Wiring fixture

Abstract

A USB outlet (10) attached to a mounting frame (110) is provided with a metal rear surface case (20) which is in thermal contact with a heat-generating component and in which a first opening (23) or a protrusion (22) to be attached to the mounting frame (110) is formed. The rear surface case (20) houses a first substrate (50) including the heat-generating component. The front end surface of the rear surface case (20) and the rear surface of the mounting frame (110) are in contact with each other. The rear surface case (20) can be divided into a box body (28) and a lid body (29).

Description

Wiring devices

[0001] The present disclosure relates to a wiring device that is attached to a mounting frame.

[0002] A wiring device is a component of electrical equipment. A wiring device is a device for connecting electric wires or electrical devices. Known examples of wiring devices include outlets and switches. Known examples of wiring device outlets include Universal Serial Bus (USB) outlets (see, for example, Patent Document 1). USB outlets supply DC power to electronic devices such as smartphones, tablet devices, and laptop computers.

[0003] The USB outlet described above includes a circuit board including heat-generating electronic components and a housing that houses the circuit board. The USB outlet is fixed to the mounting frame by attaching a mounting portion of the housing to the mounting frame. The mounting portion of the USB outlet is, for example, a resin part that is integrated with the housing.

[0004] Japanese Patent Application Laid-Open No. 2023-071650

[0005] In recent years, there has been a trend toward USB outlets becoming smaller and higher in power output. As USB outlets become smaller and higher in power output, it is necessary to improve the heat dissipation performance of the USB outlets.

[0006] Therefore, an object of the present disclosure is to provide a wiring accessory that can improve heat dissipation performance.

[0007] The wiring device according to the present disclosure is a wiring device that is attached to a mounting frame, and is characterized by including a metal heat dissipation member that is in thermal contact with a heat-generating component and has an attachment portion that is attached to the mounting frame.

[0008] According to the wiring device of the present disclosure, heat dissipation performance can be improved.

[0009] FIG. 1 is a perspective view showing a wiring fixture as an example of an embodiment; FIG. 2 is an exploded perspective view showing a wiring fixture as an example of an embodiment; FIG. 3 is a perspective view showing a first housing and a second housing as an example of an embodiment; FIG. 4 is another perspective view showing a first housing and a second housing as an example of an embodiment; FIG. 5 is a perspective view showing a first board and a second board as an example of an embodiment; FIG. 6 is a plan view showing a fixing member as an example of an embodiment; FIG. 7 is a perspective view showing a mounting frame as an example of an embodiment; FIG. 8 is a perspective view showing a mounting frame as another example of an embodiment.

[0010] An example of an embodiment of the present disclosure will be described in detail below. In the following description, specific shapes, materials, directions, numerical values, etc. are examples for facilitating understanding of the present disclosure, and can be appropriately changed according to the application, purpose, specifications, etc.

[0011] [Wiring Device] A USB outlet 10 as a wiring device will be described with reference to FIGS. 1 and 2. FIG.

[0012] The USB outlet 10 as a wiring device is a device to which a USB connector (not shown) can be connected, has a power conversion component that converts AC power to DC power, and supplies DC power to electronic devices such as smartphones, tablet devices, laptop computers, etc. The USB outlet 10 can improve heat dissipation performance, as will be described in detail later.

[0013] As described above, the wiring device of this embodiment is a USB outlet 10. However, the wiring device of the present invention may also be a general outlet that outputs 100V or 200V AC power. The USB outlet 10 of this embodiment includes various generations (transfer speed standards) of USB, such as USB 1.0, USB 1.1, USB 2.0, USB 3.0, USB 3.1, USB 3.2, and USB 4.0. The USB terminal shape is not particularly limited and may be any of A terminal, B terminal, C terminal, mini USB, micro USB, etc. Furthermore, the USB charging standard may be USB PD (USB Power Delivery), USB-BC (USB Battery Charging), Quick Charge, etc.

[0014] In the following description of the USB outlet 10, the side on which the surface case 30 (described in detail later) is disposed may be referred to as the front side, and the side opposite the front side may be referred to as the back side. The front side may also be referred to as the front side (arrow F in the figure), and the back side may also be referred to as the back side (arrow B in the figure). Furthermore, the direction from the front side to the back side may also be referred to as the front-to-rear direction, and directions perpendicular to the front-to-rear direction may also be referred to as the left-to-right direction (arrow LR in the figure) and the up-to-down direction (arrow UD in the figure). In the left-to-right direction, the left side when facing the USB outlet 10 is referred to as the left side.

