WIRING COMPONENT FOR ELECTRICAL EQUIPMENT

A wiring component for electrical equipment comprises a plurality of bus bars, a housing made of resin in which the plurality of bus bars are each exposed at both ends and embedded inside at an interval to each other, and a hollow portion is provided in which an opening through which an intermediate portion of each of the plurality of bus bars is exposed is formed, a filling material made of an elastomer filled in the hollow portion and covering an entire periphery of the bus bars at least at a boundary portion between the intermediate portions and the housing, and a lid member including a lid portion that closes the opening and an embedded portion that extends from the lid portion toward the filling material and is embedded in the filling material.

TECHNICAL FIELD

The present application relates to a wiring component for electrical equipment.

BACKGROUND ART

In order to promote the reduction of the number of wire harnesses for electrical equipment, the reduction of wire diameters, and the electrification for mechanically operated parts (power steering, engine intake and exhaust devices) in an internal combustion passenger car, it is desirable to boost the voltage to a voltage higher than the rated voltage 12 V. In this case, when a circuit to which the rated voltage 12 V and the boosted high voltage are applied is provided in a circuit of an electrical connection box that distributes the power, a leakage current due to the potential difference is likely to occur. Therefore, a circuit unit having a structure in which an insulating resin is filled between a low-voltage bus bar and a high-voltage bus bar and between high-voltage bus bars, in which a leakage current is likely to occur, for preventing the occurrence of the leakage current has been disclosed (for example, refer to Patent Document 1).

CITATION LIST

Patent Document

SUMMARY OF INVENTION

Problems to be Solved by Invention

However, since the metal bus bar and the filled resin have different linear expansion coefficients, a minute gap may be generated due to displacement caused by a temperature change. Therefore, when the bus bar is exposed to the outside, there is a possibility that liquid such as water entering from one end side through the minute gap advances toward the other end side, and a leakage current is generated at the other end side connected to another equipment.

The present application discloses a technique for solving the above-described problem, and an object of the present application is to obtain a highly reliable wiring component for electrical equipment that prevents a leakage current.

Means for Solving Problems

A wiring component for electrical equipment disclosed in the present application includes, a plurality of bus bars, a housing made of resin in which the plurality of bus bars are each exposed at both ends and embedded inside at an interval to each other, and a hollow portion is provided in which an opening through which an intermediate portion of each of the plurality of bus bars is exposed is formed, a filling material made of an elastomer filled in the hollow portion and covering an entire periphery of the bus bars at least at a boundary portion between the intermediate portions and the housing, and a lid member including a lid portion that closes the opening and an embedded portion that extends from the lid portion toward the filling material and is embedded in the filling material.

Advantageous Effect of Invention

According to the wiring component for electrical equipment disclosed in the present application, since at least the boundary portion between the intermediate portions of the bus bars and the housing is covered with the elastomer, it is possible to obtain a highly reliable wiring component for electrical equipment that prevents a leakage current caused by a gap between the bus bars and the housing.

MODE FOR CARRYING OUT INVENTION

FIG.1A,FIG.1BtoFIG.4A, andFIG.4Bare for describing a configuration of a wiring component for electrical equipment according to Embodiment 1,FIG.1Ais a perspective view of the wiring component for electrical equipment as viewed from above,FIG.1Bis a perspective view of a housing in a see-through manner for showing a state of a lid portion and bus bars from the same viewpoint asFIG.1A, andFIG.2is a perspective view of the housing in a see-through manner for showing a state of the lid portion and the bus bars when the wiring component for electrical equipment is viewed from below. Further,FIG.3is a plan view of the housing in a see-through manner for showing a state of the bus bars of the wiring component for electrical equipment,FIG.4Ais a cross-sectional view corresponding to a line A-A ofFIG.3, andFIG.4Bis a cross-sectional view corresponding to a line B-B ofFIG.3.

Before describing the configuration of the wiring component for electrical equipment1according to each embodiment of the present application, a basic configuration and a usage mode common to a typical wiring component for electrical equipment will be described. The basic configuration is that, as shown inFIG.1AandFIG.3, both ends (end portion2ea, end portion2eb) of a bus bar2whose intermediate portion is embedded in the housing3protrude from the housing3. In many cases, for example, in a state where one end (end portion2ea) is connected to another equipment that requires hermeticity or a wiring component, the other end (end portion2eb) is exposed to the outside and used.

