JP5950013B2 - Terminal module - Google Patents

Description

  The present invention relates to a terminal module for electrically connecting an electrical element arranged on a heat sink and a circuit board in a power module such as an ECU (engine control unit) or a PCU (power control unit) of an automobile. .

  As shown in FIG. 61, a power module such as an ECU or PCU of an automobile generally has a heat radiating plate 902 to which a plurality of electric elements 901 are attached and a frame member 904 to which a plurality of conductive terminals 903 are attached in a comb shape. And a component unit 900 formed of a plurality of through holes 905 and a circuit board 906 having an electric circuit. In the component unit 900, the conductive terminal 903 that electrically connects the plurality of electric elements 901 arranged on the heat sink 902 and the through hole 905 of the circuit board 906 is provided between the heat sink 902 and the circuit board 906. The frame member 904 is integrated with the frame member 904 by press-fitting into the intervening frame member 904, or by insert molding when the frame member 904 is molded.

  On the other hand, as a prior art related to the present invention, for example, there is “a manufacturing method of a power module, a terminal and a power module” described in Patent Document 1.

JP 2013-211499 A

  In the component unit 900 as shown in FIG. 61, when the frame member 904 is enlarged, warpage and deformation are likely to occur, and this deteriorates the plane accuracy. Therefore, the conductive terminal 903 on the frame member 904 side and the heat sink 902 This causes a bonding failure with the upper electric element 901. Further, the position accuracy may be deteriorated due to shrinkage of the synthetic resin forming the frame member 904.

  Further, when an integrated frame member 904 having a plurality of conductive terminals 903 incorporated therein is manufactured by insert molding, in order to improve the arrangement pitch and planar accuracy of the conductive terminals 903, a plurality of insert molds are usually modified. However, since the plurality of conductive terminals 903 are all arranged separately in the frame member 904, it is extremely difficult to perform accurate correction at the stage of mold correction, and finally the target value is reached. The reality is that there is a possibility that it cannot be corrected.

  Furthermore, it is known that if the frame member 904 is formed using a resin material with less heat shrinkage or a resin material with good filling properties, the arrangement pitch and planar accuracy of the conductive terminals 903 are improved. Molding the entire frame member 904 with an excellent resin material often leads to an increase in cost, and in fact, these resin materials may not be used.

  It is estimated that such a problem also occurs in the manufacturing process of the power module described in Patent Document 1.

  Therefore, the problem to be solved by the present invention is that the position accuracy of the conductive terminal with respect to the heat radiating plate is hardly deteriorated due to the warp, deformation, and contraction of the frame member, and the electric element mounted on the conductive terminal and the heat radiating plate. It is an object of the present invention to provide a terminal module that is less likely to cause a bonding failure with the other and excellent in versatility.

The terminal module of the present invention is a terminal attached to the heat sink via a frame member for electrically connecting an electric element mounted on the heat sink and a circuit board disposed to face the heat sink. A module,
A conductive terminal having a connection part for connecting to the electrical element and a contact part inserted into a through hole of the circuit board, and holding the part of the conductive terminal, the conductive terminal is fixed in a fixed posture. An insulating base member,
The base member includes a base portion that is fixed to the frame member, and a holder portion that is formed upright on the base portion and holds a part of the conductive terminal.

  With such a configuration, the conductive terminal is attached to the heat radiating plate through the frame member integrated with the base member while being held by the base member, and thus is caused by warping, deformation, and contraction of the frame member. The position accuracy of the conductive terminal with respect to the heat sink is difficult to deteriorate. In addition, since the position accuracy of the conductive terminal with respect to the heat sink becomes good, bonding failure between the conductive terminal and the electric element on the heat sink is less likely to occur. Furthermore, even a terminal module having a different number of poles (number of conductive terminals) can be manufactured without changing the mold, and can be used for products with different specifications.

  Here, it is desirable to provide a press-fit mechanism that can be elastically expanded / contracted in the radial direction of the through hole in at least a part of the contact portion.

  In addition, a floating mechanism having higher elasticity and flexibility than other portions of the conductive terminal can be provided in a region near the contact portion of the conductive terminal.

  In this case, as the floating mechanism, it is possible to provide flexible pieces that face each other with a through portion interposed between the conductive terminals.

  Further, as the floating mechanism, a flexible portion in which a plurality of rectangular prism-shaped flexible pieces are arranged at equal intervals around the virtual axis can be provided on the conductive terminal.

  On the other hand, the conductive terminal may be accommodated in a groove provided in the holder portion of the base member, or the conductive terminal may be integrally fixed to the base member.

  Furthermore, the press-fit mechanism can be formed of a plurality of contact pieces that can be elastically expanded and contracted in the radial direction of the through hole.

  According to the present invention, the positional accuracy of the conductive terminal with respect to the heat sink due to the warp, deformation, and contraction of the frame member hardly occurs, and bonding failure between the conductive terminal and the electric element mounted on the heat sink also occurs. Therefore, it is possible to provide a terminal module that is difficult to perform and excellent in versatility.

