Patent Publication Number: US-2016225496-A1

Title: Protector and busbar module

Description:
BACKGROUND 
     1. Field of the Invention 
     The invention relates to a protector for protecting a member to be protected. 
     2. Description of the Related Art 
     A protector for protecting a wiring harness is disclosed, for example, in Japanese Unexamined Patent Publication No. 2005-318740 or Japanese Unexamined Patent Publication No. 2004-357415. The protectors described in Japanese Unexamined Patent Publication No. 2005-318740 and Japanese Unexamined Patent Publication No. 2004-357415 are configured so that a main body and a lid are connected by a hinge. A lock claw and a lock frame are locked on a side opposite to the hinge. 
     However, depending on the protector, the main body and the lid may not be connected on an opposite side facing the lock across an accommodation space and the lock may not be provided. In this case, the side of the lid opposite the lock may be lifted relative to the main body and a member to be accommodated may be caught between the main body and the lid or external matter may enter the accommodation space. 
     Accordingly, the invention aims to provide a technology capable of suppressing the lift of a lid relative to a main body. 
     SUMMARY 
     The invention relates to a protector with a main body shaped substantially along an extending direction of a member to be protected and a lid that cooperates with the main body for at least partly surrounding the member to be protected. The protector further has at least one pressing piece including a first hinge with a first end connected to the lid and a projecting piece connected to the second end of the first hinge. The lid and the projecting piece are biased in opening directions by the first hinge. At least one lock is provided on the main body, and at least one locked portion is provided on the projecting piece. The lockable portion locks to the lock with the projecting piece held close to the lid. Thus, a lift of the lid relative to the main body can be suppressed by the action of a reaction force caused by the resilient deformation of the pressing piece in a direction to press the lid. 
     In one embodiment, the first end of the first hinge is connected to an outward facing surface of the lid. 
     The locked portion may be lockable to the lock with the projecting piece held close to the outward facing surface of the lid. 
     The main body and the lid may be connected via a second hinge at a position distant from the lock along an extending direction of the main body. Thus, the lid is lifted easily relative to the main body. Even in this case, the lift of the lid relative to the main body can be suppressed since the reaction force caused by the resilient deformation of the pressing piece acts in the direction to press the lid. 
     The lock and the locked portion may be locked between the first and second hinges along the extending direction of the main body. Thus, a reaction force caused by resilient deformation of the pressing piece acts on a side more distant from the second hinge along the extending direction of the lid. Therefore, the lift of the lid relative to the main body can be suppressed more reliably. 
     Extending directions of the first and second hinges may be substantially parallel. Thus, the reaction force of the second hinge is canceled out easily by that of the first hinge. This enables the lift of the lid relative to the main body to be suppressed more reliably. 
     A busbar may be accommodated as the member to be protected. Accordingly, one embodiment of the invention relates to a busbar module that includes the above described protector and a busbar at least partly accommodated in the protector. Thus, a possibility of a short circuit caused by the entrance of external matter or the like through a clearance formed by the lift can be suppressed by preventing a lift of the lid relative to the main body. 
     These and other objects, features and advantages of the invention will become more apparent upon reading of the following detailed description of preferred embodiments and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a protector according to an embodiment. 
         FIG. 2  is a front view of the protector of  FIG. 1 . 
         FIG. 3  is a perspective view showing a lid of the protector closed. 
         FIG. 4  is a front view showing the lid of the protector is closed 
         FIG. 5  is a perspective view showing a state where the protector is locked. 
         FIG. 6  is a front view showing the state where the protector is locked. 
         FIG. 7  is a rear view showing the state where the protector is locked. 
         FIG. 8  is a bottom view showing the state where the protector is locked. 