Therefore, water should not be allowed to enter another equipment connected through the wiring component for electrical equipment1. For example, when the wiring component for electrical equipment having a gap between the bus bar and the resin described in the background art is used in a severe environment in which a rapid temperature change is repeated, a pressure difference occurs between the inside and the outside of the component, and thus liquid may enter the gap. Then, there is a possibility that the entered liquid becomes a path and a short-circuit failure occurs between exposed portions of the bus bars to which different voltages are applied. Therefore, a waterproof structure is required for the wiring component for electrical equipment in which the bus bars are exposed to the outside.

Therefore, the wiring component for electrical equipment1according to Embodiment 1 of the present application is configured such that the entire periphery of intermediate portions2mof the bus bars2embedded in a housing3by integral molding is covered with a filling material5made of an elastomer resin. To be specific, as shown inFIG.1B,FIG.2, andFIG.4B, in the housing3in which the intermediate portions of the bus bars2are embedded with their both ends (end portion2eaand end portion2eb) exposed and, a hollow portion3vthat is opened in the vertical direction (z direction in the figures) and in which the intermediate portions2mof the bus bars2are exposed is formed. The entire periphery of the intermediate portions2mof the bus bars2are covered with the filling material5with elasticity formed by curing a potting material filled in the hollow portion3vby potting as shown inFIG.4A.

For example, a bus bar2is formed of a conductor having excellent electrical conductivity such as Cu and Al, a total of two bus bars of a bus bar2A and a bus bar2B to which respective different voltages are applied are embedded by insert molding in the housing3at an interval. For the housing3, for example, in addition to a thermoplastic resin such as polyphenylene sulfide (PPS), a thermosetting resin can also be used as long as the insert molding can be performed and the resin has strength as the housing3.

Then, for the integrally molded product of the bus bars2and the housing3, a lower opening (negative side in the z direction) of the hollow portion3vopened vertically is closed by attaching a support member9, and the potting material is poured from an upper opening (positive side in the z direction). When the poured potting material is cured, the filling material5covering the intermediate portions2mis formed. Further, before the potting material is cured, a lid member4for closing the other opening is placed so that a portion (an embedded portion4b) is embedded in the potting material, whereby the wiring component for electrical equipment1is completed.

Also in the wiring component for electrical equipment1configured as described above, since the resin material constituting the housing3and the metal material constituting the bus bars2have different linear expansion coefficients, displacement occurs between the housing3and the bus bars2due to a temperature change. At this time, since the resin material having rigidity (bending strength, tensile strength) as the housing is used for the housing3, it is difficult to follow the displacement, and as described in the background art, a gap is generated between the housing3and the bus bars2.

In contrast, since the elastomer resin like silicone rubber is used as the potting material used for the filling material5, the potting material does not have rigidity as the housing, but has flexibility as compared with the resin constituting the housing3, so that the potting material can follow the displacement with the bus bars2. For this reason, at least in the portion covering the bus bars2, no gap is formed between the bus bars2and the potting material.

Furthermore, the adhesion between and the housing3and the potting material is also good in the hollow portion3v. Therefore, even if gaps between a bus bar2and the housing3are continuously formed between the end portion2eaand the hollow portion3vand between the end portion2eband the hollow portion3v, the gaps to each other are cut off by the filling material5. Therefore, even if water enters the hollow portion3vfrom the end portion2ea, the water does not reach the end portion2eb, and vice versa.

Note that, as described above, the filling material5is superior to the housing3in followability and adhesion, that is, a function of maintaining sealing, but is lower in rigidity than the resin material constituting the housing3. Therefore, when an external force is applied, there is a possibility that deformation, chipping, or the like occurs and the sealing is impaired. Whereas the lid member4is provided to close the opening of the upper portion of the hollow portion3vand prevent an external force from being applied to the filling material5.

