JP2009105026A - Connection structure and connection method - Google Patents

Abstract

An object of the present invention is to provide a connection structure and a connection method capable of easily connecting an electronic component to an electric cable.
An LED unit includes an upper case that holds an LED chip and a resistor, a pierce terminal that electrically connects the LED chip and the resistor to a flat cable, and a flat cable. The lower case 9 that is fitted to the upper case 7 and is sandwiched and attached to the upper case 7, the LED chip 3 and the resistor 4 are held in the upper case 7 and connected to the pierce terminal 6. An intermediate terminal 5 was provided. The intermediate terminal 5 includes two pairs of convex spring portions 51 and 52 corresponding to the number of LED chips 3 and resistors 4 that are electronic components, and one convex portion of the convex spring portions 51 and 52. The springs 51a and 52a were locked to the upper case 7, and the LED chip 3 and the resistor 4 were pressed against the pierce terminal 6 by the other convex springs 51b and 52b.
[Selection] Figure 2

Description

  The present invention relates to a connection structure and a connection method for connecting an electronic component used in, for example, a vehicle lighting device or a control device to an electric cable.

  2. Description of the Related Art Conventionally, an electronic component mounting module in which a plurality of electronic components are mounted on a printed circuit board is used for various control units and lighting devices of automobiles. In such an electronic component mounting module, for example, an electronic component is mounted on a board by solder connection, and the module and the external electric circuit are connected by a connector having terminals soldered to the board (see Patent Document 1). .

However, since electronic components and circuit conductors are connected by soldering, for example, when connecting electronic components that are increasingly miniaturized, such as LED chips that are 2 mm × 2 mm square in plan view, much man-hours or capital investment is required. There was a problem of requiring quality control.
In particular, when connecting a miniaturized electronic component to an electric cable, there has been a problem that much man-hours and quality control are required according to solder connection.

JP 2004-111435 A

  An object of this invention is to provide the connection structure and the connection method which can connect an electronic component to an electric cable easily.

  The present invention includes a first box that holds an electronic component, a connection terminal that electrically connects the electronic component to an electric cable, and a second that is fitted to the first box and is sandwiched and attached to the electric cable. A connection structure comprising a box and a terminal member for holding the electronic component in the first box and connecting the electronic component to the connection terminal, wherein the terminal member has at least one pair of convex shapes. A connection structure comprising: a formed convex spring portion; one convex spring portion is locked to the first box, and the electronic component is pressed against the connection terminal by the other convex spring portion. It is characterized by being.

As an aspect of the present invention, the electronic component and the connection terminal against which the electronic component is pressed can be disposed between a pair of convex spring portions.
As an aspect of the present invention, a plurality of electronic components can be arranged, and a number of pairs of convex spring portions can be provided according to the number of electronic components arranged.

  As an aspect of the present invention, the electric cable includes a plurality of flat conductors disposed at a predetermined interval in the width direction and a covering member that integrally covers the plurality of flat conductors in a flat plate shape. A flat cable may be provided, and the flat cable may be provided with a box hooking portion that hooks the first box or the second box.

  Further, as an aspect of the present invention, the connection terminal is provided with a through connection part that penetrates and connects the flat conductor, and the second box body is prevented from coming out of the through connection part that penetrates the flat cable. A retaining means can be provided.

Further, as an aspect of the present invention, the through-connecting portion is formed in a substantially rectangular cross-sectional shape, the retaining means is formed in a substantially circular hole shape, and the hole diameter of the substantially circular hole-shaped retaining means is It can be made to substantially coincide with the length in the longitudinal direction of the rectangular cross section of the through connection portion.
As an aspect of the present invention, the retaining means can be formed separately from the second box.

As an aspect of the present invention, the electric cable includes a plurality of flat conductors disposed at a predetermined interval in the width direction and a covering member that integrally covers the plurality of flat conductors in a flat plate shape. A flat cable is provided, and the connection terminal is provided with a through connection portion that penetrates and connects the flat conductor, and the through connection portion is assembled to the electronic component between the pair of convex spring portions. It can arrange | position in the crossing direction which cross | intersects an attaching direction.
As an aspect of the present invention, the crossing direction can be set in the longitudinal direction of the flat cable.

  Further, the present invention is a connection method for connecting an electronic component to a flat cable, and a terminal for temporarily assembling a connection terminal for electrically connecting the electronic component to an electric cable in a first box holding the electronic component An electronic component is assembled in an assembling step, a terminal member assembling step in which a terminal member is temporarily assembled in the first box in which the connection terminals are temporarily assembled, and a first box in which the terminal member and the connection terminals are temporarily assembled. In addition, the first box main assembly process for assembling the electronic component and the connection terminal in the first box, and the second box body are temporarily provided with retaining means for preventing the penetration connection portion penetrating the flat cable from coming out. The retaining means assembling step for assembling, the case hooking portion forming step for forming the case hooking portion to be hooked to the second box by bending, and the case hooking portion for the second case. A hooking process for hooking on the body, and the first box Wherein the serial and the second box-body, which is the connection method and a box body fitted step of sandwiching by fitting wear flat cable in between.

The electronic component includes a light source device such as an LED chip, various sensors, and a resistor for adjusting a supply voltage.
The plurality of connection terminals that are electrically connected to the electrical cable include a terminal that directly connects the electronic component to the electrical cable and a terminal that is indirectly connected to the electrical cable by connecting the electronic components.

The penetration connection portion includes a piercing blade, and the connection terminal includes a piercing terminal having a plurality of piercing blades.
In addition, although the ribbon electric wire which arranged and integrated the round strand wire in the width direction may be used as an electrical cable, the flat cable with a high heat dissipation effect is more preferable.

  According to the present invention, it is possible to provide a connection structure and a connection method capable of easily connecting an electronic component to an electric cable.

  An embodiment of the present invention will be described below with reference to the drawings.

  The LED unit 1 of the present invention includes an upper case 7 that holds the LED chip 3 and the resistor 4, and a pierce terminal 6 (6A, 6B) that electrically connects the LED chip 3 and the resistor 4 to the flat cable 100. The lower case 9 is provided so as to be fitted to the upper case 7 and sandwich the flat cable 100 to be attached.

  The LED unit 1 also includes an intermediate terminal 5 for holding the LED chip 3 and the resistor 4 in the upper case 7 and connecting the LED chip 3 and the resistor 4 to the pierce terminal 6.

  The intermediate terminal 5 includes two pairs of convex spring portions 51 and 52 corresponding to the number of LED chips 3 and resistors 4 that are electronic components, and one convex portion of the convex spring portions 51 and 52. The springs 51 a and 52 a are locked to the upper case 7, and the LED chip 3 and the resistor 4 are pressed against the pierce terminal 6 by the other convex springs 51 b and 52 b.

  The LED chip 3 and the contact plate 61 of the piercing terminal 6a against which the LED chip 3 is pressed are arranged between the pair of convex spring portions 51, and the resistor 4 and the piercing to which the resistor 4 is pressed. The contact plate 61 of the terminal 6b is disposed between the pair of convex spring portions 52.

The flat cable 100 includes two conductors 101 disposed at a predetermined interval in the width direction and a non-conductive laminate sheet 102 that integrally covers the two conductors 101 in a flat plate shape. And the hooking convex part 110 hooked to the lower case 9 is formed on the flat cable 100 by bending.
Further, the lower case 9 is provided with a backup plate 8 for preventing the pierce plate 63 of the pierce terminal 6 connected through the conductor 101 from coming out.

  The pierce plate 63 is formed in a substantially rectangular cross-sectional shape, and the backup plate 8 is formed in a substantially circular hole shape, that is, a donut shape. The hole diameter of the substantially circular hole-like backup plate 8 and the pierce plate 63 are formed. The length of the rectangular cross section in the longitudinal direction is substantially the same. Further, the backup plate 8 is formed separately from the lower case 9.

  The above configuration relating to the LED unit 1 will be described in detail with reference to FIG. 1 showing a perspective view of the LED unit 1 and FIG. 2 showing an exploded perspective view of the LED unit 1. The LED unit 1 connects the LED chip 3 to the flat cable 100. At the same time, the resistor 4 that adjusts the voltage is also a connecting unit for mounting at the same time.

  The flat cable 100 is composed of two strip-like conductors 101 arranged in parallel at a predetermined interval in the width direction, and a non-conductive laminate sheet 102 that sandwiches the conductors 101 from the front and back and surrounds them integrally. is doing.

