JP2000201417A - Wiring board assembly and method of manufacturing the same - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To reduce costs and prevent leakage from bus bars. A plurality of bus bars (3, 4) arranged in parallel on wiring boards (1) and (2) have terminals (5) to (8) at opposite ends, and a bus bar (4) of a second-layer wiring board (2) is a first-layer wiring board. The terminal 5 on one side of the wiring board 1 and the terminal 8 on the other side of the wiring board 2, and the terminal 6 on the other side of the wiring board 1 and one side of the wiring board 2 Are the same length. Terminals 5 and 6 are formed on one end and the other end of the bus bar 3 so as to protrude in opposite directions, and the bus bar 3 is provided on the first-layer wiring board 1. 2 is provided.
A part of the bus bar 3 (4) was exposed in the recess of the wiring board 1 (2), and a protruding portion engaging with the recess was formed on the wiring board 2 (1). Each protruding portion of each of the wiring boards 1 and 2 is located adjacent to each recess. The recess and the protrusion are tapered. The electric wire 12 is brought into point contact with the projection for resistance welding provided on the bus bar 3 for welding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wiring board assembly in which a plurality of wiring boards having a plurality of bus bars are stacked and housed in an electric junction box or the like, and a method of manufacturing the same.

[0002]

2. Description of the Related Art FIG. 11 shows an example of a conventional wiring board assembly. In the wiring board assembly 80, a strip-shaped wiring board 81 is folded in a bellows shape, and terminals 82 are pressed and connected to electric wires 83 of the wiring board 81 at upper and lower terminals of the wiring board 81.

The electric wires 83 are provided on the surface of the wiring board 81 in parallel. The wiring board 81 is folded in three so that the electric wires 83 are located on the upper surface 81a and the lower surface 81b of the folded wiring board 81. Each terminal 82 has a tab 84 on one side,
The other end has a press contact portion 85, and the press contact portion 85 is pressed against the electric wire 83. The wiring board 81 and the terminals 82 constitute a wiring board assembly 80. The wiring board assembly 80 is accommodated in an electric junction box (not shown) in a folded state. The tab portions 84 are arranged in upper and lower connector portions (not shown) of the electric connection box.

However, in the above-mentioned conventional structure, the terminal 82 can be arranged only on the upper surface 81a and the lower surface 81b of the wiring board 81, that is, only at the terminal portion of the wiring board 81. Is limited by the width of the wiring board 81, that is, the number of the electric wires 83.

Accordingly, the present applicant has filed Japanese Patent Application No. 10-2366.
In No. 50, as shown in FIG. 12, wiring boards 87 to 89 have a three-layer structure, bus bars 90 to 92 formed integrally with wiring boards 87 to 89, and electric wires routed on wiring boards 87 to 89. As shown in FIG. 13, the wires 93 and 93 are connected by resistance welding using the electrodes 94 and 95, and the electric wires 93 and terminals (not shown) are press-connected to the wiring boards 87 and 89 at longitudinally intermediate portions. A wiring board assembly 97 and a method of manufacturing the same have been proposed. In FIG. 13, the bus bar 90 is connected to the connection hole 9.
6 and is exposed.

[0006]

However, in the above-described conventional structure and method, the bus bars 90 to 92 can be punched in various shapes depending on, for example, the length of the terminal tab terminal (not shown). The cost of the molding die such as punches and dies increases, and the wiring board assembly 9
7 has a problem that the cost increases.

Further, when the wiring boards 87 to 89 are stacked in a plurality of layers, water 98 or dust due to, for example, dew condensation accumulates in the concave connection holes (more precisely, the connection holes) 96, and the wiring boards 87 and 88.
The exposed portions of the bus bars 90, 91, in particular, the exposed surfaces 90b, 91b opposite to the welding surfaces 90a, 91a with the electric wires 93 may cause a short circuit or leak due to the water 98 or the like.

