Abstract:
The present invention provides a busbar laminate assembly structure. The invention includes a plurality of busbars each having a bent portion, and a plurality of terminal strips, a respective of the plurality of terminal strips depending from a respective bent portion of the busbar. Additionally, a plurality of insulation plates are provided, a respective insulation plate located above a respective busbar and adapted to electrically isolate each respective busbar. The insulation plates include a through-hole adapted to accept a terminal strip therethrough, and a fastening hole adapted to fasten a terminal strip is provided, the fastening hole being provided in the insulation plate farthest from the bent portion of the terminal strip.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a busbar laminate assembly structure to be housed in an electrical connection box, and more specifically to a busbar laminate assembly structure in which a plurality of busbars is assembled in a laminated form under an electrically isolated condition through an insulation plate. 
     2. Description of the Related Art 
     An electrical connection box is used for housing electrical equipment containing various electrical circuits and electronic components for automobiles and the like, and is also used as a connection junction for wire harnesses and the like. 
     Generally, in an electrical connection box, a busbar is housed as a wiring board connected with terminals of various electrical equipment. Such a busbar forms a laminated structure, thereby making it possible to produce complicated wiring. 
     Below follows a description of the conventional assembly structure of such busbars in reference to FIGS. 5-7. As shown in FIG. 5, a wiring board  40  is formed of first to fourth busbars  1 F to  4 F formed with certain respective wiring patterns, and first to fourth insulation plates IP 1  to IP 4  which electrically isolate respective laminates between busbars  1 F to  4 F. 
     As shown in FIGS. 5 and 6, respective terminal strips  41  to  44  are bent to a vertical direction (i.e., orthogonal to the busbars and insulation plates) at a predetermined position of respective laminate of busbars  1 F to  4 F. The length of respective terminal strips  41  and  44  are set so that the strips are positioned of the same height in a laminate assembled condition as described later. Therefore, the terminal strip  41  of the first laminate busbar  1 F is set as the shortest terminal strip while the terminal strip  44  of the fourth laminate busbar  4 F is the longest terminal strip. 
     At the position corresponding to the aforementioned respective terminal strips  41  to  44  on the first laminate insulation plate IP 1 , through-holes  51   a  to  51   d  are respectively provided. At the second laminate insulation plate IP 2 , a fastening hole  52  is provided at a position corresponding to the terminal strip  42 , while through-hole  53   a  and  53   b  are provided at the positions corresponding to respective terminal strips  43  and  44 . At the third laminate insulation plate IP 3 , a fastening hole  54  is provided at the position corresponding to the terminal strip  43 , while a through-hole  55  is provided at the position corresponding to the terminal strip  44 . At the fourth laminate insulation plate IP 4 , a fastening hole  56  is provided at the position corresponding to the terminal strip  44 . 
     The respective through-holes  51   a  to  51   d,    53   a,    53   b,  and  55  are each provided on respective laminate insulation plates IP 1  to IP 4  form a rectangular hole, with its shorter dimension t 2  being greater than the plate thickness t 1  for the aforementioned respective terminal strips  41  to  44 , thereby making it possible for respectively corresponding terminal strips  41  to  44  to easily be inserted into respective through-holes  51   a  to  51   d,    53   a,    53   b,  and  55 . In addition, the fastening hole  52 ,  54  and  56  form a tapered opening in an inserting direction for receiving respective terminal strips  42  to  44  as shown in FIG.  6 . The width of the upper edge of the fastening hole  52 ,  54 , and  56  is narrower than the plate thickness t 1  of the respective terminal strips  41  to  44 . Terminal strips  42  to  44  can thus be press-fit into respective fastening holes  52 ,  54 , and  56 . 
     As shown in FIG. 6, each laminate of busbars  1 F to  4 F is assembled in a laminated state, by press-fitting each of the terminal strips  42  to  44  into a respective fastening hole  52 ,  54  and  55 ; and by inserting respective terminal strips  41  to  44  into respective corresponding through-holes  51   a  to  51   d,    53   a,    53   b,  and  55 . In this case, the lowest portion of the base edge (i.e., the bent portion)  42 ′,  43 ′ and  44 ′ of respective terminal strips  42  to  44  is held and then fastened between the fastening holes  52 ,  54 , and  56 , respectively. 