  The flat cable 100 is flexible, and is bent to form a case that is formed by a convex shape in a side view, that is, a step shape higher than other portions, and a planar body corresponding to the length of the lower case 9. Part 110 is formed.

  Although only a part of the flat cable 100 is shown in the figure, the flat cable 100 is formed to have a required length and is configured to be routed at a predetermined location inside the vehicle or the like.

  As shown in FIG. 2, the LED unit 1 includes an upper case 7 that is a first box, an LED chip 3 that is attached to the upper case 7, and a resistor 4 that is also attached to the upper case 7. Pierce terminals 6 (6A, 6B) for connecting the LED chip 3 and the resistor 4 to the flat cable 100, an intermediate terminal 5 for fixing the LED chip 3 and the resistor 4, and a cover member for covering the intermediate terminal 5 from above 2, a backup plate 8 that prevents the piercing terminal 6 from coming out, and a lower case 9 that is a second box on which the backup plate 8 is mounted.

  The cover member 2 includes a cover body 2a having a vertically long rectangular shape in plan view formed of a resin plate, and both ends of the cover body 2a in the longitudinal direction of the flat cable 100 (hereinafter simply referred to as “longitudinal direction”). And an engaging claw portion 2b that engages with the upper surface flange of the upper case 7, and covers the LED chip 3, the resistor 4, the intermediate terminal 5, and the pierce terminal 6 assembled to the upper case 7 from above. In this way, the upper case 7 is assembled from above.

  In the cover main body 2a, the light emission of the LED chip 3 mounted inside the cover main body 2a when mounted on the upper case 7 is in the center of the flat cable 100 in the width direction (hereinafter simply referred to as “width direction”). A circular window 21 having a circular shape in plan view that allows the part 31 to be visually recognized from the outside is provided.

  The LED chip 3 includes a light emitting portion 31 that is circular in plan view on the top surface, and L-shaped contact terminals 32 that are continuous from the bottom surface on both side surfaces. The resistor 4 is configured as a horizontally long flat plate-like rectangular body, and includes concave contact terminals 41 and 41 on both side surfaces.

  The intermediate terminal 5 is formed from one copper plate having appropriate elasticity. Specifically, the component placement openings 53 and 54 in which the LED chip 3 and the resistor 4 are placed are punched out by press working, and two parallel longitudinal direction portions 5a are arranged at a predetermined interval in the longitudinal direction. It is formed in the shape of a Japanese character in a plan view constituted by the crossing part 5b in the width direction.

  Further, the opposing positions of the longitudinal direction portions 5a in the vicinity of the center between the crossing portions 5b are pressed downward in a U-shape in a side view, and the intermediate terminal 5 as a whole is formed in a substantially W-shape. Convex spring portions 51 (51a, 51b) and 52 (52a, 52b) are formed by convex portions formed in a U-shape in a side view U.

  And the contact point 55 is provided in the part which contacts the contact terminal 32 of the LED chip 3 of the convex spring part 51b, and the contact terminal 41 of the resistor 4 of the convex spring part 52b. The intermediate terminal 5 may be other than a metal member as long as it has conductivity.

  There are two types of piercing terminals 6, an LED piercing terminal 6 </ b> A connected to the LED chip 3 and a resistance piercing terminal 6 </ b> B connected to the resistor 4. A contact plate 61 having a contact convex portion 61 a that contacts the four contact terminals 32, 41, a horizontal plate portion 62 substantially perpendicular to the contact plate 61, and a substantially right angle to the horizontal plate portion 62, A piercing plate 63 provided with a convex portion 63a projecting in the longitudinal direction in the vicinity of the upper end portion is continuously formed in a bowl shape.

  The horizontal plate portion 62 of the LED piercing terminal 6A is formed shorter than the horizontal plate portion 62 of the resistance piercing terminal 6B. Further, the contact convex portion 61a is curved so that an urging force is generated in the width direction. The pierce terminal 6 may be any one having conductivity, preferably made of metal, more preferably copper or copper alloy having excellent conductivity.

  The upper case 7 is formed of a resin-made plan view vertically long rectangular body, and is formed with cover fitting portions 71 to which the cover members 2 are fitted over both side surfaces and the upper surface in the longitudinal direction. An engaging claw 72 that engages with the lower case 9 is provided at the center lower end. In addition, a collar projecting piece 79 projecting downward is provided at the center lower end of both collar surfaces in the longitudinal direction.

  Further, as shown in FIG. 3 for explaining the mounting of the pierce terminal 6 to the upper case 7 with a perspective view from the bottom side, the mounting recess 73 that allows the LED piercing terminal 6A to be mounted on the bottom surface of the upper case 7. A mounting recess 74 that allows mounting of the resistance piercing terminal 6B is provided.

  At the center in the width direction of the upper surface on the inner side of the cover fitting portion 71, the first housing portion 75 that houses the LED chip 3 and the second housing portion 76 that houses the resistor 4 are arranged in parallel at a predetermined interval in the longitudinal direction. is doing. The first storage portion 75 and the second storage portion 76 communicate with through holes 73a and 74a that allow the contact plate 61 provided in the mounting recesses 73 and 74 to pass therethrough, and the earrings mounted in the mounting recesses 73 and 74. The pierce terminal 6 can be mounted in such a manner that the contact plate 61 of the terminal 6 penetrates the through holes 73a and 74a and protrudes toward the first housing portion 75 and the second housing portion 76.

  Further, insertion concave portions 77 and 78 that allow insertion of the convex spring portions 51 and 52 of the intermediate terminal 5 are provided on both outer sides in the width direction of the first storage portion 75 and the second storage portion 76. Convex spring portions 51a and 52a are inserted into the insertion recesses 77 disposed on the outer side of the through holes 73a and 74a. The insertion recess 78 on the opposite side communicates with the first housing portion 75 and the second housing portion 76, and the convex spring portions 51b and 52b are inserted therein.

  As shown in FIG. 2, the backup plate 8 is formed of a circular donut-shaped plate member made of conductive metal. One backup plate 8 is provided so as to correspond to each of the first piercing terminal 6A and the second piercing terminal 6B. The inner diameter of the center fitting hole 81 of the backup plate 8 is set so as to substantially match the width of the pierce plate 63 of the pierce terminal 6 (in addition, if the backup plate also has conductivity, a metal member) Other than).

  The lower case 9 is made of a resin-made plan view vertically long rectangular dish, and a cable fitting portion into which the case hooking portion 110 of the flat cable 100 is fitted over both side surfaces in the longitudinal direction, that is, both flange portions and the upper surface. 91 is formed, a position defining portion 92 for defining the position of the backup plate 8 is formed on the upper surface inside the cable fitting portion 91, and the upper case 7 is engaged and fixed near the center of the side surface in the width direction. A case engaging portion 93 that allows the engaging claw 72 of the upper case 7 to be engaged is provided.

  In addition, an interference prevention recess 92 a that prevents interference with the piercing plate 63 that has passed through the fitting hole 81 of the backup plate 8 is formed in the center of the position defining portion 92 in plan view.

  Note that the width of the pierce plate 63 that protrudes downward due to the difference in the length of the horizontal plate portion 62 of the pierce terminal 6 that is mounted in the mounting recesses 73 and 74 of the upper case 7 with the position in the width direction of the contact plate 61 being the same. Although the direction position is different, this is in accordance with the position of the conductor 101 penetrating through the pierce plate 63, and the position defining portion 92 of the lower case 9 is formed so that the backup plate 8 is disposed at that position. ing.

Next, the assembly method of the LED unit 1 and the attachment method of the flat cable 100 will be described.
The connection method of the LED unit 1 which connects the LED chip 3 and the resistor 4 to the flat cable 100 of the present invention includes a terminal assembly process, an intermediate terminal assembly process, an upper case main assembly process, and a backup plate assembly process. , A hooking convex part forming step, a hooking step, and a box fitting step.

The terminal assembling step is a step of temporarily assembling the pierce terminal 6 that electrically connects the LED chip 3 and the resistor 4 to the flat cable 100 in the upper case 7 that holds the LED chip 3 and the resistor 4.
The intermediate terminal assembling step is a step of temporarily assembling the intermediate terminal 5 in the upper case 7 in which the pierce terminal 6 is temporarily assembled.

  In the upper case main assembly process, the LED chip 3 and the resistor 4 are assembled to the upper case 7 in which the intermediate terminal 5 and the pierce terminal 6 are temporarily assembled, and the LED chip 3 and the resistor 4 and the pierce terminal 6 are assembled to the upper case 7. This is the process of assembly.

