Patent Application
20140334117
This application is based on Japanese Patent Application No. 2013-97760 filed on May 7, 2013, the disclosure of which is incorporated herein by reference.
The present disclosure relates to an electric device for a vehicle and a manufacturing method of the same.
Conventionally, an electric device for a vehicle includes a circuit board, on which an electric element for providing an electric circuit is mounted, a casing for accommodating and supporting the circuit board, and a bracket for attaching the casing to an attachment unit of the vehicle. JP-A-2010-40992 teaches that the circuit board and the electric element are arranged in a forming mold, and the casing is formed together with the circuit board and the electric element integrally by a low-pressure transfer molding method with thermo-setting resin components.
Here, in general, a conventional electric device includes a casing for accommodating a circuit board and a bracket for attaching the casing to an attachment unit of the vehicle. Accordingly, the number of elements in the electric device may easily increase, and a structure of the electric device may be complicated. Thus, it is required to simplify the structure of the device.
It is an object of the present disclosure to provide an electric device and a manufacturing method of the same. A structure of the electric device is simplified, and the number of elements in the electric device is reduced.
According to a first aspect of the present disclosure, an electric device for a vehicle includes: a circuit board having an attachment unit, which is attachable to a vehicular attachment unit, wherein an electric element for providing an electric circuit is mounted on the circuit board; and a shrinkage cover covering a surface of the electric element and a surface of the circuit board. The attachment unit of the circuit board is directly attachable to the vehicular attachment unit with a fastening element.
In the above electric device, the circuit board includes the attachment unit, which is attachable to the vehicle attachment unit. The attachment unit is attached to the vehicle attachment unit with the fastening element. Further, the circuit board and the electric element mounted on the circuit board are protected by the cover, which seals the surface thereof. Accordingly, it is not necessary to prepare a casing and a bracket in a conventional electric device. Thus, the structure of the electric device is simplified, and the number of elements in the electric device is reduced.
According to a second aspect of the present disclosure, a manufacturing method of an electric device for a vehicle, which includes: a circuit board having an attachment unit attachable to a vehicular attachment unit, wherein an electric element for providing an electric circuit is mounted on the circuit board; and a cover covering a surface of the electric element and a surface of the circuit board, the manufacturing method includes: plating with metal on the attachment unit so that a metal thick film is formed, and mounting the electric element on the circuit board so that the circuit board is prepared; accommodating the circuit board, on which the electric element is mounted, in the cover made of resin or rubber and having a pouch shape; thermally press-bonding a periphery of the cover along an outer circumference of an opening of the cover to the circuit board; and shrinking the cover.
In the above manufacturing method, the structure of the electric device is simplified, and the number of elements in the electric device is reduced.
According to a third aspect of the present disclosure, a manufacturing method of an electric device for a vehicle, which includes: a circuit board having an attachment unit attachable to a vehicular attachment unit, wherein an electric element for providing an electric circuit is mounted on the circuit board; and a cover covering a surface of the electric element and a surface of the circuit board, the manufacturing method includes: sticking a sheet of the cover to a surface of the circuit board, on which the electric element is mounted; thermally press-bonding an outer periphery of the cover to the circuit board; shrinking the cover; and attaching a metal member for reinforcing the attachment unit in a through hole in the attachment unit of the circuit board from an outside of the cover.
In the above manufacturing method, the structure of the electric device is simplified, and the number of elements in the electric device is reduced.
The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
An electric device for a vehicle according to the first embodiment is suitably used for an air bag ECU. As shown in
The circuit board 10 is a substrate of the air bag ECU for detecting acceleration of the vehicle and for executing an inflation control process of the air bag based on a detection result. The circuit board 10 includes a printed board 11, on which a printed wiring (not shown) is formed, an acceleration sensor 12 and a connector 13, which are mounted on the printed board 11, and an electric element Z. The printed board 11 is made of resin and has a plate shape with a rectangular shape. An attachment unit 14 as a device side attachment unit to be attached to an attachment unit 36 of the vehicle as a vehicle side attachment unit, as shown in
Each attachment unit 14 includes a through hole 15, through which an attachment bolt 31 as a press-bonding member is inserted. The attachment unit 14 is reinforced with a metallic thick film 16, which is formed by plating a metal around the through hole 15 on a front surface and a rear surface of the printed board 11. the metallic thick film 16 is connected to the printed wiring. The thickness of the metallic thick film 16 is larger than the thickness of the printed wiring.
The electric circuit of the circuit board 10 includes the printed wiring made of predetermined metallic material on the printed board 11 and various electric elements arranged on the printed board 11 such as an acceleration sensor 12, a connector 13 and other electric elements Z. The acceleration sensor 12 is a G sensor for detecting acceleration of the vehicle as one of physical quantities of behavior of the vehicle. The connector 13 is connected to the electric circuit and disposed on the circuit board 10. The connector 13 is connected to a vehicular wiring such as a vehicular harness.
