.
[0047] (1-2) In Embodiment 1, the resin portion 40 has a portion that protrudes from the first connection portion 24 and the second connection portion 34 and includes a peripheral wall portion 42 that is arranged around the chip fuse 50.
[0048] With this configuration, the peripheral wall portion 42 can protect the chip fuse 50.
[0049] (1-3) In Embodiment 1, the peripheral wall portion 42 surrounds the first connecting portion 24 and the second connecting portion 34.
[0050] With this configuration, the peripheral wall portion 42 prevents foreign matter from coming into contact with the chip fuse 50, thereby suppressing the generation of stress at the connection portion between the first connection portion 24 and the first electrode 51, and at the connection portion between the second connection portion 34 and the second electrode 52.
[0051] (1-4) A method for manufacturing the fuse unit 10 of the present disclosure comprises: a terminal forming step of forming a first terminal 20 and a second terminal 30; a resin part forming step of forming a resin part 40 by insert molding, which covers a part of the first terminal 20 and a part of the second terminal 30, with the outer surface of the first terminal 20 exposed as a first connection part 24 and the outer surface of the second terminal 30 exposed as a second connection part 34; and a mounting step of mounting the first electrode 51 of a chip fuse 50 having a first electrode 51 and a second electrode 52 on the first connection part 24 and mounting the second electrode 52 on the second connection part 34.
[0052] According to this method of manufacturing the fuse unit 10, by forming the first connection portion 24, the second connection portion 34, and the exposed resin portion 40 in the resin portion forming process, the chip fuse 50 can be easily incorporated into the fuse unit 10 in the mounting process. Furthermore, even if the mating components to which the first terminal 20 and the second terminal 30 are connected are changed, it may not be necessary to redesign the fuse unit 10, thus reducing the manufacturing cost of the fuse unit 10.
[0053] <Embodiment 2> Embodiment 2 of this disclosure will be described with reference to Figures 8 and 9. The fuse unit 110 according to Embodiment 2 is configured in the same way as Embodiment 1, except that it further includes a lid portion 144 (an example of a cover member). Therefore, the same members and effects as in Embodiment 1 will not be described.
[0054] (Lid part 144) The cover portion 144 is made of an insulating synthetic resin or insulating tape. As shown in Figure 9, the cover portion 144 is attached to the upper end surface of the peripheral wall portion 42 and closes the opening 42A formed by the peripheral wall portion 42. The cover portion 144 and the chip fuse 50 are separated by a space. The fuse unit 110 of Embodiment 2 can be manufactured by attaching the cover portion 144 to the fuse unit 10 of Embodiment 1.
[0055] According to the configuration of Embodiment 2, the cover portion 144 prevents water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 blows, it is possible to prevent electrical contact between the first connection portion 24 and the second connection portion 34 via water droplets.
[0056] <Embodiment 3> Embodiment 3 of this disclosure will be described with reference to Figures 10 and 11. The fuse unit 210 according to Embodiment 3 is configured in the same way as Embodiment 1, except that it further includes a sealing portion 245 (an example of a cover member). Therefore, the same members and effects as in Embodiment 1 will not be described.
[0057] (Sealing section 245) The sealing portion 245 is made of a curable insulating resin. The sealing portion 245 may be made of a different resin from the synthetic resin that constitutes the resin portion 40. The sealing portion 245 may be transparent. In Embodiment 3, the sealing portion 245 is, for example, a potting agent. As shown in Figure 11, the sealing portion 245 is arranged to fill the space in the opening 42A of the peripheral wall portion 42. The sealing portion 245 is in close contact with the outer surface of the chip fuse 50, the first connection portion 24, the second connection portion 34, and the mounting surface 41. The sealing portion 245 is formed after the mounting process by filling the opening 42A with liquid insulating resin before curing and curing the insulating resin. Furthermore, a bottomed recess is formed on the inside of the peripheral wall portion 42 by the inner circumferential surface of the peripheral wall portion 42, the surface of the portion of the resin portion 40 between the first terminal 20 and the second terminal 30 that is exposed to the inside of the peripheral wall portion 42, the surface of the first terminal 20 that is exposed to the inside of the peripheral wall portion 42, and the surface of the second terminal 30 that is exposed to the inside of the peripheral wall portion 42. Therefore, by placing the molten sealing portion 245 in this recess, the chip fuse 50, the connection portion between the first connection portion 24 and the first electrode 51, and the connection portion between the second connection portion 34 and the second electrode 52 can be easily covered by the sealing portion 245.
