Wiring module

This application is a continuation of U.S. application Ser. No. 15/872,276, filed Jan. 16, 2018, and claims the benefit of Japanese Application No. JP2017-008400, filed on Jan. 20, 2017, the contents of both of which are hereby incorporated by reference in their entirety.

The present invention relates to a wiring module including a plurality of conductive plates.

JP 2016-101046A discloses a wiring module formed by stacking a plurality of flat wiring bodies. This wiring module is a large module molded in one piece into a shape for mounting to a vehicle.

JP 2016-101046A is an example of related art.

However, a wiring module molded in one piece in this manner cannot be mounted in a vehicle having a shape that is different from a shape for which the wiring module has been designed.

To address this, it is an object of the present design to provide a wiring module capable of being used in various layouts depending on the shapes of vehicles.

To solve the foregoing problems, a wiring module according to a first aspect includes a plurality of conductive plates, and first coupling portions and second coupling portions that are provided on outer peripheral portions of the plurality of conductive plates and have mutually connectable shapes, wherein the plurality of conductive plates are electrically connected by coupling the first coupling portions and the second coupling portions.

A second aspect is the wiring module according to the first aspect, wherein the plurality of conducive plates have the same shape, the first coupling portions provided on the outer peripheral portions of the plurality of conducive plates have the same shape, and the second coupling portions provided on the outer peripheral portions of the plurality of conducive plates have the same shape.

A third aspect is the wiring module according to the first or second aspect, wherein the first coupling portions and the second coupling portions each include a screwed portion, and a common screw is inserted into the first coupling portion provided on the outer peripheral portion of one of the adjacent two conductive plates and the second coupling portion provided on the outer peripheral portion of the other to couple the first coupling portion and the second coupling portion.

A fourth aspect is the wiring module according to the third aspect, wherein, in each of the plurality of conductive plates, the first coupling portion is provided at one end in a longitudinal direction, and the second coupling portion is provided at the other end in the longitudinal direction.

A fifth aspect is the wiring module according to the fourth aspect, wherein, in each of the plurality of conductive plates, the first coupling portion is provided at a corner portion at the one end, and the second coupling portion is provided at a corner portion at the other end.

A sixth aspect is the wiring module according to the fourth or fifth aspect, wherein, in each of the plurality of conductive plates, at least one of the first coupling portion and the second coupling portion is provided at an intermediate portion in a longitudinal direction.

A seventh aspect is the wiring module according to the first or second aspect, wherein the first coupling portions are parts of the outer peripheral portions of the plurality of conductive plates that have been processed into a protruding shape, the second coupling portions are parts of the outer peripheral portions of the plurality of conductive plates that have been processed into a recessed shape, and the first coupling portion provided on the outer peripheral portion of one of the adjacent two conductive plates is fitted to the second coupling portion provided on the outer peripheral portion of the other to couple the first coupling portion and the second coupling portion.

An eighth aspect is the wiring module according to the seventh aspect, wherein, in each of the plurality of conductive plates, the first coupling portion is provided at one end in a longitudinal direction, and the second coupling portion is provided at the other end in the longitudinal direction.

A ninth aspect is the wiring module according to the eighth aspect, wherein, in each of the plurality of conductive plates, at least one of the first coupling portion and the second coupling portion is provided at an intermediate portion in a longitudinal direction.

A tenth aspect is the wiring module according to any one of the first to ninth aspects, and further includes a branch conductive plate, and branch coupling portions that are provided at at least three positions on an outer peripheral portion of the branch conductive plate and can be coupled to one of the first coupling portion or the second coupling portion.

An eleventh aspect is the wiring module according to any one of the first to tenth aspects, and further includes a fuse, an insulating base that holds the fuse, a coupling portion for a fuse that is provided on an outer peripheral portion of the base and can be coupled to at least one of the first coupling portion and the second coupling portion, and a conductive member that has a conductive path including the fuse and is electrically connected to the conductive plate coupled via the coupling portion for a fuse.

With the first to eleventh aspects, in the wiring module, the plurality of conductive plates are electrically connected by coupling the first coupling portions and the second coupling portions. Therefore, changing a manner in which the conductive plates are coupled makes it possible to use the wiring module in various layouts depending on the shapes of vehicles.

With the second aspect, the elements of each type included in the wiring module have the same shape, thus making it possible to improve the productivity.

With the third aspect, the adjacent conductive plates can be coupled via a simple structure using a screw.

With the fourth aspect, in each of the conductive plates, the first coupling portion is provided at one end in the longitudinal direction and the second coupling portion is provided at the other end in the longitudinal direction. Therefore, even when a small number of conductive plates are used, it is easy to lay out the wiring module over a long distance.

With the fifth aspect, the first coupling portions and the second coupling portions are coupled at the corner portions of the conductive plates, thus making it possible to adjust the coupling angles between the conductive plates in a broad range.

With the sixth aspect, in each of the conductive plates, at least one of the first coupling portion and the second coupling portion is provided at an intermediate portion in the longitudinal direction. Flexibility of the layout of the wiring module is improved by providing the coupling portions at both ends and the intermediate portion in the longitudinal direction in this manner.

With the seventh aspect, the first coupling portion and the second coupling portion are coupled via a fitting structure, and therefore, it is easy to couple the conductive plates.

