Terminal block and method for manufacturing bus bar terminal

Abstract

The purpose of the present invention is to reduce noise with a small configuration in a terminal block. The terminal block includes a conductive path forming body including a bus bar terminal, an annular magnetic core, and an insulating base. The conductive path forming body includes a first connection part, a second connection part, and an intermediate part between the first connection part and the second connection part. When viewed along the extension direction of the intermediate part, the first connection part and the second connection part are wider than the intermediate part. The magnetic core includes a plurality of divided cores, and the magnetic core surrounds the intermediate portion with the plurality of divided cores being disposed so as to form an annular shape. The insulating base holds the intermediate part and the magnetic core surrounding the intermediate part with at least a part of the first connection part and at least a part of the second connection part being exposed.

Description

Terminal block and bus bar terminal manufacturing method

[0001] The present disclosure relates to a terminal block and a method for manufacturing a bus bar terminal.

[0002] Patent Document 1 discloses a terminal block including a housing having a resin portion, and a bus bar integrally including an embedded portion embedded in the resin portion and a connection portion protruding outward from the resin portion.

[0003] International Publication No. 2017 / 154543

[0004] There is a demand for terminal blocks that have a compact configuration and that reduce noise.

[0005] Therefore, an object of the present disclosure is to provide a terminal block that can reduce noise with a compact configuration.

[0006] The terminal block of the present disclosure comprises a conductive path forming body including a bus bar terminal, a ring-shaped magnetic core, and an insulating base that holds the conductive path forming body and the magnetic core, wherein the conductive path forming body includes a first connection portion, a second connection portion, and an intermediate portion between the first connection portion and the second connection portion, and when viewed along the extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion, the magnetic core includes a plurality of split cores that are arranged to form a ring, and the magnetic core surrounds the intermediate portion, and the insulating base holds the intermediate portion and the magnetic core surrounding the intermediate portion, with at least a portion of the first connection portion and at least a portion of the second connection portion exposed.

[0007] In addition, the manufacturing method of a bus bar terminal of the present disclosure is a manufacturing method of a bus bar terminal that includes preparing a cylindrical metal material, pressing an end of the cylindrical metal material into a flat shape, bending the cylindrical metal material, and positioning the end of the cylindrical metal material at a position that is off the extension of the middle portion of the cylindrical metal material.

[0008] According to the present disclosure, noise can be reduced in a terminal block with a compact configuration.

[0009] Furthermore, a bus bar terminal suitable for the terminal block can be manufactured.

[0010] FIG. 1 is a perspective view showing a terminal block according to a first embodiment. FIG. 2 is a front view showing the terminal block. FIG. 3 is an exploded perspective view showing the terminal block. FIG. 4 is an exploded perspective view showing the terminal block. FIG. 5 is a cross-sectional view taken along line V-V in FIG. 2. FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. 2. FIG. 7 is an explanatory diagram showing a method for manufacturing a bus bar terminal. FIG. 8 is an explanatory diagram showing a method for manufacturing a bus bar terminal. FIG. 9 is an explanatory diagram showing a method for manufacturing a terminal block. FIG. 10 is an explanatory diagram showing a method for manufacturing a terminal block. FIG. 11 is an explanatory diagram showing a method for manufacturing a terminal block. FIG. 12 is a perspective view showing a terminal block according to a modified example. FIG. 13 is a perspective view showing the internal structure of the terminal block. FIG. 14 is a perspective view showing a terminal block according to a second embodiment. FIG. 15 is a perspective view showing the internal structure of the terminal block. FIG. 16 is a cross-sectional view taken along line XVI-XVI in FIG. 15. FIG. 17 is a cross-sectional view taken along line XVII-XVII in FIG. 15.

[0011] [Description of Embodiments of the Present Disclosure] First, embodiments of the present disclosure will be listed and described.

[0012] The terminal block of the present disclosure is as follows.

[0013] (1) A terminal block comprising: a conductive path forming body including a bus bar terminal; an annular magnetic core; and an insulating base that holds the conductive path forming body and the magnetic core, wherein the conductive path forming body includes a first connection portion, a second connection portion, and an intermediate portion between the first connection portion and the second connection portion, and when viewed along the extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion, the magnetic core includes a plurality of split cores, and the magnetic core surrounds the intermediate portion with the plurality of split cores arranged to form a ring, and the insulating base holds the intermediate portion and the magnetic core surrounding the intermediate portion with at least a portion of the first connection portion and at least a portion of the second connection portion exposed.

[0014] According to this terminal block, the magnetic core includes multiple split cores. Therefore, by combining the multiple split cores around the middle section, which is smaller in width than the first and second connection sections, the middle section can be surrounded by the magnetic core. Surrounding the middle section of the conductive path forming body with an annular magnetic core reduces noise. Furthermore, since the first or second connection section does not need to be inserted into the annular magnetic core, the inner circumference of the magnetic core can be reduced. This, combined with the magnetic core surrounding the narrowed middle section, allows for the magnetic core to be made smaller.

[0015] (2) In the terminal block of (1), the inner peripheral portion of the magnetic core may be formed in a shape that restricts passage between the first connection portion and the second connection portion, while allowing passage of the intermediate portion.

[0016] This makes it easier to place the magnetic core close to the middle part, which makes it possible to reduce the size of the magnetic body and improve the noise reduction effect.

[0017] (3) In the terminal block according to (1) or (2), the bus bar terminal may be a pressed part made of a single metal material.

[0018] This allows the bus bar terminal to be easily processed.

[0019] (4) In the terminal block of any one of (1) to (3), the conductive path forming body may include a plurality of the busbar terminals, each of which includes a first busbar end portion, a second busbar end portion, and a busbar intermediate portion between the first busbar end portion and the second busbar end portion, the plurality of busbar intermediate portions extending parallel to each other with a gap therebetween, at least one of the plurality of first busbar end portions extending in a direction intersecting with the plurality of busbar intermediate portions so that the first connection portion is wider than the intermediate portion, and at least one of the plurality of second busbar end portions extending in a direction intersecting with the plurality of busbar intermediate portions so that the second connection portion is wider than the intermediate portion.

[0020] This allows the first and second bus bar ends to be bent relative to the bus bar intermediate portion according to the layout of the mating component of the bus bar terminal. In this case, the first and second connection portions may be wider than the intermediate portion. In such a case, a magnetic core with a small inner periphery can be disposed around the intermediate portion.

[0021] (5) In a terminal block according to any one of (1) to (4), the conductive path forming body may include a cylindrical bus bar terminal as the bus bar terminal, and the cylindrical bus bar terminal may include a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, and the end portion of the cylindrical intermediate portion may be curved, and the flat end portion may extend in a direction that intersects with the extension direction of the intermediate portion of the cylindrical intermediate portion.

[0022] In this case, the cylindrical intermediate portion can be easily bent in any direction, which makes it easy to process the flat end portion so that it extends in any direction.

