Electronic component assembly structure and electrical junction box

An electronic component including a lead terminal is inserted into a housing member, and the lead terminal is fitted to a terminal fitting held by the housing member, so that the electronic component is assembled to the housing member. The lead terminal includes a connection portion which is continuous to a base end and is suspended along a side surface of a component main body. The housing member includes a first housing chamber which accommodates the component main body and a second housing chamber which holds the terminal fitting, the first housing chamber is surrounded by a frame-shaped wall portion. The terminal fitting is disposed so as to face the side surface of the component main body, in which a spring portion pressing the connection portion is accommodated in the first housing chamber, with the wall portion interposed therebetween.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an electronic component assembly structure and an electrical junction box, and particularly, to an electronic component assembly structure provided in an electrical junction box mounted on a mobile vehicle such as an automobile.

2. Description of the Related Art

Generally, a mobile vehicle such as an automobile is equipped with an electrical junction box which accommodates an electronic component such as a relay for controlling a connection between a power supply and an electric component (see Japanese Patent Application Laid-open No. 2010-221787).

As illustrated inFIG. 14, a relay of the related art includes a rectangular parallelepiped relay body11and a plurality of plate-shaped lead terminals12which linearly protrudes from one surface (a bottom surface) of the relay body11. For example, such a relay forms a relay module while being assembled to a resinous holding member15holding a terminal fitting14to which an electrical wire13is connected, and the relay module (the holding member15) is assembled to an electrical junction box. The terminal fitting14is provided with a spring portion16to which the lead terminal12is connected, and the front ends of the plurality of lead terminals12are respectively fitted into the spring portions16, so that the relay is held by the holding member15. In addition,FIG. 149is basically a longitudinal sectional view of the relay module of the related art, but only a relay body191is illustrated as a side view.

Incidentally, in the relay module ofFIG. 14, the relay body11including a portion of the center of gravity of the relay and the terminal fitting14(the spring portion16) supporting the relay body11are disposed so as to be separated from each other in the assembly direction of the relay (the up and down direction ofFIG. 14). For this reason, for example, when the electrical junction box is vibrated with the rolling of a vehicle, the relay is vibrated with respect to the holding member15, for example, in the direction of the arrow. Then, a burden on the spring portion16that supports the relay body11increases as the distance between the center of gravity of the relay body11and the spring portion16of the terminal fitting14in the assembly direction of the relay increases.

As a method of preventing the vibration of such a relay body11, a method may be supposed which increases a holding force (a spring force) causing the spring portion16of the terminal fitting14to hold the lead terminal12. However, there is a concern that the terminal fitting14or the holding member15may be increased in size. Further, a case may be supposed in which, for example, another member holding the relay body11may be provided other than the terminal fitting14. However, there is a concern that the structure of the relay module may be complex and the component cost may be increased.

SUMMARY OF THE INVENTION

The present invention is made in consideration of the above-mentioned situations and an object thereof is to suppress a vibration of an electronic component with a simple configuration.

In order to solve the above mentioned problem and achieve the object, an electronic component assembly structure according to one aspect of the present invention includes an electronic component configured to include a rectangular parallelepiped component main body and a plurality of lead terminals provided in the component main body; a housing member configured to accommodate the electronic component inserted thereinto; and a plurality of terminal fittings configured to be held by the housing member and cause the plurality of lead terminals to be fitted thereinto, wherein the lead terminal includes a base end and a connection portion which is continuous to the base end and is suspended along a side surface of the component main body in the insertion direction of the electronic component, with a gap with respect to the side surface, the housing member includes a first housing chamber which guides and accommodates the component main body and a second housing chamber which accommodates and holds the terminal fitting, the first housing chamber is surrounded by a frame-shaped wall portion uprightly formed from a bottom wall on every side, and the second housing chamber is formed at the outside of the first housing chamber with the wall portion interposed therebetween, the terminal fitting includes a spring portion which presses the connection portion connected to the terminal fitting, and the spring portion is disposed so as to face the side surface of the component main body accommodated in the first housing chamber with the wall portion interposed therebetween, and the electronic component is inserted and accommodated in the housing member, and the plurality of lead terminals is respectively fitted to the plurality of terminal fittings, so that the electronic component is assembled to the housing member.

In this way, in the invention, the electronic component is essentially used in which the lead terminal extends along the side surface of the component main body. Then, when the component main body and the lead terminal of the electronic component are respectively inserted and accommodated in the first housing chamber and the second housing chamber of the housing member, a distance between the height position of the center of gravity of the component main body and the height position of the spring portion in the insertion direction of the electronic component may be shortened. Thus, since it is possible to effectively suppress a vibration mainly in a direction intersecting the insertion direction of the electronic component and to reduce a burden on the terminal fitting supporting the component main body, it is possible to suppress the vibration of the electronic component with a simple configuration without increasing the size of the terminal fitting or the housing member.

Incidentally, the component main body radiates heat when the electronic component is operated. For that reason, there is a need to release the heat generated from the component main body to the outside in order to satisfactorily maintain the function of the electronic component. However, the heat is easily accumulated in the component main body when the component main body is surrounded by the wall portion.

It is preferable that the electronic component includes a locking protrusion which is provided in a surface, facing the wall portion, of the component main body, the housing member is formed of a resin material and includes a penetration groove which is formed in the wall portion of the first housing chamber and to which the locking protrusion is locked when the component main body is accommodated in the first housing chamber, and the penetration groove is formed so that the component main body is exposed in a state where the locking protrusion is locked to the penetration groove

Accordingly, when the locking protrusion is locked to the penetration groove, the heat of the component main body is radiated to the outside from a gap formed in the penetration groove so as to suppress an increase in the temperature of the component main body. For this reason, the function of the electronic component may be satisfactorily maintained. Further, the locking protrusion of the component main body is locked to the penetration groove so as to hold the component main body in the wall portion of the first housing chamber. For this reason, the rattling of the component main body may be suppressed, and hence the vibration of the electronic component may be further suppressed.