[0015] The USB outlet 10 of this embodiment is installed on a wall (not shown), but the wiring device of the present disclosure may also be installed on furniture such as a desk, shelf, counter, or bed, or on a vehicle such as an automobile, airplane, or railroad car.

[0016] The USB outlet 10 is attached to a mounting frame 110, which will be described in detail later. The USB outlet 10 is configured to be attached to a plurality of mounting frames 110, 120, which will be described in detail later. The mounting frame 110 is provided around a drilling hole formed in a wall. A frame-shaped decorative plate with an opening for exposing the USB outlet 10 may be provided on the front side of the mounting frame 110.

[0017] In this embodiment, three USB outlets 10 are arranged adjacent to one another in the vertical direction. However, the number and arrangement of the USB outlets 10 are not particularly limited. In addition, other wiring devices such as AC outlets may be arranged adjacent to the USB outlets.

[0018] The USB outlet 10 comprises a rear case 20 in thermal contact with the heat-generating components, a front case 30 attached to the front side of the rear case 20, heat transfer sheets (front upper heat transfer sheet 71, rear upper heat transfer sheet 72, lower heat transfer sheet 73) as heat transfer members that transfer heat generated by the first board 50 to the rear case 20, insulating sheets (upper insulating sheet 81, lower insulating sheet 82) that insulate the first board 50 from the rear case 20, and a bushing 90 as a fixing member that fixes the power line 40 to the rear case 20, each of which will be described in detail below.

[0019] [Rear Case (First Housing)] The rear case 20 as the first housing will be described with reference to FIGS. 3 and 4. FIG.

[0020] As described above, the rear case 20 serving as the first housing is in thermal contact with the heat-generating components. The heat-generating components are described in detail below, but are, for example, components included in at least the first substrate 50, such as semiconductor elements and the transformer 53. Specifically, being in thermal contact with the heat-generating components means that the rear case 20 forms a heat transfer path with the first substrate 50 via a heat transfer member and an insulating sheet.

[0021] The rear case 20 is provided on the rear side (rear side) of the USB outlet 10. The rear case 20 is attached to the mounting frame 110 and is located rearward of the mounting frame 110. The rear case 20 is formed in a substantially rectangular box shape. The volume of the rear case 20 is sufficiently larger than the volume of the front case 30, which will be described later.

[0022] The rear case 20 is preferably made of metal, and is preferably made of a metal material with high thermal conductivity, which can improve the heat dissipation performance of the USB outlet 10. The metal from which the rear case 20 is made is not particularly limited, but aluminum or an aluminum alloy is preferred from the viewpoints of rigidity, thermal conductivity, light weight, workability, etc.

[0023] An attachment portion for attaching the rear case 20 to the mounting frame 110 is formed on the front side (front side) of the rear case 20. The attachment portion allows the rear case 20 and the mounting frame 110 to be in thermal contact with each other, thereby improving the heat dissipation performance of the USB outlet 10. A plurality of attachment portions are formed to correspond to the mounting frames 110, 120 to which they are attached. The attachment portion includes a protrusion 22 and a first opening 23.

[0024] The protrusions 22 are mounting portions for mounting to the mounting frame 110. The protrusions 22 are fitted into mounting openings 112 of the mounting frame 110. The protrusions 22 are formed at the front ends of the left and right side surfaces of the rear case 20. Four protrusions 22 are formed, two on each of the left and right sides. The protrusions 22 are formed integrally with the rear case 20. Note that the number or arrangement of the protrusions 22 is not particularly limited.

[0025] By forming the protrusions 22 at the front end of the rear case 20, the front end surface of the rear case 20 and the rear surface of the mounting frame 110 come into contact with each other. This increases the area of ​​thermal contact between the rear case 20 and the mounting frame 110. As a result, heat generated by the USB outlet 10 can be dissipated by the mounting frame 110. This improves the heat dissipation performance of the USB outlet 10.