     It is necessary to bend the terminal strips  41  to  44  in such a manner that each forms a right angle to respective laminate busbars  1 F to  4 F. Since the bending for terminal strips  41  to  44  is subjected to plastic deformation and retains a slight elastic rebound, there is a limit to the bending accuracy for the respective terminal strips  41  to  44 . Therefore, since it is difficult to bend respective terminal strips accurately to the vertical direction (i.e., orthogonal to the busbars), the normal state of terminal strips  41  to  44  has often been slightly obliquely inclined from the vertical direction. 
     For example, when the terminal strip  44  on tie fourth laminate busbar  4 F is bent under a slightly inclined state, as shown in FIG. 7, the terminal strip  44  becomes inclined by an angle θ from the original position (i.e., vertical), as illustrated with a two-dot chain line, even when in a laminate assembled condition. This inclination is caused by a shorter dimension t 2  of the respective through-holes  51   d,    53   b,  and  55  being set wider than the thickness t 1  of the terminal strip  44 , thereby contributing to the degree of freedom of the terminal strip  44  that exists in the through-holes  51   d,    53   b,  and  55 ; and the terminal strip  44  being held and then fastened only on the nearest fastening hole  56  to the bent portion. The terminal strip  44  is thus inclined by angle θ, the top edge position of terminal strip  44  comes to a position shifted by a distance d from the original position. 
     Consequently, positioning difficulties have been encountered when mounting a connector, electrical component, and the like on the terminal strip  44 . The difficulty of insertion/withdrawal of connectors, electrical components, and the like to the terminal strip becomes greater, thereby causing possible mounting failures. 
     It is thus desirable to provide a busbar laminate assembly structure capable of maintaining the bending accuracy of the terminal strip bent under the busbar laminate. 
     SUMMARY OF THE INVENTION 
     The present invention provides a busbar laminate assembly structure. The invention includes a plurality of busbars each having a bent portion, and a plurality of terminal strips, a respective terminal strip depending from a respective bent portion of each busbar. Additionally provided is a plurality of insulation plates, a respective insulation plate located above a respective busbar and adapted to electrically isolate each respective busbar. The insulation plates comprise a through-hole adapted to accept a terminal strip therethrough, and according to one aspect of the invention, a fastening hole adapted to fasten a terminal strip is provided, the fastening hole being provided on the insulation plate farthest from the bent portion of the terminal strip. Additionally, the width of the fastening hole may be greater than, less than or equal to the thickness of the terminal strip. The fastening hole may further include a tapered opening to facilitate the insertion of the terminal strip 
     According to another aspect of the invention, a protrusion is provided on the terminal strip, the projection being adapted to press-fit a terminal strip to a through-hole. 
     According to a further aspect of the invention, the projection of each terminal strip is present between a predetermined distance from the tip of the terminal strip and the bent portion. 
     Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of certain embodiments of the present invention, in which like numerals represent like elements throughout the several views of the drawings, and wherein: 
     FIG. 1 represents a sectional view showing a first embodiment of the present invention; 
     FIG.  2 ( a ) represents a perspective view showing a terminal strip of a second embodiment of the present invention; 
     FIG.  2 ( b ) represents a sectional view of the second embodiment as seen from a line A—A in FIG.  2 ( a ); 
     FIG. 3 represents a sectional view showing the second embodiment; 
     FIG. 4 represents a sectional view showing a third embodiment of the present invention; 
     FIG. 5 represents an exploded perspective view of the prior art; 
     FIG. 6 represents a sectional view of the prior art; and 
     FIG. 7 represents a sectional view of the prior art showing a single terminal strip. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings wherein like numerals represent like elements, FIG. 1 shows a first embodiment of the present invention. 