Meanwhile, in the electronic component, the base end of the lead terminal extends from the first housing chamber to the second housing chamber, and the conductive portion thereof is exposed to the outside. For this reason, there is a concern that an operator may be shocked when touching the conductive portion by a hand during work. Further, there is a concern that a short circuit may occur between the base ends when a tool contacts the adjacent base ends.

It is preferable that a part or the entirety of the base end of the lead terminal in the electronic component is coated by an insulation member. Accordingly, it is possible to prevent a trouble such as an electric shock and a short circuit in the lead terminal.

It is preferable to further include a cover member configured to cover an insertion opening of the first housing chamber into which the component main body is inserted, wherein the cover member is formed so as to be attachable to and detachable from the housing member.

Accordingly, since the component main body is surrounded by the first housing chamber and the cover member, it is possible to protect the component main body from the outside. Further, since it is possible to suppress the vibration of the component main body by the cover member, it is possible to reduce a burden on the terminal fitting. In this case, the cover member is formed so as to press the component main body accommodated in the first housing chamber. Accordingly, it is possible to more reliably suppress the vibration of the electronic component.

Further, the housing member may be assembled to the box-shaped frame instead of the cover member. That is, the electronic component assembly structure includes a box-shaped frame in which a frame-shaped side plate is uprightly formed from a side wall in the substantially horizontal direction and the plurality of housing members is accommodated and held along the side plate, and the housing member is held by the frame while the insertion opening into which the electronic component is inserted faces the side wall.

Accordingly, since the electronic component may be surrounded by the housing member and the side wall of the frame, it is possible to prevent water from adhering to the electronic component and to suppress the vibration of the electronic component. Further, since the insertion opening of the housing member is disposed so as to face the side wall of the frame, it is possible to shorten the dimension of the frame in the thickness direction and hence to decrease the installation space.

The present invention is briefly explained as described above. Further, a detail of the present invention will be more clarified by reading through a mode for carrying out the invention described below (hereinafter referred to as “embodiment”) by referring to the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an embodiment of a relay module including an electronic component assembly structure according to the invention will be described with reference to the drawings. In the embodiment, a relay module will be described in which a relay is used as an electronic component and the relay is accommodated in a housing member. However, an electronic component assembly structure according to the invention may be also, of course, applied to an electronic component other than the relay.

In the embodiment, the application example of the relay module is not particularly limited. However, a case may be supposed in which the relay module is used in electronic equipment controlling a connection state between an electric component and a power supply in a mobile vehicle such as an automobile. Specifically, a case may be supposed in which the relay module is assembled to, for example, an electrical junction box (a junction box) provided between a battery and an electric component mounted on an automobile so as to control an electric power on/off state. Such a relay module may be integrated with the electrical junction box or may be separated therefrom.

FIG. 1is an assembly diagram of a relay module20according to the embodiment, andFIG. 2is an entire configuration diagram of the relay module20ofFIG. 1.FIG. 3is a longitudinal sectional view when viewed from the direction of the arrow A-A ofFIG. 2. Here, a part of a configuration of a housing member that accommodates a relay is omitted. In the following description, a direction indicated by the arrow X ofFIG. 1is set as the front to back direction, a direction indicated by the arrow Y is set as the left and right direction, and a direction indicated by the arrow Z is set as the up and down direction (hereinafter, the same applies to the drawings other thanFIG. 1). Further, regarding the up and down direction, the upward direction ofFIG. 1is set as the upward side (the upside) and the downward direction thereof is set as the downward side (the downside). However, the up and down direction, the left and right direction, and the front to back direction may not match the respective directions in a state where the relay module20is actually mounted on a vehicle. Moreover, various components accommodated inside a relay body24are not illustrated inFIG. 3(the same applies toFIGS. 4 and 6).

As illustrated inFIG. 1, the relay module20of the embodiment has a structure in which a relay21, a terminal fitting22, and a housing member23are assembled. In the embodiment, an example will be described in which one relay module20includes two relays21. However, the number of the relays constituting the relay module is not limited to two. For example, the relay module may include only one relay or three or more relays. In addition, in a case where the relay module includes a plurality of relays, the relays21may have the same configuration as illustrated inFIG. 1. Further, the relays may have different configurations as will be described later (for example, seeFIGS. 7 to 11).

The relay21includes the relay body24which corresponds to a rectangular parallelepiped component main body formed of a resin or the like and lead terminals25(25ato25d) which correspond to four plate-shaped lead terminals protruding from the relay body24. The relay body24includes surfaces (hereinafter, referred to as a top surface24aand a bottom surface24b) which face each other in the up and down direction, surfaces (hereinafter, referred to as a left side surface24cand a right side surface24d) which face each other in the left and right direction, and surfaces (hereinafter, referred to as a front surface24eand a back surface24f) which face each other in the front to back direction. The relay body24of the embodiment is formed in a rectangular parallelepiped shape which is elongated in the left and right direction, and four surfaces of the left side surface24c, the right side surface24d, the front surface24e, and the back surface24fbecome the side surfaces. In addition, the front surface24eis provided with a locking protrusion27which engages with a penetration groove26formed in the housing member23as will be described later.