With the eighth aspect, in each of the conductive plates, the first coupling portion is provided at one end in the longitudinal direction and the second coupling portion is provided at the other end in the longitudinal direction. Therefore, even when a small number of conductive plates are used, it is easy to lay out the wiring module over a long distance.

With the ninth aspect, in each of the conductive plates, at least one of the first coupling portion and the second coupling portion is provided at an intermediate portion in the longitudinal direction. Flexibility of the layout of the wiring module is improved by providing the coupling portions at both ends and the intermediate portion in the longitudinal direction in this manner.

With the tenth aspect, the branch coupling portions capable of being coupled with one of the first coupling portion or the second coupling portion are provided at at least three positions on the outer peripheral portion of the branch conductive plate. Using this branch conductive plate makes it easy to form branches in the wiring module.

With the eleventh aspect, a fuse can be easily incorporated in the wiring module.

FIG. 1 is a schematic perspective view showing a wiring module 1 .

FIG. 2 is a longitudinal cross-sectional view showing one conductive plate 30 , and a first coupling portion 10 and a second coupling portion 20 that are provided on the outer peripheral portion of the conductive plate 30 .

FIG. 3 is a longitudinal cross-sectional view of the wiring module 1 shown in FIG. 1 .

FIG. 4 is a plan view showing a layout of a wiring module 1 A.

FIG. 5 is a plan view showing a layout of a wiring module 1 B.

FIG. 6 is a plan view showing a layout of a wiring module 1 C.

FIG. 7 is a longitudinal cross-sectional view showing a unit module 100 D.

FIG. 8 is a schematic perspective view showing a wiring module 1 E.

FIG. 9 is a plan view showing a layout of a wiring module 1 F.

FIG. 10 is a plan view showing a layout of a wiring module 1 G.

FIG. 11 is a schematic perspective view showing a configuration of a conductive portion including a fuse.

FIG. 12 is a schematic plan view showing a configuration of a conductive portion including a fuse.

First Embodiment

Hereinafter, a wiring module according to a first embodiment will be described. FIG. 1 is a schematic perspective view showing a wiring module 1 . FIG. 2 is a longitudinal cross-sectional view showing one conductive plate 30 , and a first coupling portion 10 and a second coupling portion 20 that are provided on the outer peripheral portion of the conductive plate 30 . FIG. 3 is a longitudinal cross-sectional view of the wiring module 1 shown in FIG. 1 .

The wiring module 1 includes a plurality of conductive plates 30 , and first coupling portions 10 and second coupling portions 20 that are provided on the outer peripheral portions of the conductive plates 30 and have mutually connectable shapes.

Hereinafter, with reference to FIGS. 1 to 3 , a case will be described in which the wiring module 1 includes four conductive plates 30 , and first coupling portions 10 and second coupling portions 20 that are provided on the outer peripheral portions of the four conductive plates and have mutually connectable shapes.

It should be noted that, in the example shown in FIGS. 1 to 3 , the wiring module 1 is formed by stacking, one on top of the other, two conductive plates 30 a and 30 b coupled in the horizontal direction and two conductive plates 30 c and 30 d coupled in the horizontal direction. Hereinafter, when the individual conductive plates 30 a to 30 d are distinguished from one another, they are denoted by additional alphabetical characters, and when they are not distinguished, they are referred to merely as “conductive plates 30 ”. The same applies to the first coupling portions 10 and the second coupling portions 20 . Moreover, a configuration including one conductive plate 30 , and first coupling portions 10 and second coupling portions 20 provided on the conductive plate 30 is referred to as “unit module 100 ”. It should be noted that, in this embodiment, the conductive plates 30 a to 30 d have the same shape, the first coupling portions 10 a to 10 d have the same shape, and the second coupling portions 20 a to 20 d have the same shape.

Each of the conductive plates 30 includes a flattened conductor 31 and a coating portion 32 .

The flattened conductor 31 is formed in an elongated shape such that a cross section taken along a plane orthogonal to the longitudinal direction has a flattened shape (here, a rectangular shape elongated in one direction). The flattened conductor 31 is made of a metal plate having an elongated band shape. The flattened conductor 31 is made of a material such as copper, a copper alloy, aluminum, or an aluminum alloy. The flattened conductor 31 may be plated with metal such as tin or nickel.

The coating portion 32 is an insulating member for covering the flattened conductor 31 in a flattened shape. The coating portion 32 is formed by performing extrusion coating to cover the periphery of the flattened conductor 31 with a resin and then stripping off a portion of the coating, for example. The periphery of the flattened conductor 31 is coated with the coating portion 32 having a uniform thickness, and therefore, a cross section of the conductive plate 30 that is orthogonal to the longitudinal direction has a flattened shape. It should be noted that, as shown in FIG. 2 , side surfaces 311 and 312 , and top surfaces 313 and 314 , on both sides of the flattened conductor 31 in the longitudinal direction are exposed to the outside due to the coating, which is a portion of the coating portion 32 , being stripped off.

In each of the conductive plates 30 , two first coupling portions 10 spaced apart from each other in the short direction are provided at one end in the longitudinal direction, and two second coupling portions 20 spaced apart from each other in the short direction are provided at the other end in the longitudinal direction. More specifically, in each of the conductive plates 30 , two first coupling portions 10 are provided at both corner portions at one end in the longitudinal direction, and two second coupling portions 20 are provided at both corner portions at the other end in the longitudinal direction.

The first coupling portions 10 each include a screwed portion 11 and a coating portion 12 .

