Electrical connection box

Abstract

This invention discloses an electrical connection box that can save space and reduce working hours and the number of components to connect the connector located therein to the connection part of the branch circuit structure. The electrical connection box (10) includes: a branch circuit structure (12) for distributing battery power to various devices; a housing (14) for housing the branch circuit structure (12); an opening (54) for penetrating the side wall (22) of the housing (14); a cover (62) for blocking the opening (54); and multiple external connectors (66a-66h) for mounting in multiple through holes (64) penetrating the cover (62) and protruding from the outer surface (68) of the cover (62). The branch circuit structure (12) is fixed to the inner surface (70) of the cover (62). Multiple connection points (72a-72h) of the branch circuit structure (12) are connected to the connection terminals of the corresponding external connectors (66a-66h). The external connector module (156) is composed of multiple external connectors (66a-66h), the cover (62), and the branch circuit structure (12).

Description

Technical Field

[0001] This disclosure relates to electrical connection boxes. Background Technology

[0002] Patent Document 1 discloses an electrical connection box for use in vehicles such as electric vehicles and hybrid vehicles, used to distribute power from a storage battery to various vehicle-mounted devices. The electrical connection box includes: a housing constructed of metal components such as aluminum; and branch circuit structures housed within the housing and configured to include power lines such as busbars, relays, fuses, and other electrical components. Multiple connectors connected to the branch circuit structures are respectively disposed on multiple side walls within the housing, and external connectors located at the ends of wires extending from various devices are assembled to these multiple connectors. This enables the distribution of power from the storage battery to various devices via the electrical connection box.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-106770 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] However, in the electrical connection box of Patent Document 1, since connectors are distributed on the four side walls of the housing, it is difficult to manage the dimensional tolerances of the connection points between each connector and the branch circuit structure. Therefore, a structure is adopted that connects each connector to each connection point by wires with terminals at both ends. As a result, the operation of connecting multiple connectors and multiple connection points separately with wires cannot avoid increasing the time required for connection operations and the number of parts. In addition, the space required for wire connection operations and wire arrangement between each connector and each connection point may not be able to cope with the miniaturization of the electrical connection box.

[0008] Therefore, an electrical connection box is disclosed, which can save space by reducing working hours and the number of parts to connect the connector disposed in the housing to the connection part of the branch circuit structure housed in the housing.

[0009] Technical solutions for solving the problem

[0010] The electrical connection box disclosed herein comprises: a branch circuit structure for distributing power from a battery to various devices; a housing for housing the branch circuit structure; an opening penetrating the side wall of the housing; a cover for blocking the opening and fixing it to the side wall; and a plurality of external connection connectors assembled in a plurality of through holes penetrating the cover along the thickness direction and protruding from the outer surface of the cover. The branch circuit structure is fixed to the inner surface of the cover, and a plurality of connection portions disposed on the branch circuit structure are connected to the connection terminals of corresponding external connection connectors. The external connection connector module comprises the plurality of external connection connectors, the cover, and the branch circuit structure.

[0011] Invention Effects

[0012] According to the electrical connection box disclosed herein, the connection between the connector disposed in the housing and the connection part of the branch circuit structure housed in the housing can be realized in a space-saving manner while reducing working hours and the number of parts. Attached Figure Description

[0013] Figure 1 This is a perspective view of the electrical connection box involved in Embodiment 1.

[0014] Figure 2 yes Figure 1 A magnified view of the decomposed plane.

[0015] Figure 3 Viewed from the left front Figure 1 The enlarged 3D view of the electrical connection box shows the battery high-voltage connector being removed to the front.

[0016] Figure 4 yes Figure 1 An exploded perspective view (where is the state with the cover removed and the high-voltage battery connector not removed).

[0017] Figure 5 yes Figure 4 The diagram shows an exploded three-dimensional enlarged view of the connector module used for external connections.

[0018] Figure 6 yes Figure 5 A further exploded perspective view of the connector module for external connection shown.

[0019] Figure 7 yes Figure 5 An exploded 3D view of the branch circuit structure shown.

[0020] Figure 8 yes Figure 4 The exploded three-dimensional enlarged view of the connector module on the substrate side is shown. Detailed Implementation

[0021] <Description of Embodiments of this Disclosure>

[0022] First, embodiments of this disclosure will be described.

[0023] The electrical connection box disclosed herein is as follows:

[0024] (1) An electrical connection box comprising: a branch circuit structure for distributing power supplied from a storage battery to various devices; a housing for housing the branch circuit structure; an opening penetrating a side wall of the housing; a cover for blocking the opening and fixing it to the side wall; and a plurality of external connection connectors assembled in a plurality of through holes penetrating the cover along the thickness direction and protruding from the outer surface of the cover, wherein the branch circuit structure is fixed to the inner surface of the cover, and a plurality of connection portions disposed on the branch circuit structure are connected to the connection terminals of corresponding external connection connectors, the external connection connector module comprising the plurality of external connection connectors, the cover and the branch circuit structure.