It is the perspective view which looked at the terminal module which is embodiment of this invention from the front and the left side. It is a perspective view which shows the conductive terminal which comprises the terminal module shown in FIG. It is a figure which shows the assembly process of the terminal module shown in FIG. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 1 and an electroconductive terminal differs. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 1 and an electroconductive terminal differs. It is a perspective view which shows a circuit board, a terminal module, a frame member, and a heat sink. It is a partially-omission perspective view which shows the state which incorporates the terminal module shown in FIG. 1 in a frame member. It is a perspective view which shows the component unit which assembled | attached the electric element, the frame member, the terminal module, etc. to the heat sink. It is the figure seen from the arrow X direction in FIG. It is sectional drawing in the AA line in FIG. It is sectional drawing in the BB line in FIG. It is a figure which shows the state which attached the circuit board to the component unit shown in FIG. It is sectional drawing in the CC line | wire in FIG. It is sectional drawing in the DD line | wire in FIG. It is a figure which shows the process of mounting a circuit board in the component unit shown in FIG. It is a perspective view which shows the terminal module which is other embodiment. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 16 and an electroconductive terminal differs. It is a perspective view which shows the conductive terminal which comprises the terminal module shown in FIG. It is a perspective view which shows the terminal module which is other embodiment. FIG. 20 is a perspective view showing a conductive terminal constituting the terminal module shown in FIG. 19. It is a figure which shows the assembly process of the terminal module shown in FIG. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 19 and an electroconductive terminal differs. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 19 and an electroconductive terminal differs. It is a perspective view which shows the component unit which assembled | attached the electric element, the frame member, the terminal module, etc. to the heat sink. It is the figure seen from the arrow Y direction in FIG. It is sectional drawing in the EE line | wire in FIG. It is sectional drawing in the FF line in FIG. It is a figure which shows the state which attached the circuit board to the component unit shown in FIG. It is sectional drawing in the GG line in FIG. It is sectional drawing in the HH line | wire in FIG. It is a perspective view which shows the terminal module which is other embodiment. FIG. 32 is a perspective view showing another terminal module in which the arrangement state of the terminal module shown in FIG. 31 and the conductive terminals is different. FIG. 32 is a perspective view showing a conductive terminal constituting the terminal module shown in FIG. 31. It is a perspective view which shows the terminal module which is other embodiment. It is a perspective view which shows the conductive terminal which comprises the terminal module shown in FIG. It is a figure which shows the assembly process of the terminal module shown in FIG. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 34 and an electroconductive terminal differs. It is a perspective view which shows the other terminal module from which the arrangement state of the terminal module shown in FIG. 34 and an electroconductive terminal differs. It is a perspective view which shows the component unit which assembled | attached the electric element, the frame member, the terminal module, etc. to the heat sink. It is the figure seen from the arrow Z direction in FIG. It is sectional drawing in the JJ line | wire in FIG. It is a perspective view which shows the terminal module which is other embodiment. FIG. 43 is a perspective view showing another terminal module in which the arrangement state of the conductive module and the terminal module shown in FIG. 42 are different. FIG. 43 is a perspective view showing a conductive terminal constituting the terminal module shown in FIG. 42. It is a perspective view which shows the terminal module which is other embodiment. It is a perspective view which shows the conductive terminal which comprises the terminal module shown in FIG. It is the figure seen from the arrow line V direction in FIG. It is sectional drawing in the KK line | wire in FIG. It is sectional drawing in the LL line in FIG. It is a figure which shows the assembly process of the terminal module shown in FIG. It is a partially-omission perspective view which shows the state which attached the circuit board to the component unit using the terminal module of this embodiment. It is a figure which shows the process in which the conductive terminal of the terminal module of this embodiment is inserted in the through hole of a circuit board. It is a perspective view which shows the terminal module which is other embodiment. It is a perspective view which shows the other conductive terminal from which the arrangement state of a terminal module shown in FIG. 53 and a conductive terminal differs. It is a perspective view which shows the conductive terminal which comprises the terminal module shown in FIG. It is a partially-omission perspective view which shows the process of attaching the terminal module which is other embodiment to a frame member. FIG. 57 is a partially omitted perspective view showing a state in which the attaching step shown in FIG. 56 is completed. It is a figure which shows the component unit formed through the process shown in FIG. It is sectional drawing in the MM line | wire in FIG. It is sectional drawing in the NN line | wire in FIG. It is a perspective view which shows the conventional integrated frame member, the heat sink with an electric element, and a circuit board.

  Hereinafter, based on FIGS. 1-15, the terminal module 100 etc. which are embodiment of this invention are demonstrated. In addition, the arrow Q direction shown in FIG. 1 is made into an up-down direction, the arrow R is made into the front-back direction (front back direction), and the arrow S is made into the left-right direction (hereinafter the same).

  As shown in FIGS. 1 and 6, the terminal module 100 includes a plurality of electrical elements 20 mounted on the heat sink 10 and a circuit board 40 with a through hole 41 disposed to face the heat sink 10. It is a member that is attached to the heat sink 10 via the frame member 30 for electrical connection. The terminal module 100 holds a conductive portion 110 having a connection portion 111 for connecting to the electric element 20 and a contact portion 112 inserted into the through hole 41 of the circuit board 40, and a part of the conductive terminal 110. And an insulating base member 130 that fixes the conductive terminal 110 in a fixed posture.

  As shown in FIG. 2, the conductive terminal 110 is formed by pressing and bending a metal plate having conductivity and elasticity, and the entire shape thereof is substantially L-shaped. A contact portion 112 is provided on the upper end side of the L-shaped vertical portion, and a connection portion 111 is provided on the end portion side of the L-shaped horizontal portion. A flexible portion 113, a holding portion 114, an engaging portion 115, and an elbow portion 116 are successively formed in order from the contact portion 112 toward the connecting portion 111. A width 116w of the elbow portion 116 between the engagement portion 115 and the connection portion 111 is set to be smaller than the width of other regions.

  The outer peripheral shape of the contact portion 112 has a spindle shape. A pair of contact pieces 112a and 112b facing each other are formed by opening a spindle-shaped through-hole 112c having a shape similar to the outer peripheral shape in the center region of the contact portion 112. The contact pieces 112a and 112b each have a banana shape and are arranged with the recessed portions facing each other. The contact pieces 112a and 112b can be elastically deformed in a direction approaching and separating from each other, whereby a press-fit mechanism capable of elastic expansion and contraction in the radial direction of the through hole 41 of the circuit board 40 is formed in the contact portion 112. Has been.

  A pair of flexible pieces 113a and 113b facing each other in parallel are formed by opening an oval through portion 113c in the flexible portion 113 formed in a region near the contact portion 112 of the conductive terminal 110. Yes. Since the flexible pieces 113a and 113b have higher elastic displacement than other portions of the conductive terminal 110, a floating mechanism described later is formed in the flexible portion 113. The holding part 114 and the engaging part 115 are formed to have a width and thickness that can be press-fitted into a groove 131 of the base member 130 described later.