[0023] (6) In a terminal block according to any one of (1) to (5), the conductive path forming body may include a cylindrical bus bar terminal as the bus bar terminal, and the cylindrical bus bar terminal may include a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, and the flat end portion may be curved in its thickness direction, and the tip portion of the flat end portion may extend in a direction that intersects with the extension direction of the cylindrical intermediate portion.

[0024] In this case, by processing the direction of the flat end portion relative to the cylindrical intermediate portion in any direction, the flat end portion can be easily processed to extend in any direction.

[0025] (7) In the terminal block of any one of (1) to (6), the conductive path forming body may include a first cylindrical bus bar terminal and a second cylindrical bus bar terminal as the bus bar terminals, each of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal including a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, the cylindrical intermediate portions of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal extending in parallel with a gap therebetween, and the end portion or the flat end portion of the cylindrical intermediate portion of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal may be bent at the same position in the extension direction of the plurality of cylindrical intermediate portions.

[0026] As a result, the end or flat end of each cylindrical intermediate portion of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal is bent at the same position in the extension direction of the plurality of cylindrical intermediate portions, which makes it easier to arrange the flat end of each cylindrical bus bar terminal and the second cylindrical bus bar terminal in a position suitable for connection to a mating component. This reduces the need for installation space for the magnetic core. This allows the magnetic core to be larger in the extension direction of the plurality of cylindrical intermediate portions.

[0027] (8) In the terminal block according to any one of (1) to (7), the magnetic core may include a magnetic filler material interposed between the plurality of split cores.

[0028] In this case, the magnetic filler material interposed between the multiple split cores suppresses the air gap, thereby improving noise reduction performance.

[0029] The bus bar terminal of the present disclosure is manufactured by the following method.

[0030] (9) A method for manufacturing a bus bar terminal, comprising the steps of preparing a cylindrical metal material, pressing an end of the cylindrical metal material into a flat shape, bending the cylindrical metal material, and positioning the end of the cylindrical metal material at a position that is off the extension of a middle portion of the cylindrical metal material.

[0031] In this way, by pressing the end of the cylindrical metal material into a flat shape, the flattened end can be easily connected to a mating part by surface contact. By bending the cylindrical part in any direction or by arbitrarily setting the flat direction relative to the cylindrical part, it is easy to arbitrarily set the extension direction of the flat part of the end relative to the middle part of the cylindrical metal material.

[0032] [Details of the Embodiments of the Present Disclosure] Specific examples of the terminal block and the manufacturing method of the bus bar terminal of the present disclosure will be described below with reference to the drawings. Note that the present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims.

[0033] [Embodiment 1] A terminal block 20 according to embodiment 1 will be described below. Fig. 1 is a perspective view showing the terminal block 20. Fig. 2 is a front view showing the terminal block 20. In Fig. 2, the housing 11 of the device 10 to which the terminal block 20 is fixed, the mating connection terminals 14 and 15 that are the mating connection components, and the wiring components 16 and 17 are shown by two-dot chain lines. Figs. 3 and 4 are exploded perspective views showing the terminal block 20. Fig. 5 is a cross-sectional view taken along line V-V in Fig. 2, and Fig. 6 is a cross-sectional view taken along line VI-VI in Fig. 2.

[0034] <Overall Configuration of Terminal Block> The terminal block 20 is attached to the housing 11 of the device 10. The device 10 is, for example, a rotating electrical machine or an inverter. The housing 11 is a case that covers the internal components of the device 10. Mounting holes 11h are formed in the housing 11. The terminal block 20 is attached to the housing 11 in a portion surrounding the mounting holes 11h. The terminal block 20 electrically connects electrical components inside the device 10 to electrical components outside the device 10 via the mounting holes 11h.

[0035] For example, the device 10 may be a rotating electric machine, and the terminal block 20 may be used as a component that electrically connects electrical components within the rotating electric machine with an inverter external to the rotating electric machine. In this case, it may be necessary to remove noise from the drive current passing through the terminal block 20. In particular, when a silicon carbide (SiC) semiconductor is used in the inverter, the noise level may become high. The terminal block 20 includes a magnetic core 50 and is configured to remove noise from the drive current passing through the terminal block 20.

[0036] The terminal block 20 includes a conductive path forming body 30 , a magnetic core 50 , and an insulating base 60 .

[0037] The conductive path forming body 30 is a portion that forms a conductive path that connects the inside and outside of the device 10. In the present embodiment, the conductive path forming body 30 includes a plurality of (here, three) bus bar terminals 40A, 40B, and 40C. The conductive path forming body may also be configured to include only one bus bar terminal.

[0038] The conductive path formation 30 includes a first connection portion 32, a second connection portion 34, and an intermediate portion 36 between the first connection portion 32 and the second connection portion 34. The first connection portion 32 and the second connection portion 34 are portions that are connected to electrical components inside or outside the device 10. The intermediate portion 36 is a portion that electrically connects the first connection portion 32 and the second connection portion 34.

[0039] When the conductive path formation body 30 includes a plurality of bus bar terminals 40A, 40B, and 40C, the first connection portion 32 is a portion that includes a plurality of one-side ends (first bus bar ends 42A, 42B, and 42C described later) of the plurality of bus bar terminals 40A, 40B, and 40C. Similarly, the second connection portion 34 is a portion that includes a plurality of other-side ends (second bus bar ends 44A, 44B, and 44C described later) of the plurality of bus bar terminals 40A, 40B, and 40C, and the intermediate portion 36 is a portion that includes a plurality of intermediate portions (bus bar intermediate portions 46A, 46B, and 46C described later) of the plurality of bus bar terminals 40A, 40B, and 40C.

[0040] When viewed along the extending direction A of the intermediate portion 36, the first connecting portion 32 and the second connecting portion 34 are wider than the intermediate portion 36. This makes it easy to arrange the first connecting portion 32 and the second connecting portion in a layout suitable for connection with the mating connection terminal 14 or the mating connection terminal 15. Furthermore, by configuring the intermediate portion 36 to be narrower than the first connecting portion 32 and the second connecting portion 34, it is easy to make the intermediate portion 36 of the conductive path forming body 30 smaller.

[0041] The magnetic core 50 is a component formed into an annular shape from a magnetic material.

[0042] The magnetic core 50 is disposed so as to surround the middle portion 36 of the conductive path forming body 30. This removes noise, particularly high-frequency noise, from the current flowing through the conductive path forming body 30. For example, an inductor is formed by the magnetic core 50 and each of the bus bar terminals 40A, 40B, 40C that make up the conductive path forming body 30, and the inductor exhibits high impedance to the high-frequency current flowing through the conductive path forming body 30, thereby removing high-frequency noise.