The screwed portion 11 includes a threaded hole portion 111 having a recessed shape, and an extending portion 112 that extends from the bottom of the threaded hole portion 111 in the horizontal direction. The threaded hole portion 111 is a female screw in which a screw thread that is screwed on a screw 40 (male screw) when the screw 40 is inserted thereinto is formed on the inner circumferential surface. The screwed portion 11 is made of a conductive member. For example, the screwed portion 11 is made of a material such as copper, a copper alloy, aluminum, or an aluminum alloy. The screw 40 may be made of metal or a resin or the like.

The coating portion 12 is an insulating member that covers the outer circumferential surface of the screwed portion 11 . The coating portion 12 is formed by molding a resin around the screwed portion 11 , for example. It should be noted that a lower surface 113 on the conductive plate 30 side (right side in FIG. 2 ) of the extending portion 112 of the screwed portion 11 is not coated with the coating portion 12 and is exposed to the outside.

The screwed portion 11 is provided at one end (on the left side in FIG. 2 ) of the conductive plate 30 in the longitudinal direction. More specifically, the lower surface 113 of the extending portion 112 of the screwed portion 11 and a top surface 313 of the flattened conductor 31 are joined by welding or the like. As a result, the first coupling portion 10 and the conductive plate 30 are electrically connected.

The second coupling portion 20 includes a screwed portion 21 and a coating portion 22 .

The screwed portion 21 includes a threaded hole portion 211 having a tubular shape, and an extending portion 212 that extends from the threaded hole portion 211 in the horizontal direction and the downward direction. The threaded hole portion 211 is a tubular portion whose inner diameter is substantially the same as that of the threaded hole portion 111 and through which the screw 40 (male screw) can be inserted. The screwed portion 21 is made of a conductive member. For example, the screwed portion 21 is made of a material such as copper, a copper alloy, aluminum, or an aluminum alloy.

The coating portion 22 is an insulating member that covers the outer circumferential surface of the screwed portion 21 . The coating portion 22 is formed by molding a resin around the screwed portion 21 , for example. It should be noted that a lower surface 213 on the conductive plate 30 side (left side in FIG. 2 ) of the extending portion 212 of the screwed portion 21 is not coated with the coating portion 22 and is exposed to the outside.

The screwed portion 21 is provided at one end (on the right side in FIG. 2 ) of the conductive plate 30 in the longitudinal direction. More specifically, the lower surface 213 of the extending portion 212 of the screwed portion 21 and a top surface 314 of the flattened conductor 31 are joined by welding or the like. As a result, the second coupling portion 20 and the conductive plate 30 are electrically connected.

As a result, the unit module 100 in which the first coupling portions 10 and the second coupling portions 20 are joined to the conductive plate 30 as shown in FIG. 2 is obtained. In the unit module 100 , the top surface 114 of the threaded hole portion 111 of the first coupling portion 10 and the lower surface 214 of the threaded hole portion 211 of the second coupling portion 20 are located at substantially the same height.

Regarding the two adjacent conductive plates 30 a and 30 b , common screws 40 are inserted into two second coupling portions 20 a provided on the outer peripheral portion of the conductive plate 30 a and two first coupling portions 10 b provided on the outer peripheral portion of the conductive plate 30 b , and, in this state, the two screws 40 are screwed and fastened to two threaded hole portions 111 , so that the two first coupling portions 10 b and the two second coupling portions 20 a are coupled. As a result, a relative positional relationship between the conductive plate 30 a and the conductive plate 30 b is fixed. In this coupled state, top surfaces 114 b of the threaded hole portions 111 b of the two first coupling portions 10 b are in contact with lower surfaces 214 a of threaded hole portions 211 a of the two second coupling portions 20 a . As a result, the conductive plate 30 a and the conductive plate 30 b are electrically connected via the two first coupling portions 10 b and the two second coupling portions 20 a.

Similarly, regarding the two adjacent conductive plates 30 c and 30 d , common screws 40 are inserted into two second coupling portions 20 c provided on the outer peripheral portion of the conductive plate 30 c and two first coupling portions 10 d provided on the outer peripheral portion of the conductive plate 30 d , and, in this state, the two screws 40 are screwed and fastened to two threaded hole portions 111 d , so that the two first coupling portions 10 d and the two second coupling portions 20 c are coupled. As a result, a relative positional relationship between the conductive plate 30 c and the conductive plate 30 d is fixed. In this coupled state, top surfaces 114 d of the threaded hole portions 111 d of the two first coupling portions 10 d are in contact with lower surfaces 214 c of threaded hole portions 211 c of the two second coupling portions 20 c . As a result, the conductive plate 30 c and the conductive plate 30 d are electrically connected via the two first coupling portions 10 d and the two second coupling portions 20 c.

The wiring module 1 is formed by stacking, one on top of the other, the two conductive plates 30 a and 30 b coupled in the horizontal direction and the two conductive plates 30 c and 30 d coupled in the horizontal direction. In this case, for example, the two conductive plates 30 a and 30 b are used as a voltage supplying conductive layer, and the two conductive plates 30 c and 30 d are used as a grounding conductive layer. Adhesive sheets or the like (not shown) are respectively provided between the conductive plates 30 a and 30 c , which are stacked one on top of the other, and between the conductive plates 30 b and 30 d , which are stacked one on top of the other, thus preventing the conductive plates 30 a and 30 c and the conductive plates 30 b and 30 d from being misaligned in the horizontal direction.