The lid member4is made of resin having the same rigidity as that of the housing3, and at the distal end of a columnar portion4jextending from the lid portion4cclosing the opening toward the filling material5, the embedded portion4bembedded in the filling material5and extending in the direction (y direction) perpendicular to the extending direction (z direction) is provided. When the potting material is cured to form the filling material5, the embedded portion4bexhibits an anchor effect with respect to the attaching/detaching direction (z direction) of the lid member4, and has a structure capable of preventing the lid member4from detaching. In addition, the lid member4is provided with crush ribs4cpat intermediate portions of four sides of the lid portion4c, and has a structure capable of being temporarily fixed with respect to the opening of the hollow portion3vof the housing3. Therefore, even in a state where the anchor effect of the lid member4is not exhibited before the potting material is cured, the lid member4is not easily detached.

As a result, even when a large external force is applied to the lid member4in an environment such as strong vibration, impact, or high-pressure car washing, the lid member4can be prevented from detaching and the filling member5can be prevented from being exposed. Note that, in order to prevent an external force from being applied to the filling material5, the lower opening of the hollow portion3vmay be closed by the support member9having the same rigidity as the housing3or the lid member4. In this case, the support member9may also be provided with a portion corresponding to the embedded portion4bthat exhibits the anchor effect in the filling material5, like the lid member4.

However, for example, in a case of a configuration in which an external force is not applied to the filling material5from the lower opening by another member in an assembled state as an ASSY (Assembly), the support member9does not necessarily need to be provided. In this case, the support member9may be formed of, for example, a tape material so that the support member9is used only during a period in which the potting material is filled, and it is peeled off after the potting material is cured and the filling material5is formed.

In addition, in the wiring component for electrical equipment1of the present application, the hollow portion3vthat is opened upward and downward is formed at the stage of the integrally molded product. This makes it possible to perform integral molding using only an upper and lower mold without using a slide mold, and thus there is an advantage in that the mold cost is reduced.

In Embodiment 2, a description will be given for a configuration that is more excellent in preventing the lid member from detaching in a state before the potting material is cured as the filling material than the case exemplified in Embodiment 1.FIG.5andFIG.6are diagrams for describing a configuration of a wiring component for electrical equipment according to Embodiment 2,FIG.5is a perspective view of the wiring component for electrical equipment when viewed from above, andFIG.6is a cross-sectional view corresponding to a line C-C inFIG.5.

Note that, in the wiring component for electrical equipment according to Embodiment 2, the same configuration as that of Embodiment 1 can be applied to the configuration other than the prevention of the detachment of the lid member, the description of the same portion will be omitted, andFIG.4Bused in Embodiment 1 will be referred to.

In the wiring component for electrical equipment1according to Embodiment 2, as shown inFIG.5andFIG.6, snap fit protrusions4cfare provided at intermediate portions between two opposing sides of the lid portion4c, and recessed portions3ato be engaged with the snap fit protrusions4cfare provided at upper portions of an outer side surface3fxsurrounding the hollow portion3vof the housing3. In other words, the snap fit protrusions4cfand the recessed portions3afunction as a snap fit mechanism for forming a snap fit coupling that regulates the movement of the lid member4in the direction in which the lid member4is detached from the housing3. The assembling order is the same as that of Embodiment 1. After the bus bars2are insert-molded using the resin constituting the housing3, the support member9is attached to the housing3, and the lid member4is attached before the potting material is cured.

After the potting material is cured and the filling material5is formed, the embedded portion4bexhibits the anchor effect and the lid member4can be prevented from detaching. The present embodiment is different from Embodiment 1 in that, during a period in which the anchor effect is not exhibited, the temporary fixing is performed by using the snap fit coupling between the snap fit protrusions4cfand the recessed portions3a, so that the fixing force to the housing3is larger than that in the case of the temporary fixing by the ribs4cp. For example, this structure is useful when firm temporary fixing is required before the potting material is cured in consideration of the attachment environment of the lid member4.

In Embodiment 3, a shape of the embedded portion of the lid member is devised in contrast to the wiring component for electrical equipment according to Embodiment 1 or Embodiment 2.FIG.7andFIG.8are diagrams for describing a configuration of a wiring component for electrical equipment in Embodiment 3.FIG.7is a perspective view of a lid member as viewed from above, andFIG.8is a cross-sectional view corresponding toFIG.4A.

In the wiring component for electrical equipment according to Embodiment 3, the same configuration as that of Embodiment 1 or Embodiment 2 can be applied to the configuration other than the shape of the embedded portion, and the description of the same portion will be omitted, andFIG.1A,FIG.1B,FIG.2, andFIG.3used in Embodiment 1 will be referred to.