[0026] The first opening 23 is an attachment portion for attachment to the attachment frame 120. A protrusion 122 of the attachment frame 120 is fitted into the first opening 23. The first opening 23 is formed in a rectangular shape extending in the up-down direction in the first extension portion 24. The first extension portions 24 are formed to extend toward the front side (front side) parallel to the left and right side portions of the rear case 20. The first extension portions 24 are formed integrally with the rear case 20. The first opening 23 is formed so as to contact the front end surface of the rear case 20.

[0027] By forming the first opening 23 so that it contacts the front end of the rear case 20, the front end surface of the rear case 20 and the rear surface of the mounting frame 110 come into contact with each other. This increases the area of ​​thermal contact between the rear case 20 and the mounting frame 110. As a result, heat generated by the USB outlet 10 can be dissipated by the mounting frame 110. This improves the heat dissipation performance of the USB outlet 10.

[0028] In recent years, USB outlets have tended to become higher-powered and smaller. As USB outlets become higher-powered and smaller, it has become necessary to improve their heat dissipation performance. Therefore, by forming the protrusion 22 or the first opening 23 as a metal part integrated with the rear case 20 and forming the protrusion 22 or the first opening 23 at the front end of the rear case 20, the front end surface of the rear case 20 abuts against the rear surfaces of the mounting frames 110 and 120, increasing the area of ​​thermal contact between the rear case 20 and the mounting frame 110, thereby improving the heat dissipation performance of the USB outlet 10.

[0029] The rear case 20 is formed with second openings 25 to which the front case 30, described in detail below, is attached by a snap-fit ​​structure. Two second openings 25 are formed in a rectangular shape in the second extension portion 26. The number or arrangement of the second openings 25 is not particularly limited. The second extension portions 26 are formed by extending the top surface (upper surface) and bottom surface (lower surface) of the rear case 20 toward the front side (front side).

[0030] A third opening 27 is formed in the back surface (rear surface) of rear case 20. A bushing 90 for fixing power line 40 is provided in third opening 27. Power line 40 extends to the outside of rear case 20 through bushing 90.

[0031] The rear case 20 can be separated into a box body 28 as a first member and a lid body 29 as a second member. The box body 28 and the lid body 29 can also be separated in the vertical direction. This configuration allows the box body 28 and the lid body 29 to sandwich the first substrate 50 and the heat transfer member. This allows the heat transfer member to be in close contact with the box body 28 or the lid body 29 and the first substrate 50. As a result, the heat dissipation performance of the rear case 20 can be improved.

[0032] The box body 28 and the lid body 29 are fastened together by screws as fastening members. With this configuration, the first substrate 50 and the heat transfer member can be securely sandwiched between the box body 28 and the lid body 29.

[0033] The box body 28 has a front surface formed with the pair of first extensions 24 and a lower second extension 26. The box body 28 has a rear surface formed with the third opening 27. The lid body 29 has a front surface formed with the upper second extension 26.

[0034] [Front Case (Second Housing)] The front case 30 serving as the second housing will be described with reference to FIGS. 3 and 4. FIG.

[0035] As described above, the front case 30 serving as the second housing is a case attached to the front side of the back case 20. The front case 30 houses the second board 60. The front case 30 is provided on the front side (front side) of the USB outlet 10. The front case 30 is positioned forward of the mounting frame 110. The front case 30 is formed in the shape of a roughly rectangular parallelepiped box with an open back (rear) side. The volume of the front case 30 is sufficiently smaller than the volume of the back case 20.

[0036] The surface case 30 is made of resin. Because the front surface of the surface case 30 is the part that the user can touch, it is made of a resin material that does not easily transmit heat from the electronic components mounted on the second substrate 60. The resin that forms the surface case 30 is not particularly limited, but examples include urea resin, melamine resin, and ABS resin.

[0037] The surface case 30 has a connection port 31 formed therein, which is an opening into which a USB connector can be inserted, and the front surface of the surface case 30 serves as the front surface of the USB outlet 10 .

[0038] The front case 30 has claws 32 formed thereon for attachment to the rear case 20 by a snap-fit ​​structure. Two claws 32 are formed on the inside of the top surface (upper surface) and two on the inside of the bottom surface (lower surface) of the front case 30. The number or arrangement of the claws 32 is not particularly limited. In the snap-fit ​​structure between the front case 30 and the rear case 20, the elasticity of the material is utilized to fit the rear opening of the front case 30 into the second extension 42 of the rear case 20, and the claws 32 of the front case 30 are fitted into the second opening 25 of the rear case 20.

