Electrical equipment unit

A substrate includes a pair of surfaces opposing to each other in a direction. First electronic components are provided on one surface. Second electronic components lower than a maximum value of the height of the first electronic components in a direction are provided on the other surface. Insulating resin includes a covering part adhering and covering the second electronic components and the other surface, and side surface part extending from the periphery of the substrate to a side of the second electronic components along the direction. A lid covers the first electronic components from an opposite side of the substrate, and is fixed to the side surface part from the opposite side of the substrate.

TECHNICAL FIELD

The present invention relates to an electrical equipment unit, and specifically relates to a resin-sealed electrical equipment unit.

BACKGROUND ART

Patent document 1 discloses a technology adhering and covering electronic components and a substrate with insulating resin in a substrate with the electronic components mounted thereon. More specifically, a substrate is housed in a mold having a shape formed along the contour including the electronic components to be covered and a substrate with those electronic components mounted thereon, and the insulating resin is injected therein.

Further, patent document 2 discloses a technology covering electronic components, which are undesirable to be adhered and covered with resin, with a typical cover, and covering other electronic components by adhering with resin. More specifically, a substrate is housed in a mold formed along the contour of electronic components to be covered, electronic components provided with a cover, and a substrate including these, and the insulating resin is injected therein. The mold is provided with a space formed so as to make contact with the cover in a surface parallel to the substrate.Patent document 1: Japanese Patent Application Laid-Open No. 2004-111435Patent document 2: Japanese Patent Application Laid-Open No. 2006-190726

DISCLOSURE OF INVENTION

Problems to be Solved by the Invention

However, in the technology described in the patent document 1, it is necessary to form a shape in a mold along the contour of the electronic components to be covered, so that it is required to enhance the accuracy of positions and size of the electronic components and the accuracy of the mold as the electronic components are comparatively taller with respect to the substrate.

Moreover, in the technology described in the patent document 2, it is necessary to form a space in a shape so as to make contact with the cover in a surface parallel to the substrate, and it is required to enhance the accuracy in a direction parallel to the substrate.

It is therefore an object of the present invention to provide an electrical equipment unit reducing the required accuracy of a mold.

Means for Solving the Problems

A first aspect of an electrical equipment unit of the invention includes a substrate (1) including a first surface (1a) and a second surface (1b) opposing to each other in a predetermined direction (D); at least one or more first electronic components (2,21to25;26;27;28) provided on the first surface; at least one or more second electronic components (3) provided on the second first surface; an insulating resin (5) including a covering part (5b) which adheres and covers the second surface and at least one of the electronic components having the height lower than a maximum value of the height of the first electronic components in the predetermined direction (D) out of the second electronic components, and a side surface part (5a) extending from the periphery of the substrate to a side of the first electronic components in the predetermined direction; and a lid (6) which is a different body from the insulating resin and fixed to the side surface part at an opposite side of the substrate, covering the first electronic components from the opposite side of the substrate.

According to a second aspect of the electrical equipment unit of the invention, in the first aspect of the electrical equipment unit, the height of the side surface part (5a) in the predetermined direction (D) is lower than the maximum value of the height of the first electronic components (2,21to25;26;27;28).

According to a third aspect of the electrical equipment unit of the invention, in the second aspect of the electrical equipment unit, a plurality of the first electronic components (2,21to25;26;27;28) are provided on the first surface (1a), each having different height in the predetermined direction (D), the height of one of the first electronic components provided at a position adjacent to the side surface part (5a) is lower than that of any one of other first electronic components, and a distance from the first surface to the lid at a side of the first surface at the position where one of the first electronic components is provided, is smaller than that from the first surface to the lid at a side of the first surface at the position where any one of other first electronic components having the height higher than that of one of the first electronic components is provided.

According to a fourth aspect of the electrical equipment unit of the invention, in the second aspect of the electrical equipment unit, the lid (6) includes a second side surface part (6b) extending from one end of the side surface part (5a) at the opposite side of the substrate (1) in the predetermined direction (D); and a plane part (6c) extending from one end of the second side surface part at the opposite side of the substrate in a direction parallel to the substrate.

According to a fifth aspect of the electrical equipment unit of the invention, the first aspect of the electrical equipment unit further includes a second substrate (11) disposed to oppose to the substrate (1) in the predetermined direction (D); and third electronic components (201to203;204) provided on a surface (11a) of the second substrate at a side of said substrate, wherein the lid (6) covers the second substrate at the opposite side of the substrate.

