Electrical connection structure

Abstract

An electrical connection structure includes a first unit including a terminal and a second unit including a connection terminal. The electrical connection structure is configured to mount the second unit to the first unit so that the connection terminal is electrically connected to the terminal. The terminal has a tab in a plate shape. The connection terminal includes a socket formed with a connection groove into which the tab is inserted, and an elastic contact member provided to an inner side surface of the connection groove. The elastic contact member elastically contacts an outer surface of the tab inserted into the connection groove.

Description

Technical Field

[0001] This disclosure relates to an electrical connection structure used, for example, in a vehicle. Background Technology

[0002] The vehicle is equipped with a power source such as a battery and a large number of loads. Power from the power source is supplied to the various loads via, for example, power supply units or wiring harnesses.

[0003] Patent document JP2017-121178A discloses an electrical connection structure including: a charging device for charging a battery with power from an external power source; an inverter for converting the battery current from direct current (DC) to alternating current (AC) and supplying the AC power to a motor; and a junction box for relaying these electrical connections. In this electrical connection structure, the inverter and the junction box are connected to each other via a busbar that passes through an opening provided in a partition member.

[0004] In the aforementioned electrical connection structure, the busbar connecting the inverter and the junction box is fastened to the terminals of the inverter and the junction box respectively by bolts. Therefore, the connection operation requires time and effort, and complex torque management is necessary when tightening the bolts. Summary of the Invention

[0005] This disclosure provides an electrical connection structure that enables easy electrical connection of units to each other.

[0006] According to an exemplary aspect of this disclosure, an electrical connection structure includes: a first unit including a terminal; and a second unit including a connecting terminal. The electrical connection structure is configured to mount the second unit to the first unit such that the connecting terminal is electrically connected to the terminal. The terminal has a plate-shaped insert. The connecting terminal includes a socket and a resilient contact, the socket forming a connecting groove into which the insert is inserted, and the resilient contact being disposed on an inner surface of the connecting groove. The resilient contact makes resilient contact with the outer surface of the insert inserted into the connecting groove.

[0007] The invention has been briefly described above. The details of this disclosure will become clearer by referring to the accompanying drawings and the following description of embodiments for carrying out the invention (hereinafter referred to as "Embodiments"). Attached Figure Description

[0008] Figure 1 It is a perspective view including the power supply unit, junction box, and wiring harness according to the embodiment of the electrical connection structure.

[0009] Figure 2 It is a three-dimensional view of a power supply unit assembled with a junction box and wiring harness.

[0010] Figure 3It is a 3D view of the terminals in an unconnected state and the connected terminals.

[0011] Figure 4 It is a three-dimensional view of the terminals in the connected state and the connecting terminals.

[0012] Figure 5 It is a side cross-sectional view of the insert and socket used to illustrate the structure of the insert and socket.

[0013] Figure 6 This is a 3D view of a socket cut in the center.

[0014] Figure 7 It is a 3D view of the terminals before they are connected.

[0015] Figure 8 It is a 3D view of the connection between the terminals.

[0016] Figure 9 It is a 3D view of the connecting terminals in the connected state.

[0017] Figure 10 It is a side cross-sectional view of the connection between the plug and the socket.

[0018] Figure 11 It is a side cross-sectional view of the plug and socket in the connected state. Detailed Implementation

[0019] Examples of embodiments related to this disclosure will now be described with reference to the accompanying drawings.

[0020] Figure 1 It is a perspective view including the power supply unit, junction box, and wiring harness according to the embodiment of the electrical connection structure. Figure 2 It is a three-dimensional view of a power supply unit assembled with a junction box and wiring harness.

[0021] like Figure 1 and Figure 2 As shown, the electrical connection structure according to the embodiment is a connection structure that electrically connects the connection object to the power supply unit (first unit) 10. In this embodiment, the power supply unit 10 is, for example, a DC / DC converter to be installed in a vehicle such as an automobile. The junction box (second unit) 30 and the wiring harness (third unit) 40 are connected to the power supply unit 10 as connection objects.

