This application is based on and claims priority under 35 U.S.C. 119 with respect to Japanese Application No. 2006-270632 filed on Oct. 2, 2006, the entire content of which is incorporated herein by reference.
1. Field of the Invention
The present invention relates to an electric conductor formed to a shape which follows a predetermined circuit path with bent portions, and attached to a base portion. It also relates to a circuit unit composed of the base portion and the electric conductor.
2. Discussion of the Related Art
As electric conductors of this kind, there has been known one disclosed in Japanese unexamined, published patent application No. 2000-159083. As shown in FIG. 4 of the application, a bus bar (electric conductor) 19 for an ECU-integrated hydraulic control device is formed by a metal plate taking a bent shape and made of, e.g., copper, and is used for a high-current circuit (e.g., as high as 12 volts, 80 amperes). The bus bar 19 is attached to a low bed portion 13a of a bulkhead 13 provided as a part of a housing 7.
The electric conductor described in the aforementioned Japanese application takes a bent and complicated shape within a single plane. Therefore, where the electric conductor of the shape so complicated is blanked out in a sequential transfer line, a problem arises in that the yield is deteriorated to increase the manufacturing cost.
Accordingly, it is a primary object of the present invention to provide an improved electric conductor and a circuit unit employing the same wherein the electric conductor can be formed to a shape which follows a predetermined circuit path with bent portions, without deteriorating the yield in manufacturing and hence, without increasing the manufacturing cost.
Briefly, according to a first aspect of the present invention, there is provided an electric conductor formed to a shape which follows a predetermined circuit path including bent portions by bending a metal-made plate-like member spreading in a single plane and attachable to a base portion of a device. The plate-like member is made as a single integral member and comprises a first elongate portion formed linearly and constituting a first path portion of the electric conductor including the bent portions by being bent from the state in which the first elongate portion lies in a plane. The plate-like member further comprises a second elongate portion formed linearly and constituting a second path portion of the electric conductor and a tying portion tying the first elongate portion and the second elongate portion so that an extending direction of the first elongate portion makes a first predetermined angle with an extending direction of the second elongate portion. The tying portion is bent so that a plane including the second elongate portion makes a second predetermined angle with a plane including the first elongate portion.
With the construction in the first aspect of the invention, the plate-like member is formed approximately linearly because the first and second elongate portions each extending linearly are tied at the first predetermined angle close to zero degree. Thus, where a plurality of plate-like members taking the same shape as the aforementioned plate-like member are blanked out in a sequential transfer line, the interval between two adjoining plate-like members can be made to be short, and therefore, it can be realized to suppress the deterioration in the yield in comparison with that in a prior art and hence, to suppress an increase in the manufacturing cost. Then, by bending the plate-like member, there can be formed an electric conductor of the shape which follows the predetermined circuit path including the bent portions. Therefore, the electric conductor can be formed to the shape which follows the predetermined circuit path including the bent portions, without deteriorating the yield and hence, without increasing the manufacturing cost. In addition, since the first elongate portion is bent from the state in which it lies in a plane, it is possible to arbitrarily set the circuit path of the electric conductor.
According to a second aspect of the present invention, there is provided a circuit unit which comprises a base portion of the circuit unit and an electric conductor formed to a shape which follows a predetermined circuit path including bent portions by bending a metal-made plate-like member spreading in a single plane and attached to the base portion. The plate-like member is made as a single integral member and comprises a first elongate portion formed linearly and constituting a first path portion of the electric conductor including the bent portions by being bent from the state in which the first elongate portion lies in a plane. The plate-like member further comprises a second elongate portion formed linearly and constituting a second path portion of the electric conductor and a tying portion tying the first elongate portion and the second elongate portion so that an extending direction of the first elongate portion makes a first predetermined angle with an extending direction of the second elongate portion. The tying portion is bent so that a plane including the second elongate portion makes a second predetermined angle with a plane including the first elongate portion.
With the construction in the second aspect of the invention, there can be attained the same effects as those attained by the first aspect of the invention.
