Method of manufacturing an electrical product and electrical product

Abstract

A manufacturing method of an electrical product having an electrical component (370), a first power supply portion (322) and a second power supply portion (312) fixed to the electrical component and extending in a direction, and an insulating plate (340) disposed between the first power supply portion and the second power supply portion in an orthogonal direction orthogonal to the direction, a fixing hole (325) extending in the orthogonal direction being formed in the first power supply portion, a protruding portion (345) inserted into the fixing hole being formed in the insulating plate, in the manufacturing method of the electrical product, a jig (1000) formed with a fixed hole (1005) recessed in the orthogonal direction and having rigidity higher than that of the protruding portion is prepared, the first power supply portion is disposed in the jig so that the fixing hole is aligned with the fixed hole in the orthogonal direction, the insulating plate is disposed on the first power supply portion by passing the protruding portion through the fixing hole and the fixed hole, respectively, and the second power supply portion is disposed on the insulating plate, and the insulating plate is sandwiched between the first power supply portion and the second power supply portion by fixing the first power supply portion and the second power supply portion to the electrical component.

Description

[0001] Reference to Related Applications

[0002] This application is based on Patent Application No. 2020-170638 filed in Japan on October 8, 2020, the entire contents of which are hereby incorporated by reference. TECHNICAL FIELD

[0003] The disclosure described in this specification relates to a manufacturing method of an electrical product and an electrical product. BACKGROUND

[0004] In Patent Literature 1, a case-molding type capacitor having a capacitor element, a pair of bus bars, and an insulating plate is described. The pair of bus bars each has an overlapping portion that overlaps the insulating plate.

[0005] Prior Art Documents

[0006] Patent Literature

[0007] Patent Literature 1: Japanese Patent No. 5391797 SUMMARY

[0008] The insulating plate is formed of resin or rubber. Therefore, the insulating plate is easily deformed by shrinkage or the like. Along with this, it is possible that a positional shift occurs at the overlapping portion. In addition, it is possible that a positional shift of the case-molding type capacitor and an external device occurs.

[0009] An object of the present disclosure is to provide a manufacturing method of an electrical product and an electrical product that easily suppresses occurrence of a positional shift between two constituent elements.

[0010] One embodiment of the present disclosure relates to a manufacturing method of an electrical product, the electrical product having:

[0011] an electrical component;

[0012] a first power supply portion and a second power supply portion fixed to the electrical component and extending in a direction;

[0013] an insulating plate disposed between the first power supply portion and the second power supply portion in an orthogonal direction orthogonal to the direction,

[0014] a fixing hole formed in the first power supply portion, the fixing hole penetrating a surface side of the first power supply portion and a back surface side of the first power supply upper surface in the orthogonal direction,

[0015] a protruding portion inserted into the fixing hole is formed in the insulating plate, in the manufacturing method of the electrical product,

[0016] a jig having a fixing hole formed on the upper surface and recessed locally in the orthogonal direction,

[0017] a first power supply portion is provided on the upper surface of the jig so that the fixing hole is arranged in the orthogonal direction with respect to the fixed hole,

[0018] an insulating plate is provided on the first power supply portion by passing the protrusion through the fixing hole and the fixed hole,

[0019] a second power supply portion is provided on the insulating plate provided on the first power supply portion,

[0020] the insulating plate is sandwiched between the first power supply portion and the second power supply portion by fixing the first power supply portion and the second power supply portion to the electrical component.

[0021] In addition, an electrical product of one embodiment of the present disclosure is housed in a housing together with a switch component including a plurality of switches, in which the electrical product has:

[0022] an electrical component;

[0023] a first power supply portion and a second power supply portion that connect the electrical component and the switch component and extend in a direction; and

[0024] an insulating plate that is provided between the first power supply portion and the second power supply portion in an orthogonal direction orthogonal to the direction,

[0025] the first power supply portion has a fixing hole formed therein, the fixing hole penetrating a first power supply upper surface on a surface side of the first power supply portion and a first power supply lower surface on a back surface side of the first power supply upper surface in the orthogonal direction,

[0026] the insulating plate has a protrusion portion formed thereon, the protrusion portion extending in the orthogonal direction and being inserted into the fixing hole,

[0027] a front end of the protrusion portion passes through the fixing hole and is inserted into a fixed insertion hole formed in the housing and recessed in the orthogonal direction.

[0028] Thus, generation of positional displacement between two constituent elements can be suppressed. For example, relative positional displacement of the first power supply portion and the second power supply portion can be suppressed. Relative positional displacement of the switch component and the electrical product can be suppressed.

[0029] In addition, the reference numerals in parentheses only indicate a correspondence relationship with the structures described in the embodiments described below, and do not limit the technical scope. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 is a circuit diagram for explaining a vehicle-mounted system.

[0031] Figure 2is a plan view for explaining a manufacturing method of an electrical product.

[0032] Figure 3 is a sectional view for explaining a manufacturing method of an electrical product.

[0033] Figure 4 is a sectional view for explaining a manufacturing method of an electrical product.

[0034] Figure 5 is a sectional view for explaining a manufacturing method of an electrical product.

[0035] Figure 6 is a sectional view for explaining a manufacturing method of an electrical product. Figure 2 along the line VII-VII shown in FIG. 7.

[0036] Figure 7 is a sectional view for explaining a manufacturing method of an electrical product. Figure 2 along the line VII-VII shown in FIG. 7.

[0037] Figure 8 is a sectional view for explaining a manufacturing method of an electrical product.

[0038] Figure 9 is a plan view for explaining a manufacturing method of an electrical product.

[0039] Figure 10 is a sectional view for explaining a manufacturing method of an electrical product. Figure 9 along the line X-X shown in FIG. 8.

[0040] Figure 11 is a plan view for explaining an electrical device.

