Electrical junction box

Abstract

An electrical connection box (11) is provided with circuit elements (23, 33), and is provided with: a first circuit unit (21) having a plate-shaped first base member (22) and a basic circuit element (23) disposed on the first base member (22) and constituting a part of the circuit elements; and a second circuit unit (31) having a plate-shaped second base member (32) and an additional circuit element (33) disposed on the second base member (32) and constituting a part of the circuit element. The second circuit unit (31) is laminated on the first circuit unit (21).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an electrical connection box. BACKGROUND

[0002] Conventionally, as an electrical connection box, for example, a battery pack provided in a vehicle is sometimes used (see, for example, Patent Literature 1). The battery pack has a battery pack case, an electrical connection box, and a plurality of battery cells.

[0003] The electrical connection box is housed in the battery pack case together with the plurality of battery cells. The electrical connection box has, for example, a case and circuit elements arranged on a base member constituting a bottom surface of the case. The circuit elements are connected to the plurality of battery cells. The circuit elements include, for example, a plurality of relays, fuses, bus bars, and the like. The circuit elements achieve optimal input and output by monitoring, for example, current values, temperatures, and the like of the battery cells. In addition, depending on the class of the vehicle in which the electrical connection box is mounted, optional equipment, and the like, the number of circuit elements of the electrical connection box is sometimes increased or decreased. PRIOR ART DOCUMENTS PATENT LITERATURE

[0004] Patent Literature 1: Japanese Patent Application Publication No. 2013-16467 SUMMARY PROBLEMS TO BE SOLVED BY THE INVENTION

[0005] In recent years, the number of battery cells in a battery pack has been increasing. Due to the size and / or volume limitations of the battery pack case, there are cases in which miniaturization of the electrical connection box housed in the battery pack case together with the battery cells is required. For example, there are cases in which it is necessary to reduce the arrangement space of the electrical connection box in the battery pack case as viewed from above, and cases in which it is necessary to reduce the footprint of the electrical connection box. In addition, the electrical connection box is sometimes required to have high versatility.

[0006] An object of the present disclosure is to provide an electrical connection box that can improve versatility and achieve miniaturization. MEANS FOR SOLVING THE PROBLEMS

[0007] The electrical connection box of the present disclosure is an electrical connection box having circuit elements, and includes: a first circuit unit having a first base member that is a plate, and basic circuit elements arranged on the first base member and constituting a part of the circuit elements; and a second circuit unit having a second base member that is a plate, and additional circuit elements arranged on the second base member and constituting a part of the circuit elements, the second circuit unit being laminated on the first circuit unit. EFFECTS OF THE INVENTION

[0008] According to the electrical connection box of the present disclosure, versatility can be improved and miniaturization can be achieved. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1 FIG. 1 is a perspective view of an electrical connection box in an embodiment. Figure 2 FIG. 2 is an exploded perspective view of the electrical connection box in the embodiment. Figure 3 FIG. 3 is a plan view of a first circuit unit and a heat dissipation metal plate in the embodiment. Figure 4 FIG. 4 is a partially enlarged perspective view of the heat dissipation metal plate in the embodiment. Figure 5 FIG. 5 is a sectional view along line 5-5 of FIG. 1. Figure 3 DETAILED DESCRIPTION

[0010] [Explanation of Embodiments of the Present Disclosure] First, the embodiments of the present disclosure will be explained. [1] The electrical connection box of the present disclosure has a circuit element, and the electrical connection box has: a first circuit unit having a first base member that is plate-shaped and basic circuit elements that are arranged on the first base member and constitute a part of the circuit element; and a second circuit unit having a second base member that is plate-shaped and additional circuit elements that are arranged on the second base member and constitute a part of the circuit element, the second circuit unit being laminated on the first circuit unit.

[0011] According to this structure, since the second circuit unit is laminated on the first circuit unit, it is advantageous to reduce the occupied area of the electrical connection box, for example, compared to an electrical connection box in which all the circuit elements are arranged on the same plane. Thus, the arrangement space of the electrical connection box in the battery pack case when viewed from above can be reduced. Further, the additional circuit elements are sometimes components required when the electrical connection box is adapted to a higher grade vehicle, a vehicle to which optional equipment is added, but in a case where the additional circuit elements are not required, the second circuit unit is simply not provided in the electrical connection box or is omitted from the electrical connection box, and the electrical connection box can be used as an electrical connection box having only the basic circuit elements. That is, the first circuit unit can be applied to the electrical connection box as a general-purpose component regardless of whether the additional circuit elements required when the electrical connection box is adapted to a higher grade vehicle, a vehicle to which optional equipment is added, are required. Thus, the general-purpose property of the electrical connection box is improved.