The cover 20 is made of resin and has a pouched shape. The cover 20 accommodates the circuit board 10 and various electric elements 12, 13, Z, which are arranged on the circuit board 10, therein. After a portion around an opening of the cover 20 is thermally press-bonded, an inside of the cover 20 is evacuated so that the cover 20 is shrunk. Thus, the circuit board 10 and the electric element 12, 13, Z protected by the cover 20 are prevented from damage and have a water proof property. Here, the resin of the cover 20 is, for example, polyolefin resin, fluorine resin, silicone resin or the like.
Next, a manufacturing method of the electric device for the vehicle according to the present embodiment will be explained with reference to
At the circuit board forming step S11, as shown in
At the circuit board accommodating step S12, as shown in
As shown in
At the cover press-bonding step S13, as shown in
At the cover shrinking step S14, with using a vacuum pump (not shown), the inside of the cover 20 is evacuated through the opening 21. Thus, as shown in
As shown in
A shaft of the attachment bolt 31 is inserted into the through hole 15 and the attachment hole 37. Then, a top end of the shaft of the attachment bolt 31, which protrudes from the attachment hole 37, is fastened with the nut 32 so that the electric device is attached to the vehicle. Thus, the attachment unit 14 of the circuit board 10 is directly attached to the attachment unit 36 of the vehicle. Here, the top of the attachment bolt 31 contacts the metallic thick film 16, which is arranged on the surface of the attachment unit 14. The nut 32 fastened to the top end of the attachment bolt 31 electrically connects with the vehicle frame 35 via a washer 33. Thus, the electric circuit as a printed wiring of the circuit board 10 electrically connects with the vehicle frame 35 via the metallic thick film 16, the attachment bolt 31, the nut 32 and the washer 33, so that the electric circuit connects to ground, i.e., a body of the vehicle.
In the electric device for the vehicle according to the present embodiment, the circuit board 10 includes the attachment unit 14 to be attached to the attachment unit 36 of the vehicle. The attachment unit 14 is directly attached to the attachment unit 36 of the vehicle with the bolt 31 and the nut 32. The circuit board 10 and the electric elements mounted on the circuit board 10 are protected by the cover 20, which seals the surface of the circuit board 10 and the electric elements. Accordingly, it is not necessary to prepare a casing and a bracket in a conventional electric device. Accordingly, the structure of the electric device is simplified, and the number of elements of the electric device is much reduced.
The attachment 14 of the electric device includes the through hole 15, through which the bolt 31 is inserted. The through hole 15 is reinforced with the metallic thick film 16, which is arranged around the hole 15. Thus, the attachment unit 14 of the circuit board 20 is fixed to the attachment unit 36 of the vehicle surely and strongly.
In the present embodiment, the fastening member is provided by the attachment bolt 31, which is to be inserted into the through hole 15 of the attachment unit 14 and the attachment hole 37 of the attachment unit 36 of the vehicle, and the nut 32 to be attached to the bolt 31. Thus, the electric circuit (i.e., the printed wiring) of the circuit board 10 and the vehicle frame 35 are connected to each other via the metallic thick film 16, the attachment bolt 31 and the nut 32. Thus, it is not necessary to prepare an additional wiring for grounding to the body of the vehicle. The number of elements in the electric device is reduced, and the manufacturing cost of the electric device is also reduced. Further, the fastening manner of the bolt 31 and the nut 32 provides large fastening force and strong fixation. Thus, the behavior of the vehicle is transmitted to the circuit board 10 with high accuracy. Furthermore, the bolt 31 and the nut 32 are general purpose elements, and therefore, the manufacturing cost is reduced.
In the present embodiment, the cover 20 is made of resin and has a sac-like shape or a pouch shape. Accordingly, the circuit board 10 and various electric elements 12, 13, Z accommodated in the cover 20 are easily sealed. Thus, the circuit board 10 and various electric elements 12, 13, Z accommodated in the cover 20 are protected from water, so that the electric device has high water protection. Further, the damage of the electric device is prevented.
The manufacturing method of the electric device for the vehicle according to the present embodiment provides the electric device having the simple structure and the small number of elements, which is easily and simply manufactured.
(First Modification)
A first modification of the above embodiment will be explained with reference to
In the first modification, the cover 120 is made of rubber and has a sac-like shape having a predetermined thickness. The cover 120 has the sac-like shape with three openings 121, 122, which is similar to the cover 20 according to the first embodiment. The cover 120 is made of rubber having a contractile property (i.e., a shrinkage property), which is different from the cover 20, and has the thickness larger than the cover 20.
The cover shrinking step S14 according to the first modification is performed after the circuit board forming step S11, the circuit board accommodating step S12, and the cover press-bonding step S13, similar to the first embodiment. Thus, after the cover press-bonding step S13, the periphery of the cover 120 around the opening 121, 122 is thermally adhered to the circuit board 10 so that three openings 121, 122 of the cover 120 are sealed.