[0041] Figure 12 is a sectional view of an electrical device. Figure 11 along the line XII-XII shown in FIG. 9. DETAILED DESCRIPTION

[0042] Hereinafter, a plurality of modes for carrying out the present disclosure will be explained with reference to the drawings. In each mode, a same reference numeral is sometimes attached to a portion corresponding to a matter explained in a previous mode, and a repeated explanation is omitted. In a case where only a part of a structure is explained in each mode, other modes explained previously can be applied to other portions of the structure.

[0043] In addition, not only a combination between portions capable of being combined which are explicitly recited in each embodiment, but also embodiments can be combined with each other, embodiments and modified examples, and modified examples and each other partially, as long as a particular hindrance is not caused to the combination, even if not explicitly recited.

[0044] (First Embodiment)

[0045] First, based on Figure 1 , an in-vehicle system 100 provided with an electric device 300 including an electric product 301 will be described. The in-vehicle system 100 constitutes a system for an electric automobile. The in-vehicle system 100 has a battery 200, the electric device 300, a motor 400, and a substrate not shown.

[0046] A plurality of ECUs are mounted on the substrate. The plurality of ECUs transmit and receive signals to and from each other via a bus line. The plurality of ECUs cooperate to control the electric automobile. By the control of the plurality of ECUs, regenerative and motoring of the motor 400 corresponding to the SOC of the battery 200 is controlled. The SOC is an abbreviation of state of charge. The ECU is an abbreviation of electronic control unit.

[0047] The battery 200 has a plurality of secondary batteries. The plurality of secondary batteries constitute a battery pack connected in series. The SOC of the battery pack corresponds to the SOC of the battery 200. As the secondary battery, a lithium ion secondary battery, a nickel-hydrogen secondary battery, and an organic radical battery, etc. can be used.

[0048] < Electric Device >

[0049] The electric device 300 performs power conversion between the battery 200 and the motor 400 as an inverter. The electric device 300 converts direct-current power of the battery 200 into alternating-current power. The electric device 300 converts alternating-current power generated by power generation (regeneration) of the motor 400 into direct-current power.

[0050] The motor 400 is coupled to an output shaft of an electric automobile not shown. Rotational energy of the motor 400 is transmitted to a running wheel of the electric automobile via the output shaft. Conversely, rotational energy of the running wheel is transmitted to the motor 400 via the output shaft.

[0051] The motor 400 performs motoring by alternating-current power supplied from the electric device 300. Thereby, propulsive force is applied to the running wheel. In addition, the motor 400 regenerates by rotational energy transmitted from the running wheel. Alternating-current power generated by the regeneration is converted into direct-current power by the electric device 300. The direct-current power is supplied to the battery 200. In addition, the direct-current power is also supplied to various electric loads mounted on the electric automobile.

[0052] The electric device 300 includes semiconductor elements such as switches described later. In the present embodiment, an n-channel type IGBT is used as the switch. However, as the switches, MOSFETs can be used instead of IGBTs. In the case where MOSFETs are used as the switches, diodes can not be used.

[0053] These switches can be manufactured from a semiconductor such as Si and a wide bandgap semiconductor such as SiC. There is no particular limitation on the constituent material of the semiconductor element.

[0054] <Electrical connection of electrical equipment>

[0055] The electrical equipment 300 has an electrical product 301 connected to the battery 200 via a first power supply bus 310 and a second power supply bus 320, and a U-phase bridge branch 361, a V-phase bridge branch 362, and a W-phase bridge branch 363 connected to the electrical product 301. The electrical product 301 has the first power supply bus 310, the second power supply bus 320, and a capacitor 370.

[0056] In addition, in Figure 1 , for convenience of description, a part of the first power supply bus 310 and a part of the second power supply bus 320 are described in a frame indicating the electrical product 301, but the electrical product 301 has all of the first power supply bus 310 and all of the second power supply bus 320. The capacitor 370 corresponds to an electrical component.

[0057] The first power supply bus 310 is connected to the positive electrode of the battery 200. The second power supply bus 320 is connected to the negative electrode of the battery 200. The capacitor 370 and the U-phase bridge branch 361 to the W-phase bridge branch 363 are respectively connected between the first power supply bus 310 and the second power supply bus 320.

[0058] The capacitor 370 has two electrodes. One of the two electrodes is connected to the first power supply bus 310. The other of the two electrodes is connected to the second power supply bus 320.

[0059] The U-phase bridge branch 361 to the W-phase bridge branch 363 respectively have two switches connected in series. As the switches, the U-phase bridge branch 361 to the W-phase bridge branch 363 respectively have a high-side switch 351 and a low-side switch 352. In addition, as diodes, the U-phase bridge branch 361 to the W-phase bridge branch 363 respectively have a high-side diode 351a and a low-side diode 352a. The high-side switch 351 and the low-side switch 352 respectively correspond to the switches.

[0060] As shown in Figure 1 , the collector of the high-side switch 351 is connected to the first power supply bus 310. The emitter of the high-side switch 351 is connected to the collector of the low-side switch 352. The emitter of the low-side switch 352 is connected to the second power supply bus 320. Thus, the high-side switch 351 and the low-side switch 352 are connected in series in this order from the first power supply bus 310 toward the second power supply bus 320.

[0061] In addition, the collector of each of the high-side switches 351 is connected to the cathode electrode of the high-side diode 351a. The emitter of each of the high-side switches 351 is connected to the anode electrode of the high-side diode 351a. Thus, the high-side diode 351a is connected in antiparallel with the high-side switch 351.

[0062] Likewise, the collector of each of the low-side switches 352 is connected to the cathode electrode of the low-side diode 352a. The emitter of each of the low-side switches 352 is connected to the anode electrode of the low-side diode 352a. Thus, the low-side diode 352a is connected in antiparallel with the low-side switch 352.

[0063] Furthermore, the U-phase bus 410 is connected at a midpoint between the high-side switch 351 and the low-side switch 352 included in the U-phase bridge arm 361. The U-phase bus 410 is connected to the U-phase stator coil of the motor 400.

[0064] The V-phase bus 420 is connected at a midpoint between the high-side switch 351 and the low-side switch 352 included in the V-phase bridge arm 362. The V-phase bus 420 is connected to the V-phase stator coil of the motor 400.