The foregoing and other objects and many of the attendant advantages of the present invention may readily be appreciated as the same becomes better understood by reference to the preferred embodiment of the present invention when considered in connection with the accompanying drawings, wherein like reference numerals designate the same or corresponding parts throughout several views, and in which:
FIGS. 4(a) and 4(b) are a plan view and a front view of the bus bar, respectively;
FIGS. 16(a) and 16(b) are a plan view and a front view of a bus bar in a compared example, respectively.
Hereafter, a vehicle brake fluid pressure control device mounting thereon an electric conductor or bus bar and a circuit unit in one embodiment according to the present invention will be described with reference to the drawings.
The hydraulic brake device 10 is for applying brake forces to wheels W of a vehicle (not shown). As shown in
The vehicle brake fluid pressure control device 13 is of a single body structure and is composed of a brake actuator 23 which is in turn composed of a solenoid block 21 and a pump block 22, and a casing unit 24. The reservoir tank 14 stores brake fluid and supplies the same to the master cylinder 12 and the brake actuator 23. The reservoir tank 14 replenishes the brake fluid to the master cylinder 12 through conduits 19.
The solenoid block 21 is in fluid communication with the master cylinder 12 through conduits 17 on one hand and with the brakes 15 through conduits 18 on the other hand. The solenoid block 21 has formed therein oil passages which are connected to the respective conduits 17, 18 and a pump 22a built in the pump block 22. The solenoid block 21 is made of a metal material.
Although being illustrated as one solenoid valve in
The solenoid valves 31 are attached to the solenoid block 21 with solenoid sections thereof protruding into a first chamber R1. Terminals 31b3 of the solenoid valves 31 pass through a bulkhead 41b and are soldered at their ends to a control board 50.
The pump block 22 is assembled in close contact to a surface opposite to an assembling surface 21a of the solenoid block 21. The pump block 22 is made of a metal material. Oil passages being in fluid communication with the oil passages of the solenoid block 21 are formed in the pump block 22. The pump 22a is arranged on a part of the oil passages. The pump 22a is driven by the operation of a motor 22b assembled to the pump block 22 and draws brake fluid from a reservoir (not shown) provided in the brake actuator 23.
The brake actuator 23 is provided independently of the master cylinder 12 and is capable of independently generating a hydraulic pressure corresponding to the brake manipulation state of the brake pedal 11.
The casing unit 24 is composed of a casing 40 and the control board 50. The casing 40 is composed of a case 41 and a cover 42. The case 41 takes the form of a tray with an opening 41a. The case 41 is of the configuration that a base portion 41b as a base table portion and a lateral portion 41c upstanding from the circumferential edge of the base portion 41b are bodily made of a synthetic resin. An open end (end of the lateral portion 41c) of the opening 41a is in abutting contact fluid-tightly with the assembling surface 21a of the solenoid block 21. The first chamber R1 storing the solenoid valves 31 is defined between the solenoid block 21 and the case 41.
The cover 42 takes the form of a tray with an opening 42a. The cover 42 is of the structure that a base portion 42b and a lateral portion 42c upstanding from the circumferential edge of the base portion 42b are bodily made of a synthetic resin. An open end (end of the lateral portion 42c) of the opening 42a is adhered by vibration welding or the like to an outer side wall surface of the base portion 41b of the case 41. A second chamber R2 accommodating the control board 50 is defined between the case 41 and the cover 42.
In this manner, the casing 40 has the opening 41a and is detachably attached to the solenoid block 21 to cover the solenoid valves 31, with the open end being in abutting contact fluid-tightly with the assembling surface 21a of the solenoid block 21.
Further, the base portion 41b of the case 41 constitutes the bulkhead which partitions the interior of the casing 40 into the first chamber R1 and the second chamber R2. The bulkhead 41b is arranged to face with the control board 50. As shown in
Close to four corners of the bulkhead 41b, pillars 45 for supporting the control board 50 are formed bodily with the case 41. The pillars 45 support and hold the control board 50 through engagements of snap fasteners (snap hooks) 45a, provided on their free ends, with engaging holes formed through the control board 50.
The control board 50 is responsive to signals inputted from rotational speed sensors (not shown) or the like for detecting the rotational speeds of the wheels W and controls the motor 22b and the various solenoid valves 31 to perform various controls such as ordinary brake control, antilock brake control (ABS), side lip control (ESC: Electronic Stability Control) and the like.