Further, when the electric wire 93 is resistance-welded to the bus bar 90, since the bus bar 90 and the electric wire 93 are in line contact, the welding current is diffused, the welding boundary surface is not stabilized, and the welding strength is reduced. There was a problem of doing.

In view of the above points, the present invention reduces the cost of stamping and forming a bus bar, thereby preventing an increase in cost, and reliably preventing a leak or a short circuit from an exposed portion of a bus bar of a wiring board. It is another object of the present invention to provide a means that can reliably weld an electric wire to a bus bar.

[0010]

In order to achieve the above-mentioned object, the present invention provides a plurality of wiring boards in which a plurality of bus bars are provided in parallel, and the bus bars have oppositely oriented terminals at both ends. In the wiring board assembly in which the plurality of wiring boards are stacked, the bus bar of the second layer wiring board has a shape obtained by inverting the bus bar of the first layer wiring board, and the wiring of the first layer The terminal on one side of the board and the terminal on the other side of the wiring board of the second layer have the same length, and the terminal on the other side of the wiring board of the first layer and one side of the wiring board on the second layer A wiring board assembly having the same length as the terminals is employed (claim 1). Also, terminals are formed on one end and the other end of the bus bar in opposite directions, respectively, and the bus bar is provided on the first layer wiring board, and the bus bar having the same shape as the bus bar is inverted to form a second layer wiring board. The manufacturing method of the provided wiring board assembly is also adopted (claim 2). The first layer and / or
Alternatively, a structure is also effective in which a part of the bus bar is exposed in a concave portion of the second-layer wiring board, and a protrusion engaging with the concave portion is formed on the second-layer and / or first-layer wiring board. (Claim 3). A bus bar is provided inside the wiring board, a part of the bus bar is exposed in a concave portion of the wiring board, and in a wiring board assembly in which a plurality of the wiring boards are stacked, the wiring board includes A wiring board assembly having a protruding portion that engages with the concave portion is also employed (claim 4). The protruding portion of the first-layer wiring board and the protruding portion of the second-layer wiring board are positioned adjacent to each recess of the first-layer wiring board and the second-layer wiring board. Is also effective (claim 5). It is also effective that the concave portion and the protruding portion are formed in a tapered shape. Further, a structure is also effective in which a projection for resistance welding is provided on the bus bar in a connection hole of the wiring board, and an electric wire is point-contacted with the projection to perform resistance welding. In addition, a method for providing resistance bushing to the bus bar according to claim 2 and effecting resistance welding between the bus bar and the wire in a state where the wire is point-contacted to the protrusion in the connection hole of the wiring board is also effective. (Claim 8).

[0011]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows an electric junction box including an embodiment of a wiring board connector according to the present invention.

As shown in FIG. 2, the wiring board assembly C ₁ has a wiring board 1 of the first layer and a wiring board 2 of the second layer which are vertically overlapped with each other, and the bus bar 3 of each of the wiring boards 1 and 2. , 4 with tab terminals (terminals) 5 to 8 facing upward on one side of each wiring board 1, 2.
The wiring board 1 of the first layer is protruded downward on the other side.
The length of the upward tab terminal 5 and the length of the downward tab terminal 8 of the second layer wiring board 2 are set to be the same, and the length of the downward tab terminal 6 of the first layer wiring board 1 The length of the upward tab terminal 7 of the wiring board 2 of the second layer is set to be the same, so that the bus bars 3 and 4 of the wiring boards 1 and 2 can be commonly used.

A plurality of busbars 3 and 4 are insert-molded linearly and in parallel in the transverse direction of insulating substrates 9 and 10 made of synthetic resin, which are the base bodies of the wiring boards 1 and 2. Portions protrude from both end surfaces 11 (FIG. 2) of the insulating substrates 9 and 10, and tab terminals 5 are provided at both ends of the bus bars 3 and 4.
To 8 are formed. Busbars 3, 4 and insulating substrate 9,
10 constitute wiring boards 1 and 2. First layer wiring board 1
The upward tab terminal 5 and the downward tab terminal 8 of the second layer wiring board 2 are short, and the downward tab terminal 6 of the first layer wiring board 1 and the upward tab terminal of the second layer wiring board 2 are short. 7 is set to be long. In the state where both wiring boards 1 and 2 are stacked, the positions (heights) of the tips of the upward tab terminals 5 and 7 are the same, and the positions (heights) of the tips of the downward tab terminals 6 and 8.
Is the same.

