TERMINAL BLOCK

A terminal block that includes: a main body made of resin; and a terminal partly molded into the main body, wherein the terminal includes: a first hole extending through a first portion that protrudes outward from one surface of the main body in an inclined direction intersecting both a vertical direction and a horizontal direction; and a second hole extending through a second portion that spans from an inside of the main body to the first hole in one of the vertical direction and the horizontal direction.

BACKGROUND

The present disclosure relates to a terminal block.

The terminal block described in JP 2017-117643A includes a resin main body and a terminal formed by a bus bar. An intermediate portion of the terminal is molded into the main body through insert molding.

SUMMARY

The terminal may have a hole in a portion protruding outwardly from the main body. The hole of the terminal can be a fastening hole through which a fastening member such as a bolt is inserted. When the hole of the terminal is a fastening hole, positional accuracy of the hole of the terminal needs to be increased.

When the terminal block is formed through insert molding, the terminal can be positioned by passing a positioning pin through the hole of the terminal. The positional accuracy of the hole of the terminal can be ensured by positioning using the positioning pin.

The positioning pin normally protrudes in the same vertical direction as a movement direction of a movable upper mold or in a horizontal direction perpendicular to the vertical direction, and is passed through the hole of the terminal. In contrast, when the extension direction of the hole of the terminal is oriented in an inclined direction intersecting both the vertical direction and the horizontal direction, there is a problem that the positioning pin cannot be passed through the hole of the terminal.

An exemplary aspect of the disclosure provides a terminal block capable of ensuring the positional accuracy of the hole of the terminal.

A terminal block of the present disclosure includes a main body made of resin and a terminal partly molded into the main body, wherein the terminal has a first hole extending through a first portion that protrudes outward from one surface of the main body in an inclined direction intersecting both a vertical direction and a horizontal direction, and a second hole extending through a second portion that spans from an inside of the main body to the first hole in one of the vertical direction and the horizontal direction.

According to the present disclosure, it is possible to provide a terminal block capable of ensuring positional accuracy of the hole of the terminal.

DETAILED DESCRIPTION OF EMBODIMENTS

Description of Embodiments of Present Disclosure

A terminal block of the present disclosure

(1) includes a main body made of resin and a terminal partly molded into the main body, wherein the terminal has a first hole extending through a portion protruding outward from one surface of the main body in an inclined direction intersecting both a vertical direction and a horizontal direction, and a second hole extending through a portion spanning from the inside of the main body to the first hole in one of the vertical direction and the horizontal direction.

A portion of the terminal is molded into the main body through insert molding. A mold for insert molding can have a positioning pin protruding in one of the vertical direction and the horizontal direction. Therefore, when insert molding is performed, the positioning pin can be passed through the second hole open in a protruding direction of the positioning pin to position the terminal. The second hole is disposed in a portion spanning from the inside of the main body to the first hole. Therefore, in the terminal block, even if there is a circumstance where the positioning pin cannot be passed through the first hole due to the fact that the first hole is open in the inclined direction, since the positioning pin can be passed through the second hole disposed near the first hole, positional accuracy of the first hole can be ensured.

(2) It is preferred that the terminal has a plate-like shape, and has an attachment portion through which the first hole extends in a plate thickness direction in the portion protruding outward from the one surface of the main body.

By inserting a fastening member through the first hole and fastening the fastening member, the attachment portion is attached to an attachment object. That is, the first hole can be a fastening hole for the fastening member. Note that, in details of the embodiments described later, the attachment portion is referred to as a first extension portion.

(3) It is preferred that the terminal has a third hole extending through a portion protruding outward from another surface different from the one surface of the main body, in one of the vertical direction and the horizontal direction. When insert molding is performed, after the positioning pin is passed through the second hole, a positioning member corresponding to the positioning pin can be passed through the third hole as well, and the terminal can be favorably positioned. Note that, in the details of the embodiments described later, the positioning member passed through the third hole is of a slide type.

(4) It is preferred that the main body has a primary molded portion having an opening and a secondary molded portion filling the opening, and the opening is positioned coaxially with the second hole and extends through the primary molded portion in the vertical direction.

When insert molding is performed, the terminal can be lowered toward a lower mold that forms the primary molded portion, and the positioning pin protruding from the lower mold can be passed through the second hole of the terminal. Therefore, assembly properties of the terminal with respect to the mold are improved. Although an opening is formed in the primary molded portion as the positioning pin is pulled out, the secondary molded portion fills the opening, and thus liquid tightness of the main body can be ensured.