[0043] The magnetic core 50 surrounds the intermediate portion 36 while being insulated from the intermediate portion 36. Because the intermediate portion 36 is disposed on the inner periphery of the magnetic core 50, the inner periphery is formed in a shape that allows the intermediate portion 36 to pass through. It is preferable that the inner periphery of the magnetic core 50 be shaped so that it can be close to the outer periphery of the intermediate portion 36, while maintaining insulation from the intermediate portion 36. This reduces the distance between the intermediate portion 36 and the magnetic core 50, making it easier to increase impedance even with a small magnetic core 50. Furthermore, reducing the inner periphery of the magnetic core 50 allows the magnetic core 50 to be made smaller, contributing to the miniaturization and cost reduction of the terminal block 20.

[0044] As described above, the first connecting portion 32 and the second connecting portion 34 are wider than the intermediate portion 36. If the inner peripheral portion of the magnetic core were sized to allow the first connecting portion 32 and the second connecting portion 34 to pass through, the gap between the inner peripheral portion of the magnetic core and the intermediate portion 36 would be large when the magnetic core covers the intermediate portion 36. This could result in a decrease in impedance due to the magnetic core. Compensating for this increased gap by increasing the cross-sectional area of ​​the magnetic path of the magnetic core could result in an increase in the size of the magnetic core. Furthermore, the increase in the size of the inner peripheral portion of the magnetic core could result in an increase in the size of the magnetic core. A larger magnetic core would result in an increase in the size of the terminal block and potentially increased costs.

[0045] Therefore, the inner periphery of the magnetic core 50 is made small enough to restrict passage between the first connecting portion 32 and the second connecting portion 34. The inner periphery of the magnetic core 50 is made as small as possible within a range that maintains insulation from the intermediate portion 36. For example, the inner periphery of the magnetic core 50 may be made small enough to maintain a minimum distance of approximately 1 mm to 10 mm from the outer periphery of the intermediate portion 36.

[0046] The magnetic core 50 may also include a plurality of split cores 50A, 50B. For example, the annular magnetic core 50 may be split into two parts. The magnetic core 50 may be split into two symmetrically or asymmetrically. The magnetic core may be split into three or more parts. In this embodiment, the magnetic core 50 has a track shape with semi-annular parts connected to both ends of a pair of parallel parts. The magnetic core 50 is split into two symmetrically along a split plane perpendicular to the long side direction.

[0047] Each of the split cores 50A and 50B is made of a magnetic material. For example, the split cores 50A and 50B may be made of ferrite, laminated electromagnetic steel sheets, or dust material.

[0048] The split cores 50A, 50B are arranged with their end faces facing each other to form a ring, and the magnetic core 50 surrounds the intermediate portion 36. In this case, the first connecting portion 32 and the second connecting portion 34 do not need to pass through the magnetic core 50, so the inner peripheral portion of the magnetic core 50 can be made smaller so as to approximate the shape of the outer peripheral portion of the intermediate portion 36, regardless of the expanded shapes of the first connecting portion 32 and the second connecting portion 34.

[0049] A magnetic filler 52 may be interposed between the multiple split cores 50A, 50B. The magnetic filler 52 is a magnetic material that is softer than the split cores 50A, 50B and fills the gaps between the split cores 50A, 50B. The magnetic filler 52 is, for example, a magnetic sheet. The magnetic sheet is, for example, a sheet including a base material such as resin or rubber and magnetic powder such as ferrite dispersed within the base material. The magnetic filler 52 may also be a magnetic adhesive. The magnetic adhesive is an adhesive including a base material such as resin or rubber and magnetic powder such as ferrite dispersed within the base material. The magnetic filler 52 may also be a filler that combines a magnetic sheet and a magnetic adhesive.

[0050] By interposing the magnetic filler 52 between the end faces of the multiple split cores 50A, 50B, the air gap in the magnetic path around the intermediate portion 36 is reduced. For example, if the end faces of the multiple split cores 50A, 50B are non-parallel, the magnetic filler 52 can fill the gap between the non-parallel end faces and adhere closely to the end faces. Also, if there are small irregularities on the end faces of the multiple split cores 50A, 50B, the magnetic filler 52 can fill the irregularities and adhere closely to the end faces. This reduces the magnetic reluctance of the magnetic core 50, improving noise reduction.

[0051] The insulating base 60 is a portion that holds the conductive path forming body 30 and the magnetic core 50. The insulating base 60 keeps the multiple bus bar terminals 40A, 40B, and 40C of the conductive path forming body 30 in a constant positional relationship while insulated. The insulating base 60 also keeps the magnetic core 50 in a constant positional relationship surrounding the multiple bus bar terminals 40A, 40B, and 40C while being insulated from the multiple bus bar terminals 40A, 40B, and 40C. The insulating base 60 holds the intermediate portion 36 and the magnetic core 50 surrounding the intermediate portion 36, with at least a portion of the first connecting portion 32 and at least a portion of the second connecting portion 34 exposed.

[0052] The insulating base 60 may be, for example, a part molded from resin using one or both of the conductive path forming body 30 and the magnetic core 50 as insert parts. The insulating base 60 may also be, for example, a part molded from resin separately from the conductive path forming body 30 and the magnetic core 50.

[0053] In this embodiment, the insulating base 60 includes a first resin portion 62 and a second resin portion 66 .

[0054] The first resin portion 62 is a resin molded portion using the conductive path formation 30 as an insert portion. The first resin portion 62 maintains the multiple bus bar terminals 40A, 40B, 40C in a constant positional relationship while being insulated from one another. The first resin portion 62 also covers the periphery of the intermediate portion 36, separating the intermediate portion 36 from the magnetic core 50 so as to insulate them from each other.

[0055] More specifically, the first resin portion 62 includes a fixing plate portion 63 , a body portion 64 , and a holding protrusion portion 65 .

[0056] The fixing plate portion 63 is formed in a plate shape that is wider than the mounting hole 11h. A fixing hole 63h is formed in the fixing plate portion 63. The fixing plate portion 63 can cover the outer surface of the housing 11 around the mounting hole 11h. In this state, the terminal block 20 is fixed to the housing 11 by threading a screw into the housing 11 through the fixing hole 63h.

[0057] The body 64 protrudes from the fixing plate 63. When the fixing plate 63 is attached to the housing 11, the body 64 is disposed within the mounting hole 11h. The intermediate portion 36 of the conductive path forming body 30 is located within the body 64. The conductive path forming body 30 penetrates the fixing plate 63, and the first connection portion 32 is exposed on the surface of the fixing plate 63 opposite the body 64. In this embodiment, the first connection portion 32 includes a plurality of first bus bar ends 42A, 42B, and 42C, which are electrically connected to the respective connection mating terminals 14. The connection mating terminals 14 are, for example, plate-shaped bus bar terminals extending from an inverter. Screw insertion holes may be formed in the first bus bar ends 42A, 42B, and 42C, and the first bus bar ends 42A, 42B, and 42C may be fastened to the connection mating terminals 14 with screws.

[0058] The retaining protrusion 65 protrudes outward from the end of the body 64 opposite the fixing plate 63. In this embodiment, the retaining protrusion 65 protrudes in an annular shape from the periphery of the end of the body 64. The magnetic core 50 is disposed between the fixing plate 63 and the retaining protrusion 65, surrounding the body 64. This holds the magnetic core 50 in a fixed position relative to the body 64.