A bus bar 60 as electric conductor is attached to a surface on the control board 50 side (on the second chamber R2 side) of the bulkhead 41b. The bus bar 60 is connected at its one end to a lead terminal 22b1 which is in connection to a terminal of the motor 22b, and at its other end to the control board 50. The bus bar 60 is a conductive member for supplying a voltage (electric current) from a power supply (e.g., vehicle battery) through the control board 50 to the motor 22b. The bus bar (electric conductor) 60 and the base portion (bulkhead) 41b constitute a circuit unit.
The bus bar 60 is formed to take a shape which follows a predetermined circuit path including bent portions 61a-61d by folding or bending a metal-made plate-like member 70 spreading in a single plane surface. As shown in
The first elongate portion 71 elongates linearly and forms the first path portion 61 by being bent from the state that it lies in a plane. More specifically, the first elongate portion 71 has a first valley bending line portion 71a, a second valley bending line portion 71b, a first mountain bending line portion 71c, a second mountain bending line portion 71d and a connection portion forming portion 71e. It is to be noted that the respective valley bending line portions and the respective mountain bending line portions do not actually exist as marks and are imaginary lines for convenience in explanation.
The first and second valley bending line portions 71a, 71b are parts for valley bending and form first and second bent portions 61a, 61b by being valley-bent. The first and second mountain bending line portions 71c, 71d are parts for mountain bending and form third and fourth bent portions 61c, 61d by being mountain-bent. The connection portion forming portion 71e is formed as a connection portion 61c by being bent along an arc of a predetermined radius. The connection portion 61e is to secure the lead terminal 22bl therein by caulking. Thus, the first path portion 61 includes the first to fourth bent portions 61a-61d and the connection portion 61e. The first to fourth bent portions 61a-61d correspond to bent points on the predetermined circuit path. Herein, the term “valley bending” means a bending state that the bending line made by bending the plate-like member 70 takes a valley form to make a smaller angle than 180 degrees between the surfaces on both sides of the bending line, as viewed from one surface of a plate material or blank M1 (i.e., as viewed in
The second elongate portion 72 is elongates linearly without being bent from the state in which it lies in a plane, and forms a second path portion 62 of the bus bar 60. The second path portion 62 is a linear path and is attached onto the bulkhead 41b in surface contact with the same. Herein, the term “linear” means not only a straight line but also a line with a slight unevenness or irregularity. The expression “slight unevenness or irregularity” at this passage encompasses one of the degree that the protruding amount or the depression amount does not exceed the width of the first and second elongate portions 71, 72.
The tying portion 74 ties the first elongate portion 71 with the second elongate portion 72 so that the extending directions of the first and second elongate portions 71 and 72 make a first predetermined angle θ1 therebetween (e.g., zero degree and hence, in parallel relation in this particular embodiment). The tying portion 74 includes a bending line portion 73 along which a plane including the second elongate portion 72 is bent to make a second predetermined angle θ2 (90 degrees in this particular embodiment) with respect to a plane including the first elongate portion 71. The tying portion 74 is bent at the bending line portion 73 and forms a tying portion of the bus bar 60.
The first elongate portion 71 and the second elongate portion 72 are offset from each other at the tying portion 74 in a direction perpendicular to the direction in which they extend. That is, the respective center lines L1, L2 of the first and second elongate portions 71, 72 are shifted by a predetermined distance S. The predetermined distance S is set to the value that does not make the first and second elongate portions 71, 72 overlap with each other in the direction normal to the direction in which they extend (in other words, to the value that does not make the second elongate portion 72 overlap with an imaginary extension portion which would be made by extending the first elongate portion 71 toward the side of the second elongate portion 72).
The pair of first rectangular portions 75, 75 are those which are bodily formed to extend from the second elongate portion 72 perpendicularly of the same. The first rectangular portions 75 are bent at valley bending line portions 72a and form lead terminals 65 connected to the control board 50.