[0039] [Power Line] The power line 40 will be described with reference to FIGS. 3 to 5. FIG.

[0040] The power line 40 is a component that supplies AC power from an external power source to the USB outlet 10. The power line 40 is connected to the first board 50. The power line 40 also extends from the inside of the rear case 20 to the outside of the rear case 20 through a bushing 90. The power line 40 is connected, outside the rear case 20, to a power supply wire (not shown) that is electrically connected to an external power source (e.g., a commercial power source). As a result, AC power is supplied to the first board 50 from the external power source via the power line 40.

[0041] [Substrate] The substrate will be described with reference to FIG.

[0042] The substrates are configured to include electronic components. The substrates include a first substrate 50 housed in the rear case 20 and a second substrate 60 housed in the front case 30, each of which will be described in detail later. Note that a portion of the first substrate 50 may extend into the interior of the front case 30. Also, a portion of the second substrate 60 may extend into the interior of the rear case 20.

[0043] The first substrate 50 is a printed wiring board including electronic components arranged on a printed circuit board 51, and is housed in the rear case 20 so that the surface of the board is perpendicular to the up-down direction. The first substrate 50 includes a power supply circuit for converting AC power supplied from the power line 40 into DC current and outputting it to the terminals 62 of the second substrate 60. The power supply circuit is configured by electrically connecting power conversion components via wiring formed on the front and back of the printed circuit board 51.

[0044] The first substrate 50 includes semiconductor elements (not shown), a transformer 53, a common mode coil 54, an electrolytic capacitor 55, and other components that constitute the power supply circuit in a broad sense. Examples of the semiconductor elements include switching elements, diodes, and transistors. When the power supply circuit is in operation, at least some of the power conversion components generate heat, with the semiconductor elements and the transformer 53 generating particularly large amounts of heat. Therefore, heat generated by the power conversion components, such as the semiconductor elements and the transformer 53, is easily transferred to the terminals 62 by radiation, convection, and thermal conduction via the printed circuit board 51 and other components.

[0045] In the first substrate 50 of this embodiment, the transformer 53, the common mode coil 54, and the electrolytic capacitor 55 are disposed on the upper surface of the printed circuit board 51, and a plurality of semiconductor elements are disposed on the lower surface of the printed circuit board 51. Note that the number and arrangement of each electronic component are not particularly limited.

[0046] The second substrate 60 is a printed wiring board including terminals 62 arranged on a printed circuit board 61, and is housed in the front case 30. The second substrate 60 is electrically connected to the first substrate 50, and includes an output circuit for outputting DC power converted by the power supply circuit of the first substrate 50 from the terminals 62. In this embodiment, the second substrate 60 is arranged perpendicular to the first substrate 50. The second substrate 60 and the first substrate 50 may have, for example, a protrusion and an opening into which the protrusion is inserted, and may be fixed to each other.

[0047] In the second substrate 60, electronic components such as terminals 62 and electrolytic capacitors 63 are arranged on the front surface of a printed circuit board 61. In this embodiment, the number of terminals 62 is one, but the number of terminals 62 is not particularly limited, and two or more terminals may be used.

[0048] The terminal 62 is disposed, for example, in the center of the front surface of the printed circuit board 61. The terminal 62 is a USB terminal to which a USB connector can be connected. The terminal 62 has flat upper and lower surfaces and is formed into a flat cylindrical shape as a whole. The shape or type of the USB terminal is not particularly limited. The terminal 62 is disposed in a state in which the USB connector can be inserted and removed through the connection port 31 formed in the front case 30.

[0049] [Heat Transfer Sheet (Heat Transfer Member)] A heat transfer sheet as a heat transfer member will be described with reference to FIG.

[0050] The heat transfer sheet as a heat transfer member is a member that transfers heat generated on the first substrate 50 to the insulating sheet and the rear case 20. The heat transfer sheets include a front upper heat transfer sheet 71 provided on the front side of the upper surface of the first substrate 50, a rear upper heat transfer sheet 72 provided on the rear side of the upper surface of the first substrate 50, and a lower heat transfer sheet 73 provided on the lower surface of the first substrate 50. However, the number and arrangement of the heat transfer sheets are not limited to this.