As shown in FIG. 2, each bus bar 3, 4 is arranged at the center of the wiring boards 1, 2 in the thickness direction. Both wiring boards 1,
2 have the same thickness. Bus bar 3 of first layer wiring board 1
(Hereinafter, referred to as a first-layer bus bar) and a bus bar 4 (hereinafter, referred to as a second-layer bus bar) of the second-layer wiring board 2 are separated by a thickness of the wiring board 1 (or 2). The projecting lengths of the tab terminals 5, 7 (or 6, 8) of the 3, 4 are different by the thickness (dimension T) of the wiring board 1 (or 2). The bus bar 4 (3) of the second layer (or the first layer) is obtained by inverting and using a bus bar having the same shape as the bus bar 3 (4) of the first layer (or the second layer). even manufacturing process of the plate assembly C ₁ is effective.

The upper surface of the first wiring board 1 and the second wiring board 2
A plurality of electric wires 12 are routed in a direction orthogonal to the bus bars 3 and 4 on the lower surface of the wire. The electric wire 12 is connected to both wiring boards 1 and 2
And bends at the front end side. The first-layer wiring board 1 uses the bent portion 12a of the electric wire 12 as a hinge, and the second-layer wiring board 2
It is in a state of being inverted and placed on. The electric wire 12 is a covered electric wire, an enameled wire, or the like.

In the middle portion of the first layer wiring board 1, a plurality of pairs of through-holes 15 are formed in parallel with each other to engage the press-contact portions 14 of the standard tab terminals 13 for connection. 15, the wire 12 is cut, and the pressure contact portion 14 is attached to the end of the wire 12.
Is pressed. A through hole 18 for a standard holding terminal 16 for fuse connection is formed near the rear end of the first-layer wiring board 1, and a press-contact portion 17 of the holding terminal 16 is connected to the electric wire 12.
Is pressed against.

At the rear of the second-layer wiring board 2, a sub-wiring 2 for power supply having the same height as the first-layer wiring board 1 is provided via a step 19.
0 are integrally formed. A bus bar 21 for a power supply is arranged in the sub wiring portion 20. A bus bar 21 for power supply includes a tab terminal 22 for power reception and upper and lower clamping terminals 23 and 2 for power supply.
And 4. The electric wire 12 extends to the lower surface of the sub-wiring portion 20.
Are arranged, and the press contact portion 26 of the holding terminal 25 for the relay is pressed against the electric wire 12.

The circuit board assembly C ₁ is constituted by the two wiring boards 1 and 2 and the wire 12 and the bus bar 21 for power supply and the terminals 13,16,25. Circuit board assembly C ₁ is accommodated in the lower cover 27 made of synthetic resin, the upper cover 28 is Kutsugae設from the top of the circuit board assembly C _1. The upward tab terminals 5, 7 of the bus bars 3, 4 are connected to the connector housing 29 of the upper cover 28.
The tab terminals 6 and 8 facing downward are accommodated in the lower cover 27.
Are housed in the connector housings 30 and 30 and constitute connectors. The tab terminal 13 pressed into contact with the electric wire 12 is housed in the connector housing 31 of the upper cover 28,
The holding terminal 16 and the holding terminal 23 of the power supply bus bar 21 are housed in the fuse housing 32. Wiring board assembly C ₁
Electrical connection box E ₁ is constituted by an upper cover 28 and lower cover 27 and. The configuration is the same as that of Japanese Patent Application No. 10-236650 except that two wiring boards 1 and 2 are used and the bus bars 3 and 4 including the tab terminals 5 to 8 are shared.