  As shown in FIGS. 1 and 3, the base member 130 includes a base portion 132 that is integrally fixed to the frame member 30 (see FIG. 6) by secondary molding, and a portion near the back surface on the base portion 132. And a holder portion 133 formed in an upright shape. A flat portion 137 for holding the connection portion 111 of the conductive terminal 110 is provided at a portion near the front surface of the base portion 132. A through hole 134 and a stepped notch portion 135 are provided in portions near the left and right ends of the base portion 132, respectively.

  A plurality of grooves 131 for press-fitting the conductive terminals 110 in an upright manner are formed on the front side of the holder portion 133. A slit-like front opening 136 is provided on the front side of the groove 131. The length of the front opening 136 in the vertical direction is the same as that of the groove 131. The width of the front opening 136 in the left-right direction is smaller than the width 144 w of the holding portion 114 of the conductive terminal 110 and is equal to the width 116 w of the elbow portion 116 or slightly larger than the width 116 w.

  As shown in FIG. 3, the terminal module 100 is formed by press-fitting a plurality of conductive terminals 110 into a plurality of grooves 131 provided in the holder portion 133 of the base member 130. The conductive terminal 110 is press-fitted into the groove portion 131 from the upper opening end 131 a of the groove portion 131 toward the base portion 132 with the connecting portion 111 directed toward the base portion 132 of the base member 130. At this time, the elbow part 116 is press-fitted while passing through the front opening 136 of the groove 131, and the press-fitting is completed when the lower surface of the connection part 111 comes into contact with the base part 132.

  The conductive terminal 110 after being press-fitted into the groove 131 is in a state in which the contact portion 112 and the flexible portion 113 protrude upward from the upper opening end 131 a of the groove 131, and the lower surface of the connection portion 111 faces the flat portion 137. Hold in contact.

  As shown in FIG. 3, when the conductive terminal 110 is press-fitted into the groove 131 of the base member 130, the flat plate-shaped holding portion 114 is accommodated in the groove 131 without a gap, and is constant so that the conductive terminal 110 does not rattle. Demonstrates the ability to maintain posture.

  The engaging portion 115 is provided with a vertically long recess 115a at the center thereof, and a plurality of protrusions 115d are formed on the left and right outer surfaces of the engaging portion 115 so as to protrude in the width direction. Although not shown, a convex portion (see convex portion 115b in FIG. 47) protruding in a similar shape to the concave portion 115a is formed on the back surface of the engaging portion 115.

  When the conductive terminal 110 is press-fitted into the groove portion 131 of the base member 130, the plurality of protrusions 115 d of the engaging portion 115 are engaged so as to press the inner surface of the groove portion 131, and the conductive terminal 110 is detached from the groove portion 131. To prevent.

  The number of press-fits and press-fit positions of the conductive terminals 110 with respect to the plurality of grooves 131 can be arbitrarily set according to the type and arrangement of the electric element 20 (see FIG. 6). Therefore, by changing the number of conductive terminals 110 and the press-fitting position according to the design conditions, in addition to the terminal module 100 shown in FIG. 1, the terminal module 101 shown in FIG. 4 or the terminal module 102 shown in FIG. be able to. That is, by changing the conductive terminals 110 such as the terminal modules 100, 101, and 102, it is possible to manufacture various variations (different number of poles) of terminal modules with a single mold.

  Next, the component unit 90 formed using the terminal modules 100, 101, 102 will be described with reference to FIGS. As shown in FIG. 6, the terminal module 100 electrically connects a plurality of electrical elements 20 mounted on the heat sink 10 and a circuit board 40 with a through hole 41 disposed to face the heat sink 10. It is a member attached to the heat sink 10 via the frame member 30 for connection.

  6 and 7, the frame member 30 and the terminal module 100 are shown as independent members, but in reality, the terminal module 100 is mounted on a mold (not shown) for molding the frame member 30. After that, the frame member 30 in which the plurality of terminal modules 100 are integrated is formed by performing secondary molding.

  In the secondary molding process, as shown in FIGS. 6 and 7, the frame member 30 is formed so as to be in close contact with the back surface, the left and right side surfaces, and the bottom surface of the base portion 132 of the terminal module 100 so as to surround these surfaces. The Further, in the secondary molding step, the synthetic resin constituting the frame member 30 is filled in the left and right through holes 134 of the base portion 132 and the left and right cutout portions 135 of the base portion 132 are filled. Since the synthetic resin protrusion 31 is formed, the terminal module 100 is firmly integrated with the frame member 30.

  After fixing the frame member 30 integrally formed with a predetermined number of terminal modules 100, 101, 102, etc., to the heat sink 10 (see FIG. 6) to which the electric element 20 is attached using an adhesive, the terminal module 100, When the connecting portion 111 of the conductive terminal 110 constituting the terminals 101 and 102 and the electric element 20 are connected by the bonding wire 21 (see FIG. 10), the component unit 90 as shown in FIGS. 8 and 9 is completed.

  As described above, the conductive terminal 110 is attached to the heat radiating plate 10 through the frame member 30 integrated with the base member 130 such as the terminal modules 100, 101, 102 while being held by the base member 130. Due to the warp, deformation, and contraction of the frame member 30, the positional accuracy of the conductive terminal 110 with respect to the heat sink 10 is unlikely to deteriorate. Further, since the positional accuracy of the conductive terminal 110 with respect to the heat sink 10 is improved, a bonding failure between the conductive terminal 110 and the electric element 20 on the heat sink 10 is unlikely to occur. Furthermore, since the terminal module 100 can be used for products with different specifications if only the frame member 30 is remade, it is possible to produce products with various specifications using the same terminal module 100 or the like. Cost reduction can be achieved.