[0059] The second resin part 66 is formed in a holder shape that surrounds the outer periphery, upper surface, and lower surface of the magnetic core 50. In this embodiment, the second resin part 66 is divided into two divided holder parts 66A and 66B. One side edge of the divided holder parts 66A and 66B is connected by a thin hinge 67a so that they can be opened and closed. A locking protrusion 66Bp is formed on the other side edge of the divided holder part 66A, and a locking piece 66Ap extends from the other side edge of the divided holder part 66B. By closing the open divided holder parts 66A and 66B, the magnetic core 50 can be placed inside the divided holder parts 66A and 66B. With the magnetic core 50 covered by the split holder parts 66A and 66B, the locking protrusion 66Bp on the other side edge of the split holder part 66A is engaged with the locking hole formed in the locking piece 66Ap on the other side edge of the split holder part 66B, thereby keeping the split holder parts 66A and 66B in a closed state.

[0060] The conductive path forming body 30 penetrates the body 64, and the second connection portion 34 protrudes below the body 64. In the present embodiment, the second connection portion 34 includes a plurality of second bus bar ends 44A, 44B, 44C, which are electrically connected to the respective mating connection terminals 15. The mating connection terminals 15 are, for example, plate-shaped bus bar terminals extending from electrical components within the device 10. The second bus bar ends 44A, 44B, 44C may have screw insertion holes formed therein and be fastened to the mating connection terminals 15 with screws.

[0061] An annular seal 22 may be disposed on the surface of the fixing plate 63 facing the housing 11. The annular seal 22 is an annular elastic component positioned around the mounting hole 11 h. The annular seal 22 is interposed in a compressed state between the fixing plate 63 and the housing 11, thereby sealing off liquid around the mounting hole 11 h.

[0062] A relay connector 24 may be held on the fixing plate portion 63. The relay connector 24 is a connector that relays connection between the wiring component 16 inside the device 10 and the wiring component 17 outside the device 10. For example, the relay connector 24 has a configuration that allows connection to both the connector on the wiring component 16 side and the connector on the wiring component 17 outside the device 10, and the circuit of the wiring component 16 and the circuit of the wiring component 17 are electrically connected via a relay terminal in the relay connector 24.

[0063] The fixing plate portion 63 may be molded using the relay connector 24 as an insert portion. It is not essential that the terminal block 20 includes the relay connector 24.

[0064] <Regarding the Conductive Path Forming Body> The conductive path forming body 30 will be described in more detail. The conductive path forming body 30 includes multiple bus bar terminals 40A, 40B, and 40C. Each of the multiple bus bar terminals 40A, 40B, and 40C is preferably an integral piece made of conductive material, and is not a component formed by combining multiple components through insertion connection. For example, each of the multiple bus bar terminals 40A, 40B, and 40C may be a pressed component made of a single metal material. If each of the multiple bus bar terminals 40A, 40B, and 40C is a pressed component made of a single metal material, it is not necessary to form a spring structure or contact structure for insertion connection, thereby reducing costs. Furthermore, heat generation at the contact portions is suppressed.

[0065] Each of the bus bar terminals 40A, 40B, and 40C includes a first bus bar end portion 42A, 42B, and 42C, a second bus bar end portion 44A, 44B, and 44C, and a bus bar intermediate portion 46A, 46B, and 46C. The bus bar intermediate portions 46A, 46B, and 46C are located between the first bus bar end portion 42A, 42B, and 42C and the second bus bar end portion 44A, 44B, and 44C. The bus bar terminals 40A and 40C may have mirror symmetry with respect to a plane passing through the central axis of the bus bar terminal 40B. The first bus bar ends 42A, 42B, 42C and the second bus bar ends 44A, 44B, 44C extend in a direction intersecting with the extending direction A of the bus bar intermediate portions 46A, 46B, 46C, respectively.

[0066] The plurality of bus bar intermediate portions 46A, 46B, 46C extend parallel to one another at intervals. In this embodiment, the plurality of bus bar intermediate portions 46A, 46B, 46C are arranged in a line in this order at intervals. The intervals are set to a size corresponding to the desired insulation distance.

[0067] At least one of the plurality of first bus bar end portions 42A, 42B, 42C extends in a direction intersecting the plurality of bus bar intermediate portions 46A, 46B, 46C so that the first connection portion 32 extends wider than the intermediate portion 36.

[0068] In addition, at least one of the multiple second bus bar end portions 44A, 44B, 44C extends in a direction intersecting the multiple bus bar intermediate portions 46A, 46B, 46C so that the second connection portion 34 is wider than the intermediate portion 36.

[0069] Here, the extent of the first connecting portion 32, the second connecting portion 34, and the intermediate portion 36 may be the extent when viewed along the extending direction A of the intermediate portion 36. Moreover, the extent is the range over which each component of the first connecting portion 32, the second connecting portion 34, or the intermediate portion 36 extends. For example, the size of the extent may be evaluated by the area of ​​a convex hull (see Q1 and Q2 in FIG. 5 and Q1 and Q3 in FIG. 6) that can encompass each component of the first connecting portion 32, the second connecting portion 34, or the intermediate portion 36 when viewed along the extending direction A of the intermediate portion 36.

[0070] The extent of the expansion of the first connection portion 32, the second connection portion 34 and the intermediate portion 36 may be evaluated by the area of ​​a circumscribed circle that can encompass each component part of the first connection portion 32, the second connection portion 34 or the intermediate portion 36 when viewed along the extension direction A of the intermediate portion 36.

[0071] In the present embodiment, the first connection portion 32 is a portion that widens at the end relative to the intermediate portion 36, and includes a portion that protrudes upward from the insulating base 60. The first connection portion 32 includes first bus bar end portions 42A, 42B, 42C.

[0072] The first bus bar ends 42A, 42B, 42C are bent in a direction intersecting the bus bar intermediate portions 46A, 46B, 46C, in this case, a direction perpendicular to the bus bar intermediate portions 46A, 46B, 46C. The first bus bar end 42A is bent toward one side of the direction in which the bus bar intermediate portions 46A, 46B, 46C are aligned. The first bus bar end 42C is bent in the opposite direction to the first bus bar end 42A. The first bus bar end 42B is bent in a direction perpendicular to the direction in which the bus bar intermediate portions 46A, 46B, 46C are aligned.

[0073] The intermediate portion 36 includes bus bar intermediate portions 46A, 46B, and 46C, and the convex hull Q1 of the intermediate portion 36 is the area surrounded by the outer edges of the outer bus bar intermediate portions 46A and 46C in the direction in which the bus bar intermediate portions 46A, 46B, and 46C are arranged (see Figure 5).

[0074] The convex hull Q2 of the first connection portion 32 is the area enclosed by a convex polygon connecting the tip corners of the first bus bar ends 42A, 42B, 42C. The tip corners of the first bus bar ends 42A, 42B, 42C are located at positions away from the bus bar intermediate portions 46A, 46B, 46C, and therefore the convex hull Q2 is larger than the convex hull Q1. Therefore, the first connection portion 32 extends wider than the intermediate portion 36.