[0025] According to this structure, a cover with openings that block the sidewalls of the housing has multiple through holes, and multiple external connectors are mounted in these through holes protruding from the outer surface of the cover. A branch circuit structure housed within the housing is fixed to the inner surface of the cover, and multiple connection points on the branch circuit structure are connected to the connection terminals of corresponding external connectors. Thus, multiple external connectors and the branch circuit structure having connection points connected to each external connector are fixed to the cover, which is separated from the sidewalls of the housing. Therefore, the dimensional tolerances of the connection points between the external connectors and the branch circuit structure can be reduced, and the external connectors can be directly connected to the connection points of the branch circuit structure instead of via wires as in existing structures. As a result, the work of individually connecting multiple external connectors and multiple connection points with wires is eliminated, reducing work time and the number of parts.

[0026] Furthermore, both the branch circuit structure and the external connector are modularly assembled onto a cover separate from the housing, thus forming an external connector module. Therefore, the connection work between the connection points of the branch circuit structure and the external connector can be performed outside the housing, thereby pre-assembling the external connector module. Moreover, the assembly of multiple external connectors and branch circuit structures into the housing can be completed in a single operation by assembling the external connector module into the opening of the housing. Therefore, unlike existing structures, there is no need to ensure space inside the housing for individually wiring multiple external connectors and connection points, achieving space-saving design of the electrical connection box and improved operability.

[0027] (2) Preferably, the electrical connection box has a sealing member that is sandwiched between the outer periphery of the opening of the housing and the abutting surface of the cover. This is because the sealing member can improve the water resistance of the opening of the housing that is blocked by the cover.

[0028] (3) Preferably, the branch circuit structure includes: an internal circuit comprising busbars and electrical components; and a housing housing the internal circuit, the housing having a base and a vertical plate portion, the vertical plate portion rising from the base and contacting and being fixed to the inner surface of the cover. This is because by providing a vertical plate portion rising from the base in the housing of the branch circuit structure, the contact area between the housing and the cover can be maximized, thereby increasing the fixing strength of the cover and the branch circuit structure.

[0029] (4) Preferably, the connecting portion is disposed on the base, and the external connector connected to the connecting portion is held in the cover. Branch circuit wiring for power branches from the battery can be laid out on the base, and the external connector connected to the connecting portion disposed on the base can be stably held in place by the cover. As a result, the space efficiency and connection stability of the external connector module can be improved.

[0030] (5) Preferably, the electrical connection box further comprises: a circuit board housed in the housing; and a board-side connector module integrally formed by multiple board-side connectors mounted on the circuit board. The branch circuit structure has multiple relay connectors, which are centrally protruding from the base of the housing and connected to the multiple board-side connectors respectively to communicate with the internal circuit. Even when the circuit board connected to the branch circuit structure is housed in the housing, the board-side connector module integrally formed by multiple board-side connectors is mounted on the circuit board. Furthermore, the multiple board-side connectors are connected to the internal circuit of the branch circuit structure respectively via the multiple relay connectors centrally protruding from the base. Thus, compared with the existing structure that requires multiple wires for connecting the circuit board and the internal circuit of the branch circuit structure, the number of components and the time required for connection operations can be reduced. Moreover, since it is not necessary to ensure space for operation between the circuit board and the branch circuit structure, space-saving of the electrical connection box can also be achieved.

[0031] <Detailed Description of Embodiments of this Disclosure>

[0032] Hereinafter, specific examples of the electrical connection box of this disclosure will be described with reference to the accompanying drawings. Furthermore, this disclosure is not limited to these examples, as illustrated in the claims, and is intended to include all modifications equivalent to and within the scope of the claims.

[0033] <Implementation Method 1>

[0034] The following is for reference Figures 1 to 8 The electrical connection box 10 of Embodiment 1 of this disclosure will be described. The electrical connection box 10 is installed, for example, in vehicles such as electric vehicles and hybrid vehicles (not shown), and distributes power supplied from a battery (not shown) to various devices via a branch circuit structure 12. Furthermore, the electrical connection box 10 has a housing 14 that houses the branch circuit structure 12. In addition, the electrical connection box 10 can be configured in any orientation, but the up-down, left-right, and front-back directions shown in the figures will be used as a reference for explanation below. Also, for multiple identical components, sometimes only some components are labeled, and the labels for other components are omitted.

[0035] <Shell 14>

[0036] The housing 14 is made of metal, for example, die-cast aluminum. Figures 1-2 As shown, the housing 14 includes: a housing body 16 having a rectangular, bottomed box shape with an upward opening; and a cover 18 covering the upper opening of the housing body 16. The housing body 16 has a bottom wall 20 and side walls 22 projecting upward from the periphery of the bottom wall 20. Figure 2 and Figure 4 As shown, cylindrical retaining plate support portions 24 protrude from six locations on the bottom wall 20. The protrusion dimension of the retaining plate support portion 24 is approximately half the protrusion dimension of the side wall 22. The retaining plate support portion 24 has a tapered structure that gradually narrows towards the protruding front end. A bolt fastening hole 26 with a circular cross-section is formed by opening upward at the protruding front end of the retaining plate support portion 24. The retaining plate support portion 24 is provided with a flat reinforcing plate portion 28 that protrudes outward from the outer peripheral surface and is connected to the side wall 22 or the bottom wall 20. In addition, cylindrical branch circuit structure support portions 30 protrude from four locations on the bottom wall 20 of the housing 14. The protrusion dimension of the branch circuit structure support portion 30 is less than 1 / 10 of the protrusion dimension of the side wall 22. A bolt fastening hole 26 with a circular cross-section is formed by opening upward at the protruding front end of the branch circuit structure support portion 30.