[0012] [2] In the above [1], a heat dissipation metal plate that is installed below the first base member can be provided. According to this structure, by laminating the second circuit unit on the first circuit unit, the heat generated by the basic circuit elements is easily accumulated, but since the heat dissipation metal plate that is installed below the first base member is provided, the heat dissipation property is good.

[0013] ​[3] In the above-mentioned [2], the heat dissipation metal plate can have an internal thread, and at least one of the first base member, the second base member, and the circuit element can be fixed to the heat dissipation metal plate by a bolt that is screwed into the internal thread.

[0014] According to this structure, at least one of the first base member, the second base member, and the circuit element is fixed to the heat dissipation metal plate by a bolt that is screwed into the internal thread of the heat dissipation metal plate, and thus a nut is not required. Thus, compared to a case in which a nut is provided separately, the number of components and the assembly man-hours can be reduced.

[0015] [4] In the above-mentioned [3], the heat dissipation metal plate can have a column portion that protrudes upward, and the internal thread can be formed in the column portion. According to this structure, the heat dissipation metal plate has a column portion that protrudes upward, and the internal thread is formed in the column portion, and thus the bolt can be shortened and at least one of the first base member, the second base member, and the circuit element can be fastened well. That is, in a case in which the heat dissipation metal plate does not have a column portion, in order to fasten at least one of the first base member, the second base member, and the circuit element, the bolt needs to be lengthened, and it can not be possible to achieve good fastening, but this structure of the present disclosure can avoid this problem.

[0016] [5] In any one of the above-mentioned [2] to [4], the heat dissipation metal plate can be one heat dissipation metal plate that covers or opposes the entire lower surface of the first base member.

[0017] According to this structure, one heat dissipation metal plate covers or opposes the entire lower surface of the first base member, and thus a higher heat dissipation property can be obtained. Furthermore, compared to a case in which a plurality of heat dissipation metal plates are provided, the number of components can be reduced.

[0018] [Details of Embodiments of the Present Disclosure] Hereinafter, specific examples of an electrical connection box according to the present disclosure will be described with reference to the drawings. In each of the drawings, a part of the structure can be exaggerated or simplified for convenience of explanation. Furthermore, the dimensional proportions of each part can be different in each of the drawings. In the present specification, “parallel”, “orthogonal”, and “circular” include not only strict parallel, strict orthogonal, and strict circular, but also cases in which they are substantially parallel, substantially orthogonal, and substantially circular, within a range in which the effects of the embodiments function. Note that the present disclosure is not limited to these examples, and is intended to include all modifications within the scope of the claims and the like.

[0019] (Structure of the Electrical Connection Box 11) As Figure 1 and Figure 2As shown in FIG. 1, the electrical connection box 11 includes a first circuit unit 21, a second circuit unit 31, and a heat dissipation metal plate 41. The second circuit unit 31 is stacked on the first circuit unit 21. Further, the heat dissipation metal plate 41 is installed below the first circuit unit 21.

[0020] The electrical connection box 11 of the present embodiment is provided in a battery pack mounted on a vehicle such as an electric vehicle. That is, the electrical connection box 11 is housed in a battery pack case together with a plurality of battery cells.

[0021] Note that, in the drawings, a first axis X, a second axis Y orthogonal to the first axis X, and a third axis Z orthogonal to the first axis X and the second axis Y are shown. Further, in the drawings, a direction along the first axis X, that is, a long side direction X1, and a direction along the second axis Y, that is, a short side direction Y1 are shown. In addition, in the drawings, an upward direction Z1 along the third axis Z and a downward direction Z2 opposite to the upward direction Z1 are shown.

[0022] (Structure of the first circuit unit 21) As shown in FIG. 2, the first circuit unit 21 has a first base member 22 which is a plate, and a basic circuit element 23 which is arranged on the first base member 22 and constitutes a part of a circuit element. Figure 2 Figure 3 As shown in FIG. 2, the first circuit unit 21 has a first base member 22 which is a plate, and a basic circuit element 23 which is arranged on the first base member 22 and constitutes a part of a circuit element.

[0023] The first base member 22 is made of a resin material. The first base member 22 is rectangular when viewed from above. The first base member 22 has a concave-convex portion on which the basic circuit element 23 is positioned and arranged. The first base member 22 constitutes a bottom surface of a housing of the electrical connection box 11. Further, the first base member 22 has a side wall portion 22a which protrudes upward at an edge portion. The side wall portion 22a constitutes a side surface of the housing of the electrical connection box 11 together with a side wall of an upper side housing which is not shown.