  Here, the reason why the positional accuracy of the conductive terminal 110 is improved will be described. As described above, when the conventional frame member 904 shown in FIG. 61 (an integrated frame member 904 incorporating a plurality of conductive terminals 903) is manufactured, in order to improve the arrangement pitch and planar accuracy of the conductive terminals 903. Usually, the insert mold is corrected a plurality of times. However, since the plurality of conductive terminals 903 are all arranged separately in the frame member 904, it is extremely difficult to perform an accurate correction at the mold correction stage. The reality is that it is difficult and may not be corrected to the final target.

  On the other hand, in the case of the frame member 30 (see FIG. 8) integrally formed with a predetermined number of terminal modules 100, 101, 102, etc., the insert mold is corrected using the base member 130 in a block shape. Therefore, there is an advantage that the correction work is easy, and this leads to an improvement in the positional accuracy of the conductive terminal 110 and the positional accuracy of the base member 130.

  Further, as another excellent effect obtained by modularizing the terminal modules 100, 101, 102, etc., the molding resin material of the base member 130 is not affected by the molding resin material of the frame member 30. Therefore, it is possible to form the base member 130 with less heat shrinkage and high accuracy by selecting and using an appropriate resin material. Furthermore, even when molding using a mold having a narrow space, it is possible to form a base member 130 having an unfilled and accurate shape by selecting a resin having a good resin filling property. Excellent effect.

  Furthermore, even a terminal module with a different number of poles (number of conductive terminals 110) can be manufactured without changing the mold, and if the arrangement interval of the conductive terminals 110 is the same, it can be used for products with different specifications. Therefore, it is excellent in versatility. Further, the resin material of the base member can be appropriately selected without being influenced by the resin material of the frame member.

  The circuit board 40 shown in FIG. 6 is attached to the upper surface portion of the component unit 90 shown in FIGS. 8 and 9, and the contact portions 112 of the conductive terminals 110 are respectively inserted into the plurality of through holes 41 provided in the circuit board 40. When a plurality of screws 42 are screwed onto the female screw portion 32 of the frame member 30, the circuit board 40 is fixed to the frame member 30 as shown in FIGS. 12 and 13.

  FIG. 15 shows a process in which the insertion operation into the through hole 41 is performed in a state where the plurality of conductive terminals 110 and the through hole 41 of the circuit board 40 are slightly displaced from their original positions. As shown in FIG. 15A, when the insertion operation is started in a state where the through hole 41 of the circuit board 40 is displaced from directly above the conductive terminal 110, the upper end of the contact portion 112 of the conductive terminal 110 starts from the center of the through hole 41. It enters the through hole 41 in a displaced state.

  Here, since the contact portion 112 of the conductive terminal 110 has a spindle shape, and a flexible portion 113 having a floating mechanism is formed below the contact portion 112, as shown in FIG. While the flexible portion 113 is deformed so that the contact portion 112 is directed toward the center of the through hole 41, the contact portion 112 is inserted into the through hole 41, and the state shown in FIG.

  As described above, since the conductive terminal 110 includes the flexible portion 113 having a floating mechanism, the flexible portion 113 is deformed even if the axial center of the conductive terminal 110 and the center of the through hole 41 are slightly displaced. By doing so, it is possible to cope (absorb the displacement).

  Next, terminal modules 200 and 201 according to other embodiments will be described with reference to FIGS. In the constituent parts of the terminal modules 200 and 201, parts having the same shape and function as those of the constituent parts of the terminal module 100 are denoted by the same reference numerals as those in FIGS.

  As shown in FIG. 16, in the terminal module 200, the plurality of conductive terminals 110A are integrally fixed to the base member 130A by insert molding. A rib 138 is formed integrally with the base member 130A so as to cross a part of the connection portion 111 of the plurality of conductive terminals 110 in the left-right direction.

  As illustrated in FIG. 18, the conductive terminal 110 </ b> A includes a contact portion 112, a flexible portion 113, an elbow portion 116, and a connection portion 111, similar to the conductive terminal 110 illustrated in FIG. 2. The lateral width from the flexible part 113 to the connection part 111 is constant. A region 117 between the flexible portion 113 and the connecting portion 111 is integrally held in the holder portion 133A of the base member 130A. A penetrating portion 117 a is opened in the region 117, and a penetrating portion 111 a is also opened in the connecting portion 111.

  In the terminal modules 200 and 201, the through portion 117a of the conductive terminal 110A is filled with the synthetic resin forming the holder portion 133A, and the through portion 111a is filled with the synthetic resin forming the base portion 132A and the rib 138. Filled.

  Since the number and arrangement state of the conductive terminals 110A can be arbitrarily set according to the design conditions, in addition to the terminal module 200 shown in FIG. 16, for example, the terminal module 201 shown in FIG. Can be formed. The terminal modules 200 and 201 are used integrally with the frame member 30 (see FIG. 6) by secondary molding, like the terminal module 100 shown in FIG.

  The terminal modules 200 and 201 are insert-molded to integrally fix the plurality of conductive terminals 110A to the base member 130A. However, as with the terminal module 100 (FIG. 1) described above, the number of poles (conductive terminals) Even if it is a terminal module with a different number (110A), it can be manufactured without changing the mold, and if the arrangement interval of the conductive terminals 110A is the same, it can be used for products with different specifications. Is also excellent. Further, the resin material of the base member can be appropriately selected without being influenced by the resin material of the frame member.

  Next, based on FIGS. 19-30, the terminal module 300 etc. which are other embodiment of this invention are demonstrated. As shown in FIGS. 19, 24, and 28, the terminal module 300 includes a connection portion 111 that connects to the electrical element 20 and a conductive terminal 310 that has a contact portion 312 that is inserted into the through hole 41 of the circuit board 40. And an insulating base member 330 that holds the conductive terminal 310 in a fixed posture by holding a part of the conductive terminal 310.