[0075] The second connection portion 34 is a portion that widens toward the end portion relative to the intermediate portion 36, and includes a portion that protrudes downward from the insulating base 60. The second connection portion 34 includes second bus bar ends 44A, 44B, 44C.

[0076] The second bus bar ends 44A, 44C are bent in a direction intersecting the bus bar intermediate portions 46A, 46B, 46C, in this case, a direction intersecting at 45 degrees. The second bus bar end 44A is bent obliquely toward one side of the direction in which the bus bar intermediate portions 46A, 46B, 46C are aligned. The second bus bar end 44C is bent in the opposite direction to the second bus bar end 44A. The second bus bar end 44B extends straight without bending relative to the bus bar intermediate portion 46B.

[0077] The convex hull Q3 of the second connection portion 34 is a range that surrounds the tip corners of the second bus bar ends 44A, 44C and the outer edges of the base end portions of the second bus bar ends 44A, 44B, 44C that extend beyond the insulating base 60 (see FIG. 6 ). The tip corners of the second bus bar ends 44A, 44C are located outwardly away from the bus bar intermediate portions 46A, 46B, 46C, and the base end portions of the second bus bar ends 44A, 44B, 44C that extend beyond the insulating base 60 are also located within a range similar to that of the bus bar intermediate portions 46A, 46B, 46C. Therefore, the convex hull Q3 is larger than the convex hull Q1. Therefore, the second connection portion 34 is wider than the intermediate portion 36.

[0078] In this embodiment, the bus bar terminals 40A, 40B, and 40C are cylindrical bus bar terminals that include flat end portions and cylindrical intermediate portions that are closer to a cylinder than the flat end portions.

[0079] The cylindrical intermediate portion being closer to a cylinder than the flattened end portion means that the cross-sectional shape (cross section in a direction perpendicular to the extension direction A) of the cylindrical intermediate portion is closer to a circle than the cross-sectional shape of the flattened end portion. The flattened end portion is flatter than the cylindrical intermediate portion. The degree of flatness may be evaluated as the ratio of the lateral dimension in the direction perpendicular to the longest direction to the longitudinal dimension in the longest direction of the cross-sectional shape of the flattened end portion or the cylindrical intermediate portion. A smaller ratio of the lateral dimension to the longitudinal dimension may be evaluated as being flatter. A degree of flatness closer to 1 may be evaluated as being closer to a circle.

[0080] In this embodiment, the bus bar intermediate portions 46A, 46B, 46C, excluding the portions near the first bus bar ends 42A, 42B, 42C, and the portions near the base ends of the second bus bar ends 44A, 44B, 44C, are cylindrical intermediate portions with a circular cross section. The first bus bar ends 42A, 42B, 42C are flat end portions having a rectangular plate shape. The portions near the tip ends of the second bus bar ends 44A, 44B, 44C are also flat end portions having a rectangular plate shape.

[0081] On the second bus bar end 44A, 44C side of the bus bar terminal 40A, 40C, the end of the cylindrical intermediate portion, i.e., the base end of the second bus bar end 44A, 44C, is bent, so that the second bus bar end 44A, 44C as a flat end extends in a direction intersecting with the bus bar intermediate portion 46A, 46C, which includes the intermediate portion of the cylindrical intermediate portion. Because the end of the cylindrical intermediate portion has a circular cross section, it is easy to bend in various directions relative to the bus bar intermediate portion 46A, 46C. Therefore, the second bus bar end 44A, 44C can be easily bent in different directions from each other.

[0082] On the first bus bar end 42A, 42B, 42C side of the bus bar terminals 40A, 40B, 40C, the flat end is bent in its thickness direction, and the first bus bar end 42A, 42B, 42C, which is the tip of the flat end, extends in a direction intersecting the extension direction of the cylindrical intermediate portion.

[0083] For example, by pressing the cylindrical intermediate portion in any direction, the flattening direction of the flattened end portion relative to the cylindrical intermediate portion can be processed in any direction. By setting the flattening direction of the flattened end portion in the desired bending direction, the bending direction of the flattened end portion can be easily set in any direction.

[0084] The above will be described more specifically using a manufacturing method of the bus bar terminal 40A as an example.

[0085] 7, a cylindrical metal material 90 is prepared. The cylindrical metal material 90 is a metal material in the shape of a round bar. The cylindrical metal material 90 may be made of copper, a copper alloy, aluminum, an aluminum alloy, or the like.

[0086] Then, the ends of the cylindrical metal material 90 are press-formed into a flattened shape. By arbitrarily setting the press direction relative to the middle portion of the cylindrical metal material 90, the flattening directions of both end portions of the cylindrical metal material 90 can be arbitrarily made different from each other. For example, the flattening directions of both end portions of the cylindrical metal material 90 can be set to positions shifted by 90 degrees around the central axis of the cylindrical metal material 90.

[0087] As shown in FIG. 8, a cylindrical metal material 90 has flat end portions 92, 94 formed at both ends, and a cylindrical middle portion 96 formed therebetween.

[0088] Then, by bending the base end of the flat end 92 in its thickness direction, the tip end of the flat end 92 extends in a direction intersecting with the cylindrical intermediate portion 96. As a result, a first busbar end 42A extending in a direction intersecting with the busbar intermediate portion 46A can be formed above the busbar intermediate portion 46A where the base end of the flat end 92 is connected to the upper end of the cylindrical intermediate portion 96.

[0089] Because the flattened end portion 92 is formed by flattening the cylindrical metal material 90 by pressing, the flattening direction of the flattened end portion 92 can be easily adjusted by adjusting the pressing direction during processing. By forming the flattened end portion 92 so that it is flat in the desired bending direction, the first bus bar end portion 42A can be easily processed to extend in any direction. For example, in the bus bar terminal 40C, the first bus bar end portion 42C can be easily bent in the opposite direction to the first bus bar end portion 42A. Furthermore, in the bus bar terminal 40B, for example, by changing the flattening direction of the flattened end portion, the first bus bar end portion 42B can be easily bent in a direction different from the first bus bar ends 42A and 42C. Screw holes for fastening can be formed in the first bus bar end portion 42A as needed.

[0090] Furthermore, by bending the end of the cylindrical intermediate portion 96, the flat end portion 94 extends in a direction intersecting the middle portion of the cylindrical intermediate portion 96. This forms a second bus bar end portion 44A in which the flat end portion 94 is connected to the lower end portion of the cylindrical intermediate portion 96. Because the bending location is set at the end of the cylindrical intermediate portion 96, the bending direction can be set as desired. Therefore, in the bus bar terminal 40C, the second bus bar end portion 44C can be easily bent in the opposite direction to the second bus bar end portion 44A. If necessary, a screw-fastening hole is formed in the second bus bar end portion 44A.