[0037] A battery mounting portion 32 extending upwards and to the left and right sides is integrally formed on the side wall 22 at the front of the housing 14. For example, as Figure 3As shown, in the battery mounting portion 32, seven circumferentially separated locations are provided with bolt through holes 34 for fixing the housing 14 to the housing of a battery (not shown). On the front side wall 22 of the housing 14, in a region closer to the center than the battery mounting portion 32, a rectangular receiving recess 36 is formed facing forward, which receives the connection portion of the battery housing (not shown). A protrusion 38 with an elliptical cross-section is provided in the center of the receiving recess 36. A battery high-voltage connector through hole 40, opening forward and into the interior of the housing 14, is provided through the center of the protrusion 38. Cylindrical battery high-voltage connector supports 42 with bolt fastening holes 26 at the protruding ends are provided on the upper right and lower left sides of the protrusion 38. Furthermore, the front surface of the side wall 22 on the front side of the housing 14, which includes the battery fixing part 32, becomes the fixing surface to the housing of the battery (not shown), and therefore an annular sealing rubber 41 is provided on its outer periphery.

[0038] <Battery high voltage connector 44>

[0039] like Figure 3 As shown, the battery high-voltage connector 44 has a rectangular flat fixing part 46. Bolt insertion holes 34 are provided through two diagonally opposite portions of the fixing part 46. A pair of cylindrical terminal retaining protrusions 48, 48, protruding forward and backward and separated in the left-right direction are provided in the center of the fixing part 46. A busbar 50 bent into an L-shape is disposed within each terminal retaining protrusion 48. A battery connection portion 50a of the busbar 50 is exposed at the front end of each terminal retaining protrusion 48, and a branch circuit structure connection portion 50b of the busbar 50 is exposed at the rear end of each terminal retaining protrusion 48 (see reference). Figure 2 A bolt insertion hole 52 is provided through the branch circuit structure connection part 50b along the plate thickness direction.

[0040] <Opening 54>

[0041] like Figure 4As shown, an opening 54 is provided on the rear sidewall 22 of the housing body 16. This opening 54 is formed by cutting approximately the entire surface, opening towards the rear and into the interior of the housing body 16, and penetrating the sidewall 22 of the housing body 16. At the periphery 10 of the opening 54, a bolt hole 26 is formed penetrating the sidewall 22 of the housing body 16. A recessed sealing member receiving portion 56, opening towards the rear, is formed inside the bolt hole 26 at the periphery of the opening 54. An annular rubber sealing member 58 is received within the sealing member receiving portion 56. That is, the sealing member 58 is clamped between the outer periphery of the opening 54 of the housing body 16 and the contact surface of the cover 62 (described later). As a result, the sealing member 58 improves the water resistance of the opening 54 of the housing body 16, which is blocked by the cover 62. The housing body 16 is provided with an annular flange 60 extending outward from the upper opening in the left-right and front-back directions. The flange 60 has 14 bolt holes 26 spaced circumferentially apart.

[0042] <Lid 62>

[0043] The opening 54, which passes through the side wall 22 on the rear side of the housing body 16, is blocked by the cover 62. The cover 62 has a rectangular flat plate shape. A bolt insertion hole 34 is provided in the cover 62 at a position corresponding to the bolt fastening hole 26 on the periphery of the opening 54. After aligning the bolt insertion hole 34 of the cover 62 with the bolt fastening hole 26 on the periphery of the opening 54, as... Figure 1 The cover 62 is fixed to the rear side wall 22 of the housing 14 by bolts. Figure 6 As shown, the cover 62 has multiple (eight in this embodiment) through holes 64 extending through the cover 62 along the thickness direction. External connectors 66a, 66b, 66c, 66d, 66e, 66f, 66g, and 66h are respectively fitted into each through hole 64. For example, as... Figure 5 As shown, each external connector 66a-66h protrudes outward in the thickness direction from the outer surface 68 and inner surface 70 of the cover 62 while the bolts are tightened and it is held in place by the cover 62. This allows the external connectors 66a-66h to be stably held in place by the cover 62 and connected to the connection portions 72a-72h disposed on the base 118. Therefore, the space efficiency and connection stability of the external connector module 156, described later, can be improved. The external connectors 66a-66h protruding from the outer surface 68 of the cover 62 are connected to connectors for various devices (not shown). Furthermore, as... Figure 2 , Figure 5 and Figure 6As shown, external connectors 66a-66h protruding from the inner surface 70 of the cover 62 are connected to connection portions 72a-72h provided on the branch circuit structure 12. Furthermore, as... Figure 5 As shown, on the inner surface 70 of the cover 62, three generally cylindrical branch circuit structure fixing parts 74 are provided in three separate parts in the left and right directions. A bolt fastening hole 26 with a circular cross-section and opening towards the front is formed at the protruding front end of the branch circuit structure fixing part 74.