         FIG. 9  is a section along IX-IX of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     A protector  20  according to an embodiment is described with reference to  FIGS. 1 to 9 .  FIGS. 1 and 2  are views showing a state where a lid  40  of the protector  20  is open (opened state OS),  FIGS. 3 and 4  are views showing a state where the lid  40  of the protector  20  is closed (closed state CS), and  FIGS. 5 to 9  are views showing a state where the protector  20  is locked (locked state LS). Note that  FIGS. 1, 3 and 5  are perspective views and  FIGS. 2, 4 and 6  are front views. Further,  FIG. 7  is a rear view and  FIG. 8  is a bottom view. Further,  FIG. 9  is a section along IX-IX of  FIG. 8 . Note that  FIGS. 3 and 5  are perspective views viewed from the same direction, and  FIG. 1  is a perspective view viewed from a direction different from that of the  FIGS. 3 and 5 . 
     The protector  20  is a member for surrounding and protecting a member to be protected. Here, a busbar  12  is the member to be protected. A busbar module  10  is formed by at least partly accommodating the busbar  12  in the protector  20 . 
     The busbar  12  is a conductive member, for example, made of metal such as copper, and plating, such as tin playing, may be applied to an outer layer of the busbar  12 . The busbar  12  is laid as a part of a power transmission path to an electric drive device such as a motor. 
     The busbar  12  is formed by bending, folding and/or embossing a long flat plate member into a three-dimensional shape. Specifically, the busbar  12  is composed of an intermediate portion  14  and terminals  16   a ,  16   b  on or near opposite end parts of the intermediate portion  14 . The terminals  16   a ,  16   b  on the end parts and the intermediate portion  14  are bent so that principal surfaces of the terminals  16   a ,  16   b  and that of the intermediate portion  14  are arranged at an angle, preferably substantially orthogonal along lines orthogonal to extending directions of the terminals  16   a ,  16   b . In other words, extension directions EDa, EDb of the terminals  16   a ,  16   b  preferably are substantially perpendicular to an extension direction ED of the intermediate portion  14 . The same holds true for a normal vector NV of the intermediate portion  14  being arranged substantially perpendicular to a normal vector NVa of the terminal  16   a  and/or to a normal vector NVb of the terminal  16   b . Further, the intermediate portion  14  is bent in the same plane (or along one or more lines lying in the same plane as the intermediate portion  14 ). Note that the terminal  16   a  on one end part and the intermediate portion  14  are bent with one principal surface of the busbar  12  located at an inner side and the terminal  16   b  on the other end part and the intermediate portion  14  are bent with the other principal surface of the busbar  12  at an inner side. In other words, the terminals  16   a  and  16   b  are bent towards substantially opposite sides of the intermediate portion  14 . 
     Each terminal  16   a ,  16   b  of the busbar  12  has a through hole  17 . Using these through holes  17 , the busbar  12  is connected to an object to be connected, for example, as follows. Specifically, threaded electrodes are inserted through the through holes  17  and nuts are mounted on the electrodes inserted through the through holes  17  to connect the busbar  12  electrically to the electrodes. 
     The protector  20  includes a main body  22 , the lid  40 , a pressing piece  46 , a lock  30  and a locked portion  52 . It is assumed that the protector  20  described here is molded integrally or unitarily from a material such as resin using a mold. 
     The main body  22  is shaped along an extending direction ED of the member to be protected (e.g. of the busbar  12 , particularly of the intermediate portion  14 ). Here, a bottom surface  24  of the main body portion  22  is formed substantially along an extending direction ED of the busbar  12  and in contact with the one principal surface of the busbar  12 . 
     The lid  40  is formed to surround the member to be protected together with the main body  22 , and specifically is provided to surround the intermediate portion  14  of the busbar  12 . 
     The pressing piece  46  includes a first hinge  48  and a projecting piece  50 . The pressing piece  46  projects from an outward facing surface of the lid  40 . 
     One end of the first hinge  48  is connected to the outward facing surface of the lid  40 . The first hinge  48  is made more easily bendable than a surrounding part (here, projecting piece  50  or lid  40 ). The lid  40  and the projecting piece  50  are biased in opening directions OD by the first hinge  48  or in a direction increasing the azimuthal direction of the projecting piece  50  from the locked portion  52 . 
     The projecting piece  50  is connected to the other end of the first hinge  48 . When the projecting piece  50  approaches the lid  40  against a biasing force of the first hinge  48  (or in a direction opposite to the opening direction OD), the first hinge  48  is deformed resiliently. 
