WO2015063844A1 - Breaker, safety circuit provided therewith, secondary-battery circuit, and method for manufacturing breaker - Google Patents

Breaker, safety circuit provided therewith, secondary-battery circuit, and method for manufacturing breaker Download PDF

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Publication number
WO2015063844A1
WO2015063844A1 PCT/JP2013/079172 JP2013079172W WO2015063844A1 WO 2015063844 A1 WO2015063844 A1 WO 2015063844A1 JP 2013079172 W JP2013079172 W JP 2013079172W WO 2015063844 A1 WO2015063844 A1 WO 2015063844A1
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WO
WIPO (PCT)
Prior art keywords
case
movable piece
breaker
piece
movable
Prior art date
Application number
PCT/JP2013/079172
Other languages
French (fr)
Japanese (ja)
Inventor
勝史 浪川
信幸 中野
岡田　浩司
Original Assignee
株式会社小松ライト製作所
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 株式会社小松ライト製作所 filed Critical 株式会社小松ライト製作所
Priority to PCT/JP2013/079172 priority Critical patent/WO2015063844A1/en
Priority to JP2015544646A priority patent/JP6204988B2/en
Publication of WO2015063844A1 publication Critical patent/WO2015063844A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H37/00—Thermally-actuated switches
    • H01H37/02—Details
    • H01H37/04—Bases; Housings; Mountings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H37/00—Thermally-actuated switches
    • H01H37/02—Details
    • H01H37/32—Thermally-sensitive members
    • H01H37/52—Thermally-sensitive members actuated due to deflection of bimetallic element
    • H01H37/54—Thermally-sensitive members actuated due to deflection of bimetallic element wherein the bimetallic element is inherently snap acting
    • H01H37/5427—Thermally-sensitive members actuated due to deflection of bimetallic element wherein the bimetallic element is inherently snap acting encapsulated in sealed miniaturised housing

Definitions

  • the present invention relates to a small breaker built in a secondary battery pack or the like of an electric device.
  • a breaker is used as a protection device (safety circuit) for secondary batteries and motors of various electric devices.
  • a protection device safety circuit
  • Breakers used as such protective devices operate accurately following temperature changes (having good temperature characteristics) and have stable resistance when energized to ensure the safety of the equipment. It is required to be.
  • Patent Document 1 discloses a breaker to which a bimetal is applied as a thermally responsive element.
  • Bimetal is an element that is formed by laminating two types of plate-like metal materials having different coefficients of thermal expansion, and controls the conduction state of the contact by changing the shape in accordance with a temperature change.
  • the breaker shown in the same document is a case in which parts such as a fixed piece, a movable piece, a thermally responsive element, and a PTC thermistor are housed in a case, and terminals of the fixed piece and the movable piece are connected to an electric circuit of an electric device. Used.
  • the fixed piece is incorporated into the case body (resin base) by insert molding (see paragraph (0031) and the like of the same document).
  • the case main body and the lid member constituting the resin case are both formed of a resin material, they are firmly bonded to each other by ultrasonic welding, and high bonding strength and airtightness (sealing) between them. Property).
  • the movable piece that constitutes the electric circuit together with the fixed piece is formed of a metal material mainly composed of phosphor bronze or the like. Since the bonding strength between the metal material and the resin material is inferior to the bonding strength between the resin materials, sufficient adhesion cannot be obtained between the movable piece, the resin base, and the cover member.
  • the present invention has been made to solve the above-mentioned problems, and maintains the normal heat deformation operation of the thermoresponsive element by improving the airtightness of the case and preventing the adverse effect on the metal such as the thermoresponsive element. And it aims at providing the breaker which can acquire a favorable temperature characteristic.
  • the present invention has a fixed piece having a fixed contact, a movable contact, a movable piece that presses and contacts the movable contact with the fixed contact, and is deformed as the temperature changes.
  • a breaker comprising: a thermal response element that operates the movable piece so that the movable contact is separated from the fixed contact; and a first case that houses the fixed piece, the movable piece, and the thermal response element.
  • the movable piece further includes a second case that covers the outer side of the one case, the movable piece has a terminal extending outward from the first case, and the terminal protrudes from the first case at a base end portion.
  • a joining strengthening part for strengthening a joining force with the second case is formed, and the joining strengthening part is embedded in the second case.
  • the joint reinforcing portion has a step bend in which the movable piece is bent in a step shape.
  • the joint strengthening portion has a concave portion that is recessed from the base end portion in the thickness direction of the movable piece.
  • the joint strengthening portion has a convex portion protruding from the base end portion in the thickness direction of the movable piece.
  • the joint strengthening portion has a through hole that penetrates the movable piece in the thickness direction.
  • the joint reinforcing portion has a notch in which a part of the movable piece is cut off.
  • a safety circuit for an electrical device includes the above breaker.
  • the secondary battery pack according to the present invention includes the breaker.
  • the present invention provides a breaker manufacturing method for manufacturing the above-described breaker, wherein a primary molding step of molding a first case by filling a cavity material of a first mold with a resin material, and the joining to the movable piece A reinforcing part forming step for forming a reinforcing part, and a movable piece in which the joint reinforcing part is formed in the first case formed by the primary forming process and the fixed piece, the thermally responsive element, and the reinforcing part forming step are mounted. And mounting the first case on which the fixed piece, the movable piece, and the thermally responsive element are mounted by the mounting step into the second mold, and filling the cavity space of the second mold with a resin material. And a secondary molding step of molding the second case.
  • the joint strengthening portion that reinforces the joining force with the second case is formed at the base end portion where the terminal of the movable piece protrudes from the first case, and the joint strengthening portion is the second case.
  • the base end portion of the terminal is firmly joined to the second case.
  • the perspective view which shows schematic structure of the breaker by one Embodiment of this invention.
  • the assembly perspective view which shows the structure of the principal part of the breaker. Sectional drawing which shows the breaker in a normal charge or discharge state. Sectional drawing which shows the breaker in the overcharge state or the time of abnormality.
  • the perspective view which shows the structure of the movable piece of the breaker.
  • the perspective view which shows the 1st case and movable piece of the breaker.
  • the top view which shows the structure of the breaker.
  • the flowchart which shows the manufacturing method of the breaker.
  • the top view which shows the modification of a movable piece.
  • the top view which shows the structure of the secondary battery pack provided with the breaker of this invention.
  • the circuit diagram of the safety circuit provided with the breaker of this invention.
  • FIG. 1 shows the structure of the breaker.
  • the breaker 1 includes a fixed piece 2 and a movable piece 4 connected to an external circuit, a first case 7 that accommodates the fixed piece 2 and the movable piece 4, and a second case 9 that covers the outside of the first case 7. ing.
  • the first case 7 is embedded in the second case 9. From the side wall of the first case 7, the terminal 22 of the fixed piece 2 and the terminal 41 of the movable piece 4 extend outward from the first case 7 and project outside the first case 7.
  • the terminal 22 of the fixed piece 2 and the terminal 41 of the movable piece 4 protrude from the side wall of the second case 9 and are exposed to the outside of the second case 9.
  • the first case 7 includes a resin base 71 that houses the fixed piece 2 and the movable piece 4, a cover member 72 that is mounted on the upper surface of the resin base 71, a cover piece 8 embedded in the cover member 72, and the like. Yes. By covering the outside of the first case 7 with the second case 9, the airtightness of the internal space of the first case 7 is enhanced.
  • the resin base 71 and the cover member 72 of the first case 7 and the second case 9 are made of, for example, flame retardant polyamide, polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polybutylene terephthalate (PBT) having excellent heat resistance. It is molded by resin. A material other than the resin may be applied as long as characteristics equal to or higher than those of the above-described resin can be obtained.
  • FIG. 2 shows the configuration of the main part 10 of the breaker 1 accommodated in the second case 9.
  • the main part 10 of the breaker 1 includes a fixed piece 2 having a fixed contact 21, a movable piece 4 having a movable contact 3 at the tip, a thermally responsive element 5 that deforms with temperature change, and a PTC (PositivesTemperatureerCoefficient).
  • the thermistor 6 includes a fixed piece 2, a movable piece 4, a thermally responsive element 5, a first case 7 that accommodates the PTC thermistor 6, and the like.
  • the fixing piece 2 is formed by pressing a metal plate mainly composed of phosphor bronze or the like (other metal plate such as copper-titanium alloy, white or brass), and is embedded in the resin base 71 by insert molding. It is.
  • a terminal 22 electrically connected to an external circuit is formed at one end of the fixed piece 2, and a support portion 23 that supports the PTC thermistor 6 is formed at the other end side.
  • the PTC thermistor 6 is placed on the projections (dowels) 24a formed at three places on the support portion 23 of the fixed piece 2, and is supported by the projections 24a.
  • the fixed contact 21 is formed at a position facing the movable contact 3 by clad, plating or coating of a conductive material such as copper, silver alloy, gold-silver alloy as well as silver, nickel, nickel-silver alloy.
  • a conductive material such as copper, silver alloy, gold-silver alloy as well as silver, nickel, nickel-silver alloy.
  • the resin base 71 is exposed from a part of the opening 73b formed above.
  • the terminal 22 protrudes outward from one end of the resin base 71.
  • the fixed piece 2 is exposed to the outside of the resin base 71 on both the front and back surfaces of the terminal 22, the fixed contact 21, and the support portion 23, and resin between the terminal 22 and the fixed contact 21 and between the fixed contact 21 and the support portion 23. Embedded in the base 71. The surface of the support portion 23 of the fixed piece 2 is exposed to the accommodation space inside the case 7 and is in electrical contact with the PTC thermistor 6 through the protrusion 24a.
  • the movable piece 4 is formed in an arm shape symmetrical to the center line in the longitudinal direction by pressing a plate-shaped metal material.
  • a material of the movable piece 4 a material mainly composed of phosphor bronze or the like equivalent to the fixed piece 2 is preferable.
  • a conductive elastic material such as copper-titanium alloy, white or brass may be used.
  • a terminal 41 electrically connected to an external circuit is formed at one end in the longitudinal direction of the movable piece 4 and is exposed to the outside from the resin base 71.
  • a movable contact 3 is formed at the other end of the movable piece 4 (corresponding to the tip of the arm-shaped movable piece 4).
  • the movable contact 3 is formed of the same material as that of the fixed contact 21 and is joined to the tip of the movable piece 4 by a technique such as clad or crimping in addition to welding.
  • the surface to which the movable contact 3 is joined (that is, the lower surface in FIG. 2) is the back surface, and the opposite surface is the front surface. It is described as a surface. The relationship between the front and back of the other parts is the same.
  • the movable piece 4 has a sandwiching portion 42 and an elastic portion 43 between the movable contact 3 and the terminal 41.
  • the sandwiching portion 42 is in contact with the resin base 71 and the cover member 72 between the terminal 41 and the elastic portion 43, and is sandwiched between the resin base 71 and the cover member 72.
  • the sandwiching portion 42 has a protruding portion 42 a that protrudes in a wing shape in the short direction of the movable piece 4.
  • the elastic part 43 extends from the clamping part 42 to the movable contact 3 side.
  • the movable piece 4 is fixed by being sandwiched by the resin base 71 and the cover member 72 from the front and back sides, and the elastic part 43 is elastically deformed, so that the movable contact 3 formed at the tip thereof is the fixed contact 21.
  • the fixed piece 2 and the movable piece 4 can be energized.
  • the resin base 71 and the cover member 72 are in contact with the sandwiching portion 42 of the movable piece 4, and the contact portion 74 and the contact portion 79 that hold the sandwiching portion 42 in a fixed state.
  • a contact portion 74 is formed in a region extending from the outer edge of the housing portion 73 of the resin base 71 to the outer wall of the resin base 71.
  • the contact portion 74 constitutes a part of the bottom wall (inner bottom surface) of the case 7 in FIG.
  • a contact portion 79 is formed in a region facing the contact portion 74 with the movable piece 4 interposed therebetween.
  • the contact portion 79 constitutes a part of the top wall (inner top surface) of the case 7 in FIG.
  • the clamping part 42 comes into contact with the contact part 74 of the resin base 71 on its back surface, and comes into contact with the contact part 79 of the cover member 72 on its front surface.
  • the movable piece 4 is sandwiched from both the front and back surfaces of the sandwiching portion 42 by the contact portion 74 and the contact portion 79 and fixed to the case 7.
  • the sandwiching portion 42 has a protruding portion 42a that projects in a wing shape in the short direction of the movable piece 4, the sandwiching portion 42 is wide and large by the contact portion 74 and the contact portion 79 of the case 7.
  • the movable piece 4 is firmly fixed to the case 7 by being sandwiched.
  • the movable piece 4 is bent or bent at the elastic portion 43 by pressing.
  • the degree of bending or bending is not particularly limited as long as the thermally responsive element 5 can be accommodated, and may be appropriately set in consideration of the elastic force at the operating temperature and the return temperature, the pressing force of the contact point, and the like.
  • a pair of protrusions (contact portions) 44 a and 44 b are formed on the lower surface of the elastic portion 43 so as to face the heat-responsive element 5.
  • the protrusions 44a and 44b and the thermally responsive element 5 come into contact with each other, and the deformation of the thermally responsive element 5 is transmitted to the elastic portion 43 via the protrusions 44a and 44b (see FIGS. 3 and 4).
  • a joint reinforcing portion that reinforces the joining force between the second case 9 and the base end portion 41 a is provided at the base end portion 41 a from which the terminal 41 of the movable piece 4 projects from the first case 7. 45 is formed.
  • the joint strengthening part 45 is embedded in the second case 9.
  • the joint strengthening part 45 strengthens the joining force between the base end part 41a and the second case 9, so that the airtightness of the second case 9 is improved, and the internal space of the first case 7 that accommodates the thermally responsive element 5 and the like. Water vapor or the like is prevented from entering the water.
  • the thermoresponsive element 5 has an initial shape curved in an arc shape and is made of a composite material such as bimetal or trimetal. When the operating temperature is reached due to overheating, the curved shape is reversely warped with snap motion, and is restored when the temperature falls below the return temperature due to cooling.