[0058] (Through hole 246) Furthermore, a through-hole 246 may be formed in the resin portion 40. This through-hole 246 penetrates the mounting surface 41 and the lower surface of the resin portion 40. The through-hole 246 exposes a portion of the outer surface of the chip fuse 50 that is different from the first electrode 51 and the second electrode 52 to the outside. In other words, the entire outer surface of the chip fuse 50 is not covered by the sealing portion 245 and the resin portion 40. The first electrode 51 and the second electrode 52 are not exposed to the outside through the through-hole 246. The through-hole 246 may be formed, for example, in the resin portion forming process, or it may be formed after the resin portion forming process.
[0059] According to the configuration of Embodiment 3, the sealing portion 245 prevents water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 blows, it is possible to prevent electrical contact between the first connection portion 24 and the second connection portion 34 via water droplets.
[0060] <Embodiment 4> Embodiment 4 of this disclosure will be described with reference to Figure 12. The fuse unit 310 according to Embodiment 4 is configured substantially the same as that of Embodiment 3, except for the configuration of the sealing portion 345 (an example of a cover member). Therefore, the same members and effects as those of Embodiments 1 and 3 will not be described.
[0061] (Sealing portion 345) The sealing portion 345 in Embodiment 4 is, for example, a moisture-proof coating agent. The sealing portion 345 is in close contact with the outer surface of the chip fuse 50, the first connection portion 24, the second connection portion 34, and the mounting surface 41 within the opening 42A of the peripheral wall portion 42. The sealing portion 345 does not need to fill the entire space within the opening 42A.
[0062] <Embodiment 5> Embodiment 5 of this disclosure will be described with reference to Figure 13. The fuse unit 410 according to Embodiment 5 is configured substantially the same as that of Embodiment 1, except for the configuration of the second terminal 430, so the same components and effects as in Embodiment 1 will not be described.
[0063] (Wire holding section 435) The second terminal 430 comprises a plate-shaped portion 31, a wire connection portion 434, and a wire retaining portion 435 (an example of a fixing portion). The wire connection portion 434 is a plate-shaped member extending from the plate-shaped portion 31 in a first direction D1. The wire connection portion 434 is connected to the core wire of the electric wire 70 by soldering. The wire retaining portion 435 is positioned on the opposite side of the plate-shaped portion 31 from the wire connection portion 434. The wire retaining portion 435 comprises a base portion 435A formed continuously from the wire connection portion 434 in the first direction D1, and an extension portion 435B extending cantileveredly from the base portion 435A in a third direction D3 (the width direction of the second terminal 430). The insulating coating of the electric wire 70 is held between the base portion 435A and the extension portion 435B which is bent to approach the base portion 435A. This allows the electric wire 70 to be fixed to the second terminal 430. Note that the second terminal 430 does not necessarily need to have the electric wire retaining portion 435.
[0064] <Embodiment 6> Embodiment 6 of this disclosure will be described with reference to Figures 14 and 15. The fuse unit 510 according to Embodiment 6 is configured substantially the same as that of Embodiment 1, except that the peripheral wall portion 42 is not provided and the configuration of the plate-like portions 521 and 531 are not provided. Therefore, the same components and effects as those of Embodiment 1 will not be described.
[0065] The fuse unit 510 comprises a first terminal 520, a second terminal 530, a resin part 540, and a chip fuse 50. As shown in Figure 15, the resin part 540 does not have a peripheral wall 42. The upper surface of the resin part 540 serves as the mounting surface 41.
[0066] The plate-shaped portion 521 of the first terminal 520 comprises a first plate portion 521A, a second plate portion 521B, and a third plate portion 521C. The second plate portion 521B and the third plate portion 521C are formed to be narrower than the first plate portion 521A (see Figure 14). The first plate portion 521A is a plate-shaped member that is connected to the mating member connection portion 23 in the first direction D1. The second plate portion 521B extends upward from the end of the first plate portion 521A opposite to the mating member connection portion 23 in the first direction D1. The third plate portion 521C extends in the first direction D1 from the upper end of the second plate portion 521B. With respect to the second plate portion 521B, the third plate portion 521C and the first plate portion 521A extend in opposite directions to each other in the first direction D1. The upper surface of the third plate portion 521C is designated as the first connecting portion 24.
[0067] The plate-shaped portion 531 of the second terminal 530 comprises a first plate portion 531A, a second plate portion 531B, and a third plate portion 531C. The second plate portion 531B and the third plate portion 531C are formed to be narrower than the first plate portion 531A (see Figure 14). The first plate portion 531A is the portion that connects to the barrel portion 33 in the first direction D1. The second plate portion 531B extends upward from the end of the first plate portion 531A opposite to the barrel portion 33 in the first direction D1. The third plate portion 531C extends in the first direction D1 from the upper end of the second plate portion 531B. With respect to the second plate portion 531B, the third plate portion 531C and the first plate portion 531A extend in opposite directions to each other in the first direction D1. The upper surface of the third plate portion 531C is the second connecting portion 34.