Under the above situation, when the cover shrinking step S14 in the first modification starts, the cover 120 made of rubber material and having a pouch shape is shrunk as a whole by the heating process, as shown in
Thus, in the first modification, the cover 120 is made of rubber material having a heat-shrinkable property and has a pouch shape. Further, the cover 120 has a thickness larger than the cover 20 made of resin according to the first embodiment. Accordingly, the shrinkage rate of the cover 120 is easily controlled so as not to adhere to the various electric elements 12, 13, Z. Thus, the clearance between the cover 120 and the surface of various electric elements 12, 13, Z and the circuit board 10 is surely and easily secured. Thus, the cover 120 maintains a flat shape, so that a part of the surface of the cover 120, on which a label is attached, is easily secured. Further, since there is no convexity and concavity, a damage caused by a scratch is prevented.
The rubber material of the cover 120 having the heat shrinkage property is, for example, silicon rubber, fluoride silicon rubber, or neoprene rubber. The thickness of the cover 20 is determined according to the heat shrinkage rate of the rubber material.
An electric device for a vehicle according to a second embodiment will be explained with reference to
The circuit board 10 according to the second embodiment includes the printed board 11, the acceleration sensor 12 and the connector 13, which are mounted on the printed board 11, and other electric elements Z, similar to the circuit board 10 according to the first embodiment. Here, the through hole 15 is formed on both sides in the attachment unit 14 along the longitudinal direction of the printed board 11. The metal plate 17 having the hook as a metal member for reinforcing the attachment unit 14 is inserted in the through hole 15.
The metal plate 17 includes a base unit 17a having a rectangular shape with a through hole 17b at a center of the base unit 17, and four hooks 17c extending from a periphery around the through hole 17b in an axial direction. The metal plat 17 is attached to each attachment unit 14 such that four hooks 17c are inserted in the attachment unit 14 from one side thereof such as an upper side or a front surface in
The cover 220 according to the second embodiment includes two sheets made of resin and having a rectangular sheet shape. The resin material of the cover 220 may be the same as the cover 20 according to the first embodiment. Each sheet of the cover 220 is bonded to a respective surface of the printed board 11. The outer periphery of the cover 220 bonded to both of the front surface and the back surface of the printed board 11 is thermally press-bonded to the outer periphery of the printed board 11. Then, similar to the first embodiment, the inside of the cover 220 is vacuumed so that the cover 220 is shrunk. Thus, the electric elements 12, 13, Z and the circuit board 10 covered with the cover 220 are protected from damage and have a water proof property.
Next, a manufacturing method of the electric device for the vehicle according to the second embodiment will be explained with reference to
At the cover sticking step S21, as shown in
At the cover press-bonding step S22, the outer periphery of each sheet of the cover 220 is thermally press-bonded to the outer periphery of the circuit board 10. Specifically, as shown in
At the cover shrinking step S23, the inside of the cover 220 is vacuumed from the opening 221 with a vacuum pump (not shown), for example. As shown in
At the metal member mounting step S24, as shown in
Thus, the electric device for the vehicle according to the present embodiment is mounted to the attachment unit 36 of the vehicle, which is arranged on the vehicle frame 35 made of metal, via a fastening member such as the bolt 31 and the nut 32, similar to the first embodiment, as shown in
Thus, in the electric device for the vehicle according to the second embodiment, the circuit board 10 includes the attachment unit 14 to be attached to the attachment unit 36 of the vehicle. The attachment unit 14 is directly attached to the attachment unit 36 with the bolt 31 and the nut 32. Accordingly, the structure of the electric device is simplified, and the number of elements in the electric device is reduced, which are similar to the first embodiment.
The cover 220 according to the second embodiment is made of resin material, and has the rectangular sheet shape. Alternatively, the cover 220 may be made of rubber material having the heat shrinkage property and have the rectangular sheet shape. Further, the cover 220 may be thermally shrunk instead of the vacuum shrinkage process. In this case, the thickness of the cover 220 may be enlarged, so that the effects similar to the first embodiment are obtained.
(Second Modification)
A second modification will be explained with reference to
In the above case, one engagement element 18A includes a base unit 181A having a rectangular shape with a through hole at a center thereof, and a large diameter ring unit 182A, which is protruded from a periphery around the through hole on one side of the base unit 181A. The large diameter ring unit 182A includes a through hole, which has a circular cross sectional shape, arranged inside of the unit 182A. The other engagement element 18B includes a base unit 181B having a rectangular shape with a through hole at a center thereof, and a small diameter ring unit 182B, which is protruded from a periphery around the through hole on one side of the base unit 181B. The small diameter ring unit 182B is engaged with the inside of the large diameter ring unit 182A.
A pair of the engagement units 18A, 18B is attached to each attachment unit 14 of the printed board 11, as shown in
(Third Modification)
A third modification will be explained with reference to
The metal element 19 is attached to each attachment unit 14 of the printed board 11, similar to the second modification. As shown in
In the metal element 19 according to the third modification, the first engagement unit 19A and the second engagement unit 19B are connected by the connector 19C so that they are integrated with each other. Thus, the handling of the metal element 19 is easy, so that the attachment operation of the metal element 19 to the unit 14 is easily performed.
While the present disclosure has been described with reference to embodiments thereof, it is to be understood that the disclosure is not limited to the embodiments and constructions. The present disclosure is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the present disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-097760 | May 2013 | JP | national |