     The lock  30  is provided on the main body  22 , and a lock recess or hole  32  is adopted as the lock  30 . 
     The locked portion  52  is provided on the projecting piece  50 . The locked portion  52  is formed to be lockable to the lock  30  with the projecting piece  50  held close to the outward facing surface of the lid  40 . The pressing piece  46  is deformed resiliently against the biasing force with the locked portion  52  locked to the lock  30 . Thus, the lid  40  is pressed toward the main body  22  by the pressing piece  46  and a lift between the lid  40  and the main body  22  is suppressed. Here, a lock claw  54  is adopted as the locked portion  52 . 
     The main body  22  has an intermediate main body  23  covering the intermediate portion  14  of the busbar  12 . The intermediate main body  23  has a bottom surface  24  that is bent in the same plane to extend along the intermediate portion  14  of the busbar  12 . A side wall  25  projects from the bottom surface  24  of the intermediate main body  23  to cover a part of an outer side surface including an outer peripheral side of a bent part of a side surface of the intermediate portion  14  of the busbar  12  and an inner side surface including an inner peripheral side of the bent part. A part of the side wall  25  of the main body portion  22  covering the outer side surface of the busbar  12  is referred to herein as an outer side wall  26  and a part thereof covering the inner side surface of the busbar  12  is referred to as an inner side wall  28 . A part of the inner side wall  28  extending from the terminal  16   a  of the busbar  12  is referred to as a first inner side wall portion  28   a  and a part thereof extending from an end part of the first inner side wall portion  28   a  toward the terminal  16   b  of the busbar  12  to intersect with the first inner side wall portion  28   a  is referred to as a second inner side wall portion  28   b . The outer side wall  26  is not provided on a side opposite to the first inner side wall  28   a  and the outer side wall portion  26  is provided parallel to the second inner side wall  28   b  on a side opposite to the second inner side wall  28   b.    
     Further, the lid  40  includes a ceiling plate  42  covering the other principal surface of the intermediate portion  14  of the busbar  12  and a side wall  44  covering an outer side surface of the intermediate portion  14  of the busbar  12  from a part of the main body  22  where the outer side wall  26  is not provided. The side wall  44  extends substantially parallel to the first inner side wall portion  28   a  with the lid  40  closed. 
     The main body  22  and the lid  40  are connected via a second hinge  38 . Specifically, one end of the second hinge  38  is connected to an outward facing surface of the tip of the outer side wall portion  26  of the main body portion  22  and the other end of the second hinge  38  is connected to the ceiling plate  42  of the lid  40 . An extending direction (direction orthogonal to a direction connecting the main body  22  and the lid  40 ) of the second hinge  38  is substantially parallel to that of the outer side wall  26 . The second hinge  38  is made more easily bendable than surrounding members (here, lid  40  and main body  22 ), for example, by being thinner than the surrounding members. 
     The main body  22  and the lid  40  are connected at a position distant from the lock  30  along an extending direction of the main body  22 . Specifically, the main body  22  and the lid  40  are connected by the second hinge  38  provided on the outer side wall  26  of the main body  22  as described above. Further, the lock  30  is provided on the first inner side wall portion  28   a . Thus, the main body  22  and the lid  40  are connected at the position distant from the lock  30  along the extending direction of the main body  22 . 
     The lock  30  and the locked portion  52  are locked between the first and second hinges  48 ,  38  along the extending direction of the main body  22 . Further, an extending direction of the first hinge  48  and that of the second hinge  38  are parallel. Specifically, the first hinge  48  is provided at a position near the terminal  16   a  on an outward facing surface of the ceiling plate  42 . The extending direction of the first hinge  48  (direction orthogonal to a direction connecting the ceiling plate  42  and the projecting piece  50  on a surface of the ceiling plate  42 ) is parallel to a part of the outer edge of the ceiling plate  42  facing and extending along the outer side wall  26  of the main body  22 . Thus, the extending direction of the first hinge  48  and that of the second hinge  38  are parallel. 