[0065] The W-phase bus 430 is connected at a midpoint between the high-side switch 351 and the low-side switch 352 included in the W-phase bridge arm 363. The W-phase bus 430 is connected to the W-phase stator coil of the motor 400.

[0066] In the case of motoring the motor 400, the high-side switches 351 and the low-side switches 352 included in the U-phase bridge arm 361 to the W-phase bridge arm 363 are subjected to PWM control by a control signal from the ECU. Thus, three-phase alternating current is generated in the electric device 300. In the case of power generation (regeneration) by the motor 400, the ECU stops output of the control signal, for example. As a result, alternating current generated by power generation by the motor 400 passes through the diodes included in the U-phase bridge arm 361 to the W-phase bridge arm 363. As a result, the alternating current is converted into direct current.

[0067] Mechanical Structure of Electrical Product

[0068] Next, the mechanical structure of the electrical product 301 will be described. At this time, three directions in which the directions are orthogonal to each other are assumed to be an x direction, a y direction, and a z direction. The x direction corresponds to the arrangement direction. The y direction corresponds to the one direction. The z direction corresponds to the orthogonal direction. In addition, the description of "direction" is omitted in the drawings. In addition, the battery 200 is abbreviated as "BATT" in the drawings.

[0069] As the constituent elements explained so far, the electrical product 301 has the first power supply bus 310, the second power supply bus 320, and the capacitor 370. The electrical product 301 has the insulating board 340 and the capacitor case 371 in addition to the above-mentioned constituent elements. Further, as shown in Figure 7 and Figure 8 The capacitor 370 is formed in a substantially rectangular parallelepiped shape.

[0070] <First Power Supply Bus>

[0071] The first power supply bus 310 has a first conductive site 311 connecting the battery 200 and the capacitor 370, and second conductive sites 312 connecting the capacitor 370 and the U-phase bridge branch 361 to the W-phase bridge branch 363, respectively. The second conductive site 312 corresponds to a second power supply part.

[0072] As shown in Figures 6-8 , the second conductive site 312 is formed in a flat shape with a small thickness in the z-direction. The second conductive site 312 has a first bus upper surface 312a aligned in the z-direction and a first bus lower surface 312b on the back side thereof. Further, as shown in Figures 6-8 , a positioning hole 313 is formed in the second conductive site 312, which is opened in a cylindrical shape on the first bus upper surface 312a and the first bus lower surface 312b. Further, the description of the first conductive site 311 is omitted in Figures 2-8 . Further, the first bus upper surface 312a corresponds to a second power supply upper surface. The first bus lower surface 312b corresponds to a second power supply lower surface.

[0073] <Second Power Supply Bus>

[0074] Similarly, the second power supply bus 320 has a third conductive site 321 connecting the battery 200 and the capacitor 370, and fourth conductive sites 322 connecting the capacitor 370 and the U-phase bridge branch 361 to the W-phase bridge branch 363, respectively. The fourth conductive site 322 corresponds to a first power supply part.

[0075] As shown in Figures 3-8 , the fourth conductive site 322 is formed in a flat shape with a small thickness in the z-direction. The fourth conductive site 322 has a second bus upper surface 322a aligned in the z-direction and a second bus lower surface 322b on the back side thereof. Further, as shown in Figure 6 and Figure 7 , a first fixing hole 323 and a second fixing hole 324 are formed in the fourth conductive site 322, which are opened in a cylindrical shape on the second bus upper surface 322a and the second bus lower surface 322b. Further, the second bus upper surface 322a corresponds to a first power supply upper surface. The second bus lower surface 322b corresponds to a first power supply lower surface.

[0076] As Figures 3-8 shown, the first fixed hole 323 and the second fixed hole 324 are arranged apart in the x direction. In addition, the third conductive site 321 is omitted in Figures 2-7 the description.

[0077] <Capacitor case>

[0078] The capacitor case 371 is a frame for housing the capacitor 370. As Figure 8 shown, the capacitor case 371 has a case lower portion 372 and a case upper portion 373 arranged in the z direction, and a case connecting portion 374 connecting them. The capacitor 370 is housed in a case space divided by these case lower portion 372, case upper portion 373, and case connecting portion 374. One of the two electrodes included in the capacitor 370 is connected to the second conductive site 312. The other of the two electrodes included in the capacitor 370 is connected to the fourth conductive site 322. In addition, the capacitor case 371 corresponds to the electrical component case.

[0079] <Insulating plate>

[0080] As Figures 4-8 shown, the insulating plate 340 is formed in a flat shape with a small thickness in the z direction. The insulating plate 340 is formed of resin. The insulating plate 340 is provided between the second conductive site 312 and the fourth conductive site 322, and functions to impede the passage of electricity between the second conductive site 312 and the fourth conductive site 322.

[0081] The insulating plate 340 has an insulating plate upper surface 340a and an insulating plate lower surface 340b on the back surface side thereof, arranged in the z direction. In addition, the insulating plate 340 has a first protruding portion 341 and a second protruding portion 342 in the shape of a cylinder extending in the z direction away from the insulating plate lower surface 340b.

[0082] As Figures 4-8 shown, the first protruding portion 341 and the second protruding portion 342 are arranged apart in the x direction. In addition, the first protruding portion 341 and the second protruding portion 342 can not be connected to the insulating plate 340. The first protruding portion 341 and the second protruding portion 342 can be separate from the insulating plate 340. It is sufficient that the first protruding portion 341 and the second protruding portion 342 are connected to the insulating plate 340.

[0083] The portion of the insulating plate 340 in which the first and second protruding portions 341 and 342 are formed is thicker in the z direction than the portion of the insulating plate 340 in which the first and second protruding portions 341 and 342 are not formed. Therefore, the portion of the insulating plate 340 in which the first and second protruding portions 341 and 342 are formed is more likely to store heat than the portion of the insulating plate 340 in which the first and second protruding portions 341 and 342 are not formed. The insulating plate 340 is likely to store heat locally.