[0068] <Embodiment 7> Embodiment 7 of this disclosure will be described with reference to Figures 16 to 28. Unlike Embodiments 1 to 6 described above, the fuse unit 610 according to Embodiment 7 further includes a third terminal 680, and the second terminal 630 and the electric wire 70 are connected via the third terminal 680. Hereafter, explanations of the same components and effects as in Embodiment 1 may be omitted.
[0069] As shown in Figures 16 and 17, the fuse unit 610 comprises a first terminal 620, a second terminal 630, a resin part 640, and a chip fuse 50. Furthermore, as shown in Figure 18, the fuse unit 610 also includes a third terminal 680 located inside the resin part 640. The third terminal 680 is connected to the electric wire 70.
[0070] (First terminal 620, notch 625) As shown in Figure 28, the first terminal 620, like the first terminal 20 of Embodiment 1, has a plate-like portion 21, a through hole 22, two recesses 21A, a mating member connection portion 23, and a first connection portion 24. In addition, the first terminal 620 has a notch 625, which is a configuration different from the first terminal 20 of Embodiment 1. The notch 625 is formed in a pair recessed from one outer edge of the first terminal 620 in the extending direction. The first connection portion 24 is defined by the notch 625. In other words, the first connection portion 24 and the notch 625 are adjacent in the width direction of the first terminal 620. The notch 625 appropriately sets the area of the first connection portion 24 in plan view.
[0071] If the notch 625 is not provided, when the first electrode 51 of the chip fuse 50 and the first connection portion 24 are connected by soldering, the heat drawn to the first terminal 620 may become excessive. However, in this embodiment, the heat drawn to the first terminal 620 can be appropriately controlled by appropriately adjusting the size of the first connection portion 24 with the notch 625.
[0072] (Second terminal 630, tab portion 633) The second terminal 630, like the second terminal 30 of Embodiment 1, has a plate-like portion 31, a through hole 32, two recesses 31A, and a second connecting portion 34. The plate-like portion 31 has two recesses 31A at both ends in the width direction of the second terminal 30 (a direction perpendicular to both the extension direction of the second terminal 30 and the thickness direction of the plate-like portion 31). The recesses 31A are formed recessed from the edge of the second terminal 30 in the width direction. The second terminal 630 also includes a tab portion 633 (an example of a first terminal connecting portion). The tab portion 633 is formed in connection with the plate-like portion 31 in the extension direction of the second terminal 630. The tab portion 633 is rod-shaped and extends from the edge of the plate-like portion 31 in the extension direction of the second terminal 630.
[0073] (Notch 635) The second terminal 630, like the first terminal 620, is provided with a notch 635. The notch 635 is formed in a pair, recessed from the outer edge opposite the tab portion 633 in the extending direction of the second terminal 630. The second connection portion 34 is defined by the notch 635. In other words, the second connection portion 34 and the notch 635 are adjacent in the width direction of the second terminal 630. The notch 635 appropriately sets the area of the second connection portion 34 in plan view. By appropriately adjusting the size of the second connection portion 34 with the notch 635, the heat dissipation to the second terminal 630 can be appropriately controlled.
[0074] (3rd terminal 680) The third terminal 680 is made of a conductive metal. The metal constituting the third terminal 680 may be different from the metal constituting the first terminal 620 and the metal constituting the second terminal 630. As shown in Figure 19, the third terminal 680 includes a connecting cylinder portion 681 (an example of a second terminal connecting portion) connected to the second terminal 630, and a barrel portion 682. The barrel portion 682 is formed in conjunction with the connecting cylinder portion 681 in the extending direction of the third terminal 680. The barrel portion 682 includes a core wire crimping portion 682A that is crimped to the core wire of the electric wire 70, and an insulating coating crimping portion 682B that is crimped to the insulating coating of the electric wire 70.
[0075] (Connecting cylinder portion 681) The connecting cylinder portion 681 comprises, for example, a cylindrical wall portion 683 that is rectangular in shape, and an elastic contact piece 684 formed inside the cylindrical wall portion 683. The cylindrical wall portion 683 is open in a first direction D1. The elastic contact piece 684 extends from the inner surface of the cylindrical wall portion 683 and is elastically deformable in a direction perpendicular to the first direction D1. The connecting cylinder portion 681 also has a locking hole 683A formed through the cylindrical wall portion 683. As shown in Figures 18 to 20, the tab portion 633 of the second terminal 630 is inserted into the cylindrical wall portion 683, and the elastic contact piece 684 contacts the tab portion 633, thereby electrically connecting the third terminal 680 and the second terminal 630. That is, the connecting cylinder portion 681 and the tab portion 633 are electrically connected by fitting. Therefore, the second terminal 630 and the electric wire 70 are electrically connected via the third terminal 680.