  • the initial shape of the thermoresponsive element 5 can be formed by pressing. As long as the elastic portion 43 of the movable piece 4 is pushed up by the reverse warping operation of the thermal response element 5 at a desired temperature and returns to the original state by the elastic force of the elastic portion 43, the material and shape of the thermal response element 5 are particularly limited.
  • a rectangular shape is desirable from the viewpoint of productivity and efficiency of reverse warping operation, and it is desirable that the rectangular shape is close to a square in order to efficiently push up the elastic portion 43 while being small.
  • the material of the thermally responsive element 5 include, for example, copper, nickel-manganese alloy or nickel-chromium-iron alloy on the high expansion side and iron-nickel alloy on the low expansion side, white, brass, stainless steel.
  • a laminate of two types of materials having different coefficients of thermal expansion made of various alloys such as steel is used in combination according to the required conditions.
  • the current flowing through the PTC thermistor 6 increases.
  • the PTC thermistor 6 is a positive temperature coefficient thermistor that limits the current by increasing the resistance value as the temperature rises, the type of operation current, operation voltage, operation temperature, return temperature, etc. can be selected as necessary.
  • the material and shape are not particularly limited as long as these properties are not impaired.
  • a ceramic sintered body containing barium titanate, strontium titanate or calcium titanate is used.
  • a so-called polymer PTC in which conductive particles such as carbon are contained in a polymer may be used.
  • the resin base 71 and the cover member 72 constituting the first case 7 are formed by separate first molds (not shown).
  • the resin base 71 is formed by inserting the fixed piece 2.
  • the cover member 72 is formed by inserting the cover piece 8.
  • the resin base 71 is formed with a housing portion 73 for housing the thermally responsive element 5, the PTC thermistor 6, and the like, and openings 73 a and 73 b for housing the movable piece 4. Note that the edges of the movable piece 4, the thermally responsive element 5, and the PTC thermistor 6 incorporated in the resin base 71 are in contact with each other by a frame formed inside the storage portion 73. It will be guided at the time.
  • the resin base 71 has a window 76 for exposing the terminal 41 of the movable piece 4 to the outside.
  • the cover piece 8 is embedded in the cover member 72 by insert molding.
  • the cover piece 8 is formed by pressing a metal plate mainly composed of the above-described phosphor bronze or the like or a metal plate such as stainless steel. As shown in FIGS. 3 and 4, the cover piece 8 is appropriately brought into contact with the upper surface of the movable piece 4 to restrict the movement of the movable piece 4, and the rigidity and strength of the case 7 as a casing as a result of the cover member 72. Contributes to the downsizing of the breaker 1
  • the cover piece 8 is formed with protrusions 82a and 82b protruding to the movable piece 4 side.
  • the elastic part 43 is pressed in the direction of the thermally responsive element 5 by the projection 82b, and the contact pressure between the fixed contact 21 and the movable contact 3 at the time of energization is optimized.
  • the cover member 72 is disposed on the upper surface of the resin base 71 so as to close the opening 73 a of the resin base 71 that accommodates the fixed piece 2, the movable piece 4, the thermally responsive element 5, the PTC thermistor 6, and the like. It is attached to.
  • the resin base 71 and the cover member 72 are joined by, for example, ultrasonic welding.
  • the joining of the resin base 71 and the cover member 72 can be realized by, for example, engaging or fitting the resin base 71 and the cover member 72 in addition to ultrasonic welding. Further, the resin base 71 and the cover piece 8 may be engaged with each other. In these cases, the resin base 71, the cover member 72, and the cover piece 8 may be formed with convex portions, concave portions, or holes for engagement or the like. In the form in which the resin base 71 and the cover piece 8 are engaged, the cover member 72 is omitted by covering the entire area of the resin base 71 such as the storage portion 73 and the openings 73a and 73b with the cover piece 8. It may be.
  • FIG. 3 shows the operation of the breaker 1 in a normal charging or discharging state.
  • the thermal responsive element 5 maintains the initial shape (before reverse warping)
  • the fixed contact 21 and the movable contact 3 come into contact with each other
  • the breaker 1 passes through the elastic portion 43 of the movable piece 4.
  • the terminals 22 and 41 are electrically connected.
  • the elastic part 43 of the movable piece 4 and the thermal responsive element 5 are in contact, and the movable piece 4, the thermal responsive element 5, the PTC thermistor 6 and the fixed piece 2 are electrically connected as a circuit.
  • the resistance of the PTC thermistor 6 is overwhelmingly larger than the resistance of the movable piece 4, the current flowing through the PTC thermistor 6 is substantially larger than the amount flowing through the fixed contact 21 and the movable contact 3. It can be ignored.
  • FIG. 4 shows the operation of the breaker 1 in an overcharged state or an abnormality.
  • the thermal actuator 5 that has reached the operating temperature is warped in reverse, and the elastic portion 43 of the movable piece 4 is pushed up so that the fixed contact 21 and the movable contact 3 Are separated from each other.
  • the current flowing between the fixed contact 21 and the movable contact 3 is interrupted, and a slight leakage current flows through the thermal actuator 5 and the PTC thermistor 6.
  • FIG. 5 shows the configuration of the movable piece 4.
  • the movable piece 4 has a joint strengthening portion 45 on the terminal 41 side from the base end portion 41 a of the terminal 41, that is, the clamping portion 42.
  • the joint strengthening portion 45 includes a step bend 46 in which the movable piece 4 is bent in a step shape, a through hole 47 penetrating the movable piece 4 in the thickness direction, and a pair of notches 48 in which a part of the movable piece 4 is cut off. Have. At least one of the step bend 46, the through hole 47, and the notch 48 may be formed in the joint strengthening portion 45.
  • the step bending 46 arranges the clamping part 42 of the movable piece 4 and the tip part 41b of the terminal 41 in a stepwise manner.
  • the through hole 47 is provided between the clamping part 42 and the step bend 46.
  • the through hole 47 may be provided on the tip 41b side of the terminal 41 with respect to the step bend 46, or a part or all of the through hole 47 may be provided in the region where the step bend 46 is formed.
  • the notch 48 is provided in the end edge portion of the movable piece 4 so as to penetrate the movable piece 4.
  • the notch 48 is provided on the tip end 41 b side of the terminal 41 with respect to the step bend 46.
  • the notch 48 may be provided on the clamping portion 42 side with respect to the step bend 46 or the through hole 47, and a part or all of the notch 48 is provided in the region where the step bend 46 is formed. May be.
  • FIG. 6 shows the main part 10 of the breaker 1.
  • the main part 10 of the breaker 1 is configured such that the movable piece 4 and the like are accommodated in a resin base 71 and a cover member 72 is welded.
  • a terminal 22 of the fixed piece 2 and a terminal 41 of the movable piece 4 extend from the side wall of the first case 7 constituted by the resin base 71, the cover member 72, and the like.
  • the joint strengthening portion 45 of the movable piece 4 is formed to extend to the outside of the first case 7. Therefore, the step bend 46, the through hole 47, and the notch 48 formed in the joint strengthening portion 45 protrude to the outside of the first case 7.
  • the main part 10 of the breaker 1 is loaded (inserted) into a second mold (not shown) for molding the second case 9, and the cavity space of the second mold is filled with resin, thereby 2 Case 9 is shape
  • the joint reinforcing portion 45 including the step bend 46, the through hole 47, and the notch 48 is accommodated in the cavity space of the second mold and is embedded in the resin filled in the cavity space.
  • FIG. 7 is a plan view of the breaker 1.
  • the second case 9 covers the entire outside of the first case 7.
  • the main part 10 of the breaker 1 is sealed by the second case 9 in a region excluding the tip part 22 b of the terminal 22 and the tip part 41 b of the movable terminal 41.
  • the holding part that holds the first case 7 is provided in the second mold so as to protrude during the insert molding, the area excluding the holding part is covered with the second case 9.
  • the base end portion 22 a of the terminal 22 and the base end portion 41 a of the terminal 41 are also embedded in the second case 9. Therefore, the joint strengthening portion 45 provided at the base end portion 41 a of the terminal 41 is also embedded in the second case 9 and is not exposed to the outside of the second case 9.
  • the fluidized resin material flows around the base end 41 a of the terminal 41 of the movable piece 4. For this reason, the bonding between the metal and the resin at the base end portion 41a is stronger than the bonding between the sandwiching portion 42 and the first case 7 by ultrasonic welding, and high sealing performance is obtained.
  • the second case 9 covers the entire outside of the first case 7.
  • the joints between the resins (for example, the resin base 71 and the cover member 72) and the resin (for example, the first case 7) and the metal (for example, the fixed piece 2, the movable piece 4, and the cover) that appear in the main part 10 of the breaker 1 are used. Since the joint portion of the piece 8) is covered with the second case 9, an equivalent sealing effect can be obtained.
  • the breaker 1 may be configured so that at least the bonding portion between the resin and the metal is covered by the second case 9. .
  • the step bend 46 is embedded in the second case 9, and the second case 9 is formed around the step bend 46 bent in a stepped manner. Filled with resin. Thereby, the inside of the second case 9 is also formed in a step shape corresponding to the step bending 46.
  • the step-like step bending 46 and the second case 9 corresponding to each other are meshed and meshed with each other, whereby the bonding force between the base end portion 41a and the second case 9 is strengthened, and the airtightness of the second case 9 is increased. As a result, the water vapor and the like are prevented from entering the internal space of the first case 7 that accommodates the thermally responsive element 5 and the like.
  • the airtightness of the second case 9 is maintained high, and the thermally responsive element 5 and the like are accommodated. Water vapor or the like is prevented from entering the internal space of the first case 7.
  • the through hole 47 is embedded in the second case 9, and the through hole 47 is filled with the resin constituting the second case 9.
  • the resins constituting the second case 9 the resin filled above the movable piece 4 and the resin filled below the movable piece 4 are continuously integrated via the through hole 47. . Therefore, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
  • a part 47 a of the through hole 47 is provided inside the first case 7.
  • a part 47 a of the through hole 47 is also filled with the resin constituting the second case 9 and joined to the first case 7. Thereby, the strength and rigidity of the first case 7 and the second case 9 are improved.
  • the notch 48 is embedded in the second case 9, and the notch 48 includes the second case 9 is filled.
  • the resin filled above the movable piece 4, the resin filled below the movable piece 4, and the resin filled to the side of the movable piece 4, Are continuously integrated through the notch 48. Therefore, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
  • a concave portion recessed in the thickness direction of the movable piece 4 on the front surface and / or the back surface of the joint reinforcing portion 45 together with the through hole 47 and / or the notch 48 described above or instead of the through hole 47 and / or the notch 48. May be formed.
  • the recess is depressed without penetrating in the thickness direction of the movable piece 4 and has a bottomed form.
  • the concave portion is filled with the resin constituting the second case 9, and the bonding force between the base end portion 41a and the second case 9 is strengthened.
  • the thickness of the movable piece 4 is formed on the front surface and / or the back surface of the joint reinforcing portion 45 together with the through hole 47, the notch 48 and / or the concave portion, or in place of the through hole 47 notch 48 and / or the concave portion.
  • a convex portion protruding in the vertical direction may be formed.
  • the resin which comprises the 2nd case 9 is filled so that a convex part may be fitted to the periphery of a convex part, and the joining force of the base end part 41a and the 2nd case 9 is strengthened.
  • FIG. 8 shows a method for manufacturing the breaker 1.
  • the breaker 1 is manufactured by a primary molding process (S1), a reinforced part forming process (S2), a mounting process (S3), a cover welding process (S4), and a secondary molding process (S5).
  • the resin material is filled in the cavity space of the first mold, and the resin base 71 and the cover member 72 are molded.
  • the reinforcing portion forming step (S2) the joint reinforcing portion 45 is formed on the movable piece 4. That is, a step bend 46, a through hole 47, a notch 48, and the like are formed in the movable piece 4 by pressing or the like.
  • the step bend 46, the through hole 47, the notch 48 and the like may be formed at the same time when the metal plate is punched to form the movable piece 4, and after the movable piece 4 is punched from the metal plate, it is separately pressed. It may be formed.
  • the joint reinforcing portion 45 is formed on the resin base 71 molded in the primary molding step (S1) by the fixing piece 2, the PTC thermistor 6, the thermal actuator 5 and the reinforcing portion forming step (S2).
  • the formed movable piece 4 or the like is mounted.
  • the fixed piece 2 is accommodated in the resin base 71 by being inserted into the resin base 71 in the primary molding step (S1), a part of the primary molding step (S1)
  • the part of the mounting process (S3) is executed at the same time.
  • the cover member 72 is welded to the resin base 71 on which the PTC thermistor 6, the thermally responsive element 5, the movable piece 4 and the like are mounted in the mounting step (S3). Is completed.
  • the cover member 72 or the cover piece 8 is replaced with the cover welding step (S4).
  • a cover mounting engagement process for mounting and engaging with the resin base 71 is applied.
  • the secondary molding step (S5) the first case 7 on which the fixed piece 2, the movable piece 4, the thermal responsive element 5 and the like are mounted is loaded into the second mold, and is placed in the cavity space of the second mold.
  • the second case 9 is molded by filling the resin material.
  • FIG. 9 shows a movable piece 4 ⁇ / b> A that is a modification of the movable piece 4.
  • the movable piece 4A is different from the movable piece 4 in that a resin film 49 is formed in a region extending from the clamping portion 42 to the joint strengthening portion 45 indicated by hatching in FIG.
  • the resin film 49 is formed on the front surface and / or the back surface of the movable piece 4A by a technique such as coating or printing. Thereby, the resin film 49 adheres to the front surface and the back surface of the movable piece 4A.
  • the resin film 49 is firmly bonded to the resin constituting the first case 7 and the second case 9 in the cover welding step (S4) and the secondary molding step (S5). Thereby, the joining force between the clamping part 42 and the first case 7 and the joining force between the joining strengthening part 45 and the second case 9 are enhanced.
