Patent Publication Number: US-6905346-B2

Title: Junction box, connector, and connecting terminal for use in the box and connector

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is based upon and claims the benefit of priority from the prior Japanese Patent Applications No. 2001-326147, filed Oct. 24, 2001, No. 2001-326148, filed Oct. 24, 2001, No. 2001-326150, filed Oct. 24, 2001, No. 2001-326151, filed Oct. 24, 2001, No. 2001-326152, filed Oct. 24, 2001; and No. 2001-326157, filed Oct. 24, 2001, the entire contents of all of which are incorporated herein by reference. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a junction box and connector which include connecting terminals for electrically connecting a connector, fuse, and the like to a wiring circuit, and particularly to a junction box, connector, and connecting terminals for use in the junction box and connector which are lightweight and thin, have a high attachment freedom degree in freely changing connection positions with outer wiring circuits such as a harness, and can have waterproof/dustproof capabilities. 
   2. Description of the Related Art 
   In general, to branch a wiring of a car or the like, a junction box (J/B) has been used for purposes of space saving and cost reduction.  FIG. 31  is a plan view of the junction box,  FIG. 32  is a plan view of a bus bar contained in the junction box,  FIG. 33  is a sectional view of a part VII of  FIG. 31 , and  FIG. 34  is a sectional view of a part VIII of FIG.  31 . 
   This type of a junction box  101  is constituted of a lower cover  102 , a bus bar  103  attached to the lower cover  102 , and an upper cover  105  which seals the lower cover and bus bar and to which a connector, fuse, and the like are attached. In the junction box  101 , as shown in  FIG. 32 , the bus bar  103  formed, for example, of a pressed/punched metal plate of copper alloy, aluminum alloy, or the like is used to branch the wiring. Moreover, the junction box  101  also includes a function, for example, of a fuse box, when a fuse  107  is incorporated halfway in the wiring circuit constituted by the bus bar  103 . 
   A connector  107  shown in  FIG. 33  is a connector connected to the wiring circuit constituted of the bus bar  103 . A connector  105   a  can be connected to the connector  107 , when a connecting terminal portion  103   a  formed by bending a tip end of the bus bar  103  upwards by 90° is passed upwards through an upper cover  105  via a through hole  105   b  formed in the cover. Moreover, for a fuse attachment portion  105   c  to which a fuse  108  is attached as shown in  FIG. 34 , a connecting terminal portion  103   d  is formed by bending the tip end of the bus bar  103  with a slit  103   b  formed therein upwards by 90°, and is passed upwards through the upper cover  105  through a through hole  105   d  formed in the cover. Thereby, the connecting terminal portion can directly be connected to a leg  108   a  for connecting the fuse  108 , or can be connected using a so-called female to female (F—F) terminal. 
   Moreover, as shown in  FIG. 35 , the bus bars  103  and insulation plates (IP)  109  having functions of supporting and insulating the bus bars  103  are alternately superimposed to form a wiring circuit (multilayered wiring circuit)  110  which has a multilayered structure. A junction box  112  structured to contain the multilayered wiring circuit  110  in a housing for entirely protecting the outside of the circuit as shown in  FIG. 36  is frequently used. 
   However, in the above-described junction box  101 , the bus bar  103  is manufactured by punching the metal plate with a die and the wiring circuit is formed. Therefore, when the bus bars  103  having various shapes are manufactured, different dies are required, and much cost is taken. Moreover, the bus bar  103  is formed of a thick metal, a weight of the junction box  101  therefore increases, and there is a problem that it is difficult to thin the junction box  101 . Furthermore, in the junction box  112 , the number of layers of the multilayered wiring circuit  110  needs to be minimized in order to prevent the weight and cost of the entire junction box from increasing. Additionally, the multilayered wiring circuit  110  having a small number of layers is used in accordance with a connection mode. For this, a circuit is drawn so as to avoid a wiring circuit of another layer and through holes  111  through which the connecting terminal portions  103   a ,  103   d  are passed, and a long circuit needs to be formed. This causes a problem that it is very difficult to lighten and thin the junction box  112 . Furthermore, a portion to which the connector or the fuse is attached is integrally formed in the box. Therefore, each of these junction boxes  101 ,  112  has problems that a size is large to some degree and an attachment position of the box in the car is restricted. Moreover, the portion to which the connector or the fuse is attached has an integral structure. In this case, for example, the fuse attached portion is disposed in a front surface of an instrument panel of the car with the conventional junction box  101  or  112  disposed therein in consideration of enhancement of maintenance properties. This possibly conversely causes a problem that connection operation properties for connecting the connector of the outer wiring circuit are deteriorated. Furthermore, instead of using the connecting terminal portions  103   a ,  103   d , connecting terminals are connected to the wiring circuit in order to attach the connector, fuse, and the like. In this case, it cannot be said that connection reliability is secure. 
   BRIEF SUMMARY OF THE INVENTION 
   An object of the present invention is to provide a junction box, connector, and connecting terminal for use in the box and connector in which weight saving and thinning are realized, freedom degree of layout is enhanced, and waterproof/dustproof capabilities can be achieved. 