The lead terminals25respectively include plate-shaped base ends28(28ato28d) which protrude from at least one surface of the relay body24and plate-shaped connection portions29(29ato29d) which continuously extend from the base ends28. The lead terminals25aand25brespectively include the base ends28aand28bwhich are separated from each other with a gap therebetween in the front to back direction ofFIG. 1and protrude from the left side surface24cof the relay body24in the perpendicular direction and connection portions29aand29bin which the base ends28aand28bare bent in the perpendicular direction and are suspended along the left side surface24cof the relay body24in the insertion direction (the direction of the arrow ofFIG. 1) of the relay21toward the housing member23, with a predetermined gap with respect to the left side surface24c. Meanwhile, the lead terminals25cand25drespectively include base ends28cand28dwhich are separated from each other with a gap therebetween in the front to back direction ofFIG. 1and protrude from the right side surface24dof the relay body24in the perpendicular direction and connection portions29cand29din which the base ends28cand28dare bent in the perpendicular direction and are suspended along the right side surface24dof the relay body24in the insertion direction of the relay21toward the housing member23, with a predetermined gap with respect to the right side surface24d.

The base ends28ato28drespectively protrude in a direction parallel to the top surface24aand the bottom surface24bof the relay body24, and the protruding position is set to a common height position which is lower than the top surface24aof the relay body24. Meanwhile, the connection portions29ato29dextend in a direction parallel to the insertion direction of the relay21, and the distance with respect to the facing side surface of the relay body24are common. Further, the connection portions29ato29dare set so that the height positions of the front ends (the lower ends) in the insertion direction of the relay21are common and higher than the bottom surface24bof the relay body24. In addition, the lead terminals25ato25dare formed so that the width of the base ends28ato28dand the connection portions29ato29din a direction (the front to back direction) perpendicular to the extension direction is the same.

The terminal fitting22is an interface member that is connected to a terminal portion of an electrical wire30in order to electrically connect the electrical wire30to the relay21. The terminal fitting22includes a female fitting portion31which is formed by processing a conductive metal plate member so that the connection portion29of the lead terminal25is fitted thereto, a pair of core wire crimping pieces34which swages a core wire33exposed when an insulation coating32of a terminal of the electrical wire30is peeled off, and a pair of external crimping pieces35which swages a front end portion of the insulation coating32of the electrical wire30.

The fitting portion31includes a flat plate portion36which has a flat plate shape and supports the connection portion29of the fitted lead terminal25and a spring portion37which presses the connection portion29, and the connection portion29which is pressed against the flat plate portion36by the spring portion37is fitted between the flat plate portion36and the spring portion37. The spring portion37is formed as a pair of convex curved portions in which both ends of the flat plate portion36in the front to back direction are uprightly formed and the front end portions thereof are curved toward the vicinity of the center portion of the flat plate portion36in the front to back direction. That is, the spring portion37elastically deforms the front end thereof in a direction separated from the flat plate portion36so as to apply a pressing force (an elastic restoration force) to the connection portion29and to support the connection portion29.

The fitting portion31includes a tapered surface in which the upper end surface of the spring portion37is gently inclined downward in a direction from a portion in which the spring portion37protrudes most from the flat plate portion36toward the flat plate portion36. Thus, when the connection portion29of the lead terminal25is fitted into the fitting portion31, the connection portion29is guided by the tapered surface of the spring portion37so that the connection portion29is smoothly fitted into the fitting portion31.

Further, inFIG. 1, an example of the terminal fitting22is described in which the fitting portion31is of a so-called fastening type. However, the terminal fitting22is not limited to this type. For example, a configuration may be employed in which the fitting portion31is formed so as to have a rectangular cylindrical cross-section, a flat-plate-shaped spring portion is provided inside the fitting portion31, and the connection portion29of the lead terminal25is pressed against the inner wall of the fitting portion31by the spring portion.

The housing member23is a resinous frame which accommodates and holds the relay21and the terminal fitting22, and includes a first housing chamber38which guides and accommodates the relay body24and a second housing chamber39which accommodates and holds the terminal fitting22. Further, in the embodiment, the housing member23is handled as a single member separated from the electrical junction box. However, the housing member23may be integrated with the electrical junction box as a part of a frame formed inside the electrical junction box.

As illustrated inFIG. 1, the housing member23of the embodiment is provided with two first housing chambers38, and a pair of second housing chambers39is disposed so as to face each other with each first housing chambers38interposed therebetween. That is, the housing member23includes two housing spaces each including one first housing chamber38and two second housing chambers39. Then, two terminal fittings22are respectively accommodated at predetermined positions in the second housing chamber39so as to correspond to the lead terminals25of the relay21inserted into the housing space.

As illustrated inFIG. 3, the first housing chamber38is surrounded by a bottom wall40and a wall portion41uprightly formed from the bottom wall40, and is formed as a concave space of which the upside is opened to the outside. The wall portion41is uprightly formed from the bottom wall40so as to surround the side surface (the left side surface24c, the right side surface24d, the front surface24e, and the back surface24f) of the relay body24on every side, and guides and accommodates the relay body24in the first housing chamber38. The first housing chamber38is formed in a rectangular parallelepiped shape a size larger than the relay body24and is used to smoothly accommodate the relay body24guided by the wall portion41and to keep the posture of the relay body24by the interference of the wall portion41with respect to four side surfaces of the accommodated relay body24.

Further, as illustrated inFIG. 1, the penetration groove26which extends in the height direction of a wall portion41e(the insertion direction of the relay body24) so as to expose the first housing chamber38to the outside of the housing member23is formed in the wall portion41e(the wall portion facing the front surface24eof the relay body24) other than a wall portion41fwhich divides the adjacent first housing chambers38and two wall portions41cand41das the partition walls with respect to the second housing chamber39among four wall portions41forming the first housing chamber38. The locking protrusion27which protrudes from the side surface of the relay body24may be locked to the upper end of the penetration groove26when the relay body24is accommodated in the first housing chamber38. The penetration groove26is formed so as to be larger than the locking protrusion27. Specifically, since the entire length of the penetration groove26in the height direction is set to be longer than the entire length of the locking protrusion27in the height direction, the relay body24is exposed to the outside through the penetration groove26while the locking protrusion27is locked to the penetration groove26and the penetration groove26is not blocked by the locking protrusion27.