[0024] The basic circuit element 23 is a circuit element which is necessary regardless of the class of a vehicle on which the electrical connection box 11 is mounted, optional equipment, and the like. The basic circuit element 23 includes, for example, a relay 24, a fuse 25, a bus bar 26, and the like.

[0025] (Structure of the second circuit unit 31) As shown in FIG. 3, the second circuit unit 31 has a second base member 32 which is a plate, and an additional circuit element 33 which is arranged on the second base member 32 and constitutes a part of a circuit element. Figure 1 Figure 2 As shown in FIG. 3, the second circuit unit 31 has a second base member 32 which is a plate, and an additional circuit element 33 which is arranged on the second base member 32 and constitutes a part of a circuit element.

[0026] ​​The second base member 32 is made of resin material. The second base member 32 is rectangular when viewed from above. The second base member 32 is formed as a rectangle that is within the rectangular range of the first base member 22 when viewed from above and is slightly shorter than the first base member 22. The second base member 32 has protrusions and recesses that can position and arrange additional circuit elements 33.

[0027] Additional circuit elements 33 are circuit elements added to and / or connected to the basic circuit elements 23 depending on the vehicle class, optional equipment, etc., of the vehicle equipped with the electrical connection box 11. Additional circuit elements 33 may include, for example, a control unit 34 containing a microcomputer, a busbar 35, etc. It should be noted that the number and configuration of the basic circuit elements 23 and additional circuit elements 33 in each figure are not strictly limited to those shown, but are illustrated as examples.

[0028] The second circuit unit 31 is stacked on top of the first circuit unit 21 and fixed to the first circuit unit 21. In addition, an additional circuit element 33 is added to the second circuit unit 31 and connected to the basic circuit element 23.

[0029] (Structure of heat dissipation metal plate 41) The heat dissipation metal plate 41 is made of a metal material with high heat dissipation properties, such as aluminum. The heat dissipation metal plate 41 is formed, for example, by stamping an aluminum plate.

[0030] like Figure 3 As shown, the heat dissipation metal plate 41 is formed as a single heat dissipation metal plate covering or adjacent to the entire lower surface of the first base member 22. In other words, the heat dissipation metal plate 41 is shaped to encompass the entire first base member 22 when viewed from above. Furthermore, the heat dissipation metal plate 41 is formed as a rectangle slightly larger than the first base member 22 in both directions along the first axis X and in both directions along the second axis Y.

[0031] like Figure 4 and Figure 5 As shown, the heat dissipation metal plate 41 has an internal thread 42. More specifically, the heat dissipation metal plate 41 has an upwardly projecting post 43. In this embodiment, the post 43 is provided at a location corresponding to the relay 24 of the basic circuit element 23. Specifically, each relay 24 has a pair of posts 43. Furthermore, the internal thread 42 is formed on the post 43. The internal thread 42 is formed to penetrate the heat dissipation metal plate 41 from the top of the post 43.

[0032] Further, at least one of the first base member 22, the second base member 32, the basic circuit element 23, and the additional circuit element 33 is fixed to the heat dissipation metal plate 41 by a bolt 44 screwed into the internal thread 42. In the present embodiment, the relay 24 and the first base member 22 are fixed to the heat dissipation metal plate 41 by the bolt 44 screwed into the internal thread 42. In detail, the relay 24 has a housing fixing leg portion 24a, and the bolt 44 screwed into the internal thread 42 is fastened and fixed to the heat dissipation metal plate 41 through the housing fixing leg portion 24a. Further, the first base member 22 is fixed to the heat dissipation metal plate 41 by being sandwiched between the housing fixing leg portion 24a and the heat dissipation metal plate 41.

[0033] Next, the operation of the electrical connection box 11 configured as described above will be described. In the electrical connection box 11, the circuit elements including the basic circuit element 23 and the additional circuit element 33 are electrically connected to the battery cells housed in the battery pack case together with the electrical connection box 11. Further, the circuit elements achieve optimal input and output by monitoring the current value, temperature, and the like of the battery cells.

[0034] Further, the additional circuit element 33 is a component required when the electrical connection box 11 is adapted to a higher class vehicle, a vehicle to which optional equipment is added, but in a case where the additional circuit element 33 is not required, the electrical connection box 11 is housed in the battery pack case without the second circuit unit 31 being provided.