     For the same elements as the prior art configuration shown in FIGS. 5-7, the same reference numerals are used, thereby omitting the necessity of further description. 
     As shown in FIG. 1, a wiring board  10  is provided having first to fourth laminate busbars  1 F to  4 F and first to fourth laminate insulation plates IP 1  to IP 4  in the same manner as the aforementioned prior art configuration of FIGS. 5-8. At the position corresponding to each of terminal strips  41  to  44  of each laminate of busbars  1 F to  4 F, fastening holes  11   a  to  11   d,  are respectively provided on the first insulation plate IP 1 . Each fastening hole  11   a  to  11   d  forms a tapered opening in an insertion direction of each terminal strip  41  to  44 . Each laminate of busbars  1 F to  4 F and each laminate of insulation plates IP 1  to IP 4  is assembled in a laminated condition in the same manner as the aforementioned prior art configuration. In the first embodiment, on the first laminate insulation plate IP 1 , assembly is carried out by press-fitting each terminal strips  41  to  44  through respective fastening holes  11   a  to  11   d,  each corresponding to a respective terminal strip  41  to  44 . Since each of the fastening holes  11   a  to  11   d  forms a tapered opening in the insertion direction of each of terminal strips  41  to  44 , even if each of terminal strips  41  to  44  is bent in an inclined state to the vertical direction (i.e., orthogonal to the busbars), the terminal strips can easily be press-fit, as the terminal strips are guided along the tapered surface of fastening holes  11   a - 11   d.    
     When assembled, the terminal strip  41  of the first laminate busbar  1 F is held and fastened in the fastening hole  11   a  of the first laminate insulation plate IP 1 . In addition, the terminal strip  42  of the second laminate busbar  2 F is held and fastened in both the fastening hole  11   b  of the first laminate insulation plate IP 1  and the fastening hole  52  of the second laminate insulation plate IP 2 . Similarly, the terminal strip  43  of the third laminate busbar  3 F is held and fastened in both the fastening hole  11   c  of the first laminate insulation plate IP 1  and the fastening hole  54  of the third laminate insulation plate IP 3 . The terminal strip  44  of the fourth laminate busbar  4 F is held and fastened in both the fastening hole  11   d  of the first laminate insulation plate IP 1  and the fastening hole  56  of the fourth laminate insulation plate IP 4 . 
     Therefore, with the each of terminal strips  41  to  44  held and fastened in each of fastening holes  11   a  to  11   d  of the first laminate insulation plate IP 1 , and respective busbars  1 F to  4 F and each insulation plates IP 1  to IP 4  are assembled in a laminated state, the separation of the insulation plate is prevented. As a result, after assembling a wiring board  10  in a laminated state at a production line, separation of the busbars  1 F to  4 F and insulation plates IP 1  to IP 4  is prevented when transferring the wiring board  10  to the next assembly process. Therefore, control of the laminated wiring board  10  is facilitated. 
     Furthermore, the terminal strip  44  is held and fastened between two fastening holes  56  and  11   d,  namely, a fastening hole  56  of the fourth laminate insulation plate IP 4  positioned nearest to the bent portion, and a fastening hole  11   d  of the first laminate insulation plate IP 1  positioned furthest from the bent portion. Therefore, even when the terminal strip  44  is bent in an oblique state from the vertical position, the terminal strip  44  is rectified from the oblique state to the vertical direction with high accuracy by respective fastening holes  56  and  11   d.  Furthermore, other terminal strips  41  to  43  are rectified from an oblique state to the vertical directions with high accuracy by being held and fastened by each of the fastening holes  11   a  to  11   c,    52 , and  54 . 
     Since the terminal strip  41  is held and fastened solely by the fastening hole  11   a,  the rectifying force to the vertical direction of the terminal strip  41  at the fastening hole  11   a  is small relative to the required rectifying force of the other terminal strips. However, terminal strip length becomes progressively smaller from the terminal strip  44  to terminal strip  41 . Therefore, even when each of the terminal strips  41  to  44  is inclined to an oblique state with the same angle, the shifted amounts at the tip is the least at terminal strip  41 . Therefore, all respective terminal strips  41  to  44  may be maintained in the vertical direction with high accuracy, even though terminal strip  41  is held and fastened solely by the fastening hole  11   a.    