In the wiring component for electrical equipment1according to Embodiment 3, as shown inFIG.7andFIG.8, the cross-sectional shape of the embedded portion4bof the lid member4is a shape close to a rhombus: that is, it is inclined with respect to the direction of insertion toward the filling material5. To be more specific, the embedded portion4bis provided with an inclined surface formed such that, toward the distal end away from the lid portion4c, an area in the direction perpendicular to the extending direction from the lid portion4cis widened, and an inclined surface formed such that an area toward the lid portion4cis narrowed from the area that is fully widened.

Even in this case, the assembling order is the same as that of Embodiment 1. After the bus bars2are insert-molded using the resin constituting the housing3, the support member9is attached to the housing3, and the lid member4is attached before the filling material5(potting material) is cured. When the embedded portion4benters the filling material5, the filling material5easily goes around along the inclination of the embedded portion4b, so that the possibility of air being caught in the filling material5is reduced. For example, in the case of having a surface perpendicular to the inserting direction as shown inFIG.4A, when the embedded portion4benters the filling material5, air enters before the filling material5goes around the embedded portion4b, and when the potting material is cured, air bubbles are connected inside, which may cause a leak path.

In particular, in a structure in which the filling amount of the filling material5is small, in a case where air bubbles enter the inside of the filling material5when the lid member4is attached, the ratio of the air bubbles to the filling amount of the filling material5increases, and thus the possibility that a leak path is probabilistically generated increases. Therefore, this increases the advantage of the present configuration. In addition, in the assembly process of the lid member4, when it is desired to shorten the attachment time of the lid member4as much as possible, it is necessary to increase the attachment speed of the lid member4. In the case of an assembly process in which the attachment speed is high, since air bubbles are likely to be mixed before the filling material5goes around the embedded portion4b, the structure in which the embedded portion4bis inclined with respect to the inserting direction is effective. In particular, by making the cross-sectional shape rhombic, the embedded portion4bhas the inclined surface such that the area is narrowed from the fully widened portion toward the lid portion4c, which further prevents the filler material5that has gone around the buried portion4bfrom peeling off.

After the potting material is cured to form the filling material5, the embedded portion4bexhibits the anchor effect to the filling material5to prevent the lid member4from detaching.

In Embodiment 4, a volume of the embedded portion of the lid member is increased in order to reduce the amount of the filling material used in contrast to the wiring component for electrical equipment according to Embodiments 1 to 3.FIG.9andFIG.10are diagrams for describing a configuration of a wiring component for electrical equipment according to Embodiment 4,FIG.9is a perspective view of a lid member as viewed from above, andFIG.10is a cross-sectional view corresponding toFIG.4A.

Note that, in the wiring component for electrical equipment according to Embodiment 4, the same configuration as those of Embodiment 1 to Embodiment 3 can be applied to the configuration other than the shape of the embedded portion, the description of the same portions will be omitted, andFIG.1A,FIG.1B,FIG.2, andFIG.3used in Embodiment 1 will be referred to.

In the wiring component for electrical equipment1according to Embodiment 4, as shown inFIG.9andFIG.10, the volume of the embedded portion4bof the lid member4is made larger than those of the embedded portions4bof Embodiment 1 to Embodiment 3, and the columnar portion4jis not distinguished from the embedded portions4b. The assembling order is the same as that of Embodiment 1. After the bus bars2are insert-molded using the resin constituting the housing3, the support member9is attached to the housing3, and the lid member4is attached before the potting material is cured.

In Embodiment 4, a structure is provided in which the volume of the portion of the lid member4inserted into the filling material5(the embedded portion4bincluding the portion corresponding to the columnar portion4jin Embodiment 1) is increased. In this case, although the filling amount of the filling material5is reduced, the filling amount can be reduced as long as the amount of the filling material5is sufficient to satisfy the waterproof function as the purpose of filling the filling material5and the insulation performance between the bus bars with different voltages. Therefore, the filling amount of the filling material5can be reduced by increasing the size of the embedded portion4buntil the filling amount reaches the above-described amount. In general, the material cost of the potting material constituting the filling material5is higher than that of the resin material constituting the housing3and the like. Therefore, according to the present configuration, the material cost is lower than those of Embodiment 1 to Embodiment 3.