The wiring module 1 of this embodiment is used as a wiring member for electrically connecting a battery and a DC-DC converter, starter generator or inverter in a vehicle, for example. In this case, for example, after the four unit modules 100 are individually transported to an assembly factory, the wiring module 1 can be completed by coupling the unit modules 100 in the assembly factory and then mounted in a vehicle. The unit modules 100 can be individually transported in this manner, and therefore, the transportation is facilitated compared with a case where a wiring module (e.g., wiring module described in JP 2016-101046A) molded in one piece into a shape for mounting to a vehicle is transported.

In the wiring module 1 of this embodiment, the two conductive plates 30 a and 30 b are electrically connected by coupling the second coupling portions 20 a and the first coupling portions 10 b . Similarly, the two conductive plates 30 c and 30 d are electrically connected by coupling the second coupling portions 20 c and the first coupling portions 10 d . Therefore, changing a manner in which the conductive plates 30 are coupled (for example, changing the number of coupled conductive plates, the coupling positions thereof, or the coupling angles thereof) makes it possible to use the wiring module 1 in various layouts. Specifically, the unit modules 100 according to this embodiment may be used in common as components for different types of vehicles. Examples in which the layout of the wiring module 1 is changed will be described later with reference to FIGS. 4 to 6 .

In this embodiment, the conductive plates 30 have the same shape, the first coupling portions 10 have the same shape, and the second coupling portions 20 have the same shape. The elements of each type included in the wiring module have the same shape in this manner, thus making it possible to improve the productivity.

In the wiring module 1 of this embodiment, the adjacent conductive plates 30 can be coupled via a simple structure using a screw.

In the wiring module 1 of this embodiment, in each of the conductive plates 30 , the first coupling portions 10 are provided at one end in the longitudinal direction and the second coupling portions 20 are provided at the other end in the longitudinal direction. Therefore, even when a small number of conductive plates 30 are used, it is easy to lay out the wiring module 1 over a long distance.

Modified Examples of First Embodiment

Although a multilayered wiring module 1 in which two conductive plates 30 are stacked is described in the first embodiment, the wiring module may be constituted by a single layer or a plurality of layers including three or more layers.

FIG. 4 is a plan view showing a layout of a wiring module 1 A according to a modified example of the first embodiment.

As shown in FIG. 4 , the wiring module 1 A includes eight conductive plates 30 e to 30 l , and first coupling portions 10 e to 10 l and second coupling portions 20 e to 20 l that are provided on the outer peripheral portions of the eight conductive plates 30 e to 30 l and have mutually connectable shapes. The conductive plates 30 are electrically connected by coupling the first coupling portions 10 and the second coupling portions 20 .

More specifically, as described below, the conductive plates 30 are connected using a plurality of screws 40 . One of the two second coupling portions 20 e provided on the outer peripheral portion of the conductive plate 30 e and one of the two first coupling portions 10 f provided on the outer peripheral portion of the conductive plate 30 f are coupled using one screw 40 . The two second coupling portions 20 f provided on the outer peripheral portion of the conductive plate 30 f and the two first coupling portions 10 g provided on the outer peripheral portion of the conductive plate 30 g are coupled using two screws 40 . One of the two second coupling portions 20 g provided on the outer peripheral portion of the conductive plate 30 g and one of the two first coupling portions 10 h provided on the outer peripheral portion of the conductive plate 30 h are coupled using one screw 40 . One of the two second coupling portions 20 h provided on the outer peripheral portion of the conductive plate 30 h and one of the two first coupling portions 10 i provided on the outer peripheral portion of the conductive plate 30 i are coupled using one screw 40 . One of the two second coupling portions 20 i provided on the outer peripheral portion of the conductive plate 30 i and one of the two first coupling portions 10 j provided on the outer peripheral portion of the conductive plate 30 j are coupled using one screw 40 . One of the two second coupling portions 20 h provided on the outer peripheral portion of the conductive plate 30 h and one of the two first coupling portions 10 k provided on the outer peripheral portion of the conductive plate 30 k are coupled using one screw 40 . The two second coupling portions 20 k provided on the outer peripheral portion of the conductive plate 30 k and the two first coupling portions 10 l provided on the outer peripheral portion of the conductive plate 30 l are coupled using two screws 40 . As a result, wiring branches are formed between the three conductive plates 30 h , 30 i and 30 k.

In this modified example, there are some positions at which one first coupling portion 10 and one second coupling portion 20 are coupled using one screw 40 between the adjacent conductive plates 30 . In this case, a relative positional relationship between the adjacent conductive plates 30 can be adjusted by rotating the adjacent conductive plates 30 around the one screw 40 in a state in which the screw 40 is fastened loosely. Thereafter, the screw 40 can be fastened firmly to fix the relative relationship between the adjacent conductive plates 30 .

In this modified example, in each of the conductive plates 30 , two first coupling portions 10 are provided at the corner portions at one end in the longitudinal direction and two second coupling portions 20 are provided at the corner portions at the other end in the longitudinal direction. The first coupling portions 10 and the second coupling portions 20 are coupled at the corner portions of the conductive plates 30 . Therefore, the coupling angles between the conductive plates 30 can be adjusted in a broad range. The layout of the wiring module 1 A is changed as appropriate depending on the position at which the wiring module 1 A is to be mounted. For example, this wiring module 1 A is mounted in a vehicle, the coupling angles between the conductive plates 30 are adjusted such that the wiring module 1 A may avoid other members (e.g., console box located at substantially the center of the vehicle) in the vehicle.