[0076] In this embodiment, the second terminal 630 is not directly connected to the wire 70, but rather the second terminal 630 and the wire 70 are indirectly connected via the third terminal 680. Therefore, for example, when electrically connecting the fuse unit 610 and the wire 70, damage to the connection between the chip fuse 50 and the second terminal 630 due to stress or the like can be suppressed. Thus, the reliability of the electrical connection between the fuse unit 610 and the wire 70 can be more easily ensured.
[0077] (Resin part 640) As shown in Figure 25, the resin portion 640 covers a part of the first terminal 620 and a part of the second terminal 630. Similar to Embodiment 1, the resin portion 640 is integrally formed with the first terminal 620 and the second terminal 630 by insert molding. The first terminal 620 and the second terminal 630 are fixed to the resin portion 640. The resin portion 640 has an intermediate portion 641 positioned between the first terminal 620 and the second terminal 630 in the first direction D1. The resin portion 640 maintains the distance between the first terminal 620 and the second terminal 630. The resin portion 640 exposes a first connecting portion 24, which is part of the outer surface of the plate-like portion 21, and a second connecting portion 34, which is part of the outer surface of the plate-like portion 31. The first connecting portion 24 and the second connecting portion 34 are positioned at a predetermined distance apart in the first direction D1 by the resin portion 640. Furthermore, the resin part 640 has its mating member connection part 23 exposed to the outside.
[0078] As shown in Figure 26, the end face on one side (upper) of the intermediate portion 641 in the second direction D2 is designated as the reference surface 641A. The reference surface 641A is flush with the first connecting portion 24 (outer surface of the plate-like portion 21) and the second connecting portion 34 (outer surface of the plate-like portion 31). The reference surface 641A is perpendicular to the second direction D2 (vertical direction). The second direction D2 coincides with the thickness direction of the plate-like portions 21 and 31.
[0079] As shown in Figure 18, the resin portion 640 may have a through hole 246, similar to Embodiment 3. The through hole 246 penetrates the intermediate portion 641 in the second direction D2.
[0080] As shown in Figures 26 and 27, the resin portion 640 includes a peripheral wall portion 42, similar to Embodiment 1. The peripheral wall portion 42 extends from the reference plane 641A to one side (upwards) in the second direction D2. That is, the peripheral wall portion 42 has a portion that protrudes above the first connection portion 24 and the second connection portion 34. The peripheral wall portion 42 is arranged around the chip fuse 50. Furthermore, the peripheral wall portion 42 surrounds the first connection portion 24 and the second connection portion 34 in a direction perpendicular to the second direction D2.
[0081] (Groove 641B) The intermediate portion 641 has a groove 641B that is recessed from the reference surface 641A toward the other side (downward) in the second direction D2. The groove 641B is recessed downward relative to the first connection portion 24 and the second connection portion 34. As shown in Figure 26, the groove 641B is composed of a bottom surface BS that is substantially parallel to the reference surface 641A, a first inner surface S1 that connects the bottom surface BS to the first connection portion 24, a second inner surface S2 that connects the bottom surface BS to the second connection portion 34, and a third inner surface S3 that connects the bottom surface BS to the reference surface 641A. The groove 641B is adjacent to the first connection portion 24 and the second connection portion 34 when viewed from a direction perpendicular to the first connection portion 24 and the second connection portion 34 (second direction D2). As shown in Figure 18, the bottom surface BS faces the chip fuse 50 in the second direction D2. A gap is provided between the bottom surface BS and the chip fuse 50. As shown in Figures 26 and 27, a portion of the groove 641B is located inside the notches 625 and 635.
[0082] As shown in Figure 27, by providing a groove 641B in the resin part 640, a part of the side surface of the first terminal 620, which is continuous with the outer edge of the first connection part 24 (hereinafter referred to as the first side surface SP1), may be exposed from the resin part 640. The first connection part 24 and the first inner surface S1 may be connected via the first side surface SP1. Similarly, by providing a groove 641B in the resin part 640, a part of the side surface of the second terminal 630, which is continuous with the outer edge of the second connection part 34 (hereinafter referred to as the second side surface), may be exposed from the resin part 640. The second connection part 34 and the second inner surface S2 may be connected via the second side surface.
[0083] Note that the first connecting part 24 and the groove 641B The inner surface may be directly connected to the second connecting part 34 and the groove. 641B It may be directly connected to its inner self.
[0084] If groove 641B is not provided, when the resin part 640 is formed by insert molding, the molten resin may move to the outer surface (upper surface) of the first connection part 24 and the second connection part 34, and burrs may be generated on the first connection part 24 and the second connection part 34. In such a case, the burrs may cause a poor electrical connection between the first connection part 24 and the first electrode 51 or between the second connection part 34 and the second electrode 52. However, in this embodiment, since groove 641B is provided in the intermediate part 641, when the resin part 640 is formed, the molten resin is more likely to move into groove 641B than to the upper surface of the first connection part 24 and the second connection part 34. Therefore, the generation of burrs on the first connection part 24 and the second connection part 34 can be suppressed.