  The backup plate assembling step is a step of temporarily assembling the backup plate 8 for preventing the piercing portion 52 penetrating the flat cable 100 from coming out of the lower case 9 which is the second box.

The hooking convex portion forming step is a step of forming the hooking convex portion 110 that hooks into the lower case 9 on the flat cable 100 by bending.
The engaging step is a step of engaging the engaging protrusion 110 with the lower case 9.
The box fitting process is a process in which the flat cable 100 is sandwiched and fitted between the upper case 7 and the lower case 9.

Each of the above steps will be described in detail below with reference to the drawings.
As shown in FIG. 3A, which is an explanatory diagram for explaining the terminal assembling process, the upper case 7 is turned upside down, the bottom side is turned up, and the LED pierce terminal 6A contacts the through hole 73a. The plate 61 is inserted to mount the LED piercing terminal 6A in the mounting recess 73, and the contact plate 61 of the resistance piercing terminal 6B is inserted into the through hole 74a to mount the resistance piercing terminal 6B in the mounting recess 74.

  As a result, as shown in FIG. 3B, the piercing plates 63 of the LED piercing terminal 6A and the resistance piercing terminal 6B protrude downward from the bottom surface of the upper case 7 at positions shifted in the width direction and the longitudinal direction. In this manner, the LED piercing terminal 6A and the resistor piercing terminal 6B can be assembled to the upper case 7.

  The intermediate terminal assembling step and the upper case main assembling step will be described with reference to a perspective view of the upper case 7, as shown in FIG. 4A, so that the cover fitting portion 71 of the upper case 7 is on the upper surface side. When returned, the contact plate 61 of the pierce terminal 6 assembled in the terminal assembly process passes through the through holes 73a and 74a and protrudes from the bottom surfaces of the first housing portion 75 and the second housing portion 76.

  In this state, the convex spring portions 51 a and 52 a are inserted into the insertion concave portion 77 from the upper side of the upper case 7, the convex spring portions 51 b and 52 b are inserted into the insertion concave portion 78, and the intermediate terminal 5 is connected to the upper case 7. Installing. Here, the component arrangement opening 53 and the first accommodation portion 75 of the intermediate terminal 5, and the component arrangement opening 54 and the second accommodation portion 76 are positions corresponding to the upper and lower sides.

  Then, as shown in FIG. 4B, the LED chip 3 and the resistor 4 are passed through the component arrangement opening 53 and the component arrangement opening 54 from above the upper case 7, and as shown in FIG. The first housing part 75 and the second housing part 76 are attached.

  5A, which is a plan view of this state, and FIG. 5B, which is a view taken along the line aa in FIG. 5A, are provided in the first housing portion 75 with an LED piercing terminal 6A. The contact plate 61 and the contact 55 of the convex spring part 51b inserted in the LED chip 3 and the insertion recess 78 are arranged in this order, and the convex spring part 51b places the LED chip 3 on the contact plate 61 via the contact 55. Pressing to the side. Therefore, the contact terminal 32 on the contact plate 61 side of the LED chip 3 is in contact with the contact convex portion 61 a of the contact plate 61, and the contact terminal 32 on the opposite side is in contact with the contact 55.

  Further, as shown in FIG. 5C, which is a view taken along the line bb in FIG. 5A, the contact plate 61 of the resistance piercing terminal 6 </ b> B disposed in the second housing portion 76, and the resistor 4. And the contact 55 of the convex spring portion 52b inserted in the insertion recess 78 is arranged in this order, and the convex spring portion 52b presses the resistor 4 toward the contact plate 61 via the contact 55. Therefore, the contact terminal 41 on the contact plate 61 side of the resistor 4 is in contact with the contact convex portion 61 a of the contact plate 61, and the contact terminal 41 on the opposite side is in contact with the contact 55.

  Since the intermediate terminal 5 electrically connected to the LED chip 3 and the resistor 4 via the contact 55 is composed of a copper plate as a conductive member, the LED piercing terminal 6A → LED chip 3 → intermediate An electronic circuit of terminal 5 → resistor 4 → resistance piercing terminal 6B is formed.

  Since the convex spring portion 51a and the convex spring portion 52a are inserted into the insertion concave portion 77, the relative position of the intermediate terminal 5 with respect to the upper case 7 is fixed. The pierce terminal 6 is also mounted in mounting recesses 73 and 74 provided on the bottom surface of the upper case 7, and the relative position with respect to the upper case 7 is fixed by the contact plate 61 passing through the through holes 73 a and 74 a.

  The LED chip 3 and the resistor 4 are sandwiched between the pierce terminal 6 and the intermediate terminal 5 that are fixed relative to the upper case 7, and are positioned relative to the upper case 7. Is fixed. Thus, the intermediate terminal 5 functions as a fixture for the LED chip 3 and the resistor 4 and also functions as a circuit component.

Further, the LED chip 3 and the resistor 4 are formed in a convex shape of the intermediate terminal 5 as shown in FIG. 6 in a perspective view of the state in which the upper case 7 is transmitted in the upper case main assembly process. The upper case 7 is fixed in a suspended state because it is sandwiched and fixed by being biased by the spring plate 51b, 52b and the contact plate 61 of the LED piercing terminal 6A and the resistance piercing terminal 6B. Will be.
In this state, the cover member 2 is mounted from above the upper case 7 in which the LED chip 3, the resistor 4, the intermediate terminal 5, and the pierce terminal 6 are incorporated.

  Subsequently, the backup plate assembling step, the hooking convex portion forming step, the hooking step, and the box fitting step will be described with reference to FIGS. First, as shown in FIG. 7A for explaining the backup plate assembling step, the backup plate 8 is mounted on the position defining portion 92 from above the lower case 9. At this time, the positions of the fitting hole 81 of the backup plate 8 attached to the position defining portion 92 and the interference preventing recess 92 a of the position defining portion 92 coincide with each other.

  As shown in FIG. 7B for explaining the hooking convex portion forming step, the flat cable 100 is folded at a valley fold line A, and is folded at a mountain fold line B to form a convex case hooking portion 110 in side view. To do. In addition, the space | interval of the valley fold line A and the mountain fold line B is formed substantially the same as the height inside the cable fitting part 91 of the lower case 9, and the space | interval of the mountain fold line B is the cable fitting part 91 of the lower case 9. It is formed approximately the same as the inner length.

  Therefore, as shown in FIG. 8A for explaining the hooking process, the case hooking portion 110 is put on the cable fitting portion 91 from above the lower case 9 in which the backup plate 8 is mounted on the position defining portion 92. The case hooking portion 110 can be hooked to the lower case 9.

  In this state, the cover member 2, the LED chip 3, the resistor 4, the intermediate terminal 5 and the pierce terminal 6 are assembled in the upper case main assembly process as shown in FIG. The upper case 7 and the lower case 9 are engaged by engaging the engaging claw 72 of the upper case 7 from which the piercing plate 63 protrudes from the bottom surface with the case engaging part 93 of the lower case 9 with which the case engaging part 110 is engaged. To fit.

  At this time, the case of the flat cable 100 is formed by both side surfaces in the longitudinal direction forming the cable fitting portion 91 of the lower case 9, that is, both flange portions and the upper surface, and the bottom surface of the upper case 7 and the inner side of the flange protruding piece 79. The hooking portion 110 is sandwiched.

  Further, the pierce terminal 6 and the conductor 101 of the flat cable 100 can be connected by fitting the upper case 7 and the lower case 9 together. In detail, it explains in full detail with FIGS. 9-11 which are explanatory drawings about the connection structure of the pierce terminal 6 and the backup plate 8. FIG.

  FIG. 9A is an upper perspective view showing a state in which the piercing plate 63 of the piercing terminal 6 is fixed to the flat cable 100, and FIG. 9B is a state in which the piercing terminal 63 of the piercing terminal 6 is fixed to the flat cable 100. 10A is a side view of the piercing plate 63 in the through-fixing state seen from the side, FIG. 10B is a bottom view of the piercing plate 63 in the through-fixing state from below, and FIG. Fig. 10A is a cross-sectional view taken along the line I-I in Fig. 10A, Fig. 10B is a cross-sectional view taken along the line II-II, and Fig. 10C is a cross-sectional view taken along the line III-III. Further, (d) is a cross-sectional view taken along line IV-IV.

  As shown in FIG. 9, the piercing plate 63 of the piercing terminal 6 (6A, 6B) penetrates through the conductor 101 of the flat cable 100 and enters the fitting hole 81 of the backup plate 8 arranged on the back side thereof. This penetration state is fixed by inserting and fitting.