[0022] The power supply unit 10 has a housing 11. A power supply circuit is built into the housing 11. The housing 11 includes an outer shell 12 and a cover 13, and is mounted such that the cover 13 covers the upper part of the outer shell 12.

[0023] The power supply unit 10 includes a terminal block 15. The terminal block 15 is assembled to the housing 12 of the housing 11. The terminal block 15 has a plurality of (three in this embodiment) connection portions 16, and terminals 20 are respectively disposed in the connection portions 16. These terminals 20 are connected to a circuit board (not shown) disposed in the housing 11.

[0024] Junction box 30 includes a housing 31. Circuit board 32 is housed within housing 31. Junction box 30 includes a connection terminal section 33. Multiple (three in this embodiment) connection terminals 50 are housed in the connection terminal section 33. These connection terminals 50 are electrically connected to the circuit board 32 housed within housing 31.

[0025] Junction box 30 is installed from above to power supply unit 10 (see Figure 2 When the junction box 30 is installed into the power supply unit 10, the connecting terminal part 33 is assembled into the terminal block 15 of the power supply unit 10. Therefore, the connecting terminal 50 of the junction box 30 is electrically connected to the terminal 20 provided on the terminal block 15 of the power supply unit 10.

[0026] A locking structure (not shown), such as a snap-fit ​​structure, is provided between the housing 11 of the power supply unit 10 and the housing 31 of the junction box 30. Therefore, when the junction box 30 is installed to the power supply unit 10, the housing 31 of the junction box 30 is locked to the housing 11 of the power supply unit 10, maintaining the electrical connection between the connection terminals 50 in the housing 31 and the terminals 20 of the terminal block 15 of the power supply unit 10. With the junction box 30 installed to the power supply unit 10, the housing 31 of the junction box 30 can be threaded onto the housing 11 of the power supply unit 10.

[0027] The wiring harness 40 includes wires 41 formed by multiple (three in this embodiment) power lines. Each wire 41 is an insulated wire, wherein the outer periphery of the conductor 42 is covered by a sheath 43 made of insulating resin. A housing 44 is assembled to the ends of the wires 41. Multiple (three in this embodiment) connecting terminals 50 are housed in the housing 44. The exposed conductors 42 at the ends of the wires 41 are connected to these connecting terminals 50 by, for example, welding or ultrasonic bonding.

[0028] like Figure 2 As shown, the housing 44 of the wiring harness 40 is mounted to the power supply unit 10 from above. When the housing 44 of the wiring harness 40 is mounted to the power supply unit 10, the connection terminal 50 in the housing 44 is electrically connected to the terminal 20 provided on the terminal block 15 of the power supply unit 10.

[0029] A locking structure (not shown), such as a snap-fit ​​structure, is also provided between the housing 11 of the power supply unit 10 and the housing 44 of the wiring harness 40. Therefore, when the housing 44 of the wiring harness 40 is installed to the power supply unit 10, the housing 44 of the wiring harness 40 is locked to the housing 11 of the power supply unit 10, and the electrical connection between the connection terminal 50 in the housing 44 and the terminal 20 of the terminal block 15 of the power supply unit 10 is maintained. With the housing 44 of the wiring harness 40 installed to the power supply unit 10, the housing 44 of the wiring harness 40 can be threaded to the housing 11 of the power supply unit 10.

[0030] Figure 3 and Figure 4 This is a view showing the structure of the terminals and connecting terminals. Specifically, Figure 3 It is a 3D view showing the terminals and connecting terminals in an unconnected state, and Figure 4 This is a 3D view showing the terminals and connecting terminals in a connected state. (Refer to...) Figure 3 and Figure 4 Describe terminal 20 and connection terminal 50.

[0031] like Figure 3 and Figure 4 As shown, terminal 20 is made of a conductive metal plate, such as copper or a copper alloy, and is formed by stamping. Terminal 20 includes a body portion 21, a pair of legs 22, and a pair of inserts 23.