[0085] As shown in Figures 18 and 25, the resin portion 640 includes a housing portion 643 that is formed continuously with the intermediate portion 641 and the peripheral wall portion 42. The housing portion 643 extends from the intermediate portion 641 on the side opposite to the first terminal 620. The housing portion 643 has a cavity 644 in which the third terminal 680 is housed. The cavity 644 extends in a first direction D1 and opens on one side (right side in the figure) in the first direction D1. At the other end of the cavity 644 in the first direction D1 (left side in the figure), the tab portion 633 of the second terminal 630 and a part of the plate-like portion 31 which is the base end of the tab portion 633 are arranged.
[0086] As shown in Figure 25, the housing portion 643 comprises a bottom wall 643A (see Figure 18), a pair of side walls 643B, and a ceiling wall 643C. As shown in Figure 22, the pair of side walls 643B extend from both ends of the bottom wall 643A in the third direction D3 to one side (upwards) in the second direction D2. As shown in Figure 18, the ceiling wall 643C faces the bottom wall 643A in the second direction D2. As shown in Figure 25, the ceiling wall 643C connects one end (upper end) of the pair of side walls 643B in the second direction D2. The cavity 644 is an internal space composed of the bottom wall 643A, the pair of side walls 643B, and the ceiling wall 643C.
[0087] As shown in Figure 18, a first communication hole 643C1 is provided in the middle portion 641 of the ceiling wall 643C. The first communication hole 643C1 penetrates the ceiling wall 643C in the second direction D2 and communicates with the cavity 644. A second communication hole 643A1 is provided in the middle portion 641 end of the bottom wall 643A. The second communication hole 643A1 penetrates the bottom wall 643A in the second direction D2 and communicates with the cavity 644.
[0088] As shown in Figure 25, a mounting recess 645 for mounting a retainer 690 (described later) is formed in approximately two-thirds of the other side (left side in the figure) of the housing portion 643 in the first direction D1. The mounting recess 645 has a first mounting recess 645A recessed from the outer surface of the ceiling wall 643C and a second mounting recess 645B recessed from the outer surfaces of the pair of side walls 643B. The end of the first mounting recess 645A near the middle portion 641 extends into the peripheral wall portion 42. As shown in Figure 18, the first mounting recess 645A communicates with the first communication hole 643C1.
[0089] As shown in Figure 25, the second mounting recess 645B is in communication with the first mounting recess 645A. The housing portion 643 includes a shaft portion 646, a temporary locking portion 647, and a permanent locking portion 648 that protrude from the inner wall of the second mounting recess 645B in the third direction D3. The shaft portion 646 is generally cylindrical in shape. The shaft portion 646 is located on the inner wall of the second mounting recess 645B, near the intermediate portion 641 in the first direction D1. The temporary locking portion 647 and the permanent locking portion 648 are located on the inner wall of the second mounting recess 645B, at the end opposite to the intermediate portion 641 in the first direction D1. The temporary locking portion 647 and the permanent locking portion 648 are located close to each other. The temporary locking portion 647 is located on one side (right side in the figure) of the permanent locking portion 648 in the first direction D1. Furthermore, as shown in Figure 22, the temporary locking portion 647 is positioned on one side (above) in the second direction D2 relative to the main locking portion 648.
[0090] (Retainer 690) As shown in Figures 16 to 18, the fuse unit 610 of this embodiment includes a retainer 690 that is assembled to the resin part 640. The retainer 690 is made of an insulating synthetic resin. The retainer 690 is assembled to the resin part 640 in a temporary locking position (see Figure 23) and a permanent locking position (see Figure 21). As shown in Figure 22, the retainer 690 has a roughly gate shape when viewed from the first direction D1. As shown in Figure 16, the retainer 690 includes a main body 691, a pair of locking pieces 692, and a pair of side walls 693. The pair of locking pieces 692 and the pair of side walls 693 extend from both ends of the main body 691 in the third direction D3. The locking pieces 692 are positioned on one side (right side in the figure) in the first direction D1 relative to the side walls 693. As shown in Figure 22, the main body 691 is housed in the first mounting recess 645A. A pair of locking pieces 692 and a pair of side walls 693 are arranged to be housed in the second mounting recess 645B.
[0091] As shown in Figure 18, the retainer 690 comprises a lance 694 and a retaining portion 695. The lance 694 extends from the main body 691 to the other side in the first direction D1 (left side in the figure) and to the other side in the second direction D2 (downward). The lance 694 is elastically deformable relative to the main body 691. The retaining portion 695 protrudes from the main body 691 to the other side in the second direction D2 (downward). The retaining portion 695 is substantially block-shaped.