According to a sixth aspect of the electrical equipment unit of the invention, the fifth aspect of the electrical equipment unit further includes fourth electronic components (211to213) provided on a surface (11b) of the second substrate (11) at the opposite side of the substrate (1); a third substrate (12) disposed to oppose to the second substrate at the opposite side of the substrate in the predetermined direction (D); and fifth electronic components (221,222) provided on a surface (12a) of the third substrate at a side of the second substrate, wherein the lid (6) covers the third substrate from the opposite side of the substrate (1).

According to a seventh aspect of the electrical equipment unit of the invention, in any one of first to sixth aspects of the electrical equipment unit, at least one of the first electronic components (2) is a connector (24,25), and any one of first to sixth aspects of the electrical equipment unit further includes trenches (6a,5c) provided at a boundary of the lid (6) and the side surface part (5a); and a wiring (7) electrically connected to the connector and extending to outside through the trenches.

According to a eighth aspect of the electrical equipment unit of the invention, any one of first to seventh aspects of the electrical equipment unit further includes a sixth electronic component (32) provided on the second surface (1b) and having the height lower than the maximum value of the height of the first electronic components (2) in the predetermined direction (D); and a radiator (300) attached to the sixth electronic component at an opposite side of the second surface, making contact therewith, wherein the covering part (5b) covers the sixth electronic component except at least the contact part with the radiator, and the radiator makes contact with the covering part from the opposite side of the substrate.

According to a ninth aspect of the electrical equipment unit of the invention, in any one of first to eighth aspects of the electrical equipment unit, the side surface part (5a) covers a part of at least one of the first electronic components (28).

According to a tenth aspect of the electrical equipment unit of the invention, any one of first to ninth aspects of the electrical equipment unit further includes a second radiator (302) attached to at least one of the first electronic components (28) and extending to outside through the side surface part (5a).

According to a eleventh aspect of the electrical equipment unit of the invention, any one of first to tenth aspects of the electrical equipment unit further includes a connecting mechanism (53) buried in the side surface part (5a) and electrically connecting the substrate (1) and an external wiring (71).

According to a twelfth aspect of the electrical equipment unit of the invention, in the eleventh aspect of the electrical equipment unit, the connecting mechanism (53) includes a lead frame (29), one end of which is electrically connected to the substrate (1); and a conductive female screw (75) making contact with the lead frame and buried in the side surface part (5a) to fix the external wiring (71) by screwing.

According to a thirteenth aspect of the electrical equipment unit of the invention, in the eleventh aspect of the electrical equipment unit, the connecting mechanism (53) includes: a lead frame (29), one end of which is electrically connected to the substrate (1), and extending to outside through the side surface part (5a), and the side surface part (5a) has a connector-like shape surrounding the lead frame with respect to an extending direction of the lead frame extending at the other end.

According to a fourteenth aspect of the electrical equipment unit of the invention, any one of first to thirteenth aspects of the electrical equipment unit further includes a sealing member (4) air-tightly sealing between the lid (6) and the side surface part (5a).

According to a fifteenth aspect of the electrical equipment unit of the invention, any one of first to fourteenth aspects of the electrical equipment unit further includes a heat transfer member (304) making contact with the first electronic components (2,21to25;26;27;28) and the lid (6).

Effects of the Invention

According to the first aspect of the electrical equipment unit of the invention, the second electronic components covered by a covering part that is insulating resin are short, thus not requiring to enhance the accuracy of a mold. On the other hand, the first electronic components that are tall are air-tightly sealed by the side surface part formed with insulating resin, and the lid, thus not requiring to be covered with the insulating resin. The lid is fixed to the side surface part at the opposite side of the substrate, eliminating the need for the accuracy of a position of the side surface part in a direction parallel to the substrate, and thus reducing the required accuracy of the mold in forming the shape of the side surface part to the mold.

According to the second and fourth aspects of the electrical equipment unit of the invention, the heights of the side surface part are suppressed to reduce the amount of the insulating resin for that part, thus allowing to reduce the manufacturing cost.

According to the third aspect of the electrical equipment unit of the invention, the height of the side surface part at the position which one of the first electronic components is provided is allowed to be shorter so that the amount of the insulating resin for that part is reduced and the lid is dented in accordance with the height of one of the first electronic components, thus reducing the size of the electronic equipment unit.

According to the fifth aspect of the electronic equipment unit of the invention, the electronic equipment unit with the substrate and the second substrate mounted thereon is provided.

According to the sixth aspect of the electronic equipment unit of the invention, the electronic equipment unit with the substrate, the second substrate, and the third substrate mounted thereon is provided.

According to the seventh aspect of the electronic equipment unit of the invention, the connector is air-tightly sealed by the side surface part and the lid, thus eliminating the need for an expensive connector for waterproof and reducing the manufacturing cost.