  This penetrating state is obtained by lowering the piercing plate 63 of the piercing terminal 6 from the upper side to the lower side by inserting the lower end portion of the piercing plate 63 into the conductor 101 as described above. By making the material of the conductor 101 softer than the pierce plate 63 of the pierce terminal 6, such a penetrating state can be easily obtained.

  However, if the backup plate 8 is not set at an appropriate position, a reliable penetrating state cannot be obtained due to the malleability of the conductor 101. Therefore, the backup plate 8 is set to an appropriate position by being attached to the position defining portion 92 (FIG. 2) of the lower case 9.

  Thus, by setting the backup plate 8 to an appropriate position, the clearance (distance) between the fitting hole 81 of the backup plate 8 and the pierce plate 63 of the pierce terminal 6 is appropriately set, and the conductor 101 A shearing force can be applied to the piercing plate 63 so that the piercing plate 63 of the piercing terminal 6 can be appropriately penetrated.

  Further, since the backup plate 8 moves freely within the range of the position defining portion 92, when the pierce terminal 6 is inserted from above, the backup plate 8 is automatically aligned, The conductor 101 of the flat cable 100 can be penetrated with the center of the pierce terminal 6 and the center of the backup plate 8 aligned.

Specifically, the insertion is fixed in the state shown in FIGS.
As shown in the cross-sectional view taken along the line I-I in FIG. 11A, the conductor 101 is greatly bent downward at a position close to the center O of the pierce terminal 6. This is a deformed state because the clearance L1 between the pierce terminal 6 and the backup plate 8 is large. Since the conductor 101 is deformed in this manner, a sufficient connection pressure of the conductor 101 to the pierce terminal 6 cannot be ensured, so that a current cannot be appropriately supplied to the pierce terminal 6.

  On the other hand, as shown in the cross-sectional view taken along the line II-II in FIG. 11B, the conductor 101 is not greatly bent and the backup plate 8 is also close at a position slightly separated from the center O of the pierce terminal 6. Since it exists in a position, the connection pressure with respect to the pierce terminal 6 of the conductor 101 can be raised. For this reason, an electric current can be appropriately sent to the pierce terminal 6 in this part.

  However, as further shown in the sectional view taken along the line III-III in FIG. 11C, at the side end of the pierce terminal 6 further away from the center line O of the pierce terminal 6, the pierce terminal 6 and the backup plate 8 are reached. The clearance L2 is small. For this reason, since the conductor 101 hardly deforms, a sufficient connection pressure cannot be obtained. For this reason, current hardly flows to the pierce terminal 6 in this portion.

Thus, since the clearances L1 and L2 (distance) between the pierce terminal 6 and the backup plate 8 change depending on the arc and the plane (straight line), the shearing state and the malleable state of the conductor 101 are different from each other. Therefore, at least in a predetermined place, a portion having an appropriate connection state can be obtained.
For this reason, according to the connection structure using this backup plate 8, since fine adjustment of a penetration position becomes unnecessary, there exists an advantage that a connection operation becomes very easy.

  11D, the width H of the piercing plate 63 of the piercing terminal 6 and the diameter d of the fitting hole 81 of the backup plate 8 are set so as to substantially coincide with each other. Therefore, the side end surface 631 of the piercing plate 63 of the piercing terminal 6 and the inner peripheral surface 81a of the backup plate 8 are surely brought into contact with each other, and a frictional force is generated between the two. The fitting state between the plate 63 and the backup plate 8 is maintained. For this reason, the electrical connection state of the pierce terminal 6 and the flat cable 100 can be reliably maintained.

  Thus, by fitting the upper case 7 assembled with the cover member 2, the LED chip 3, the resistor 4, the intermediate terminal 5 and the pierce terminal 6, and the lower case 9 with which the case hooking part 110 is hooked. The pierced terminal 6 and the conductor 101 can be connected, whereby the LED chip 3 and the resistor 4 can be connected to the conductor 101.

  Next, the operation and effect of the LED unit 1 in this embodiment will be described. The upper case 7 that holds the LED chip 3 and the resistor 4 and the pierce that electrically connects the LED chip 3 and the resistor 4 to the flat cable 100. The terminal 6 is disposed on the opposite side of the flat cable 100, and is fitted to the upper case 7 so as to sandwich and attach the flat cable 100, and the upper case 7 holds the LED chip 3 and the resistor 4. In addition, the LED unit 1 includes an intermediate terminal 5 for connecting the LED chip 3 and the resistor 4 to the pierce terminal 6, and the intermediate terminal 5 is formed with two pairs of convex spring portions 51 (51 a, 51 a, 51b), 52 (52a, 52b), one convex spring portion 51a, 52a is locked to the insertion concave portion 77 of the upper case 7, and the convex spring portion 51b, By pressing the LED chip 3 and the resistor 4 against the piercing terminal 6 by 2b, the intermediate terminal 5 is electrically connected to the LED chip 3 and the resistor 4, and the LED piercing terminal 6A → LED chip 3 → intermediate terminal. An electronic circuit of 5 → resistor 4 → resistance piercing terminal 6B can be configured.

  Further, the LED chip 3 and the resistor 4 can be sandwiched and fixed between the pierce terminal 6 and the intermediate terminal 5 whose relative positions are fixed with respect to the upper case 7. Thus, the intermediate terminal 5 functions as a fixture for the LED chip 3 and the upper case 7 of the resistor 4 and also functions as a circuit component.

  Thus, the LED chip 3 is sandwiched between the convex spring portion 51b of the intermediate terminal 5 and the contact plate 61 of the LED piercing terminal 6A, and the resistor 4 is connected to the convex spring portion 52b of the intermediate terminal 5 and the resistance piercing terminal. In this state, the convex spring part 51a inserted into the insertion concave part 77 and fixed to the upper case 7 is fixed between the convex spring part 51b and the convex spring part 51b. In the meantime, an urging force is exerted by widening the interval, and the electrical connection of the LED chip 3, the LED piercing terminal 6A and the intermediate terminal 5 can be maintained.

  Similarly, a biasing force is applied between the convex spring portion 52a inserted into the insertion concave portion 77 and fixed to the upper case 7 and the convex spring portion 52b. 4. The electrical connection between the resistance piercing terminal 6B and the intermediate terminal 5 can be maintained.

  The urging force generated between the convex spring portions 51 and between the convex spring portions 52 is generated by extending the transition portion 5 b of the intermediate terminal 5. As described above, the biasing force with respect to the displacement in the longitudinal direction of the plate-shaped member generates a large biasing force by a slight displacement as compared with the biasing force due to the deformation of the plate-shaped member in the thickness direction.

  Therefore, an urging force necessary for stable connection can be obtained by a small displacement in a small space, the parts can be reduced in size, and the reliability of electrical connection can be improved.

  Further, the LED chip 3 and the resistor 4 are sandwiched between the convex spring portions 51b and 52b of the intermediate terminal 5 and the contact plate 61 of the LED piercing terminal 6A and the resistance piercing terminal 6B. Since the upper case 7 is fixed in a suspended state, a stable electrical connection can be obtained and the reliability can be improved.

  Specifically, the LED chip 3 and the resistor 4 generate heat when the light emitting unit 31 of the LED chip 3 emits light, and each member around the LED chip 3 and the resistor 4 is thermally expanded by the generated heat. However, the coefficient of thermal expansion of each member differs depending on the material, and the upper case 7 that is a resin member is more likely to thermally expand than the intermediate terminal 5 and the pierce terminal 6 that are metal members.

  Therefore, when the LED chip 3 and the resistor 4 are directly fixed to the upper case 7, the positional relationship between components may be shifted, and the connection may become unstable. However, in the LED unit 1 of the present invention, by using the intermediate terminal 5, even if the positional relationship between components is deviated, the intermediate terminal 5 is deformed as needed so that the pierce terminal 6 -LED chip 3 and the resistor 4. -Since the positional relationship of the upper case 7 is maintained, a stable electrical connection can be obtained even if a dimensional change due to heat generation occurs, and the reliability can be improved.

  Further, the LED chip 3 and the LED piercing terminal 6A against which the LED chip 3 is pressed are disposed between the pair of convex spring portions 51a and 51b, and the resistor 4 and the resistor 4 are pressed against each other. The direction of the urging force generated between the convex spring portions 51a and 51b and between the convex spring portions 52a and 52b by arranging the resistance piercing terminal 6B between the pair of convex spring portions 52a and 52b. That is, the direction of the transition portion 5b of the intermediate terminal 5 and the direction of pressing the LED chip 3 and the resistor 4 against the pierce terminal 6 coincide.