FIG. 5 is a plan view showing a layout of a wiring module 1 B according to a modified example of the first embodiment.

As shown in FIG. 5 , the wiring module 1 B includes three conductive plates 30 m to 30 o , and first coupling portions 10 m to 10 o and second coupling portions 20 m to 20 o that are provided on the outer peripheral portions of the three conductive plates 30 m to 30 o and have mutually connectable shapes. The conductive plates 30 are electrically connected by coupling the first coupling portions 10 and the second coupling portions 20 .

More specifically, as described below, the conductive plates 30 are connected using a plurality of screws 40 . One of the two first coupling portions 10 m provided on the outer peripheral portion of the conductive plate 30 m and one of the two second coupling portions 20 n provided on the outer peripheral portion of the conductive plate 30 n are coupled using one screw 40 . One of the two first coupling portions 10 n provided on the outer peripheral portion of the conductive plate 30 n and one of the two second coupling portions 20 o provided on the outer peripheral portion of the conductive plate 30 o are coupled using one screw 40 .

In the wiring module 1 B according to this modified example, the coupling angles between conductive plates 30 are adjusted such that the angle between the adjacent conductive plates 30 m and 30 n and the angle between the adjacent conductive plates 30 n and 30 o are minimized. The wiring module 1 B is laid out in a space-saving manner in a plan view, and thus is favorable when transported to an assembly factory.

FIG. 6 is a plan view showing a layout of a wiring module 1 C according to a modified example of the first embodiment.

As shown in FIG. 6 , the wiring module 1 C includes four conductive plates 30 p to 30 s , and first coupling portions 10 p to 10 s and second coupling portions 20 p to 20 s that are provided on the outer peripheral portions of the four conductive plates 30 p to 30 s and have mutually connectable shapes. The conductive plates 30 are electrically connected by coupling the first coupling portions 10 and the second coupling portions 20 .

In the wiring module 1 C, in each of the conductive plates 30 , three first coupling portions 10 in total are provided at both corner portions at one end in the longitudinal direction and an intermediate portion in the longitudinal direction, and three second coupling portions 20 in total are provided at both corner portions at the other end in the longitudinal direction and an intermediate portion in the longitudinal direction.

As described below, the conductive plates 30 are connected using a plurality of screws 40 . One second coupling portion 20 p provided at the corner portion out of the three second coupling portions 20 p provided on the outer circumferential portion of the conductive plate 30 p and one first coupling portion 10 q provided at the intermediate portion in the longitudinal direction out of the three first coupling portions 10 q provided on the outer circumferential portion of the conductive plate 30 q are coupled using a screw 40 . Two second coupling portions 20 q provided at the two corner portions out of the three second coupling portions 20 q provided on the outer circumferential portion of the conductive plate 30 q and two first coupling portion 10 s provided at the two corner portions out of the three first coupling portions 10 s provided on the outer circumferential portion of the conductive plate 30 s are coupled using two screws 40 . Two second coupling portions 20 r provided at the two corner portions out of the three second coupling portions 20 r provided on the outer circumferential portion of the conductive plate 30 r and two first coupling portion 10 q provided at the two corner portions out of the three first coupling portions 10 q provided on the outer circumferential portion of the conductive plate 30 q are coupled using two screws 40 .

In the wiring module 1 C according to this modified example, in each of the conductive plates 30 , the first coupling portions 10 and the second coupling portions 20 are provided at both ends and intermediate portions in the longitudinal direction. Therefore, wiring branches can be easily formed, and flexibility of the layout of the wiring module is improved. It should be noted that it is not essential to provide both the first coupling portion 10 and the second coupling portion 20 at the intermediate portions in the longitudinal direction, and at least one of the first coupling portion 10 and the second coupling portion 20 may be provided at intermediate portions in the longitudinal direction.

FIG. 7 is a longitudinal cross-sectional view showing a unit module 100 D according to a modified example of the first embodiment.

As shown in FIG. 7 , the unit module 100 D includes one conductive plate 30 D, and a first coupling portion 10 D and a second coupling portion 20 D that are provided on the conductive plate 30 D.

The conductive plate 30 D includes a flattened conductor 31 D and a coating portion 32 D. The flattened conductor 31 D is made of a metal plate having an elongated band shape as is the case with the flattened conductor 31 according to the above-mentioned first embodiment. The coating portion 32 D is an insulating member for covering the flattened conductor 31 D in a flattened shape. It should be noted that, as shown in FIG. 7 , both ends of the flattened conductor 31 D in the longitudinal direction are not covered with the coating portion 32 D and are exposed to the outside.

The first coupling portions 10 D includes a screwed portion 11 D and a coating portion 12 D. The screwed portion 11 D includes a threaded hole portion 111 D having a recessed shape, and an extending portion 112 D that extends from the bottom of the threaded hole portion 111 D in the horizontal direction. The coating portion 12 D is an insulating member that covers the outer circumferential surface of the screwed portion 11 D. The coating portion 12 D is formed by molding a resin around the screwed portion 11 D, for example. It should be noted that a top surface 113 D on the conductive plate 30 D side (right side in FIG. 7 ) of the extending portion 112 D of the screwed portion 11 D is not coated with the coating portion 12 D and is exposed to the outside. The screwed portion 11 D is provided at one end (on the left side in FIG. 7 ) of the conductive plate 30 D in the longitudinal direction. More specifically, the top surface 113 D of the extending portion 112 D of the screwed portion 11 D and a lower surface 313 D of the flattened conductor 31 D are joined by welding or the like. As a result, the first coupling portion 10 D and the conductive plate 30 D are electrically connected.