As shown in FIG. 3 (only the first layer wiring board 1 is shown), connection holes 33 and cutting holes 34 exposing the bus bar 3 are formed in each of the wiring boards 1 and 2. Required connection hole 3
3, the electric wire 12 is welded to the exposed portion 3a of the bus bar 3,
The bus bar 3 is cut in the required cutting hole 34. The cutting hole 34 can be used as the connection hole 33. FIG.
, The bus bar 3 is integrated with the chain portion 35,
By cutting the chain portion 35 of the chain bus bar 36, a plurality of bus bars 3 are formed. The chain bus bar 36 is in a state punched and formed by a die.

The chain bus bar 36 is commonly used for the first-layer wiring board 1 and the second-layer wiring board 2 (FIG. 1). Accordingly, only one type of chain bus bar 36 (if punched) is required, which is extremely economical. Of course, a plurality of busbars 3 having the same shape are commonly used for the first-layer wiring board 1 and the second-layer wiring board 2 without using the chain portion 35 (insert molding).
You can also.

As shown in FIG. 4, the bus bar 3
The welding of the exposed portion 3a and the electric wire 12 in FIG. 3 is performed by a pair of upper and lower electrodes 37 and 38. At this time, as a means for filling a gap in the plate thickness direction in the connection hole 33, a configuration of a concave portion and a protruding portion shown in FIG. 10 described later can be applied.

As shown in FIGS. 5 and 6, a projection 79 is provided on the exposed portion 3a of the bus bar 3 exposed in each connection hole 33 of the wiring board 1, and the electric wire 12 is brought into contact with the projection 79. The bus bar 3 and the electric wire 12 can be resistance-welded between the electrodes 37 and 38.

The projection 79 is formed in a substantially hemispherical bulging shape, and the bus bar 3 has a substantially hemispherical groove 78 on the back side of the projection 79.
(FIG. 6) is formed. The projection 79 is provided on the chain bus bar 36.
Is preferably formed when punching from a metal plate (not shown). However, as shown in FIG.
6 can also be formed after molding.
The projection 79 has a small diameter of about １ ／ of the width of the bus bar 3. In the embodiment shown in FIGS.
Is welded to the bus bar 3 from above, but it is of course possible to provide a projection 79 on the lower surface side of the exposed portion 3a of the bus bar 3 and weld the electric wire 12 from below the wiring board 1 as shown in FIG. .

The electric wire 12 is placed orthogonally to the bus bar 3 in the width direction of the bus bar 3, and extends over the gap 76 between the inner surface 33 a (FIG. 6) of the connection hole 33 and the side surface 77 of the bus bar 3. Touching the surface of By placing the electric wire 12 in the width direction of the bus bar 3, unnecessary contact between the electric wire 12 and the bus bar 3 is prevented as compared with the case where the electric wire 12 is arranged in the longitudinal direction of the bus bar 3. The electric wire 12 is the protrusion 7 of the bus bar 3
Contact with only 9 (point contact). In that state, the upper and lower electrodes 3
7, 38 (FIG. 6), resistance welding is performed.

Since resistance welding is performed in a state where the electric wire 12 is in point contact with the projection 79, current is concentrated on the projection 79, and the welding boundary surface is stabilized. That is, the diffusion of the welding current in the longitudinal direction of the electric wire 12 does not occur as in the related art, and the penetration is concentrated at one point, whereby insufficient penetration is eliminated, and the welding strength and the reliability of the electrical connection are improved.

Further, when the bus bar 3 is insert-molded into the wiring board 1, the projection 79 of the bus bar 3 in the connection hole 33 is used as a positioning portion for a molding die (not shown). An engagement hole is provided), and the positional accuracy of the bus bar 3 with respect to the wiring board 1 is improved.