     The first hinge  48  is made more easily bendable than surrounding members (here, projecting piece  50  and lid  40 ), for example, by being formed to be thinner than the surrounding members. If the first hinge  48  is thin, the first hinge  48  can bias the projecting piece  50  and the lid  40  in opening directions by integrally or unitarily molding the pressing piece  46  and the lid  40  with the projecting piece  50  and the lid  40  in an open state. 
     The projecting piece  50  is a flat plate and one principal surface thereof is held in contact with or faces the outward facing surface of the ceiling plate  42  with the lock  30  and the locked portion  52  locked to each other. At this time, the projecting piece  50  is tilted toward the second hinge  38 . In this way, the lid  40  is closed and the projecting piece  50  is tilted toward the lid  40 , and the locked portion  52  provided on the tip of the projecting piece  50  is locked to the lock portion  30  between the first and second hinges  48 ,  38 . 
     The projecting piece  50  is formed into a substantially L shape because the ceiling plate  42  is bent at an obtuse angle in the same plane and the extending directions of the first hinge  48  and the second hinge  38  are parallel and because of the position of the lock  30 . The shape of the projecting piece  50  is not so limited. The shape of the projecting piece  50  may be appropriately set if the locked portion  52  provided on the projecting piece  50  is lockable to the lock  30  provided on the main body  22 . 
     Specific shapes of the lock  30  and the locked portion  52  are described here. The lock claw  54  is the locked portion  52  and the lock recess  32 , into which the lock claw  54  is fittable, is the lock portion  30 . Specifically, the lock claw  54  constituting the locked portion  52  projects from a side edge part of the projecting piece  50  orthogonally to the principal surface of the projecting piece  50 . More specifically, the lock claw  54  projects on the principal surface of the projecting piece  50  facing the outward facing surface of the ceiling plate  42  when the projecting piece  50  is tilted in the direction toward the second hinge  38 . Further, a thick portion  54   a  is provided on a tip part of the lock claw  54  and gradually thickens from a tip side toward a base end side of the lock claw  54 . Further, a step  54   b  is created on a base end edge part of the thick portion  54   a.    
     The lock  30  includes two first frame body pieces  34  projecting on the first inner side wall portion  28   a  of the main body  22  near the terminal portion  16   a  while being spaced apart in the extending direction of the main body  22  (corresponding to the extending direction ED of the intermediate portion  14 ) and a second frame body piece  36  connecting the tips or distal portions of the first frame body pieces. In this way, a space enclosed by the first inner side wall portion  28   a  of the main body  22 , the first frame body pieces  34  and the second frame body piece  36  function as the lock recess or hole  32 . 
     A distance between the inner surfaces of the first frame body pieces  34  is equal to or longer than a width of the lock claw  54 . Here, since the projecting piece  50  and the locked portion  52  rotate about the first hinge  48  when the lock  30  and the locked portion  52  are locked, the distance between the inner surfaces of the first frame body pieces  34  is set longer than the width of the lock claw  54  so that the projecting piece  50  and the locked portion  52  are lockable while rotating. 
     Further, a distance between the outer surface of the first inner side wall portion  28   a  of the main body  22  and the inner surface of the second frame body piece  36  is set shorter than a thickness of a thickest part of the thick portion  54   a  of the lock claw  54 . 
     Note that the protector  20  is produced by being molded integrally or unitarily from the material such as resin using the mold as described above here. This causes various restrictions on the shape of the protector  20 . For example, the lid  40  and the main body  22  are biased in opening directions OD′ by the second hinge  38 . Thus, the main body  22  and the lid  40  are lifted easily. This particularly is due to integral or unitary molding with the main body portion  22  and the lid portion  40  in an open state and the like. Further, the outer side wall  26  is not provided on the side of the main body portion  22  opposite to the first inner side wall portion  28   a . Thus, it is difficult to adopt a lock structure or a hinge structure on the side opposite to the lock  30 . This is because of the presence of another part of the mold on the side opposite to the lock  30 . The restrictions as described above are caused mainly to facilitate the removal of the mold. 