In Embodiment 5, a through hole is provided in an intermediate portion of a bus bar so that the through hole makes it easier for the filling material to go around.FIG.11is a perspective view of an integrally molded product of bus bars and the housing as viewed from above for describing a configuration of a wiring component for electrical equipment according to Embodiment 5.

In the wiring component for electrical equipment according to Embodiment 5, the same configuration as those of Embodiment 1 to Embodiment 4 can be applied to the configuration other than the shape of the bus bars, the description of the same portions will be omitted, andFIG.4AandFIG.4Bused in Embodiment 1 will be referred to for the relationship between the embedded portion and the filling material.

In the wiring component for electrical equipment1according to Embodiment 3, as shown inFIG.11, the through hole2hpenetrating in the vertical direction (z) is provided on a surface of the bus bar2facing the opening in the intermediate portion2mthat is to be covered with the filling material5. The assembling order is the same as that of Embodiment 1. That is, after the bus bars2are insert-molded using the resin constituting the housing3, the support member9is attached to the housing3, and the lid member4is attached before the potting material is cured.

Since it is desired to fill the space3vwith the filling material5without inclusion of air bubbles, it takes a sufficient time to fill the space3vwith the filling material5. However, it is difficult to completely eliminate the air bubbles generated inside the filling material5only by injecting the potting material in the atmosphere. Therefore, in Embodiment 5, the through hole2hpenetrating the bus bar2in the vertical direction is formed in the intermediate portion2mof the bus bar2exposed in the hollow portion3v.

When the potting material is injected to the integrally molded product in which the support member9is attached to the bottom of the hollow portion3v, the potting material is gradually filled from the bottom of the hollow portion3v, and the air bubbles to be accumulated on the lower surface of the bus bar2can be released from the through hole2h. Therefore, a structure is obtained in which the air bubbles are less likely to be accumulated inside the filling material5formed by curing the potting material. Further, the through hole2hcan be used for positioning the bus bar2at the time of insert molding, and the through hole2hof the bus bar2is not exposed to the outside after the potting material is filled.

When the bus bars are insert-molded using the resin constituting the housing, positioning of the bus bars are important. When a pin of a mold is kept inserted into the through hole during molding, the portion of the bus bar where the through hole is formed is exposed to the outside after the molding. When used in such a state, a conductive substance such as salt is deposited on the wiring component for electrical equipment, which may cause a short circuit within the wiring component for electrical equipment. Therefore, a step of filling the exposed portion with an adhesive is required in some cases. However, in the structure of the wiring component for electrical equipment1according to Embodiment 5, since the portion exposed from the housing3in which the through hole2his formed is to be covered with the filling material5, the through hole2hused for positioning the bus bar2is not exposed. Therefore, there is an advantage in that an additional adhesive application process is not required.

In Embodiment 6, a cover plate that covers the upper surface of the filling material is provided on the lid member in order to reduce the exposed area of the filling material in contrast to the wiring component for electrical equipment according to Embodiment 1 to Embodiment 5.FIG.12andFIG.13are diagrams for describing a configuration of a wiring component for electrical equipment according to Embodiment 6,FIG.12is a perspective view of a lid member as viewed from the lower side, andFIG.13is a cross-sectional view corresponding toFIG.4A.

In the wiring component for electrical equipment according to Embodiment 6, the same configuration as those of Embodiment 1 to Embodiment 5 can be applied to the configuration other than the cover plate of the lid member, the description of the same portions will be omitted, andFIG.1A,FIG.1B,FIG.2, andFIG.3used in Embodiment 1 will be referred to.

In the wiring component for electrical equipment1according to Embodiment 6, as shown inFIG.12andFIG.13, a cover plate4tthat covers an upper surface of the filling material5is provided in an intermediate portion in the columnar portion4jof the lid member4between the embedded portion4band the lid portion4c. With this structure, even when a harmful substance that adversely affects the filling material5enters through a gap between the lid member4and the upper opening of the hollow portion3v, the upper surface of the filling material5is covered with the cover plate4t, thereby reducing the area to be contact with a harmful substance in the upper surface. In addition, by making the outer shape of the cover plate4tin the x-y plane fit with the inner peripheral surface of the hollow portion3v, the entire upper surface of the filling material5can be covered with the cover plate4t.