In FIG. 5, reference numerals 5 and 6 denote tab terminals of the bus bar 3. The welding structure and the welding method of FIGS. 5 and 6 can be applied to the connection between the bus bars 46 and 48 and the electric wire 51 in the embodiment of FIG.

FIGS. 7 and 8 show an electric junction box including another embodiment of the wiring board assembly according to the present invention. In FIG. 7, reference numerals 41 and 42 denote wiring boards stacked in two layers,
Reference numeral 3 denotes a power supply bus bar disposed near one end of the first-layer wiring board 41, 44 denotes an upper cover, and 45 denotes a lower cover.

In this embodiment, the wiring board 42 of the second layer is formed larger than the wiring board 41 of the first layer,
1, a tab terminal (terminal) 47 of a standard bus bar 46 (FIG. 8) is arranged upward, and the first layer wiring board 4
The tab terminals (terminals) 4 of the standard bus bar 48 (FIG. 8) are located near one side of the wiring board 42 of the second layer protruding outward from
9 (FIG. 7) are arranged upward, and both tab terminals 47, 49
Are arranged in parallel and housed in the connector housing 50 of the upper cover 44. A plurality of electric wires 51 are continuously arranged in parallel from the upper surface of the first layer wiring board 41 to the lower surface of the second layer wiring board 42.

On one end side of the first layer wiring board 41, that is, on the side opposite to the bent portion 51a of the electric wire 51, the clamping terminal 52 is opposed to the tip of the electric wire 51, for example, the second layer wiring board 42.
Are provided to pass through. As shown in FIG. 8, the press-contact portion 54 of the standard hold-down terminal 53 is connected to the electric wire 51 by press-contact facing the hold-down terminal 52. Each of the clamping terminals 52 and 53 and the tab terminal 55 of the power supply bus bar 43 are located in the fuse accommodating portion 56 and are connected to the fuse 57.

The downward holding terminal 58 of the power supply bus bar 43 penetrates both wiring boards 41 and 42 and is located, for example, in a relay connection portion 59 of the lower cover 45. The upwardly-facing power receiving tab terminal 60 of the power supply bus bar 43 is located in the connector housing 61 of the upper cover 44. On the other side of the lower cover 45, a connector housing 63 for accommodating the tab terminals (terminals) 62 of the wiring board 42 of the second layer in FIG. Layer wiring board 42
A standard holding terminal 65 for connecting the standard tab terminal 64 is disposed on the connector housing 66.

As shown in FIG. 8, in a state where the two wiring boards 41 and 42 are arranged in front and back in parallel on one plane, a plurality of electric wires 51 are routed linearly on each of the wiring boards 41 and 42. Is done. A plurality of standard bus bars 46, 48 are integrally formed on each of the wiring boards 41, 42 in a direction orthogonal to the electric wires 51,
The electric wires 51 and the bus bars 46 and 48 are arranged in a matrix.

The bus bar 46 of the first-layer wiring board 41 (hereinafter referred to as the first-layer bus bar) is provided with one end of the tab terminal 4 facing upward.
7 and a tab terminal (terminal) 67 at the other end downward. The bus bar 42 of the second-layer wiring board (hereinafter referred to as the second-layer bus bar) has a tab terminal 49 at one end downward and a tab terminal 62 at the other end upward. The tab terminals 47, 49, 62, 67 project at right angles from the upper and lower surfaces of the wiring boards 41, 42. As compared with the previous example, the tab terminals 47, 49, 62, 67 are directly supported by the insulating substrates 68, 69, which are the bases of the wiring boards 41, 42, so that the tab terminals 47, 49, 62, 67 are connected. Strength is increasing.