According to the eighth aspect of the electronic equipment unit of the invention, after the sixth electronic component is covered with the insulating resin except the contact part, a radiator is attached to the sixth electronic component. Accordingly, it is unnecessary to house the radiator in the mold and form the shape of the radiator to the mold, thus allowing to reduce the required accuracy of the mold.

According to the ninth aspect of the electronic equipment unit of the invention, for instance, in the situation where temperature of a space surrounding the first electronic components is higher than that of outside air, the first electronic components radiate heat through the side surface part to the outside air, thus allowing to improve the effect of heat radiation of the first electronic components.

According to the tenth aspect of the electronic equipment unit of the invention, the effect of the heat radiation of the first electronic components is improved.

According to the eleventh aspect of the electronic equipment unit of the invention, the substrate and the external wiring are easily connected.

According to the twelfth aspect of the electronic equipment unit of the invention, the external wiring and the substrate are electrically connected by fixing with a screw.

According to the thirteenth aspect of the electronic equipment unit of the invention, the side surface part have a connector-like shape, thus easily and electrically connecting to a connector provided to the external wiring with the other end of the lead frame as a connector terminal.

According to the fourteenth aspect of the electrical equipment unit of the invention, the air tightness of the first electronic components is improved.

According to the fifteenth aspect of the electrical equipment unit of the invention, the heat radiation of the first electronic components is improved.

BEST MODE FOR CARRYING OUT THE INVENTION

First Preferred Embodiment

FIG. 1is a block diagram schematically showing a cross section of one example of the electrical equipment unit according to the first preferred embodiment, seen from a direction parallel to a substrate1(described later). The electrical equipment unit includes the substrate1, electronic components2and3, insulating resin5, and a lid6.

The substrate1includes surfaces1aand1bopposing to each other in a predetermined direction D.

The electronic components2are provided on the surface1a. InFIG. 1, as the electronic components2, insertion type electronic components21and23such as an electrolytic capacitor, a relay, a coil and the like, a surface mount type electronic component22such as a bare chip and the like, a connector24, and a connector25coupled to the connector24are illustrated. A wiring7is attached to the connector25for electrically connecting to an external device. At least one or more electronic components2may be provided on the surface1a.

The electronic component3is provided on the surface1b. InFIG. 1, as the electronic component3, a surface mount electronic component of small size such as a resistor, a diode, an IC, and the like is illustrated. At least one or more electronic components3may be provided.

The insulating resin5includes a covering part5band a side surface part5a. The side surface part5ais continuous from the covering part5b, extending from the periphery of the substrate1to a side of the electronic components2in the direction D. The covering part5badheres and covers the electronic component3. The electronic component3has the height lower than the maximum value of the height of the electronic component2in the direction D. In the case where a plurality of the electronic components3are provided, and the covering part5bcovers the plurality of the electronic components3, an insulation distance among the electronic components3is allowed to be longer by the covering part5bthat is insulating resin. Accordingly, the intervals among the electronic components3that are covered are allowed to be shorter.

In the present preferred embodiment, the case where at least any one of the electronic components3is lower than the maximum value of the height of the electronic components2is assumed. At least any one of the electronic components3lower than this maximum value is covered by the covering part5b. In the present preferred embodiment, the case where the one of the electronic components3having the height higher than this maximum value is covered by the covering part5b, is not assumed.

The lid6is a different body from the insulating resin5, and is fixed to the side surface part5aat the opposite side of the substrate1, covering the electronic components2from the opposite side of the substrate1. The side surface part5aand the lid6are fixed by screwing, for example, with a screw61.

A wiring7is provided to the connector25, and is drawn to outside, for example, through a boundary of the lid6and the side surface part5a. More specifically, as shown inFIG. 2, for example, the wiring7extends to outside through a through hole formed by a trench6aprovided in the lid6and a trench5cprovided in the side surface part5ato oppose to the trench6a. The trenches6aand5care regarded to be provided to the boundary of the lid6and the side surface part5a.

In the electrical equipment unit configured as above, the electronic components3that are comparatively short are air-tightly sealed by the insulating resin5at a side of the surface1b. The electronic components2that are comparatively tall are air-tightly sealed by the side surface part5aand the lid6at a side of the surface1a. In view of the airtightness, the boundary of the lid6and the side surface part5amay be sealed with a sealing member, for example.FIG. 3is a cross sectional view schematically showing one example of a configuration of the electrical equipment unit sealed with a sealing member. The electrical equipment unit further includes a sealing member4such as an O-ring, for example, comparing to the electrical equipment unit shown inFIG. 1. The sealing member4is interposed between the side surface part5aand the lid6. This improves the airtightness of the electronic components2. The wiring7, the trenches6aand5cmay be sealed with such as a thermoplastic fluid sealant, for example. Both of the trenches6aand5cmay be not necessarily provided, but only either one of the trenches may be provided. In this case, the airtightness of the electrical equipment unit may be secured by extending the wiring7to outside through the either one of the trenches and sealing a gap between the either one of the trenches and the wiring7with the sealing member and the like.