In Embodiment 7, a configuration in which a labyrinth structure is formed between the lid member and the housing in order to strengthen the isolation between the filling material and the outside will be described.FIG.14toFIG.16are diagrams for describing a configuration of a wiring component for electrical equipment according to Embodiment 7,FIG.14is a perspective view of an integrally molded product of bus bars and a housing as viewed from above,FIG.15is a perspective view of a lid member as viewed from below, andFIG.16is a cross-sectional view corresponding toFIG.4A.

Note that, in the wiring component for electrical equipment according to Embodiment 7, the same configuration as those of Embodiment 1 to Embodiment 6 can be applied to the configuration other than the labyrinthine structure between the lid member and the housing, the description of the same portions will be omitted, andFIG.1A,FIG.1B,FIG.2, andFIG.3used in Embodiment 1 will be referred to.

In the wiring component for electrical equipment1according to Embodiment 7, as shown inFIG.14, a groove portion3drecessed in the z direction is formed over the entire periphery of the inner edge portion of the upper opening of the hollow portion3vin the housing3, and a ridge portion3rprotruding in the z direction is formed over the entire periphery in the inner side of the groove portion3din the x-y plane. In accordance with this, in the lid member4, as shown inFIG.15, a ridge portion4rcorresponding to the groove portion3dis provided at the outer edge portion of a surface4ffof the lid portion4copposed to the hollow portion3vover the entire periphery, and a groove portion4dcorresponding to the ridge portion3ris formed inside the ridge portion4rover the entire periphery.

Accordingly, when the lid member4is put on the housing3, as shown inFIG.16, the ridge portion3ris fitted into the groove portion4d, and the ridge portion4ris fitted into the groove portion3d, thereby forming a labyrinth seal structure and isolating the hollow portion3vfrom the outside. That is, the groove portion4d, the ridge portion3r, the groove portion3d, and the ridge portion4rare combined to function as a labyrinthine seal mechanism. By forming the labyrinth seal structure, when the wiring component for electrical equipment1is installed outside, it is possible to prevent liquid such as salt water or water from entering from a gap between the lid member4and the housing3.

In Embodiment 8, a configuration in which the lid member and the housing are fixed by a thread structure will be described.FIG.17andFIG.18are diagrams for describing a configuration of a wiring component for electrical equipment according to Embodiment 8,FIG.17is a perspective view of an integrally molded product of bus bars and a housing as viewed from above, andFIG.18is a perspective view of a lid member as viewed from below.

In the wiring component for electrical equipment according to Embodiment 8, the same configuration as those of Embodiment 1, Embodiment 3 to Embodiment 7 can be applied to the configuration other than the structure for fixing the lid member and the housing to each other, the description of the same portions will be omitted, andFIG.4AandFIG.4Bused in Embodiment 1 will be referred to for the relationship between the bus bars, the embedded portion, and the filling material.

In the wiring component for electrical equipment1according to Embodiment 8, as shown inFIG.17, at least the opening of the hollow portion3vof the housing3is formed in a cylindrical shape having a circular shape in the x-y plane, and a female thread3fsis formed on the inner peripheral surface of the upper opening. In accordance with this, in the lid member4as shown inFIG.18, the lid portion4cis made circular in shape, and a male thread4cmscorresponding to the female thread3fsis formed on the outer peripheral surface.

As a result, when the lid member4is put on the housing3, the lid member4is inserted while being rotated along the thread and fixed by the thread structure, and the fixing force is larger than that in the case where the lid member4is temporarily fixed simply by the (crushed) ribs4cp. In addition, the attachment state of the lid member4can be easily visually recognized as compared with the temporary fixation using the ribs4cp. For example, when the direction of the load applied to the lid member4in the temporary fixation using the ribs4cpis inclined from the vertical direction (z direction), there may be a case where the lid member4is attached with a rib4cpnot crushed exists and an expected fixing force is not exerted.

Even in such a case, the lid member4is positioned at a specified height with respect to the housing3, and there is a possibility that it is erroneously recognized that the lid member4has been attached. In contrast, as the fixation method, the attachment method of the lid member4having the thread structure is easy, and the above concern can be eliminated. In addition, in the case of the thread structure, the lid member4can be detached, and even when the attachment of the lid member4fails, the lid member4can be repeatedly attached and detached before the potting material is cured.