[0084] To release this stored heat, a first recessed portion 343 that is recessed in a cylindrical shape from the upper surface 340a of the insulating plate toward the lower surface 340b is intentionally formed in the projected area of the first protruding portion 341 in the z direction of the insulating plate 340. Similarly, a second recessed portion 344 that is recessed in a cylindrical shape from the upper surface 340a of the insulating plate toward the lower surface 340b is intentionally formed in the projected area of the second protruding portion 342 in the z direction of the insulating plate 340. The first recessed portion 343 corresponds to the recessed portion.

[0085] In addition, the first recessed portion 343 can not be formed in the projected area of the first protruding portion 341 in the z direction of the insulating plate 340. Similarly, the second recessed portion 344 can not be formed in the projected area of the second protruding portion 342 in the z direction of the insulating plate 340.

[0086] In addition, the first recessed portion 343 has the same extension length in the x and y directions as the positioning hole 313.

[0087]

[0088] Based on Figures 2-8 A method of manufacturing the electrical product 301 will be described.

[0089] First, a jig 1000 that restricts the positions of the fourth conductive portions 322 in the x and y directions is prepared.

[0090] The jig 1000 is formed of a material having high rigidity such as metal. In addition, the jig 1000 has higher rigidity than the first and second protruding portions 341 and 342 described above.

[0091] The jig 1000 is formed in a substantially rectangular parallelepiped shape. The jig 1000 has an upper surface 1000a and a lower surface 1000b arranged apart in the z direction and a connecting surface 1001 that connects them.

[0092] As Figure 2 ​As shown, the connecting surface 1001 includes a first connecting surface 1001a and a third connecting surface 1001c spaced apart in the x-direction, and a second connecting surface 1001b and a fourth connecting surface 1001d spaced apart in the y-direction. The first connecting surface 1001a, the second connecting surface 1001b, the third connecting surface 1001c, and the fourth connecting surface 1001d are connected in a clockwise annular shape along a circumference around the z-direction.

[0093] like Figure 2 As shown, a through hole 1002 is formed on the second connecting surface 1001b side of the clamp 1000, penetrating the lower surface 1000b and the upper surface 1000a. Figure 3 As shown, a first fixed hole 1003 and a second fixed hole 1004 are formed on the upper surface 1000a of the clamp 1000, which is located closer to the fourth connecting surface 1001d than the through hole 1002, and are recessed toward the lower surface 1000b.

[0094] like Figures 3-8 As shown, the first fixed hole 1003 is provided on the first connecting surface 1001a side. The second fixed hole 1004 is provided on the third connecting surface 1001c side. The first fixed hole 1003 and the second fixed hole 1004 are arranged separately in the x direction.

[0095] Furthermore, the extension lengths of the first fixed hole 1003 in the x and y directions are equal to the extension lengths of the first fixing hole 323. The extension lengths of the second fixed hole 1004 in the x and y directions are equal to the extension lengths of the second fixing hole 324.

[0096] For ease of description, the first fixing hole 323 and the second fixing hole 324 are collectively referred to as fixing holes 325. The first fixed hole 1003 and the second fixed hole 1004 are collectively referred to as fixed holes 1005. The first protrusion 341 and the second protrusion 342 are collectively referred to as protrusions 345.

[0097] Then, if Figure 3 As shown, the fourth conductive portion 322 is disposed on the upper surface 1000a of the jig 1000 such that the fixing hole 325 communicates with the fixed hole 1005 in the z-direction. Specifically, the fourth conductive portion 322 is disposed on the upper surface 1000a of the jig 1000 such that the first fixing hole 323 communicates with the first fixed hole 1003 in the z-direction. The fourth conductive portion 322 is disposed on the upper surface 1000a of the jig 1000 such that the second fixing hole 324 communicates with the second fixed hole 1004 in the z-direction.

[0098] In addition, if Figure 5As shown, the fourth conductive site 322 extends in the y direction from the fourth connecting surface 1001d toward the end portion of the fourth connecting surface 1001d side of the through-hole 1002. Then, the fourth conductive site 322 extends in the z direction toward the lower surface 1000b along the wall surface that forms the through-hole 1002. The fourth conductive site 322 that extends along the lower surface 1000b extends in the y direction toward the second connecting surface 1001b in the hollow of the through-hole 1002.

[0099] Next, as shown in FIG. 12, the insulating plate 340 is arranged on the second bus upper surface 322a of the fourth conductive site 322 in such a manner that the protruding portions 345 pass through the fixing holes 325 and the fixed holes 1005, respectively. Specifically, the insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the first protruding portions 341 pass through the first fixing holes 323 and the first fixed holes 1003, respectively. The insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the second protruding portions 342 pass through the second fixing holes 324 and the second fixed holes 1004, respectively. Thus, the position of the fourth conductive site 322 with respect to the x direction and the y direction of the jig 1000 is restricted. Figure 4 In addition, as described above, the rigidity of the jig 1000 is higher than that of the protruding portions 345. By inserting the protruding portions 345 into the fixed holes 1005, the x direction, the y direction, and the z direction of the insulating plate 340 are corrected.

[0100] Next, as shown in FIG. 12, the insulating plate 340 is arranged on the second bus upper surface 322a of the fourth conductive site 322 in such a manner that the protruding portions 345 pass through the fixing holes 325 and the fixed holes 1005, respectively. Specifically, the insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the first protruding portions 341 pass through the first fixing holes 323 and the first fixed holes 1003, respectively. The insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the second protruding portions 342 pass through the second fixing holes 324 and the second fixed holes 1004, respectively. Thus, the position of the fourth conductive site 322 with respect to the x direction and the y direction of the jig 1000 is restricted.

[0101] Figure 5 Next, as shown in FIG. 12, the insulating plate 340 is arranged on the second bus upper surface 322a of the fourth conductive site 322 in such a manner that the protruding portions 345 pass through the fixing holes 325 and the fixed holes 1005, respectively. Specifically, the insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the first protruding portions 341 pass through the first fixing holes 323 and the first fixed holes 1003, respectively. The insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the second protruding portions 342 pass through the second fixing holes 324 and the second fixed holes 1004, respectively. Thus, the position of the fourth conductive site 322 with respect to the x direction and the y direction of the jig 1000 is restricted.