In this embodiment, the wiring board 42 of the second layer is formed wider than the wiring board 41 of the first layer, and the bus bar 48 of the second layer is shifted from the bus bar 46 of the first layer in the longitudinal direction of the bus bar. Are located. Thereby, the wiring board 4 of FIG.
The tab terminals 47 of the first-layer bus bar 46 (FIG. 8) and the tab terminals 49 of the second-layer bus bar 48 (FIG. 8) are opposed in parallel in the longitudinal direction of the bus bar without collision in the superposed state of the bus bars 1 and 42. To position. The tab terminals 67 pass through the insulating substrate 69. In this case, the bus bars 46 of the first layer and the bus bars 48 of the second layer are commonly used with the same shape and the same length being inverted as in the previous example. This configuration is a circuit board assembly C
It is also effective as the manufacturing method of ₂ .

The second-layer bus bar 48 can be set longer than the first-layer bus bar 46. In this case, the tab terminal 67 of the first-layer bus bar 46 and the second-layer bus bar 48 It is necessary to escape the tab terminal 67 so as not to interfere with the terminal. In this case, at least two types of standard bus bars 46 and 48 are required.
Only the lengths of the tab terminals 47 and 4 differ.
Since the shapes of 9, 62 and 67 are the same, the die cost required for the punch forming is not so high.

In FIG. 8, the wiring board 42 of the second layer is rotated about the crossing portion (the part to be bent) 51a of the electric wire 51 as a fulcrum as shown by the arrow A to overlap the lower surface side of the wiring board 41 of the first layer. it is, obtain a wiring board assembly C ₂ in FIG. Electrical connection box E ₂ is composed of a circuit board assembly C ₂ and the upper cover 44 and lower cover 45.

FIG. 9 shows an embodiment of the connection structure between the standard bus bars 46 and 48 and the electric wire 51. The busbars 46 and 48 are not limited to those extending through the electric wire 51, and those arranged on one side of the electric wire 51.
8c. In this case, the bus bars 48b, 48
Although c has upward or downward tab terminals 62 and 49, by inverting one bus bar 48b, the other bus bar 48c can be obtained, and the common use of the bus bar 48b is possible. Of course, it is also possible to obtain the bus bar 48 by inverting the bus bar 46.

The bus bars 46 and 48 are located in the middle portion in the longitudinal direction, and the bus bars 48b and 48c are located at the tab terminals 49 and 6.
2 are welded to the electric wires 51 at the opposite ends. The welding method is the same as the resistance welding using the electrodes 37 and 38 in FIG. In FIG. 9, reference numeral 53 denotes a standard pin terminal having a press contact portion 54 and a pin portion (53), 64 denotes a standard tab terminal having a press contact portion 70 and a tab portion (64), and both are electric wires 51. Is pressed against. Tab terminal 64
Are arranged in four rows in this example. Each bus bar 46, 48, 4
The structure shown in FIG. 10 is applied to the welded portion between 8b, 48c and the electric wire 51.

FIG. 10 shows, for example, a cross section taken along the line AA of FIG. 7, in which the welded portions between the bus bars 46, 48 of the wiring boards 41, 42 of the first and second layers and the electric wires 51 are made of synthetic resin. Connection holes (concave portions) 71 in insulating substrates 68 and 69 made of
Exactly protrusion opposed to the exposed surface 46a _1, 48a ₁ of the bus bars 46, 48 in the connecting hole (recess) 71 72 73
Are formed, and the bus bars 4 are formed by the projections 72 and 73.
₆ , 48 exposed surfaces 46a ₁ , 48a ₁ and insulating substrate 68,
The recess (concave portion) between the busbars 46 and 4 is prevented by blocking the recess (recess) between the busbars 46 and 4.
Leakage from the exposed surfaces 46a ₁ and 48a _{1 of} 8 and short circuit between the bus bars 46 and 48 are prevented.

The bus bars 46, 48 are provided on insulating substrates 68, 69.
The upper and lower surfaces of the bus bars 46 and 48 are exposed in the connection hole 71 in the thickness direction of the first wiring board 4.
Wire 51 on the upper surface 46a ₂ of the bus bar 46 in 1 are welded, the lower surface of the wiring board 42 in the bus bar 48 of the second layer 48a
_An electric wire 51 is welded to ₂ . This is because the two wiring boards 41 and 42 are arranged in a plane as shown in FIG.
Is welded to the bus bars 46 and 48, and the wiring board 42 of the second layer is inverted as shown by the arrow A to be laminated on the wiring board 41 of the first layer.