The second coupling portion 20 D includes a screwed portion 21 D and a coating portion 22 D. The screwed portion 21 D includes a threaded hole portion 211 D having a tubular shape, and an extending portion 212 D that extends from the threaded hole portion 211 D in the horizontal direction and the downward direction. The coating portion 22 D is an insulating member that covers the outer circumferential surface of the screwed portion 21 D. The coating portion 22 D is formed by molding a resin around the screwed portion 21 D, for example. It should be noted that a top surface 213 D on the conductive plate 30 D side (left side in FIG. 7 ) of the extending portion 212 D of the screwed portion 21 D is not coated with the coating portion 22 D and is exposed to the outside. The screwed portion 21 D is provided at one end (on the right side in FIG. 7 ) of the conductive plate 30 D in the longitudinal direction. More specifically, the top surface 213 D of the extending portion 212 D of the screwed portion 21 D and a lower surface 314 D of the flattened conductor 31 D are joined by welding or the like. As a result, the second coupling portion 20 D and the conductive plate 30 D are electrically connected.

As described in this modified example, the electrical connection form between the conductive plate and the first coupling portion and second coupling portion may be different from that of the above-mentioned first embodiment. Various forms (e.g., connection form using not a screw structure but a rivet) may be used as the form for coupling between the first coupling portion and the second coupling portion.

Second Embodiment

Next, a wiring module 1 E according to a second embodiment will be described. FIG. 8 is a schematic perspective view showing the wiring module 1 E according to the second embodiment.

The wiring module 1 E includes a plurality of conductive plates 30 E, and first coupling portions 10 E and second coupling portions 20 E that are provided on the outer peripheral portions of the conductive plates 30 E and have mutually connectable shapes.

Hereinafter, with reference to FIG. 8 , a case will be described in which the wiring module 1 E includes two conductive plates 30 E, and first coupling portions 10 E and second coupling portions 20 E that are provided on the outer peripheral portions of the two conductive plates 30 E and have mutually connectable shapes. Hereinafter, when the individual conductive plates 30 Ea and 30 Eb are distinguished from each other, they are denoted by additional alphabetical characters, and when they are not distinguished, they are referred to merely as “conductive plates 30 E”. The same applies to the first coupling portions 10 E and the second coupling portions 20 E. It should be noted that, in this embodiment, the conductive plates 30 E have the same shape, the first coupling portions 10 E have the same shape, and the second coupling portions 20 E have the same shape.

Each of the conductive plates 30 E is formed in an elongated shape such that a cross section taken along a plane orthogonal to the longitudinal direction has a flattened shape (here, a rectangular shape elongated in one direction). The conductive plate 30 E is made of a metal plate having an elongated band shape. The conductive plate 30 E is made of a material such as copper, a copper alloy, aluminum, or an aluminum alloy. The conductive plate 30 E may be plated with metal such as tin or nickel. As described above, the conductive plate 30 E according to the second embodiment is a constituent corresponding to the flattened conductor 31 according to the above-mentioned first embodiment.

In each of the conductive plates 30 E, one first coupling portion 10 E is provided at the center in the short direction of one end (on the left side in FIG. 8 ) in the longitudinal direction, and one second coupling portion 20 E is provided at the center in the short direction of the other end (on the right side in FIG. 8 ) in the longitudinal direction.

The first coupling portion 10 E is a part of the outer peripheral portion of the conductive plate 30 E that has been processed into a protruding shape. The second coupling portion 20 E is a part of the outer peripheral portion of the conductive plate 30 E that has been processed into a recessed shape. Regarding the adjacent two conductive plates 30 Ea and 30 Eb, as indicated by long dashed double-short dashed lines in FIG. 8 , the first coupling portion 10 Eb provided on the outer peripheral portion of the conductive plate 30 Eb is fitted to the second coupling portion 20 Ea provided on the outer peripheral portion of the conductive plate 30 Ea, and thus the first coupling portion 10 Eb and the second coupling portion 20 Ea are coupled. As a result, the conductive plates 30 Ea and 30 Eb are electrically connected.

In the second embodiment, the adjacent conductive plates 30 Ea and 30 Eb are coupled via a fitting structure, and therefore, it is easy to couple the conductive plates 30 Ea and 30 Eb without using another member for connection (e.g., screw 40 ).

In the second embodiment, in each of the conductive plates 30 E, the first coupling portion 10 E is provided at one end in the longitudinal direction, and the second coupling portion 20 E is provided at the other end in the longitudinal direction. Therefore, even when a small number of conductive plates 30 E are used, it is easy to lay out the wiring module 1 E over a long distance.