[0032] The main body 21 is formed in the shape of a plate. Legs 22 are formed on the left and right sides of the main body 21, and inserts 23 are formed on the front and rear sides of the main body 21.

[0033] The legs 22 bend downward at the left and right edges of the main body 21, and a plurality of downwardly protruding pins 25 are formed at the ends of the legs 22. The pins 25 formed in each leg 22 are inserted into and fixed into through holes (not shown) formed in a circuit board, which is housed in the housing 11 of the power supply unit 10. The pins 25 of each leg 22 are soldered and electrically connected to the conductor pattern of the circuit board.

[0034] The insert 23 bends upward and extends at the front and rear edges of the main body 21 in the opposite direction to the leg 22. Each insert 23 has a tapered surface 26 on both sides of its end, which gradually slopes towards the center in the thickness direction as it extends toward the end.

[0035] Each connection terminal 50 includes a connecting plate 51 and a socket 52. The connecting plate 51 is made of a conductive metal plate, such as copper or a copper alloy, and an insertion hole 54 for inserting a screw 53 is formed in the end of the connecting plate 51. The socket 52 is made of a conductive metal material, such as copper or a copper alloy, and is formed in a block shape. A screw hole (not shown) is formed in the upper part of the socket 52, and a bolt 53 inserted into the insertion hole 54 of the connecting plate 51 is screwed into the screw hole. Therefore, the socket 52 is fastened and fixed to the end of the connecting plate 51 by the screw 53 and is electrically connected to the end of the connecting plate 51.

[0036] In junction box 30, connecting plate 51 is fixed to circuit board 32 housed in housing 31, such that connecting terminal 50 is electrically connected to conductor pattern of circuit board 32. In wire harness 40, connecting plate 51 is coupled to conductor 42 of wire 41, such that connecting terminal 50 is electrically connected to conductor 42 of wire 41.

[0037] Figure 5 It is a side cross-sectional view of the insert and socket used to illustrate the structure of the insert and socket. Figure 6 This is a 3D view of a socket cut in the center.

[0038] like Figure 5 As shown, the socket 52 has a connecting groove 61. The connecting groove 61 opens on the side of the socket 52 opposite to the side fixed to the connecting plate 51, and has a groove width slightly larger than the thickness of the prong 23 of the terminal 20. The prong 23 of the terminal 20 is inserted between the opposing inner surfaces 62 of the connecting groove 61 of the socket 52. On the opposing inner surfaces 62 of the connecting groove 61, a guide surface 63 is formed at the opening end of the connecting groove 61, which gradually slopes outward as it extends toward the end.

[0039] like Figure 6 As shown, the socket 52 has a plurality of resilient contacts 70. These resilient contacts 70 are formed by shaping spring steel into a rod shape, and a plurality of (four in this embodiment) resilient contacts 70 are fitted to the respective inner surfaces 62 of the connecting groove 61.

[0040] Mounting recesses 65 are formed in the inner surfaces 62 of the connecting groove 61, and resilient contacts 70 are arranged and mounted in the mounting recesses 65 along the insertion / removal direction of the insert 23 relative to the connecting groove 61. Locking grooves 66 are formed in the corners between the bottom and side surfaces of the mounting recesses 65, and the resilient contacts 70 are arranged in parallel in the mounting recesses 65 with both ends locked into the locking grooves 66. The resilient contacts 70 mounted to the mounting recesses 65 bulge toward the center of the connecting groove 61.

[0041] Next, taking the case where the junction box 30 is connected to the terminal block 15 of the power supply unit 10 as an example, the connection between the terminal 20 and the connecting terminal 50 will be explained.

[0042] Figures 7 to 9 This is a view illustrating a method of connecting the connection terminals to the terminals. Specifically, Figure 7 This is a 3D view of the terminals before they are connected. Figure 8 It is a 3D diagram of its connection, and Figure 9 It is a 3D diagram of its connection state. Figure 10 and Figure 11 This is a view illustrating the connection process between the plug and the socket. Specifically, Figure 10 It is a side cross-sectional view of the connection between the plug and the socket, and Figure 11 This is a side cross-sectional view of its connected state. The diagram above shows... Figure 5 A side cross-sectional view corresponding to the connection between the plug and the socket.