[0102] Next, as shown in FIG. 12, the insulating plate 340 is arranged on the second bus upper surface 322a of the fourth conductive site 322 in such a manner that the protruding portions 345 pass through the fixing holes 325 and the fixed holes 1005, respectively. Specifically, the insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the first protruding portions 341 pass through the first fixing holes 323 and the first fixed holes 1003, respectively. The insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the second protruding portions 342 pass through the second fixing holes 324 and the second fixed holes 1004, respectively. Thus, the position of the fourth conductive site 322 with respect to the x direction and the y direction of the jig 1000 is restricted. Figure 6 Next, as shown in FIG. 12, the insulating plate 340 is arranged on the second bus upper surface 322a of the fourth conductive site 322 in such a manner that the protruding portions 345 pass through the fixing holes 325 and the fixed holes 1005, respectively. Specifically, the insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the first protruding portions 341 pass through the first fixing holes 323 and the first fixed holes 1003, respectively. The insulating plate 340 is arranged on the second upper surface 320a of the fourth conductive site 322 in such a manner that the second protruding portions 342 pass through the second fixing holes 324 and the second fixed holes 1004, respectively. Thus, the position of the fourth conductive site 322 with respect to the x direction and the y direction of the jig 1000 is restricted.

[0103] ​Next, prepare a cylindrical positioning pin 1100 extending in the z-direction. Insert the positioning pin 1100 through the positioning hole 313 and the first recess 343, respectively. The extension lengths of the positioning pin 1100 in the x- and y-directions are equal to the extension lengths of the positioning hole 313 and the first recess 343, respectively. By inserting the positioning pin 1100 into the positioning hole 313 and the first recess 343, the position of the second conductive portion 312 relative to the insulating plate 340 in the x- and y-directions is restricted. The positioning pin 1100 acts as an auxiliary jig.

[0104] like Figure 7 As shown, the second conductive portion 312 extends in the y-direction from the fourth connecting surface 1001d toward the end of the through-hole 1002 on the fourth connecting surface 1001d side. The second conductive portion 312 then extends in the z-direction away from the upper surface 1000a along the side surface of the capacitor 370. The second conductive portion 312, extending in the z-direction away from the upper surface 1000a, extends in the y-direction toward one of the two electrodes included in the capacitor 370.

[0105] Next, the second conductive portion 312 and the fourth conductive portion 322 are fixed together using a clamp (not shown). In this state, one of the two electrodes of the capacitor 370 is connected to the second conductive portion 312 by welding or other means. Similarly, the other of the two electrodes of the capacitor 370 is connected to the fourth conductive portion 322 by welding or other means. Afterwards, the positioning pin 1100 is removed from the electrical product 301. The electrical product 301 is then removed from the fixture 1000.

[0106] The electrical product 301 removed from the jig 1000 is stored in the capacitor housing 371. Figure 8 As shown, capacitor 370, a portion of second conductive portion 312, a portion of fourth conductive portion 322, and a portion of insulating plate 340 are housed within capacitor case 371. A portion of second conductive portion 312, a portion of fourth conductive portion 322, and a portion of insulating plate 340 are exposed from capacitor case 371.

[0107] Finally, the capacitor case 371 is filled with a covering resin 375 and cured. This secures the capacitor 370, the second conductive portion 312, the fourth conductive portion 322, and the insulating plate 340 to the capacitor case 371. The insulating plate 340 is sandwiched between the second conductive portion 312 and the fourth conductive portion 322.

[0108] In addition, if Figure 8 As shown, the protrusion 345 formed on the insulating plate 340 is exposed from the fixing hole 325 formed in the fourth conductive portion 322 exposed from the capacitor case 371 .

[0109] <Structure of electrical equipment>

[0110] As the components described so far, the electric device 300 includes the electric product 301 and the U-phase bridge arm 361 to the W-phase bridge arm 363 .

[0111] like Figure 1 As shown, collector terminal 353 is connected to the collector of high-side switch 351 included in U-phase bridge branch 361 through W-phase bridge branch 363. Emitter terminal 354 is connected to the emitter of low-side switch 352 included in U-phase bridge branch 361 through W-phase bridge branch 363. A connection terminal (not shown) is connected to the midpoint between high-side switch 351 and low-side switch 352 included in U-phase bridge branch 361 through W-phase bridge branch 363. Gate terminals (not shown) are connected to the gate electrodes of high-side switch 351 and low-side switch 352 included in U-phase bridge branch 361 through W-phase bridge branch 363.

[0112] The U-phase bridge arm 361 to the W-phase bridge arm 363 , the collector terminal 353 , the emitter terminal 354 , and the connection terminal and gate terminal (not shown) are sealed with resin by the resin member 360 , thereby constituting a switch module 368 .

[0113] Furthermore, the electric device 300 includes a cooler 364 and a housing 380 in addition to the above-mentioned components.

[0114] Cooler

[0115] like Figure 11 As shown, cooler 364 includes a supply pipe 365, a discharge pipe 367, and a plurality of relay pipes 366. Supply pipe 365 and discharge pipe 367 are connected via the plurality of relay pipes 366. Refrigerant is supplied to supply pipe 365. Refrigerant flows from supply pipe 365 to discharge pipe 367 via the plurality of relay pipes 366.

[0116] The supply pipe 365 and the discharge pipe 367 extend in the x-direction. The supply pipe 365 and the discharge pipe 367 are spaced apart in the y-direction. A plurality of relay pipes 366 extend in the y-direction from the supply pipe 365 toward the discharge pipe 367. The plurality of relay pipes 366 are spaced apart in the x-direction.