In each of the above-described embodiments, an example in which the hollow portion for collectively exposing the intermediate portions of a plurality of the bus bars is provided has been described. In Embodiment 9, a description will be given for an example in which a plurality of hollow portions partitioned by a partition wall are provided in order to expose individual intermediate portions of the bus bars.FIG.19toFIG.22are diagrams for describing a configuration of a wiring component for electrical equipment according to Embodiment 9,FIG.19is a perspective view of an integrally molded product of the bus bars and a housing as viewed from above,FIG.20is a perspective view of a lid member as viewed from below, andFIG.21is a perspective view of the wiring component for electrical equipment as viewed from above.FIG.22is a cross-sectional view taken along a line D-D ofFIG.21.

Note that, in the wiring component for electrical equipment according to Embodiment 9, the same configuration as those of Embodiment 1 to Embodiment 8 can be applied to the configuration other than the configuration in which the hollow portion is individually provided corresponding to each bus bar, and the description of the same portion will be omitted.

In the wiring component for electrical equipment1according to Embodiment 9, as shown inFIG.19, the intermediate portions2mof the bus bars2A and2B are partitioned by a partition wall3p, and hollow portions3vA and3vB are provided to expose individually the bus bars2A and2B, respectively. Then, as shown inFIG.20, the lid member4is provided with columnar portions4jA and4jB that extend to the hollow portions3vA and3vB, respectively and in which the embedded portions4bA and4bB are formed at the respective distal ends, in the lid portion4cthat collectively closes the two hollow portions3vA and3vB.

The assembling order is the same as that in each of the above-described embodiments, and after the bus bars2are insert-molded using the resin constituting the housing3, the support member9is attached to the housing3. However, the potting material serving as the filling material5(filling materials5A and5B) is separately potted in each of the hollow portions3vA and3vB. After the potting material is injected into each of the hollow portions3vA and3vB, the lid member4is attached before the potting material is cured as the filling material5.

When the potting material is cured to form the filling material5, as shown inFIG.21andFIG.22, each of the embedded portions4bA and4bB exhibits the anchor effect in the attachment/detachment direction (z direction) of the lid member4, and has a structure capable of preventing the lid member4from detaching. In addition, since the air clearance and creepage distance between the bus bars2A and2B can be secured in advance by the partition wall3p, even if the filling state of the filling material5varies, the insulation between the bus bars2A and2B can be reliably secured.

Note that, in the present example, an example in which the embedded portion4bis provided for each of the plurality of hollow portions3vhas been described, but this is not a limitation. For example, it may be provided for either of the hollow portions3vwith respect to one lid portion4c. Further, an example in which the plurality of hollow portions3vare collectively closed has been described, but this is not a limitation, and the lid member4may be provided for each of the hollow portions3v.

Although various exemplary embodiments and examples are described in the present application, various features, aspects, and functions described in one or more embodiments are not inherent in an application of the contents disclosed in a particular embodiment, and can be applicable alone or in their various combinations to each embodiment. Accordingly, countless variations that are not illustrated are envisaged within the scope of the art disclosed herein. For example, the case where at least one component is modified, added or omitted, and the case where at least one component is extracted and combined with a component disclosed in another embodiment are included.

For example, an example in which PPS is used for the housing3, copper is used for the bus bars2, and silicone rubber is used for the filling material5has been described, but this is not a limitation. For example, as the filling material5, another thermosetting elastomer or thermoplastic elastomer may be used as long as it satisfies adhesion and followability, and any so-called elastic polymer material is applicable.

In this example, the entire intermediate portion2marranged in the hollow portion3vis covered with the filling material5that is continuous to the boundary portion with the housing3. However, this is not necessarily a limitation from the viewpoint of preventing water from entering through a gap formed between the end portion2eaand the end portion2eb. In order to block only the leak path between the bus bar2A and the bus bar2B in the hollow portion3v, for example, as in Embodiment 9, it is sufficient to form the partition wall3pextending in the x-z plane direction in the housing3and partitioning the space between the bus bar2A and the bus bar2B in the hollow portion3v. In this case, it is not necessary to cover the further intermediate portion of the intermediate portion2mwith the filling material5, and if the boundary portion between the intermediate portion2mand the housing3is covered over the entire periphery, it is possible to achieve both the blocking of the leak path and the prevention of the entry of water through the gaps between the housing3and the bus bars2.