[0043] like Figure 7 As shown, the connection terminal portion 33 of the junction box 30 is positioned above the terminal block 15 of the power supply unit 10. Therefore, as Figure 5 As shown, the socket 52 of the connecting terminal 50 of the connecting terminal part 33 is arranged above the corresponding insert 23 of the terminal 20 of the terminal block 15.

[0044] like Figure 8 As shown, the junction box 30 is positioned downwards relative to the power supply unit 10. Figure 7 Move in the direction of arrow A in the diagram. Therefore, as... Figure 10 As shown, the end portion of the insert 23 of terminal 20 enters the connection groove 61 of the socket 52 connecting terminal 50. Here, the end of the insert 23 has a tapered surface 26 that gradually slopes towards the center in the thickness direction as it extends towards the end, and the socket 52 has a guide surface 63 at the opening end of the connection groove 61 that gradually slopes outward as it extends towards the end. Therefore, the tapered surface 26 is guided by the guide surface 63, so that the insert 23 is smoothly guided into the connection groove 61 of the socket 52.

[0045] like Figure 9 As shown, it is pushed downward relative to the power supply unit 10 (along) Figure 8 (The direction of arrow B in the diagram) Junction box 30 is fully fitted. Therefore, as... Figure 11As shown, the insert 23 of terminal 20 is inserted into the connecting groove 61 of the socket 52 of connecting terminal 50. Therefore, a plurality of elastic contacts 70, provided on the inner surface of the connecting groove 61 and bulging towards the center of the connecting groove 61, are pressed outward and elastically deformed, causing these elastic contacts 70 to elastically contact the two surfaces of the insert 23. Thus, the insert 23 and the socket 52 are electrically connected to each other through the plurality of elastic contacts 70, and terminal 20 and connecting terminal 50 are electrically connected to each other.

[0046] As described above, according to the electrical connection structure of this embodiment, when the junction box 30 is installed to the power supply unit 10, the insert 23 of the terminal 20 of the power supply unit 10 is inserted into the connection slot 61 of the socket 52 provided in the connection terminal 50 of the junction box 30. Then, the plurality of elastic contacts 70 of the socket 52 make elastic contact with the two surfaces of the insert 23. Therefore, the terminal 20 of the power supply unit 10 and the connection terminal 50 of the junction box 30 can be easily electrically connected to each other with a small insertion force, without the need for time-consuming and laborious tightening operations or torque management. Furthermore, since the plurality of elastic contacts 70 are in contact with the two surfaces of the insert 23, a large current can flow through the connection while reducing contact resistance.

[0047] The connection terminal 50 on the wire 41 of the wiring harness 40 can also be connected to the terminal 20 of the power supply unit 10. Thus, by connecting the connection terminal 50 of the wire 41 of the wiring harness 40 to the terminal 20 of the power supply unit 10, the insert 23 of the terminal 20 of the power supply unit 10 is inserted into the connection slot 61 of the socket 52 provided in the connection terminal 50 of the wire 41. Then, the plurality of elastic contacts 70 of the socket 52 make elastic contact with the two surfaces of the insert 23. Therefore, the terminal 20 of the power supply unit 10 and the connection terminal 50 of the wire 41 of the wiring harness 40 can be easily electrically connected to each other with a small insertion force, without the need for time-consuming and laborious tightening operations or torque management.

[0048] As described above, since the terminal 20 of the power supply unit 10 includes a pair of plugs 23, the connection terminals 50 of both the junction box 30 and the wire 41 can be connected to the pair of plugs 23 of the power supply unit 10.

[0049] The elastic contact 70 provided in the socket 52 can be a blade type formed as a wide curved plate, or a comb type in which multiple slits are formed in the wide curved plate portion, etc.

[0050] This invention is not limited to the above embodiments, and can be appropriately modified and improved. Furthermore, the material, shape, size, quantity, and arrangement of the components in the above embodiments are arbitrary and are not limited as long as they achieve the purpose of this disclosure.

