Connector and cable protective cover and electric vehicle

Abstract

The invention relates to a protective cover for a connector and a cable and an electric vehicle. A protective cover for a connector of an electrical device mounted on a vehicle and a cable connected to the connector is provided with: a first rigid protective member covering the connector; a second rigid protection member covering the cable extending from the connector at a location away from the connector; and a flexible connection member disposed in a gap between the first rigid protection member and the second rigid protection member and connecting the first rigid protection member and the second rigid protection member in a state of being bent so as to be separated from the cable.

Description

Technical Field

[0001] The technology disclosed in this specification relates to, for example, a protective cover for a connector and a cable of an electrical device mounted on a vehicle, and an electric vehicle. Background Art

[0002] Electrified vehicles are equipped with various electrical devices, such as motors and inverters, to drive the wheels. For example, these devices are equipped with connectors for connecting cables that transmit high-voltage electricity. A protective cover has been proposed to protect these connectors and cables from external factors (Japanese Patent Application Laid-Open No. 2013-66327).

[0003] However, the protective cover may reduce visibility when checking for foreign matter intrusion near the cable, or the protective cover may narrow the space for inspecting the cable. Summary of the Invention

[0004] This specification provides a technology that ensures the required protection performance of a connector and a cable and improves the ease of maintenance of the cable.

[0005] The technology disclosed in this specification is embodied in a connector of an electric device mounted on a vehicle and a protective cover of a cable connected to the connector.

[0006] The protective cover includes: a first rigid protective member covering the connector; and a second rigid protective member covering the cable extending from the connector at a position away from the connector.

[0007] The protective cover further includes a flexible connecting member that is disposed in a gap between the first rigid protective member and the second rigid protective member and connects the first rigid protective member and the second rigid protective member in a state of being bent so as to be separated from the cable.

[0008] With this protective cover, the first and second rigid protective members protect the connector and cable from external impacts and foreign object intrusion. Furthermore, the flexible connecting member, sandwiched between the gaps between these rigid protective members, ensures visibility and accessibility of the cable within the vehicle. This protective cover not only protects the connector and cable, but also helps improve detection of adverse conditions such as foreign object intrusion into and around cables of electrical equipment installed in the vehicle.

[0009] Furthermore, such a protective cover can also easily accommodate the bent shape of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Hereinafter, features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and wherein:

[0011] Figure 1 This is a cross-sectional view of a protective cover mounted on the vehicle left side of an electric axle mounted on the vehicle, as viewed from the front of the vehicle.

[0012] Figure 2 Viewed from the left side of the vehicle Figure 1 The diagram of the protective cover shown shows a portion of the cable cover and the connecting member on the vehicle front side in a cutaway state.

[0013] Figure 3A It means that the impact is input from the left side of the vehicle to Figure 1 An example of the diagram of the situation when the protective cover is shown.

[0014] Figure 3B It means that the impact is input from the left side of the vehicle to Figure 1 Another example of the condition of the diagram when the protective cover is shown. DETAILED DESCRIPTION

[0015] One embodiment disclosed in this specification is a protective cover for a connector of an electrical device mounted on a vehicle and a cable connected to the connector. The protective cover may include: a first rigid protective member that covers the connector; a second rigid protective member that covers the cable extending from the connector at a position away from the connector; and a flexible connecting member that is arranged in a gap between the first rigid protective member and the second rigid protective member and connects the first rigid protective member and the second rigid protective member in a state of being bent so as to be separated from the cable.

[0016] In one aspect of the above embodiment, the connector may be mounted on a side surface of the electrical equipment in the vehicle width direction, and the flexible connecting member may be configured to bend so as to bulge in the vehicle width direction. According to this aspect, when a load is applied to the first rigid protective member or the second rigid protective member, the flexible connecting member connects the two rigid protective members, thereby preventing the load from being transferred to the other.

[0017] In one embodiment of the present invention, the flexible connecting member may be a mesh-shaped sheet. This embodiment ensures that the flexible connecting member is not susceptible to foreign matter intrusion and improves its flexibility. Furthermore, the mesh-shaped sheet contributes to improved visual recognition.

[0018] In one aspect of the above embodiment, the electrical device may be an electric drive module of a vehicle including at least a drive motor. According to this aspect, cables connected to the electric drive module of the vehicle can be protected and easy maintenance can be ensured.