  As shown in FIG. 20, the conductive terminal 310 is formed by subjecting a metal plate having conductivity and elasticity to pressing and bending, and the entire shape thereof is substantially L-shaped. A contact portion 312 is provided on the upper end side of the L-shaped vertical portion, and a connection portion 111 is provided on the end side of the L-shaped horizontal portion. A shoulder portion 313, a holding portion 114, an engaging portion 115, and an elbow portion 116 are successively formed in order from the contact portion 312 toward the connecting portion 111. Since the shape, function, and the like of the portion from the holding portion 114 to the connection portion 111 are the same as those of the conductive terminal 110 shown in FIG. 2, the same reference numerals as those in FIG. .

  The contact portion 312 has a quadrangular prism shape, and a flat shoulder portion 313 is formed across a portion where the lower portion of the contact portion 312 is continuously widened. The width 313 w of the shoulder portion 313 is larger than the width 312 w of the contact portion 312 and smaller than the width 114 w of the holding portion 114.

  As shown in FIG. 19, the base member 330 is erected in a base portion 132 that is integrally fixed to the frame member 30 (see FIG. 24) by secondary molding and a portion near the back surface on the base portion 132. And a holder portion 333 formed in the above. The base member 330 and the base member 130 shown in FIG. 1 are the same except that the vertical sizes of the holder portions 333 and 133 are different. Therefore, the same reference numerals as those in FIG. Is omitted.

  As shown in FIG. 21, the terminal module 300 is formed by press-fitting a plurality of conductive terminals 310 into a plurality of grooves 131 provided in the holder portion 333 of the base member 330. The conductive terminal 310 is press-fitted into the groove portion 131 from the upper opening end 131 a of the groove portion 131 toward the base portion 132 with the connecting portion 111 facing the base portion 132 of the base member 330. At this time, the elbow part 116 is press-fitted while passing through the front opening 136 of the groove part 131, and the press-fitting is completed when the lower surface of the connection part 111 comes into contact with the base part 132.

  The conductive terminal 310 after being press-fitted into the groove 131 is in a state in which the contact portion 312 and the shoulder portion 313 protrude upward from the upper opening end 131 a of the groove 131, and the connection portion 111 has a lower surface of the base portion 132. The flat portion 137 is held in contact.

  The number of press-fits and the press-fit positions of the conductive terminals 310 with respect to the plurality of grooves 131 of the base member 330 can be arbitrarily set according to the type and arrangement state of the electric element 20 (see FIG. 24). Therefore, by changing the number of conductive terminals 310 and the press-fitting position according to the design conditions, in addition to the terminal module 300 shown in FIG. 19, the terminal module 301 shown in FIG. 22, the terminal module 302 shown in FIG. be able to.

  Next, the component unit 91 and the like formed using the terminal modules 300, 301, and 302 will be described with reference to FIGS. As shown in FIG. 24, the terminal modules 300, 301, 302, etc. include a plurality of electric elements 20 mounted on the heat sink 10, and a circuit board 40 with a through hole 41 disposed to face the heat sink 10. Are electrically attached to the heat sink 10 via the frame member 30.

  Specifically, after the terminal modules 300, 301, 302 and the like are mounted on a mold (not shown) for forming the frame member 30, a plurality of terminal modules 300, 301, The frame member 30 in which 302 and the like are integrated is formed.

  As shown in FIGS. 24 to 27, after fixing the frame member 30 integrally formed with a predetermined number of terminal modules 300, 301, 302 and the like to the heat radiating plate 10 to which the electric element 20 is attached using an adhesive. When the connecting portion 111 of the conductive terminal 310 and the electric element 20 constituting the terminal modules 300, 301, 302 and the like are connected by the bonding wire 21, the component unit 91 is completed.

  As described above, the conductive terminal 310 is attached to the heat sink 10 through the frame member 30 integrated with the base member 330 such as the terminal modules 300, 301, and 302 while being held by the base member 330. Due to the warp, deformation, and contraction of the frame member 30, the positional accuracy of the conductive terminal 310 with respect to the heat sink 10 is unlikely to deteriorate. Further, since the position accuracy of the conductive terminal 310 with respect to the heat sink 10 is improved, a bonding failure between the conductive terminal 310 and the electric element 20 on the heat sink 10 is hardly generated.

  As shown in FIGS. 28 to 30, the circuit board 40 shown in FIG. 6 is attached to the upper surface portion of the component unit 91 (see FIG. 24), and the conductive terminals 310 are respectively connected to the plurality of through holes 41 provided in the circuit board 40. When the contact portion 312 is inserted and the plurality of screws 42 are screwed onto the female screw portion 32 of the frame member 30, the circuit board 40 is fixed to the frame member 30.

  Next, terminal modules 400 and 401 which are other embodiments will be described based on FIGS. 31 to 33. In the constituent parts of the terminal modules 400 and 401, parts having the same shape and function as those of the constituent parts of the terminal module 300 are denoted by the same reference numerals as those in FIGS.

  As shown in FIG. 31, in the terminal module 400, a plurality of conductive terminals 310A are integrally fixed to the base member 330A by insert molding. The contact portion 312 and the shoulder portion 313 of the conductive terminal 310A are held in a state of protruding from the upper end surface of the holder portion 333A of the base member 330A. A rib 138 that is integrated with the base member 330A is formed so as to cross a part of the connection portion 111 of the plurality of conductive terminals 310A in the left-right direction.

  As illustrated in FIG. 33, the conductive terminal 310 </ b> A includes a contact portion 312, a shoulder portion 313, an elbow portion 116, and a connection portion 111, similar to the conductive terminal 310 illustrated in FIG. 20. The lateral width from the shoulder portion 313 to the connecting portion 111 is constant. A region 118 between the shoulder portion 313 and the connection portion 111 is integrally held in the holder portion 333A of the base member 330A. A penetrating portion 118 a is opened in the region 118, and a penetrating portion 111 a is also opened in the connecting portion 111.

  In the terminal modules 400 and 401, the through portion 118a of the conductive terminal 310A is filled with the synthetic resin forming the holder portion 333A, and the through portion 111a is filled with the synthetic resin forming the base portion 132A and the rib 138. Filled.