[0044] <Cover Section 18>

[0045] like Figure 1 and Figure 2 As shown, the cover portion 18 covering the upper opening of the housing body 16 has a rectangular, shallow-bottomed, box-shaped structure with an opening facing downwards. An annular flange-like portion 75 is provided on the cover portion 18, extending outwards in both left-right and front-back directions from the lower opening. Bolt insertion holes 34 are provided on the flange-like portion 75 at 14 locations corresponding to the bolt fastening holes 26 of the housing body 16. By bolting the cover portion 18 to the housing body 16, the sealing rubber 73 disposed on the upper surface of the side wall 22 of the housing body 16 is clamped between the upper surface of the side wall 22 of the housing body 16 and the flange-like portion 75 of the cover portion 18, ensuring a tight seal.

[0046] <Branch Circuit Structure 12>

[0047] For example, Figure 7 As shown, the branch circuit structure 12 includes a lower housing 76a located below and an upper housing 76b located above when mounted in a vehicle, and the housing 76 is formed by including the lower housing 76a and the upper housing 76b. The housing 76 is formed by injection molding an insulating synthetic resin into a predetermined shape. The synthetic resin constituting the housing 76 may also contain fillers such as glass fibers. For example, the housing 76 is... Figure 2 As shown, it has a roughly T-shaped appearance when viewed from above. For example, as... Figure 7 As shown, a busbar 78a extending in the front-to-back direction is arranged inside the housing 76. The busbar 78a is connected to the battery via a high-voltage battery connector 44 and is subjected to a high voltage. To the rear right of the busbar 78a are arranged a busbar 78b, for example, connected to a 12V power supply, and a busbar 78c, connected to an AC power supply. Between the busbars 78b and 78c is a wiring harness 80 for transmitting the low-voltage power generated by the substrate-side connector module 128 (described later) from the substrate-side connector 140b to the external connection connector 66b via a relay connector 98b. To the rear left of the busbar 78a is a busbar 78d, which is connected to the busbar 78a via a fuse 82, which is an electrical component.

[0048] <Upper box 76b>

[0049] The upper housing 76b, when viewed from above, has a similar shape, slightly larger than the lower housing 76a. The upper housing 76b also has a roughly T-shaped form similar to the lower housing 76a. At the front end of the portion extending forward in the upper housing 76b, a pair of busbar insertion holes 84, 84 are provided, extending separately in the left-right direction. (As...) Figure 7 As shown, the front end of busbar 78a is bent into a crank shape and protrudes outward from the busbar insertion hole 84. Figure 2 As shown, the rear end of the relay bus 86, which is bent into a crank shape, is connected relative to the front end of the bus 78a, and the front end of the relay bus 86 is connected to the branch circuit structure connection portion 50b of the battery high-voltage connector 44. This allows high voltage to be supplied from the battery to the bus 78a. For example, as... Figure 5 As shown, legs 88 protruding outward in the shape of rectangular flat plates are provided on both the left and right ends of the front end of the upper housing 76b. Additionally, in the upper housing 76b, legs 88 protruding outward in the shape of rectangular flat plates are also provided on the front sides of both the left and right ends at the portions extending in the left and right directions. A bolt insertion hole 90 with a circular cross-section is provided through the center of each leg 88.

[0050] Furthermore, on the right side of the top wall portion 92 extending laterally from the rear end of the upper housing 76b, four relay connector housings 94a, 94b, 94c, and 94d are provided at positions corresponding to the substrate-side connectors 140a to 140d described later. Each of the four relay connector housings 94a to 94d has a square cylindrical shape, protruding upwards from the top wall portion 92 and open vertically. A pair of busbar insertion holes 96 are provided through the rear of the relay connector housing 94a. Moreover, the rear end of the busbar 78b disposed in the lower housing 76a is bent into a crank shape and exposed externally through the busbar insertion hole 96 (see reference). Figure 7 The rear end of the exposed busbar 78b forms the connection portion 72a. Furthermore, the front end of the busbar 78b, disposed in the lower housing 76a, is bent upwards into an L-shape and disposed within the repeater connector housing 94a. The repeater connector 98a is formed by arranging the front ends of a pair of buses 78b, 78b within the repeater connector housing 94a. The front end of the repeater busbar 110, bent into a crank shape, is connected relative to the rear end of the busbar 78b, and the rear end of the repeater busbar 110 is connected to the connection terminal 112 within the external connection connector 66a (see reference). Figure 5 Thus, for example, a 12V power supply can be supplied from an external connection connector 66a.

[0051] like Figure 7As shown, a pair of busbar insertion holes 100, 100 are also provided through the center of the top wall portion 92 extending laterally from the rear end of the upper housing 76b. The rear end of the busbar 78a located in the lower housing 76a is bent into a crank shape and protrudes outward from the busbar insertion hole 100. Figure 5 As shown, the rear end of the exposed busbar 78a forms the connection portion 72e. Furthermore, the front end of the relay busbar 114, bent into a crank shape, is connected relative to the rear end of the busbar 78a, and the rear end of the relay busbar 114 is connected to the connection terminal 116 within the external connection connector 66e. Thus, the high voltage of the battery is supplied from the external connection connector 66e. A pair of L-shaped busbars 102, 102 are assembled on the rear side of the busbar 78a disposed in the lower housing 76a. More specifically, one end of the busbar 102 is bolted to the rear side of the busbar 78a, and the other end of the busbar 102 is bent upwards into an L-shape and housed within the relay connector housing 94d. The relay connector 98d is formed by housing the other ends of the pair of busbars 102, 102 within the relay connector housing 94d.