[0019] Another embodiment disclosed in this specification is an electric vehicle including: an electric device; and the protective cover provided on the electric device. According to this embodiment, a vehicle is provided that is excellent in cable visibility and ease of maintenance.

[0020] The protective cover for a vehicle disclosed in this specification is described below with appropriate reference to the accompanying drawings. It should be noted that, in this specification, the vehicle is an electric vehicle. Electric vehicles are not particularly limited and include, for example, battery electric vehicles (BEVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell electric vehicles (FCEVs), and other vehicles whose drive wheels are driven by a motor.

[0021] Figure 1 1 is a diagram showing an example of a connector 20, a cable 30, and a protective cover 40 mounted on an electric axle 10 of a vehicle, and the protective cover 40 is shown as a cross-sectional view viewed from the front side of the vehicle. Figure 2 This is a view of the protective cover 40 viewed from the side of the vehicle and in the left direction (L direction), showing a portion of the cable cover 50 and the connecting member 60 on the vehicle front side in a cutaway state. Figure 1 and Figure 2 , X represents the vehicle width direction, Y represents the vehicle front-rear direction, and Z represents the vehicle up-down direction. In the following description, unless otherwise specified, the up-down direction, the left-right direction, and the front-rear direction refer to the up-down direction, the left-right direction, and the front-rear direction of the vehicle.

[0022] The protective cover 40 protects the cable 30 attached to the electric axle 10 mounted on the vehicle and the connector 20 to which the cable 30 is connected.

[0023] The electric axle 10 is an electric module that includes an inverter 12, a motor 14, and a transmission. The electric axle 10 is, for example, located near the center of the front cabin of a vehicle. The electric axle 10 is an example of an electrical device as used herein. For example, the electric axle 10 has an inverter 12 located in its upper portion to generate the driving power for the motor 14, and a motor 14 located in its lower portion. The electric axle 10 includes an inverter housing 12a that houses the inverter 12 and a motor housing 14a that houses the motor 14.

[0024] In this specification, electrical equipment is not particularly limited, but it is sometimes preferred to be supplied with high-voltage power (over approximately 60V DC, over approximately 30V AC). This is due to the increasing demand for improved safety. It should be noted that electrical equipment is not limited to electric drive modules such as the electric axle 10; it can also include motors, inverters, A / C compressors, and the like.

[0025] Connector 20 is provided in inverter housing 12a. Connector 20 electrically connects cables 30 to inverter 12. Connector 20 includes one or two or more terminals (e.g., six terminals, not shown) mounted on terminal block 100 on the left side wall of inverter housing 12a, and cable connectors 22 that connect inverter-side plugs 32 of six cables 30 to the six terminals, respectively.

[0026] Although not shown, six terminals are arranged side by side along the front-to-back direction on the terminal block 100. These terminals are respectively connected to the inverter 12. The cable connector 22 is configured to be inserted into a socket (not shown) formed on the lower side of the six terminals of the terminal block 100, for example. The cable connector 22 has six insertion ports 22a into which the plugs 32 on the inverter 12 side of the six cables 30 can be inserted. The cable connector 22 extends obliquely downward to the left away from the inverter housing 12a, and the lower end of the cable connector 22 serves as the insertion port 22a. By inserting the plugs 32 of the six cables 30 into the six insertion ports 22a, the six cables 30 are respectively connected to the terminals on the terminal block 100.

[0027] A connector 24 is provided on the motor housing 14a. The connector 24 electrically connects the cables 30 to the motor 14. The connector 24 includes six terminals (not shown) mounted on a terminal block 120 on the upper wall of the motor housing 14a, and a cable connector 26 that allows the motor 14-side plugs 34 of the six cables 30 to be connected to the terminals.

[0028] Although not shown, six terminals are arranged side by side in the front-to-back direction on the terminal block 120. These terminals are respectively connected to the motor 14. The cable connector 26 is configured to be inserted into a socket (not shown) formed on the left side of the six terminals of the terminal block 120. The cable connector 26 has six insertion ports 26a into which the plugs 34 on the motor 14 side of the six cables 30 can be inserted. The cable connector 26 extends approximately horizontally to the left in a manner away from the motor housing 14a from near the center of the vehicle, and the left end of the cable connector 26 serves as the insertion port 26a. By inserting the plugs 34 of the six cables 30 into the six insertion ports 26a, the six cables 30 are respectively connected to the terminals on the terminal block 120.