  Since the number and arrangement state of the conductive terminals 310A can be arbitrarily set according to the design conditions, in addition to the terminal module 400 shown in FIG. 31, for example, the terminal module 401 shown in FIG. 32 or other types of terminal modules Can be formed. Similar to the terminal module 100 shown in FIG. 1, the terminal modules 400 and 401 are used integrally with the frame member 30 (see FIG. 6) by secondary molding.

  In the case of the conductive terminal 310 of the terminal module 300 shown in FIG. 19 and the conductive terminal 310 </ b> A of the terminal module 400 shown in FIG. 31, the size (outer diameter) of the contact portion 312 is the size of the through hole 41 of the circuit board 40. Since the inner diameter is considerably smaller than the inner diameter, the contact portion 312 can be inserted into the through hole 41 without providing a flexible portion on the proximal end side of the contact portion 312. As shown in FIG. After that, the contact portion 312 and the through hole 41 are connected by the solder 45, but like the other conductive terminals, a through hole can be provided in the shoulder portion 313 to make a flexible portion.

  Next, a terminal module 500 as another embodiment will be described with reference to FIGS. It should be noted that parts having the same shape and function as the constituent parts of the terminal module 100 in the constituent parts such as the terminal module 500 are denoted by the same reference numerals as in FIGS.

  As shown in FIG. 34 and FIG. 35, the terminal module 500 includes a conductive portion 510 having a connection portion 111 for connecting to an electric element and a contact portion 512 to be inserted into a through hole of a circuit board. And an insulating base member 130 that holds the conductive terminal 510 in a fixed posture by holding a part thereof.

  As shown in FIG. 35, the conductive terminal 510 is formed by pressing and bending a metal plate having conductivity and elasticity, and the overall shape thereof is substantially L-shaped. A contact portion 512 is provided on the upper end side of the L-shaped vertical portion. A flexible portion 113, a holding portion 114, an engaging portion 115, and an elbow portion 116 are successively formed in order from the contact portion 512 toward the connecting portion 111. The shape and function of the portion from the flexible portion 113 to the connecting portion 111 are the same as those of the conductive terminal 110 shown in FIG.

  The contact portion 512 is roughly formed by arranging a plurality of contact pieces 512a bent in an obtuse elbow shape around the virtual axis 512c at regular intervals with the respective protruding portions facing outward. It is formed so as to form a shape. C-shaped connecting portions 512b and 512d are provided on the upper and lower sides of the plurality of contact pieces 512a so as to bundle the plurality of contact pieces 512a, respectively. A front end portion 512e provided above the connecting portion 512b located on the upper side has a tapered shape toward the upper end. The continuous portion 512d located on the lower side continues to the flexible portion 113 with the constricted portion 119 interposed therebetween.

  In addition, a shaft body 512g (see FIG. 41) extending from the continuous portion 512b is bent 180 degrees (folded in an inverted J shape) in a state in which a part of the distal end portion 512e is notched, thereby allowing a plurality of portions to be obtained. A shaft body 512g is disposed at a position of a virtual axis 512c surrounded by the contact piece 512a. The curved portion 512f of the shaft body is exposed at the notch portion of the distal end portion 512e.

  The plurality of contact pieces 512a are formed of an elastic metal, and each contact piece 512a can be deformed so as to approach and separate from the virtual axis 512c of the contact part 512. Therefore, the contact part 512 has a virtual axis 512c. It can be elastically scaled around. Therefore, the contact portion 512 has a press-fit mechanism that can be elastically expanded and contracted in the inner diameter direction of the through hole 41 of the circuit board 40.

  As shown in FIG. 36, the terminal module 500 shown in FIG. 34 is formed by press-fitting the plurality of conductive terminals 510 into the plurality of groove portions 131 provided in the holder portion 133 of the base member 130. The conductive terminal 510 after being press-fitted into the groove 131 is in a state in which the contact portion 512 and the flexible portion 113 protrude upward from the upper opening end 131 a of the groove 131, and the connection portion 111 has a lower surface on the flat portion 137. Hold in contact.

  The number of press-fits and press-fit positions of the conductive terminals 510 with respect to the plurality of grooves 131 can be arbitrarily set according to the type and arrangement state of the electric element 20 (see FIG. 6). Therefore, by changing the number of conductive terminals 510 and the press-fitting position according to the design conditions, in addition to the terminal module 500 shown in FIG. 34, the terminal module 501 shown in FIG. 37, the terminal module 502 shown in FIG. be able to.

  Next, the component unit 92 formed using the terminal modules 500, 501, and 502 will be described with reference to FIGS. After the frame member 30 integrally molded with a predetermined number of terminal modules 500, 501, 502, etc. is fixed to the heat sink 10 to which the electric element 20 is attached using an adhesive, the terminal modules 500, 502, 503 are configured. When the connecting portion 111 of the conductive terminal 510 and the electric element 20 are connected by the bonding wire 21, the component unit 92 as shown in FIGS. 39 and 40 is completed.

  As shown in FIGS. 34, 35, and 41, the front end portion 512e of the contact portion 512 of the conductive terminal 510 constituting the terminal module 500 or the like has a tapered shape, and the notch portion of the front end portion 512 faces the front end direction. Since there is a curved portion 512f having a smooth convex curved surface projecting, the workability when inserting the through-hole (not shown) of the circuit board into the contact portion 512 is good. Further, since the plurality of contact pieces 512a constituting the contact portion 512 have a press-fit function that can be elastically expanded / contracted, the contact reliability after being inserted into the through hole of the circuit board is also excellent.

  Furthermore, since the conductive terminal 510 includes the flexible portion 113 having a floating mechanism, the flexible portion 113 is deformed even if the axial center of the conductive terminal 510 and the center of the through hole of the circuit board are slightly displaced. By doing so, it is possible to cope (absorb the displacement).

  Next, terminal modules 600 and 601 which are other embodiments will be described based on FIGS. 42 to 44. In the constituent parts of the terminal modules 600 and 601, the parts having the same shape and function as those of the constituent parts of the terminal modules 200 and 500 described above have the same reference numerals as those in FIGS. 16 to 18 and FIGS. A description thereof will be omitted.