Further, the material constituting the housing3is not limited to the thermoplastic resin, and a thermosetting resin may be used as long as it is a material in which the bus bars2are embedded and which has rigidity as the housing. Further, an example in which the hollow portion3vis opened to the upper and lower sides so that molding can be performed only by the upper and lower molds has been described, but this not a limitation, and only one side may be opened as long as the filling material5can be filled. Furthermore, in addition to aluminum, any conductor having excellent conductivity can be applied to the bus bars2, and the number of bus bars2is not limited to two.

As described above, the wiring component for electrical equipment1according to the present application is configured to include, a plurality of bus bars2, a housing3made of resin in which the plurality of bus bars2are each exposed at both ends (end portion2ea, end portion2eb) and embedded inside at an interval to each other, and a hollow portion3vis provided in which an opening through which an intermediate portion2mof each of the plurality of bus bars2is exposed is formed, a filling material5made of an elastomer filled in the hollow portion3vand covering an entire periphery of the bus bars2at least at a boundary portion between the intermediate portions2mand the housing3, and a lid member4including a lid portion4cthat closes the opening and an embedded portion4bthat extends from the lid portion4ctoward the filling material5and is embedded in the filling material5. As a result, it is possible to prevent a leakage current caused by the gap between the bus bars2and the resin constituting the housing3, and thus it is possible to obtain the wiring component for electrical equipment1with high reliability. At this time, since the opening is closed by the lid portion4c, it is possible to protect the filling material5, which is excellent in adhesion between the bus bars2and the housing3and followability with respect to displacements but is inferior in rigidity, from an external force and to maintain the adhesion.

When the hollow portion3vis configured to have a second opening on the opposite side of the opening to be closed by the lid portion4c, molding by upper and lower molds without using a slide mold becomes possible.

Since the housing3is an integrally molded product with the plurality of bus bars2, the housing3can be easily manufactured, and in particular, when the housing3has the second opening, the housing3can be more easily manufactured only by upper and lower molds.

When the embedded portion4bis configured to have the portion whose area in a direction (x-y direction) perpendicular to a direction (z direction) in which the embedded portion extends from the lid portion4cis widened toward a distal end of the embedded portion away from the lid portion4c, it is possible to prevent the lid member from detaching by the anchor effect after the filling material5is cured.

At this time, when the embedded portion4bis configured such that, from the portion where the area is widened toward the distal end, an inclined surface is formed so as to narrow the area as the distance from the lid portion4cincreases, it is possible to suppress inclusion of air bubbles into the filling material5when the lid member4is attached. Further, when an inclined surface is formed so as to narrow the area from the fully widened area of the portion toward the lid portion4c, it is possible to further suppress the separation of the filling material5having gone around the embedded portion4b.

When the through hole2his formed on the surface of the intermediate portion2mfacing the opening, the air bubbles can be allowed to escape as the filling of the filling material5progresses.

When the filling material5is configured to cover the entire periphery over the entire length of the intermediate portions2m, even if the plurality of bus bars2are arranged without a partition wall in the hollow portion3v, the leakage current between the bus bars2can be reliably prevented.

When the ridge portion4rprotruding in the thickness direction and the groove portion4drecessed in the thickness direction are formed over the entire periphery of the outer edge portion of the surface4ffof the lid portion4cfacing the opening, and a second groove portion (groove portion3d) and a second ridge portion (ridge portion3r) to be fitted to the ridge portion4rand the groove portion4d, respectively, are formed in the inner edge portion of the opening of the housing3, the labyrinthine structure can be formed to reliably prevent water from entering through the gap between the lid portion4cand the opening.

If the lid member4and the housing3are provided with the snap fit mechanism for forming the snap fit coupling that regulates movement of the lid member4in the direction of removal from the housing3when the lid portion4ccloses the opening, the lid member4can be prevented from detaching from the housing3even before the potting material is cured.

Alternatively, even when the male thread4cmsis formed on the outer peripheral surface of the lid portion4cand the female thread3fscorresponding to the male thread4cmsis formed on the inner peripheral surface of the opening of the housing3, the lid member4can be prevented from detaching from the housing3even before the potting material is cured.

DESCRIPTION OF REFERENCE NUMERALS AND SIGNS