  • the resin film 49 may be formed on either the front surface or the back surface of the movable piece 4. Further, the resin film 49 is desirably formed in a region extending from the sandwiching portion 42 to the joint strengthening portion 45, but it is sufficient that the resin film 49 is formed at least on the joint strengthening portion 45. Further, when a sufficient bonding force is obtained between the bonding reinforcing portion 45 and the second case 9 by the resin film 49, the step bend 46, the through hole 47 and / or the notch 48 may be omitted as appropriate. Good.
  • the joint strengthening portion 45 that reinforces the joining force with the second case 9 on the base end portion 41 a where the terminal 41 of the movable piece 4 protrudes from the first case 7.
  • the joint strengthening portion 45 is embedded in the second case 9, the base end portion 41 a of the terminal 41 is firmly joined to the second case 9.
  • the joint strengthening part 45 has a step bend 46 in which the movable piece 4 is bent in a step shape, the resin constituting the second case 9 is filled around the step bend 46.
  • the bonding force between the base end portion 41a and the second case 9 is strengthened, the airtightness of the second case 9 is improved, and water vapor or the like is generated in the internal space of the first case 7 that accommodates the thermally responsive element 5 and the like. Intrusion is prevented.
  • the joint strengthening portion 45 has a concave portion that is recessed from the base end portion 41a in the thickness direction of the movable piece 4 or a convex portion that protrudes from the base end portion 41a in the thickness direction of the movable piece, similar effects can be obtained. can get.
  • the joint strengthening portion 45 has a through hole 47 that penetrates the movable piece 4 in the thickness direction, the through hole 47 is filled with a resin constituting the second case 9. Thereby, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
  • the joint strengthening part 45 has a notch 48 in which a part of the movable piece 4 is cut, the notch 48 is filled with a resin constituting the second case 9. Thereby, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
  • the joining force between the joint strengthening portion 45 and the second case 9 is increased, and the airtightness of the second case 9 is improved.
  • the breaker 1 According to the breaker manufacturing method including the primary forming step (S1), the strengthening portion forming step (S2), the mounting step (S3), and the secondary forming step (S5), the breaker 1 according to this embodiment can be manufactured. it can.
  • this invention is not restricted to the structure of the said embodiment,
  • the 2nd case which covers the outer side of the 1st case 7 which accommodates at least the fixed piece 2, the movable piece 4, and the thermally responsive element 5 at least.
  • the movable piece 4 has a terminal 41 extending outward from the first case 7, and a base end 41 a from which the terminal 41 protrudes from the first case 7 has a second case 9 and It is only necessary that the joint strengthening portion 45 that strengthens the joint force is formed and the joint strengthening portion 45 is embedded in the second case 9.
  • a joint strengthening portion that strengthens the joining force with the second case 9 is formed and embedded in the second case 9.
  • a step bend, a through hole, a notch, and / or a resin film may be formed on the base end portion 22 a of the terminal 22. In this case, the joining force between the base end portion 22a of the terminal 22 and the second case 9 is strengthened.
  • the movable piece 4 or the movable piece 4A may be subjected to a surface roughening process such as a satin finish.
  • a surface roughening process such as a satin finish.
  • Such surface roughening treatment increases the bonding force between the metal constituting the movable piece 4 and the resin constituting the first case 7 and the second case 9 and contributes to the improvement of the airtightness.
  • the bonding force between the metal constituting the movable piece 4A and the resin film 49 is increased, which contributes to the improvement of the airtightness.
  • the position, size, shape, and number of the step bend 46, the through hole 47, and the notch 48 can be appropriately set according to the size of the breaker 1, the air tightness required for the second case 9, and the like.
  • the joining technique between the resin base 71 and the cover member 72 is not limited to ultrasonic welding, and any technique can be applied as long as both are firmly joined.
  • a liquid or gel adhesive may be applied, filled, and cured to bond them together.
  • the case 7 is not limited to the form constituted by the resin base 71 and the cover member 72 and the like, but may be any form as long as the movable piece 4 is sandwiched and held by two or more parts.
  • the PTC thermistor 6 has a self-holding circuit, but it can be applied even in a form in which such a configuration is omitted, while ensuring stable temperature followability and resistance value.
  • the breaker 1 can be downsized.
  • the structure which forms the movable piece 4 and the thermally responsive element 5 integrally by forming the movable piece 4 with a bimetal or a trimetal etc. may be sufficient.
  • the heat transfer part is formed in the integrated movable piece, the structure of the breaker is simplified, and further miniaturization can be achieved.
  • the movable piece 4 is structurally separated into the terminal 41 side and the movable contact 3 side in the clamping portion 42 or in the vicinity thereof. May be applied.
  • the arm terminal and the movable arm may be fixed by welding or the like.
  • the clamping part 42 and the terminal 41 may be insert-molded in the resin base 71 together with the fixed piece 2 and the like.
  • FIG. 10 shows the secondary battery pack 100.
  • the secondary battery pack 100 includes a secondary battery 101 and a breaker 1 provided in the output terminal circuit of the secondary battery 101.
  • FIG. 11 shows a safety circuit 102 for electrical equipment.
  • the safety circuit 102 includes a breaker 1 in series in the output circuit of the secondary battery 101. According to the secondary battery pack 100 or the safety circuit 102 provided with the breaker 1, the secondary battery pack 100 or the safety circuit 102 in which safety is ensured by excellent temperature characteristics can be manufactured.

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Thermally Actuated Switches (AREA)
  • Manufacture Of Switches (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Abstract

This breaker (1) is provided with a first case (7) and a second case (9) that encloses the first case (7). The first case (7) contains a fixed strip (2), a movable strip (4), and a heat-sensitive element. The movable strip (4) has a terminal (41) that extends outside the first case (7). A base section (41a) of said terminal (41), where the terminal (41) protrudes from the first case (7), has a join-strengthening section (45) that strengthens a join with the second case (9). Said join-strengthening section (45) is embedded inside the second case (9). As a result of the join-strengthening section (45), the base section (41a) of the terminal (41) joins to the second case (9) tightly, improving the hermeticity of the second case (9).

Description

ブレーカー及びそれを備えた安全回路並びに２次電池回路、並びにブレーカーの製造方法Breaker, safety circuit including the same, secondary battery circuit, and method for manufacturing breaker
　本発明は、電気機器の２次電池パック等に内蔵される小型のブレーカーに関するものである。 The present invention relates to a small breaker built in a secondary battery pack or the like of an electric device.
　従来、各種電気機器の２次電池やモーター等の保護装置（安全回路）としてブレーカーが使用されている。ブレーカーは、充放電中の２次電池の温度が過度に上昇した場合、又は自動車、家電製品等の機器に装備されるモーター等に過電流が流れた場合等の異常が生じた際に、２次電池やモーター等を保護するために電流を遮断する。このような保護装置として用いられるブレーカーは、機器の安全を確保するために、温度変化に追従して正確に動作する（良好な温度特性を有する）ことと、通電時の抵抗値が安定していることが求められる。 Conventionally, a breaker is used as a protection device (safety circuit) for secondary batteries and motors of various electric devices. When the temperature of the secondary battery during charging / discharging rises excessively, or when an abnormality occurs such as when an overcurrent flows through a motor or the like equipped in a device such as an automobile or home appliance, Cut off current to protect secondary batteries and motors. Breakers used as such protective devices operate accurately following temperature changes (having good temperature characteristics) and have stable resistance when energized to ensure the safety of the equipment. It is required to be.
　ブレーカーには、温度変化に応じて動作し、電流を導通又は遮断する熱応動素子が備えられている。特許文献１には、熱応動素子としてバイメタルを適用したブレーカーが示されている。バイメタルとは、熱膨張率の異なる２種類の板状の金属材料が積層されてなり、温度変化に応じて形状を変えることにより、接点の導通状態を制御する素子である。同文献に示されたブレーカーは、固定片、可動片、熱応動素子、ＰＴＣサーミスター等の部品が、ケースに収納されてなり、固定片及び可動片の端子が電気機器の電気回路に接続されて使用される。上記特許文献１に示されたブレーカーにおいて、固定片は、ケース本体（樹脂ベース）にインサート成形により組み込まれる（同文献の段落（００３１）等参照）。 The breaker is equipped with a thermally responsive element that operates according to temperature changes and conducts or cuts off current. Patent Document 1 discloses a breaker to which a bimetal is applied as a thermally responsive element. Bimetal is an element that is formed by laminating two types of plate-like metal materials having different coefficients of thermal expansion, and controls the conduction state of the contact by changing the shape in accordance with a temperature change. The breaker shown in the same document is a case in which parts such as a fixed piece, a movable piece, a thermally responsive element, and a PTC thermistor are housed in a case, and terminals of the fixed piece and the movable piece are connected to an electric circuit of an electric device. Used. In the breaker disclosed in Patent Document 1, the fixed piece is incorporated into the case body (resin base) by insert molding (see paragraph (0031) and the like of the same document).
ＷＯ２０１１／１０５１７５号公報WO2011 / 105175 gazette
　特許文献１において、樹脂ケースを構成するケース本体と蓋部材とは、共に樹脂材料によって形成されているので、超音波溶着によって互いに強固に接合し、両者の間で高い接合強度と気密性（密封性）が得られる。一方、固定片と共に電気回路を構成する可動片は、リン青銅等を主成分とする金属材料によって形成されている。金属材料と樹脂材料との接合強度は、樹脂材料同士の接合強度に比べて劣るため、可動片と樹脂ベース及びカバー部材との間では、十分な密着性が得られず、極めて温度及び湿度の高い雰囲気で長時間に亘ってブレーカーが使用される場合、熱応動素子等を収容する内部空間に水蒸気の他、例えば、ブレーカーの周囲環境から発生した気体等が侵入する虞がある。ブレーカーの内部空間に侵入した水蒸気等は、熱応動素子等を構成する金属に悪影響を及ぼすことが懸念される。 In Patent Document 1, since the case main body and the lid member constituting the resin case are both formed of a resin material, they are firmly bonded to each other by ultrasonic welding, and high bonding strength and airtightness (sealing) between them. Property). On the other hand, the movable piece that constitutes the electric circuit together with the fixed piece is formed of a metal material mainly composed of phosphor bronze or the like. Since the bonding strength between the metal material and the resin material is inferior to the bonding strength between the resin materials, sufficient adhesion cannot be obtained between the movable piece, the resin base, and the cover member. When a breaker is used over a long period of time in a high atmosphere, there is a risk that, for example, gas generated from the surrounding environment of the breaker may enter into the internal space that accommodates the thermally responsive element or the like. There is a concern that water vapor or the like that has entered the internal space of the breaker may adversely affect the metal constituting the thermally responsive element.
　また、近年、生産効率の向上を狙って、ブレーカーを回路基板に直接的に実装する形態が検討されており、さらには、ブレーカーの端子と回路基板のリードとの接続にリフロー方式のはんだ付けを用いることが検討されている。ところが、可動片と樹脂ベース及びカバー部材の間に生じた僅かな隙間からフラックスが侵入することがあり、上述した懸念の一因となっている。 In recent years, with the aim of improving production efficiency, a form in which the breaker is directly mounted on the circuit board has been studied. Furthermore, reflow soldering is used to connect the breaker terminal and the circuit board lead. Use is under consideration. However, the flux may enter from a slight gap generated between the movable piece, the resin base, and the cover member, which contributes to the above-mentioned concern.
　本発明は、上記課題を解決するためになされたものであり、ケースの気密性を高めて、熱応動素子等の金属への悪影響を防止することにより熱応動素子の正常な熱変形動作を維持し、良好な温度特性を得ることができるブレーカーを提供することを目的とする。 The present invention has been made to solve the above-mentioned problems, and maintains the normal heat deformation operation of the thermoresponsive element by improving the airtightness of the case and preventing the adverse effect on the metal such as the thermoresponsive element. And it aims at providing the breaker which can acquire a favorable temperature characteristic.
　上記目的を達成するために、本発明は、固定接点を有する固定片と、可動接点を有し、この可動接点を前記固定接点に押圧して接触させる可動片と、温度変化に伴って変形することにより前記可動接点が前記固定接点から離反するように前記可動片を作動させる熱応動素子と、前記固定片、可動片及び熱応動素子を収容する第１ケースとを備えたブレーカーにおいて、前記第１ケースの外側を覆う第２ケースをさらに備え、前記可動片は、前記第１ケースの外方に延出された端子を有し、前記端子が前記第１ケースから突出する基端部には、前記第２ケースとの接合力を強化する接合強化部が形成され、前記接合強化部は、前記第２ケースに埋設されていることを特徴とする。 To achieve the above object, the present invention has a fixed piece having a fixed contact, a movable contact, a movable piece that presses and contacts the movable contact with the fixed contact, and is deformed as the temperature changes. A breaker comprising: a thermal response element that operates the movable piece so that the movable contact is separated from the fixed contact; and a first case that houses the fixed piece, the movable piece, and the thermal response element. The movable piece further includes a second case that covers the outer side of the one case, the movable piece has a terminal extending outward from the first case, and the terminal protrudes from the first case at a base end portion. A joining strengthening part for strengthening a joining force with the second case is formed, and the joining strengthening part is embedded in the second case.
　本発明に係るブレーカーにおいて、前記接合強化部は、前記可動片が階段状に曲げられた段曲げを有することが望ましい。 In the breaker according to the present invention, it is preferable that the joint reinforcing portion has a step bend in which the movable piece is bent in a step shape.
　本発明に係るブレーカーにおいて、前記接合強化部は、前記基端部から前記可動片の厚さ方向に陥没する凹部を有することが望ましい。 In the breaker according to the present invention, it is desirable that the joint strengthening portion has a concave portion that is recessed from the base end portion in the thickness direction of the movable piece.
　本発明に係るブレーカーにおいて、前記接合強化部は、前記基端部から前記可動片の厚さ方向に突出する凸部を有することが望ましい。 In the breaker according to the present invention, it is desirable that the joint strengthening portion has a convex portion protruding from the base end portion in the thickness direction of the movable piece.
