Yazaki Corporation

Toyota Jidosha Kabushiki Kaisha

Shinya Onoda

Yoshinori Ishikawa

Takahiro Shiohama

Norio Matsumura

Toshiharu Kudo

Yoshinori Kitano

Mitsuhiko Totsuka

Motofumi Kato

Tatsumasa Itagaki

Muneyuki Fujisaka

Masahi Iwata

Takayoshi Endo

Shigemitsu Inaba

Yusuke Matsumoto

Tatsuya Aoki

Takanori Kawai

Yoshihiko Nakahama

Shigeru Kimura

Masanobu Suzuki

Naoya Akiyama

Yukinori Koie

Atsushi Hikage

A fusible link unit () includes a battery () with a battery post () projecting on an upper surface of the battery (), a fuse unit () arranged on the upper surface of the battery () and having a battery terminal () connected to the battery post (), and a fuse cover () covering an outer circumference of the fuse unit (). A deck board () is arranged above the fuse cover () so as to be capable of being opened and closed. The fuse cover () is fixed by being held between the battery () and the deck board () in a closed state of the deck board ().

Fusible link unit

A fuse unit includes a fusible link, a holding mechanism, and a locking mechanism. The fusible link is connected to a battery terminal and includes a fusible element that melts when an overcurrent flows through the fusible link. The holding mechanism includes a base portion disposed between a post standing surface of a battery housing and the battery terminal in a state where the battery terminal is fastened to a battery post provided on the post standing surface, and a holding portion that is formed next to the base portion and that holds the fusible link above the post standing surface. The locking mechanism locks the holding mechanism onto the post standing surface. With this configuration, the fuse unit can suppress a load acting on the battery post.

Fuse unit

A molding method includes: setting a bus bar at a first mold main body portion of a fixed mold by supporting a terminal base of a tuning-fork terminal with a terminal base receiving portion of the fixed mold in a state where the tuning-fork terminal is protruded outside a cavity formed by the first mold main body portion of the fixed mold and a second mold main body portion of a movable mold being joined together; joining the movable mold together with the fixed mold by abutting an abut step portion of the movable mold to a receiving abut step portion of the fixed mold and nipping the terminal base of the tuning-fork terminal with the terminal base receiving portion and a terminal base abut portion of the movable mold; and injecting resin into the cavity in the nipped state.

Molding method using mold structure

A battery connection unit includes an electronic component electrically connected to a battery terminal and a terminal of an electric wire, and an insulating support member that includes a first support body and a second support body and that supports the electronic component, where the first support body is disposed across a space in such a way that a first gap to a first surface becomes a first reference gap, the second support body is disposed across a space in such a way that a second gap to a second surface becomes a second reference gap, at least one first spring member that contacts the first surface while maintaining the first reference gap after attachment to the battery is disposed on the first support body, and at least one second spring member that contacts the second surface while maintaining the second reference gap is disposed on the second support body.

Battery connection unit, and attachment structure for battery connection unit

A busbar includes a plurality of main terminals (upstream side terminal, downstream side terminals) and one auxiliary terminal conductively connected to one of the main terminals and is press-formed in an integrated manner. The auxiliary terminal is connected to the main terminals through connection bars which are all cut off, except for one, in a cutting process after a pressing process, and the circuit configuration can be changed by selectively cutting off the connection bars. Therefore, there is no need to change the shape of a press die, and the production efficiency can be improved using a die having a uniform shape.

Busbar

A fuse unit includes: a fusible link which is connected to a battery terminal and of which a fuse is fused when overcurrent flows therein; and a holding mechanism including a base portion that is interposed between a post-standing surface and the battery terminal in a state in which the battery terminal is fastened to a battery post provided on the post-standing surface of a battery housing, and a holding portion that is connected to the base portion and holds the fusible link on the post-standing surface. Accordingly, a load acting on the battery post can be suppressed.

A connection portion of a locking member is bent such that the connection portion is made apart from a second upper surface portion as the connection portion is made apart from a first arm portion, and is bent such that the connection portion is made apart from a side surface portion as the connection portion is made apart from a second arm portion. Even when a tolerance is generated in a direction substantially orthogonal to the side surface portion at the time of installing a base body in an installation surface portion of a battery, it is possible to absorb the tolerance by deforming the connection portion, and to lock a locked portion in a lower end edge.