     To lock the lock claw  54  and the lock recess  32 , the lid  40  first is closed to approach the main body  22  and the projecting piece  50  is brought closer to the lid  40 . This causes the lock claw  54  to be inserted gradually into the lock recess  32 . 
     As the lock claw  54  is inserted into the lock recess  32 , the thick portion  54   a  of the lock claw  54  is caught by an inner peripheral edge part of the lock recess  32 . If a force is further applied in this state, the lock claw  54  is deformed resiliently to slightly thin the thick portion  54   a  of the lock claw  54  and at least one of the first inner side wall portion  28   a  and the second frame body pieces  36  is deformed resiliently to widen the distance between the outer surface of the first inner side wall portion  28   a  of the main body  22  and the inner surface of the second frame body piece  36 . Thus, the thick portion  54   a  of the lock claw  54  is inserted into the lock recess  32 . When the thick portion  54   a  of the lock claw  54  passes over the lock recess  32 , the resilient deformation thereof is alleviated and the step  54   b  of the lock claw  54  is caught by the bottom surface  24  of the second frame body piece  36  and the lid  40  and the main body  22  are locked. 
     The lock  30  and the locked portion  52  lock the lid  40  and the main body  22  at the position of the first inner side wall portion  28   a . Thus, the lid  40  is difficult to lift relative to the main body  22 . Further, the lid  40  and the main body  22  are connected via the second hinge  38  at the position of the outer side wall  26 , the lid  40  is difficult to lift relative to the main body  22  due to a reaction force of the second hinge  38  biasing the lid  40  in the opening direction OD′. However, the lid  40  and the main body  22  are neither locked nor connected on the side opposite to the first inner side wall portion  28   a , and are lifted easily. The lid  40  is provided with the pressing piece  46  to make these parts difficult to lift. 
     Specifically, when the lock claw  54  is inserted into the lock recess  32 , the projecting piece  50  is tilted toward the ceiling plate  42  of the lid  40  while being rotated about the first hinge  48  to approach the second hinge  38  (in a direction substantially opposite to the opening direction OD). At this time, the first hinge  48  is bent and deformed resiliently. The first hinge  48  is maintained in a resiliently deformed state with the lock claw  54  and the lock recess  32  locked. Thus, a reaction force caused by the resilient deformation of the first hinge  48  is applied to the ceiling plate  42  of the lid  40  with the lock claw  54  and the lock recess  32  locked. This reaction force acts in a direction to press the ceiling plate  42 . Thus, the lift of the lid  40  relative to the main body  22  can be suppressed. 
     At this time, if the main body  22  and the lid  40  are connected via the second hinge  38  at a position distant from the lock  30  along the extending direction of the main body  22 , the lid  40  is lifted easily relative to the main body portion  22  by the reaction force of the second hinge  38 . 
     If the lock  30  and the locked portion  52  are locked between the first and the second hinges  48 ,  38  along the extending direction of the main body  22 , a reaction force caused by the resilient deformation of the pressing piece  46  acts on a side more distant from the second hinge  38  along the extending direction of the lid  40  from the first hinge  48  to the second hinge  38 . Therefore the lift of the lid  40  relative to the main body  22  can be suppressed more reliably. 
     Further, if the extending directions of the first and second hinges  48  are parallel, a reaction force of the second hinge  38  is canceled out easily by that of the first hinge  48 . This enables the lift of the lid  40  relative to the main body  22  to be suppressed more reliably. 
     The protector  20  according to the embodiment includes the main body  22  shaped along the extending direction of the member (e.g. the extending direction ED of the intermediate portion  14 ) to be protected. The lid  40  is capable of surrounding the member to be protected together with the main body  22 . The pressing piece  46  includes the first hinge  48  having the one end connected to the outward facing surface of the lid  40  and the projecting piece  50  is connected to the other end of the first hinge  48 . The lid  40  and the projecting piece  50  are biased in the opening directions OD by the first hinge  48 . The lock  30  on the main body  22  and the locked portion  52  on the projecting piece  50  and lockable with the projecting piece  50  held close to the outward facing surface of the lid  40 . Thus, the lift of the lid  40  relative to the main body  22  can be suppressed by the action of a reaction force caused by the resilient deformation of the pressing piece  46  in a direction to press the lid  40 . 