  Therefore, the urging force generated at the intermediate terminal 5 can be efficiently applied to the LED chip 3 and the resistor 4, the components can be further downsized, and the reliability of electrical connection can be further improved. it can.

  Further, by providing the intermediate terminal 5 with two pairs of convex spring portions 51 and 52 corresponding to the number of LED chips 3 and resistors 4 to be arranged, the urging force generated in the convex spring portions 51 and 52 with certainty. Can be made to act on the LED chip 3 and the resistor 4, and the reliability of electrical connection can be further improved.

  A flat cable 100 comprising two conductors 101 disposed at a predetermined interval in the width direction and a non-conductive laminate sheet 102 that integrally covers the two conductors 101 in a flat plate shape is connected to the lower case. 9 is provided with the case hooking portion 110 that is hooked to the cable fitting portion 91, thereby connecting the two conductors 101 of the piercing plate 63 of the LED piercing terminal 6 </ b> A and the piercing plate 63 of the resistance piercing terminal 6 </ b> B. Can be made more reliable.

  Specifically, when the pierce plate 63 penetrates the conductor 101, the conductor 101 is drawn toward the penetration direction of the pierce plate 63, that is, toward the penetration center of the pierce plate 63 in plan view. In the case where there are two piercing plates 63 penetrating the conductor 101, when the timings of the two piercing plates 63 penetrating the conductor 101 are different, the conductor 101 due to the penetration of the conductor 101 of the subsequent piercing plate 63 is different. By pulling, the tensile force is applied to the connection portion of the piercing plate 63 that has penetrated the conductor 101 first, and the connection portion moves. Normally, there is no problem in the connection part even if it moves slightly, but it is preferable not to move if the reliability of the connection part is particularly important.

  As in this embodiment, the case hooking portion 110 obtained by bending the flat cable 100 into a convex shape is hooked to the cable fitting portion 91 of the lower case 9 and then fixed so as to be sandwiched between the upper case 7 and the lower case 9. As a result, even when the timing of penetrating the conductor 101 of the piercing plate 63 of the LED piercing terminal 6A and the piercing plate 63 of the resistance piercing terminal 6B is shifted, the case hooking portion 110 is connected to the cable fitting portion 91. Therefore, the position of the case hooking portion 110 relative to the cable fitting portion 91 does not move.

  Therefore, it is possible to prevent a load on the connection portion between the pierce plate 63 and the conductor 101 due to the movement of the flat cable 100 caused by the shift of the penetration timing of the two pierce plates 63. Therefore, it is possible to eliminate the difficulty in connecting a plurality of pierce plates 63 in the connection between the upper case 7 and the lower case 9, and to further improve the reliability of the connection between the pierce plates 63 and the conductor 101. it can.

  Further, the case hooking portion 110 hooked to the cable fitting portion 91 is sandwiched between the longitudinal side surface and the upper surface of the lower case 9 forming the cable fitting portion 91, and the bottom surface of the upper case 7 and the inner surface of the flange protruding piece 79. Therefore, even when a longitudinal external force is applied to the LED unit 1, the flat cable 100 is fixed to the upper case 7 and the lower case 9 by the case hooking portion 110, and the pierce plate 63 and the case hooking. It is possible to prevent a large external force from being applied to the connection portion with the portion 110. Therefore, the electrical connection state between the piercing plate 63 and the conductor 101 can be secured stably.

  Further, since the case hooking portion 110 is sandwiched between the upper case 7 and the lower case 9, the reaction force caused by the case hooking portion 110 being sandwiched causes the mounting recess 73 of the upper case 7 and the case of the lower case 9. The engagement with the engaging portion 93 can be further strengthened.

  Further, the pierce terminal 6 is provided with a pierce plate 63 that penetrates and connects the conductor 101, and the lower case 9 is provided with a backup plate 8 that prevents the pierce plate 63 that passes through the flat cable 100 from coming out. Since the pierce plate 63 penetrating the conductor 101 can be easily prevented from coming out of the flat cable, and the electrical connection between the flat cable and the pierce terminal 6 is stabilized, the reliability of the connection in the LED unit 1 is improved. improves.

  Further, the pierce plate 63 is formed in a substantially rectangular cross-sectional shape, the backup plate 8 is formed in a substantially circular hole shape having a fitting hole 81, and the diameter of the fitting hole 81 of the substantially circular hole-shaped backup plate 8 is set. By substantially matching the longitudinal length of the rectangular cross section of the pierce plate 63, the backup plate 8 having a substantially circular hole prevents the pierce plate 63 having a substantially rectangular cross section from slipping out, and the backup plate 8 and the pierce plate 63 Can be easily aligned, and the degree of freedom in assembly can be increased.

  In addition, the inner peripheral edge of the fitting hole 81 of the backup plate 8 and both side ends of the piercing plate 63 are in contact with each other, so that the piercing plate 63 can be reliably prevented from coming out. Therefore, the connection work between the conductor 101 of the flat cable 100 and the pierce terminal 6 can be easily performed, and the reliability of the connection structure between the flat cable and the pierce terminal 6 can be further improved.

  Further, since the backup plate 8 is formed separately from the lower case 9, the material and hardness of the backup plate 8 can be freely set without being affected by the material of the lower case 9. Further, the retaining force of the backup plate 8 can be reliably increased without increasing the production cost of the lower case 9 and the like. Therefore, the reliability of the connection structure between the flat cable and the pierce terminal 6 can be reliably increased without increasing the production cost.

  As another embodiment, the backup plate 8 can be integrally formed with the lower case 9. In this case, it is necessary to increase the strength by forming the lower case 9 with a material mixed with glass fiber or the like. However, the assembly process of the backup plate 8 is not required in the assembly process. The number of steps can be reduced by one step.

  In this embodiment, in the connection method of connecting the LED chip 3 and the resistor 4 to the flat cable 100, the LED chip 3 and the resistor 4 are connected to the upper cable 7 that holds the LED chip 3 and the resistor 4. A terminal assembling step for temporarily assembling the pierce terminal 6 electrically connected to the intermediate terminal 5; an intermediate terminal assembling step for temporarily assembling the intermediate terminal 5 to the upper case 7 where the piercing terminal 6 is temporarily assembled; and the intermediate terminal 5 And an upper case main assembly process in which the LED chip 3 and the resistor 4 are assembled to the upper case 7 temporarily assembled with the pierce terminal 6, and the LED chip 3 and the resistor 4 and the pierce terminal 6 are assembled into the upper case 7. A backup plate for temporarily assembling a backup plate 8 for preventing the piercing plate 63 from passing through the flat cable 100 from coming out in the lower case 9. An assembly step, a case hooking portion forming step for forming the case hooking portion 110 hooked to the lower case 9 on the flat cable 100 by bending, and the case hooking portion 110 hooking to the lower case 9 And a box fitting process for fitting the upper case 7 and the lower case 9 with the flat cable 100 interposed therebetween.

As a result, the LED chip 3 and the resistor 4 held by the upper case 7 can be easily connected to the flat cable 100. In particular, once the pierce terminal 6 and the intermediate terminal 5 are temporarily assembled to the upper case 7, the LED chip 3 and the resistor 4 are assembled, thereby “holding” and “connecting” the LED chip 3 and the resistor 4. Can be performed at the same time using the intermediate terminal 5, so that the assembly workability can be improved.
Therefore, according to the method of this embodiment, a connection method that can easily connect the LED chip 3 and the resistor 4 to the flat cable 100 can be provided.

  The LED unit 1 in this embodiment is assumed to be attached to a flat cable 100 arranged in a vehicle, and a resistor 4 for adjusting the supply voltage 12V to 3.7V suitable for the LED chip 3. However, if the supply voltage is originally 3.7 V, the resistor 4 is not necessary, and the intermediate terminal 5 may be a pair of convex spring portions 51, which makes the structure simpler. Even in this case, the same effect as the LED unit 1 in the present embodiment can be obtained.

  In addition, the LED unit 1 in a present Example is the structure which hooks the case hooking part 110 of the flat cable 100 on the cable fitting part 91 of the lower case 9, and fits the upper case 7 and the lower case 9 together. However, the upper case 7 and the lower case 9 are fitted after the case hooking portion 110 is hooked to the upper case 7 while the flat cable 100 is passed through the upper case 7 with the earring terminal 6 attached thereto. It may be configured to.