  As shown in FIG. 42, in the terminal module 600, a plurality of conductive terminals 510A are integrally fixed to the base member 130A by insert molding. A rib 138 that is integrated with the base member 130A is formed so as to cross a part of the connecting portion 111 of the plurality of conductive terminals 510A in the left-right direction.

  As shown in FIG. 44, the conductive terminal 510A includes a contact portion 512, a flexible portion 113, an elbow portion 116, and a connection portion 111, like the conductive terminal 510 shown in FIG. The width of the part from the flexible part 113 to the connecting part 111 is constant. A region 117 between the flexible portion 113 and the connecting portion 111 is integrally held in the holder portion 133A of the base member 130A. A penetrating portion 117 a is opened in the region 117, and a penetrating portion 111 a is also opened in the connecting portion 111.

  Since the number and arrangement state of the conductive terminals 510A can be arbitrarily set according to the design conditions, in addition to the terminal module 600 shown in FIG. 42, for example, the terminal module 601 shown in FIG. Can be formed. Similarly to the terminal module 500 shown in FIG. 34, the terminal modules 600 and 601 are used by being integrated with the frame member 30 (see FIG. 6) by secondary molding.

  Next, based on FIGS. 45-52, the terminal module 700 which is other embodiment is demonstrated. In the constituent parts of the terminal module 700, parts having the same shape and function as those of the constituent parts of the terminal module 500 described above are denoted by the same reference numerals as those in FIGS.

  As shown in FIGS. 45 and 46, the terminal module 700 includes a conductive portion 710 having a connection portion 111 for connecting to an electric element and a contact portion 512 inserted into a through hole of a circuit board, and a conductive terminal 710. And an insulating base member 130 that holds the conductive terminal 710 in a fixed posture by holding a part thereof. A flexible portion 713 is formed below the contact portion 512 so as to protrude from the base member 130.

  As shown in FIGS. 46 to 49, the conductive terminal 710 is formed by subjecting a metal plate having conductivity and elasticity to pressing and bending, and the entire shape is substantially L-shaped. A contact portion 512 is provided on the upper end side of the L-shaped vertical portion. In order from the contact portion 512 toward the connection portion 111, a flexible portion 713, a holding portion 114, an engaging portion 115, and an elbow portion 116 are continuously formed. The shape and function of the portion from the contact portion 512 and the holding portion 114 to the connection portion 111 are the same as those of the conductive terminal 510 shown in FIG. As shown in FIGS. 46 and 47, a convex portion 115 b is formed on the back side of the concave portion 115 a of the engaging portion 115.

  As shown in FIG. 46, FIG. 47 and FIG. 49, the flexible portion 713 is formed by arranging a plurality of flexible pieces 713a having a quadrangular prism shape around the virtual axis 512c at equal intervals. . C-shaped connecting portions 713b and 713c are provided on the upper and lower sides of the plurality of flexible pieces 713a so as to bundle the plurality of flexible pieces 713a, respectively. The continuous portion 713b located on the upper side is connected to the continuous portion 512d in a state where the diameter is continuously reduced toward the contact portion 512. The connecting portion 713c located on the lower side is connected to the constricted portion 119 in a state where the diameter is continuously reduced toward the holding portion 114.

  Since the plurality of flexible pieces 713a constituting the flexible portion 713 have higher elastic displacement than other portions of the conductive terminal 710, it is possible when the contact portion 512 or the like receives an external force in a direction intersecting the virtual axis 512c. A floating mechanism that can be accommodated by bending the bending portion 713 preferentially is formed.

  As shown in FIG. 50, the terminal module 700 shown in FIG. 45 is formed by press-fitting a plurality of conductive terminals 710 into the plurality of grooves 131 provided in the holder part 133 of the base member 130. The conductive terminal 710 after being press-fitted into the groove 131 is in a state in which the contact portion 512 and the flexible portion 713 protrude upward from the upper opening end 131a of the groove 131, and the connection portion 111 has a lower surface on the flat portion 137. Hold in contact.

  As shown in FIG. 51, the frame member 30 in which the terminal module 700 is integrated by secondary molding is attached to a heat sink to which the electric element 20 is attached, and the connection portion 111 of the conductive terminal 710 and the electric element 20 Are connected by the bonding wires 21, the circuit board 40 is attached so as to cover the upper surface portion of the frame member 30. At this time, the contact portions 512 of the plurality of conductive terminals 710 are respectively inserted into the through holes 41 of the circuit board 40. Since the contact portion 512 includes a press-fit mechanism, the contact reliability after being inserted into the through hole 41 is excellent.

  Further, since the flexible portion 713 of the conductive terminal 710 has a floating mechanism, as shown in FIG. 52, when the circuit board 40 is attached, the position of the conductive terminal 710 and the position of the through hole 41 are shifted. Even if there is, it is possible. That is, since the tip end portion 512e of the contact portion 512 of the conductive terminal 710 has a tapered shape, the tip end portion 512e comes into contact with the inner periphery of the through hole 41 in which the position shift occurs, so that the contact portion 512 has the through hole 41. The flexible portion 713 is elastically deformed by the pressing force that the contact portion 512 receives from the inner periphery of the through-hole 41 during the insertion process, and the displacement can be absorbed.

  Next, terminal modules 701 and 702 as other embodiments will be described with reference to FIGS. 53 to 55. Note that in the constituent parts of the terminal modules 701 and 702, the parts having the same shape and function as the constituent parts of the terminal modules 600 and 700 described above have the same reference numerals as those in FIGS. 42 to 44 and 45 to 47. A description thereof will be omitted.

  As shown in FIG. 53, in the terminal module 701, a plurality of conductive terminals 710A are integrally fixed to the base member 130A by insert molding. A rib 138 that is integrated with the base member 130A is formed so as to cross a part of the connection portion 111 of the plurality of conductive terminals 710A in the left-right direction.