[0091] In this way, the cylindrical metal material 90 can be bent so that the end of the cylindrical metal material 90 can be easily positioned at a position that is not on the extension of the middle part of the cylindrical metal material 90.

[0092] It is noted that either the process of flattening the end portion of the cylindrical metal material 90 or the process of bending the cylindrical metal material 90 may be performed first.

[0093] As shown in Figures 3 and 4, if cylindrical bus bar terminals are used as the bus bar terminals 40A, 40B, and 40C, it is easy to arbitrarily set the bending directions of the first bus bar ends 42A, 42B, and 42C and the second bus bar ends 44A, 44B, and 44C.

[0094] This makes it easy to align the bending points of the bus bar intermediate portions 46A, 46B, 46C in the extension direction A at the same position, while aligning the first bus bar ends 42A, 42B, 42C at the same position in the same direction, and aligning the second bus bar ends 44A, 44B, 44C at the same position.

[0095] For example, let us consider the first bus bar ends 42A, 42B, and 42C. The bent portions 42V on the first bus bar ends 42A, 42B, and 42C sides are aligned at the same position in the extension direction A of the bus bar intermediate portions 46A, 46B, and 46C. The first bus bar ends 42A, 42B, and 42C are also positioned at the same position in the same direction. Note that the bent portions 42V being at the same position and the first bus bar ends 42A, 42B, and 42C being at the same position include cases where they are the same within a tolerance range, for example, cases where they are the same within a range of ±5 mm.

[0096] In this case, any one of the first bus bar ends 42A, 42B, 42C can be considered to be an example of a first cylindrical bus bar terminal, and any other one can be considered to be an example of a second cylindrical bus bar terminal.

[0097] Also, for example, attention is focused on the second bus bar ends 44A, 44B, and 44C. The bent portions 44V on the second bus bar ends 44A and 44C sides are aligned at the same position in the extension direction A of the bus bar intermediate portions 46A, 46B, and 46C. The second bus bar ends 44A and 44C are located at the same position in the same direction. The second bus bar end 44B is shifted relative to the second bus bar ends 44A and 44C in the above direction depending on the position of the connection mating terminal 15.

[0098] In this case, one of the second bus bar ends 44A, 44C can be considered to be an example of a first cylindrical bus bar terminal, and the other can be considered to be an example of a second cylindrical bus bar terminal.

[0099] <Method of Manufacturing Terminal Block> An example of a method of manufacturing the terminal block 20 will be described.

[0100] As shown in Fig. 9, a plurality of bus bar terminals 40A, 40B, 40C are grouped together. The grouping is performed by arranging bus bar intermediate portions 46A, 46B, 46C in parallel with one another at intervals. The grouping and arrangement of the plurality of bus bar terminals 40A, 40B, 40C may be performed, for example, by setting the bus bar terminals 40A, 40B, 40C in a mold 98 used to mold the first resin portion 62. A relay connector 24 may be set in the mold 98.

[0101] Then, molten resin is supplied into the mold 98, with the bus bar intermediate portions 46A, 46B, and 46C of the bus bar terminals 40A, 40B, and 40C serving as insert portions. As a result, the first resin portion 62 is mold-molded with the bus bar intermediate portions 46A, 46B, and 46C disposed therein.

[0102] 10 , the bus bar terminals 40A, 40B, 40C and the first resin portion 62 are removed from the mold 98. In this state, the first bus bar ends 42A, 42B, 42C are exposed from the fixing plate portion 63, and the second bus bar ends 44A, 44B, 44C are exposed downward from the body portion 64. Between the fixing plate portion 63 and the retaining protrusion 65, the bus bar intermediate portions 46A, 46B, 46C are covered by the body portion 64. A space is formed on the outer periphery of the body portion 64 between the fixing plate portion 63 and the retaining protrusion 65, in which the magnetic core 50 can be disposed.

[0103] 11 , split cores 50A and 50B move from both outside edges of body 64 toward body 64. Split cores 50A and 50B combine to form a ring with their end faces facing each other. At this time, magnetic filler 52 is disposed between the end faces of split cores 50A and 50B.

[0104] Thereafter, the second resin portion 66 is set around the magnetic core 50 so as to cover the outer periphery of the magnetic core 50. This keeps the split cores 50A and 50B in a combined state, and also protects and insulates the magnetic core 50 from the surroundings.

[0105] <Effects, etc.> With the terminal block 20 configured as described above, the magnetic core 50 includes multiple split cores 50A, 50B. Therefore, by combining the multiple split cores 50A, 50B around the intermediate portion 36, which is smaller in size than the first connecting portion 32 and the second connecting portion 34, the magnetic core 50 can surround the intermediate portion 36. Surrounding the intermediate portion 36 of the conductive path forming body 30 with the annular magnetic core 50 enables noise reduction. Furthermore, since the first connecting portion 32 or the second connecting portion 34 does not need to be inserted into the annular magnetic core 50, the inner circumference of the magnetic core 50 can be reduced. This allows for a more compact magnetic core 50. Furthermore, the distance between the magnetic core 50 and the intermediate portion 36 can be reduced, improving noise reduction.

[0106] By forming the inner peripheral portion of the magnetic core 50 into a shape that restricts passage between the first connecting portion 32 and the second connecting portion 34, but allows passage of the intermediate portion 36, it becomes easier to bring the magnetic core 50 close to the intermediate portion 36. This makes it possible to reduce the size of the magnetic core 50 and improve the noise reduction effect.

[0107] Furthermore, by forming the bus bar terminals 40A, 40B, 40C as press-formed components made of a single metal material, the bus bar terminals can be processed more easily than when the bus bar terminals are formed as combined components made of multiple parts.

[0108] Furthermore, the conductive path forming body 30 includes a plurality of bus bar terminals 40A, 40B, 40C, the plurality of bus bar intermediate portions 46A, 46B, 46C extending parallel to one another at intervals, at least one of the plurality of first bus bar end portions 42A, 42B, 42C extending in a direction intersecting the plurality of bus bar intermediate portions 46A, 46B, 46C so that the first connection portion 32 is wider than the intermediate portion 36, and at least one of the plurality of second bus bar end portions 44A, 44B, 44C extending in a direction intersecting the plurality of bus bar intermediate portions 46A, 46B, 46C so that the second connection portion 34 is wider than the intermediate portion 36. Therefore, the first bus bar ends 42A, 42B, 42C and the second bus bar ends 44A, 44B, 44C can be bent appropriately relative to the bus bar intermediate portions 46A, 46B, 46C in accordance with the layout of the mating connection terminals 14, 15. In this case, the first connecting portion 32 and the second connecting portion 34 may widen more than the intermediate portion 36. In such a case, a magnetic core 50 with a small inner periphery can be disposed around the intermediate portion 36.

[0109] Furthermore, the bus bar terminals 40A, 40C are cylindrical bus bar terminals, and the lower end of the cylindrical intermediate portion 96 is bent, and the flat end portion 94 extends in a direction intersecting with the extending direction A of the intermediate portion of the cylindrical intermediate portion 96. The cylindrical intermediate portion 96 is easier to bend in any direction than when it is shaped like an elongated plate. This makes it easier to process the flat end portion 94 to extend in any direction.