[0092] As shown in Figures 19 and 20, when the retainer 690 is in the temporary locking position, the retaining portion 695 has not entered the cavity 644, and only the tip of the lance 694 has entered the cavity 644 through the first communication hole 643C1. When the retainer 690 is in the temporary locking position, it is permitted to insert the third terminal 680 from the opening on one side (right side in the figure) in the first direction D1 of the cavity 644. This is because the retaining portion 695 is not positioned to interfere with the third terminal 680, and the lance 694 can be elastically deformed even if it interferes with the third terminal 680.
[0093] As shown in Figure 18, with the retainer 690 in its locked position, the lance 694 and the retaining portion 695 are positioned within the cavity 644 via the first communication hole 643C1. When the third terminal 680 is positioned in its normal location within the cavity 644, the lance 694 engages with the inner wall of the locking hole 683A of the third terminal 680. The retaining portion 695 engages with one end (right side in the figure) of the connecting cylinder portion 681 in the first direction D1. This allows the third terminal 680 to be held within the cavity 644. In other words, the third terminal 680 can be held relative to the resin portion 640. Furthermore, the third terminal 680 is restricted from moving from its normal position within the cavity 644 to the other side (left side in the figure) in the first direction D1 by contacting the edge (see Figure 25) of the plate-shaped portion 31 of the second terminal 630, which is positioned within the cavity 644. Whether the third terminal 680 is in the correct position or partially inserted within the cavity 644 can be confirmed by the second communication hole 643A1.
[0094] As shown in Figures 21 and 23, the retainer 690 is provided with an insertion hole 693A that penetrates the side wall 693 in a third direction D3. The shaft portion 646 is inserted through the insertion hole 693A. The retainer 690 is rotatable about the shaft portion 646 and can move between a temporary locking position and a permanent locking position.
[0095] As shown in Figure 24, the retainer 690 is provided with a locking projection 692A that protrudes from the tip of the locking piece 692 toward the inner wall of the second mounting recess 645B. The locking projection 692A is positioned between the temporary locking portion 647 and the main locking portion 648 so that the retainer 690 is held in the temporary locking position. As shown in Figure 22, the locking projection 692A is positioned on the other side (downward) in the second direction D2 relative to the main locking portion 648 so that the retainer 690 is held in the main locking position. In detail, when the retainer 690 is in the main locking position, the locking projection 692A and the main locking portion 648 engage, preventing the retainer 690 from rotating counterclockwise from the main locking position in Figure 21. Furthermore, the locking of the main body 691 with the inner wall of the first mounting recess 645A prevents the retainer 690 from rotating clockwise from its locked position in Figure 21.
[0096] (Manufacturing method for fuse unit 610) The above describes the configuration of the fuse unit 610, and below, an example of a manufacturing method for the fuse unit 610 will be described. First, similar to the example of manufacturing method for the fuse unit 10 in Embodiment 1, the resin part 640 is integrally molded to the first terminal 620 and the second terminal 630 by insert molding (see Figure 25). Then, the first electrode 51 and the second electrode 52 of the chip fuse 50 are mounted to the first connection part 24 and the second connection part 34, respectively.
[0097] Next, the retainer 690 is attached to the resin part 640, and the retainer 690 is positioned in the temporary locking position. That is, the shaft part 646 is inserted through the insertion hole 693A, and the locking projection 692A is positioned in the gap between the temporary locking part 647 and the permanent locking part 648.
[0098] With the retainer 690 in a temporary locking position, the third terminal 680, which has been pre-formed from a metal plate and connected to the electric wire 70, is inserted (see Figure 19). During the insertion of the third terminal 680, the lance 694 interferes with the connecting cylinder portion 681 and undergoes elastic deformation. When the third terminal 680 is inserted into its proper position within the cavity 644, the lance 694 elastically returns to its original position and enters the locking hole 683A (see Figure 20).
[0099] Once the third terminal 680 is positioned in its proper place within the cavity 644, the retainer 690 is moved to its permanent locking position. When the retainer 690 is rotated clockwise from its temporary locking position in Figure 23, the locking piece 692 elastically deforms, and the locking projection 692A overcomes the permanent locking portion 648. When the locking projection 692A moves to the other side (downward) in the second direction D2 relative to the permanent locking portion 648, the locking piece 692 elastically returns to its original position, and the retainer 690 reaches its permanent locking position (see Figure 22). During this time, the lance 694 enters into the locking hole 683A, and the lance 694 and the inner wall of the locking hole 683A are positioned to lock together (see Figure 18). The retaining portion 695 is positioned on one side (right side in the figure) in the first direction D1 relative to the connecting cylinder portion 681, and is positioned to lock together with the connecting cylinder portion 681. This ensures that the third terminal 680 is held within the cavity 644. With this, the manufacturing of the fuse unit 610 is complete.