The second housing chamber39is disposed at the outside of the wall portions41cand41d(hereinafter, simply referred to as the wall portion41) of the first housing chamber38, that is, the opposite side to the first housing chamber38with the wall portions41cand41dinterposed therebetween, and is surrounded by a rectangular cylindrical frame formed by the wall portions41and a frame portion42of the housing member23, so that a rectangular parallelepiped space of which upper and lower portions are exposed to the outside is formed. The second housing chamber39is provided with a lance43(a locking piece) which holds the terminal fitting22. The lance43is formed as a integral member that is stretched in a cantilevered state from the wall portion41or the frame portion42toward the second housing chamber39, and is deformable elastically.

InFIG. 3, the left lance43is stretched from the wall portion41, and the right lance43is stretched from the frame portion42. Thus, the lance43is formed as a so-called spring mechanism and presses and locks the lower edge of the spring portion37of the terminal fitting22by a restoration force in which the lance is restored from the elastically deformed state. Accordingly, the terminal fitting22is held by the second housing chamber39while the terminal fitting22is retained in the second housing chamber39. Further, in the embodiment, the left and right lances43are formed so as to be stretched in the same direction, but may be formed in a bilaterally symmetric shape while being stretched in the opposite directions.

In order that the terminal fitting22is accommodated in the second housing chamber39and is held by the lance43, the terminal fitting22is inserted from a lower opening44of the second housing chamber39. Then, the terminal fitting22is inserted into the second housing chamber39until the front end portion (the fitting portion31) contacts the lance43. When an upward force (an insertion force) is applied to the terminal fitting22so that the terminal fitting22is further inserted into the second housing chamber39from this state, the lance43is elastically deformed while being pressed by the terminal fitting22. InFIG. 3, the left lance43is elastically deformed so as to approach the wall portion41, and the right lance43is elastically deformed so as to approach the frame portion42. Then, when an insertion force is applied to the terminal fitting22against the restoration force for the elastic deformation, the terminal fitting22moves upward while the lance43slides on the fitting portion31. When the terminal fitting22moves in this state and the lance43relatively reaches the lower edge of the spring portion37along the fitting portion31, the lance43is elastically deformed so as to engage with the lower edge of the spring portion37. In this way, since the lance43engages with the terminal fitting22so that the terminal fitting22is locked to the lance43, it is possible to prevent the terminal fitting22from being separated from the second housing chamber39. That is, the terminal fitting22is held by the second housing chamber39.

Meanwhile, in the embodiment, the position of the relay21in the up and down direction in a state where the relay21is accommodated in the housing member23, that is, the connection portion29of the lead terminal25is fitted to the spring portion37of the terminal fitting22is set to a predetermined height position so that the relay body24does not protrude from the upper end of the housing member23as illustrated inFIGS. 2 and 3. Here, the height position of the relay body24is determined by a position where the connection portion29of the lead terminal25is fitted to the spring portion37of the terminal fitting22. That is, the terminal fittings22are held at a height position (the same height position) where the spring portion37directly holding the connection portion29of the lead terminal25faces the side surface of the relay body24accommodated in the first housing chamber38with the wall portion41interposed therebetween in the second housing chamber39. Then, the upper end surface of the wall portion41is disposed at a predetermined height position lower than the upper end surface of the housing member23so as not to contact the base end28of the lead terminal25when the connection portion29of the lead terminal25is fitted to the spring portion37of the terminal fitting22, and the bottom wall40is disposed at a predetermined height position where the bottom wall does not contact the bottom surface24bof the relay body24. Thus, since the relay21is held by the housing member23without the interference with the bottom wall40or the upper end surface of the wall portion41except for a portion where the connection portion29of the lead terminal25is fitted to the spring portion37of the terminal fitting22in the height direction of the housing member23, the lead terminal25and the terminal fitting22may be reliably connected to each other, and hence a force of holding the relay21may be stabilized.

In a case where the relay21is assembled to the housing member23with such a configuration, the relay body24is guided along the wall portion41so as to be inserted into the first housing chamber38while the relay body24is brought into contact with the wall portion41of the first housing chamber38so that the relay21is not excessively inclined with respect to the first housing chamber38in a stable posture. When the vicinity of the lower end of the relay body24is accommodated in the first housing chamber38, the front end (the lower end) of the connection portion29of the lead terminal25is positioned so as to face the fitting portion31above the terminal fitting22. When the relay body24is inserted into the vicinity of the bottom wall40of the first housing chamber38while the connection portion29is positioned in this way, the connection portion29is inserted into a gap between the spring portion37and the flat plate portion36of the fitting portion31, and is fitted by the pressing force of the spring portion37. As illustrated inFIG. 2, in the relay module20which is assembled in this way, the relay21is held by the housing member23, and the relay21is electrically connected to the electrical wire30through the terminal fitting22.