     Each of the terminal strips  41  to  44  is held and fastened under the laminated assembly of the wiring board  10  in the corresponding fastening holes  11   a  to  11   d  respectively. The bending accuracy of each of terminal strips  41  to  44  is thus accurately maintained under the same condition. Therefore, electronic components and the like may be easily positioned when mounting such components to the respective terminal strips  41  to  44 . Also, the resistance for insertion and withdrawal is reduced for a connectors or electronic components mounted to the terminal strips  41  to  44 , thereby reducing the possibility of mounting failures of electronic components and the like. 
     For instance, in an assembly or production line, after mounting and laminating a wiring board  10 , possible separation of the busbars  1 F to  4 F from insulation plates IP 1  to IP 4  is reduced during transport to the next assembly process. Furthermore, handling of the laminated wiring board  10  is facilitated. 
     Each of the fastening holes  11   a  to  11   d,    52 ,  54 , and  56  form a tapered portion facing the insertion direction of each of the terminal strips  41  to  44 . Thus, when each of the terminal strips  41  to  44  is bent in an obliquely inclined state from the vertical direction, insertion of the terminal strips can easily be made through each of the tapered fastening holes  11   a  to  11   d,    52 ,  54  and  56 . 
     Referring to FIGS.  2 ( a ) and ( b ) and FIG. 3, a second embodiment of the present invention is shown. 
     To further assist in the securing of the terminal strips  41  to  44  to the respective fastening holes  11   a  to  11   d,  it is preferable that the width of the fastening holes be no greater than the thickness of the terminal strips. Alternatively, the width of the fastening holes  11   a  to  11   d  may be less than the thickness of the terminal strips  41  to  44 . Furthermore, it may also be preferable that the area of the fastening holes be no greater than the cross-sectional area of the terminal strips. Alternatively, the area of the fastening holes  11   a  to  11   d  may be less than the cross-sectional of the terminal strips  41  to  44 . 
     As shown in FIGS.  2 ( a ) and ( b ), a parallel protrusion  31  is provided on the bent portion at a predetermined distance from the tip of the terminal strip  43  of the third laminate busbar  3 F. The protrusion  31  is formed by punching the terminal strip  43  with a press or the like, and the total thickness t 3  of the terminal strip  43  can be set to the same thickness or slightly thicker than width of each of the through-holes  53   a ,  53   b,  and  55  in the first embodiment. In addition, on the upper edge of the protrusion  31 , a tapered surface  32  is provided. 
     As shown in FIG. 3, at the position corresponding to the terminal strip  43  in the first to third laminate insulation plates IP 1  to IP 3 , through-holes  33  to  35  are provided. These through holes  33  to  35  are similarly configured to through-holes  53   a ,  53   b , and  55  of the first embodiment. The terminal strip  43  is inserted successively through each through-hole  33  to  35  without clearance. Even if the terminal strip  43  is bent in an obliquely inclined state from the vertical position, the terminal strip  43  can be accurately rectified to the vertical direction by each through-hole  33  to  35 . 
     When the terminal strip  43  is bent in a state obliquely inclined from the vertical position, the terminal strip may be easily inserted into respective through-holes  33  to  35  because the protrusion  31  is riot provided on the tip of the terminal strip  43 . Furthermore, the upper end of the protrusion  31  is provided with a tapered surface  32 . The terminal strip  43  is inserted through the through-holes  33  to  35  and is guided by the tapered surface  32 . Therefore, even when the terminal strip  43  is bent in a state obliquely inclined from the vertical position, insertion through the through-holes  33  to  35  of the terminal strip  43  is facilitated. 