     The main body  22  and the lid  40  are connected via the second hinge  38  at the position distant from the lock  30  along the extending direction of the main body  22 . Thus, the lid  40  is lifted easily relative to the main body  22 . Even in this case, the lift of the lid  40  relative to the main body  22  can be suppressed since the reaction force caused by the resilient deformation of the pressing piece  46  acts in the direction to press the lid  40 . 
     The lock  30  and the locked portion  52  are locked between the first and second hinges  48 ,  38  along the extending direction of the main body  22 . Thus, a reaction force caused by the resilient deformation of the pressing piece  46  acts on the side more distant from the second hinge  38  along the extending direction of the lid  40 . Therefore the lift of the lid  40  relative to the main body  22  can be suppressed more reliably. 
     The extending direction of the first hinge  48  and that of the second hinge  38  are substantially parallel. Thus, the reaction force of the second hinge  38  is easily canceled out by that of the first hinge  48 . This enables the lift of the lid  40  relative to the main body  22  to be suppressed more reliably. 
     Further, since the busbar  12  is accommodated as the member to be protected, a possibility of a short circuit caused by the entrance of an external matter or the like through a clearance formed by the lift can be suppressed by suppressing the lift of the lid  40  relative to the main body  22 . 
     The outer side wall is not provided on the side of the main body opposite to the first inner side wall portion  28   a  across the accommodation space for the busbar  12  in the illustrated embodiment. However, an outer side wall may be provided on the side opposite to the first inner side wall portion  28   a . In this case, a lock, a second hinge or the like may be also provided on the outer side wall portion on the side opposite to the first inner side wall portion  28   a.    
     The lock  30  is provided between the first and second hinges  48 ,  38  with the lid  40  closed. However, the first hinge may be on a side closer to the second hinge than the lock. In this case, the projecting piece is tilted in a direction away from the second hinge to lock the lock and the locked portion. 
     The extending directions of the first hinge  48  and the second hinge  38  are substantially parallel with the lid  40  closed in the illustrated embodiment. However, the extending directions of the first hinge  48  and the second hinge  38  may not be parallel. For example, it is also considered to set the extending direction of the first hinge in a direction along the extending direction of the lid (extending direction of the intermediate portion of the busbar). In this case, the projecting piece is tilted toward the lock along a direction (width direction of the lid) orthogonal to the extending direction of the lid. 
     Although the protector  20  is molded integrally or unitarily from resin or the like in the embodiment, this is not essential. The protector  20  may be formed by combining a plurality of separately formed members. For example, the lid portion and the pressing piece may be separately formed. In this regard, the thin form of the first hinge  48  is not essential. Another configuration such as a springy hinge, i.e. a so-called spring hinge, may be adopted as the first hinge. That is, the first hinge has only to be able to bias the projecting piece in the opening direction and resiliently deformable in a direction to close the projecting piece. 
     The lid and the main body may be formed separately without being connected. In this case, a lock and a locked portion may be provided at the position of the second hinge. 
     The lock recess  32  is adopted as the lock  30  and the lock claw  54  is adopted as the locked portion  52  in the illustrated embodiment, but this is not essential. For example, a lock claw may be adopted as the lock and a lock recess may be adopted as the locked portion. 
     The protector  20  protects the busbar  12  in the illustrated embodiment, but the object to be protected is not limited to the busbar. The object to be protected by the protector may be, for example, a wire, a wiring harness or the like. 
     Note that the respective configurations described in the above embodiment and each modification can be appropriately combined unless they contradict each other. 
     Although this invention has been described in detail above, the above description is illustrative in all aspects and this invention is not limited thereby. It should be understood that unillustrated numerous modifications can be made without departing from the scope of this invention. 
     REFERENCE SIGNS 
     
         
           10  busbar module 
           12  busbar (member to be protected) 
           20  protector 
           22  main body 
           30  lock 
           38  second hinge 
           40  lid 
           46  pressing piece 
           48  first hinge 
           50  projecting piece 
           52  locked portion