  The LED unit 1 ′ of the second embodiment shown in FIG. 12 electrically connects the LED chip 3 and the resistor 4 to the flat cable 100 and the upper case 7 ′ that holds the LED chip 3 and the resistor 4. A pierce terminal 6 ′ (6A ′, 6B ′) and a lower case 9 ′ that is fitted to the upper case 7 ′ and sandwiched and attached to the flat cable 100 are provided.

  The LED unit 1 ′ includes an intermediate terminal 5 that holds the LED chip 3 and the resistor 4 in the upper case 7 ′ and connects the LED chip 3 and the resistor 4 to the pierce terminal 6 ′.

  The intermediate terminal 5 includes two pairs of convex spring portions 51 and 52 corresponding to the number of LED chips 3 and resistors 4 that are electronic components, and one convex portion of the convex spring portions 51 and 52. The springs 51a and 52a are locked to the upper case 7 ', and the LED chip 3 and the resistor 4 are pressed against the pierce terminal 6' by the other convex springs 51b and 52b.

  The LED chip 3 and the contact plate 61 ′ of the piercing terminal 6A ′ against which the LED chip 3 is pressed are disposed between the pair of convex spring portions 51, and the resistor 4 and the resistor 4 are pressed against each other. The contact plate 61 ′ of the pierced terminal 6 B ′ is disposed between the pair of convex spring portions 52.

  The pierced terminal 6 ′ is provided with a pierced part 63 ′ having a pierced blade 63 a ′ that penetrates and connects the conductor 101 of the flat cable 100, and the pierced part 63 ′ has a pair of convex spring parts 51, The LED chip 3 and the resistor 4 are interleaved between the flat cable 100 and the longitudinal direction of the flat cable 100 (hereinafter simply referred to as “longitudinal direction”). ing.

  About the said structure regarding LED unit 1 ', when it explains in full detail with FIG. 12 which shows the perspective view of LED unit 1', and FIG. 13 which shows the disassembled perspective view of LED unit 1 ', similarly to LED unit 1 of Example 1, The LED unit 1 ′ is a connection unit for connecting the LED chip 3 to the flat cable 100 and simultaneously attaching the resistor 4 for adjusting the voltage.

The LED chip 3, the resistor 4, the intermediate terminal 5, and the flat cable 100 are the same as those in the above-described first embodiment, and thus detailed description thereof is omitted.
The flat cable 100 has a convex shape in a side view, that is, a step shape higher than other portions, and a surface corresponding to the length of the lower case 9 ′, like the case hooking portion 110 formed in the flat cable 100 of the first embodiment. A case hooking portion 110 ′ composed of a body is formed.

  As shown in FIG. 13, the LED unit 1 ′ includes an upper case 7 ′ that is a first box, an LED chip 3 and a resistor 4 that are assembled to the upper case 7 ′, and the LED chip 3 and a resistor. Pierce terminals 6 ′ (6A ′, 6B ′) for connecting the device 4 to the flat cable 100, an intermediate terminal 5 for fixing the LED chip 3 and the resistor 4, a lower case 9 ′ as a second box, The terminal cover 8 ′ is used.

  There are two types of piercing terminals 6 ′, an LED piercing terminal 6 A ′ connected to the LED chip 3 and a resistance piercing terminal 6 B ′ connected to the resistor 4. And a contact plate 61 ′ having a contact convex portion 61a ′ that contacts the contact terminals 32 and 41 of the resistor 4, and a horizontal hook plate portion 62 ′ that is substantially perpendicular to the contact plate 61 ′ and has a hook shape in plan view. The pierced portion 63 ′ provided with a plurality of pierced blades 63a ′ formed in a thin plate shape having a side surface substantially perpendicular to the horizontal hook-shaped plate portion 62 ′ and substantially parallel to the longitudinal direction and the penetrating direction. It has a visual hook shape.

The horizontal hook plate portion 62 ′ of the LED piercing terminal 6A ′ is formed longer than the horizontal hook plate portion 62 ′ of the resistance piercing terminal 6B ′.
Further, the piercing portion 63 ′ is formed by bending the piercing blades 63a ′ by three in two rows in the width direction so as to be curved in an inverted U shape when viewed from the front. The pierce terminal 6 ′ may be any one having conductivity, preferably made of metal, more preferably copper or copper alloy having excellent conductivity.

  The upper case 7 ′ is formed of a resin-made plan view vertically long rectangular body, upper surface opening portions 71 ′ are formed on both side surfaces and the upper surface in the longitudinal direction, An engagement claw 72 ′ that engages with the case engagement portion 93 ′ of the side case 9 ′ is provided. Furthermore, an engagement groove portion 79 ′ that allows the engagement of the horizontal hook-shaped plate portion 62 ′ of the piercing terminal 6 ′ is provided at the lower end of the center of the flange surface on the front side in the longitudinal direction. At the center lower end, a collar projecting piece 78 ′ (see FIG. 14) is provided.

  Further, the upper case 7 ′ includes a mounting recess 73 ′ having a through hole 73a ′, a mounting recess 74 ′ having a through hole 74a ′, a first storage portion 75 ′, a second storage portion 76 ′, and an insertion recess 77 ′. (77a ′, 77b ′).

  The lower case 9 ′ is formed of a resin-made plan view vertically long rectangular dish (longitudinal direction is about twice as long as the width direction), and extends over both side surfaces of the longitudinal direction, that is, both flanges and the upper surface. A cable fitting portion 91 ′ into which the case hooking portion 110 ′ of the flat cable 100 is fitted is formed, and a piercing blade 63a of a piercing portion 63 ′ penetrating the case hooking portion 110 is formed on the upper surface inside the cable fitting portion 91 ′. An interference preventing recess 92 ′ for preventing interference with “is formed.

  In addition, a rear side of the side surface in the width direction is provided with a case engagement portion 93 ′ that allows engagement of an engagement claw 72 ′ for engaging and fixing the upper case 7 ′. A cover engagement portion 94 ′ that allows engagement of an engagement claw 82 ′ for engaging and fixing the cover 8 ′ is provided.

  The terminal cover 8 'includes a square-shaped cover body 81' formed of a resin plate, engaging claws 82 'disposed at both ends in the width direction of the cover body 81', and the front side in the longitudinal direction. It is comprised by the collar part protrusion piece 83 'arrange | positioned at the center lower end of collar surface 81a'.

  The engaging claw 82 'engages with the cover engaging portion 94' of the lower case 9 '. The collar projecting piece 83 ′ is disposed in a manner projecting downward from the front collar surface 81a ′. When the terminal cover 8 ′ is mounted, the inside of the collar projecting piece 83 ′ and the cable fitting part 91 ′ are disposed. Thus, the case hooking portion 110 ′ of the flat cable 100 hooked to the cable fitting portion 91 ′ is sandwiched.

Next, an assembly method of the LED unit 1 ′ and an attachment method to the flat cable 100 will be described.
The connection method of LED unit 1 'which connects the LED chip 3 and the resistor 4 to the flat cable 100 of this invention is a terminal assembly process, an intermediate terminal assembly process, an upper case main assembly process, and a hook convex part formation process. And a hooking process and a box fitting process.

The terminal assembling step is a step of temporarily assembling a pierce terminal 6 ′ for electrically connecting the LED chip 3 and the resistor 4 to the flat cable 100 in the upper case 7 ′ holding the LED chip 3 and the resistor 4. It is.
The intermediate terminal assembling step is a step of temporarily assembling the intermediate terminal 5 in the upper case 7 ′ in which the pierced terminal 6 ′ is temporarily assembled.

  In the upper case main assembly process, the LED chip 3 and the resistor 4 are assembled to the upper case 7 ′ in which the intermediate terminal 5 and the pierce terminal 6 ′ are temporarily assembled, and the LED chip 3 and the resistor 4, the intermediate terminal 5, This is a step of assembling the pierce terminal 6 ′ and the upper case 7 ′.

The hooking convex portion forming step is a step of forming the hooking convex portion 110 ′ hooked to the lower case 9 ′ on the flat cable 100 by bending.
The hooking step is a step of hooking the hooking convex portion 110 ′ with the lower case 9 ′.

  The box fitting step is a step of fitting the upper case 7 'and the lower case 9' with the flat cable 100 sandwiched therebetween, and further fitting the terminal cover 8 'to the lower case 9'. .