[0100] (Effects of Embodiment 7) (7-1) The fuse unit 610 according to Embodiment 7 further comprises a third terminal 680 to which a wiring member (electric wire 70) is connected, the second terminal 630 comprises a first terminal connection portion (tab portion 633) connected to the third terminal 680, and the third terminal 680 comprises a second terminal connection portion (connecting cylinder portion 681) connected to the first terminal connection portion by mating.
[0101] This configuration facilitates the connection between the wiring component and the second terminal 630.
[0102] (7-2) The fuse unit 610 according to Embodiment 7 further comprises a retainer 690 which is assembled to the resin part 640 and holds the third terminal 680.
[0103] With this configuration, the third terminal 680 can be held in relation to the resin part 640, making it easier to determine the position of the third terminal 680 relative to the resin part 640.
[0104] (7-3) In Embodiment 7, the first terminal 620 or the second terminal 630 has notches 625, 635 recessed from the outer edge, and the notches 625, 635 define the first connection portion 24 or the second connection portion 34.
[0105] With this configuration, the notches 625 and 635 define the first connection portion 24 or the second connection portion 34, allowing the size of the first connection portion 24 or the second connection portion 34 to be appropriately adjusted, and enabling control of heat dissipation from the first connection portion 24 or the second connection portion 34 when mounting the chip fuse 50.
[0106] (7-4) In Embodiment 7, the resin portion 640 has a groove 641B that is recessed relative to the first connecting portion 24 and the second connecting portion 34. The inner surfaces (first inner surface S1 and second inner surface S2) that constitute the groove 641B are connected to the first connecting portion 24 and the second connecting portion 34, and a portion of the groove 641B is located inside the notches 625 and 635.
[0107] With this configuration, when forming the resin portion 640, it is possible to suppress the movement of molten resin through the notches 625 and 635 to the outer surfaces of the first connecting portion 24 and the second connecting portion 34. This makes it possible to suppress the generation of burrs on the first connecting portion 24 and the second connecting portion 34.
[0108] (Other embodiments) Embodiments 1 to 7 described above can be implemented with the following modifications. Embodiments 1 to 7 described above and the following modifications can be combined with each other to the extent that they do not contradict each other technically.
[0109] The shapes of the first terminal, the second terminal, and the resin parts, as well as their relative arrangement, are not limited to those described in Embodiments 1 to 7 above, and can be modified as appropriate to the extent that the objectives of this disclosure can be achieved.
[0110] In Embodiment 1 described above, the end faces of the first terminal 20 and the second terminal 30 in the third direction D3 were substantially flush with the end face of the resin part 40 in the third direction D3 (see Figure 1). However, the end faces of the first terminal and the second terminal in the third direction D3 do not necessarily have to be substantially flush with the end face of the resin part in the third direction D3. For example, as a modification of Embodiment 1, as shown in Figure 29, an embodiment may be adopted in which the resin part 40 covers the end faces of the first terminal 20 and the second terminal 30 in the third direction D3.
[0111] In the above embodiment 1, the mating member was a busbar 60, but the mating member does not have to be a busbar; for example, it may be an electrode terminal.
[0112] In the above embodiment 1, the wiring member was an electric wire 70, but the wiring member does not have to be an electric wire. For example, as shown in Figure 30, the fuse unit 710 may have a second terminal 730 connected to a flexible circuit board 770, which is an example of a wiring member. Here, the flexible circuit board 770 is, for example, a flexible printed circuit board or a flexible flat cable. The flexible circuit board 770 and the second terminal 730 may be connected, for example, by soldering.
[0113] In the above embodiment 1, the mounting surface 41 of the resin part 40 was arranged flush with the first connection part 24 of the first terminal 20 and the second connection part 34 of the second terminal 30, but the mounting surface may be formed with a step relative to the first connection part and the second connection part.
[0114] In the above embodiment 1, the resin part 40 had a mounting surface 41 on which the chip fuse 50 was placed, but the resin part does not have to have a mounting surface. That is, the resin part does not have to have a surface that contacts the chip fuse, and it is sufficient that the first electrode and the second electrode of the chip fuse are connected to the first connection part of the first terminal and the second connection part of the second terminal, respectively.
[0115] In the above embodiment 7, the fuse unit 610 was equipped with a retainer 690 assembled to the resin part 640, but the fuse unit does not need to be equipped with a retainer. If a retainer is not provided, a retaining part may be provided in the housing to hold the third terminal in the cavity.
[0116] In the above embodiment 7, a tab portion 633 is exemplified as the first terminal connection portion and a connecting cylinder portion 681 is exemplified as the second terminal connection portion. However, for example, the first terminal connection portion may be a connecting cylinder portion and the second terminal connection portion may be a tab portion.