　本発明に係るブレーカーにおいて、前記接合強化部は、前記可動片を厚さ方向に貫通する貫通穴を有することが望ましい。 In the breaker according to the present invention, it is preferable that the joint strengthening portion has a through hole that penetrates the movable piece in the thickness direction.
　本発明に係るブレーカーにおいて、前記接合強化部は、前記可動片の一部が切除された切り欠きを有することが望ましい。 In the breaker according to the present invention, it is desirable that the joint reinforcing portion has a notch in which a part of the movable piece is cut off.
　本発明に係るブレーカーにおいて、前記接合強化部には、樹脂皮膜が形成されていることが望ましい。 In the breaker according to the present invention, it is desirable that a resin film is formed on the joint strengthening portion.
　本発明に係るブレーカーにおいて、前記接合強化部には、表面粗し処理が施されていることが望ましい。 In the breaker according to the present invention, it is desirable that a surface roughening treatment is performed on the joint strengthening portion.
　本発明の電気機器用の安全回路は、前記ブレーカーを備えたことを特徴とする。 A safety circuit for an electrical device according to the present invention includes the above breaker.
　本発明の２次電池パックは、前記ブレーカーを備えたことを特徴とする。 The secondary battery pack according to the present invention includes the breaker.
　本発明は、上記ブレーカーを製造するブレーカー製造方法であって、第１金型のキャビティ空間に樹脂材料を充填して、前記第１ケースを成形する１次成形工程と、前記可動片に前記接合強化部を形成する強化部形成工程と、前記１次成形工程によって成形された第１ケースに前記固定片、熱応動素子及び前記強化部形成工程によって前記接合強化部が形成された可動片を実装する実装工程と、前記実装工程によって前記固定片、可動片及び熱応動素子が実装された第１ケースを第２金型内に装填し、前記第２金型のキャビティ空間に樹脂材料を充填して前記第２ケースを成形する２次成形工程とを含むことを特徴とする。 The present invention provides a breaker manufacturing method for manufacturing the above-described breaker, wherein a primary molding step of molding a first case by filling a cavity material of a first mold with a resin material, and the joining to the movable piece A reinforcing part forming step for forming a reinforcing part, and a movable piece in which the joint reinforcing part is formed in the first case formed by the primary forming process and the fixed piece, the thermally responsive element, and the reinforcing part forming step are mounted. And mounting the first case on which the fixed piece, the movable piece, and the thermally responsive element are mounted by the mounting step into the second mold, and filling the cavity space of the second mold with a resin material. And a secondary molding step of molding the second case.
　本発明のブレーカーによれば、可動片の端子が第１ケースから突出する基端部に、第２ケースとの接合力を強化する接合強化部が形成され、かつ接合強化部が、第２ケースに埋設されているので、端子の基端部が第２ケースに強固に接合される。これにより、第２ケースの気密性が向上し、熱応動素子等を収容する第１ケースの内部空間に水蒸気等が侵入することが防止される。従って、熱応動素子の正常な熱変形動作が維持され、良好な温度特性を得ることができる。 According to the breaker of the present invention, the joint strengthening portion that reinforces the joining force with the second case is formed at the base end portion where the terminal of the movable piece protrudes from the first case, and the joint strengthening portion is the second case. The base end portion of the terminal is firmly joined to the second case. Thereby, the airtightness of the second case is improved, and water vapor or the like is prevented from entering the internal space of the first case that accommodates the thermally responsive element or the like. Therefore, normal thermal deformation operation of the thermoresponsive element is maintained, and good temperature characteristics can be obtained.
本発明の一実施形態によるブレーカーの概略構成を示す斜視図。The perspective view which shows schematic structure of the breaker by one Embodiment of this invention. 同ブレーカーの主要部の構成を示す組立て斜視図。The assembly perspective view which shows the structure of the principal part of the breaker. 通常の充電又は放電状態における同ブレーカーを示す断面図。Sectional drawing which shows the breaker in a normal charge or discharge state. 過充電状態又は異常時などにおける同ブレーカーを示す断面図。Sectional drawing which shows the breaker in the overcharge state or the time of abnormality. 同ブレーカーの可動片の構成を示す斜視図。The perspective view which shows the structure of the movable piece of the breaker. 同ブレーカーの第１ケース及び可動片を示す斜視図。The perspective view which shows the 1st case and movable piece of the breaker. 同ブレーカーの構成を示す平面図。The top view which shows the structure of the breaker. 同ブレーカーの製造方法を示すフローチャート。The flowchart which shows the manufacturing method of the breaker. 可動片の変形例を示す平面図。The top view which shows the modification of a movable piece. 本発明のブレーカーを備えた２次電池パックの構成を示す平面図。The top view which shows the structure of the secondary battery pack provided with the breaker of this invention. 本発明のブレーカーを備えた安全回路の回路図。The circuit diagram of the safety circuit provided with the breaker of this invention.
　本発明の一実施形態によるブレーカーについて図面を参照して説明する。図１はブレーカーの構成を示す。ブレーカー１は、外部の回路に接続される固定片２及び可動片４と、固定片２及び可動片４を収容する第１ケース７と、第１ケース７の外側を覆う第２ケース９を備えている。第１ケース７は、第２ケース９に埋設されている。第１ケース７の側壁からは、固定片２の端子２２及び可動片４の端子４１が第１ケース７の外方に延出され、第１ケース７の外部に突出している。固定片２の端子２２及び可動片４の端子４１は、第２ケース９の側壁から突出し、第２ケース９の外部に露出している。 A breaker according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows the structure of the breaker. The breaker 1 includes a fixed piece 2 and a movable piece 4 connected to an external circuit, a first case 7 that accommodates the fixed piece 2 and the movable piece 4, and a second case 9 that covers the outside of the first case 7. ing. The first case 7 is embedded in the second case 9. From the side wall of the first case 7, the terminal 22 of the fixed piece 2 and the terminal 41 of the movable piece 4 extend outward from the first case 7 and project outside the first case 7. The terminal 22 of the fixed piece 2 and the terminal 41 of the movable piece 4 protrude from the side wall of the second case 9 and are exposed to the outside of the second case 9.
　第１ケース７は、固定片２及び可動片４を収容する樹脂ベース７１と、樹脂ベース７１の上面に装着されるカバー部材７２と、カバー部材７２に埋設されたカバー片８等によって構成されている。第１ケース７の外側が第２ケース９によって覆われることにより、第１ケース７の内部空間の密閉性が高められる。 The first case 7 includes a resin base 71 that houses the fixed piece 2 and the movable piece 4, a cover member 72 that is mounted on the upper surface of the resin base 71, a cover piece 8 embedded in the cover member 72, and the like. Yes. By covering the outside of the first case 7 with the second case 9, the airtightness of the internal space of the first case 7 is enhanced.
　第１ケース７の樹脂ベース７１及びカバー部材７２並びに第２ケース９は、例えば、難燃性のポリアミド、耐熱性に優れたポリフェニレンサルファイド（ＰＰＳ）、液晶ポリマー（ＬＣＰ）、ポリブチレンテレフタレート（ＰＢＴ）などの樹脂により成形されている。上述した樹脂と同等以上の特性が得られるのであれば、樹脂以外の材料が適用されていてもよい。 The resin base 71 and the cover member 72 of the first case 7 and the second case 9 are made of, for example, flame retardant polyamide, polyphenylene sulfide (PPS), liquid crystal polymer (LCP), polybutylene terephthalate (PBT) having excellent heat resistance. It is molded by resin. A material other than the resin may be applied as long as characteristics equal to or higher than those of the above-described resin can be obtained.
　図２は、第２ケース９に収容されるブレーカー１の主要部１０の構成を示している。ブレーカー１の主要部１０は、固定接点２１を有する固定片２と、先端部に可動接点３を有する可動片４と、温度変化に伴って変形する熱応動素子５と、ＰＴＣ（Positive Temperature Coefficient）サーミスター６と、固定片２、可動片４、熱応動素子５及びＰＴＣサーミスター６を収容する第１ケース７等によって構成されている。 FIG. 2 shows the configuration of the main part 10 of the breaker 1 accommodated in the second case 9. The main part 10 of the breaker 1 includes a fixed piece 2 having a fixed contact 21, a movable piece 4 having a movable contact 3 at the tip, a thermally responsive element 5 that deforms with temperature change, and a PTC (PositivesTemperatureerCoefficient). The thermistor 6 includes a fixed piece 2, a movable piece 4, a thermally responsive element 5, a first case 7 that accommodates the PTC thermistor 6, and the like.
　固定片２は、リン青銅等を主成分とする金属板（この他、銅－チタン合金、洋白、黄銅などの金属板）をプレス加工することにより形成され、樹脂ベース７１にインサート成形により埋め込まれている。固定片２の一端には外部回路と電気的に接続される端子２２が形成され、他端側には、ＰＴＣサーミスター６を支持する支持部２３が形成されている。ＰＴＣサーミスター６は、固定片２の支持部２３に３箇所形成された凸状の突起（ダボ）２４ａの上に載置されて、突起２４ａに支持される。固定接点２１は、銀、ニッケル、ニッケル－銀合金の他、銅－銀合金、金－銀合金などの導電性の良い材料のクラッド、メッキ又は塗布等により可動接点３に対向する位置に形成され、樹脂ベース７１の上方に形成されている開口７３ｂの一部から露出されている。端子２２は樹脂ベース７１の一端から外側に突き出されている。 The fixing piece 2 is formed by pressing a metal plate mainly composed of phosphor bronze or the like (other metal plate such as copper-titanium alloy, white or brass), and is embedded in the resin base 71 by insert molding. It is. A terminal 22 electrically connected to an external circuit is formed at one end of the fixed piece 2, and a support portion 23 that supports the PTC thermistor 6 is formed at the other end side. The PTC thermistor 6 is placed on the projections (dowels) 24a formed at three places on the support portion 23 of the fixed piece 2, and is supported by the projections 24a. The fixed contact 21 is formed at a position facing the movable contact 3 by clad, plating or coating of a conductive material such as copper, silver alloy, gold-silver alloy as well as silver, nickel, nickel-silver alloy. , The resin base 71 is exposed from a part of the opening 73b formed above. The terminal 22 protrudes outward from one end of the resin base 71.
　固定片２は、端子２２、固定接点２１及び支持部２３の表裏両面において樹脂ベース７1の外部に露出し、端子２２と固定接点２１との間及び固定接点２１と支持部２３との間において樹脂ベース７１に埋設される。固定片２の支持部２３の表面は、ケース７の内部の収容空間に露出し、突起２４ａを介してＰＴＣサーミスター６と電気的に接触している。 The fixed piece 2 is exposed to the outside of the resin base 71 on both the front and back surfaces of the terminal 22, the fixed contact 21, and the support portion 23, and resin between the terminal 22 and the fixed contact 21 and between the fixed contact 21 and the support portion 23. Embedded in the base 71. The surface of the support portion 23 of the fixed piece 2 is exposed to the accommodation space inside the case 7 and is in electrical contact with the PTC thermistor 6 through the protrusion 24a.
　可動片４は、板状の金属材料をプレス加工することにより、長手方向の中心線に対して対称なアーム状に形成されている。可動片４の材料としては、固定片２と同等のリン青銅等を主成分とするものが好ましい。この他、銅－チタン合金、洋白、黄銅などの導電性弾性材料を用いてもよい。可動片４の長手方向の一端には外部回路と電気的に接続される端子４１が形成されて樹脂ベース７１から外側に露出される。可動片４の他端（アーム状の可動片４の先端に相当）には可動接点３が形成されている。可動接点３は、固定接点２１と同等の材料によって形成され、溶接の他、クラッド、かしめ（crimping）等の手法によって可動片４の先端部に接合されている。なお、本出願においては、可動片４において、可動接点３が接合されている面（すなわち図２において下側の面）を裏（うら）面、その反対側の面を表（おもて）面として説明している。他の部品についても表裏の関係は同様である。可動片４は、可動接点３と端子４１の間に、挟持部４２及び弾性部４３を有している。挟持部４２は、端子４１と弾性部４３との間で樹脂ベース７１及びカバー部材７２と当接し、樹脂ベース７１及びカバー部材７２に挟持される。挟持部４２は、可動片４の短手方向に翼状に突出する突出部４２ａを有する。弾性部４３は、挟持部４２から可動接点３の側に延出されている。挟持部４２において樹脂ベース７１とカバー部材７２によって裏表両面側から挟み込まれて可動片４が固定され、弾性部４３が弾性変形することにより、その先端に形成されている可動接点３が固定接点２１の側に押圧されて接触し、固定片２と可動片４とが通電可能となる。 The movable piece 4 is formed in an arm shape symmetrical to the center line in the longitudinal direction by pressing a plate-shaped metal material. As a material of the movable piece 4, a material mainly composed of phosphor bronze or the like equivalent to the fixed piece 2 is preferable. In addition, a conductive elastic material such as copper-titanium alloy, white or brass may be used. A terminal 41 electrically connected to an external circuit is formed at one end in the longitudinal direction of the movable piece 4 and is exposed to the outside from the resin base 71. A movable contact 3 is formed at the other end of the movable piece 4 (corresponding to the tip of the arm-shaped movable piece 4). The movable contact 3 is formed of the same material as that of the fixed contact 21 and is joined to the tip of the movable piece 4 by a technique such as clad or crimping in addition to welding. In the present application, in the movable piece 4, the surface to which the movable contact 3 is joined (that is, the lower surface in FIG. 2) is the back surface, and the opposite surface is the front surface. It is described as a surface. The relationship between the front and back of the other parts is the same. The movable piece 4 has a sandwiching portion 42 and an elastic portion 43 between the movable contact 3 and the terminal 41. The sandwiching portion 42 is in contact with the resin base 71 and the cover member 72 between the terminal 41 and the elastic portion 43, and is sandwiched between the resin base 71 and the cover member 72. The sandwiching portion 42 has a protruding portion 42 a that protrudes in a wing shape in the short direction of the movable piece 4. The elastic part 43 extends from the clamping part 42 to the movable contact 3 side. In the clamping part 42, the movable piece 4 is fixed by being sandwiched by the resin base 71 and the cover member 72 from the front and back sides, and the elastic part 43 is elastically deformed, so that the movable contact 3 formed at the tip thereof is the fixed contact 21. The fixed piece 2 and the movable piece 4 can be energized.