   According to an aspect of the present invention, the above object is achieved by providing a junction box comprising: a junction box main body to which an electric component to be connected is attached; a connector portion which connects a connector of an outer wiring circuit, and is formed separately from the junction box main body; and a cable portion which is constituted of a flexible printed circuit with a circuit portion including a conductor pattern formed on an insulating film, and electrically connects the junction box main body to the connector portion, wherein the flexible printed circuit includes: a strip portion which connects the junction box main body to the connector portion; and a terminal connecting portion extending from a side edge of a position of the strip portion in which the junction box main body and connector portion are arranged in a short direction of the strip portion, the junction box main body includes: a junction box housing including a component attachment port to which the electric component to be connected is attached; and a plate-shaped connecting terminal on a junction box main body side, which is connected to the terminal connecting portion of the flexible printed circuit and contained in the junction box housing so as to be connected to the electric component to be connected, and the connector portion includes: a connector housing which is engaged with the connector of the outer wiring circuit; and a plate-shaped connecting terminal on a connector portion side, which is connected to the terminal connecting portion of the flexible printed circuit and contained in the connector housing so as to be connected to the connector of the outer wiring circuit. 
   Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention. 
       FIG. 1  is a perspective view showing an appearance of a junction box according to one embodiment of the present invention. 
       FIG. 2  is an exploded perspective view showing a constitution of a cable portion. 
       FIGS. 3A  to  3 D are explanatory views of a connecting terminal according to one embodiment of the present invention. 
       FIGS. 4A and 4B  are explanatory views of the connecting terminal. 
       FIGS. 5A  to  5 D are explanatory views of the connecting terminal. 
       FIGS. 6A and 6B  are explanatory views of the connecting terminal. 
       FIG. 7  is a sectional view of a resin molded portion. 
       FIG. 8  is a partially sectional view showing that the connecting terminal is attached to a junction box housing. 
       FIG. 9  is a partially sectional view showing that the connecting terminal is attached to a connector housing. 
       FIG. 10  is a perspective view showing the appearance of another junction box according to the embodiment. 
       FIGS. 11A and 11B  are diagrams showing a constitution of the cable portion of the junction box. 
       FIGS. 12A  to  12 C are diagrams showing the constitution of the cable portion of the junction box. 
       FIGS. 13A  to  13 C are diagrams showing the constitution of the cable portion of the junction box. 
       FIGS. 14A and 14B  are diagrams showing the constitution of the cable portion of the junction box. 
       FIG. 15  is a partially sectional view showing that the connecting terminal is attached to the junction box housing. 
       FIG. 16  is a partially sectional view showing that the connecting terminal is attached to the connector housing. 
       FIGS. 17A and 17B  are partially sectional views of the connector portion, showing that connector housings having different shapes are used. 
       FIGS. 18A and 18B  are a top plan view of the junction box, and a top plan view showing that a structure of the junction box is used to realize a junction box having an integral structure. 
       FIGS. 19A and 19B  are perspective views showing the appearance of the junction box according to another embodiment of the present invention. 
       FIGS. 20A  to  20 D are explanatory views of various fixing mechanisms for use in the junction box. 
       FIG. 21  is a perspective view showing the junction box according to another embodiment of the present invention. 
       FIG. 22  is a perspective view showing the appearance of another junction box according to still further embodiment of the present invention. 
       FIGS. 23A and 23B  are perspective views showing the appearance of the junction box according to another embodiment of the present invention. 
       FIGS. 24A and 24B  are a side view and partially sectional view showing the junction box according to another embodiment of the present invention. 
       FIGS. 25A and 25B  are a side view and partially sectional view showing another pattern of the junction box. 
       FIGS. 26A  to  26 C are explanatory views of another structure of the cable portion. 
       FIGS. 27A  to  27 B are explanatory views of another structure of the cable portion. 
       FIGS. 28A and 28B  are diagrams showing that the junction box according to one embodiment of the present invention is disposed in an instrument panel of a car. 
       FIGS. 29A and 29B  are perspective views showing the appearance of the junction box according to still another embodiment of the present invention. 
       FIGS. 30A and 30B  are perspective views showing the appearance of the junction box according to still another embodiment of the present invention. 
       FIG. 31  is a plan view of a conventional junction box. 
       FIG. 32  is a plan view of a bus bar contained in the junction box. 
       FIG. 33  is a sectional view of a portion VII of FIG.  31 . 
       FIG. 34  is a sectional view of a portion VIII of FIG.  31 . 
       FIG. 35  is an upward perspective view showing a conventional wiring circuit having a multilayered structure. 
       FIG. 36  is an upward perspective view showing the junction box in which the conventional wiring circuit having the multilayered structure is contained. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Embodiments of the present invention will be described hereinafter with reference to the accompanying drawings. 
     FIG. 1  is a perspective view showing an appearance of a junction box according to one embodiment of the present invention. 
   A junction box  1  is constituted of a junction box main body  10 , connector portion  20 , and cable portion  30  for connecting the junction box main body  10  to the connector portion  20 . The cable portion  30  is formed by laminating a plurality of strip-shaped flexible printed circuits (hereinafter abbreviated as “FPC”)  30   a  to  30   d  in a non-bonded state and bendable manner. The junction box main body  10  includes a junction box housing  13  formed of a resin molded member and a lid body  16  which is attachable/detachable with respect to the junction box housing  13 , and is disposed on one end of the cable portion  30 . In a surface (corresponding to a front surface) of the junction box housing  13  on the same side as main surfaces of FPCs  30   a  to  30   d , a plurality of fuse attachment portions  14  and relay attachment portion  15  for attaching a plurality of fuses  11  and relay  12  are formed in two rows along a longitudinal direction of the cable portion  30 . The connector portion  20  includes connector housings  22   a ,  22   b  formed of resin molded members, and case portions  23   a ,  23   b  in which the connector housings  22   a ,  22   b  are partially contained and which can be divided in a thickness direction of the cable portion  30 . The connector portion is disposed in the other end of the cable portion  30 . The connector housings  22   a ,  22   b  include a plurality of connector engagement portions  25  which are arranged along opposite side edges of the cable portion  30 , and into which plug connectors  21   a ,  21   b  are inserted (arranged) from opposite sides. 