[0052] And, as Figure 5 As shown, a cylindrical intermediate connector housing 104a is provided on the rear side of the relay connector housing 94b. The intermediate connector housing 104a has a cylindrical shape that protrudes upward from the top wall portion 92. A rod-shaped terminal 80a connected to one end of the wire harness 80 is housed within the relay connector housing 94b, thus forming a relay connector 98b. A rod-shaped terminal 80a connected to the other end of the wire harness 80 is housed within the intermediate connector housing 104a, thus forming an intermediate connector 106a. The connection portion 72b is formed by this intermediate connector 106a. A pair of cylindrical intermediate connector housings 104b, 104b are provided on the rear side of the relay connector housing 94c. The intermediate connector housing 104b has a cylindrical shape that protrudes upward from the top wall portion 92. Within the relay connector housing 94c, one end of each of four busbars 78c is bent upward to form an L-shape and arranged to form the relay connector 98c. Inside the intermediate connector housing 104b, the other ends of the two busbars 78c are bent upwards to form an L-shape and configured to form a pair of intermediate connectors 106b and 106b. The connection parts 72c and 72d are formed by the pair of intermediate connectors 106b and 106b, respectively.

[0053] At the left end of the top wall portion 92 extending laterally from the rear end of the upper housing 76b, three cylindrical intermediate connector housings 104c are provided. Each intermediate connector housing 104c has a cylindrical shape protruding upwards from the top wall portion 92. Within each intermediate connector housing 104c, one end of a busbar 78d connected to busbar 78a via fuse 82 is bent upwards to form an L-shape. Furthermore, within each intermediate connector housing 104c, one end of a grounding busbar 108 connected to the grounding potential is bent upwards to form an L-shape. This constitutes each intermediate connector 106c. These three intermediate connectors 106c respectively form connection portions 72f, 72g, and 72h.

[0054] <Box 76>

[0055] The enclosure 76 is configured to include an upper enclosure 76b and a lower enclosure 76a. The enclosure 76 houses an internal circuit comprising busbars 78a-78d and a fuse 82 as an electrical component. The enclosure 76 has a base 118 on which the upper enclosure 76b and lower enclosure 76a are assembled, and a vertical plate 120 rising from the base 118. Furthermore, four relay connectors 98a-98d are centrally located and protrude from a portion of the base 118 of the enclosure 76 (in this embodiment, the right side of the front end). These connectors connect to the four baseboard-side connectors 140a-140d (described later) and are connected to the internal circuitry within the enclosure 76. That is, when the branch circuit structure 12 and the circuit board 130 (described later) are assembled within the housing body 16, each baseboard-side connector 140a-140d is connected to its corresponding relay connector 98a-98d.

[0056] <Standing part 120>

[0057] like Figures 5-7As shown, the upright plate portion 120 has a rectangular flat plate shape, is connected to the rear end of the side wall 122 of the upper housing 76b, and protrudes upward beyond the top wall portion 92. Approximately rectangular cross-sectional cutouts 124a, 124b, 124c, 124d, 124e, 124f, 124g, and 124h are provided through eight locations on the upright plate portion 120. External connection connectors 66a and 66e are respectively assembled and supported at the cutouts 124a and 124e, and connected to connection portions 72a and 72e disposed on the base 118 via relay buses 110 and 114. Additionally, external connectors 66b-66d and 66f-66h are assembled and supported at the cutouts 124b-124d and 124f-124h, respectively, and connected to the connection portions 72b-72d and 72f-72h located on the base 118 via energized components (not shown). Bolt insertion holes 126 are provided through the three portions on the upper part of the upright plate 120. After aligning the bolt insertion holes 126 of the upright plate 120 with the bolt fastening holes 26 of the branch circuit structure fixing portion 74 on the cover 62, the upright plate 120 is fixed by contacting the inner surface 70 of the cover 62 with bolts. By providing the upright plate 120 on the upper housing 76b, a larger contact area with the cover 62 can be ensured. Therefore, the fixing strength between the cover 62 and the housing 76 of the branch circuit structure 12 can be improved. Furthermore, the vertical plate portion 120 allows for the stable connection of external connectors 66a-66h with connection portions 72a-72h disposed on the base 118. Therefore, the space efficiency and connection stability of the external connector module 156, described later, can be improved.

[0058] <Circuit board 130>

[0059] A circuit board 130 is housed within the housing 14, and a board-side connector module 128, described later, is mounted on the circuit board 130. For example... Figure 8As shown, the circuit board 130 is held on a rectangular flat metal plate 132. The circuit board 130 has a generally rectangular flat shape, for example, formed from a known insulating material such as glass epoxy resin. A power supply pattern is formed on the circuit board 130 by printed wiring (not shown). In this embodiment, a vehicle charger is mounted on the circuit board 130. Furthermore, the metal plate 132 is preferably made of a metal with good thermal conductivity, but it can also be made of relatively lightweight materials such as aluminum or aluminum alloys. Two sets of a pair of connection portions 134 are provided on the circuit board 130. Each connection portion 134 has an insulating terminal fixing portion 134a and a terminal 134b protruding from the circuit board 130. The terminal 134b is bent into an L-shape, and one end is connected to the printed wiring of the circuit board 130 by soldering or the like. The other end of the terminal 134b rests on the protruding end face of the terminal fixing portion 134a. One side (right side) of a pair of connection portions 134, 134 is supplied with, for example, a 12V power supply from the circuit board 130. On the other side (left side) of the pair of connection portions 134, 134, a high-voltage power supply is supplied to the circuit board 130, for example, by connecting to a battery.

