Wiring material, electrical connection unit, and method for manufacturing wiring material

Abstract

The wiring material has a bus bar and a heat storage member. The heat storage member is attached to the bus bar by a caulked fixing portion.

Description

Technical Field

[0001] The embodiments of the present invention relate to a wiring material, an electrical connection unit, and a method for manufacturing the wiring material. Background Technology

[0002] An electrical connection unit is known, which has electronic components and a busbar electrically connected to the electronic components.

[0003] Prior technology documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2024-037492 Summary of the Invention

[0006] The technical problem that the invention aims to solve

[0007] Furthermore, improvements in thermal properties are expected for the electrical connection unit.

[0008] One embodiment provides a wiring material, an electrical connection unit, and a method for manufacturing the wiring material that can improve thermal properties.

[0009] Technical means to solve technical problems

[0010] One embodiment of the wiring material includes a busbar and a heat storage component. The heat storage component is mounted to the busbar by a riveted fastener.

[0011] One embodiment of the electrical connection unit includes wiring material and a connection object connected to the wiring material. The wiring material has a busbar and a heat storage member. The heat storage member is mounted to the busbar by a riveted fixing portion.

[0012] One embodiment of a method for manufacturing a wiring material includes: forming a fixing hole in a first member, which is one of a busbar and a heat storage member; overlapping a second member, which is the other of the busbar and the heat storage member, onto the first member; deforming a portion of the second member by applying pressure and inserting it into the fixing hole; and fixing the busbar and the heat storage member by riveting.

[0013] Invention Effects

[0014] According to one implementation method, it is possible to improve thermal properties. Attached Figure Description

[0015] Figure 1 This is a cross-sectional view showing the electrical connection unit of the first embodiment.

[0016] Figure 2 This is a perspective view showing the wiring material of the first embodiment.

[0017] Figure 3 This is a diagram used to explain the fixing part of the first embodiment.

[0018] Figure 4 This is a diagram used to illustrate the manufacturing method of the wiring material according to the first embodiment.

[0019] Figure 5 This is a cross-sectional view used to illustrate the manufacturing method of the wiring material according to the first embodiment.

[0020] Figure 6 This is a diagram used to explain the fixing part of the second embodiment.

[0021] Figure 7 This is a cross-sectional view used to illustrate the manufacturing method of the wiring material according to the second embodiment.

[0022] Figure 8 This is a perspective view of the wiring material in the first variation of the embodiment.

[0023] Figure 9 This is a cross-sectional view of the electrical connection unit in the second variation of the embodiment.

[0024] Figure 10 This is a perspective view used to illustrate the heat storage member of the second variation of the embodiment. Detailed Implementation

[0025] Hereinafter, embodiments will be described with reference to the accompanying drawings. In the following description, components having the same or similar functions will be labeled with the same reference numerals. Furthermore, repeated descriptions of these components will sometimes be omitted. Additionally, the components described below do not limit the scope of the embodiments.

[0026] In this disclosure, the terms are defined as follows: The term "connection" is not limited to mechanical connections and may include electrical connections. That is, "connection" is not limited to the case where two elements that are the objects of connection are directly connected, but may include the case where two elements that are the objects of connection are connected with other elements interposed between them. The term "facing" means that, when viewed from a specific direction, the virtual projected images of two objects overlap each other. That is, "facing" is not limited to the case where two objects are directly opposite each other, but may include the case where two objects are opposite each other with other components between them. The terms "parallel," "orthogonal," or "identical" may respectively include the cases of "approximately parallel," "approximately orthogonal," or "approximately identical."

[0027] In this disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows. The +X direction is, for example, the extension direction of at least a portion of the extension 63 of the busbar 60 described later (see reference). Figure 2 The -X direction is the direction opposite to the +X direction. Hereinafter, without distinguishing between the +X and -X directions, it will be simply referred to as the "X direction". The +Y and -Y directions are directions that intersect (e.g., are orthogonal) the X direction. The +Y direction is, for example, the width direction of the extension 63 of the busbar 60 (see...). Figure 2 The -Y direction is the direction opposite to the +Y direction. Hereinafter, without distinguishing between the +Y and -Y directions, it will be simply referred to as the "Y direction". The +Z and -Z directions are directions that intersect (e.g., are orthogonal) the X and Y directions. The +Z direction is the direction from the extension 63 of the busbar 60 toward the heat storage member 70 described later (see [reference]). Figure 2 The -Z direction is the opposite of the +Z direction. Hereinafter, without distinguishing between the +Z and -Z directions, it will be simply referred to as the "Z direction".

[0028] (First Embodiment)

[0029] <1. Composition of Electrical Connection Unit>

[0030] Figure 1 This is a cross-sectional view showing the electrical connection unit 1 according to the first embodiment. The electrical connection unit 1 is, for example, an on-board device installed in vehicles such as EVs (Electric Vehicles), HEVs (Hybrid Electric Vehicles), or PHEVs (Plug-in Hybrid Electric Vehicles). The electrical connection unit 1 may also be referred to as an "electrical connection box" or "junction box." However, the electrical connection unit 1 is not limited to a box-shaped device. The electrical connection unit 1, for example, has a housing 5 and a main body MU.