[0051] According to a first aspect of this disclosure, an electrical connection structure includes: a first unit (power supply unit 10) including a terminal (20); and a second unit (junction box 30) including a connection terminal (50). The electrical connection structure is configured such that the second unit (30) is mounted to the first unit (10) such that the connection terminal (50) is electrically connected to the terminal (20). The terminal (20) has a plate-shaped insert (23). The connection terminal (50) includes a socket (52) and a resilient contact (70), the socket (52) forming a connection groove (61) into which the insert (23) is inserted, and the resilient contact (70) is disposed on an inner surface (62) of the connection groove (61). The resilient contact (70) makes resilient contact with the outer surface of the insert (23) inserted into the connection groove (61).

[0052] According to the electrical connection structure having the first aspect of its construction, when the second unit is installed onto the first unit, the prongs of the terminals of the first unit are inserted into the connection slots of the socket provided in the connection terminals of the second unit. Thus, multiple resilient contacts of the socket make resilient contact with the two surfaces of the prongs. Therefore, the terminals of the first unit and the connection terminals of the second unit can be easily electrically connected to each other with a small insertion force, without the need for time-consuming and laborious tightening operations or torque management. Furthermore, since multiple resilient contacts are in contact with the two surfaces of the prongs, a large current can flow through the connection while reducing contact resistance.

[0053] According to a second aspect of this disclosure, the third unit (wire harness 40) includes a wire (41) and a connecting terminal (50) disposed at the end of the wire (41). The connecting terminal (50) of the third unit (40) is connected to the terminal (20) of the first unit (power supply unit 10) such that the resilient contact (70) of the socket (52) makes resilient contact with the outer surface of the insert (23).

[0054] According to the electrical connection structure having the second aspect of its construction, when the connecting terminal provided on the wire of the wire harness is connected to the terminal of the first unit, the insert of the terminal of the first unit is inserted into the connecting groove of the socket provided on the connecting terminal of the wire. Thus, the multiple elastic contacts of the socket make elastic contact with the two surfaces of the insert. Therefore, the connecting terminal of the wire harness can be easily electrically connected to the terminal of the first unit with a small insertion force, without the need for time-consuming and laborious tightening operations or torque management.

[0055] According to a third aspect of this disclosure, the terminal (20) includes a pair of tabs (23). The connection terminal (50) of the second unit (junction box 30) is connected to one of the pair of tabs (23), and the connection terminal (50) of the third unit (wire harness 40) is connected to the other of the pair of tabs (23).

[0056] According to the electrical connection structure with the third aspect, the connection terminals of both the second unit and the wire can be connected to a pair of inserts of the terminals of the first unit.

[0057] According to this disclosure, an electrical connection structure that can easily connect units to each other can be provided.

Claims

1. An electrical connection structure, comprising: A first unit, the first unit including terminals; as well as The second unit includes a first connection terminal. The third unit includes a wire and a second connecting terminal disposed at the end of the wire. The electrical connection structure is configured such that by mounting the second unit to the first unit, the first connection terminal and the second connection terminal are respectively electrically connected to the terminal. The terminal includes a main body, a pair of legs, and a pair of plate-shaped inserts, wherein the inserts are curved upward and extend upward at the front and rear edges of the main body in a direction opposite to that of the legs. The first connecting terminal includes a first socket and a first resilient contact. The first socket has a first connecting groove for inserting one of the pair of prongs, and the first resilient contact is disposed on the inner surface of the first connecting groove. The second connection terminal includes a second socket and a second resilient contact. The second socket has a second connection groove for inserting the other of the pair of prongs, and the second resilient contact is disposed on the inner surface of the second connection groove. Wherein, the first elastic contact of the first connecting terminal of the second unit makes elastic contact with the outer surface of the outer surface of one of the pair of inserts inserted into the first connecting groove, and The second elastic contact of the second connecting terminal of the third unit makes elastic contact with the outer surface of the other insert of the pair of inserts inserted into the second connecting groove.

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