[0110] Furthermore, bus bar terminals 40A, 40B, 40C are cylindrical bus bar terminals, and flat end portions 92 are bent in the thickness direction thereof, with the tips of the flat end portions 92 extending in a direction intersecting with the extending direction A of the cylindrical intermediate portion 96. Therefore, by processing the direction of the flat end portions 92 relative to the cylindrical intermediate portion 96 in any direction, it is easy to process the flat end portions 92 to extend in any direction.

[0111] Furthermore, the bus bar terminals 40A, 40B, and 40C are cylindrical bus bar terminals, and the ends of the cylindrical intermediate portions are bent to form the bends 44V, or the flat ends are bent to form the bends 42V. This reduces the space required for installing the magnetic core 50 compared to bus bar terminals in which each end is bent at a different position. In other words, it is easy to increase the length of the linearly extending bus bar intermediate portions 46A, 46B, and 46C. This allows the magnetic core 50 to be larger in the direction A of extension of the multiple cylindrical intermediate portions 96, i.e., the intermediate portion 36. Increasing the height of the magnetic core 50 allows for a smaller outer peripheral shape of the magnetic core 50.

[0112] Furthermore, if magnetic filler 52 is interposed between the plurality of split cores 50A, 50B, noise reduction performance can be improved.

[0113] According to the manufacturing method of the bus bar terminal 40A, a cylindrical metal material 90 is prepared, the ends of the cylindrical metal material 90 are pressed into a flat shape to form flat end portions 92, 94, and the cylindrical metal material 90 is bent to position the ends of the cylindrical metal material 90 at positions that are off the extension of the intermediate portion of the cylindrical metal material. By pressing the ends of the cylindrical metal material 90 into a flat shape, the flattened ends can be easily connected to the mating terminals 14, 15 by making surface contact with them. By bending the cylindrical portion of the cylindrical metal material 90 in any direction or by arbitrarily setting the flattened direction relative to the cylindrical portion, it is easy to arbitrarily set the extension direction of the flat portion of the end relative to the intermediate portion of the cylindrical metal material. Therefore, it is easy to set the extent of the intermediate portion 36 to be smaller than the extent of the first connecting portion 32 and the second connecting portion 34, while still ensuring a large space between the first connecting portion 32 and the second connecting portion 34 to install the magnetic core 50.

[0114] In the first embodiment, the terminal block 20 includes three bus bar terminals 40A, 40B, and 40C. The number of bus bar terminals included in the terminal block is arbitrary.

[0115] 12 and 13 , a terminal block 120 according to a modified example includes two bus bar terminals 40A and 40C. That is, the terminal block 120 is configured such that the intermediate bus bar terminal 40B in the terminal block 20 is omitted, thereby making the terminal block 120 smaller in width. The terminal block 120 also omits the relay connector 24.

[0116] In this modification, the first bus bar end portions 42A, 42C of the two bus bar terminals 40A, 40C are also bent relative to the bus bar intermediate portions 46A, 46C. Therefore, the first connection portion 132 of the conductive path formation body 130 including the two bus bar terminals 40A, 40C is wider than the intermediate portion 136. Furthermore, the second bus bar end portions 44A, 44C of the two bus bar terminals 40A, 40C are also bent relative to the bus bar intermediate portions 46A, 46C. Therefore, the second connection portion 134 of the conductive path formation body 130 is wider than the intermediate portion 136.

[0117] As in the first embodiment, by dividing the magnetic core 50, it is possible to reduce noise and make the magnetic core smaller.

[0118] The terminal block may include only one bus bar terminal. For example, it may include only bus bar terminal 40A. Even in this case, the first connection portion including first bus bar end 42A and the second connection portion including second bus bar end 44A can each be made wider than the intermediate portion including bus bar intermediate portion 46A, and by using a divided magnetic core, it is possible to reduce noise and make the magnetic core more compact.

[0119] [Embodiment 2] A terminal block 220 according to embodiment 2 will be described. Fig. 14 is a perspective view showing the terminal block 220 according to embodiment 2. Fig. 15 is a perspective view showing bus bar terminals 240A, 240B, 240C and magnetic core 250 of the terminal block. Fig. 16 is a cross-sectional view taken along line XVI-XVI in Fig. 15, and Fig. 17 is a cross-sectional view taken along line XVII-XVII in Fig. 15. Note that in embodiment 2, differences from embodiment 1 will be mainly described.

[0120] The terminal block 220 includes a conductive path formation body 230 , a magnetic core 250 , and an insulating base 260 .

[0121] The conductive path formation member 230 includes a plurality of bus bar terminals 240A, 240B, and 240C. The main difference between the terminal block 220 and the terminal block 20 is the configuration of the bus bar terminals 240A, 240B, and 240C.

[0122] That is, while the bus bar terminals 40A, 40B, and 40C of the first embodiment are formed by processing a cylindrical metal material, the bus bar terminals 240A, 240B, and 240C of the second embodiment are formed by bending a thin metal plate material. The metal plate material is formed from, for example, copper, a copper alloy, aluminum, or an aluminum alloy.

[0123] Since a thin metal plate is easier to bend in its thickness direction than in its width direction, the following configuration is used to make the first connection portion 232 and the second connection portion 234 of the conductive path formation body 230 wider than the middle portion 236.

[0124] That is, bus bar intermediate portions 246A, 246B, and 246C of bus bar terminals 240A, 240B, and 240C are arranged in parallel with a gap therebetween. Bus bar intermediate portions 246A, 246B, and 246C are arranged overlapping each other in the same region in the thickness direction.

[0125] That is, the first bus bar ends 242A, 242B, and 242C at the upper ends of the bus bar terminals 240A, 240B, and 240C are bent in the thickness direction, for example, at a right angle. The base ends of the first bus bar ends 242A, 242B, and 242C are arranged parallel to each other with a gap between them in the vertical direction. The end of the first bus bar end 242A is formed into an L-shape and is arranged at a position spaced apart on one side outward from the first bus bar end 242B. The end of the first bus bar end 242C is formed into the opposite L-shape and is arranged at a position spaced apart on the other side outward from the first bus bar end 242B.

[0126] In order to align the ends of the first bus bar ends 242A, 242B, 242C at the same position in the extension direction A of the bus bar intermediate portions 246A, 246B, 246C, a step portion is provided at the first bus bar ends 242B, 242C.

[0127] As a result, a convex hull R2 surrounding the first bus bar end portions 242A, 242B, 242C is larger than a convex hull R1 surrounding the bus bar intermediate portions 246A, 246B, 246C (see FIG. 17).