Incidentally, there is a case where the electrical junction box which accommodates the relay module is vibrated with the rolling of the vehicle. In this case, the vibration is transmitted to the relay module, and hence there is a concern that the relay may be vibrated. For this reason, in the embodiment, since a distance between the height position of the center of gravity of the relay body24and the height position of the spring portion37of the terminal fitting22in the insertion direction of the relay21is shorter than the structure of the relay module (FIG. 14) of the related art, a vibration in a direction intersecting the insertion direction of the relay21is mainly suppressed, and hence a burden on the terminal fitting22holding the lead terminal25is reduced. Thus, the vibration resistance of the relay21may be improved. Further, according to the embodiment, since there is no need to improve a force of holding the lead terminal25, for example, by providing a new structure for holding the relay21or increasing the size of the terminal fitting22in order to improve the force of holding the relay21, it is possible to prevent a problem in which the relay module20has a complex structure or a large size. Further, the spring portion37which is held by the second housing chamber39may more effectively suppress the vibration of the relay21as the distance from the center of gravity of the relay body24decreases in the height direction.

Further, in the embodiment, the locking protrusion27is provided in the front surface24e, facing the wall portion41e, of the relay body24, and the penetration groove26with which the locking protrusion27engages is provided in the wall portion41eof the first housing chamber38. For this reason, since the locking protrusion27engages with the penetration groove26so as to be locked to the upper end of the penetration groove26when the relay body24is accommodated in the first housing chamber38, the relay21may be held by the housing member23with a high holding force, and hence the vibration of the relay21may be reliably suppressed. Further, since the force of holding the relay21is improved, it is possible to reduce a burden on the terminal fitting22that holds the lead terminal25.

Further, since the entire length of the penetration groove26in the height direction is set to be longer than the entire length of the locking protrusion27in the height direction, the relay body24is exposed from the penetration groove26while the locking protrusion27is locked to the penetration groove26. Accordingly, the heat of the relay body24may be radiated from the first housing chamber38to the outside through the penetration groove26even when the locking protrusion27is locked. In addition, the penetration groove26is not limited to the shape of the embodiment as long as the penetration groove is larger than the locking protrusion27and the relay body24is exposed while the locking protrusion27is locked.

Next, another embodiment of the relay21of the embodiment will be described with reference toFIG. 4. InFIG. 3, the conductive portion of the lead terminal25is completely exposed. However, as illustrated inFIG. 4, a part of the lead terminal25, for example, a shoulder portion of the base end28may be coated by an insulation member45that protrudes from the side surface of the relay body24. Since the base end28is coated in this way, it is possible to prevent a trouble such as an electric shock caused when a hand or a tool contacts the conductive portion of the relay21assembled to the housing member23or a short circuit generated between the lead terminals25. The insulation member45of the embodiment may be integrally molded with the relay body24by resin molding (for example, insert-molding) when the relay21is manufactured. Regarding the coating of the lead terminal25, at least a surface of a portion exposed to the outside from the first housing chamber38and the second housing chamber39and possibly touched by a hand or a tool may be coated. Further, the insulation member45may not be continuous to the relay body24as illustrated inFIG. 4, and may formed only at a predetermined position separated from the relay body24. Further, the insulation member45may be formed of an insulation material other than a resin.

Next, an example will be described in which the relay21is protected while another member covers the housing member23of the embodiment.FIG. 5is an assembly diagram in which the cover member covers the upper portion of the housing member23accommodating the relay21, andFIG. 6is a longitudinal sectional view illustrating a state where the cover member ofFIG. 5is assembled when viewed from the direction of the arrow C. As illustrated inFIG. 5, the housing member23that accommodates the relay21is covered by a cover member46from the upside thereof.

The cover member46is a box-shaped case (lid) which is formed of a resin and has an opening at the lower portion thereof, and forms a concave space which is surrounded by a ceiling wall47and four wall portions48uprightly formed from the ceiling wall47so that the lower portion of the concave space is opened to the outside. The wall portions48are uprightly formed from the ceiling wall47so as to surround the housing member23on every side, and the housing member23is accommodated in the space. The cover member is formed so as to be attachable or detachable along the wall surface of the housing member23.

An elastically deformable locking hook49is provided in the frame portion42of the housing member23so as to protrude in a cantilevered state. Meanwhile, the wall portion facing the frame portion42in the cover member46is provided with a locking protrusion50which protrudes so as to be locked to the locking hook49when the cover member46is attached to the housing member23.

In a case where the cover member46is assembled to the housing member23, the cover member46moves toward the lower portion of the housing member23while covering the upper portion of the housing member23. At this time, the wall portion48of the cover member46is guided along the wall surface of the frame portion42of the housing member23. When the locking protrusion50of the cover member46contacts the locking hook49of the housing member23, the locking hook49slides on the locking protrusion50so as to be pressed by the locking protrusion50, and is elastically deformed in a direction moving close to the frame portion42of the housing member23. Then, when the cover member46is further pressed so that the locking protrusion50climbs over the locking hook49, the locking hook49is restored from the elastically deformed state and the cover member46is locked while being attached to the housing member23.

Meanwhile, in a case where the cover member46locked to the housing member23is separated from the housing member23, a tool is inserted from a tool insertion hole51formed in the cover member46, and the tools is pressed against the locking hook49so as to deform the locking hook49elastically in a direction moving close to the frame portion42. Thus, the cover member46may be separated from the housing member23when the locking state between the locking hook49and the locking protrusion50is released. Further, in the embodiment, an example has been described in which the relay module20is provided with the locking hook49and the locking protrusion50that make a pair. However, the invention is not limited to this example as long as the cover member46is locked to the housing member23.

When the cover member46is locked to the housing member23, the ceiling wall47of the cover member46contacts at least one of the relay body24and the upper end of the frame portion42of the housing member23due to, for example, the own weight of the cover member46.

Accordingly, since the relay21may be surrounded by the housing member23and the cover member46, the water repellence of the relay21may be improved. Further, since the cover member46is attached, the relay body24is held inside a space surrounded by the first housing chamber38and the ceiling wall47of the cover member46. That is, since the vibration of the relay body24is limited within the space when the relay module20is vibrated, the vibration of the relay body24may be suppressed. As a result, a burden on the terminal fitting22that holds the lead terminal25may be reduced.