[0060] <Retaining Plate 132>

[0061] The retaining plate 132 is, for example, formed of die-cast aluminum. A circuit board 130 is held on the right side of the retaining plate 132. A transformer 136 is held on the left side of the retaining plate 132. As described later, the retaining plate 132 is assembled to the housing 14 in a heat-conducting manner, thus allowing heat generated by the circuit board 130 and the transformer 136 to be transferred to the housing 14 via the retaining plate 132. Therefore, the heat dissipation of the electrical connection box 10 can be improved, and the transformer 136 can be stably connected to the circuit board 130. The transformer 136 is connected to the circuit board 130 via a connection structure not shown. The transformer 136 is used to transform the high voltage of the battery to the desired voltage. At the rear end of the right side of the retaining plate 132, a rectangular housing-shaped board-side connector receiving portion 138 is provided protruding rearward. The board-side connector receiving portion 138 houses four integrated board-side connectors 140a, 140b, 140c, and 140d constituting the board-side connector module 128. The peripheral wall on the rear side of the substrate-side connector receiving portion 138 protrudes upwards with a larger protrusion dimension than the peripheral walls of other portions. This rear peripheral wall forms a protective wall portion 142 surrounding the outer peripheral walls of the four substrate-side connectors 140a-140d constituting the substrate-side connector module 128. This suppresses interference between the substrate-side connector module 128 and other components. Furthermore, the protective wall portion 142 suppresses or prevents deformation when the substrate-side connectors 140a-140d are engaged with the relay connectors 98a-98d. As a result, it helps ensure a stable connection between the substrate-side connectors 140a-140d and the relay connectors 98a-98d, ensuring durability. Additionally, fixing legs 144 are provided at both ends of the substrate-side connector receiving portion 138 in the left-right direction, protruding outwards. Furthermore, legs 146 are provided at six locations on the outer periphery of the retaining plate 132.

[0062] <Baseboard-side connector module 128>

[0063] Four substrate-side connectors 140a to 140d are integrated to form a substrate-side connector module 128. Legs 148 protrude outwards from both ends of the substrate-side connector module 128 in the left-right direction. The substrate-side connector module 128 is fixed to the retaining plate 132 by bolting the legs 148 against the fixing legs 144 of the retaining plate 132. Furthermore, the four substrate-side connectors 140a to 140d constituting the substrate-side connector module 128 are mounted on the circuit board 130 mounted on the retaining plate 132. More specifically, substrate-side connectors 140a and 140d are each bolted to terminals 134b on the connection portion 134 via a pair of relay terminals 150, 150 bent into a crank shape. Additionally, substrate-side connector 140b is connected to the printed wiring of a low-voltage power line connected within the circuit board 130 via a relay connector 152. Furthermore, the substrate-side connector 140c is connected to the printed wiring of the AC power line connected in the circuit board 130 via the terminal wire 154.

[0064] <Assembly method of electrical connection box 10>

[0065] The assembly method of the electrical connection box 10 according to Embodiment 1 of this disclosure will be described in summary. First, a housing body 16 and a cover 18 constituting the housing 14 are prepared. Next, a branch circuit structure 12, a cover 62, and external connection connectors 66a to 66h are prepared. After the external connection connectors 66a to 66h are assembled into the through holes 64 of the cover 62, the external connection connectors 66a to 66h are bolted to the cover 62. Furthermore, the bolts are bolted after aligning with the bolt fastening holes 26 of the branch circuit structure fixing part 74 provided on the inner surface 70 of the cover 62 and the bolt insertion holes 126 provided on the upright plate part 120 of the branch circuit structure 12. As a result, the housing 76 of the branch circuit structure 12 is fixed to the inner surface 70 of the cover 62. Then, the external connectors 66a to 66h protruding from the inner surface 70 of the cover 62 are connected to the connection portions 72a to 72h of the internal circuit provided in the branch circuit structure 12. For example, the connection terminal 112 of the external connector 66a is connected to the connection portion 72a using a relay bus 110. As a result, the external connector module 156 is configured to include the external connectors 66a to 66h, the cover 62, and the branch circuit structure 12.

[0066] Next, the branch circuit structure 12 of the external connection connector module 156 is inserted into the housing body 16 through the opening 54. Then, the bolt through hole 34 of the cover 62 of the external connection connector module 156 is aligned with the bolt fastening hole 26 of the periphery of the opening 54, and the cover 62 is bolted to the housing body 16. In addition, the leg 88 of the branch circuit structure 12 is aligned with the branch circuit structure support 30 protruding from the bottom wall 20 of the housing body 16 and bolted. Next, the battery high-voltage connector 44 and a pair of relay buses 86 are prepared. The relay buses 86 are connected to the branch circuit structure connection portion 50b that houses and is arranged in the bus 50 of the battery high-voltage connector 44. The battery high-voltage connector 44 thus configured is fixed to the battery high-voltage connector support 42 provided in the housing body 16. In addition, the relay buses 86 are connected to the bus 78a arranged in the branch circuit structure 12. Next, prepare the substrate-side connector module 128. For example, as shown... Figure 8 As shown, the substrate-side connector module 128 is constructed by mounting the circuit board 130 of the vehicle charger and the transformer 136 on the retaining plate 132. The substrate-side connector receiving section 138, located on the rear right side of the retaining plate 132, houses and fixes the substrate-side connector module 128, which is composed of integrated substrate-side connectors 140a to 140d. Each substrate-side connector 140a to 140d is connected to the printed wiring of the circuit board 130 via a relay terminal 150, a relay connector 152, and a terminal wire 154. Then, the retaining plate 132, which holds the circuit board 130 and the transformer 136 mounted on it, is assembled from above into the branch circuit structure 12 housed within the housing body 16.