[0041] In FIG. 10, lower surface (exposed surface) of the first layer of the bus bar 46 46a ₁ and the upper surface (exposed surface) 48a ₁ of the bus bar 48 of the second layer are completely exposed, occurs leakage or short circuit While the easy state, the lower surface (exposed surface) 46a ₁ of the first layer of the bus bar 46 upward projecting portion 73 is adjacent the second layer of insulating substrate 69, or contact located, the bus bar of the second layer the top surface (exposed surface) 48a ₁ 48 proximate the downward projecting portion 72 of the insulating substrate 68 of the first layer, or in contact with that position, the respective bus bars 46, 48 in between both circuit boards 41 and 42 Exposed surfaces 46a ₁ , 48a ₁
Is covered and protected, and the dents below or above the exposed surfaces 46a ₁ and 48a ₁ are eliminated, thereby preventing accumulation of water, dust, and the like.

The protruding portions 72 and 73 are provided adjacent to each other on the left and right sides, and the first layer wiring board 41 and the second layer wiring board 42
Each of the adjacent connection holes 71, 71 is not filled with water continuously. The connection hole 71 is the connection hole 33 in FIG.
The bus bars 46 and 48 are tightly attached or fixed to the insulating substrates 68 and 69 without gaps. The tapered connection hole 71 is preferably formed at the same time as the insert molding of the bus bars 46, 48. The connection hole 71 is vertically partitioned by the bus bar 46 (48) to form a recess or a depression.

In this embodiment, the projections 72 and 73 are formed in a trapezoidal longitudinal section in conformity with the shape of the connection hole 71, and have tapered surfaces 72a and 73a on both sides. Positioning is easy. The protrusions 72 and 73 are engaged with the respective connection holes 71 so that both the wiring boards 4
Positioning of the first and second members 42 and prevention of misalignment in the length direction and the width direction are performed.

When the connection hole 33 is formed in a straight circular shape as shown in FIG.
It is formed in a short columnar shape according to. When the connection holes 71 of the upper and lower wiring boards 41 and 42 are not close to each other, it is possible to provide the protruding portion 72 only on one of the wiring boards 41 or 42.

[0045]

As described above, according to the first and second aspects of the present invention, by inverting the bus bar in each wiring board and commonly using the bus bar, for example, each of the first layer and the second layer in the connector housing is provided. Wiring boards can be positioned at the same height, and the terminals can be positioned facing each other in parallel. Low-cost wiring can be achieved by using a common busbar molding die without impairing the dimensional quality of the terminals. A plate assembly can be obtained.

According to the third and fourth aspects of the present invention,
For example, when the protrusion of the other wiring board is engaged with the recess of one wiring board, the space of the recess is filled with the protrusion,
Accumulation of water, dust and the like in the recess is prevented. This prevents leakage or short circuit from the exposed portion of the bus bar in the recess. In addition, when the protruding portion comes into contact with the exposed portion of the bus bar, the exposed portion is reliably insulated, thereby preventing leakage and short circuit. Further, according to the invention of claim 5, a phenomenon that water accumulates over the concave portion of the first-layer wiring board and the concave portion of the second-layer wiring board is prevented, and the bus bar of each wiring board is prevented. The short circuit between the exposed portions is reliably prevented. According to the invention of claim 6, positioning and joining of each wiring board can be easily, smoothly and reliably performed by the tapered concave portion and the projecting portion. In addition, the concave portion and the protruding portion are securely brought into close contact with each other by the wedge action, and the waterproof and dustproof properties are enhanced.