[0051] The heat transfer sheet may be, for example, a flat sheet of a uniform thickness, and may be formed from an insulating material such as an insulating resin material. The resin forming the heat transfer sheet may be any flexible material that can be elastically deformed, and examples thereof include silicone resin, acrylic resin, urethane resin, and epoxy resin. The thermally conductive filler dispersed in the resin is preferably an insulating filler with high thermal conductivity, and examples thereof include aluminum oxide, aluminum nitride, and boron nitride. Conventionally known materials may be used for the heat transfer sheet.

[0052] [Insulating Sheet] The insulating sheet will be described with reference to FIG.

[0053] The insulating sheet is a member that insulates the first substrate 50 from the rear case 20. The insulating sheet includes an upper insulating sheet 81 formed in a box shape so as to cover the top and side surfaces of the first substrate 50, and a lower insulating sheet 82 formed in a box shape so as to cover the bottom and side surfaces of the first substrate 50. However, the number and arrangement of the insulating sheets are not particularly limited. The insulating sheet may be formed, for example, by folding a flat sheet of a constant thickness and made of polycarbonate. Note that conventionally known materials may be used for the insulating sheet.

[0054] [Bush (Fixed Member)] A bush 90 as a fixed member will be described with reference to FIG.

[0055] The bushing 90 serving as a fixing member has a cylindrical shape and fixes the power line 40 to the third opening 27 of the rear case 20. The bushing 90 has rubber elasticity and is formed from an elastomer such as silicone rubber or urethane rubber. The bushing 90 is slightly larger than the third opening 27 and seals the gap that occurs between the third opening 27 and the power line 40.

[0056] The above configuration suppresses misalignment of the power line 40 due to bending, pulling, or pushing of the power line 40 near the third opening 27, thereby suppressing the resulting failure of the power line 40, such as breakage. The shape of the bushing 90 is not particularly limited. A conventionally known material may be used for the bushing 90.

[0057] A protrusion 91 is provided inside the bushing 90. The power line 40 is arranged along the protrusion 91, thereby forming a bent portion 40A. This makes it possible to prevent the power line 40 from breaking inside the bushing 90. Note that a plurality of protrusions 91 may be provided, and a plurality of bent portions of the power line 40 may be provided. Furthermore, the protrusion may be provided inside the rear case 20. The bent portion of the power line 40 may be formed along a protrusion provided inside the rear case 20. Furthermore, protrusions may be provided both inside the bushing 90 and inside the rear case 20. The bent portion of the power line 40 may be formed along a protrusion provided inside the bushing 90 and a protrusion provided inside the rear case 20.

[0058] [Mounting Frame] The mounting frame 110 will be described with reference to FIG.

[0059] The mounting frame 110 is a frame to which the USB outlets 10 and the rear case 20 are attached. The mounting frame 110 is provided around a drilling hole formed in a wall. The mounting frame 110 is made of a resin material, a steel plate (iron-based material), aluminum, an aluminum alloy, or the like. Note that the number of USB outlets 10 attached to the mounting frame 110 is not particularly limited.

[0060] The mounting frame 110 is formed with a receptacle opening 111 in which the three USB receptacles 10 are arranged adjacent to one another in the vertical direction, and mounting openings 112 into which the protrusions 22 on the rear case 20 of each USB receptacle 10 fit. The mounting openings 112 are formed in extensions 113 that extend rearward from the left and right ends of the mounting frame 110.

[0061] [Mounting Frame (Another Embodiment)] A mounting frame 120 according to another embodiment will be described with reference to FIG.

[0062] The mounting frame 120 is a frame to which the USB outlets 10 and the rear case 20 are attached. The mounting frame 120 is provided around a drilling hole formed in the wall. The mounting frame 120 is made of steel plate (iron-based material), aluminum, aluminum alloy, or the like. Note that the number of USB outlets 10 attached to the mounting frame 120 is not particularly limited.

[0063] The mounting frame 120 is formed with a socket opening 121 to which one USB socket 10 is attached, and protrusions 122 and 123 that fit into the first opening 23 of the rear case 20 of the USB socket 10. The protrusion 123 is formed on a connecting portion 124 that connects the upper and lower frames of the mounting frame 120. The connecting portion 124 is formed with a width that allows it to be deformed by pressing a tool against it.