Subsequently, a manufacturing process of the electrical equipment unit will be described.FIGS. 4 to 6are views illustrating the manufacturing process. First, as shown inFIG. 4, each of an insertion type electronic component21, surface mount type electronic components22and23, a connector24, and an electronic component3is mounted on the substrate1.

Next, as shown inFIG. 5, the substrate1after mounting is housed in a mold9. The mold9is composed of an upper mold9aand a lower mold9b. A recess part903having the same shape as the contour of the covering part5bis formed in the mold9b. In other words, an inner surface of the mold9bhas a shape along with the contour of a part composed of the surface1band the electronic component3.

A recess part904having the same shape as the contour of the side surface part5aand a recess part905covering the electronic components2are formed in the mold9a. A protruding part901protruding to a side of the substrate1may be provided in the recess part904. The protruding part901is for forming a screw hole in a surface of the side surface part5aat the opposite side of the substrate1.

An inlet902for injecting the insulating resin5that is thermoplastic, for example, is provided to a matching surface of the molds9aand9b.

The substrate1is disposed in the mold9bhaving such a configuration through insulating resin (not shown) which is melted by heat, for example. That is, a space for molding the insulating resin5is generated between the mold9band the substrate1.

Then, the mold9ais closed onto the mold9b, matching the matching surfaces. Thereafter, thermoplastic insulating resin is injected from the inlet902to thermoset that insulating resin, thereby molding the insulating resin5. As insulating resin, thermoset resin having curing temperature lower than heat resistant temperature of the electronic components2,3, and the substrate1, or hot-melt resin having melting temperature lower than heat resistant temperature of the electronic components2,3, and the substrate1may be used.

Next, referring toFIG. 6, the substrate1is detached from the mold9, and the connector25is coupled to the connector24. Then, the wiring7is extracted through the trench5c(seeFIG. 2). Next, the lid6is disposed to the side surface part5afrom the opposite side of the substrate1, and is fixed to the side surface part5awith the screw61. In this manner, the electrical equipment unit shown inFIG. 1is manufactured.

As described above, a shape along the contour of the electronic component3is formed in the mold9b. This electronic component3is comparatively short, thereby eliminating the need for enhancing the accuracy of the position and size of the electronic component3, and the accuracy of the mold9b. On the other hand, since the electronic components2including the insertion type electronic part21that is tall is air-tightly sealed with the side surface part5aformed with the insulating resin5and the lid6, it is unnecessary to be adhered and covered by insulating resin. Thus, it is unnecessary to form the shape along the contour of the electronic components2in the mold9a, and it is not required to necessarily enhance the accuracy of the position and size of the electronic component2, and the accuracy of the mold.

Further, the lid6is fixed to the side surface part5aat the opposite side of the substrate1, thereby not requiring the accuracy of the position of the side surface part5ain a direction parallel to the substrate. Thus, the required accuracy of the mold is reduced in forming the contour of the side surface part5ain the mold9a. The necessity to enhance the accuracy of the side surface part5ain a direction perpendicular to the substrate1is low, and thus the required accuracy of the mold in that direction is also low.

At least one or more electronic components3are provided on the surface1b, and all the electronic components3have the heights lower than the maximum value of the height of the electronic components2. The covering part5bmay adhere and cover all the electronic components3. In this case, the size of the electrical equipment unit in the direction D is reduced.

Further, the connectors24and25are disposed in a space air-tightly and hermetically sealed (hereinafter, also referred to as a hermetic space), so that it is unnecessary to use an expensive connector for waterproof, thus suppressing the increase of the manufacturing cost.

When any of the electronic components2is broken, the broken electronic component2is easily repaired or exchanged by removing the lid6, and thus improving the repair ability.

In the electrical equipment unit shown inFIG. 1, the height of the side surface part5aadjacent to a pair of the electronic components24and25, for example, is lower than the maximum value of the height of the electronic components2(height of the electronic component21). This reduces the amount of the insulating resin. It will be described more in detail in the following. In the electrical equipment unit shown inFIG. 1, there exists the electronic component21higher than the pair of the electronic components24and25provided at the position adjacent to the side surface part5a, for example. Then, the distance from the surface1ato a side of the surface1aof the lid6at the position in which the electronic component21is provided is longer than that from the surface1ato the side of the surface1aof the lid6at the position in which the pair of the electronic components24and25are provided. In this case, the height of the side surface part5aadjacent to the pair of the electronic components24and25is suppressed, and the lid6is dented in accordance with the height of the pair of the electronic components24and25, in addition to reduce the amount of resin. Thereby, the size of the electrical equipment unit is reduced.