Each of the above steps will be described in detail below with reference to the drawings.
As shown in FIG. 14A, which is an explanatory diagram for explaining the terminal assembling step, the upper case 7 ′ is turned upside down and the bottom surface side is turned up, and the through hole 73a ′ (see FIG. 15) is formed. The contact plate 61 ′ of the LED piercing terminal 6A ′ is inserted to mount the LED piercing terminal 6A ′ in the mounting recess 73 ′, and the contact plate 61 of the resistance piercing terminal 6B ′ is inserted into the through hole 74a ′ (see FIG. 15). Insert 'and insert the resistance piercing terminal 6B' into the mounting recess 74 '.

  As a result, as shown in FIG. 14B, the upper case 7 in such a manner that the pierced portion 63 ′ of the LED piercing terminal 6A ′ and the resistance piercing terminal 6B ′ protrudes in the longitudinal direction of the upper case 7 ′. Can be assembled to.

  The intermediate terminal assembling step and the upper case main assembling step will be described with reference to the perspective view of the upper case 7 ′. As shown in FIG. 15A, the upper surface opening 71 ′ of the upper case 7 ′ is the upper surface side. In this manner, the contact plate 61 ′ of the pierce terminal 6 ′ assembled in the terminal assembly process described above passes through the through holes 73a ′ and 74a, and the first accommodating portion 75 ′ and the second accommodating portion 76 ′. Projects from the bottom.

  In this state, the convex spring portions 51a and 52a are inserted into the insertion concave portion 77a ′ from the upper side of the upper case 7 ′, the convex spring portions 51b and 52b are inserted into the insertion concave portion 77b ′, and the intermediate terminal 5 is moved upward. Attach to case 7 '. Here, the component placement opening 53 and the first housing portion 75 ′ of the intermediate terminal 5, and the component placement opening 54 and the second housing portion 76 ′ are in positions corresponding to the top and bottom.

  Then, as shown in FIG. 15B, the LED chip 3 and the resistor 4 are passed from above the upper case 7 ′ through the component arrangement opening 53 and the component arrangement opening 54 in the assembly direction X indicated by the arrow. As shown in FIG. 15 (c), the first housing portion 75 ′ and the second housing portion 76 ′ are assembled.

  Subsequently, the hooking convex portion forming step, the hooking step, and the box fitting step will be described with reference to FIGS. 16 and 17. As shown in FIG. 16A for explaining the hooking convex portion forming step, the flat cable 100 is folded at the valley fold line A, folded at the mountain fold line B, and the case hooking portion 110 ′ having a convex shape in side view is formed. Form.

  In addition, the space | interval of the valley fold line A and the mountain fold line B is formed substantially the same as the height inside cable fitting part 91 'of lower case 9', and the space | interval of mountain fold lines B is cable fitting of lower case 9 '. The length is substantially the same as the inner length of the wearing portion 91 ′.

  Accordingly, as shown in FIG. 16 (c) for explaining the hooking process, the case hooking portion 110 ′ is lowered from the upper side of the lower case 9 ′ so that the case hooking portion 110 ′ covers the cable fitting portion 91 ′. It can be engaged with the side case 9 '.

  In this state, as shown in FIG. 17A for explaining the box fitting process, the LED chip 3, the resistor 4, the intermediate terminal 5 and the pierce terminal 6 ′ are assembled in the upper case main assembly process, and the upper case is assembled. The engaging claw 72 of the upper case 7 ′ from which the pierced portion 63 ′ protrudes from the front side in the longitudinal direction of 7 ′ is engaged with the case engaging portion 93 ′ of the lower case 9 ′ engaged with the case engaging portion 110 ′. Then, the upper case 7 ′ and the lower case 9 ′ are fitted.

  At this time, the piercing blade 63 a ′ of the piercing portion 63 ′ penetrates the conductor 101 together with the nonconductive laminate sheet 102 of the flat cable 100. Note that the tip of the piercing blade 63a 'penetrating the flat cable 100 is inserted into the interference prevention recess 92'.

  Then, the terminal cover 8 ′ is mounted from above the piercing portion 63 ′ penetrating the flat cable 100 with the piercing blade 63 a ′. Specifically, the engagement claw 82 ′ of the terminal cover 8 ′ is engaged with the cover engagement portion 94 ′ of the lower case 9 ′, and the terminal cover 8 ′ and the lower case 9 ′ are fitted.

  In this state, both side surfaces in the longitudinal direction forming the cable fitting portion 91 ′ of the lower case 9 ′, that is, both flange portions and the upper surface, the bottom surface of the upper case 7 ′, and the inner side of the flange protruding piece 78 ′, The case hooking portion 110 ′ of the flat cable 100 is sandwiched between the bottom surface of the terminal cover 8 ′ and the flange protruding piece 83 ′.

  Thus, LED unit 3, resistor 4, intermediate terminal 5 and pierce terminal 6 'are assembled, and LED unit 1' attached to flat cable 100 is a plan view of this state. As shown in FIG. 18 (b), which is a view taken along the line aa in FIG. 18 (a), the contact plate 61 ′ of the LED piercing terminal 6A ′ and the LED chip 3 are disposed in the first housing portion 75 ′. The contact 55 of the convex spring portion 51b inserted in the insertion recess 78 is arranged in this order, and the convex spring portion 51b presses the LED chip 3 toward the contact plate 61 ′ via the contact 55.

  Therefore, the contact terminal 32 on the contact plate 61 ′ side of the LED chip 3 is in contact with the contact convex portion 61 a ′ of the contact plate 61 ′, and the contact terminal 32 on the opposite side is in contact with the contact 55.

  Further, as shown in FIG. 18 (c), which is a view taken along the line bb in FIG. 18 (a), a contact plate 61 ′ of the piercing terminal 6B ′ for resistance arranged in the second accommodating portion 76 ′, The resistor 4 and the contact 55 of the convex spring portion 52b inserted in the insertion recess 78 are arranged in this order, and the convex spring portion 52b presses the resistor 4 toward the contact plate 61 ′ via the contact 55. ing.

  Therefore, the contact terminal 41 on the contact plate 61 ′ side of the resistor 4 is in contact with the contact convex portion 61 a ′ of the contact plate 61 ′, and the contact terminal 41 on the opposite side is in contact with the contact 55.

  Since the intermediate terminal 5 electrically connected to the LED chip 3 and the resistor 4 via the contact 55 is composed of a copper plate that is a conductive member, the LED piercing terminal 6A ′ → the LED chip 3 → An electronic circuit of intermediate terminal 5 → resistor 4 → resisting piercing terminal 6B ′ can be configured.

  Since the convex spring portion 51a and the convex spring portion 52a are inserted into the insertion concave portion 77a ', the relative position of the intermediate terminal 5 with respect to the upper case 7' is fixed. The pierce terminal 6 ′ is also mounted in the mounting recesses 73 ′ and 74 provided on the bottom surface of the upper case 7 ′, and the contact plate 61 ′ penetrates the through holes 73a ′ and 74a, so that the relative position with respect to the upper case 7 ′ is increased. It is fixed.

  Then, the LED chip 3 and the resistor 4 are sandwiched between the pierce terminal 6 ′ and the intermediate terminal 5 that are fixed relative to the upper case 7 ′, and are sandwiched between the upper case 7 ′ and the upper case 7 ′. The position is fixed. Thus, the intermediate terminal 5 functions as a fixture for the LED chip 3 and the resistor 4 and also functions as a circuit component.

  Thus, by fitting the upper case 7 ′ assembled with the LED chip 3, the resistor 4, the intermediate terminal 5 and the pierce terminal 6 ′ and the lower case 9 ′ engaged with the case engaging portion 110 ′. The pierce terminal 6 ′ can be connected to the conductor 101, and the LED chip 3 and the resistor 4 can be connected to the conductor 101 in the same manner as the LED unit 1 of the first embodiment.

  Thus, in addition to the effects of the LED unit 1 of the first embodiment described above, the LED unit 1 ′ has a pierce portion 63 ′ that intersects the assembly direction X of the LED chip 3 and the resistor 4, that is, a flat Since the cable 100 is arranged at an eccentric position in the longitudinal direction, the influence of the penetration load when the piercing blade 63 a ′ penetrates the flat cable 100 is urged by the piercing terminal 6 ′ and the intermediate terminal 5. It is possible to prevent the circuit configuration of the LED chip 3 and the resistor 4 sandwiched in the state from being reached, and to realize a highly reliable connection.