Further, since the assembly directions of the cover member46and the relay21with respect to the housing member23are the same, the relay21may be also assembled to the housing member23when the cover member46is assembled to the housing member23. For example, the cover member46is formed so that the relay21is inserted to an appropriate position of the housing member23in the insertion direction when the cover member46is assembled and locked to the housing member23. Thus, initially even when the relay21is not inserted to an appropriate position of the housing member23, the cover member46covers the housing member23from the upside thereof so that the cover member is locked to the housing member. In this way, the relay21may be assembled. Further, since the vibration of the relay body24with respect to the housing member23may be regulated when the cover member46is assembled to the housing member23, it is possible to reduce a load (an insertion force) generated when the connection portion29is inserted into the spring portion37by weakly setting the holding force of the relay21with respect to the housing member23, that is, the holding force of holding the relay body24by fitting the connection portion29of the lead terminal25to the spring portion37of the terminal fitting22. Accordingly, according to the embodiment, since it is possible to reduce a work burden generated when the relay21is inserted and assembled to the housing member23, it is possible to improve the work efficiency in the assembly of the relay21.

In the embodiment, an example has been described in which the ceiling wall47of the cover member46contacts the relay body24of the relay21accommodated in the housing member23by the own weight while the cover member46is locked to the housing member23, but the invention is not limited to this example. For example, the ceiling wall47may be provided with a step shape or a shape of a protrusion portion contacting the relay body24so that the ceiling wall47presses the relay body24downward by a predetermined pressing force while the cover member46is locked to the housing member23. Accordingly, since the relay21may be interposed between the housing member23and the cover member46, the vibration of the relay21with respect to the housing member23may be prevented. Further, since the holding force of holding the relay body24may be weakly set by fitting the connection portion29of the lead terminal25to the spring portion37of the terminal fitting22, the work efficiency in the assembly of the relay21may be further improved.

Further, the cover member46of the embodiment is formed so as to cover both insertion openings of the first housing chamber38and the second housing chamber39of the housing member23, but may be formed so as to cover at least the insertion opening of the first housing chamber38. For example, in a case where the cover member is formed by the ceiling wall47and four wall portions48as in the cover member46of the embodiment, an opening may be formed at a position corresponding to the insertion opening of the second housing chamber39of the ceiling wall47. When at least the insertion opening of the first housing chamber38is covered in this way, it is possible to improve the vibration resistance of the relay21and the work efficiency in the assembly of the relay21.

Next, another embodiment of the cover member46will be described. The above-described cover member46is used while being assembled to each housing member23. However, instead of this configuration, a configuration may be employed in which a frame capable of accommodating the plurality of housing members23is formed so that the frame accommodates and assembles the housing members23and forms a single relay module as a whole.

FIG. 7is an assembly diagram of the relay module of the embodiment, andFIG. 8is a perspective view illustrating an entire configuration after assembly inFIG. 7. A relay module60of the embodiment has a configuration in which the housing members23(23aand23b) holding the relay21are assembled to a frame61. The frame61is formed as a box-shaped container which is formed by molding a resin or the like so that an upper portion and a side portion are opened. The frame61has a configuration in which a bottom plate63, side plates64and65, and partitions66and67are uprightly formed substantially in the perpendicular direction (substantially in the horizontal direction) from a side plate62having a flat plate shape. The partition66is provided so as to be substantially parallel to the bottom plate63, and the upper and lower portions thereof are respectively provided with an upper space68and a lower space69. The lower space69is provided with the partition67which contacts the partition66substantially in the perpendicular direction, and hence the lower space is divided into two left and right spaces69aand69b. The left and right lower spaces69aand69bwhich are formed in this way respectively accommodate laterally the housing members23aand23beach accommodating the relay21so that the insertion opening of the relay21, that is, the top surface24aof the relay body24faces the side plate62(in the direction of the arrow).

Each of the side plates64and65forming the lower space69is provided with a guide member70which protrudes toward the lower space69so as to guide the housing member23and to support the accommodated housing member23. Each of the side plates64and65forming the upper space68is provided with a guide member71which protrudes toward the upper space68so as to guide electronic components when receiving the housing member23or other electronic components (hereinafter, referred to as electronic components) in the upper space and to support the accommodated electronic components. In addition, the electronic components which are accommodated in the upper space68may be directly placed on the partition66or an electrical wire accommodating space may be formed while a gap is formed with respect to the partition66.

As described above, since the posture of the relay21with respect to the housing member23is kept even when the housing member23is disposed laterally while the relay is accommodated in the housing member23, any problem does not arise even when the housing member23accommodating the relay21is assembled to, for example, the frame61while falling down laterally. The housing member23is received into each of the lower spaces69aand69bof the frame61along the guide member70in the horizontal direction (the arrow ofFIG. 7), and is held inside the frame61by using a known structure. Thus, the relay21is interposed between the side plate62and the housing member23, and the periphery thereof is surrounded by the bottom plate63, the side plate64or the side plate65, and the partitions66and67. Accordingly, since it is possible to prevent water from adhering to the relay21and to prevent the vibration of the relay21, it is possible to obtain the same effect when the cover member46is attached to the housing member23.

Further, in the embodiment, since the housing member23is laterally accommodated in the frame61, the thickness (the thickness in the left and right direction) of the relay module60may be decreased. For this reason, the installation space for the relay module may be decreased. Accordingly, it is possible to improve the space utilization efficiency of the electrical junction box and to improve a degree of freedom in design of the electrical junction box. Further, inFIG. 8, the electronic components accommodated in the upper space68are omitted, but the upper space68may accommodate the electronic components in the lateral direction or the longitudinal direction as in the lower space. In this way, since the frame61is provided with the guide members70and71that support the housing member23or the electronic components, the accommodating direction of each space may be freely set.