In the electrical equipment unit shown inFIG. 1, the distance from the surface1ato the side of the surface1aof the lid6at the position in which the electronic component23is provided, is smaller than that from the surface1ato the side of the surface1aof the lid6at the position in which the electronic component21is provided. Thereby, the lid6is dented in accordance with the height of the electronic component23, allowing to further reduce the size of the electrical equipment unit.

In terms of suppressing the height of the side surface part5a, the lid6may not necessarily have an uneven shape shown inFIG. 1. For instance, one example of the electrical equipment unit not having the uneven shape is shown inFIG. 7.FIG. 7is a cross sectional view of another example of a schematic configuration of the electrical equipment unit. The lid6includes a side surface part6bextending from the end of the side surface part5ato the opposite side of the substrate1in the direction D, and a plane part6cextending from the end of the side surface part6bat the opposite side of the side surface part5ato a direction parallel to the substrate1.

A through hole extending in the direction D is provided in the side surface part6b. This through hole extends to a portion of the plane part6coverlapping with the side surface part6bin the direction D. Further, a through hole extending in the direction D is provided in the plane part6coverlapping with the side surface part5aadjacent to the electronic component21in the direction D. Then, the side surface parts5aand6bare fixed by inserting the screws61into these through holes.

According to the electrical equipment unit having such a configuration, the height of the side surface part5ais reduced by the height of the side surface part6bin the direction D. Thus, the amount of resin composing the side surface part5ais reduced, thereby allowing to reduce the manufacturing cost.

Second Preferred Embodiment

FIG. 8is block diagram schematically showing a cross section of one example of the electrical equipment unit according to a second preferred embodiment, seen from the direction parallel to the substrate1.

An electrical equipment unit according to the second preferred embodiment includes substrates1,11, electronic components2,3,200, and insulating resin5,51.

The substrate1, the electronic components2,3, and the insulating resin5are same as those in the first preferred embodiment. However, inFIG. 8, an insertion type electronic component21, a surface mount type electronic component22, and connectors24to27are illustrated as the electronic components2.

The substrate11is disposed to oppose to the substrate1in the direction D. The substrate11includes surfaces11aand11bopposing to each other in the direction D. The surface11ais a surface at the side of the substrate1in the direction D.

Electronic components200are provided on the surface11a. InFIG. 8, a connector201, a surface mount type electronic component202, and a connector203are illustrated as the electronic components200.

The connectors27and201are straight header type connectors, for example, and are connected to each other in the direction D, electrically connecting the substrates1and11. Connectors provided at both ends of the wiring70are connected to the connectors26and203, respectively, and then the substrates1and11are electrically connected to each other with the connectors26,203, and the wiring70.

The insulating resin51is a different body from the insulating resin5, and is fixed to the side surface part5afrom the opposite side of the substrate1, covering the substrate11from the opposite side of the substrate1. More specifically, for example, the insulating resin51includes a covering part51badhering and covering the surface11b, and a side surface part51aextending to a side of the electronic components200in the direction D from the periphery of the substrate11so as to be continuous with the covering part51b, for example. This insulating resin51is molded by injecting thermoset resin, for example, into a mold housing the substrate11, similarly to the first preferred embodiment. The insulating resin51is also regarded as the lid6to the insulating resin5.

The side surface parts5aand51aare fixed to each other in the direction D. For instance, on a contact surface of the side surface parts5aand51a, a recess part and a salient part fitting to each other are provided in the side surface parts5aand51a, respectively, so as to fix the side surface parts5aand51aby fitting these parts. The wiring7extends to outside through trenches provided in the side surface parts5aand51a, similarly to the first preferred embodiment.

As described above, the electrical equipment unit with two substrates1and11connecting to each other mounted thereon is provided, reducing the manufacturing cost in addition to exercise the same function, comparing to the mode connecting two electrical equipment units shown inFIG. 1to each other with the wiring7, for example.

Further, as shown inFIG. 8, the electronic components200are preferably adjacent to at least one of the electronic components2on a surface P perpendicular to the direction D. More specifically, each of the connector201and the surface mount type electronic component202out of the electronic components200is adjacent to the insertion type electronic component21on the surface P.

In this case, at least one of the electronic components2and at least one of the electronic components200are adjacent on the surface P, allowing to reduce the size of the electrical equipment unit in the predetermined direction D.

Further, the substrates1and11are electrically connected to each other in a space air-tightly sealed with the connectors27,201, the connectors26,203, and the wiring70. Accordingly, it is unnecessary to use an expensive connector for waterproof, and thus suppressing the increase of the manufacturing cost.