[0029] As described above, each of the plurality of cables 30 connects the connector 20 and the connector 24. Each cable 30 is formed by bundling a plurality of electric wires, has a diameter of several tens of millimeters as a whole, and is flexible.

[0030] As described above, each cable 30 includes a plug 32 electrically connectable to the connector 20 of the inverter case 12a. Each cable 30 also includes a plug 34 electrically connectable to the connector 24 of the motor case 14a.

[0031] For example, Figure 1 As shown, when cable 30 is connecting connector 20 and connector 24, due to the positional relationship between connectors 20 and 24, cable 30 curves from the lower end of connector 20 toward the lower left, then bends toward the center of the vehicle, and then curves in a generally horizontal direction toward connector 24. In other words, cable 30 has a generally L-shape with a bend P that bends to the far left.

[0032] The protective cover 40 covers the left side of the connector 20 and the cable 30 including six terminals (not shown) and the cable connector 22 on the terminal block 100. The protective cover 40 includes a connector cover 42, a cable cover 50, and a connecting member 60.

[0033] The connector cover 42 covers the left side of the connector 20. The connector cover 42 includes a terminal cover portion 44 and a contact cover portion 46.

[0034] The terminal cover 44 is formed so as to bulge out to the left side so as to form a space mainly surrounding the six terminals corresponding to the plurality of cables 30. The connector cover 46 extends obliquely downward and leftward from the lower edge 44a of the terminal cover 44, thereby covering the cable connector 22. The terminal cover 44 and the connector cover 46 are each formed from a steel plate of a predetermined thickness having high rigidity, thereby forming an integral connector cover 42. The connector cover 42 is fixed to the left side wall of the inverter housing 12a at a flat flange portion 48 provided at the front and rear end edges of the terminal cover 44, for example, by bolting. The connector cover 42 is an example of a first rigid protective member in this specification.

[0035] The cable cover 50 covers the left side of the portion of the cable 30 that is a predetermined distance away from the plug 32. The cable cover 50 also covers the left side of the portion of the cable 30 that is near the bent portion P and below the bent portion P.

[0036] The cable cover 50 is spaced a predetermined distance downward and leftward from the lower edge 42a of the connector cover 42 and is positioned substantially along the lower edge 42a. The cable cover 50 is a generally plate-shaped member having an upper edge 50a that extends along the vicinity of the bend P of the six cables 30. The cable cover 50 is positioned to the left side of the vehicle relative to the lower edge 42a of the connector cover 42. A portion of the cable cover 50 is secured to the left side wall of the motor case 14a, for example, by bolts. The cable cover 50 is an example of a second rigid protective member as used in this specification.

[0037] The connecting member 60 is positioned in the gap G between the connector cover 42 and the cable cover 50. The connecting member 60 is a flexible sheet formed of a mesh of metal wires. The mesh size of the connecting member 60 is sufficient to block the intrusion of foreign matter, such as water droplets and small foreign objects, from the left side that could cause damage to the cable 30. Furthermore, the connecting member 60 covers the gap G and is formed to a thickness sufficient to create a sufficient space around the cable 30. The connecting member 60 is an example of a flexible connecting member described in this specification.

[0038] The connecting member 60 primarily covers the left side of the connector 32 of the cable 30 and the area near and below the bend P. Furthermore, the connecting member 60 includes an open portion 60a on the vehicle's front side of the gap G between the connector cover 42 and the cable cover 50. Furthermore, the connecting member 60 is positioned in the gap G, bent to the left and separated from the connector 32 of the cable 30. Consequently, sufficient space is created near the gap G, around the connector 32 of the cable 30 and the bend P, from the vehicle's front toward the rear.

[0039] The connecting member 60 is fixed at its upper edge 62 to the joint cover 46 of the connector cover 42 by, for example, bolts, and the lower edge 64 is fixed to the upper edge 50 a of the cable cover 50 by, for example, bolts.

[0040] Next, the function of the protective cover 40 will be described. The protective cover 40 protects the connector 20 and the portion of the cable 30 away from the connector 20 from various external inputs that enter from the vehicle exterior of the protective cover 40 by the connector cover 42 and the cable cover 50 .