In the above-described embodiment, a configuration of the relay module20in which the relay21ofFIG. 1is assembled has been described as the electronic component assembly structure of the invention, but the configuration of the electronic component is not limited to this example. That is, another relay module may be employed as long as a rectangular parallelepiped (including a cubic) component main body (the relay body24) and a lead terminal (the lead terminal25) protruding from at least one surface of the component main body are provided and the lead terminal includes a base end (the base end28) protruding from at least one surface of the component main body and a connection portion (the connection portion29) continuous to the base end and extending along the side surface with a gap with respect to the side surface of the component main body in the insertion direction of the electronic component. For example, even in a case where an electronic component (hereinafter, a relay) of another embodiment illustrated inFIGS. 9 to 13is assembled, the same effect as the relay21ofFIG. 1may be obtained. Hereinafter, an embodiment different from the relay21ofFIG. 1will be described with reference toFIGS. 9 to 13. However, the same reference sign will be given to the same component ofFIG. 1, and the description thereof will not be repeated.

In the relay21ofFIG. 1, two lead terminals25are provided in each of a pair of parallel surfaces of the relay body24. However, in a relay81ofFIG. 9, two lead terminals25are provided in the two adjacent side surfaces (for example, the front surface24eand the right side surface24d) among four side surfaces excluding the top surface24aand the bottom surface24b. In this case, in the housing member23accommodating the relay81, the second housing chambers39are disposed at two positions with the first housing chamber38and the wall portion41interposed therebetween so as to correspond to the arrangement of the lead terminals25, and are disposed so as to perpendicular to each other. Then, each second housing chamber39holds the terminal fitting22as many as the lead terminal25so as to correspond to the lead terminal25inserted thereinto.

Further, the lead terminal25is provided at two side surfaces of the relay body24, but may be provided at three or more side surfaces. In a relay82ofFIG. 10, the lead terminal25is provided in each of three side surfaces (for example, the front surface24e, the right side surface24d, and the left side surface24c) among four side surfaces excluding the top surface24aand the bottom surface24b. In the relay82, the front surface24eis provided with two lead terminals25band25c, the right side surface24dis provided with the lead terminal25d, and the left side surface24cis provided with the lead terminal25a. In this case, the housing member that accommodates the relay82is provided with three second housing chambers39so as to correspond to the arrangement of the lead terminals25, interposing the wall portion41between the second housing chamber39and the first housing chamber38, and the second housing chamber39holds the terminal fitting22as many as the lead terminal25so as to correspond to the lead terminal25inserted thereinto.

Further, the lead terminal25is provided at a plurality of side surfaces of the relay body24, but may be provided at one side surface. In a relay83ofFIG. 11, four lead terminals25are provided in one side surface (for example, the front surface24e) among four side surfaces excluding the top surface24aand the bottom surface24b. The relay83is formed so that the height position of the front end (the lower end) of the connection portion29of each of the lead terminals25ato25dis set to the same height position higher than the bottom surface24bof the relay body24. However, the base ends28band28dprotrude from the same height position on the relay body24, and the base ends28aand28cprotrude from the same height position higher than the base ends28band28d. In the lead terminals25aand25b, the base ends28aand28band the connection portions29aand29bare disposed in parallel with a predetermined gap therebetween, and the lead terminal25bis disposed at the inside of the curved portion of the lead terminal25aso as to be hidden when the relay body24is viewed from the front surface24eside. Even in the lead terminals25cand25d, the base ends28cand28dand the connection portions29cand29dare disposed in parallel with a predetermined gap therebetween, and the lead terminal25dis disposed at the inside of the curved portion of the lead terminal25cso as to be hidden when the relay body24is viewed from the front surface24eside. In this case, the housing member that accommodates the relay83is provided with one second housing chambers39so as to correspond to the arrangement of the lead terminals25, interposing the wall portion41between the second housing chamber39and the first housing chamber38, and the second housing chamber39holds four terminal fittings22so as to correspond to the lead terminals25.

Meanwhile, in the above-described relays, the lead terminal25is provided at the side surface of the relay body24. However, as illustrated inFIG. 12, the lead terminal25may be provided at the top surface24aof the relay body24. In a relay84ofFIG. 12, four lead terminals25are provided at the top surface24a. In the lead terminals25aand25b, the base ends28aand28bprotrude from the vicinity of the front surface24eof the top surface24aof the relay body24and extend at the same height so as to extend while being bent forward in the substantially perpendicular direction. In the other two lead terminals25cand25d, the base ends28cand28dprotrude from the vicinity of the back surface24fof the top surface24aof the relay body24and extend at the same height so as to extend while being bent backward in the substantially perpendicular direction. The connection portions29aand29bof the lead terminals25aand25bare curved substantially perpendicularly and downward from the protruding front ends of the base ends28aand28b, and extend in parallel with a predetermined gap with respect to the front surface24eof the relay body24. The connection portions29cand29dof the remaining two lead terminals25cand25dare curved substantially perpendicularly and downward from the protruding front ends of the base ends28cand28d, and extend in parallel with a predetermined gap with respect to the back surface24fof the relay body24. In this case, the housing members that accommodate the relay84are provided with two second housing chambers39so as to correspond to the arrangement of the lead terminals25and are disposed in parallel, interposing the wall portion41between the second housing chamber39and the first housing chamber38. Then, each second housing chamber39holds the terminal fitting22as many as the lead terminal25so as to correspond to the lead terminal25inserted thereinto. In addition, the relay84has a configuration in which the lead terminal25extends in parallel to the front surface24eand the back surface24fof the relay body24, but the invention is not limited to this example. For example, the lead terminal may extend in parallel to other one or plural side surfaces.