An electronic component lower than the maximum value of the height of the electronic components2and200may be provided on the surface11b. Even in this case, the required accuracy of the mold is reduced, similarly to the first preferred embodiment.

When any electronic components are not provided on the surface11b, the surface11bis not necessarily adhered and covered with the insulating resin51. For instance, the insulating resin51may be molded independently of the substrate11. In this case, a structure fitting and fixing to the substrate11may provided to the insulating resin51so as to attach the substrate1to the insulating resin51after molding the insulating resin51. A spacer, for example, may be disposed between the substrates1and11so as to fix each of the substrates1and11at both ends of the spacer in the direction D.

FIG. 9is a block diagram schematically showing a cross section of another example of the electrical equipment unit according to the second preferred embodiment, seen from a direction parallel to the substrate1.

Comparing toFIG. 8, the electrical equipment unit further includes a substrate12, electronic components210, and electronic components220.

The electronic components210are provided on the surface11b. InFIG. 9, surface mount type electronic components211,213, and a connector212are illustrated as the electronic components210.

The substrate12is disposed to oppose to the substrate11at the opposite side of the substrate1in the direction D. The substrate12includes a surface12aopposing to the surface11bin the direction D.

The electronic components220are provided on the surface12a. InFIG. 9, a surface mount type electronic component221and a connector222are illustrated as the electronic components220.

The connectors212and222are straight header type connectors, for example, and are connected to each other, electrically connecting the substrates11to12.

The insulating resin51covers the substrate12at the opposite side of the substrate1. More specifically, the insulating resin51includes a covering part51bcovering a surface12bof the substrate12positioned at the opposite side of the surface12a, and a side surface part51aextending to a side of the electronic components220toward the direction D from the periphery of the substrate12so as to be continuous with the covering part51b, for example, and then, is fixed to the side surface part5asimilarly to the insulating resin51shown inFIG. 8. The insulating resin51may be regarded as the lid6to the insulating resin5.

The substrate11may be fixed by grasping the substrate11with the side surface parts5aand51a, for example. A spacer may be disposed and fixed between the substrate1and the substrate11.

As described above, the electrical equipment unit with a plurality of the substrates1,11, and12connecting to one another mounted thereon is provided, reducing the manufacturing cost in addition to exercise the same function, comparing to the mode connecting three electrical equipment units shown inFIG. 1to one another with the wiring7, for example.

As shown inFIG. 9, the electrical components220are preferably adjacent to at least one of the electrical components210on a surface perpendicular to the direction D. More specifically, the surface mount type electronic component221is adjacent to the connector212and the surface mount type electronic component213on that surface.

In this case, the size of the electrical equipment unit in the direction D is reduced with the plurality of the substrates1,11, and12mounted thereon.

Third Preferred Embodiment

An electrical equipment unit according to a third preferred embodiment will be described. In the electrical equipment unit according to the first preferred embodiment and the second preferred embodiment, there is a case that heat generated from the electronic components is accumulated in the electrical equipment unit. Therefore, an object of the electrical equipment unit according to the third preferred embodiment is to radiate heat of the electronic equipments.

FIG. 10is a block diagram schematically showing one example of a cross section of the electrical equipment unit according to the third preferred embodiment, seen from a direction parallel to the substrate1. Comparing to the first preferred embodiment, the electrical equipment unit according to the third preferred embodiment includes a radiator300.

InFIG. 10, an electronic component32that is a Dual Inline Package (DIP) type integrated circuit chip, for example, is illustrated as the electrical component3.

The radiator300is a metallic heat sink, for example, and is attached to the electronic component32on a surface at the opposite side of the surface1b, radiating the electronic component32. InFIG. 10, the radiator300is attached to the electronic component32by screwing.

The covering part5bincluded in the insulating resin5adheres and covers the electronic component32except at least the contact part with the radiator300. The radiator300makes contact with the covering part5bfrom the opposite side of the substrate1. InFIG. 10, a through hole is provided to the covering part5bfor screwing the electronic component32and the radiator300. The surface1bis in communication with a surface at the side of the surface1bof the electronic component32through this through hole. A through hole through which the surface1ais in communication with the surface1bis provided to the substrate1so as to be continuous with this through hole.

A screw301fixes the electronic component32and the radiator300through these through holes.

Subsequently, a manufacturing method of the electrical equipment unit will be described. First, the electronic components2and32are mounted on the substrate1. A through hole is provided to the substrate1in the direction D.

Next, as shown inFIG. 11, the substrate1after mounting is housed in a mold91. The mold91includes an upper mold91aand a lower mold91b. Similarly to the first preferred embodiment, a recess part904having the same shape as the contour of the side surface part5aand a recess part905covering the electronic components2are formed in the mold91a. The mold91aextends to the electronic component32through the through hole provided on the substrate1, and includes a through hole forming part906abutting the electronic component32.