The second rectangular portion 76 is an elongate one which extends from an end portion of the first elongate portion 71 perpendicularly (i.e., in a direction normal to the extending direction of the first elongate portion 71 within the same plane). The second rectangular portion 76 forms a first insert portion 66 in the state that it is not bent with respect to the first elongate portion 71. The first insert portion 66 is inserted into a first socket hole 41b1 formed in the bulkhead (base portion) 41b. Thus, the first path portion 61 of the bus bar 60 is attached and secured to the bulkhead 41b. In this particular embodiment, the second rectangular portion 76 is formed at a shoe portion 76a which protrudes from the first elongate portion 71 perpendicularly (i.e., in a direction normal to the extending direction of the first elongate portion 71 within the same plane). The shoe portion 76 functions as a spacer 66a which keeps a space between the first path portion 61 and the bulkhead 41b. It is to be noted the second rectangular portions 76 may be provided at any other portion (e.g., a center portion) than the end portion of the first elongate portion 71.
The third rectangular portion 77 extends from the second elongate portion 72 perpendicularly (in a direction normal to the second elongate portion 72 within the same plane). The third rectangular portion 77 is bent along a mountain bending line portion 72b to form a second insert portion 67. The second insert portion 67 is inserted into a second socket hole 41b2 formed in the bulkhead 41b. Thus, the second path portion 62 of the bus bar 60 is attached and secured to the bulkhead 41b.
Further, as shown in
Next, description will be made regarding the manufacturing of the plate-like member 70. The plate-like member 70 is manufactured by a sequential transfer line (not shown). First of all, the blank M1 is subjected to blanking, as shown in
Then, from the state in which the first elongate portion 71 lies in a plane shown in
Then, the tying portion 74 is bent along the bending line portion 73 by press-forming, whereby the second elongate portion 72 is set upright at the predetermined angle θ2 (90 degrees in this particular embodiment) relative to the horizontal plane of the blank M, that is, relative to the first elongate portion 71. Thus, the bus bar 60 is formed from the plate-like member 70. Finally, the connecting portions 81c, 81d are struck out, whereby the bus bar 60 is separated from the blank M1.
As clear from the foregoing explanation, in the present embodiment, the plate-like member 70 is formed to an approximately linear shape, because the first elongate portion 71 and the second elongate portion 72 both being linear extend in parallel to each other and are mutually offset to the degree that the bending line portion 73 is secured therebetween. Thus, where the plate-like members 70 are blanked out successively in the sequential transfer line, the interval between each plate-like member 70 and the next can be minimized, so that compared with the prior art, it becomes possible to suppress the deterioration in yield and hence, to suppress an increase in the manufacturing cost.
For example, one shown as a compared example in
In the manner as described above, the bus bar 60 taking the shape which follows the predetermined circuit path including the bent portions 61a-61d is formed by bending the plate-like member 70. Accordingly, it can be realized to form the bus bar 60 to the shape which follows the predetermined circuit path including the bent portions 61a-61d, without deteriorating the yield and hence, without increasing the manufacturing cost. Further, since the first elongate portion 71 is bent from the state that it lies in a plane, it can be realized to arbitrarily set the circuit path (the first path portion 61) of the bus bar 60.
Further, since the first elongate portion 71 and the second elongate portion 72 are offset at the tying portion 74 from each other in a direction perpendicular to the direction in which they extend, it can be realized to secure the bending line portion 73 certainly, to shorten the length of the bending line portion 73, and to make the machining easy.
Further, the plate-like member 70 is further provided with the first elongate rectangular portions 75 formed bodily with the second elongate portion 72 perpendicularly of the same. The first rectangular portions 75 are bent to form the lead terminals 65 which are to be connected to the control board 50 being a first connection destination. The plate-like member 70 is attached in the state that the second path portion 62 constituted by the second elongate portion 72 is held in surface contact with the base portion 41b. Thus, where a temperature change causes the lead terminals 65 to expand or contract, the stress caused by such expansion and contraction at the juncture between the control board 50 and each read terminal 65 can be relieved through elastic deformation of the second path portion 62.
Further, since the base end portions of the lead terminals 65 at the second path portion 62 are spaced away from the base portion 41b as shown in
In addition, the plate-like member 70 is further provided with the second rectangular portion 76 extending from the first elongate portion 71 in a direction perpendicular thereto and being insertable into the first socket hole 41b1 formed in the base portion 41b, and a third rectangular portion 77 which forms an insert portion 67 extending from the second elongate portion 72 in a direction perpendicular thereto and bent to be insertable into the second socket hole 41b2 formed in the base portion 41b. Thus, it is possible to securely attach to the base portion 41b the bus bar 60 which is formed by bending the plate-like member 70.