     FIG. 2  is an exploded perspective view showing a constitution of the cable portion  30 . Additionally, the cable portion  30  may also be constituted of one FPC, but in this example a plurality of FPCs superimposed upon one another in the non-bonded state will be described. 
   First, each of the strip-shaped FPCs  30   a ,  30   b ,  30   c ,  30   d  constituting the cable portion  30  is constituted by disposing a circuit portion  32  formed by patterning a conductor material such as a copper foil on a base film  31  made of an insulating film such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN) and polyimide (PI). If necessary, a cover layer (not shown) is added onto this structure. 
   A plurality of terminal connecting portions  34  are formed so as to extend from opposite side edges of a strip portion  33  of each of the FPCs  30   a  to  30   d  by predetermined lengths in a short direction of the strip portion  33 . Each tip end of these terminal connecting portions  34  is connected to: a connecting terminal  39   a  (hereinafter referred to as a “first connecting terminal”) which is contained in the junction box housing  13 , constitutes a part of the junction box main body  10 , has a metal plate shape and is disposed on a side of the junction box main body; and a connecting terminal  39   b  (hereinafter referred to as a “second connecting terminal”) which is contained in the connector housing  22   a  ( 22   b ), constitutes a part of the connector portion  20 , has a metal plate shape and is disposed on a side of the connector portion  20 . Additionally, in this example, the first connecting terminal  39   a  is a so-called fork terminal whose tip end is branched into two, holds legs (connecting portions) of the fuses  11  and relay  12  between opposite surfaces of the branched tip end and achieves electric connection. The second connecting terminal  39   b  is a so-called male connecting terminal connected to each female connecting terminal (not shown) of the plug connectors  21   a ,  21   b . Moreover, the terminal connecting portions  34  may also be formed only on one side edge of the strip portion  33 . Furthermore, engagement holes  39   c  engaged with a lance mechanism disposed in the junction box housing  13  or the connector housing  22   a  ( 22   b ) as described later may also be formed in the first and second connecting terminals  39   a ,  39   b.    
     FIGS. 3  to  6  are explanatory views of the connecting terminals according to one embodiment of the present invention:  FIG. 3  show detailed diagrams of the first connecting terminal  39   a ;  FIG. 4  show diagrams of modification examples of  FIG. 3 ;  FIG. 5  show detailed diagrams of the second connecting terminal  39   b ; and  FIG. 6  show diagrams of modification examples of FIG.  5 . 
   As shown in  FIGS. 3A and 5A , the first and second connecting terminals  39   a ,  39   b  include terminal portions  39   a   1 ,  39   b   1  directly connected to female connecting terminals of the fuses  11 , relay  12 , and plug connectors  21 , and connecting ends  39   a   2 ,  39   b   2  connected to the circuit portions  32  of the terminal connecting portions  34  of the FPCs  30   a  to  30   d . The terminal portions  39   a   1 ,  39   b   1  are formed to have a thickness two or more times the thickness of the connecting ends  39   a   2 ,  39   b   2  (in other words, the connecting ends  39   a   2 ,  39   b   2  are formed to have a thickness which is a half or less of the thickness of the terminal portions  39   a   1 ,  39   b   1 ). Examples of a method of forming the terminal portions  39   a   1 ,  39   b   1  include: a method of punching metal parent materials having the same thickness as the thickness of the connecting ends  39   a   2 ,  39   b   2  beforehand, arranging the portions constituting the connecting ends  39   a   2 ,  39   b   2  as such, bending the portions constituting the terminal portions  39   a   1 ,  39   b   1  in predetermined positions, and superimposing and forming the terminal portions as shown in  FIGS. 3B  to  3 D and  5 B to  5 D; and a method of punching metal parent materials having the same thickness as the thickness of the terminal portions  39   a   1 ,  39   b   1  beforehand, arranging the portions constituting the terminal portions  39   a   1 ,  39   b   1  as such, lengthening the portions constituting the connecting ends  39   a   2 ,  39   b   2  with a press to be thin, and setting the thickness of the terminal portions to be two or more times the thickness of the connecting ends  39   a   2 ,  39   b   2 . Moreover, as shown in  FIGS. 4 and 6 , the portions constituting the terminal portions  39   a   1 ,  39   b   1  are each bent in two positions and superimposed, and the terminal portions  39   a   1 ,  39   b   1  may also be formed to have the thickness about three times the thickness of the connecting ends  39   a   2 ,  39   b   2 . The thickness of the connecting ends  39   a   2 ,  39   b   2  of the first and second connecting terminals  39   a ,  39   b  is set to be a half or less of the thickness of the terminal portions  39   a   1 ,  39   b   1  in this manner. Then, the connecting ends  39   a   2 ,  39   b   2  can securely be connected to the circuit portion  32 , for example, by resistance welding with a less energy as compared with the connecting ends having the same thickness as that of the terminal portions  39   a   1 ,  39   b   1 . Additionally, with the terminal portions  39   a   1 ,  39   b   1  having twice or more times the thickness of the connecting ends  39   a   2 ,  39   b   2 , while a sufficient mechanical strength is obtained, contact areas and volumes of the terminal portions  39   a   1 ,  39   b   1  can be increased for the connection to the fuses  11  and relay  12 . Therefore, heat values of the connecting terminals  39   a ,  39   b  and terminal connecting portions  34  by the turning-on of power can be reduced. 