A recess part903having a shape along the contour of the surface1band the electronic component32is formed in the mold91b. It should be noted that a surface of the electronic component32at the opposite side of the surface1bmakes contact with the mold91b.

Then, similarly to the first preferred embodiment, for example, thermoplastic insulating resin is injected into an inlet902provided to a matching surface of the molds9aand9bso as to be thermoset to mold the insulating resin5.

Thereafter, the mold91is detached, and the radiator300is attached to the electronic component32.FIG. 12is a block diagram schematically showing a part of the electrical equipment unit when the radiator300is attached to the electronic component32. As shown inFIG. 12, the screw301is inserted into the through hole from the side of the surface1aso as to fix the electronic component32and the radiator300by screwing.

As described above, in the electronic equipment unit according to the third preferred embodiment, the radiator300is attached to the electronic component32after the electronic component32is covered with the insulating resin51except the contact part. Thus, it is unnecessary to house the radiator300in the mold91so that there is no need for forming a shape of the radiator300to the mold91, thereby reducing the required accuracy of the mold91.

Fourth Preferred Embodiment

An electrical equipment unit according to a fourth preferred embodiment will be described. While the heat of the electronic component32is radiated in the electrical equipment unit according to the third preferred embodiment, it is difficult to radiate the heat of the electronic components2. Also, a radiator is needed to be newly attached, thereby causing the increase of the manufacturing cost. It is therefore an object of the fourth preferred embodiment to suppress the increase of the manufacturing cost and radiate the heat of the electronic components2.

FIG. 13is a block diagram schematically showing a cross section of one example of the electrical equipment unit according to the fourth preferred embodiment, seen from a direction parallel to the substrate1.FIG. 14is a plane view schematically showing a part of the electronic component21in the electrical equipment unit. It should be noted that the lid6is removed. Comparing to the first preferred embodiment, the side surface part5aadheres and covers at least a part of one of the electronic components2. More specifically, the side surface part5aadheres and covers a part of the electronic component21, for example. InFIG. 14, the side surface part5aadhering and covering each part of three electronic components21is illustrated.

Subsequently, a manufacturing method of the electrical equipment unit will be described. First, each of the electronic components2and3is mounted on the substrate1.

Next, as shown inFIG. 15, the substrate1after mounting is housed in a mold92. The mold92includes an upper mold92aand a lower mold92b. The mold92bis identical to the mold9bdescribed in the first preferred embodiment. While the mold92ais almost identical to the mold9adescribed in the first preferred embodiment, an inner surface of the side surface part5a(a surface at the side of the electronic component21) has a shape of a part of the contour of the electronic component21so as to reflect the shape of the part of the electronic component21.

Thereafter, the electrical equipment unit shown inFIG. 13is manufactured by the same process as the first preferred embodiment.

In the electrical equipment unit according to the fourth preferred embodiment, for instance, when the temperature in the hermetic space at the side of the electronic components2is high and the temperature outside the electrical equipment unit is low, the electronic component21radiates heat to outside through the side surface part5a, thereby allowing to improve the effect of heat radiation of the electronic component21. It is desirable to use resin having a high heat transfer coefficient as the insulating resin51.

Fifth Preferred Embodiment

An electrical equipment unit according to a fifth preferred embodiment will be described. It is difficult to radiate the heat of the electronic components2in the third preferred embodiment. Also, in the fourth preferred embodiment, since radiation is conducted through the side surface part5athat is resin, there is a case that the sufficient effect of the heat radiation is not expected. It is therefore an object of the fifth preferred embodiment to further improve the effect of the heat radiation of the electronic components2.

FIG. 16is a cross sectional view showing a conceptual configuration of the electrical equipment unit. Comparing to the electrical equipment unit shown inFIG. 1, a radiator304is further included. The radiator304is, for example, formed of metal material, and is interposed between the electronic component21and the lid6, making contact with the electronic component21and the lid6. This promotes the transfer of the heat generated from the electronic component21to outside through the radiator304and the lid6, thereby allowing to improve the heat radiation of the electronic component21.

In the case where the electronic component21can be electrically in contact with the radiator304, the radiator304has preferably insulating properties. In this case, for instance, the radiator304may be resin having high thermal conductivity and insulating properties. Thereby, property degradation and failure of the electrical component21are prevented.

FIG. 17is a block diagram schematically showing a plane of a part of another example of the electrical equipment unit. It should be noted that the lid6is removed. Comparing to the first preferred embodiment, the electrical equipment unit further includes a radiator302. The radiator302is a metallic heat sink, for example, and is attached to at least one of the electronic components2, extending to outside through the side surface part5a.