[0067] At this time, the legs 146 of the retaining plate 132 are placed on the retaining plate support portion 24 protruding from the bottom wall 20 of the housing body 16 and fixed by bolts. By bolting the retaining plate 132 to the retaining plate support portion 24 provided on the metal housing body 16, the retaining plate 132 is assembled to the housing 14 in a heat-conducting manner. As a result, a heat dissipation path can be constructed to transfer the heat generated on the circuit board 130 to the housing 14 via the metal retaining plate 132, which has a better thermal conductivity than synthetic resin or the like. Therefore, this is particularly useful when installing electronic devices such as DC / DC converters and car chargers that are likely to generate heat on the circuit board 130. Here, the power supplied to the circuit board 130 via the board-side connector 140d is converted by the board-side connector module 128 and output from other board-side connectors 140a to 140c to the relay connectors 98a to 98c of the branch circuit structure 12. Furthermore, the relay connectors 98a-98c are connected to the connectors of various devices (not shown) via the connection portions 72a-72h and the relay terminals (e.g., relay buses 110, 114) through the external connection connectors 66a-66h. Finally, by overlapping the flange-shaped portion 75 of the cover portion 18 onto the flange-shaped portion 60 of the housing body 16 and tightening it with bolts, the upper opening of the housing body 16 is covered by the cover portion 18, thus completing the process. Figure 1 The electrical connection box 10 is shown. Furthermore, the electrical connection box 10 is used with the battery fixing part 32 of the housing 14 fixed to the housing of a battery (not shown).

[0068] According to the electrical connection box 10 of this disclosure, which is constructed in this way, the cover 62 of the housing 14, which blocks the opening 54, has eight through holes 64. External connection connectors 66a to 66h are assembled into each through hole 64, and the external connection connectors 66a to 66h protrude from the outer surface 68 of the cover 62. In addition, the branch circuit structure 12, which is fixed to the inner surface 70 of the cover 62, has eight connection points 72a to 72h, which are connected to the connection terminals of the corresponding external connection connectors 66a to 66h. As a result, the branch circuit structure 12 and the external connection connectors 66a to 66h are both fixed to the same cover 62, thus reducing the dimensional tolerances when connecting the branch circuit structure 12 and the external connection connectors 66a to 66h. Furthermore, compared with the existing structure that uses wires in the connection between the branch circuit structure 12 and the external connection connectors 66a to 66h, wires are not required. As a result, it is possible to reduce operation time and the number of parts.

[0069] Furthermore, the branch circuit structure 12 and the external connection connectors 66a-66h are assembled onto the cover 62 to form the external connection connector module 156. Therefore, the external connection connector module 156 can be pre-configured by assembling the branch circuit structure 12 and the external connection connectors 66a-66h onto the cover 62 before being assembled into the housing 14. Additionally, when assembling the branch circuit structure 12, the external connection connectors 66a-66h, and the cover 62 into the housing 14, the work can be completed simply by assembling the external connection connector module 156 into the opening 54 of the housing 14. Therefore, it is not necessary to separately assemble the branch circuit structure 12, the external connection connectors 66a-66h, and the cover 62 relative to the housing 14, and to separately connect the branch circuit structure 12 and the external connection connectors 66a-66h using wires, as is required in existing structures. Therefore, it is not necessary to ensure sufficient workspace, and space-saving and improved operability of the electrical connection box 10 can be achieved.

[0070] Furthermore, sometimes the circuit board 130 connected to the branch circuit structure 12 is housed within the same housing 14. Even in such cases, a substrate-side connector module 128, which integrates substrate-side connectors 140a to 140d, is mounted on the circuit board 130, and relay connectors 98a to 98d are provided on the branch circuit structure 12. These relay connectors 98a to 98d are concentrated and protrude from a portion of the base 118 and are respectively connected to the substrate-side connectors 140a to 140d. By connecting the relay connectors 98a to 98d together with the substrate-side connectors 140a to 140d, the connection between the circuit board 130 and the branch circuit structure 12 can be performed. As a result, compared to the existing structure that requires wires in the connection between the circuit board and the branch circuit structure, the number of components and the time required for connection operations can be reduced. Moreover, since there is no need to ensure space for operation between the circuit board 130 and the branch circuit structure 12, space-saving of the electrical connection box 10 can also be achieved.

[0071] <Other Implementation Methods>

[0072] The technology described in this specification is not limited to the embodiments described above and illustrated in the accompanying drawings. For example, the following embodiments are also included within the technical scope of the technology described in this specification.

[0073] (1) In the above embodiment 1, the case in which four substrate-side connectors 140a to 140d and four relay connectors 98a to 98d are described is illustrated, but the number and structure of the connectors can be chosen arbitrarily. As for the external connection connectors 66a to 66h, any number and shape of connectors can also be used.