[0117] A gap is formed between adjacent relay tubes 366 in the plurality of relay tubes 366 spaced apart in the x-direction. A total of three gaps are formed in cooler 364. Three-phase switch modules 368 are individually installed in each of these three gaps. This constitutes power module 369. Power module 369 is equivalent to a switch component.

[0118] <Housing>

[0119] As Figure 11 and Figure 12 illustrated, the housing 380 has a bottom portion 381 which is thin in the z direction, and a side wall portion 390 which is annularly raised from an inner bottom surface 381a of the bottom portion 381 in the z direction.

[0120] The side wall portion 390 has a first side wall 391 and a third side wall 393 which are opposed to each other in the y direction, and a second side wall 392 and a fourth side wall 394 which are opposed to each other in the x direction. The first side wall 391, the second side wall 392, the third side wall 393, and the fourth side wall 394 are annularly linked in the circumferential direction around the z direction.

[0121] Accordingly, a receiving space is formed between the bottom portion 381 and the side wall portion 390 of the housing 380. The power module 369 and the electrical product 301 described above are received in this receiving space.

[0122] <Receiving method of housing>

[0123] As Figure 11 and Figure 12 illustrated, the power module 369 is received in the receiving space on the first side wall 391 side of the housing 380. The electrical product 301 is received in the receiving space on the third side wall 393 side of the housing 380.

[0124] The power module 369 is fixed to the bottom portion 381 by a bolt or the like which is not illustrated. The collector terminal 353 and the emitter terminal 354 respectively extend in the z direction away from the bottom portion 381 from the three-phase switching modules 368 included in the power module 369. In addition, the power module 369 can not be fixed to the bottom portion 381. The power module 369 can be fixed to the housing 380.

[0125] Similarly, the electrical product 301 is fixed to the bottom portion 381 by a bolt or the like which is not illustrated. The capacitor housing 371 is fixed to the bottom portion 381 by a bolt or the like which is not illustrated. The second conductive site 312, the fourth conductive site 322, and the insulating plate 340 described above extend in the y direction from the capacitor housing 371 toward the power module 369.

[0126] As Figure 11 and Figure 12 illustrated, three first through holes 314 which open on the first bus bar upper surface 312a and the first bus bar lower surface 312b are formed in the second conductive site 312. These three first through holes 314 are arranged in the x direction. First terminals 315 which extend in the z direction away from the bottom portion 381 from edges of the three first through holes 314 on the second side wall 392 side of each of the three first through holes 314 are respectively formed in the three first through holes 314. The first terminals 315 correspond to external connection terminals.

[0127] In addition, the three first terminals 315 are arranged separately from the positioning holes 313 in the y direction. The positioning holes 313 are located between the first terminal 315 on the second side wall 392 side among the three first terminals 315 and the first terminal 315 adjacent thereto in the x direction.

[0128] Likewise, as shown in Figure 11 and Figure 12 In the fourth conductive site 322, three second through holes 327 and three third through holes 328 are formed which open on the second bus bar upper surface 322a and the second bus bar lower surface 322b. The three second through holes 327 are arranged separately in the x direction. The three third through holes 328 are arranged separately in the x direction.

[0129] In addition, as shown in Figure 12 The three second through holes 327 are formed on the first side wall 391 side of the fourth conductive site 322. As shown in Figure 12 The three third through holes 328 are formed on the third side wall 393 side of the fourth conductive site 322. The three third through holes 328 are arranged in a manner that communicates with the three first through holes 314 in the z direction.

[0130] In the three second through holes 327, a second terminal 329 is formed which extends from the edge of the respective second side wall 392 side of the three second through holes 327 in a manner that is away from the bottom 381 in the z direction.

[0131] In addition, the collector terminal 353 is exposed from the communication hole in the z direction which communicates with the three first through holes 314 and the three third through holes 328 described above. The collector terminal 353 exposed from the three communication holes is connected to the first terminal 315 formed on the edge of the three first through holes 314 by soldering or the like, respectively.

[0132] Likewise, the emitter terminal 354 is exposed from the three second through holes 327. The emitter terminal 354 exposed from the three second through holes 327 is connected to the second terminal 329 formed on the edge of the three second through holes 327 by soldering or the like, respectively.

[0133] In addition, as shown in Figure 12 On the bottom 381, an elongated portion 384 is formed which extends from the inner bottom surface 381a in a manner that is away in the z direction and which extends toward the second conductive site 312 and the fourth conductive site 322 which connect the capacitor 370 and the power module 369.

[0134] The elongated portion 384 has a first elongated portion 382 and a second elongated portion not shown. The first elongated portion 382 is formed on the inner bottom surface 381a on the second side wall 392 side in the bottom 381. The second elongated portion is formed on the inner bottom surface 381a on the fourth side wall 394 side in the bottom 381.

[0135] As Figure 12 illustrated, the first elongated portion 382 is provided between the power module 369 and the capacitor housing 371 in the y direction. The first elongated portion 382 is arranged opposite to the power module 369 and the capacitor 370 in the y direction. In addition, the inserted hole 383 is formed in the first elongated portion 382, which is recessed from the front end away from the bottom 381 toward the bottom 381.

[0136] In addition, although not illustrated, a second elongated portion is also provided between the power module 369 and the capacitor housing 371 in the y direction. The second elongated portion is arranged opposite to the power module 369 and the capacitor 370 in the y direction. The inserted hole 383 is formed in the second elongated portion, which is recessed from the front end away from the bottom 381 toward the bottom 381.

[0137] As explained so far, the protruding portion 345 formed in the insulating plate 340 is exposed from the fixing hole 325. As Figure 12 illustrated, the protruding portion 345 extends toward the elongated portion 384 provided between the capacitor 370 and the power module 369. Moreover, the protruding portion 345 is inserted into the inserted hole 383 of the elongated portion 384.

[0138] Specifically, the first protruding portion 341 exposed from the first fixing hole 323 is inserted into the inserted hole 383 of the first elongated portion 382. The second protruding portion 342 exposed from the second fixing hole 324 is inserted into the inserted hole 383 of the second elongated portion. Thereby, the electrical product 301 is fixed to the first elongated portion 382 and the second elongated portion, respectively.