  Further, for example, even when the LED chip 3 or the resistor 4 is inserted by replacement or the like with the piercing blade 63a ′ penetrating the flat cable 100, the assembly direction X of the LED chip 3 or the resistor 4 is X Since the pierced part 63 ′ is also eccentric in the longitudinal direction of the flat cable 100, it is possible to prevent a bad influence on the connection state between the pierced part 63 ′ and the flat cable 100, and to ensure a highly reliable connection state. it can.

  In this example, after completion of the upper case main assembly process, a box fitting process was performed to attach the LED unit 1 ′ to the flat cable 100, but the pierce terminal 6 ′ was assembled in the intermediate terminal assembly process. After performing the box fitting process in which the upper case 7 ′ and the lower case 9 ′ are fitted and attached to the flat cable 100, the LED chip 3, the resistor 4 and the intermediate terminal 5 are assembled to the upper case 7 ′. The upper case main assembly process may be performed.

  Even in this case, since the piercing portion 63 'is arranged at a position eccentric from the assembly direction X of the LED chip 3 and the resistor 4 in the longitudinal direction of the flat cable 100, the piercing blade 63'a is already flat. Even when the pierced part 63 ′ and the conductor 101 are connected through the cable 100, the pierced part 63 ′ and the conductor 101 by inserting the LED chip 3, the resistor 4 and the intermediate terminal 5 Can adversely affect the connection state.

  Further, the cover member 2 described in the first embodiment may be attached to the upper surface opening 71 '. Thereby, the LED chip 3, the resistor 4, the intermediate terminal 5 and the pierce terminal 6 'assembled to the upper case 7' can be protected.

As described above, in the correspondence between the configuration of the present invention and the above-described embodiment,
The electronic component of the present invention corresponds to the LED chip 3 and the resistor 4,
Similarly,
The first box corresponds to the upper case 7, 7 '
The electric cable and flat cable correspond to the flat cable 100,
The connection terminals correspond to the piercing terminals 6 and 6 ′, the LED piercing terminals 6A and 6A ′, and the resistance piercing terminals 6B and 6B ′.
The second box corresponds to the lower case 9, 9 '
Connection structure corresponds to LED unit 1, 1 ',
The terminal member corresponds to the intermediate terminal 5,
The flat conductor corresponds to the conductor 101,
The covering member corresponds to the non-conductive laminate sheet 102,
The box hooks correspond to the case hooks 110 and 110 ',
The through connection portion corresponds to the piercing plate 63 and the piercing blade 63a ′ of the piercing portion 63 ′,
The retaining means corresponds to the backup plate 8, but the present invention is not limited to the configuration of the above-described embodiment, and many embodiments can be obtained.

  The flat cable 100 may be the flat cable 100 covered with the non-conductive laminate sheet 102 which is an insulating member to which the pierce terminal 6 is easily connected, and is not particularly limited to the one in the present embodiment. Specifically, the non-conductive laminate sheet 102 is preferably PET resin.

  Further, the conductor 101 may be a conductor having a round cross section as well as a strip-shaped conductor excellent in heat dissipation, and the conductor 101 may be any material as long as it has conductivity. Preferably, it is made of metal, more preferably copper or copper alloy having excellent conductivity.

  In particular, the terminal member may have a shape such as “H”, “□”, and “U” in addition to the “day” shape shown in the figure, and “hold” the LED chip 3 and the resistor 4 when assembled. In addition, any shape may be used as long as it is “connected”.

Further, the box may be fitted after the flat cable and the piercing blade are first subjected to through curling.
In addition, the said longitudinal direction means the length direction of the conductor 101 which is a flat conductor.

The perspective view of a LED unit. The disassembled perspective view of an LED unit. Explanatory drawing by the perspective view from the bottom face side of mounting | wearing of the piercing terminal to an upper case. Explanatory drawing by the perspective view of an upper case about an intermediate terminal assembly | attachment process and an upper case main assembly process. The top view of the upper case after completion of the upper case main assembly process. The explanatory perspective view which the upper case in the upper case main assembly process permeate | transmitted. Explanatory drawing about a backup plate assembly | attachment process, a latching convex part formation process, a latching process, and a box fitting process. Explanatory drawing about a backup plate assembly | attachment process, a latching convex part formation process, a latching process, and a box fitting process. Explanatory drawing about the connection structure of a pierce terminal and a backup plate. Explanatory drawing about the connection structure of a pierce terminal and a backup plate. Explanatory drawing about the connection structure of a pierce terminal and a backup plate. The perspective view of the LED unit of a 2nd Example. The disassembled perspective view of the LED unit of a 2nd Example. Explanatory drawing explaining the terminal assembly | attachment process of a 2nd Example. Explanatory drawing about the intermediate terminal assembly | attachment process and upper case main assembly | attachment process of 2nd Example. Explanatory drawing about the engagement convex part formation process and engagement process of a 2nd Example. Explanatory drawing about the box fitting process of a 2nd Example. Explanatory drawing by the top view, sectional drawing, etc. of the LED unit of a 2nd Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,1 '... LED unit 3 ... LED chip 4 ... Resistor 5 ... Intermediate terminal 6, 6' ... Pierce terminal 6A, 6A '... LED piercing terminal 6B, 6B' ... Resistance piercing terminal 7, 7 '... Upper side Case 8 ... Backup plate 9, 9 '... Lower case 51a, 51b, 52a, 52b ... Convex spring part 63 ... Pierce plate 63a' ... Pierce blade 100 ... Flat cable 101 ... Conductor 102 ... Non-conductive laminate sheet 110 , 110 '... Case hooking part X ... Assembly direction

Claims (10)

A first box that holds electronic components;
A connection terminal for electrically connecting the electronic component to an electric cable;
A second box that fits into the first box and sandwiches and attaches the electric cable;
A connection structure comprising a terminal member for holding the electronic component in the first box and connecting the electronic component to the connection terminal,
The terminal member includes a convex spring portion formed in at least one pair of convex shapes,
One convex spring part is locked to the first box,
A connection structure, wherein the electronic component is pressed against the connection terminal by the other convex spring portion. The electronic component and a connection terminal against which the electronic component is pressed,
The connection structure according to claim 1, wherein the connection structure is disposed between the pair of convex spring portions. Arrange multiple electronic components,
The connection structure according to claim 1, further comprising a pair of convex spring portions according to the number of electronic components to be arranged. The electrical cable,
A flat cable comprising a plurality of flat conductors arranged at predetermined intervals in the width direction and a covering member that integrally covers the plurality of flat conductors in a flat plate shape,
To the flat cable,
The connection structure according to claim 1, 2, or 3, further comprising a box engaging portion that engages with the first box or the second box. In the connection terminal,
Providing a through-connection for connecting through the flat conductor;
In the second box,
The connection structure according to claim 4, further comprising a retaining means for preventing the penetration connecting portion penetrating the flat cable from coming off. The through connection portion is formed in a substantially rectangular cross-sectional shape,
The retaining means is formed in a substantially circular hole shape,
The connection structure according to claim 5, wherein a hole diameter of the substantially circular hole-shaped retaining means is made substantially equal to a longitudinal length of a rectangular cross section of the through-connection portion. The connection structure according to claim 5 or 6, wherein the retaining means is formed separately from the second box. The electrical cable,
A flat cable composed of a plurality of flat conductors arranged at predetermined intervals in the width direction and a covering member that integrally covers the plurality of flat conductors in a flat plate shape;
In the connection terminal,
Providing a through-connection for connecting through the flat conductor;
The feedthrough
The connection structure according to claim 3, wherein the connection structure is disposed in a crossing direction that intersects an assembly direction in which the electronic component is assembled between the pair of convex spring portions. The crossing direction is
The connection structure according to claim 8, which is a longitudinal direction of the flat cable. A connection method for connecting an electronic component to a flat cable,
A terminal assembly step of temporarily assembling a connection terminal for electrically connecting the electronic component to an electric cable in the first box holding the electronic component;
A terminal member assembling step of temporarily assembling a terminal member to the first box in which the connection terminals are temporarily assembled;
Assembling an electronic component to the first box temporarily assembled with the terminal member and the connection terminal, a first case main assembly process of assembling the electronic component and the connection terminal into the first case,
A retaining means assembling step for temporarily assembling a retaining means for preventing the penetration connecting portion penetrating the flat cable from coming out of the second box,
A box hooking portion forming step for forming a box hooking portion hooked to the second box by bending, on the flat cable,
A hooking step of hooking the box hooking portion with the second box;
A connection method comprising a box fitting step of fitting the first box and the second box with the flat cable sandwiched therebetween.

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