(Modifications)
Although in the foregoing embodiment, the first predetermined angle e1 is set to zero degree, it may be set to a value which is not zero degree. In this (first) modified case, as shown in
In this (first) modified form, where the first predetermined angle θ1 is made to be greater than zero degree without the alternation in the length in the extending direction of the first elongate portion 71 (or the second elongate portion 72), the length of the plate-like member 70 in the longitudinal direction becomes shorter in comparison with that in the case of the first predetermined angle θ1 being zero degree. As a result, the plate-like members 70 can be blanked out from a blank M2 whose width W2 is narrower than the width W1 of the aforementioned blank M1, at a layout angle β and at an interval P1. Thus, since one which is narrower in width can be used as the material (blank) for the sequential transfer line, it becomes possible to reduce the material cost. The layout angle β represents the angle which the center line L1 of the first elongate portion 71 makes with the lengthwise direction of the blank M2. In
The first predetermined angle θ1 is set to the value which does not make the interval of the adjoining plate-like members 70 (i.e., the interval between the same portions on the adjoining plate-like members 70 in the lengthwise direction of the blank M2) become greater than the interval in the case of the first predetermined angle θ1 being set to zero degree. This advantageously results in preventing the yield from deteriorating in the case that the interval between the adjoining plate-like members 70 exceeds the interval P1.
Also in the modified form, it is preferable that the bending line portion 73 is set at an angle different from the bending line portion 73 in the aforementioned case (that is, in the case of the first predetermined angle θ1 being zero degree), and that the first path portion 61 is arranged along the upper surface of the base portion 41b.
Further, in the foregoing embodiment, the bus bar 60 is attached to the base portion 41b by inserting the first and second insert portions 66, 67 of the bus bar 60 respectively into the first and second socket holes 41b1, 41b2 of the base portion 41b. Instead, in another (second) modified form, as shown in
In this (second) modified form, as shown in
The fourth rectangular portion 78 extends from the first elongate portion 71 perpendicularly of the same (i.e., in a normal direction within the same plane) and is made to be shorter than the aforementioned second rectangular portion 76. The fourth rectangular portion 78 is bent at the mountain bending line portion 71d to form the first engaging piece 78. A hole 78a constituting the first engaging hole 68a is formed through the fourth rectangular portion 78 for engagement with the first engaging protruding portion 41b4 formed on the base portion 41b.
The fifth rectangular portion 79 extends from the second elongate portion 72 perpendicularly of the same (i.e., in a normal direction within the same plane) and is made to be shorter than the third rectangular portion 77. The fifth rectangular portion 79 forms the second engaging piece 69 with itself remaining not to be bent relative to the second elongate portion 72. A hole 79a constituting the second engaging hole 69a is formed through the fifth rectangular portion 79 for engagement with the second engaging protruding portion 41b5 formed on the base portion 41b.
Further, as shown in
In the foregoing embodiment, the bus bar 60 is attached to the base portion 41b by inserting the first and second insert portions 66, 67 of the bus bar 60 respectively into the first and second socket holes 41b1, 41b2 of the base portion 41b. Instead, in still another (third) modified form, as shown in
In this modified form, as shown in
In the foregoing embodiment, the plate-like member 70 has respective rectangular portions formed at the first and second elongate portions 71, 72. Instead, in a further (fourth) modified form shown in
In a still further (fifth) modified form of the foregoing embodiment, the connection portion 61e (the connection portion forming portion 71e) may be offset from the first path portion 61 (the first elongate portion 71), as shown in
In a yet further (sixth) modified form of the foregoing embodiment, as shown in
Various features and many of the attendant advantages in the foregoing embodiment as well as in the foregoing modifications will be summarized as follows:
In the bus bar and the circuit unit in the foregoing embodiment typically shown in
Also in the foregoing embodiment typically shown in
In the first modified form shown in
Also in the foregoing embodiment typically shown in
Also in the foregoing embodiment typically shown in
In the second modified form shown in
In the third modified form shown in
In the fourth modified form shown in
Obviously, numerous further modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.
Number | Date | Country | Kind |
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2006-270632 | Oct 2006 | JP | national |