Details of Embodiments of Present Disclosure

A specific example of embodiments of the present disclosure will be described below with reference to the drawings. Note that the present disclosure is not limited to this example, but is indicated by the scope of the claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of the claims.

A terminal block10according to the present embodiment includes a main body20made of resin and a terminal40made of metal. As illustrated inFIG.1, an intermediate portion of the terminal40is molded into and held integrally with the main body20.

As illustrated inFIG.2, the main body20includes a primary molded portion21(primary mold) and a secondary molded portion22(secondary mold) that covers the primary molded portion21. The primary molded portion21and the terminal40are integrated through primary insert molding to form an intermediate assembly10A illustrated inFIG.3. The primary molded portion21, the secondary molded portion22, and the terminal40are integrated through secondary insert molding to form the terminal block10into a finished product illustrated inFIGS.1and2.

In this specification, the term “insert molding” simply means the primary insert molding. In addition, an up-down direction is based on an up-down direction in each figure. The up-down direction is an extending direction of a third extension portion43of the terminal40, which will be described later, and may also be referred to as a vertical direction Y The vertical direction Y corresponds to a moving direction of an upper mold61, which will be described later. A left-right direction is based on a left-right direction in each figure. The left-right direction is an extending direction of a second extension portion42of the terminal40, which will be described later, and is also referred to as a horizontal direction X. The horizontal direction X corresponds to a moving direction of a slide mold63, which will be described later. The horizontal direction X and vertical direction Y are perpendicular to each other. The horizontal direction X and the vertical direction Y are not limited to a horizontal direction and a vertical direction in a strict sense, but are concepts that include errors in the respective moving directions of the upper mold61and the slide mold63. Further, in this specification, an inclined direction D means a direction intersecting both the horizontal direction X and the vertical direction Y Specifically, the inclined direction D means a direction inclined at an angle other than a right angle with respect to both the horizontal direction X and the vertical direction Y The horizontal direction X, the vertical direction Y, and the inclined direction D are indicated by arrows in the drawings.

Terminal

The terminal40is formed by bending a plate member made of conductive metal. Although not illustrated, a plurality of terminals40are molded into the main body20in parallel in the depth direction of the sheet ofFIG.1.

The terminal40has a shape extending continuously in a strip shape, and as illustrated inFIGS.1to3, includes the second extension portion42extending in the horizontal direction X, a first extension portion41extending obliquely upward from a right end (one end) of the second extension portion42via one end bent portion44, and the third extension portion43extending downward from a left end (the other end) of the second extension portion42via another end bent portion45. The one end bent portion44connects an upper surface of the first extension portion41and an upper surface of the second extension portion42at an obtuse angle. The other end bent portion45connects the upper surface of the second extension portion42and a rear surface of the third extension portion43at a right angle.

The second extension portion42has a second hole46. The second hole46has a circular cross-section and extends through the second extension portion42in the vertical direction Y, which is the plate thickness direction of the second extension portion42. The second hole46is disposed in a portion of the second extension portion42spanning from the center of the second extension portion42in the left-right direction to the right end.

The first extension portion41has a first hole47. The first hole47has a circular cross-section and extends through the first extension portion41in the inclined direction D, which is the plate thickness direction of the first extension portion41. The first hole47has an opening diameter that is larger than that of the second hole46. The first extension portion41is inclined in a direction perpendicular to an extension direction of the first hole47.

A mating terminal (not illustrated) serving as an attachment object is assembled to the first extension portion41so as to overlap the first extension portion41. The mating terminal has a hole that is in communication with the first hole47when assembled. A fastening member such as a bolt (not illustrated) is inserted into the first hole47of the terminal40and the hole of the mating terminal and fastened to electrically connect the terminal40and the mating terminal to each other. In this manner, the first extension portion41serves as the attachment portion (attachment) to which the mating terminal serving as the attachment object is to be attached. In addition, the first hole47serves as the fastening hole through which the fastening member is to be inserted.

The third extension portion43has a third hole48. The third hole48has a circular cross-section and extends through the third extension portion43in the horizontal direction X, which is the plate thickness direction of the third extension portion43. The third hole48is disposed at a lower end portion of the third extension portion43. The opening diameter of the third hole48is the same as the opening diameter of the first hole47. Similarly to the first hole47, the third hole48also serves as a fastening hole through which a fastening member is to be inserted.