   These first and second connecting terminals  39   a ,  39   b  are laid on the terminal connecting portions  34  so as to adhere to the circuit portion  32  on the terminal connecting portions  34 , subsequently bonded to the circuit portion  32 , for example, by the resistance welding and connected to the terminal connecting portions  34  as described above. After the first and second connecting terminals  39   a ,  39   b  are connected to the terminal connecting portions  34 , the FPCs  30   a  to  30   d  are superimposed upon one another and constitute the cable portion  30 . In this case, the terminal connecting portions  34  of the respective FPCs  30   a  to  30   d  are formed so that the first and second connecting terminals  39   a ,  39   b  are arranged in positions corresponding to connecting terminal arrangement positions of the junction box housing  13  and connector housing  22   a  ( 22   b ). 
   After the strip-shaped FPCs  30   a  to  30   d  are superimposed upon one another and the cable portion  30  is formed in this manner, for example, each bonded portion of the connecting terminal  39   a  ( 39   b ) with the terminal connecting portion  34  is sealed by a resin molded portion  37 . Then, connection reliability of the bonded portion can be enhanced. Additionally, as shown in  FIG. 2 , the resin molded portion  37  may also be formed for each bonded portion of each connecting terminal with the terminal connecting portion (the bonded portion of the connecting terminal  39   b  with the terminal connecting portions  34  in this example). However, as shown in  FIG. 7 , the bonded portions of a plurality of connecting terminals  39   a  ( 39   b ) to the terminal connecting portions  34  may collectively be sealed by the resin molded portion  37 . In this case, while the arrangement of the connecting terminals  39   a  ( 39   b ) is fixed in a predetermined mode, the strip portions  33  of the respective FPCs  30   a  to  30   d  are held in the non-bonded state, and the cable portion  30  can be constituted. Therefore, while the flexibility of the cable portion  30  is maintained, the connecting terminals  39   a  ( 39   b ) can collectively be inserted into the junction box housing  13  and connector housing  22   a  ( 22   b ), and the inserting operation can be simplified. Moreover, the terminal connecting portions  34  connected to the second connecting terminals  39   b  are arranged as such. For the terminal connecting portions  34  connected to the first connecting terminals  39   a , each first connecting terminal  39   a  is bent such that the terminal extends in a vertical direction with respect to the surface of the cable portion  30  with the circuit portion  32  formed thereon, and is contained in a predetermined connecting terminal arrangement position of the junction box housing  13 . Then, the first connecting terminal  39   a  is attached to the junction box housing  13 , and the second connecting terminal  39   b  is attached to the connector housing  22   a  ( 22   b ). 
     FIG. 8  is a partially sectional view showing that the first connecting terminals  39   a  are attached to the junction box housing  13  of the junction box main body  10 , and  FIG. 9  is a partially sectional view showing that the second connecting terminals  39   b  are attached to the connector housing  22   a  ( 22   b ) of the connector portion  20 . 
   As shown in  FIG. 8 , in predetermined positions of the junction box housing  13  of the junction box main body  10 , there are formed: terminal containing holes  24   a  through which the first connecting terminals  39   a  are passed and in which the terminals having tip ends exposed are contained; and lance portions  26   a  as a lance mechanism which are engaged with engagement holes  39   c  of the first connecting terminals  39   a  and lock/fix the first connecting terminals  39   a  in the junction box housing  13 . The FPCs  30   a  to  30   d  constituting the cable portion  30  are contained in the junction box housing  13  while the surfaces with the circuit portions  32  formed thereon are disposed in a two-dimensional manner and the terminal connecting portions  34  are bent in the vertical direction. In this manner, the terminal connecting portions  34  are bent and directed in a direction crossing at right angles to the main surfaces of the FPCs  30   a  to  30   d , and the cable portion  30  is contained in the junction box main body  10  in a structure for locking/fixing the first connecting terminals  39   a  by the lance portions  26   a . Then, a height h 3  of the junction box main body  10  can be suppressed, the connecting terminals  39   a  connected to the flexible FPCs  30   a  to  30   d  are securely held, and a predetermined connection strength can be achieved. 
   On the other hand, as shown in  FIG. 9 , in the connector housing  22   a  ( 22   b ) of the connector portion (not shown), there are formed: the connector engagement portion  25  with which the connector (outer connector) of an outer wiring circuit (not shown) and plug connector  21   a  ( 21   b ) are engaged; a plurality of terminal containing holes  24   b  through which the second connecting terminals  39   b  are passed and in which the tip ends of the terminals projected into the connector engagement portion  25  are contained; and an insertion hole  27  into which the FPCs  30   a  to  30   d  having the second connecting terminals  39   b  passed through the terminal containing holes  24   b  and constituting the cable portion  30  are inserted in a side edge direction of the strip portion  33 . In a plurality of terminal containing holes  24   b , lance portions  26   b , engaged with the engagement holes  39   c  of the second connecting terminals  39   b , for locking/fixing the second connecting terminals  39   b  in the connector housing  22   a  ( 22   b ) are formed as the lance mechanism in predetermined positions. The respective FPCs  30   a  to  30   d  constituting the cable portion  30  are contained in the connector housing  22   a  ( 22   b ) so that a width a direction of the connector housing  22   a  ( 22   b ) crosses at right angles to a width b direction of the cable portion  30 . When the cable portions  30  are attached to the respective housings  13 ,  22   a  ( 22   b ) and subsequently attached to the lid body  16  and case portion  23 , the junction box  1  is completed as shown in FIG.  1 . 
   For the first and second connecting terminals  39   a ,  39   b , when the terminal connecting portions  34  are bent in desired shapes, the arrangement positions of the connecting terminals  39   a  ( 39   b ) are freely changed and it is possible to form the junction box  1  in a desired shape. A degree of design freedom can be enhanced. For example, as shown in  FIG. 1 , when the terminal connecting portions  34  extended in the short direction of the strip portion  33  are contained in the connector portion  20 , a height h of the connector portion  20  can be remarkably lower than that of the conventional junction box, and space saving is possible. 