　図３及び図４に示されるように、樹脂ベース７１とカバー部材７２には、可動片４の挟持部４２と当接し、挟持部４２を固定状態で保持する当接部７４と当接部７９がそれぞれ形成されている。本実施形態では、樹脂ベース７１の収納部７３の外縁から樹脂ベース７１の外壁に亘る領域に当接部７４が形成されている。当接部７４は、図２中、ケース７の底壁（内底面）の一部を構成する。また、カバー部材７２において、可動片４を挟んで当接部７４と対向する領域に当接部７９が形成されている。当接部７９は、図２中、ケース７の天壁（内天面）の一部を構成する。挟持部４２は、その裏面において樹脂ベース７１の当接部７４と当接し、その表面においてカバー部材７２の当接部７９と当接する。可動片４は、当接部７４及び当接部７９によって挟持部４２の裏表両面から挟み込まれて、ケース７に対して固定される。本実施形態においては、挟持部４２が可動片４の短手方向に翼状に突出する突出部４２ａを有するので、挟持部４２が幅広く大きな領域でケース７の当接部７４及び当接部７９によって挟み込まれ、可動片４がケース７に対して強固に固定される。 As shown in FIGS. 3 and 4, the resin base 71 and the cover member 72 are in contact with the sandwiching portion 42 of the movable piece 4, and the contact portion 74 and the contact portion 79 that hold the sandwiching portion 42 in a fixed state. Are formed respectively. In the present embodiment, a contact portion 74 is formed in a region extending from the outer edge of the housing portion 73 of the resin base 71 to the outer wall of the resin base 71. The contact portion 74 constitutes a part of the bottom wall (inner bottom surface) of the case 7 in FIG. In the cover member 72, a contact portion 79 is formed in a region facing the contact portion 74 with the movable piece 4 interposed therebetween. The contact portion 79 constitutes a part of the top wall (inner top surface) of the case 7 in FIG. The clamping part 42 comes into contact with the contact part 74 of the resin base 71 on its back surface, and comes into contact with the contact part 79 of the cover member 72 on its front surface. The movable piece 4 is sandwiched from both the front and back surfaces of the sandwiching portion 42 by the contact portion 74 and the contact portion 79 and fixed to the case 7. In the present embodiment, since the sandwiching portion 42 has a protruding portion 42a that projects in a wing shape in the short direction of the movable piece 4, the sandwiching portion 42 is wide and large by the contact portion 74 and the contact portion 79 of the case 7. The movable piece 4 is firmly fixed to the case 7 by being sandwiched.
　可動片４は、弾性部４３において、プレス加工により湾曲又は屈曲されている。湾曲又は屈曲の度合いは、熱応動素子５を収納できる限り特に限定はなく、動作温度及び復帰温度における弾性力、接点の押圧力などを考慮して適宜設定すればよい。また、弾性部４３の下面には、熱応動素子５に対向して一対の突起（接触部）４４ａ，４４ｂが形成されている。突起４４ａ，４４ｂと熱応動素子５とは接触して、突起４４ａ，４４ｂを介して熱応動素子５の変形が弾性部４３に伝達される（図３及び図４参照）。 The movable piece 4 is bent or bent at the elastic portion 43 by pressing. The degree of bending or bending is not particularly limited as long as the thermally responsive element 5 can be accommodated, and may be appropriately set in consideration of the elastic force at the operating temperature and the return temperature, the pressing force of the contact point, and the like. In addition, a pair of protrusions (contact portions) 44 a and 44 b are formed on the lower surface of the elastic portion 43 so as to face the heat-responsive element 5. The protrusions 44a and 44b and the thermally responsive element 5 come into contact with each other, and the deformation of the thermally responsive element 5 is transmitted to the elastic portion 43 via the protrusions 44a and 44b (see FIGS. 3 and 4).
　図１，２に示されるように、可動片４の端子４１が第１ケース７から突出する基端部４１ａには、第２ケース９と基端部４１ａとの接合力を強化する接合強化部４５が形成されている。接合強化部４５は、第２ケース９に埋設されている。接合強化部４５が基端部４１ａと第２ケース９との接合力を強化することにより、第２ケース９の気密性が向上し、熱応動素子５等を収容する第１ケース７の内部空間に水蒸気等が侵入することが防止される。 As shown in FIGS. 1 and 2, a joint reinforcing portion that reinforces the joining force between the second case 9 and the base end portion 41 a is provided at the base end portion 41 a from which the terminal 41 of the movable piece 4 projects from the first case 7. 45 is formed. The joint strengthening part 45 is embedded in the second case 9. The joint strengthening part 45 strengthens the joining force between the base end part 41a and the second case 9, so that the airtightness of the second case 9 is improved, and the internal space of the first case 7 that accommodates the thermally responsive element 5 and the like. Water vapor or the like is prevented from entering the water.
　熱応動素子５は円弧状に湾曲した初期形状をなし、バイメタル、トリメタルなどの複合材料からなる。過熱により動作温度に達すると湾曲形状はスナップモーションを伴って逆反りし、冷却により復帰温度を下回ると復元する。熱応動素子５の初期形状は、プレス加工により形成することができる。所期の温度で熱応動素子５の逆反り動作により可動片４の弾性部４３が押し上げられ、かつ弾性部４３の弾性力により元に戻る限り、熱応動素子５の材質及び形状は特に限定されるものでないが、生産性及び逆反り動作の効率性の観点から矩形が望ましく、小型でありながら弾性部４３を効率的に押し上げるために正方形に近い長方形であるのが望ましい。なお、熱応動素子５の材料としては、例えば、高膨脹側に銅－ニッケル－マンガン合金又はニッケル－クロム－鉄合金、低膨脹側に鉄－ニッケル合金をはじめとする、洋白、黄銅、ステンレス鋼など各種の合金からなる熱膨張率の異なる２種類の材料を積層したものが、所要条件に応じて組み合わせて使用される。 The thermoresponsive element 5 has an initial shape curved in an arc shape and is made of a composite material such as bimetal or trimetal. When the operating temperature is reached due to overheating, the curved shape is reversely warped with snap motion, and is restored when the temperature falls below the return temperature due to cooling. The initial shape of the thermoresponsive element 5 can be formed by pressing. As long as the elastic portion 43 of the movable piece 4 is pushed up by the reverse warping operation of the thermal response element 5 at a desired temperature and returns to the original state by the elastic force of the elastic portion 43, the material and shape of the thermal response element 5 are particularly limited. Although not intended, a rectangular shape is desirable from the viewpoint of productivity and efficiency of reverse warping operation, and it is desirable that the rectangular shape is close to a square in order to efficiently push up the elastic portion 43 while being small. Examples of the material of the thermally responsive element 5 include, for example, copper, nickel-manganese alloy or nickel-chromium-iron alloy on the high expansion side and iron-nickel alloy on the low expansion side, white, brass, stainless steel. A laminate of two types of materials having different coefficients of thermal expansion made of various alloys such as steel is used in combination according to the required conditions.
　熱応動素子５の逆反り動作により固定片２と可動片４との通電が遮断されたとき、ＰＴＣサーミスター６に流れる電流が増大する。ＰＴＣサーミスター６は、温度上昇と共に抵抗値が増大して電流を制限する正特性サーミスターであれば、動作電流、動作電圧、動作温度、復帰温度などの必要に応じて種類を選択でき、その材料及び形状はこれらの諸特性を損なわない限り特に限定されるものではない。本実施形態では、チタン酸バリウム、チタン酸ストロンチウム又はチタン酸カルシウムを含むセラミック焼結体が用いられる。セラミック焼結体の他、ポリマーにカーボン等の導電性粒子を含有させたいわゆるポリマーＰＴＣを用いてもよい。 When the energization of the fixed piece 2 and the movable piece 4 is interrupted by the reverse warp operation of the thermal response element 5, the current flowing through the PTC thermistor 6 increases. As long as the PTC thermistor 6 is a positive temperature coefficient thermistor that limits the current by increasing the resistance value as the temperature rises, the type of operation current, operation voltage, operation temperature, return temperature, etc. can be selected as necessary. The material and shape are not particularly limited as long as these properties are not impaired. In the present embodiment, a ceramic sintered body containing barium titanate, strontium titanate or calcium titanate is used. In addition to the ceramic sintered body, a so-called polymer PTC in which conductive particles such as carbon are contained in a polymer may be used.
　第１ケース７を構成する樹脂ベース７１及びカバー部材７２は、それぞれ別個の第１金型（図示せず）によって成形される。樹脂ベース７１は、固定片２をインサートして成形される。カバー部材７２は、カバー片８をインサートして成形される。樹脂ベース７１には、熱応動素子５及びＰＴＣサーミスター６などを収容するための収納部７３及び可動片４を収納するための開口７３ａ，７３ｂなどが形成されている。なお、樹脂ベース７１に組み込まれた可動片４、熱応動素子５及びＰＴＣサーミスター６の端縁は、収納部７３の内部に形成されている枠によってそれぞれ当接され、熱応動素子５の逆反り時に案内される。また、樹脂ベース７１は、可動片４の端子４１を外部に露出させるための窓７６を有する The resin base 71 and the cover member 72 constituting the first case 7 are formed by separate first molds (not shown). The resin base 71 is formed by inserting the fixed piece 2. The cover member 72 is formed by inserting the cover piece 8. The resin base 71 is formed with a housing portion 73 for housing the thermally responsive element 5, the PTC thermistor 6, and the like, and openings 73 a and 73 b for housing the movable piece 4. Note that the edges of the movable piece 4, the thermally responsive element 5, and the PTC thermistor 6 incorporated in the resin base 71 are in contact with each other by a frame formed inside the storage portion 73. It will be guided at the time. The resin base 71 has a window 76 for exposing the terminal 41 of the movable piece 4 to the outside.
　カバー部材７２には、カバー片８がインサート成形によって埋め込まれている。カバー片８は、上述したリン青銅等を主成分とする金属板又はステンレス鋼等の金属板をプレス加工することにより形成される。カバー片８は、図３及び図４に示すように、可動片４の上面と適宜当接し、可動片４の動きを規制すると共に、カバー部材７２のひいては筐体としてのケース７の剛性・強度を高めつつブレーカー１の小型化に貢献する。カバー片８には、可動片４の側に突出する突起８２ａ、８２ｂが形成されている。突起８２ｂによって弾性部４３が熱応動素子５の方向に押圧され、通電時における固定接点２１と可動接点３との接触圧力が適正化される。 The cover piece 8 is embedded in the cover member 72 by insert molding. The cover piece 8 is formed by pressing a metal plate mainly composed of the above-described phosphor bronze or the like or a metal plate such as stainless steel. As shown in FIGS. 3 and 4, the cover piece 8 is appropriately brought into contact with the upper surface of the movable piece 4 to restrict the movement of the movable piece 4, and the rigidity and strength of the case 7 as a casing as a result of the cover member 72. Contributes to the downsizing of the breaker 1 The cover piece 8 is formed with protrusions 82a and 82b protruding to the movable piece 4 side. The elastic part 43 is pressed in the direction of the thermally responsive element 5 by the projection 82b, and the contact pressure between the fixed contact 21 and the movable contact 3 at the time of energization is optimized.
　図２に示すように、固定片２、可動片４、熱応動素子５及びＰＴＣサーミスター６等を収容した樹脂ベース７１の開口７３ａ等を塞ぐように、カバー部材７２が、樹脂ベース７１の上面に装着される。樹脂ベース７１とカバー部材７２とは、例えば超音波溶着によって接合される。 As shown in FIG. 2, the cover member 72 is disposed on the upper surface of the resin base 71 so as to close the opening 73 a of the resin base 71 that accommodates the fixed piece 2, the movable piece 4, the thermally responsive element 5, the PTC thermistor 6, and the like. It is attached to. The resin base 71 and the cover member 72 are joined by, for example, ultrasonic welding.
　樹脂ベース７１とカバー部材７２との接合は、超音波溶着の他、例えば、樹脂ベース７１とカバー部材７２とを係合又は嵌合させることによっても実現できる。また、樹脂ベース７１とカバー片８とが係合等される形態であってもよい。これらの場合、樹脂ベース７１並びにカバー部材７２及びカバー片８には、係合等のための凸部又は凹部若しくは孔が形成されていてもよい。樹脂ベース７１とカバー片８とが係合される形態にあっては、カバー片８にて樹脂ベース７１の収納部７３及び開口７３ａ，７３ｂ等の全域を覆うことにより、カバー部材７２が省略されていてもよい。 The joining of the resin base 71 and the cover member 72 can be realized by, for example, engaging or fitting the resin base 71 and the cover member 72 in addition to ultrasonic welding. Further, the resin base 71 and the cover piece 8 may be engaged with each other. In these cases, the resin base 71, the cover member 72, and the cover piece 8 may be formed with convex portions, concave portions, or holes for engagement or the like. In the form in which the resin base 71 and the cover piece 8 are engaged, the cover member 72 is omitted by covering the entire area of the resin base 71 such as the storage portion 73 and the openings 73a and 73b with the cover piece 8. It may be.
　図３は、通常の充電又は放電状態におけるブレーカー１の動作を示している。通常の充電又は放電状態においては、熱応動素子５は初期形状を維持し（逆反り前であり）、固定接点２１と可動接点３は接触し、可動片４の弾性部４３などを通じてブレーカー１の両端子２２、４１間は導通している。可動片４の弾性部４３と熱応動素子５とは接触しており、可動片４、熱応動素子５、ＰＴＣサーミスター６及び固定片２は、回路として導通している。しかし、ＰＴＣサーミスター６の抵抗は、可動片４の抵抗に比べて圧倒的に大きいため、ＰＴＣサーミスター６を流れる電流は、固定接点２１及び可動接点３を流れる量に比して実質的に無視できる程度である。 FIG. 3 shows the operation of the breaker 1 in a normal charging or discharging state. In a normal charging or discharging state, the thermal responsive element 5 maintains the initial shape (before reverse warping), the fixed contact 21 and the movable contact 3 come into contact with each other, and the breaker 1 passes through the elastic portion 43 of the movable piece 4. The terminals 22 and 41 are electrically connected. The elastic part 43 of the movable piece 4 and the thermal responsive element 5 are in contact, and the movable piece 4, the thermal responsive element 5, the PTC thermistor 6 and the fixed piece 2 are electrically connected as a circuit. However, since the resistance of the PTC thermistor 6 is overwhelmingly larger than the resistance of the movable piece 4, the current flowing through the PTC thermistor 6 is substantially larger than the amount flowing through the fixed contact 21 and the movable contact 3. It can be ignored.