More specifically, the radiator302is adhered and attached to a part of the electronic component28that is one example of electronic components2, penetrating the side surface part5ato extend to outside. InFIG. 17, the radiator302adhered and attached to three electronic components21is illustrated.

Subsequently, a manufacturing method of the electrical equipment unit will be described. First, each of the electronic components2and3is mounted on the substrate1. Then, the radiator302is attached to the electronic component28. For instance, the radiator302may be attached on the surface1aafter adhering to the electronic component28.

Next, as shown inFIG. 18, the substrate1after mounting is housed in a mold93. The mold93includes an upper mold93aand a lower mold93b. The mold93bis identical to the mold9bdescribed in the first preferred embodiment. While the mold93ais almost identical to the mold9adescribed in the first preferred embodiment, an inner surface of the recess part904(a surface at the side of the radiator302) has a shape of a part of the contour of the radiator302so as to mold the side surface part5athrough which the radiator302penetrates.

Thereafter, the electrical equipment unit is manufactured by the same process as the first preferred embodiment.

In the electrical equipment unit according to the fifth preferred embodiment, the heat generated from the electronic component28is radiated to outside through the radiator302having high thermal conductivity, allowing to further improve the effect of the heat radiation of the electronic component21.

Sixth Preferred Embodiment

A sixth preferred embodiment will be described. In the first preferred embodiment, a connector is housed and a wiring is extracted from the electrical equipment unit so as to connect the electrical equipment unit to an external device. It is therefore an object of the sixth preferred embodiment to connect the electrical equipment unit to an external device by not using a connector, thereby reducing the manufacturing cost.

FIG. 19is a block diagram schematically showing one example of a cross section of a part of the electrical equipment unit according to the sixth preferred embodiment, seen from a direction parallel to the substrate1.

Comparing to the first preferred embodiment, the electrical equipment unit further includes a connection structure53. The connection structure53is buried in the side surface part5aso as to electrically connect the external wiring71to the substrate1. The external wiring71is a wiring for connecting to the external device.

More specifically, the connection structure53includes a lead frame29and a conductive female screw74. One end of the lead frame29is connected to the substrate1. InFIG. 19, the entire lead frame29is buried in the side surface part5a, extending from the substrate1to the direction D.

The female screw74makes contact with the other end of the lead frame29, and is buried in the side surface part5a. The side surface part5ahas a shape so as to screw the female screw74and a screw73from outside. For instance, the side surface part5aincludes a through hole5dpenetrating to outside in communication with a screw hole of the female screw74, and the conductive screw73is inserted into the female screw74through this through hole5d.

The external wiring71includes a metal part72at one end. The metal part72has a ring-like shape, for example.

Then, the screw73is inserted into the female screw74through this metal part72and the through hole5d. Thus, the external wiring71is electrically connected to the substrate1through the metal part72, the screw73, the female screw74, and the lead frame29.

The electrical equipment unit having the above configuration is manufactured by, for example, molding the insulating resin5with a predetermined mold after connecting the lead frame29fixed to the female screw74to the substrate1, and thereafter providing the through hole5dand attaching the lid6. When the female screw74is exposed to outside, the through hole5dis not required.

According to the electrical equipment unit of the present preferred embodiment, the connection structure53electrically connecting a substrate to outside is integrally molded with the insulating resin5. Thus, there is no need to provide a connector to a substrate, thereby reducing the manufacturing cost.

FIG. 20is a block diagram schematically showing another example of a cross section of a part of the electrical equipment unit according to the sixth preferred embodiment, seen from a direction parallel to the substrate1. Comparing toFIG. 19, the connection structure53is different.

More specifically, one end of the lead frame29is connected to the substrate1, and the other end extends to outside through the side surface part5a. InFIG. 20, the lead frame29is buried in the side surface part5aat one end connected to the substrate1.

The side surface part5ahas a connector-like shape so as to surround a part of the lead frame29extending to outside. More specifically, the side surface part5ahas a shape surrounding this part with an extending direction of this part as a center.

The external wiring71includes a connector75at one end. The external wiring71is electrically connected to the substrate1through the lead frame29by connecting this connector75to the lead frame29.

The electrical equipment unit having the above configuration is manufactured by molding the insulating resin5with a predetermined mold after mounting the electronic components2and3on the substrate1and connecting the lead frame29to the substrate1, and attaching the id6.

Even in this electrical equipment unit, the connection structure53electrically connecting the substrate1to outside is integrally molded with the insulating resin5. Further, the other end of the lead frame29is easily and electrically connected to the connector75provided to the external wiring71as a connector terminal.