[0035] Next, the effects of the above-described embodiment will be described as follows. (1) Since the second circuit unit 31 is stacked on the first circuit unit 21, it is possible to reduce the occupied area of the electrical connection box, for example, as compared with an electrical connection box in which all the circuit elements are arranged on the same plane. Thus, it is possible to reduce the arrangement space of the electrical connection box 11 in the battery pack case as viewed from above. Further, the additional circuit element 33 is a component required when the electrical connection box is adapted to a higher class vehicle, a vehicle to which optional equipment is added, but in a case where the additional circuit element 33 is not required, it is possible to use the electrical connection box 11 having only the basic circuit element 23 by not providing the second circuit unit 31 or omitting the second circuit unit from the electrical connection box. That is, it is possible to apply the first circuit unit 21 as a general-purpose component to the electrical connection box 11 regardless of whether the additional circuit element 33 required when the electrical connection box is adapted to a higher class vehicle, a vehicle to which optional equipment is added, is required. Thus, the general-purpose property of the electrical connection box 11 is improved.

[0036] (2) By stacking the second circuit unit 31 on the first circuit unit 21, the heat generated by the basic circuit element 23 tends to accumulate, but since the heat dissipation metal plate 41 is provided under the first base member 22, the heat dissipation property is good.

[0037] (3) Since the relay 24 and the first base member 22 are fixed to the heat dissipation metal plate 41 by the bolt 44 screwed with the internal thread 42 of the heat dissipation metal plate 41, a nut is not required. Thus, compared with a case where a nut is provided separately, the number of components and the assembly man-hours can be reduced.

[0038] (4) The heat dissipation metal plate 41 has the column portion 43 protruding upward, and the internal thread 42 is formed in the column portion 43, so that the bolt 44 can be shortened and the relay 24 and the first base member 22 can be fastened well. That is, in a case where the heat dissipation metal plate 41 does not have the column portion 43, in order to fasten the relay 24 and the first base member 22, the bolt 44 needs to be lengthened, and good fastening can not be achieved, but the present embodiment can avoid this problem.

[0039] (5) Since the heat dissipation metal plate 41 is one heat dissipation metal plate formed so as to cover or oppose the entire lower surface of the first base member 22, higher heat dissipation can be obtained. Further, compared with a case where a plurality of heat dissipation metal plates 41 are provided, the number of components can be reduced.

[0040] The present embodiment can be changed as follows. The present embodiment and the following modified examples can be implemented in combination with each other within a range where they are not technically contradictory. In the above embodiment, the electrical connection box 11 is provided with the heat dissipation metal plate 41 installed below the first base member 22, but is not limited thereto, and a structure in which the heat dissipation metal plate 41 is not provided below the first base member 22 can be adopted. Further, although not particularly mentioned in the above embodiment, the electrical connection box 11 can be provided with a heat dissipation metal plate installed on the first base member 22, and can be provided with a heat dissipation metal plate installed below or above the second base member 32.

[0041] In the above embodiment, the heat dissipation metal plate 41 has the internal thread 42, but is not limited thereto, and a structure in which the heat dissipation metal plate 41 does not have the internal thread 42 can be adopted. In this case, for example, a nut can be used. That is, a nut screwed with the bolt 44 can be arranged below the first base member 22. Further, other structures in which at least one of the first base member 22, the second base member 32, the basic circuit component 23, and the additional circuit component 33 is fixed by the bolt 44 screwed with the internal thread 42 can be adopted.

[0042] In the above embodiment, the heat dissipation metal plate 41 has the column portion 43 protruding upward and having the internal thread 42 formed therein, but is not limited thereto, and a structure in which the heat dissipation metal plate 41 does not have the column portion 43 can be adopted. That is, the internal thread 42 can be formed in a portion of the heat dissipation metal plate 41 where the column portion 43 is not formed.

[0043] In the above embodiment, the heat dissipation metal plate 41 is formed as a single heat dissipation metal plate covering or opposite the entire lower surface of the first base member 22, but it is not limited to this. For example, the heat dissipation metal plate 41 may also be formed in a shape smaller than the first base member 22. In addition, the electrical connection box 11 may also adopt a structure having multiple heat dissipation metal plates.

[0044] In the above embodiments, the basic circuit element 23 includes, for example, a relay 24, a fuse 25, a busbar 26, etc., but is not limited to this and may also include other circuit elements.

[0045] In the above embodiments, the additional circuit element 33 may include, for example, a control unit 34 containing a microcontroller, a busbar 35, etc., but is not limited to this, and may also include other circuit elements.