[0064] When attaching the USB outlet 10 to the mounting frame 120, the protrusion 122 is fitted into the first opening 23 on one side of the rear case 20 of the USB outlet 10, and the protrusion 123 is tightened toward the rear case 20 to fit into the first opening 23 on the other side.

[0065] [Summary] The present disclosure is further described by the following embodiments. Configuration 1: A wiring device to be attached to a mounting frame, comprising a metal heat dissipation member that is in thermal contact with a heat-generating component and has a mounting portion that is attached to the mounting frame. Configuration 2: The wiring device according to Configuration 1, wherein the heat dissipation member is a housing that houses a board that includes the heat-generating component. Configuration 3: The wiring device according to Configuration 2, wherein one surface of the heat dissipation member abuts against the other surface of the mounting frame. Configuration 4: The wiring device according to any one of Configurations 1 to 3, wherein the mounting portion is a plurality of protrusions. Configuration 5: The wiring device according to Configuration 4, wherein the plurality of protrusions are formed integrally with the heat dissipation member at front ends of left and right side surfaces of the heat dissipation member, respectively. Configuration 6: The wiring device according to any one of Configurations 1 to 3, wherein the mounting portion is a plurality of openings. Configuration 7: The wiring device according to configuration 6, wherein the openings are formed in a rectangular shape extending in the up-down direction in a first extending portion, and the first extending portions are formed extending to one side parallel to left and right side surfaces of the heat dissipation member.Configuration 8: The wiring device according to any one of configurations 1 to 3, wherein the first housing is dividable into at least a first member and a second member.Configuration 9: The wiring device according to configuration 8, wherein the first member and the second member are fastened by a fastening member.

[0066] It should be noted that the present disclosure is not limited to the above-described embodiments and their variations, and it goes without saying that various modifications and improvements are possible within the scope of the matters described in the claims of the present application.

[0067] 10 USB outlet (wiring device), 20 rear case (heat dissipation member), 22 protrusion, 23 first opening, 24 first extension portion, 25 second opening, 26 second extension portion, 27 third opening, 28 box body (first member), 29 lid body (second member), 30 front case, 31 connection port, 32 claw portion, 40 power line, 50 first board (board), 51 printed circuit board, 52 semiconductor element, 53 transformer, 54 common mode coil, 55 electrolytic capacitor, 60 second board, 61 printed circuit board, 62 terminal, 63 electrolytic capacitor, 71 front upper heat transfer sheet (heat transfer member), 72 rear upper heat transfer sheet (heat transfer member), 73 lower heat transfer sheet (heat transfer member), 81 upper insulating sheet, 82 lower insulating sheet, 90 bush (fixing member), 91 protrusion, 110 mounting frame, 111 outlet opening, 112 Mounting opening, 113 extension, 120 mounting frame, 121 outlet opening, 122 protrusion, 123 protrusion, 124 connecting portion

Claims

1. A wiring device to be attached to a mounting frame, the wiring device comprising a metal heat dissipation member that is in thermal contact with a heat-generating component and has a mounting portion that is attached to the mounting frame.

2. A wiring device according to claim 1, wherein the heat dissipation member is a housing that houses a substrate including the heat-generating component.

3. A wiring device according to claim 2, wherein one surface of the heat dissipation member and the other surface of the mounting frame are in contact with each other.

4. A wiring device according to any one of claims 1 to 3, wherein the attachment portion is a plurality of protrusions.

5. A wiring device according to claim 4, wherein the plurality of protrusions are formed integrally with the heat dissipation member at the front ends of the left and right side surfaces of the heat dissipation member, respectively.

6. A wiring device according to any one of claims 1 to 3, wherein the attachment portion is a plurality of openings.

7. A wiring device according to claim 6, wherein the plurality of openings are formed in a rectangular shape extending in the vertical direction in the first extending portion, and the first extending portion is formed to extend to one side, respectively, in parallel with the left and right side portions of the heat dissipating member.

8. A wiring device according to any one of claims 1 to 3, wherein the heat dissipation member is separable into at least a first member and a second member.

9. The wiring device according to claim 8, wherein the first member and the second member are fastened together by a fastening member.

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