In the second embodiment, the first coupling portion 10 E has a protruding shape whose width increases toward the leading end, and the second coupling portion 20 E has a recessed shape whose width decreases toward the opening portion. Therefore, when the first coupling portion 10 E is fitted to the second coupling portion 20 E, the leading end of the first coupling portion 10 E is locked to the opening portion of the second coupling portion 20 E, and thus the coupling state of the adjacent conductive plates 30 E is retained. In this coupling state, the lateral surface of one conductive plate 30 E on which the first coupling portion 10 E has been provided is in surface contact with the lateral surface of the other conductive plate 30 E on which the second coupling portion 20 E has been provided, and therefore, positional shifts between the adjacent two conductive plates 30 E are suppressed. It should be noted that the first coupling portion and the second coupling portion may have substantially columnar recessed and protruding shapes as described later with reference to FIGS. 9 and 10 , or other shapes. Even in this case, the leading end of the first coupling portion is locked to the opening portion of the second coupling portion 20 , and the lateral surfaces of the conductive plates are in surface contact with each other, so that the coupling state of these conductive plates is retained.

Also in the wiring module 1 E of the second embodiment, as in the modified example of the first embodiment shown in FIG. 6 , at least one of the first coupling portion 10 E and the second coupling portion 20 E may be provided at the intermediate portion of the conductive plate 30 E in the longitudinal direction.

Modified Examples of Second Embodiment

FIG. 9 is a plan view showing a layout of a wiring module 1 F according to a modified example of the second embodiment.

As shown in FIG. 9 , the wiring module 1 F includes: two conductive plates 30 F; first coupling portions 10 F and second coupling portions 20 F that are provided on the outer peripheral portions of the two conductive plates 30 F and have mutually connectable shapes; a branch conductive plate 50 F; and branch coupling portions 60 F that can be coupled to the second coupling portions 20 F, two branch coupling portions 60 F being provided on each of the four sides of the outer peripheral portion of the branch conductive plate 50 F.

Each of the conductive plates 30 F is made of a metal plate having an elongated band shape. In each of the conductive plates 30 F, two first coupling portions 10 F spaced apart from each other in the short direction are provided at one end in the longitudinal direction, and two second coupling portions 20 F spaced apart from each other in the short direction are provided at the other end in the longitudinal direction.

Each of the first coupling portions 10 F is a part of the outer peripheral portion of the conductive plate 30 F that has been processed into a protruding shape. Each of the second coupling portions 20 F is a part of the outer peripheral portion of the conductive plate 30 E that has been processed into a recessed shape.

The branch conductive plate 50 F is made of a metal plate having substantially a rectangular shape in a plan view. Two coupling portions 60 F spaced apart from each other are provided on each of the four sides of the outer periphery of the branch conductive plate 50 F.

Each of the coupling portions 60 F is a part of the outer peripheral portion of the branch conductive plate 50 F that has been processed into a protruding shape, and can be coupled to the second coupling portion 20 F of the conductive plate 30 F.

Therefore, the two coupling portions 60 F provided on one side of the outer periphery of the branch conductive plate 50 F are fitted to two second coupling portions 20 Fa provided on a conductive plate 30 Fa, and thus the two coupling portions 60 F are coupled to the two second coupling portions 20 Fa. As a result, the branch conductive plate 50 F and the conductive plate 30 Fa are electrically connected.

Similarly, the two coupling portions 60 F provided on one side of the outer periphery of the branch conductive plate 50 F are fitted to two second coupling portions 20 Fb provided on a conductive plate 30 Fb, and thus the two coupling portions 60 F are coupled to the two second coupling portions 20 Fb. As a result, the branch conductive plate 50 F and the conductive plate 30 Fa are electrically connected.

In the wiring module 1 F according to this modified example, using the branch conductive plate 50 F makes it easy to form branches.

It should be noted that an embodiment in which the coupling portions 60 F are provided on the four sides of the outer periphery of the branch conductive plate 50 F has been described in this modified example, but the coupling portions 60 F may be provided at at least three positions on the outer peripheral portion of the branch conductive plate 50 F.

Although an embodiment in which the coupling portions 60 F of the branch conductive plate 50 F can be coupled to the second coupling portions 20 F has been described in this modified example, an embodiment in which the coupling portions 60 F of the branch conductive plate 50 F can be coupled to the first coupling portions 10 F may be possible.

FIG. 10 is a plan view showing a layout of a wiring module 1 G according to a modified example of the second embodiment. FIG. 11 is a schematic perspective view showing a configuration of a conductive portion including a fuse.

As shown in FIG. 10 , the wiring module 1 G includes: two conductive plates 30 G; first coupling portions 10 G and second coupling portions 20 G that are provided on the outer peripheral portions of the two conductive plates 30 G and have mutually connectable shapes; fuses 72 G; an insulating base 70 G that holds the fuses 72 G; coupling portions 80 G for fuses that are provided on the outer peripheral portion of the base 70 G and can be coupled to the second coupling portions 20 G; coupling portions 90 G for fuses that are provided on the outer peripheral portion of the base 70 G and can be coupled to the first coupling portions 10 G; and a conductive member 71 G that has a conductive path including the fuses 72 G and is electrically connected to conductive plates coupled via the coupling portions 80 G and 90 G for fuses.

Each of the conductive plates 30 G are made of a metal plate having an elongated band shape. In each of the conductive plates 30 G, one first coupling portion 10 G is provided at one end in the longitudinal direction, and one second coupling portion 20 G is provided at the other end in the longitudinal direction.

The first coupling portion 10 G is a part of the outer peripheral portion of the conductive plate 30 G that has been processed into a protruding shape. The second coupling portions 20 G is a part of the outer peripheral portion of the conductive plate 30 G that has been processed into a recessed shape.