[0046] In the above embodiments, the electrical connection box 11 is installed in the battery pack of an electric vehicle or other vehicle, but it is not limited to this and may also be installed in other devices.

[0047] The electrical connection box 11 shown in the illustration, which is a non-limiting embodiment, is sometimes referred to as a stacked electrical connection box that can be switched between a minimum stacking configuration including the heat dissipation metal plate 41 and the first circuit unit 21 and an extended stacking configuration in which a second circuit unit 31 is added after the minimum stacking configuration.

[0048] like Figure 1 , 2 As shown, the plate-shaped first base member 22 in a non-limiting embodiment is an example of a first synthetic resin frame or tray having an upper surface or first mounting surface configured to mount a plurality of basic circuit elements 23. The first base member 22 includes an outermost edge that defines the area occupied by the first base member 22.

[0049] like Figure 1 , 2 As shown, in a non-limiting embodiment, the heat dissipation metal plate 41 may have an upper surface adjacent to or opposite to the lower surface of the first base member 22, and may directly exchange heat with the lower surface of the first base member 22 or indirectly through an air gap. In one example, the heat dissipation metal plate 41 and the first base member 22 may be in direct contact at least at the pillar 43 of the heat dissipation metal plate 41. The heat dissipation metal plate 41 and the first base member 22 may sometimes be separated by an air gap at predetermined positions on the upper surface of the heat dissipation metal plate 41 other than the pillar 43. The heat dissipation metal plate 41 includes an outermost edge that defines the area occupied by the heat dissipation metal plate 41. In one example, the entire outermost edge or substantially the entire outermost edge of the heat dissipation metal plate 41 may be aligned with the entire outermost edge of the first base member 22, such that the area occupied by the heat dissipation metal plate 41 is substantially the same as the area occupied by the first base member 22.Figure 5 As shown, in a non-limiting embodiment, the operator can fasten the first base member 22 to the heat dissipation metal plate 41 by screwing the bolt 44 onto the column portion 43 of the heat dissipation metal plate 41 from the upper side of the first base member 22. In one example, the heat dissipation metal plate 41 may define the lowest layer or bottom surface of the electrical connection box 11.

[0050] like Figure 1 , 2 As shown, the plate-shaped second base member 32 in a non-limiting embodiment is an example of a second synthetic resin frame or tray having a second mounting surface configured to mount a plurality of additional circuit elements 33 and may be the upper surface of the second base member 32. The second base member 32 includes an outermost edge that defines the area occupied by the second base member 32. The area occupied by the second base member 32 may be smaller than the area occupied by the first base member 22, but may also be substantially the same. Symbol Explanation

[0051] 11 Electrical connection box

[0052] 21 Circuit Unit 1

[0053] 22 First base component

[0054] 22a Side wall portion

[0055] 23. Basic circuit elements (part of a circuit element)

[0056] 24 Relays

[0057] 24a Housing fixing feet

[0058] 25. Fuse

[0059] 26. Busbar

[0060] 31 Circuit Unit 2

[0061] 32. Second base component

[0062] 33. Adding circuit elements (forming part of a circuit element)

[0063] 34 Control Unit

[0064] 35. Busbar

[0065] 41 Heat dissipation metal plate

[0066] 42 Internal Thread

[0067] 43. Column

[0068] 44 bolts

[0069] X Axis 1

[0070] X1 Long side direction

[0071] Y-axis 2

[0072] Y1 Short side direction

[0073] Z Third Axis

[0074] Z1 Upward

[0075] Z2 Downward direction.

Claims

1. An electrical connection box, comprising circuit elements, The electrical connection box includes: The first circuit unit has a plate-shaped first base member and basic circuit elements disposed on the first base member and constituting part of the circuit elements; and The second circuit unit has a plate-shaped second base member and additional circuit elements disposed on the second base member and forming part of the circuit element. The second circuit unit is stacked on top of the first circuit unit.

2. The electrical connection box according to claim 1, wherein, The electrical connection box also includes a heat dissipation metal plate installed below the first base component.

3. The electrical connection box according to claim 2, wherein, The heat dissipation metal plate has internal threads. At least one of the first base component, the second base component, and the circuit element is fixed to the heat dissipation metal plate by bolts that engage with the internal threads.

4. The electrical connection box according to claim 3, wherein, The heat dissipation metal plate has an upwardly protruding column. The internal thread is formed on the column portion.

5. The electrical connection box according to claim 2, wherein, The heat dissipation metal plate is a piece of heat dissipation metal plate that covers or is formed opposite to the entire lower surface of the first base member.

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