Main Body

As illustrated inFIGS.2and3, the primary molded portion21of the main body20covers a portion of the terminal40and is in close contact with the covered portion. Specifically, the primary molded portion21is in close contact with a portion extending from a lower surface of the second extension portion42excluding the right end thereof to a front surface on the upper end side of the third extension portion43and a portion extending from a left upper surface of the second extension portion42to a rear surface on the upper end side of the third extension portion43. The primary molded portion21is in close contact with the other end bent portion45of the terminal40, but is not in close contact with the peripheral edge portion of the opening of the second hole46on the upper surface of the second extension portion42, and the peripheral edge portion of the opening of the second hole46is exposed at the stage of the intermediate assembly10A.

Further, the primary molded portion21has an opening23extending through a portion in close contact with the lower surface of the second extension portion42in the vertical direction Y coaxially with the second hole46. The opening23has a circular cross-section and is aligned with and is in communication with the second hole46. The opening diameter of the opening23is the same as the opening diameter of the second hole46.

As illustrated inFIG.2, the secondary molded portion22of the main body20covers the entire outer surface of the primary molded portion21and is in close contact with the entire outer surface of the primary molded portion21. The secondary molded portion22forms an outer shape of the main body20of the terminal block10. The opening23of the primary molded portion21and the second hole46of the terminal40are filled with a resin portion of the secondary molded portion22.

The secondary molded portion22has a base portion24that is elongated in the left-right direction, and a protrusion25protruding downward from a lower surface of the base portion24. A seal groove26for mounting a seal ring (not illustrated) is provided in the lower surface of the base portion24. Note that the terminal block10is attached to a case (not illustrated). The seal ring is fitted into the seal groove26to seal space between the main body20and the case in a liquid-tight manner.

Aright end surface of the base portion24is one surface27of the main body20and is disposed vertically in the up-down direction. The right end of the second extension portion42of the terminal40horizontally protrudes laterally from the one surface27of the main body20. The first extension portion41and the one end bent portion44are exposed laterally from the one surface27of the main body20.

A lower end surface of the protrusion25is another surface28of the main body20and is disposed horizontally in the left-right direction. The lower end portion of the third extension portion43of the terminal40vertically protrudes downward from the other surface28of the main body20.

Method for Manufacturing Terminal Block

As illustrated inFIG.4, a mold60for forming the intermediate assembly10A of the terminal block10includes the upper mold61, a lower mold62, and the slide mold63. The upper mold61is a movable mold that can move in the vertical direction Y The lower mold62is a fixed mold. A cavity is formed between the upper mold61and the lower mold62.

The lower mold62has a positioning pin65protruding upward on a cavity forming surface64that is an upper surface of the lower mold62. The positioning pin65can be fitted into the second hole46of the terminal40. Further, the lower mold62has a slit66that extends in the vertical direction Y and is open to the cavity forming surface64, and further has a guide portion67that extends in the horizontal direction X and intersecting the slit66. The slide mold63is slidably disposed on the guide portion67of the lower mold62.

When the terminal40is set in the mold60, the slide mold63is retracted laterally and the upper mold61is retracted upward to open the mold60, the third extension portion43of the terminal40is inserted into the slit66of the lower mold62, and the positioning pin65is fitted into the second hole46of the second extension portion42. The second hole46of the terminal40is positioned in the mold60by the positioning pin65. Subsequently, the slide mold63is moved along the guide portion67and a leading end portion of the slide mold63is inserted into the third hole48of the third extension portion43. The third hole48of the terminal40is positioned in the mold60by the slide mold63.

Next, the upper mold61is lowered to close the mold60, and the cavity formed in the mold60is filled with molten resin through injection. In this manner, insert molding is performed with the terminal40serving as an insert. After the molten resin has cooled and solidified, the slide mold63is moved laterally and the upper mold61is moved upward to open the mold60, and a molded article is taken out. Thus, as illustrated inFIG.3, the intermediate assembly10A in which the primary molded portion21and the terminal40are integrated is obtained. Note that the opening23in communication with the second hole46is formed in the primary molded portion21of the intermediate assembly10A by pulling out the positioning pin65when opening the mold. In the intermediate assembly10A, since the other end bent portion45of the terminal40is molded by the primary molded portion21, the terminal40is less likely to be deformed, and a relative positional relationship between the second hole46and the third hole48can be kept constant.