     FIG. 10  is a perspective view showing the appearance of another junction box according to the embodiment of the present invention. 
   A junction box  1 ′ of this example is different from the junction box  1  according to the above-described embodiment in that a cable portion  30 ′ is branched into two in a superimposition direction of the FPCs  30   a  to  30   d , two connector portions  20   a ,  20   b  are disposed on branched ends, and the fuse attachment portion  14  and relay attachment portion  15  of a junction box main body  10 ′ are inserted into opposite side edges of the cable portion  30 ′ from opposite sides in each row. In the embodiment, each of the connector portions  20   a ,  20   b  includes the connector engagement portion  25  only in one side edge of the cable portion  30 ′. 
     FIGS. 11A  to  14 B are diagrams showing the constitution of the cable portion  30 ′ of this example. 
   First, as shown in  FIG. 11A , the strip FPC  30   a  constituting a part of the cable portion  30 ′ is constituted by disposing the patterned/formed circuit portion  32  on the base film  31  formed of the insulating film such as PET, PEN and PI. Additionally, as not shown, the cover layer is formed on the constitution if necessary. A plurality of terminal connecting portions  34  are formed to extend in the short direction of the strip portion  33  by the desired length from opposite side edges of the strip portion  33  of the FPC  30   a . For example, first and second connecting terminals  39   a ,  39   b  having metal plate shapes are connected to the tip ends of the terminal connecting portions  34 . In this example, the terminal connecting portions  34  on one side are formed to be longer than the terminal connecting portions  34  on the other side. Additionally, the terminal connecting portions  34  may also be formed only on one side edge of the strip portion  33 . Moreover, in the first and second connecting terminals  39   a ,  39   b , the engagement holes  39   c  engaged with the lance mechanism disposed, for example, in a junction box housing  13   a  ( 13   b ) or the connector housing  22   a  ( 22   b ) are formed. 
   As shown in  FIG. 11B , each connecting terminal  39   a  ( 39   b ) is disposed on the terminal connecting portion  34  so as to adhere to the circuit portion  32  on the terminal connecting portion  34 . Thereafter, the terminal is subjected to the resistance welding by a pair of electrodes  38   a ,  38   b  of a series welding apparatus (not shown) allowed to abut on the terminal from above the connected portion with the circuit portion  32 , bonded to the circuit portion  32  and connected to the terminal connecting portion  34 . Additionally, since the resistance welding is a known technique, the description thereof is omitted. Additionally, the connecting terminal  39   a  ( 39   b ) may also be connected to the terminal connecting portion  34  by other methods such as ultrasonic welding, laser welding and soldering. When the terminals are connected to the portions in these connection methods, a high connection reliability can be secured. 
   Subsequently, as shown in  FIGS. 12A and 12B , the strip FPC  30   a  ( 30   b ) formed by connecting the connecting terminals  39   a  ( 39   b ) to the terminal connecting portions  34  in the method is superimposed to constitute the cable portion  30 ′.  FIG. 12A  is a top plan view showing the cable portion  30 ′ constituted by superimposing the FPCs  30   a ,  30   b  upon each other,  FIG. 12B  is a partial side view of the cable portion  30 ′, and  FIG. 12C  is a partial sectional view of the cable portion  30 ′. In this case, the terminal connecting portions  34  constituting the FPCs  30   a ,  30   b  constituting the cable portion  30 ′ may be disposed and formed in the desired positions of the side edges of the strip portion  33  so that the connecting terminal  39   a  ( 39   b ) is disposed in a predetermined position corresponding to the connecting terminal arrangement position of the junction box housing  13   a  ( 13   b ) or the connector housing  22   a  ( 22   b ). 
   After a plurality of FPCs  30   a ,  30   b  are superimposed to form the cable portion  30 ′ in this manner, as shown in  FIGS. 13A and 13B , the connected portion of each connecting terminal  39   a  ( 39   b ) to the terminal connecting portion  34  is sealed by the resin molded portion  37 . In this case, a certain number of connecting portions are collectively resin-molded at once as shown in  FIG. 13A , the desired terminal arrangement state of the connecting terminals  39   a  ( 39   b ) can be realized without separating bonding the strip portions  33  of the FPCs  30   a ,  30   b  having the non-bonded states. Moreover, since the strip portions  33  of the FPCs  30   a ,  30   b  are not attached, it is possible to flexibly move the respective FPCs  30   a ,  30   b . Furthermore, as not shown, the resin molded portions  37  which are independent of one another for the respective connected portions may also be formed as described above.  FIG. 13A  is a top plan view showing the cable portion  30 ′ to which the resin mold is applied,  FIG. 13B  is a partial side view of the cable portion  30 ′, and  FIG. 13C  is a partial sectional view of the cable portion  30 ′. 