　図４は、過充電状態又は異常時などにおけるブレーカー１の動作を示している。過充電又は異常により高温状態となると、ＰＴＣサーミスター６が過熱され、動作温度に達した熱応動素子５は逆反りし、可動片４の弾性部４３が押し上げられて固定接点２１と可動接点３とが離反する。このとき、固定接点２１と可動接点３の間を流れていた電流は遮断され、僅かな漏れ電流が熱応動素子５及びＰＴＣサーミスター６を通して流れることとなる。ＰＴＣサーミスター６は、このような漏れ電流の流れる限り発熱を続け、熱応動素子５を逆反り状態に維持させつつ抵抗値を激増させるので、電流は固定接点２１と可動接点３の間の経路を流れず、上述の僅かな漏れ電流のみが存在する（自己保持回路を構成する）。この漏れ電流は安全装置の他の機能に充てることができる。 FIG. 4 shows the operation of the breaker 1 in an overcharged state or an abnormality. When the PTC thermistor 6 is overheated due to overcharging or abnormality, the thermal actuator 5 that has reached the operating temperature is warped in reverse, and the elastic portion 43 of the movable piece 4 is pushed up so that the fixed contact 21 and the movable contact 3 Are separated from each other. At this time, the current flowing between the fixed contact 21 and the movable contact 3 is interrupted, and a slight leakage current flows through the thermal actuator 5 and the PTC thermistor 6. Since the PTC thermistor 6 continues to generate heat as long as such a leakage current flows, the resistance value is drastically increased while maintaining the thermally actuated element 5 in the reverse warped state, so that the current is a path between the fixed contact 21 and the movable contact 3. There is only the above-described slight leakage current (which constitutes a self-holding circuit). This leakage current can be used for other functions of the safety device.
　過充電状態を解除し、又は異常状態を解消すると、ＰＴＣサーミスター６の発熱も収まり、熱応動素子５は復帰温度に戻り、元の初期形状に復元する。そして、可動片４の弾性部４３の弾性力によって可動接点３と固定接点２１とは再び接触し、回路は遮断状態を解かれ、図３に示す導通状態に復帰する。 When the overcharge state is canceled or the abnormal state is resolved, the heat generation of the PTC thermistor 6 is also stopped, and the thermal actuator 5 returns to the return temperature and is restored to the original initial shape. Then, the movable contact 3 and the fixed contact 21 come into contact again by the elastic force of the elastic portion 43 of the movable piece 4, the circuit is released from the interruption state, and returns to the conduction state shown in FIG. 3.
　図５は、可動片４の構成を示している。可動片４は、端子４１の基端部４１ａすなわち挟持部４２から端子４１の側に接合強化部４５を有している。接合強化部４５は、可動片４が階段状に曲げられた段曲げ４６、可動片４を厚さ方向に貫通する貫通穴４７及び可動片４の一部が切除された一対の切り欠き４８を有している。接合強化部４５には、段曲げ４６、貫通穴４７又は切り欠き４８のうち、少なくともいずれか一つが形成されていればよい。 FIG. 5 shows the configuration of the movable piece 4. The movable piece 4 has a joint strengthening portion 45 on the terminal 41 side from the base end portion 41 a of the terminal 41, that is, the clamping portion 42. The joint strengthening portion 45 includes a step bend 46 in which the movable piece 4 is bent in a step shape, a through hole 47 penetrating the movable piece 4 in the thickness direction, and a pair of notches 48 in which a part of the movable piece 4 is cut off. Have. At least one of the step bend 46, the through hole 47, and the notch 48 may be formed in the joint strengthening portion 45.
　段曲げ４６は、可動片４の挟持部４２と、端子４１の先端部４１ｂとを段違いに配置する。貫通穴４７は、挟持部４２と段曲げ４６との間に設けられている。貫通穴４７は、段曲げ４６に対して端子４１の先端部４１ｂ側に設けられていてもよく、段曲げ４６が形成されている領域に貫通穴４７の一部又は全部が設けられていてもよい。切り欠き４８は、可動片４の端縁部に可動片４を貫通して設けられている。切り欠き４８は、段曲げ４６に対して端子４１の先端部４１ｂ側に設けられている。切り欠き４８は、段曲げ４６又は貫通穴４７に対して挟持部４２の側に設けられていてもよく、段曲げ４６が形成されている領域に切り欠き４８の一部又は全部が設けられていてもよい。 The step bending 46 arranges the clamping part 42 of the movable piece 4 and the tip part 41b of the terminal 41 in a stepwise manner. The through hole 47 is provided between the clamping part 42 and the step bend 46. The through hole 47 may be provided on the tip 41b side of the terminal 41 with respect to the step bend 46, or a part or all of the through hole 47 may be provided in the region where the step bend 46 is formed. Good. The notch 48 is provided in the end edge portion of the movable piece 4 so as to penetrate the movable piece 4. The notch 48 is provided on the tip end 41 b side of the terminal 41 with respect to the step bend 46. The notch 48 may be provided on the clamping portion 42 side with respect to the step bend 46 or the through hole 47, and a part or all of the notch 48 is provided in the region where the step bend 46 is formed. May be.
　図６は、ブレーカー１の主要部１０を示している。ブレーカー１の主要部１０は、樹脂ベース７１に可動片４等が収容され、カバー部材７２が溶着されてなる。樹脂ベース７１及びカバー部材７２等によって構成される第１ケース７の側壁からは、固定片２の端子２２及び可動片４の端子４１が延出されている。 FIG. 6 shows the main part 10 of the breaker 1. The main part 10 of the breaker 1 is configured such that the movable piece 4 and the like are accommodated in a resin base 71 and a cover member 72 is welded. A terminal 22 of the fixed piece 2 and a terminal 41 of the movable piece 4 extend from the side wall of the first case 7 constituted by the resin base 71, the cover member 72, and the like.
　可動片４の接合強化部４５は、第１ケース７の外側に延出して形成されている。従って、接合強化部４５に形成されている段曲げ４６、貫通穴４７及び切り欠き４８は、第１ケース７の外側に突出している。ブレーカー１の主要部１０は、第２ケース９を成形するための第２金型（図示せず）に装填（インサート）され、第２金型のキャビティ空間に樹脂が充填されることにより、第２ケース９が成形され、ブレーカー１が製造される。このインサート成形の際に、段曲げ４６、貫通穴４７及び切り欠き４８を含む接合強化部４５は、上記第２金型のキャビティ空間に収容されており、キャビティ空間に充填された樹脂に埋設される。 The joint strengthening portion 45 of the movable piece 4 is formed to extend to the outside of the first case 7. Therefore, the step bend 46, the through hole 47, and the notch 48 formed in the joint strengthening portion 45 protrude to the outside of the first case 7. The main part 10 of the breaker 1 is loaded (inserted) into a second mold (not shown) for molding the second case 9, and the cavity space of the second mold is filled with resin, thereby 2 Case 9 is shape | molded and the breaker 1 is manufactured. At the time of this insert molding, the joint reinforcing portion 45 including the step bend 46, the through hole 47, and the notch 48 is accommodated in the cavity space of the second mold and is embedded in the resin filled in the cavity space. The
　図７は、ブレーカー１の平面図である。本実施形態において、第２ケース９は、第１ケース７の外側全体を覆っている。これにより、ブレーカー１の主要部１０が、端子２２の先端部２２ｂ及び可動端子４１の先端部４１ｂを除く領域で、第２ケース９によって密閉される。インサート成形の際に第１ケース７を保持する保持部が上記第２金型内に突出して設けられている場合には、保持部を除く領域が第２ケース９に覆われる。また、端子２２の基端部２２ａ及び端子４１の基端部４１ａも、第２ケース９の内部に埋設されている。従って、端子４１の基端部４１ａに設けられている接合強化部４５も、第２ケース９の内部に埋設され、第２ケース９の外部に露出しない。 FIG. 7 is a plan view of the breaker 1. In the present embodiment, the second case 9 covers the entire outside of the first case 7. Thereby, the main part 10 of the breaker 1 is sealed by the second case 9 in a region excluding the tip part 22 b of the terminal 22 and the tip part 41 b of the movable terminal 41. When the holding part that holds the first case 7 is provided in the second mold so as to protrude during the insert molding, the area excluding the holding part is covered with the second case 9. Further, the base end portion 22 a of the terminal 22 and the base end portion 41 a of the terminal 41 are also embedded in the second case 9. Therefore, the joint strengthening portion 45 provided at the base end portion 41 a of the terminal 41 is also embedded in the second case 9 and is not exposed to the outside of the second case 9.
　ブレーカー１の主要部１０を第２金型に装填し、第２ケース９を形成する工程においては、流動化した樹脂材料が可動片４の端子４１の基端部４１ａ等の周囲に流れ込む。このため、基端部４１ａにおける金属と樹脂との接合は、超音波溶着による挟持部４２と第１ケース７との接合よりも強く、高い密閉性が得られる。 In the process of loading the main part 10 of the breaker 1 into the second mold and forming the second case 9, the fluidized resin material flows around the base end 41 a of the terminal 41 of the movable piece 4. For this reason, the bonding between the metal and the resin at the base end portion 41a is stronger than the bonding between the sandwiching portion 42 and the first case 7 by ultrasonic welding, and high sealing performance is obtained.
　第２ケース９による密閉効果を最大限に発揮させるためには、第２ケース９によって第１ケース７の外側全体が覆われているのが望ましい。しかしながら、ブレーカー１の主要部１０に現れる樹脂同士（例えば、樹脂ベース７１及びカバー部材７２）の接合部及び樹脂（例えば、第１ケース７）と金属（例えば、固定片２、可動片４及びカバー片８）の接合部が、第２ケース９によって覆われていることにより、同等の密閉効果を得ることができる。一般に、樹脂と金属との接合強度は、樹脂同士の接合強度に比べて劣るため、少なくとも、樹脂と金属の接合部が第２ケース９によって覆われるように、ブレーカー１が構成されていてもよい。 In order to maximize the sealing effect of the second case 9, it is desirable that the second case 9 covers the entire outside of the first case 7. However, the joints between the resins (for example, the resin base 71 and the cover member 72) and the resin (for example, the first case 7) and the metal (for example, the fixed piece 2, the movable piece 4, and the cover) that appear in the main part 10 of the breaker 1 are used. Since the joint portion of the piece 8) is covered with the second case 9, an equivalent sealing effect can be obtained. Generally, since the bonding strength between the resin and the metal is inferior to the bonding strength between the resins, the breaker 1 may be configured so that at least the bonding portion between the resin and the metal is covered by the second case 9. .
　図３及び図４によく示されるように、段曲げ４６は、第２ケース９の内部に埋設されており、階段状に曲げられた段曲げ４６の周辺には、第２ケース９を構成する樹脂が充填されている。これにより、第２ケース９の内部も段曲げ４６に対応する階段状に形成されている。このような互いに対応する階段状の段曲げ４６と第２ケース９とが、符合して噛み合うことにより、基端部４１ａと第２ケース９との接合力が強化され、第２ケース９の気密性が向上し、熱応動素子５等を収容する第１ケース７の内部空間に水蒸気等が侵入することが防止される。例えば、ブレーカー１が機器の回路基板に組み込まれる際に、端子４１に大きな外力が付与された場合であっても、第２ケース９の気密性が高く維持され、熱応動素子５等を収容する第１ケース７の内部空間に水蒸気等が侵入することが防止される。 As well shown in FIGS. 3 and 4, the step bend 46 is embedded in the second case 9, and the second case 9 is formed around the step bend 46 bent in a stepped manner. Filled with resin. Thereby, the inside of the second case 9 is also formed in a step shape corresponding to the step bending 46. The step-like step bending 46 and the second case 9 corresponding to each other are meshed and meshed with each other, whereby the bonding force between the base end portion 41a and the second case 9 is strengthened, and the airtightness of the second case 9 is increased. As a result, the water vapor and the like are prevented from entering the internal space of the first case 7 that accommodates the thermally responsive element 5 and the like. For example, even when a large external force is applied to the terminal 41 when the breaker 1 is incorporated in the circuit board of the device, the airtightness of the second case 9 is maintained high, and the thermally responsive element 5 and the like are accommodated. Water vapor or the like is prevented from entering the internal space of the first case 7.
　図１、図３、図４及び図５に示されるように、貫通穴４７は、第２ケース９の内部に埋設されており、貫通穴４７には、第２ケース９を構成する樹脂が充填されている。これにより、第２ケース９を構成する樹脂のうち、可動片４の上方に充填された樹脂と、可動片４の下方に充填された樹脂とが、貫通穴４７を介して一体的に連続する。従って、基端部４１ａと第２ケース９との接合力が強化されると共に、第２ケース９の強度・剛性が向上する。 As shown in FIGS. 1, 3, 4, and 5, the through hole 47 is embedded in the second case 9, and the through hole 47 is filled with the resin constituting the second case 9. Has been. As a result, among the resins constituting the second case 9, the resin filled above the movable piece 4 and the resin filled below the movable piece 4 are continuously integrated via the through hole 47. . Therefore, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
　本実施形態にあっては、図６及び図７に示されるように、貫通穴４７の一部４７ａが第１ケース７の内部に設けられている。この貫通穴４７の一部４７ａにも第２ケース９を構成する樹脂が充填され、第１ケース７と接合する。これにより、第１ケース７及び第２ケース９の強度・剛性が向上する。 In this embodiment, as shown in FIGS. 6 and 7, a part 47 a of the through hole 47 is provided inside the first case 7. A part 47 a of the through hole 47 is also filled with the resin constituting the second case 9 and joined to the first case 7. Thereby, the strength and rigidity of the first case 7 and the second case 9 are improved.