[0128] Additionally, second bus bar ends 244A, 244B, 244C at the lower ends of bus bar terminals 240A, 240B, 240C are bent in the thickness direction, for example, at a right angle. The base ends of second bus bar ends 244A, 244B, 244C are arranged parallel to each other with a gap between them in the vertical direction. Second bus bar end 244A and second bus bar end 244C are formed in a shape that extends outward on both sides of second bus bar end 244B. Portions extending from the side edges of these extending portions are bent to extend along extension direction A of bus bar intermediate portions 246A, 246C. Additionally, the tip end of second bus bar end 244B is bent to extend along extension direction A of bus bar intermediate portion 246B. As a result, the ends of the second bus bar end portions 244A, 244B, 244C extend in parallel with a gap between them along the extension direction A of the bus bar intermediate portions 246A, 246B, 246C.

[0129] As a result, a convex hull R3 surrounding the second bus bar end portions 244A, 244B, 244C is larger than a convex hull R1 surrounding the bus bar intermediate portions 246A, 246B, 246C (see FIG. 16).

[0130] The insulating base 260 holds the bus bar intermediate portions 246A, 246B, 246C, the base ends of the first bus bar ends 242A, 242B, 242C, and the base ends of the second bus bar ends 244A, 244B, 244C in fixed positions while insulating them from each other.

[0131] The magnetic core 250 has split cores 250A and 250B surrounding the bus bar intermediate portions 246A, 246B, and 246C, as in the first embodiment. The insulating base 260 also maintains the state in which the split cores 250A and 250B surround the bus bar intermediate portions 246A, 246B, and 246C.

[0132] In the terminal block 220 according to the second embodiment, the magnetic core 250 includes a plurality of split cores 250A, 250B. Therefore, as in the first embodiment, by combining the plurality of split cores 250A, 250B, the magnetic core 250 can surround the middle portion 236, thereby reducing noise. Furthermore, since the first connecting portion 232 or the second connecting portion 234 does not need to be inserted into the annular magnetic core 250, the inner peripheral portion of the magnetic core 250 can be made smaller. This allows the magnetic core 250 to be made more compact.

[0133] In addition, except for the effects due to the cylindrical bus bar terminal, the same effects as those of the first embodiment can be obtained.

[0134] The configurations described in the above embodiment and modifications can be combined as appropriate as long as they are not mutually inconsistent.

[0135] For example, cylindrical bus bar terminals and plate-shaped bus bar terminals may be used in combination in the same terminal block.

[0136] REFERENCE SIGNS LIST 10 Device 11 Housing 11h Mounting hole 14, 15 Mating terminal 16, 17 Wiring component 20, 120, 220 Terminal block 22 Annular seal 24 Relay connector 30, 130, 230 Conductive path forming body 32, 132, 232 First connecting portion 34, 134, 234 Second connecting portion 36, 136, 236 Intermediate portion 40A, 40B, 40C, 240A, 240B, 240C Bus bar terminal 42A, 42B, 42C, 242A, 242B, 242C First bus bar end 42V Bending portion 44A, 44B, 44C, 244A, 244B, 244C Second bus bar end 44V Bending portion DESCRIPTION OF THE REFERENCE NUMERALS 46A, 46B, 46C, 246A, 246B, 246C Busbar intermediate portion 50, 250 Magnetic core 50A, 50B, 250A, 250B Split core 52 Magnetic filler 60, 260 Insulating base 62 First resin portion 63 Fixing plate portion 63h Fixing hole 64 Body portion 65 Retaining protrusion 66 Second resin portion 66A, 66B Split holder portion 66Ap Locking piece 66Bp Locking protrusion 67a Thin hinge 90 Cylindrical metal material 92, 94 Flat end portion 96 Cylindrical intermediate portion 98 Mold Q1, Q2, Q3, R1, R2, R3 Convex hull

Claims

1. A terminal block comprising: a conductive path forming body including a bus bar terminal; a ring-shaped magnetic core; and an insulating base that holds the conductive path forming body and the magnetic core, wherein the conductive path forming body includes a first connection portion, a second connection portion, and an intermediate portion between the first connection portion and the second connection portion, and when viewed along the extension direction of the intermediate portion, the first connection portion and the second connection portion are wider than the intermediate portion, the magnetic core includes a plurality of split cores, the magnetic core surrounds the intermediate portion with the plurality of split cores arranged to form a ring, and the insulating base holds the intermediate portion and the magnetic core surrounding the intermediate portion with at least a portion of the first connection portion and at least a portion of the second connection portion exposed.

2. A terminal block as claimed in claim 1, wherein the inner peripheral portion of the magnetic core is formed into a shape which restricts the passage of the first connection portion and the second connection portion, while allowing the passage of the intermediate portion.

3. The terminal block according to claim 1 or 2, wherein the bus bar terminal is a pressed part made of a single metal material.

4. A terminal block as described in claim 1 or 2, wherein the conductive path forming body includes a plurality of the bus bar terminals, each of the plurality of bus bar terminals includes a first bus bar end, a second bus bar end, and a bus bar intermediate portion between the first bus bar end and the second bus bar end, the plurality of bus bar intermediate portions extend parallel to each other with a gap therebetween, at least one of the plurality of first bus bar ends extends in a direction intersecting with the plurality of bus bar intermediate portions so that the first connection portion is wider than the intermediate portion, and at least one of the plurality of second bus bar ends extends in a direction intersecting with the plurality of bus bar intermediate portions so that the second connection portion is wider than the intermediate portion.

5. A terminal block as described in claim 1 or 2, wherein the conductive path forming body includes a cylindrical bus bar terminal as the bus bar terminal, the cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, and the end portion of the cylindrical intermediate portion is curved so that the flat end portion extends in a direction intersecting with the extension direction of the intermediate portion of the cylindrical intermediate portion.

6. A terminal block as described in claim 1 or 2, wherein the conductive path forming body includes a cylindrical bus bar terminal as the bus bar terminal, the cylindrical bus bar terminal includes a flat end portion and a cylindrical intermediate portion that is closer to a cylinder than the flat end portion, and the flat end portion is bent in its thickness direction, and the tip portion of the flat end portion extends in a direction intersecting the extension direction of the cylindrical intermediate portion.

7. A terminal block as claimed in claim 1 or 2, wherein the conductive path forming body includes a first cylindrical bus bar terminal and a second cylindrical bus bar terminal as the bus bar terminals, each of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal includes a flat end and a cylindrical intermediate portion that is closer to a cylinder than the flat end, the cylindrical intermediate portions of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal extend in parallel with a gap between them, and the end or the flat end of the cylindrical intermediate portion of the first cylindrical bus bar terminal and the second cylindrical bus bar terminal is bent at the same position in the extension direction of the multiple cylindrical intermediate portions.

8. A terminal block according to claim 1 or 2, wherein the magnetic core includes a magnetic filler material interposed between the plurality of split cores.

9. A method for manufacturing a bus bar terminal, comprising the steps of: preparing a cylindrical metal material; pressing an end of the cylindrical metal material into a flat shape; and bending the cylindrical metal material to position the end of the cylindrical metal material at a position that is off the extension of a middle portion of the cylindrical metal material.

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