   Additionally, as shown in  FIG. 14A , for example, the terminal connecting portions  34  formed on one side edge of the strip portion  33  of the cable portion  30 ′ formed in this manner are folded back on the side of the terminal connecting portions  34  formed in the other side edge. The terminal connecting portions  34  and connecting terminals  39   a  ( 39   b ) may also be disposed on one side edge of the cable portion  30 ′ in a concentrated manner. As shown in  FIG. 14B , for example, only the terminal connecting portions  34  formed on one side edge of the cable portion  30 ′ to be contained in the connector portion  20   a  ( 20   b ) of the cable portion  30 ′ may also be folded back toward the terminal connecting portions  34  formed on the other side edge to constitute the cable portion  30 ′. When the terminal connecting portions  34  and connecting terminals  39   a  ( 39   b ) are arranged on one side edge, the entire height and width of the junction box can be suppressed. When only some of the terminal connecting portions  34  and connecting terminals  39   a  ( 39   b ) are disposed on one side edge, as in the junction box  1 ′ of this example, the height of one structure of the junction box main body  10 ′ or the connector portion  20   a  ( 20   b ) is suppressed, and the connection is possible from an upward/downward direction in the other structure. Moreover, when the cable portion  30 ′ in the state shown in  FIGS. 12A and 12B  are used, a width c of the junction box main body  10 ′ and a width d of the connector portion  20   a  ( 20   b ) are reduced. In this case, a structure in which the connection from the upward/downward direction is possible both in the junction box main body and connector portion can be realized. 
     FIG. 15  is a partially sectional view showing that the first connecting terminals are attached to the junction box housings  13   a ,  13   b  of the junction box main body  10 ′, and  FIG. 16  is a partially sectional view showing that the second connecting terminals  39   b  are attached to the connector housing  22   a  ( 22   b ) of the connector portion  20   a  ( 20   b ). 
   As shown in  FIG. 15 , in the junction box housing  13   a  ( 13   b ) of the junction box main body  10 ′, the terminal containing holes  24   a  through which the first connecting terminals  39   a  are passed and in which the terminals having tip ends exposed are contained, and the lance portions  26   a  as the lance mechanism which are engaged with the engagement holes  39   c  of the first connecting terminals  39   a  and lock/fix the first connecting terminals  39   a  in both the junction box housings  13   a ,  13   b  are formed in the predetermined positions. The junction box housings  13   a ,  13   b  are locked by a lock mechanism (not shown). When the mechanism is unlocked, the housings can be separated (for example, vertically divided) in the structure. The FPCs  30   a ,  30   b  constituting the cable portion  30 ′ are contained in the junction box housings  13   a ,  13   b  while the surfaces with the circuit portions  32  formed thereon are longitudinally disposed and the terminal connecting portions  34  are extended as such from the opposite side edges. 
   On the other hand, as shown in  FIG. 16 , in the connector housing  22   a  ( 22   b ), there are formed: the connector engagement portion  25  which is engaged with the connector of the outer wiring circuit; a plurality of terminal containing holes  24   b  through which the second connecting terminals  39   b  are passed and in which the terminals having the tip ends projected in the connector engagement portion  25  are contained; and the insertion hole  27  into which the cable portion  30 ′ having the second connecting terminals  39   b  passed through the terminal containing holes  24   b  is inserted in the side edge direction of the strip portion  33 . In a plurality of terminal containing holes  24   b , the lance portions  26   b , engaged with the engagement holes  39   c  of the second connecting terminals  39   b , for locking/fixing the second connecting terminals  39   b  in the connector housing  22   a  ( 22   b ) are formed in the predetermined positions. The terminal connecting portions  34  of the FPCs  30   a ,  30   b  constituting the cable portion  30 ′ are contained in the insertion hole  27  in the connector housing  22   a  ( 22   b ) so that the terminal connecting portions constitute the predetermined connecting terminal arrangement positions in a state shown in FIG.  16 . Additionally, since a cover layer  30   a   1  is disposed on the circuit portion  32  of the FPC  30   a , the circuit portion is structured not to have a short circuit with the circuit portion  32  of the folded-back terminal connecting portion  34  of the FPC  30   b.    
   With the above-described attachment structure of the connecting terminal  39   b  to the connector housing  22   a  ( 22   b ), as shown in  FIGS. 17A and 17B , when the connector housing  22   a  ( 22   b ) is just replaced with a housing having a different shape, the connector portion  20   a  ( 20   b ) can inexpensively be realized in accordance with various connector shapes. For example, a height h 1  of an outer wall constituting the connector engagement portion  25  of the connector housing  22   a  ( 22   b ) shown in  FIG. 17A  is different from a height h 2  of the outer wall constituting the connector engagement portion  25  of the connector housing  22   a  ( 22   b ) shown in FIG.  17 B. Therefore, without changing the fold-back modes of the connecting terminals  39   b  and terminal connecting portions  34 , cable portion  30 ′ and case portion  23   a  ( 23   b ), it is possible to connect the connectors (outer connectors) of different types of outer wiring circuits, plug connectors  21   a ,  21   b , and the like in accordance with the respective heights h 1 , h 2 . Thereby, it is possible to provide the junction box  1  for various connectors while the cost is suppressed. 
   Additionally, the junction box  1  of this example includes a structure in which the junction box main body  10 ′ is connected to the first and second connector portions  20   a ,  20   b  via the cable portion  30 ′ including a plurality of flexible strip FPCs  30   a  to  30   d . Therefore, as shown in  FIG. 18A , of course, the junction box main body  10 ′ and the connector portion  20   a  ( 20   b ) may be formed with different housings and connected to each other so that the respective housings can freely be moved via the cable portion  30 ′. Moreover, as shown in  FIG. 18B , the junction box main body  10 ′ and connector portion  20   a  ( 20   b ) are arranged in one housing  36 , the cable portion  30 ′ is contained in a connecting state of the junction box main body  10 ′ to the first and second connector portions  20   a ,  20   b  in the housing  36 , and a junction box  1 ″ having an integral structure may be formed. When the cable portion  30 ′ having flexibility is used, various types of junction boxes having different shapes can easily be realized at a low cost. 
   Moreover, not only the integral structure shown in  FIG. 18B  but also an integral structure shown in  FIG. 19  may be used. 
     FIGS. 19A and 19B  show perspective views of the appearance of the junction box according to another embodiment of the present invention. 