Subsequently, the intermediate assembly10A is set in a secondary mold (not illustrated), and the intermediate assembly10A is subjected to secondary insert molding. Thus, as illustrated inFIG.2, the terminal block10is obtained as a finished product in which the second hole46and the opening23are filled with resin, and the surrounding region of the primary molded portion21is covered by the secondary molded portion22.

In the case of the present embodiment, since the first hole47of the terminal40extends through the first extension portion41in the inclined direction D, when insert molding is performed, there are circumstances where it is difficult to pass the positioning pin65through the first hole47. However, in the present embodiment, since the second hole46of the terminal40extends through the second extension portion42in the vertical direction Y, when insert molding is performed, the positioning pin65can be passed through the second hole46. Since the first hole47of the terminal40is provided near the second hole46, the first hole47can be positioned in the mold60together with the second hole46during insert molding. Therefore, the terminal block10obtained through this insert molding can maintain high positional accuracy of the first hole47.

Further, the terminal40has the third hole48extending through the third extension portion43in the horizontal direction X. Therefore, when performing insert molding, after the positioning pin65has been passed through the second hole46, the slide mold63can be passed through the third hole48, and the terminal40can be favorably positioned.

Furthermore, since the opening23of the primary molded portion21is positioned coaxially with the second hole46and extends through the primary molded portion21in the vertical direction Y, when insert molding is performed, the terminal40can be lowered toward the lower mold62, and the positioning pin65protruding from the lower mold62can be passed through the second hole46of the terminal40. Therefore, the assembly properties of the terminal40with respect to the mold60are improved. Although the opening23is formed in the primary molded portion21as the positioning pin65is pulled out, since the secondary molded portion22fills the opening23, when the terminal block10is attached to a case (not illustrated), the liquid tightness of the main body20can be ensured.

Other Embodiments of the Present Disclosure

It should be considered that the above embodiment disclosed here are illustrative in all respects and not restrictive.

In the case of the above embodiment, the terminal has a shape that is bent via the other end bent portion. However, according to another embodiment, the terminal may have a shape extending in a straight line. When the terminal extends in a straight line, it is preferred that one surface and the other surface of the main body are arranged facing opposite sides.

In the case of the above embodiment, the extension direction of the second hole is set in the vertical direction. However, according to another embodiment, the extension direction of the second hole may be set horizontally. When the extension direction of the second hole is the horizontal direction, a portion of the terminal corresponding to the second extension portion may have a shape extending in the vertical direction.

In the case of the above embodiment, the extension direction of the third hole is set in the horizontal direction. However, according to another embodiment, the extension direction of the third hole may be set in the vertical direction. When the extension direction of the third hole is the vertical direction, a portion of the terminal corresponding to the third extension portion may have a shape extending in the horizontal direction.

In the above embodiment, the terminal has the third hole. However, according to another embodiment, the terminal does not need to have the third hole. Further, when the terminal does not have the third hole, the terminal does not need to have a portion protruding outward from the other surface of the main body.

In the case of the above embodiment, the secondary molded portion is in close contact with the primary molded portion so as to cover the entire primary molded portion. However, according to another embodiment, the secondary molded portion may be in close contact with a portion of the primary molded portion so as to cover the portion of the primary molded portion. For example, the secondary molded portion may include only a portion filling the opening of the primary molded portion.

In the case of the above embodiment, the opening of the primary molded portion and the second hole of the terminal are in communication with each other without a gap. However, according to another embodiment, the opening of the primary molded portion and the second hole of the terminal may be coaxially arranged so as to be spaced apart.

In the case of the above embodiment, the second hole of the terminal is closed by the secondary molded portion inside the main body. However, according to another embodiment, the second hole of the terminal may be disposed outside the main body. When the second hole is disposed outside the main body, the main body can have a structure without an opening, and can be formed through primary molding alone.

In the case of the above embodiment, the positioning pin is provided on the fixed lower mold. However, according to another embodiment, the positioning pin may be provided on the movable upper mold. Alternatively, the positioning pin may be provided on a positioning member separate from the lower mold and the upper mold. For example, the positioning member may be of a slide type.