　図１、図３、図４及び図５に示されるように、貫通穴４７と同様に、切り欠き４８は、第２ケース９の内部に埋設されており、切り欠き４８には、第２ケース９を構成する樹脂が充填されている。これにより、第２ケース９を構成する樹脂のうち、可動片４の上方に充填された樹脂と、可動片４の下方に充填された樹脂と、可動片４の側方に充填された樹脂とが、切り欠き４８を介して一体的に連続する。従って、基端部４１ａと第２ケース９との接合力が強化されると共に、第２ケース９の強度・剛性が向上する。 As shown in FIGS. 1, 3, 4, and 5, like the through hole 47, the notch 48 is embedded in the second case 9, and the notch 48 includes the second case 9 is filled. Thereby, out of the resin constituting the second case 9, the resin filled above the movable piece 4, the resin filled below the movable piece 4, and the resin filled to the side of the movable piece 4, Are continuously integrated through the notch 48. Therefore, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
　上述した貫通穴４７及び／若しくは切り欠き４８と共に、又は貫通穴４７及び／若しくは切り欠き４８に替えて、接合強化部４５の表面及び／又は裏面に、可動片４の厚さ方向に陥没する凹部が形成されていてもよい。凹部は、可動片４の厚さ方向に貫通することなく陥没し、有底の形態である。この場合、凹部に第２ケース９を構成する樹脂が充填され、基端部４１ａと第２ケース９との接合力が強化される。 A concave portion recessed in the thickness direction of the movable piece 4 on the front surface and / or the back surface of the joint reinforcing portion 45 together with the through hole 47 and / or the notch 48 described above or instead of the through hole 47 and / or the notch 48. May be formed. The recess is depressed without penetrating in the thickness direction of the movable piece 4 and has a bottomed form. In this case, the concave portion is filled with the resin constituting the second case 9, and the bonding force between the base end portion 41a and the second case 9 is strengthened.
　同様に、貫通穴４７、切り欠き４８及び／若しくは上記凹部と共に、又は貫通穴４７切り欠き４８及び／若しくは上記凹部に替えて、接合強化部４５の表面及び／又は裏面に、可動片４の厚さ方向に突出する凸部が形成されていてもよい。この場合、凸部の周辺に凸部と嵌合するように第２ケース９を構成する樹脂が充填され、基端部４１ａと第２ケース９との接合力が強化される。 Similarly, the thickness of the movable piece 4 is formed on the front surface and / or the back surface of the joint reinforcing portion 45 together with the through hole 47, the notch 48 and / or the concave portion, or in place of the through hole 47 notch 48 and / or the concave portion. A convex portion protruding in the vertical direction may be formed. In this case, the resin which comprises the 2nd case 9 is filled so that a convex part may be fitted to the periphery of a convex part, and the joining force of the base end part 41a and the 2nd case 9 is strengthened.
　図８には、ブレーカー１の製造方法が示される。ブレーカー１は、１次成形工程（Ｓ１）、強化部形成工程（Ｓ２）、実装工程（Ｓ３）、カバー溶着工程（Ｓ４）及び２次成形工程（Ｓ５）によって製造される。 FIG. 8 shows a method for manufacturing the breaker 1. The breaker 1 is manufactured by a primary molding process (S1), a reinforced part forming process (S2), a mounting process (S3), a cover welding process (S4), and a secondary molding process (S5).
　１次成形工程（Ｓ１）においては、第１金型のキャビティ空間に樹脂材料が充填され、樹脂ベース７１及びカバー部材７２が成形される。強化部形成工程（Ｓ２）においては、可動片４に接合強化部４５が形成される。すなわち、プレス加工等によって、可動片４に段曲げ４６、貫通穴４７及び切り欠き４８等が形成される。段曲げ４６、貫通穴４７及び切り欠き４８等は、金属板を打ち抜いて可動片４を形成する際に同時に形成されてもよく、金属板から可動片４を打ち抜いた後、別途プレス加工等によって形成されてもよい。実装工程（Ｓ３）においては、１次成形工程（Ｓ１）によって成形された樹脂ベース７１に固定片２、ＰＴＣサーミスター６、熱応動素子５及び強化部形成工程（Ｓ２）によって接合強化部４５が形成された可動片４等が実装される。本実施形態にあっては、固定片２は、１次成形工程（Ｓ１）において樹脂ベース７１にインサートされることにより樹脂ベース７１に収容されるため、１次成形工程（Ｓ１）の一部と、実装工程（Ｓ３）の一部とは、同時に実行される。 In the primary molding step (S1), the resin material is filled in the cavity space of the first mold, and the resin base 71 and the cover member 72 are molded. In the reinforcing portion forming step (S2), the joint reinforcing portion 45 is formed on the movable piece 4. That is, a step bend 46, a through hole 47, a notch 48, and the like are formed in the movable piece 4 by pressing or the like. The step bend 46, the through hole 47, the notch 48 and the like may be formed at the same time when the metal plate is punched to form the movable piece 4, and after the movable piece 4 is punched from the metal plate, it is separately pressed. It may be formed. In the mounting step (S3), the joint reinforcing portion 45 is formed on the resin base 71 molded in the primary molding step (S1) by the fixing piece 2, the PTC thermistor 6, the thermal actuator 5 and the reinforcing portion forming step (S2). The formed movable piece 4 or the like is mounted. In the present embodiment, since the fixed piece 2 is accommodated in the resin base 71 by being inserted into the resin base 71 in the primary molding step (S1), a part of the primary molding step (S1) The part of the mounting process (S3) is executed at the same time.
　カバー溶着工程（Ｓ４）においては、実装工程（Ｓ３）にてＰＴＣサーミスター６、熱応動素子５及び可動片４等が実装された樹脂ベース７１に、カバー部材７２が溶着され、第１ケース７が完成する。上述したように、樹脂ベース７１とカバー部材７２又はカバー片８とが係合等によって接合される形態にあっては、かかるカバー溶着工程（Ｓ４）の替わりに、カバー部材７２又はカバー片８を樹脂ベース７１に装着し係合させるカバー装着係合工程が適用される。そして、２次成形工程（Ｓ５）では、固定片２、可動片４及び熱応動素子５等が実装された第１ケース７が第２金型内に装填され、第２金型のキャビティ空間に樹脂材料が充填されて第２ケース９が成形される。 In the cover welding step (S4), the cover member 72 is welded to the resin base 71 on which the PTC thermistor 6, the thermally responsive element 5, the movable piece 4 and the like are mounted in the mounting step (S3). Is completed. As described above, when the resin base 71 and the cover member 72 or the cover piece 8 are joined by engagement or the like, the cover member 72 or the cover piece 8 is replaced with the cover welding step (S4). A cover mounting engagement process for mounting and engaging with the resin base 71 is applied. In the secondary molding step (S5), the first case 7 on which the fixed piece 2, the movable piece 4, the thermal responsive element 5 and the like are mounted is loaded into the second mold, and is placed in the cavity space of the second mold. The second case 9 is molded by filling the resin material.
（変形例）
　図９は、可動片４の変形例である可動片４Ａを示している。可動片４Ａは、図９においてハッチングで示される挟持部４２から接合強化部４５に亘る領域に樹脂皮膜４９が形成されている点で可動片４とは異なる。樹脂皮膜４９は、塗布又は印刷等の手法により、可動片４Ａの表面及び／又は裏面に形成される。これにより、樹脂皮膜４９は、可動片４Ａの表面及び裏面に密着する。一方、樹脂皮膜４９は、カバー溶着工程（Ｓ４）及び２次成形工程（Ｓ５）において、第１ケース７及び第２ケース９を構成する樹脂と強固に接合する。これにより、挟持部４２と第１ケース７との接合力及び接合強化部４５と第２ケース９との接合力が高められる。 (Modification)
FIG. 9 shows a movable piece 4 </ b> A that is a modification of the movable piece 4. The movable piece 4A is different from the movable piece 4 in that a resin film 49 is formed in a region extending from the clamping portion 42 to the joint strengthening portion 45 indicated by hatching in FIG. The resin film 49 is formed on the front surface and / or the back surface of the movable piece 4A by a technique such as coating or printing. Thereby, the resin film 49 adheres to the front surface and the back surface of the movable piece 4A. On the other hand, the resin film 49 is firmly bonded to the resin constituting the first case 7 and the second case 9 in the cover welding step (S4) and the secondary molding step (S5). Thereby, the joining force between the clamping part 42 and the first case 7 and the joining force between the joining strengthening part 45 and the second case 9 are enhanced.
　樹脂皮膜４９は、可動片４表面又は裏面のいずれかに形成されていてもよい。また、樹脂皮膜４９は、挟持部４２から接合強化部４５に亘る領域に形成されるのが望ましいが、少なくとも接合強化部４５に形成されていればよい。さらに、樹脂皮膜４９によって接合強化部４５と第２ケース９との間で十分な接合力が得られる場合には、段曲げ４６、貫通穴４７及び／又は切り欠き４８が適宜省略されていてもよい。 The resin film 49 may be formed on either the front surface or the back surface of the movable piece 4. Further, the resin film 49 is desirably formed in a region extending from the sandwiching portion 42 to the joint strengthening portion 45, but it is sufficient that the resin film 49 is formed at least on the joint strengthening portion 45. Further, when a sufficient bonding force is obtained between the bonding reinforcing portion 45 and the second case 9 by the resin film 49, the step bend 46, the through hole 47 and / or the notch 48 may be omitted as appropriate. Good.
　以上のように、本実施形態のブレーカー１によれば、可動片４の端子４１が第１ケース７から突出する基端部４１ａに、第２ケース９との接合力を強化する接合強化部４５が形成され、かつ接合強化部４５が、第２ケース９に埋設されているので、端子４１の基端部４１ａが第２ケース９に強固に接合される。これにより、第２ケース９の気密性が向上し、熱応動素子５等を収容する第１ケース７の内部空間に水蒸気等が侵入することが防止される。従って、熱応動素子５の正常な熱変形動作が維持され、良好な温度特性を得ることができる。 As described above, according to the breaker 1 of the present embodiment, the joint strengthening portion 45 that reinforces the joining force with the second case 9 on the base end portion 41 a where the terminal 41 of the movable piece 4 protrudes from the first case 7. And the joint strengthening portion 45 is embedded in the second case 9, the base end portion 41 a of the terminal 41 is firmly joined to the second case 9. Thereby, the airtightness of the second case 9 is improved, and water vapor or the like is prevented from entering the internal space of the first case 7 that accommodates the thermally responsive element 5 or the like. Therefore, the normal thermal deformation operation of the thermoresponsive element 5 is maintained, and good temperature characteristics can be obtained.
　接合強化部４５が、可動片４が階段状に曲げられた段曲げ４６を有するので、段曲げ４６の周辺には、第２ケース９を構成する樹脂が充填される。これにより、基端部４１ａと第２ケース９との接合力が強化され、第２ケース９の気密性が向上し、熱応動素子５等を収容する第１ケース７の内部空間に水蒸気等が侵入することが防止される。 Since the joint strengthening part 45 has a step bend 46 in which the movable piece 4 is bent in a step shape, the resin constituting the second case 9 is filled around the step bend 46. As a result, the bonding force between the base end portion 41a and the second case 9 is strengthened, the airtightness of the second case 9 is improved, and water vapor or the like is generated in the internal space of the first case 7 that accommodates the thermally responsive element 5 and the like. Intrusion is prevented.
　接合強化部４５が、基端部４１ａから可動片４の厚さ方向に陥没する凹部又は基端部４１ａから可動片の厚さ方向に突出する凸部を有する構成においても、同様の作用効果が得られる。 Even in a configuration in which the joint strengthening portion 45 has a concave portion that is recessed from the base end portion 41a in the thickness direction of the movable piece 4 or a convex portion that protrudes from the base end portion 41a in the thickness direction of the movable piece, similar effects can be obtained. can get.
　接合強化部４５が、可動片４を厚さ方向に貫通する貫通穴４７を有するので、かかる貫通穴４７には、第２ケース９を構成する樹脂が充填される。これにより、基端部４１ａと第２ケース９との接合力が強化されると共に、第２ケース９の強度・剛性が向上する。 Since the joint strengthening portion 45 has a through hole 47 that penetrates the movable piece 4 in the thickness direction, the through hole 47 is filled with a resin constituting the second case 9. Thereby, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
　接合強化部４５が、可動片４の一部が切除された切り欠き４８を有するので、かかる切り欠き４８には、第２ケース９を構成する樹脂が充填される。これにより、基端部４１ａと第２ケース９との接合力が強化されると共に、第２ケース９の強度・剛性が向上する。 Since the joint strengthening part 45 has a notch 48 in which a part of the movable piece 4 is cut, the notch 48 is filled with a resin constituting the second case 9. Thereby, the joining force between the base end portion 41a and the second case 9 is strengthened, and the strength and rigidity of the second case 9 are improved.
　接合強化部４５に樹脂皮膜４９が形成されている構成によれば、接合強化部４５と第２ケース９との接合力が高められ、第２ケース９の気密性が向上する。 According to the configuration in which the resin film 49 is formed on the joint strengthening portion 45, the joining force between the joint strengthening portion 45 and the second case 9 is increased, and the airtightness of the second case 9 is improved.
　１次成形工程（Ｓ１）、強化部形成工程（Ｓ２）、実装工程（Ｓ３）及び２次成形工程（Ｓ５）を含むブレーカー製造方法によれば、本実施形態に係るブレーカー１を製造することができる。 According to the breaker manufacturing method including the primary forming step (S1), the strengthening portion forming step (S2), the mounting step (S3), and the secondary forming step (S5), the breaker 1 according to this embodiment can be manufactured. it can.