     Description is made only for the terminal strip  43  of the third laminate busbar  3 F, but because the structure of each of terminal strips  41 ,  42 , and  44  of other respective laminate busbars  1 F,  2 F and  4 F is structurally identical to the terminal strip  43 , description of terminal strips  41 ,  42  and  44  is thus omitted. In addition, at the position corresponding to each of the terminal strips  41 ,  42  and  44  on respective insulation plates IP 1  to IP 4 , through-holes (not shown) structurally identical to through-holes  33  to  35  are provided. 
     When each terminal strip  41  to  44  is bent in a state obliquely inclined from the vertical direction, the bending accuracy of each terminal strip  41  to  44  is maintained in the laminated wiring board  10  because the oblique inclination is rectified to the vertical direction by each of the through-holes  33  to  35  (through-holes corresponding to terminal strips  41 ,  42  and  44  are not shown). Therefore, positioning is facilitated when mounting electronic components and the like to the terminal strips  41  to  44 . The resistance to insertion/withdrawal of connectors, electrical components, and the like to the terminal strips  41  to  44  is reduced, thereby reducing mounting failures of electrical components and the like. 
     When a total thickness t 3  of the terminal strip  43  is slightly greater than the width of the through-holes  33  to  35 , it becomes difficult to separate each laminate of busbars  1 F to  4 F from each laminate of insulation plates IP 1  to IP 4  of a laminated board  10 . It also becomes difficult to separate the laminate of busbars  1 F to  4 F from each laminate of insulation plates IP 1  to IP 4  when the cross sectional area of the terminal strip  43  is slightly greater than the width of the through-holes  33  to  35 . Therefore, after laminated assembly at a production line, for example, possible separation between the busbars  1 F to  4 F and the insulation plates IP 1  to IP 4  is reduced when transporting the board  10  to the next assembly process. Moreover, control of the laminated wiring board  10  is facilitated. 
     Each of the aforementioned embodiments can be modified as follows: 
     In the first embodiment, each of the fastening holes  11   a  to  11   d  is respectively provided at the position corresponding to respective terminal strips  41  to  44  in the first laminate insulation plate IP 1 . As shown in FIG. 4, each of these fastening holes  11   a  to  11   d  may be embodied as through-holes  21   a  to  21   d,  and each of the through-holes  53   a  and  53   b  of the second laminate insulation plate IP 2  may be embodied as fastening holes  22   a  and  22   b.  For example, with this modification, if the first laminate insulation plate IP 1  is not a component of the wiring board  10  but is instead a housing component or the like, of electronic components separately formed for an electronic connection box (not shown), separation of the housing board or the like from the wiring board  10  can easily be made, thereby facilitating the performance of maintenance for the wiring board  10 . 
     In the first embodiment, the through-holes  53   a,    53   b,  and  55  may be changed to fastening holes  11 ,  52 ,  54 ,  56 . In the first and second embodiments, the tip of each terminal strip  41  to  44  may be formed with a taper. 
     When the fastening holes  11 ,  52 ,  54 ,  56  have a tapered opening in an insertion direction of the terminal strip  41  to  44 , the terminal strip can easily be inserted into a fastening hole. The busbar laminate assembly structure may have a tapered surface  32  on the edge of the tip side of the terminal strip  41  to  44  on the protrusion  31 , whereby the terminal strip can be easily inserted into a fastening hole. 
     The terminal strip  41  to  44  can be held and fastened by a fastening hole  11 ,  52 ,  54 ,  56 , making it possible to maintain high bending accuracy of the laminated terminal strip. Additionally, insertion into a through-hole  21   a - 21   d,    33 ,  34 ,  35 ,  53   a ,  53   b,    55  can easily be made even if the terminal strip  41  to  44  is bent in a condition obliquely inclined from the vertical position relative to the busbar  1 F to  4 F. 
     It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to certain embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. 
     Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. 
     The present disclosure relates to subject matter contained in Japanese Utility Model Application No. JP 10-63084, filed Mar. 13, 1998, which is expressly incorporated herein by reference in its entirety.