  As illustrated in FIG. 55, the conductive terminal 710 </ b> A includes a contact portion 512, a flexible portion 713, an elbow portion 116, and a connection portion 111, similar to the conductive terminal 710 illustrated in FIG. 46. A region 120 extending from the holding portion 114 to the connection portion 111 is integrally held in the holder portion 133A of the base member 130A. The region 120 is provided with a recess 115a.

  Since the number and arrangement state of the conductive terminals 710A can be arbitrarily set according to the design conditions, in addition to the terminal module 701 shown in FIG. 53, for example, the terminal module 702 shown in FIG. Can be formed. Similarly to the terminal module 700 shown in FIG. 45, the terminal modules 701 and 702 are used integrally with the frame member 30 (see FIG. 6) by secondary molding.

  Next, a terminal module 800 according to another embodiment will be described with reference to FIGS. In the terminal module 800 shown in FIG. 56 to FIG. 60, the same reference numerals as those in FIG. 34 are given to the portions common to the terminal module 500 shown in FIG.

  As shown in FIGS. 56 and 57, the terminal module 800 is fixed to the frame member 30 by welding. A stepped portion 139 that is continuous in the left-right direction (arrow S direction) is provided in front of the lower surface of the base portion 132B of the base member 130B constituting the terminal module 800. The step portion 139 has a shape recessed toward the rear of the base portion 132B.

  A groove-shaped accommodation portion 33 into which the base portion 132 </ b> B of the terminal module 800 can be fitted is provided at a position where the terminal module 800 is attached on the frame member 30. The front wall portion 33a of the housing portion 33 is formed lower than the rear wall portion 33b, and cylindrical projections 34 are provided on the bottom surface of the housing portion 33 near the left and right end portions, respectively.

  As shown in FIG. 57, when the base portion 132B of the terminal module 800 is fitted into the accommodating portion 33, the plurality of protrusions 34 are respectively inserted into the through holes 134 of the base portion 132B, and the front wall portion 33a is Fit into the stepped portion 139.

  Thereafter, the upper surface of the protruding portion 34 protruding from the flat surface portion 137 is melted and crushed (welded), whereby the terminal module 800 is integrally fixed to the frame member 30.

  As shown in FIG. 58, the frame member 30 to which the other terminal modules 800, 801 and the like having different arrangement states of the terminal module 800 and the conductive terminals 510 are fixed by welding is fixed to the heat sink 10 with an adhesive. When the fixed electric element 20 and the connecting portion 111 of the conductive terminal 510 are connected by the bonding wire 21, the component unit 93 is completed.

  The terminal modules 100, 200, 300, 400, 500, 600, 700, 800 and the like described with reference to FIGS. 1 to 60 are examples of the present invention, and the terminal module of the present invention is the terminal module described above. It is not limited to 100, 200, 300, 400, 500, 600, 700, 800 or the like.

  The terminal module of the present invention can be widely used in the fields of the automobile industry and the electrical and electronic equipment industry as components of power modules such as ECUs (engine control units) and PCUs (power control units) of automobiles. it can.

DESCRIPTION OF SYMBOLS 10 Heat sink 11 Hole part 20 Electrical element 21 Bonding wire 30 Frame member 31 Protrusion part 32 Female thread part 33 Housing part 33a Front wall part 33b Rear wall part 34 Projection part 40 Circuit board 41 Through hole 42 Screw 45 Solder 90, 91, 92, 93 Parts unit 100, 200, 300, 400, 500, 600, 700, 800 Terminal module 110, 110A, 310, 310A, 510, 510A Conductive terminal 111 Connection portion 112, 512 Contact portion (press fit mechanism)
112a, 112b, 512a Contact piece 112c, 113c, 117a, 118a Through part 113,713 Flexible part (floating mechanism)
113a, 113b, 713a Flexible piece 114 Holding part 115 Engaging part 115a Concave part 115b Convex part 115d Protrusion 116 Elbow part 116w, 312w, 313w Width 117, 118, 120 Area 119 Constricted part 130, 130A, 130B, 330, 330A Base Member 131 Groove part 131a Upper opening end 132, 132A, 132B Base part 133, 133A, 333 Holder part 134 Through hole 135 Notch part 136 Front opening part 137 Plane part 138 Rib 139 Step part 312 Contact part 313 Shoulder part 512c Virtual axis 512b, 512d Connecting portion 512e Tip portion 512f Bending portion 512g Shaft body

Claims (7)

A terminal module attached to the heat sink via a frame member for electrically connecting an electric element mounted on the heat sink and a circuit board disposed opposite to the heat sink;
A conductive terminal having a connection part for connecting to the electrical element and a contact part inserted into a through hole of the circuit board, and holding the part of the conductive terminal, the conductive terminal is fixed in a fixed posture. An insulating base member,
The base member includes a base portion fixed to the frame member, and a holder portion that is formed upright on the base portion and holds a part of the conductive terminal.   The terminal module according to claim 1, wherein a press-fit mechanism capable of elastically expanding and contracting in a radial direction of the through hole is provided on at least a part of the contact portion of the conductive terminal.   The terminal module according to claim 1, wherein a floating mechanism having a higher elastic displacement and flexibility than other portions of the conductive terminal is provided in a region near the contact portion of the conductive terminal.   The terminal module according to claim 3, wherein as the floating mechanism, flexible pieces are provided opposite to each other with a through portion interposed between the conductive terminals.   The terminal module according to claim 3, wherein the floating mechanism is provided with a flexible portion in which a plurality of flexible pieces having a quadrangular prism shape are arranged at equal intervals around a virtual axis on the conductive terminal.   The terminal module according to claim 1, wherein the conductive terminal is accommodated in a groove provided in a holder portion of the base member, or the conductive terminal is integrally fixed to the base member.   The terminal module according to claim 2, wherein the press-fit mechanism is formed of a plurality of contact pieces that can be elastically expanded and contracted in a radial direction of the through hole.

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