[0117] The shape of the retainer 690 in Embodiment 7 described above is just one example, and the shape of the retainer can be arbitrarily changed as long as it has the function of fixing the third terminal to the resin part. For example, in Embodiment 7 described above, the retainer 690 was held in a temporary locking position and a permanent locking position relative to the resin part 640, but only the permanent locking position may be set and the temporary locking position may be omitted. Also, the retainer may move linearly rather than rotating relative to the resin part. [Explanation of Symbols]
[0118] 1: Wiring module 10: Fuse Unit 20: 1st terminal 21: Plate-like part 21A: Recess 22: Through hole 23: Connection part for mating member 24: First connection section 30: 2nd terminal 31: Plate-like part 31A: Recess 32: Through hole 33: Barrel section 33A: Core wire crimping section 33B: Insulation coating crimping part (fixed part) 34: Second connection section 40: Resin part 41: Mounting surface 42: Peripheral wall part 43: Intermediate molded body 50: Chip fuse 51: 1st electrode 52: 2nd electrode 60: Busbar (Mating component) 70: Electric wires (wiring materials) 110: Fuse unit 144: Lid (cover component) 210: Fuse Unit 245: Sealing part (cover member) 246: Through hole 310: Fuse unit 345: Sealing part (cover member) 410: Fuse unit 430: 2nd terminal 434: Wire connection part 435: Wire clamp (fixing part) 435A: Base 435B: Extension 510: Fuse Unit 520: 1st terminal 521: Plate-like part 521A: 1st plate part 521B: 2nd plate part 521C: Third plate part 530: 2nd terminal 531: Plate-like part 531A: 1st plate part 531B: 2nd plate part 531C: Third plate part 540: Resin part 610: Fuse Unit 620: 1st terminal 625: Notch 630: 2nd terminal 633: Tab section (first terminal connection section) 635: Notch 640: Resin part 641: Middle section 641A: Reference plane 641B: Groove 643: Housing Department 643A: Bottom wall 643A1: 2nd communication hole 643B: Side wall 643C: Ceiling and Wall 643C1: 1st communication hole 644: Cavity 645: Mounting recess 645A: First mounting recess 645B: Second mounting recess 646: Shaft 647: Temporary locking part 648: This locking part 680: 3rd terminal 681: Connecting tube section (second terminal connection section) 682: Barrel section 682A: Core wire crimping section 682B: Insulated coating crimping section 683: Cylinder wall 683A: Locking hole 684: Elastic contact piece 690: Retainer 691: Main body 692: Rock fragment 692A: Locking protrusion 693: Side wall 693A: Through hole 694: Lance 695: Retaining part 710: Fuse Unit 730: 2nd terminal 770: Flexible circuit board (wiring material) BS: Bottom S1: First Inner Surface S2: Second Inner Self S3: Third Inner Self SP1: 1st side part D1: 1st direction D2: Second direction D3: Third direction
Claims
1. A first terminal that is electrically connected to the mating component, A second terminal that is electrically connected directly or indirectly to the wiring component, A resin portion covering a part of the first terminal and a part of the second terminal, Equipped with a chip fuse, The resin portion maintains the distance between the first terminal and the second terminal. The first terminal includes a first connection portion exposed from the resin portion, The second terminal is provided with a second connecting portion exposed from the resin portion, The chip fuse comprises a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion. The first connecting portion and the second connecting portion are flush with each other. The first terminal and the second terminal are arranged side by side in the first direction. The resin portion has an intermediate portion disposed between the first terminal and the second terminal, The intermediate portion is formed having a mounting surface on which the chip fuse is placed, A fuse unit in which the first connection portion is exposed from the aforementioned mounting surface, and the second connection portion is exposed from the aforementioned mounting surface.
2. A first terminal that is electrically connected to the mating component, A second terminal that is electrically connected directly or indirectly to the wiring component, A resin portion covering a part of the first terminal and a part of the second terminal, Equipped with a chip fuse, The resin portion maintains the distance between the first terminal and the second terminal. The first terminal includes a first connection portion exposed from the resin portion, The second terminal is provided with a second connecting portion exposed from the resin portion, The chip fuse comprises a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion. The first connecting portion and the second connecting portion are flush with each other. The first terminal and the second terminal are arranged side by side in the first direction. The resin portion has an intermediate portion disposed between the first terminal and the second terminal, When the direction perpendicular to the first direction is defined as the second direction, one end face of the intermediate portion in the second direction is defined as the reference plane. The fuse unit is positioned flush with the first and second connection portions, and the reference surface is flush with the first and second connection portions.
3. The fuse unit according to claim 2, wherein the intermediate portion has a groove that recesses toward the other side in the second direction from the reference surface.