   That is, in the integral structure of this example, as shown in  FIG. 19A , a junction box  1 A in which a junction box main body  10 A is connected to a connector portion  20 A via a cable portion  30 A is integrally fixed via a fixing mechanism  70  ( 70   a ,  70   b ) disposed in predetermined positions of the junction box main body  10 A and connector portion  20 A. The fixing mechanism  70  includes hooks  70   a  formed on a part of the lower surface of the junction box main body  10 A, and hook engagement portions  70   b  formed in a part of a side part of the connector portion  20 A.  FIG. 19B  shows that the hooks  70   a  formed on the junction box main body  10 A are inserted in the hook engagement portions  70   b  formed in the connector portion  20 A and both the main body and connector portion are integrally locked/fixed. As the fixing mechanism  70 , for example, mechanisms shown in  FIG. 20  are considered. 
   That is, as shown in  FIGS. 20A and 20B , a metal bracket  40  is formed on the side surface of the housing or the case portion of either the junction box main body  10 A or the connector portion  20 A by an insert mold. A bracket engagement portion  41  to be engaged with the metal bracket  40  is formed in the side surface of the other housing. When the bracket is engaged with the bracket engagement portion, the junction box main body  10 A and connector portion  20 A are fixed by this fixing mechanism. 
   Moreover, as shown in  FIG. 20B , a so-called anchor clip  42  is formed on the side surface of either one housing of the junction box main body  10 A or the connector portion  20 A by integral molding. An anchor clip fixing portion  43  including a hole to be engaged with the anchor clip  42  is formed in the side surface of the other housing. The anchor clip  42  is inserted in the anchor clip fixing portion  43  so that the junction box main body  10 A and connector portion  20 A are fixed by this fixing mechanism. 
   Furthermore, as shown in  FIG. 20C , a rib  44  having a T-shaped section is formed on the side surface of one housing of either the junction box main body  10 A or the connector portion  20 A by the integral molding. A rib fixing portion  45  including a trench structure into which the rib  44  is slid, inserted and engaged is formed in the side surface of the other housing. The rib  44  is inserted into the rib fixing portion  45 , and the junction box main body  10 A and connector portion  20 A are fixed by the fixing mechanism. 
   Additionally, as shown in  FIG. 20D , a fixing protrusion  46  is formed in any one of the junction box main body  10 A and connector portion  20 A, and a lock piece  47  to be engaged with the protrusion  46  is formed in the other one. The protrusion is engaged with the piece so that the junction box main body  10 A and connector portion  20 A are fixed by the fixing mechanism. When these above-described fixing mechanisms  70  are formed beforehand in the housings of the junction box main body  10 A and connector portion  20 A, the modes of the junction box  1 A including an independent structure and integrally coupled structure can easily be selected in a design stage. This makes it possible to enhance a freedom degree of layout of the junction box  1 A. Additionally, other various fixing mechanisms for fixing the junction box main body  10 A and connector portion  20 A are considered, but the description thereof is omitted here. Moreover, needless to say, the above-described fixing mechanism  70  may also be used to fix a plurality of formed connector portions to one another. 
     FIG. 21  is a perspective view showing the appearance of the junction box according to still another embodiment of the present invention. 
   A junction box  150  of the embodiment is different from the junction box  1  of the above-described embodiment in that the cable portion  30  is passed through a flexible grommet  48  having a rectangular section (partially cut out and shown). The grommet  48  is formed of materials such as silicon rubber and ethylene propylene rubber (EPDM), and has high flexibility and durability. Since opposite ends of the grommet  48  are attached and fixed to the junction box main body  10  and the case portions  23   a ,  23   b  of the connector portion  20 , the exposed portion of the cable portion  30  (portion between the junction box main body  10  and connector portion  20 ) is covered with the grommet  48 . 
     FIGS. 22 and 23  are perspective views showing the appearance of another junction box according to still further embodiment of the present invention. 
   As shown in  FIG. 22 , a junction box  150 ′ of this example is different from the junction box  1 ′ of the above-described embodiment in that the cable portion  30 ′ branched into two in the superimposition direction of the FPCs  30   a  to  30   d  is covered with the grommet  48 . Moreover, as shown in  FIGS. 23A and 23B , a junction box  150 A of this example is different from the junction box  1 A of the above-described embodiment in that the cable portion  30 A (not shown) is covered with the grommet  48 . When the grommet  48  is disposed in this manner, moisture, dust, and the like can effectively be prevented from entering the junction box main body  10  ( 10 ′,  10 A) and connector portion  20  ( 20   a ,  20   b ,  20 A), and the cable portion  30  ( 30 ′,  30 A) can effectively be protected from damages caused by impact. 
     FIGS. 24A and 24B  show a side view and partially sectional view showing the junction box according to still another embodiment of the present invention. 
   As shown in  FIG. 24A , a junction box  1 B includes a structure in which the junction box main body  10  is connected to the connector portion  20   a  ( 20   b ) via the cable portion  30  (not shown), and the exposed portion of the cable portion  30  from the junction box main body  10  and connector portion  20   a  ( 20   b ) is covered with a grommet  48 B. As shown in  FIG. 24B , the grommet  48 B is formed of the above-described materials such as silicon rubber and ethylene propylene rubber (EPDM), has high flexibility and durability, and therefore constitutes a so-called bellows shape. Opposite ends  48   a  of the grommet  48  have engagement structures engaged with opening peripheral edges  48   b  of insertion ports of the cable portion  30  into the junction box main body  10  and connector portion  20   a  ( 20   b ), and are attached/fixed to the junction box main body  10  and connector portion  20   a  ( 20   b ). The grommet  48 B attached in this manner can effectively prevent the moisture and dust from entering the junction box main body  10  and connector portion  20   a  ( 20   b ) as described above, and can effectively protect the circuit portions  32  of the respective FPCs  30   a  to  30   d  constituting the cable portion  30  in the exposed state between the main body and portion from damage and breakage. Therefore, the durability of the junction box  1 B can be enhanced. 