Further, the above-described relays are formed so that the thickness direction of the connection portion29of the lead terminal25intersects (in a direction perpendicular to) the side surface of the relay body24facing the connection portion29, but may be formed in parallel to the side surface of the relay body24as illustrated inFIG. 13. In a relay85ofFIG. 13, fitting portions59(59ato59d) and base ends58(58ato58d) of lead terminals57(57ato57d) are respectively formed in a flat plate shape in parallel to the front surface24eand the back surface24fof the relay body24, and are disposed so that the thickness directions (the front to back directions) of the connection portions59aand59bof two lead terminals57aand57bare parallel to the right side surface24dof the relay body24, and are disposed so that the thickness directions (the front to back directions) of the connection portions59cand59dof the remaining two lead terminals57cand57dare parallel to the left side surface24cof the relay body24. In addition, each base end58protrudes from the side surface of the relay body24in the perpendicular direction, and each connection portion59extends in parallel with a gap with respect to the side surface of the relay body24as in the other relays. In this case, the housing members that accommodate the relay85are provided with two second housing chambers39so as to correspond to the arrangement of the lead terminals57and are disposed in parallel, interposing the wall portion41between the second housing chamber39and the first housing chamber38. Then, each second housing chamber39holds the terminal fitting22as many as the lead terminal57so as to correspond to the lead terminal57inserted thereinto. Of course, the terminal fitting22is disposed so as to correspond to the direction of the lead terminal57.

Further, for example, in the relay structure ofFIG. 1,FIGS. 9 to 11, andFIG. 13, the insulation member having a flat plate shape may be provided in the top surface24aof the relay body24so as to cover the lead terminal25(57). In this case, the insulation member may be integrally formed with the relay body24. Alternatively, the insulation member may be provided as a separate member and may be attached to the top surface24aof the relay body24. Here, the external shape or the dimension of the insulation member is set in accordance with the shape of the openings of the first housing chamber38and the second housing chamber39of the housing member23. Accordingly, the lead terminal25(57) may be insulated and protected from the outside by the insulation member, and hence the intrusion of water to the first housing chamber38or the second housing chamber39may be prevented. Thus, the water repellence of the relay may be improved. Further, a part of the stress acting on the lead terminal25(57) may be applied to the insulation member when the fitting portion29(59) of the lead terminal25(57) is inserted into the terminal fitting22. For this reason, a burden on the lead terminal25(57) may be reduced, and hence the deformation of the lead terminal25(57) caused by the insertion stress may be prevented. Further, it is desirable that the insulation member may be provided so as to contact the lead terminal25(57), but the insulation member may be provided so as not to contact the lead terminal.

Further, in the above-described relays, the base end of the lead terminal is completely exposed, but at least a part of the base end may be surrounded by a resin.FIG. 15Ais a perspective view of a relay in which a base end of a lead terminal is surrounded by a resin, andFIG. 15Bis a side view of the relay illustrated inFIG. 15A.

As illustrated inFIGS. 15A and 15B, a relay100has a configuration in which an insulation member102having a flat plate shape is attached along one surface (for example, a surface corresponding to the top surface21aof the embodiment) of a relay body101. The insulation member102is formed by molding an insulation resin so that the insulation member is formed in a substantially rectangular shape in the top view. The insulation member102extends in a direction perpendicular to a pair of opposite side surfaces103and104of the relay body101. Each of the side surfaces103and104is provided with two lead terminals105. The lead terminals105are disposed so that a contact portion107faces the side surfaces103and104. The insulation member102is formed so as to surround a base end106of each lead terminal105.

As illustrated inFIG. 15B, the base end106of the lead terminal105is entirely surrounded by the insulation member102in the axial direction thereof, and the contact portion107of the lead terminal105is provided so as to protrude from the lower surface of the insulation member102. A protrusion portion108is formed in a step shape at a position where the insulation member102intersects the side surfaces103and104. The protrusion portion108contacts the upper end surface of the wall portion when the relay100is assembled to the housing member. In addition, the base end106of the lead terminal105may be disposed so as to protrude from the protrusion portion108or may be disposed so as to protrude from the side surfaces103and104of the relay body101.

Accordingly, it is possible to support the base end106of each lead terminal105by the insulation member102from the upside thereof. Thus, since it is possible to largely reduce a load on the lead terminal105when the lead terminal105is fitted into each terminal fitting, it is possible to prevent the deformation of the lead terminal105. As a result, it is possible to satisfactorily keep the electric connection state between the lead terminal105and the terminal fitting and to prevent degradation in the holding force of the relay100with respect to the housing member. Further, since the base end106of each lead terminal105is surrounded by the insulation member102, the short circuit between the adjacent lead terminals105may be prevented.

While the embodiment of the invention has been described with reference to the drawings, the above-described embodiment is merely an example of the invention, and the invention is not limited to only the configuration of the above-described embodiment. Of course, modifications in design within the scope not departing from the spirit of the invention may be included in the invention.

For example, in the embodiment, a relay module in which a relay is an electronic component has been described, but the electronic component is not limited to the relay. That is, the invention may be also applied to another electronic component as long as the electronic component includes a component main body and a lead terminal similar to the relay body and the lead terminal of the embodiment. Specifically, the invention may be also applied to, for example, a fuse or a control module in which components such as an electronic circuit board are accommodated in a resin case.

The present invention can suppress the vibration of the electronic component with a simple configuration.