[0139] <Effects>

[0140] As explained so far, in the manufacturing process, the insulating plate 340 is arranged on the second busbar upper surface 322a of the fourth conductive site 322 in such a manner that the protruding portion 345 passes through the fixing hole 325 and the fixed hole 1005, respectively. Thereby, the position of the fourth conductive site 322 with respect to the x direction and the y direction of the jig 1000 is limited. In addition, the deformation of the insulating plate 340 in each of the x direction, the y direction, and the z direction is corrected by inserting the protruding portion 345 into the fixed hole 1005.

[0141] Next, the second conductive site 312 is arranged on the insulating plate upper surface 340a of the corrected insulating plate 340. Then, in this state, the second conductive site 312 and the fourth conductive site 322 are fixed to the capacitor 370. Thereby, the corrected insulating plate 340 is clamped by the first power supply busbar 310 and the second power supply busbar 320.

[0142] Therefore, it is easy to suppress the positional deviation of the second conductive site 312 and the fourth conductive site 322. As a result, it is easy to suppress the positional deviation of the terminals of the power supply bus including the first terminal 315 and the second terminal 329 and the terminals of the power module 369 including the collector terminal 353 connected to the first terminal 315 and the emitter terminal 354 connected to the second terminal 329. In addition, the first power supply bus 310 and the second power supply bus 320 are collectively referred to as a power supply bus.

[0143] Furthermore, the capacitor 370, the second conductive site 312, the fourth conductive site 322, and the insulating plate 340 are housed in the capacitor case 371. Then, the second conductive site 312, the fourth conductive site 322, the insulating plate 340, and the capacitor 370 are fixed to the capacitor case 371 by filling the capacitor case 371 with a covering resin 375.

[0144] Thus, the insulating plate 340 is fixed to the first power supply bus 310 and the second power supply bus 320. It is easy to suppress the positional deviation of the second conductive site 312 and the fourth conductive site 322. It is easy to suppress the positional deviation of the collector terminal 353 and the emitter terminal 354 connected to the second conductive site 312 and the fourth conductive site 322 and the second conductive site 312 and the fourth conductive site 322.

[0145] As described so far, after the second conductive site 312 is arranged on the insulating plate upper surface 340a of the insulating plate 340 in such a manner that the positioning hole 313 and the first recessed portion 343 communicate in the z direction, the positioning pin 1100 is inserted through the positioning hole 313 and the first recessed portion 343, respectively. Thus, the position of the first power supply bus 310 with respect to the x direction and the y direction of the insulating plate 340 is restricted. In addition, by making the positioning pin 1100 pass through the hole that communicates the positioning hole 313 and the first recessed portion 343, the movement of the line of sight during the work can be suppressed. The workability is improved.

[0146] As described so far, the first recessed portion 343 that is cylindrically recessed from the insulating plate upper surface 340a toward the insulating plate lower surface 340b is intentionally formed within the projection area of the first protruding portion 341 in the z direction of the insulating plate 340. Similarly, the second recessed portion 344 that is cylindrically recessed from the insulating plate upper surface 340a toward the insulating plate lower surface 340b is intentionally formed within the projection area of the second protruding portion 342 in the z direction of the insulating plate 340.

[0147] Therefore, it is possible to suppress the insulating plate 340 from being locally thinned in the z direction. As a result, it is possible to suppress the insulating plate 340 from being locally heated. It is easy to suppress the deformation of the insulating plate 340. The insulating plate 340 is easy to arrange in the jig 1000.

[0148] As explained so far, the first protruding portion 341 exposed from the first fixing hole 323 is inserted into the insertion hole 383 of the first elongated portion 382. The second protruding portion 342 exposed from the second fixing hole 324 is inserted into the insertion hole 383 of the second elongated portion.

[0149] Thus, the electric product 301 is fixed to the first elongated portion 382 and the second elongated portion, respectively. Therefore, it is easy to suppress the positional deviation of the electric product 301 from the power module 369. It is easy to suppress the positional deviation of the terminals of the power supply bus including the first terminal 315 and the second terminal 329 from the terminals of the power module 369 including the collector terminal 353 connected to the first terminal 315 and the emitter terminal 354 connected to the second terminal 329. Thus, it is easy to suppress the poor connection of the capacitor 370 to the switching module 368.

[0150] As explained so far, the first elongated portion 382 is arranged in the y direction between the power module 369 and the capacitor housing 371. The first elongated portion 382 is arranged opposite to the power module 369 and the capacitor 370 in the y direction. The second elongated portion is also arranged in the y direction between the power module 369 and the capacitor housing 371. The second elongated portion is arranged opposite to the power module 369 and the capacitor 370 in the y direction. Therefore, by the first elongated portion 382 and the second elongated portion, it is easy to suppress the mutual thermal interference of the power module 369 and the capacitor 370.

[0151] As explained so far, the three first terminals 315 are arranged in the y direction separately from the above-mentioned positioning hole 313, respectively. The positioning hole 313 is located in the x direction between the first terminal 315 located closest to the second side wall 392 among the three first terminals 315 and the first terminal 315 adjacent thereto. The first terminal 315 and the positioning hole 313 are arranged separately in the x direction. It is difficult to arrange the positioning hole 313 on the current path between the capacitor 370 and the power module 369. It is easy to suppress the reduction of the inductance of the current path between the capacitor 370 and the power module 369.

[0152] (First Modified Example)

[0153] In the embodiment explained so far, the manner of forming the positioning hole 313 in the second conductive site 312 is explained. However, it is also possible not to form the positioning hole 313 in the second conductive site 312. As shown in Figure 9 and Figure 10 It is sufficient that the fastening hole 316 for fastening to the housing 380 is formed in the second conductive site 312 to open on the first bus upper surface 312a and the first bus lower surface 312b, as shown in

[0154] In this case, the positioning pin 1100 can also not be prepared. It is sufficient that the extension 1200 extending away from the upper surface 1000a in the z direction is formed on the jig 1000. Alternatively, the extension 1200 can also not be formed on the jig 1000. It is sufficient that the extension 1200 is connected to the jig 1000. The extension 1200 can also be inserted into the fastening hole 316 to restrict the position of the second conductive site 312 in the x direction and the y direction.