   Additionally, for the grommet  48 B, instead of the bellows shape, for example, a tubular shape including the above-described square section (rectangular section), or a cylindrical shape including a circular shape may be used as shown in FIG.  25 A. Moreover, when it is unnecessary to cover or protect the exposed portion of the cable portion  30 , as shown in  FIG. 25B , the grommet  48  engaged with the opening peripheral edges  48   b  of the insertion ports of the junction box main body  10  and connector portion  20   a  ( 20   b ) and constituted as a packing for effectively closing the insertion ports and preventing the entrance of the moisture may be used to constitute the junction box  1 B. Additionally, the grommet  48 B described in this example can be applied to any one of the above-described embodiments. Needless to say, the circuit portions  32  of the respective FPCs  30   a  to  30   d  constituting the cable portion  30  ( 30 ′) of the junction box  150  ( 150 ′,  150 B) can effectively be protected from the damage and breakage caused by the impact. 
   Additionally, as the above-described cable portion  30 , as shown in  FIGS. 26A  to  26 C, a cable portion  30 B may also be used including a structure in which the strip portions  33  are folded back and superimposed in order to shorten a circuit width e of the circuit portion  32 . In this case, for example, as shown in  FIG. 26A , a center line  33   a  is determined which connects the vicinity of the center of the short direction of the strip portion  33  of the FPC  30   a  constituting the cable portion  30 B in the longitudinal direction. As shown in  FIG. 26B , the strip portion  33  of the FPC  30   a  is bent and superimposed along the center line  33   a  so that the surfaces with the circuit portions  32  formed thereon are disposed opposite to each other. As shown in  FIG. 26C , the FPC  30   a  is superimposed onto the FPC  30   b  with a strip portion  33 ′ formed beforehand thereon with a circuit width which meets a circuit width e′ of the folded FPC  30   a , and the cable portion  30 B is formed. When the entire circuit width of the cable portion  30 B is reduced in this manner, the entire height and width of the junction box  1  can be suppressed, and the junction box  1  can efficiently be miniaturized. Moreover, the FPC  30   a  having the folded strip portion  33  is set beforehand, for example, in a power supply circuit (power distribution circuit). As a result, a circuit area can be enlarged as compared with another FPC circuit. Therefore, the FPC which has high radiating properties and whose circuit width can be adapted to the circuit width of another FPC or shortened can be used as the power distribution circuit. 
   Moreover, as shown in  FIG. 27A , the FPCs  30   a ,  30   b  constituting the cable portion  30 B are first superimposed upon each other. Thereafter, the strip portions  33  of the respective FPCs  30   a ,  30   b  are folded so that the center line  33   a  of each strip portion  33  is positioned in the vertical direction with respect to the circuit formed surface of the circuit portion  32  (so that the center line is a bottom side of a portion folded in a trough shape or an apex of a portion folded in a mountain shape). As shown in  FIG. 27B , a part of the folded strip portion  33  is further folded, and the cable portion  30 B having a short circuit width may also be realized. 
   Additionally, the junction box  1  of the present invention is used in a mode in which the junction box main body  10  is connected to a plurality of connector portions  20  in independent states via the cable portion  30 . In this case, for example, an application method shown, for example, in  FIGS. 28A and 28B  can be realized. That is,  FIGS. 28A and 28B  show diagrams of a state in which the junction box  1  is disposed in an instrument panel of a car,  FIG. 28A  shows the instrument panel for use in a so-called right-side steering wheel mounted car, and  FIG. 28B  shows the instrument panel for use in a so-called left-side steering wheel mounted car. 
   For example, with an instrument panel  50   a  of the right-side steering wheel mounted car shown in  FIG. 28A , and an instrument panel  50   b  of a left-side steering wheel mounted car shown in  FIG. 28B , the arrangement position of the junction box main body  10  is set in the vicinity of a steering wheel. The first connector portion  20   a  is disposed on the right as facing the instrument panel  50   a  or  50   b  and the second connector portion  20   b  is disposed in the middle of the instrument panel  50   a  or  50   b . Then, the arrangement position of the connector portion  20   a  ( 20   b ) can be set in common to the right and left side steering wheel mounted cars. Therefore, a common harness can be used, the number of components can be decreased, and the cost can be reduced. As described above, according to the arrangement structure using the junction box  1 , the attachment positions of the junction box main body  10  and connector portion  20   a  ( 20   b ) can easily be changed, and the arrangement positions can freely be determined. Therefore, a large design change is not accompanied. Even in this case, it is possible to enhance the freedom degree of layout and broaden wiring design, and the like. 
   Additionally, in the above-described embodiment, several examples of the mode of the junction box  1  have been described, but the present invention is not limited to these examples. Examples of the mode include various modes of junction boxes such as: a junction box  1 C constituted of a combination of a junction box main body  10 C, connector portion  20   a  ( 20   b ) and cable portion  30 C as shown in  FIG. 29A ; a junction box  1 D constituted of a combination of a junction box main body  10 D, connector portion  20 D and cable portion  30 D as shown in  FIG. 29B ; and junction boxes  150 C and  150 D including structures in which the cable portions  30 C,  30 D of the junction boxes  1 C,  1 D are covered with the grommets  48  as shown in  FIGS. 30A and 30B . 
   Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general invention concept as defined by the appended claims and their equivalents.