　なお、本発明は上記実施形態の構成に限られることなく、少なくとも、固定片２、可動片４及び熱応動素子５を収容する第１ケース７と、第１ケース７の外側を覆う第２ケース９とを備え、可動片４は、第１ケース７の外方に延出された端子４１を有し、端子４１が第１ケース７から突出する基端部４１ａには、第２ケース９との接合力を強化する接合強化部４５が形成され、接合強化部４５が、第２ケース９に埋設されていればよい。 In addition, this invention is not restricted to the structure of the said embodiment, The 2nd case which covers the outer side of the 1st case 7 which accommodates at least the fixed piece 2, the movable piece 4, and the thermally responsive element 5 at least. 9, the movable piece 4 has a terminal 41 extending outward from the first case 7, and a base end 41 a from which the terminal 41 protrudes from the first case 7 has a second case 9 and It is only necessary that the joint strengthening portion 45 that strengthens the joint force is formed and the joint strengthening portion 45 is embedded in the second case 9.
　また、固定片２の端子２２が第１ケース７から突出する基端部２２ａに、第２ケース９との接合力を強化する接合強化部が形成され、第２ケース９に埋設されていてもよい。すなわち、端子２２の基端部２２ａに、段曲げ、貫通穴、切り欠き部及び／又は樹脂皮膜等が形成されていてもよい。この場合、端子２２の基端部２２ａと第２ケース９との接合力が強化される。 Even if the terminal 22 of the fixed piece 2 is formed at the base end portion 22 a protruding from the first case 7, a joint strengthening portion that strengthens the joining force with the second case 9 is formed and embedded in the second case 9. Good. That is, a step bend, a through hole, a notch, and / or a resin film may be formed on the base end portion 22 a of the terminal 22. In this case, the joining force between the base end portion 22a of the terminal 22 and the second case 9 is strengthened.
　また、図９においてハッチングで示される領域において、可動片４又は可動片４Ａには、梨地加工等の表面粗し処理が施されていてもよい。このような表面粗し処理は、可動片４を構成する金属と、第１ケース７及び第２ケース９を構成する樹脂との接合力を高め、気密性の向上に寄与する。可動片４Ａに表面粗し処理が施される場合には、可動片４Ａを構成する金属と樹脂皮膜４９との接合力を高め、気密性の向上に寄与する。 Further, in the area indicated by hatching in FIG. 9, the movable piece 4 or the movable piece 4A may be subjected to a surface roughening process such as a satin finish. Such surface roughening treatment increases the bonding force between the metal constituting the movable piece 4 and the resin constituting the first case 7 and the second case 9 and contributes to the improvement of the airtightness. When the surface of the movable piece 4A is roughened, the bonding force between the metal constituting the movable piece 4A and the resin film 49 is increased, which contributes to the improvement of the airtightness.
　段曲げ４６、貫通穴４７及び切り欠き部４８の位置、大きさ、形状、個数は、ブレーカー１の大きさ、第２ケース９に要求される気密性等に応じて適宜設定することができる。 The position, size, shape, and number of the step bend 46, the through hole 47, and the notch 48 can be appropriately set according to the size of the breaker 1, the air tightness required for the second case 9, and the like.
　また、樹脂ベース７１とカバー部材７２との接合手法は、超音波溶着に限られることなく、両者が強固に接合される手法であれば、適宜適用することができる。例えば、液状又はゲル状の接着剤を塗布・充填し、硬化させることにより、両者が接着されてもよい。また、ケース７は、樹脂ベース７１とカバー部材７２等によって構成される形態に限られることなく、２個以上の部品によって可動片４が挟まれて保持される形態であればよい。 Further, the joining technique between the resin base 71 and the cover member 72 is not limited to ultrasonic welding, and any technique can be applied as long as both are firmly joined. For example, a liquid or gel adhesive may be applied, filled, and cured to bond them together. Further, the case 7 is not limited to the form constituted by the resin base 71 and the cover member 72 and the like, but may be any form as long as the movable piece 4 is sandwiched and held by two or more parts.
　本実施形態では、ＰＴＣサーミスター６による自己保持回路を有しているが、このような構成を省いた形態であっても適用可能であり、安定した温度追従性と抵抗値を確保しつつ、ブレーカー１の小型化を図ることができる。また、可動片４をバイメタル又はトリメタル等によって形成することにより、可動片４と熱応動素子５を一体的に形成する構成であってもよい。この場合、一体化された可動片に伝熱部が形成されることになり、ブレーカーの構成が簡素化されて、さらなる小型化を図ることができる。 In the present embodiment, the PTC thermistor 6 has a self-holding circuit, but it can be applied even in a form in which such a configuration is omitted, while ensuring stable temperature followability and resistance value. The breaker 1 can be downsized. Moreover, the structure which forms the movable piece 4 and the thermally responsive element 5 integrally by forming the movable piece 4 with a bimetal or a trimetal etc. may be sufficient. In this case, the heat transfer part is formed in the integrated movable piece, the structure of the breaker is simplified, and further miniaturization can be achieved.
　また、特開２００５－２０３２７７号公報に示されるような、挟持部４２又はその近傍において、可動片４が端子４１の側と可動接点３の側に構造的に分離されている形態に、本発明を適用してもよい。また、アームターミナルと可動アームとが溶接等によって固定されていてもよい。この場合において、挟持部４２及び端子４１は、固定片２等と共に樹脂ベース７１にインサート成形されていてもよい。 Further, as shown in Japanese Patent Application Laid-Open No. 2005-203277, the movable piece 4 is structurally separated into the terminal 41 side and the movable contact 3 side in the clamping portion 42 or in the vicinity thereof. May be applied. Further, the arm terminal and the movable arm may be fixed by welding or the like. In this case, the clamping part 42 and the terminal 41 may be insert-molded in the resin base 71 together with the fixed piece 2 and the like.
　また、本発明のブレーカー１は、２次電池パック、電気機器用の安全回路等にも広く適用できる。図１０は２次電池パック１００を示す。２次電池パック１００は、２次電池１０１と、２次電池１０１の出力端回路中に設けたブレーカー１とを備える。図１１は電気機器用の安全回路１０２を示す。安全回路１０２は２次電池１０１の出力回路中に直列にブレーカー１を備えている。ブレーカー１を備えた２次電池パック１００又は安全回路１０２によれば、優れた温度特性によって安全性を確保した２次電池パック１００又は安全回路１０２を製造できる。 Also, the breaker 1 of the present invention can be widely applied to secondary battery packs, safety circuits for electrical devices, and the like. FIG. 10 shows the secondary battery pack 100. The secondary battery pack 100 includes a secondary battery 101 and a breaker 1 provided in the output terminal circuit of the secondary battery 101. FIG. 11 shows a safety circuit 102 for electrical equipment. The safety circuit 102 includes a breaker 1 in series in the output circuit of the secondary battery 101. According to the secondary battery pack 100 or the safety circuit 102 provided with the breaker 1, the secondary battery pack 100 or the safety circuit 102 in which safety is ensured by excellent temperature characteristics can be manufactured.
　１　ブレーカー
　２　　固定片
　３　　可動接点
　４，４Ａ　　可動片
　５　　熱応動素子
　７　　第１ケース
　８　　カバー片
　９　　第２ケース
　１０　　主要部
　４５　　接合強化部
　４６　　段曲げ
　４７　　貫通穴
　４８　　切り欠き
　４９　　樹脂皮膜
　１０１　　２次電池
　１０２　　安全回路 DESCRIPTION OF SYMBOLS 1 Breaker 2 Fixed piece 3 Movable contact 4, 4A Movable piece 5 Thermally responsive element 7 1st case 8 Cover piece 9 2nd case 10 Main part 45 Joint reinforcement part 46 Step bending 47 Through-hole 48 Notch 49 Resin film 101 Secondary Battery 102 Safety circuit

Claims (11)

  1. 　固定接点を有する固定片と、可動接点を有し、この可動接点を前記固定接点に押圧して接触させる可動片と、温度変化に伴って変形することにより前記可動接点が前記固定接点から離反するように前記可動片を作動させる熱応動素子と、前記固定片、可動片及び熱応動素子を収容する第１ケースとを備えたブレーカーにおいて、
    　前記第１ケースの外側を覆う第２ケースをさらに備え、
    　前記可動片は、前記第１ケースの外方に延出された端子を有し、
    　前記端子が前記第１ケースから突出する基端部には、前記第２ケースとの接合力を強化する接合強化部が形成され、
    　前記接合強化部は、前記第２ケースに埋設されていることを特徴とするブレーカー。     A fixed piece having a fixed contact, a movable piece having a movable contact, the movable piece pressing the movable contact against the fixed contact, and the movable contact moving away from the fixed contact by being deformed as the temperature changes. In a breaker comprising a thermally responsive element that operates the movable piece as described above, and a first case that houses the fixed piece, the movable piece, and the thermally responsive element,
    A second case covering the outside of the first case;
    The movable piece has a terminal extending outward of the first case,
    The base end portion from which the terminal protrudes from the first case is formed with a joint strengthening portion that strengthens the joining force with the second case,
    The breaker is characterized in that the joint strengthening portion is embedded in the second case.
  2. 　前記接合強化部は、前記可動片が階段状に曲げられた段曲げを有することを特徴とする請求項１に記載のブレーカー。 The breaker according to claim 1, wherein the joint strengthening portion has a step bend in which the movable piece is bent in a step shape.
  3. 　前記接合強化部は、前記基端部から前記可動片の厚さ方向に陥没する凹部を有することを特徴とする請求項１又は請求項２に記載のブレーカー。 The breaker according to claim 1 or 2, wherein the joint strengthening portion has a concave portion that is recessed from the base end portion in the thickness direction of the movable piece.
  4. 　前記接合強化部は、前記基端部から前記可動片の厚さ方向に突出する凸部を有することを特徴とする請求項１乃至請求項３のいずれか一項に記載のブレーカー。 The breaker according to any one of claims 1 to 3, wherein the joint strengthening portion includes a convex portion protruding from the base end portion in the thickness direction of the movable piece.
  5. 　前記接合強化部は、前記可動片を厚さ方向に貫通する貫通穴を有することを特徴とする請求項１乃至請求項４のいずれか一項に記載のブレーカー。 The breaker according to any one of claims 1 to 4, wherein the joint strengthening portion has a through hole penetrating the movable piece in a thickness direction.
  6. 　前記接合強化部は、前記可動片の一部が切除された切り欠きを有することを特徴とする請求項１乃至請求項５のいずれか一項に記載のブレーカー。 The breaker according to any one of claims 1 to 5, wherein the joint strengthening portion has a notch in which a part of the movable piece is cut off.
  7. 　前記接合強化部には、樹脂皮膜が形成されていることを特徴とする請求項１乃至請求項６のいずれか一項に記載のブレーカー。 The breaker according to any one of claims 1 to 6, wherein a resin film is formed on the joint strengthening portion.
  8. 　前記接合強化部には、表面粗し処理が施されていることを特徴とする請求項１乃至請求項７のいずれか一項に記載のブレーカー。 The breaker according to any one of claims 1 to 7, wherein the joint strengthening portion is subjected to a surface roughening treatment.
  9. 　請求項１乃至請求項８のいずれか一項に記載のブレーカーを備えたことを特徴とする電気機器用の安全回路。 A safety circuit for electrical equipment, comprising the breaker according to any one of claims 1 to 8.
  10. 　請求項１乃至請求項８のいずれか一項に記載のブレーカーを備えたことを特徴とする２次電池回路。 A secondary battery circuit comprising the breaker according to any one of claims 1 to 8.
  11. 　請求項１乃至請求項８のいずれか一項に記載のブレーカーを製造するブレーカー製造方法であって、
    　第１金型のキャビティ空間に樹脂材料を充填して、前記第１ケースを成形する１次成形工程と、
    　前記可動片に前記接合強化部を形成する強化部形成工程と、
    　前記１次成形工程によって成形された第１ケースに前記固定片、熱応動素子及び前記強化部形成工程によって前記接合強化部が形成された可動片を実装する実装工程と、
    　前記実装工程によって前記固定片、可動片及び熱応動素子が実装された第１ケースを第２金型内に装填し、前記第２金型のキャビティ空間に樹脂材料を充填して前記第２ケースを成形する２次成形工程とを含むことを特徴とするブレーカー製造方法。     A breaker manufacturing method for manufacturing the breaker according to any one of claims 1 to 8,
    A primary molding step of molding the first case by filling the cavity space of the first mold with a resin material;
    A reinforcing part forming step of forming the joint reinforcing part on the movable piece;
    A mounting step of mounting the fixed piece, the thermally responsive element, and the movable piece formed with the joint reinforcing portion by the reinforcing portion forming step on the first case formed by the primary forming step;
    A first case on which the fixed piece, the movable piece, and the thermally responsive element are mounted by the mounting step is loaded into a second mold, and a resin material is filled in a cavity space of the second mold, thereby the second case. A breaker manufacturing method comprising: a secondary molding step of molding the material.
PCT/JP2013/079172 2013-10-28 2013-10-28 Breaker, safety circuit provided therewith, secondary-battery circuit, and method for manufacturing breaker WO2015063844A1 (en)

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PCT/JP2013/079172 WO2015063844A1 (en) 2013-10-28 2013-10-28 Breaker, safety circuit provided therewith, secondary-battery circuit, and method for manufacturing breaker
JP2015544646A JP6204988B2 (en) 2013-10-28 2013-10-28 Breaker, safety circuit including the same, secondary battery circuit, and method for manufacturing breaker

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EP2541576B1 (en) * 2010-02-26 2017-04-19 Bourns KK Breaker
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JPH06295656A (en) * 1993-04-08 1994-10-21 Koa Corp Element for circuit protection
JP2013041798A (en) * 2011-08-19 2013-02-28 Komatsulite Mfg Co Ltd Thermal protector and manufacturing method therefor

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CN110651349A (en) * 2017-07-19 2020-01-03 柏恩氏株式会社 Circuit breaker and safety circuit with same
CN110651349B (en) * 2017-07-19 2021-09-07 柏恩氏株式会社 Circuit breaker and safety circuit with same

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