[0074] (2) In the above embodiment 1, an example of a branch circuit structure 12 having a base 118 and a vertical plate 120 is shown. However, the shape of the branch circuit structure 12 is not limited to this. As long as it can be fixed to a cover provided with multiple external connection connectors and the connection part can be connected to the connection terminal of the external connection connector, any shape can be adopted.

[0075] (3) In the above embodiment 1, a sealing member 58 is sandwiched between the abutting surfaces of the opening 54 and the cover 62, but it can also be omitted depending on the required waterproof performance.

[0076] Label Explanation

[0077] 10 Electrical connection boxes

[0078] 12-branch circuit structure

[0079] 14 shell

[0080] 16 Shell Body

[0081] 18-piece cover

[0082] 20 bottom wall

[0083] 22 sidewalls

[0084] 24 Retaining plate support section

[0085] 26 bolt fastening holes

[0086] 28 Reinforcing Plate Section

[0087] 30-branch circuit structure support section

[0088] 32 Battery mounting section

[0089] 34 bolt through hole

[0090] 36 Containment recess

[0091] 38 protrusions

[0092] 40 Battery High Voltage Connector Through Hole

[0093] 41 Sealing Rubber

[0094] 42 Battery high voltage connector support

[0095] 44 Battery High Voltage Connector

[0096] 46 Fixing parts

[0097] 48 terminal retaining protrusion

[0098] 50 busbar

[0099] 50A battery connection part

[0100] 50b branch circuit structure connection part

[0101] 52 bolt through hole

[0102] 54 openings

[0103] 56 Sealing component housing section

[0104] 58 Sealing components

[0105] 60 flange-like portion

[0106] 62 cover

[0107] 64 through holes

[0108] 66a~66h External Connection Connectors

[0109] 68 outer surface

[0110] 70 inner surface

[0111] 72a~72h connection parts

[0112] 73 Sealing Rubber

[0113] 74 Branch Circuit Structure Fixing Part

[0114] 75 flange-like portion

[0115] 76 enclosures

[0116] 76a lower housing

[0117] 76b upper box

[0118] 78a~78d busbars

[0119] 80 wire harness

[0120] 80a terminal

[0121] 82 Fuse (Electrical Component)

[0122] 84 busbar insertion hole

[0123] 86 relay bus

[0124] 88 legs

[0125] 90 bolt through hole

[0126] 92 Top wall part

[0127] 94a~94d Repeater Connector Housing

[0128] 96 busbar insertion hole

[0129] 98a~98d repeater connectors

[0130] 100 busbar insertion hole

[0131] 102 busbar

[0132] 104a~104c intermediate connector housing

[0133] 106a-106c intermediate connector

[0134] 108 grounding busbar

[0135] 110 relay bus (relay terminal)

[0136] 112 connection terminal

[0137] 114 relay bus (relay terminal)

[0138] 116 connection terminal

[0139] 118 base

[0140] 120 vertical board department

[0141] 122 sidewall

[0142] 124a~124h incision site

[0143] 126 bolt through hole

[0144] 128 substrate-side connector module

[0145] 130 circuit board

[0146] 132 retaining plate

[0147] 134 Connection Part

[0148] 134a terminal fixing part

[0149] 134b terminal

[0150] 136 Transformer

[0151] 138 board-side connector housing

[0152] 140a~140d board-side connectors

[0153] 142 Protective Wall Section

[0154] 144 fixed legs

[0155] 146 legs

[0156] 148 legs

[0157] 150 relay terminal

[0158] 152 Relay Connector

[0159] 154 wire with terminals

[0160] 156 Connector module for external connection.

Claims

1. An electrical connection box, comprising: A branch circuit structure used to distribute power from the battery to various devices; A housing that accommodates the branch circuit structure; An opening that penetrates the side wall of the housing; A cover, which plugs the opening and is fixed to the side wall; and Multiple external connectors are fitted into multiple through holes that extend through the cover along the thickness direction and protrude from the outer surface of the cover. The branch circuit structure is fixed to the inner surface of the cover, and multiple connection points on the branch circuit structure are connected to the connection terminals of corresponding external connectors. The external connection connector module comprises the plurality of external connection connectors, the cover, and the branch circuit structure.

2. The electrical connection box according to claim 1, wherein, The electrical connection box has a sealing member that is clamped between the outer periphery of the opening of the housing and the abutting surface of the cover.

3. The electrical connection box according to claim 1 or claim 2, wherein, The branch circuit structure includes: an internal circuit, comprising busbars and electrical components; and a housing that encloses the internal circuit. The box has a base and a vertical plate, which stands upright from the base and is fixed in contact with the inner surface of the cover.

4. The electrical connection box according to claim 3, wherein, The connecting portion is disposed on the base, and the external connector connected to the connecting portion is held in the cover.

5. The electrical connection box according to claim 3 or claim 4, wherein, The electrical connection box also features: Circuit board, housed in the housing; and The substrate-side connector module is an integrated assembly of multiple substrate-side connectors mounted on the circuit board. The branch circuit structure has multiple relay connectors, which are centrally located at the base of the housing and connected to multiple substrate-side connectors to communicate with the internal circuit.

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