[0155] (Second Modification Example)

[0156] In the embodiment described so far, the mode in which one electrode included in the capacitor 370 is connected to the second conductive site 312 and the other electrode included in the capacitor 370 is connected to the fourth conductive site 322 is shown. However, the one electrode included in the capacitor 370 can also not be connected to the second conductive site 312. The other electrode included in the capacitor 370 can also not be connected to the fourth conductive site 322.

[0157] The one electrode included in the capacitor 370 can also be connected to the fourth conductive site 322. The other electrode included in the capacitor 370 can also be connected to the second conductive site 312. In this case, the positioning hole 313 and the first through-hole 314 are formed in the fourth conductive site 322. The fixing hole 325, the second through-hole 327, and the third through-hole 328 are formed in the second conductive site 312.

[0158] (Other Modification Examples)

[0159] In the present embodiment, an example in which the electric device 300 is included in the vehicle-mounted system 100 for an electric automobile is shown. However, the application of the electric device 300 is not particularly limited to the above example. For example, a structure in which the electric device 300 is included in a hybrid system including the electric motor 400 and an internal combustion engine can also be adopted.

[0160] In the present embodiment, an example in which one electric motor 400 is connected to the electric device 300 is shown. However, a structure in which a plurality of electric motors 400 is connected to the electric device 300 can also be adopted. In this case, the electric device 300 has a plurality of switching modules 368 for constituting three phases of an inverter.

Claims

1. A method for manufacturing an electrical product, the electrical product comprising: electrical components; a first power supply portion and a second power supply portion fixed to the electrical component and extending in one direction; and an insulating plate provided between the first power supply portion and the second power supply portion in a direction orthogonal to the one direction, A fixing hole is formed on the first power supply portion, the fixing hole penetrating the first power supply upper surface on the front side of the first power supply portion and the first power supply lower surface on the back side of the first power supply upper surface in the orthogonal direction. A protrusion is formed on the insulating plate to be inserted into the fixing hole. In the method for manufacturing the electrical product, A jig is prepared, wherein the jig has a fixed hole formed on its upper surface and partially recessed in the orthogonal direction, and has a higher rigidity than the protrusion. The first power supply portion is arranged on the upper surface of the clamp in such a manner that the fixing holes are arranged in the orthogonal direction relative to the fixed holes. The insulating plate is placed on the first power supply portion by passing the protrusion through the fixing hole and the fixed hole, respectively. The second power supply unit is provided on the insulating plate provided on the first power supply unit. The insulating plate is sandwiched between the first power feeding portion and the second power feeding portion by fixing the first power feeding portion and the second power feeding portion to the electrical component.

2. The method for manufacturing an electrical product according to claim 1, wherein: The electrical product has: an electrical component housing for housing the electrical component; as well as a covering resin filled in the electrical component housing, The first power supply portion, the second power supply portion, and a portion of the insulating plate are housed together with the electrical component in the electrical component housing. The insulating plate is fixed to the first power feeding portion and the second power feeding portion by filling the electrical component case with the covering resin.

3. The method for manufacturing an electrical product according to claim 1 or 2, wherein: A recessed portion partially recessed in the orthogonal direction from the upper surface of the insulating plate is formed on the insulating plate. A positioning hole is formed on the second power supply portion, which passes through the second power supply upper surface and the second power supply lower surface on the back side of the second power supply upper surface in the orthogonal direction. When the second power supply portion is provided on the insulating plate provided on the first power supply portion, the positioning hole and the recess are arranged along the orthogonal direction. Auxiliary jigs extending in the orthogonal direction are inserted into the recess and the positioning hole, respectively.

4. The method for manufacturing an electrical product according to claim 1 or 2, wherein: The second power supply portion is provided with an adjustment hole penetrating the second power supply upper surface and the second power supply lower surface on the back side of the second power supply upper surface in the orthogonal direction. In addition to the fixed hole, the clamp is also connected to an extension portion extending along the orthogonal direction. When the second power supply portion is provided on the insulating plate provided on the first power supply portion, the extension portion is inserted into the adjustment hole.

5. The method for manufacturing an electrical product according to claim 3, wherein: The recessed portion and the protruding portion are aligned in the orthogonal direction.

6. An electrical product, the electrical product being housed in a housing together with a switch component comprising a plurality of switches, The electrical product has: electrical components; a first power supply portion and a second power supply portion connecting the electrical component and the switch component and extending in one direction; and an insulating plate provided between the first power supply portion and the second power supply portion in a direction perpendicular to the one direction, A fixing hole is formed on the first power supply portion, the fixing hole penetrating the first power supply upper surface on the front side of the first power supply portion and the first power supply lower surface on the back side of the first power supply upper surface in the orthogonal direction. A protrusion extending in a perpendicular direction and inserted into the fixing hole is formed on the insulating plate. The front end of the protrusion passes through the fixing hole and is inserted into an insertion hole formed in the housing and recessed in the orthogonal direction.

7. The electrical product according to claim 6, wherein: The housing has: a bottom; a side wall portion annularly connected to the bottom; and an extension portion extending in the orthogonal direction from the connecting side of the bottom portion connected to the side wall portion, The insertion hole is formed on a side of the extension portion away from the bottom portion.

8. The electrical product according to claim 7, wherein: The extension portion is opposite to the electrical component and the switch component in the one direction.

9. The electrical product according to any one of claims 6 to 8, characterized in that The second power supply portion has: an external connection terminal connected to the switch component; and a positioning hole penetrating the second power supply upper surface and the second power supply lower surface on the back side thereof in the orthogonal direction for limiting the position in the direction orthogonal to the orthogonal direction. The positioning holes are separated from the external connection terminals in arrangement directions perpendicular to the one direction and the perpendicular direction.

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