[0041] like Figure 1 and Figure 2As shown, the flexible connecting member 60 is bent to cover the gap G extending in the front-to-rear direction between the connector cover 42 and the cable cover 50. This allows the cable 30 near the gap G to be visually identified through the opening 60a, and facilitates ensuring a space for access for maintenance. Thus, the protective cover 40 protects the connector 20, cable 30, and the like, and improves the ease of maintenance of the connector 20 and cable 30.

[0042] Furthermore, the connecting member 60 has a certain degree of external input blocking capability, thereby suppressing the intrusion of water and foreign matter from the outside of the vehicle at the gap G. Furthermore, since the connecting member 60 is a mesh sheet, a certain degree of visibility of the connector 20 and cable 30 can be ensured from above the vehicle through the connecting member 60.

[0043] In addition, for example, Figure 3A and Figure 3B As shown, when a load is input from the left side of the vehicle and a member to the left of the cable cover 50 moves toward the connector 20 or the cable 30, the input of the load to the connector 20 or the cable 30 is suppressed by the connector cover 42 or the cable cover 50. Furthermore, the coupling member 60 is flexible, so the load input to the connector cover 42 or the cable cover 50 is less likely to be transmitted to the cable cover 50 or the connector cover 42. Consequently, simultaneous damage to both the connector 20 and the cable 30 is suppressed.

[0044] Although not shown, even when a load is input to the connector 20 or the cable 30 from a direction other than the vehicle left side, such as the vehicle front, the load is not easily transmitted to the cable cover 50 or the connector cover 42 due to the presence of the connecting member 60 .

[0045] Furthermore, by arranging the connector cover 42 and the cable cover 50 via the connecting member 60 , the shapes and arrangements of the connector cover 42 and the cable cover 50 that can more reliably protect the connector 20 and the cable 30 can be designed according to the expected input pattern of external loads.

[0046] It should be noted that in the embodiment described above, the connector cover 42 of the inverter 12 serves as the first rigid protective member, and the cable cover 50 of the cable 30 connected to the inverter 12 serves as the second rigid protective member. However, this is not limiting. The first and second rigid protective members may simply be components that protect the connector and cable of the electrical device to which the protective cover is applied.

[0047] The connector 20 employs a configuration in which terminals are arranged on the terminal block 100 , but the present invention is not limited thereto. For example, the terminals may be arranged on the inverter case 12 a without the terminal block 100 being interposed therebetween.

[0048] Furthermore, although the cable 30 is connected to the connector 20 via the plug 32 , the present invention is not limited thereto. One end of the cable 30 may be connected to the connector 20 without passing through the plug 32 .

[0049] Based on the above description, this specification includes the following configurations.

[0050] [1] A protective cover for a connector of an electrical device mounted on a vehicle and a cable connected to the connector, comprising: a first rigid protective member covering the connector; a second rigid protective member covering the cable extending from the connector at a position away from the connector; and a flexible connecting member disposed in a gap between the first rigid protective member and the second rigid protective member and connecting the first rigid protective member and the second rigid protective member in a state of being bent so as to be separated from the cable.

[0051] [2] The protective cover according to [1], wherein the connector is mounted on a side surface of the electrical device in the vehicle width direction, and the flexible connecting member has a shape that is bent so as to bulge in the vehicle width direction.

[0052] [3] The protective cover according to [1] or [2], wherein the flexible connecting member is a mesh-shaped sheet.

[0053] [4] The protective cover according to any one of [1] to [3], wherein the electrical device is a unit of the vehicle including at least a drive motor.

[0054] [5] An electric vehicle comprising: an electric device; and the protective cover according to any one of [1] to [4], provided on the electric device.

Claims

1. A protective cover for a connector of an electrical device mounted on a vehicle and a cable connected to the connector, comprising: a first rigid protective member covering the connector; a second rigid protective member covering the cable extending from the connector at a location remote from the connector; as well as The flexible connection member is disposed in a gap between the first rigid protection member and the second rigid protection member, and connects the first rigid protection member and the second rigid protection member in a state of being bent so as to be separated from the cable.

2. The protective cover according to claim 1, wherein: The connector is mounted on a side surface of the electrical equipment in the vehicle width direction. The flexible connecting member has a shape that is bent so as to bulge in the vehicle width direction.

3. The protective cover according to claim 1, wherein: The flexible connecting member is a mesh sheet.

4. The protective cover according to claim 1, wherein: The electric device is a unit of the vehicle including at least a driving motor.

5. An electric vehicle comprising: Electrical equipment; and The protective cover according to claim 1, provided on the electrical device.

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