The base 70 G is formed into a flattened shape by molding an insulating material such as a resin around the conductive member 71 G and the two fuses 72 G provided at intermediate portions of the path of the conductive member 71 G.

The conductive member 71 G is a busbar having a branch portion 710 G at an intermediate portion of the path with one end of the conductive member 71 G being exposed from the concave of one of the coupling portions 90 G for fuses and the other end of the conductive member 71 G being exposed from the convexes of the two coupling portions 80 G for fuses.

The fuses 72 G are provided in the sections of the conductive member 71 G between the branch portion 710 G and the coupling portions 80 G for fuses. The fuses 72 G are formed by press-punching a metal plate made of a metal material with a low melting point such as a zinc alloy (e.g., ZnAl) or a copper alloy (e.g., Cu—Fe based alloy), for example. The fuses 72 G are narrower than the conductive member 71 G and form portions that are easily fused due to Joule's heat when an excessive current flows.

In this modified example, the second coupling portions 20 G of the two conductive plates 30 G are coupled to the two coupling portions 80 G for fuses provided on the outer peripheral portion of the base 70 G. As a result, the second coupling portions 20 G of the two conductive plates 30 G are in contact with the conductive member 71 G exposed from the convexes of the two coupling portions 80 G for fuses, and thus the conductive member 71 G and the two conductive plates 30 G are electrically connected.

In this modified example, fuses can be easily incorporated in the wiring module 1 G.

FIG. 12 is a schematic plan view showing a configuration of a conductive portion including a fuse.

This conducive portion includes: fuses 72 H; an insulating base 70 H that holds the fuses 72 H; coupling portions 90 H for fuses that are provided on the outer peripheral portion of the base 70 H and can be coupled to first coupling portions of conductive plates; grooves 110 H into which terminals 210 of electric wires 200 are to be inserted; and a conductive member 71 H that has a conductive path including the fuses 72 H and is electrically connected to a conductive plate coupled via the coupling portions 90 H for fuses and the electric wires 200 connected via the grooves 110 H.

The base 70 H is formed into a flattened shape by molding an insulating material such as a resin around the conductive member 71 H and the two fuses 72 H provided at intermediate portions of the path of the conductive member 71 H.

The two coupling portions 90 H for fuses that are parts of the outer peripheral portion of the base 70 H are provided on one side (right side in FIG. 12 ) of the outer peripheral portion of the base 70 H. For example, the first coupling portions 10 G of the above-mentioned conductive plates 30 G can be coupled to the two coupling portions 90 H for fuses. The two grooves 110 H into which the terminals 210 of the two electric wires 200 obtained by performing extrusion coating to cover a core wire with a resin can be inserted are provided on another side (left side in FIG. 12 ) of the outer peripheral portion of the base 70 H.

The conductive member 71 H is a busbar having a branch portion 710 H at an intermediate portion of the path with one end of the conductive member 71 H being exposed from a portion of the lateral surface between the coupling portions 90 H for fuses and the other end of the conductive member 71 H being exposed from the lateral surfaces of the two grooves 110 H.

In this modified example, the terminals 210 of the two electric wires 200 are coupled to the grooves 110 H provided on the outer peripheral portion of the base 70 H. As a result, the terminals 210 of the two electric wires 200 are in contact with the conductive member 71 H exposed from the lateral surfaces of the two grooves 110 H, and thus the conductive member 71 H and the two electric wires 200 are electrically connected. It should be noted that an embodiment in which female connection portions (two grooves 110 H) are provided on the outer peripheral portion of the base 70 H as a configuration for connecting the conductive member 71 H and the two electric wires 200 has been described in this modified example, but an embodiment in which male connection portions are provided on the outer peripheral portion of the base 70 H is also possible.

Other Modified Examples

A plurality of conductive plates in a wiring module may have different shapes unlike those in the above-mentioned first and second embodiments. Similarly, in a wiring module, first coupling portions or second coupling portions provided on the outer peripheral portions of the conductive plates may have different shapes.

The positions and the numbers of first coupling portions and second coupling portions provided on the outer peripheral portion of a conductive plate can be changed from those in the above-described embodiment.

A connector portion to be electrically connected to an external electrical component may be further provided on conductive plates in addition to first coupling portions and second coupling portions.

It should be noted that the configurations described in the above-described embodiments and modified examples can be used in combination as appropriate as long as they are compatible with each other.

Having described the present design in detail, the foregoing description is illustrative in all aspects and the present invention is not limited thereto. It is understood that countless modified examples not illustrated herein are conceivable without deviating from the scope of the present invention.

It is to be understood that the foregoing is a description of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

As used in this specification and claims, the terms “for example,” “e.g.,” “for instance,” “such as,” and “like,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

1 , 1 A to 1 C, 1 E to 1 G Wiring module

10 , 10 a to 10 d , 10 f to 10 s , 10 D, 10 E, 10 Ea, 10 Eb, 10 F, 10 Fa, 10 Fb, 10 G First coupling portion

20 , 20 a to 20 i , 20 k , 20 m to 20 s , 20 D, 20 E, 20 Ea, 20 Eb, 20 F, 20 Fa, 20 Fb, 20 G Second coupling portion

30 , 30 a to 30 s , 30 D, 30 E, 30 Ea, 30 Eb, 30 F, 30 Fa, 30 Fb, 30 G Conductive plate

40 Screw

50 F Branch conductive plate

60 F Coupling portion

80 G, 90 G, 90 H Coupling portion for fuse