According to the seventh and eighth aspects of the present invention,
Since resistance welding is performed in a state where the electric wire and the bus bar are in point contact with each other, the diffusion of welding current is prevented, and the concentration of the current stabilizes the welding interface, improving the reliability of electrical connection, The welding strength is increased, and peeling of the electric wire during tension is prevented.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing an electric junction box including an embodiment of a wiring board assembly according to the present invention.

FIG. 2 is a front view showing a protruding shape of a tab terminal of the wiring board assembly.

FIG. 3 is an exploded perspective view showing an intermediate processed product of the wiring board.

FIG. 4 is a longitudinal sectional view showing a state where the electric wire is welded to the bus bar.

FIG. 5 is an exploded perspective view showing another embodiment of a structure and a method for welding an electric wire to a bus bar of a wiring board.

FIG. 6 is a sectional view corresponding to line BB in FIG. 5, showing a state where the electric wire is welded to the bus bar.

FIG. 7 is an exploded perspective view showing an electric junction box including another embodiment of a wiring board assembly.

FIG. 8 is a perspective view showing a state in which the wiring board assembly is similarly expanded.

FIG. 9 is an exploded perspective view showing a connection state of a bus bar, an electric wire, and a terminal.

FIG. 10 is a longitudinal sectional view (AA sectional view of FIG. 7) showing one embodiment of a waterproof structure of the wiring board assembly;

FIG. 11 is an exploded perspective view showing a conventional example.

FIG. 12 is a longitudinal sectional view showing another conventional example.

FIG. 13 is a longitudinal sectional view showing a state where the electric wire is welded to the bus bar.

[Explanation of symbols]

1, 2, 41, 42 Wiring board 3, 4, 46, 48 Bus bar 5 to 8, 47, 49, 62, 67 Tab terminal (terminal) 12 Electric wire 33 Connection hole 71 Connection hole (recess) 72, 73 Projection 79 Projection C ₁ , C ₂ wiring board assembly

Claims (8)

[Claims] 1. A wiring board assembly in which a plurality of bus bars are provided in parallel on a plurality of wiring boards, the bus bars have terminals at opposite ends at opposite ends, and the plurality of wiring boards are stacked. The bus bar of the second-layer wiring board has a shape obtained by inverting the bus bar of the first-layer wiring board, and the terminal on one side of the first-layer wiring board and the other of the second-layer wiring board A terminal on the other side of the wiring board of the first layer and a terminal on one side of the wiring board of the second layer have the same length. Three-dimensional. 2. A terminal is formed on one end and the other end of the bus bar in the opposite direction, the bus bar is provided on a first layer wiring board, and the bus bar having the same shape as the bus bar is inverted to form a second layer. A method for manufacturing a wiring board assembly, wherein the method is provided on a wiring board. 3. A part of the bus bar is exposed in a concave portion of the first and / or second layer wiring board, and the second layer and / or
2. The wiring board assembly according to claim 1, wherein the first layer wiring board is formed with a protruding portion engaging with the concave portion. 4. A wiring board assembly comprising a wiring board, wherein a bus bar is provided inside the wiring board, a part of the bus bar is exposed in a recess of the wiring board, and a plurality of the wiring boards are stacked. A wiring board assembly, wherein a protrusion is formed on the board to engage with the recess. 5. The protruding portion of the first-layer wiring board and the protruding portion of the second-layer wiring board are adjacent to the respective recesses of the first-layer wiring board and the second-layer wiring board. The wiring board assembly according to claim 3, wherein the wiring board assembly is positioned. 6. The wiring board assembly according to claim 3, wherein said concave portion and said projecting portion are formed in a tapered shape. 7. The bus bar is provided with a projection for resistance welding in a connection hole of the wiring board, and the electric wire is point-contacted to the projection to perform resistance welding. ,
The wiring board assembly according to any one of claims 5 and 6. 8. The bus bar is provided with a projection for resistance welding, and the bus bar and the electric wire are resistance-welded in a state where the electric wire is in point contact with the projection in the connection hole of the wiring board. The method for manufacturing a wiring board assembly according to claim 2.