Affixed object, fusible link, and affixing structure for fusible link

Included are a battery terminal connected to a battery post erected on a first surface of a battery, a battery connection unit provided with an electronic component connected to the battery terminal and to which ends of electric wires are connected, and a accommodating member that accommodates the battery terminal and the battery connection unit. The accommodating member has a through-hole through which the battery post is inserted, a terminal accommodating chamber in which a free end side of the battery post inserted through the through-hole is arranged and which accommodates the battery terminal connected to the free end side, and a butting portion that is projected from a periphery of the through-hole toward the first surface of the battery and made abut on the first surface.

Power source connection system

In a fusible link, a fuse element integrally formed with a metallic plate includes a battery coupling plate and two external coupling plates. The battery coupling plate is coupled to a battery terminal. The external coupling plates are coupled through fusible parts to connecting plates extending to both sides of the battery coupling plate. Three resin housings support the fuse element so as to expose the connecting plates among the housings adjacent to each other. The installation configuration of the fuse element can be selected depending on the space on the battery side, thereby achieving increased flexibility of and reduction in the space for the fusible link mounted on the battery.

Fusible link

Provided is a fusible link unit (electrical component unit) including a fusible link (electrical component), a battery terminal fixed to an electrode post (electrode) of a battery, and a support member formed as a different body from the battery terminal and fixed to the battery, the support member supporting the fusible link (electrical component), in which the fusible link (electrical component) includes a main link body (main electrical component body) and a power supply terminal made of conductive metal to be exposed from the main link body (main electrical component body) and electrically connected to the electrode post (electrode) through the battery terminal, and the support member supports the main link body (main electrical component body) such that the main link body extends in an orthogonal direction substantially orthogonal to an installation surface portion.

Electrical component unit, fusible link unit, and fixing structure

Provided is a fusible link unit in which a case includes case-side locking portions to be locked in a fusible link so as to affix the fusible link, the fusible link includes fusible link-side locking portions locked in the case-side locking portions, the fusible link-side locking portion on one side in a longitudinal direction is provided closer to a connected position of a bus bar than the fusible link-side locking portion on the other side in the longitudinal direction, and a gap size between the fusible link-side locking portion on the one side and the case-side locking portion in a vertical direction is made greater than a gap size between the fusible link-side locking portion on the other side and the case-side locking portion in the vertical direction.

Component unit, fusible link unit, and affixing structure for the component

A fusible link includes a power supply portion provided on a connection terminal that connects to a battery terminal, a circuit terminal that connects to a circuit, a power-supply side upstanding portion standing in an out-of-plane direction of a terminal mounting surface from an edge substantially parallel to an extending direction of the battery terminal out of an outer circumferential edge near the power supply portion of the connection terminal, a circuit-side upstanding portion standing in the same direction as the power-supply side upstanding portion from an edge substantially parallel to the extending direction out of an outer circumferential edge of the circuit terminal, and a bridge portion extending between the power-supply side upstanding portion and the circuit-side upstanding portion. The power-supply side upstanding portion, the circuit-side upstanding portion, and the bridge portion function as a fuse element that fuses when a current greater than a threshold value flows.

A battery terminal includes a terminal body and a component terminal. The terminal body is connected to a rod-like electrode which projects from a terminal mounting surface of a battery and extends toward an outer periphery of the terminal mounting surface. An external fuse (electrical component) is connected to the component terminal. The terminal body and the component terminal are formed by being cut integrally from a single plate made of a conductive metal.

Battery terminal

A battery terminal includes a terminal main body provided in opposed plates thereof as a pair, formed by folding approximately in a U shape a strip plate made of a conductive metal, respectively with electrode insertion holes in which a rod-like electrode projecting from a terminal attaching surface in a battery is sequentially inserted, and formed to extend toward an outer edge of the terminal attaching surface at time of being connected to the rod-like electrode, and a joint joining the pair of the opposed plates in a state in which the opposed plates surface-contact and overlap each other on an opposite side of a folded part as seen from the electrode insertion hole.

Battery terminal, fuse unit, and method for manufacturing fuse unit

A fuse unit includes: a bus bar including a plurality of fusible parts interposed between a power supply side terminal and a plurality of load side terminals; and an insulating resin portion formed by insert molding using the bus bar as an insert component. The insulating resin portion includes: first and second resin portions respectively arranged at peripheries on the sides of the power supply side terminal and the load side terminals with respect to the fusible parts; and a plurality of coupling portions coupling the first resin portion and the second resin portion in a position outside each of the fusible parts. Each of the coupling portions is formed such that a reinforcement portion having a lower heat shrinkage rate than the insulating resin portion and having a higher strength than the insulating resin portion is an insert component. The reinforcement portion is provided using the bus bar.

Growing community of inventors

Makinohara, Japan

Shinya Onoda