[0031] The housing 5 is a component that forms the outline of the electrical connection unit 1. The housing 5 is, for example, made of synthetic resin and has insulating properties. The housing 5 houses the main body MU. The housing 5, for example, has an opening 5h that exposes the connecting member 20 for external connection. Alternatively, the housing 5 may be omitted.

[0032] The main body MU is the part that performs the main functions of the electrical connection unit 1 (e.g., switching of electrical connection states or overcurrent protection). The main body MU can also be referred to as a "circuit configuration". The main body MU includes, for example, one or more electronic components 10, connecting components 20, base components 30, multiple fixing parts 40, and one or more wiring materials 50.

[0033] <2. Electronic Components>

[0034] First, the electronic component 10 will be described. The electronic component 10 is an electronic component mounted according to the functions required by the main body MU. The electronic component 10 may be, for example, a connector, a fuse, a relay (e.g., a mechanical relay or a semiconductor relay), a capacitor, a branching component, various sensors (e.g., a current sensor or a voltage sensor), an electronic control unit, or an electronic component unit consisting of two or more of these. However, the type of electronic component 10 is not limited to the examples described above. The electronic component 10 may be, for example, a heat-generating component that generates heat when energized. The electronic component 10 may have, for example, a housing 11, a main body 12, and multiple terminals 13.

[0035] The housing 11 is the outermost component that forms most of the shape of the electronic component 10. The housing 11 is made of, for example, synthetic resin and has insulating properties. The housing 11 houses the main body 12 of the component. Alternatively, the housing 11 and the main body 12 of the component may be integrally formed.

[0036] The main body 12 of the component is the part that performs the main functions of the electronic component 10. For example, if the electronic component 10 is a relay, the main body 12 includes a switching part (e.g., a contact part) that switches between an on state and a non-on state. For example, if the electronic component 10 is a fuse, the main body 12 includes a fusing part that melts when an overcurrent flows. For example, if the electronic component 10 is a capacitor, the main body 12 includes a part that stores charge.

[0037] Terminal 13 is an electrical connection portion exposed to the outside of the housing 11. Terminal 13 is electrically connected to the main body 12 of the component inside the housing 11. In this embodiment, the electronic component 10 comprises a plurality of terminals 13, including terminals 13A and 13B. One of terminals 13A and 13B is a positive terminal. The other of terminals 13A and 13B is a negative terminal. One of terminals 13A and 13B is an example of a "first terminal." The other of terminals 13A and 13B is an example of a "second terminal."

[0038] Each terminal 13 has a mounting hole 13h for inserting a fastening member 41 (e.g., a screw or bolt), described later. The mounting hole 13h may not have a threaded groove. For example, the mounting hole 13h may be a through hole extending through the terminal 13 in the Z direction. Furthermore, in this disclosure, the term "mounting hole" is not limited to a hole without a threaded groove; it may also be a hole with a threaded groove for engaging the fastening member 41. Additionally, in this disclosure, the term "mounting hole" is not limited to a through hole; it may also be a bottomed hole. For example, the mounting hole 13h may be either a hole with a threaded groove for engaging the fastening member 44, or it may be a bottomed hole.

[0039] <3. Connecting Components>

[0040] Next, the connecting member 20 will be described. The connecting member 20 is a component used for electrically connecting multiple components. The connecting member 20 forms part of the circuit in the electrical connection unit 1. The connecting member 20 is made of metal (e.g., copper, copper alloy, aluminum, or aluminum alloy). The connecting member 20 has a mounting hole 20h for inserting the fastening member 44, which will be described later. The mounting hole 20h, for example, does not have a threaded groove. The mounting hole 20h is, for example, a through hole extending through the connecting member 20 in the Z direction. Alternatively, the mounting hole 20h may have a threaded groove or be a bottomed hole.

[0041] In this embodiment, the connecting member 20 is disposed between the wiring material 50 and the busbar 9 for external connection, providing an electrical connection between the wiring material 50 and the busbar 9. The busbar 9 is a busbar used to electrically connect the electrical connection unit 1 to an external device. In this disclosure, "external device" refers to an electrical device located outside the electrical connection unit 1. External devices may include, for example, a battery cell mounted on a vehicle, or an inverter for driving a vehicle's motor, but are not limited to these examples.

[0042] Furthermore, in this disclosure, the term "connecting component" is not limited to the examples described above. A connecting component (e.g., connecting component 20) may also be a member disposed between a terminal 13 of another electronic component 10 and a wiring material 50, electrically connecting the other electronic component 10 to the wiring material 50. Additionally, a connecting component (e.g., connecting component 20) may also be a member disposed between two wiring materials 50, electrically connecting the two wiring materials 50. Furthermore, a connecting component (e.g., connecting component 20) may also be a conventional busbar disposed within the electrical connection unit 1 (e.g., busbar 8 described later, see...). Figure 9 The component that electrically connects the busbar to the wiring material 50.

[0043] <4. Base Components>

[0044] Next, the base member 30 will be described. The base member 30 is a support member that supports one or more of the electronic component 10, the connecting component 20, and the wiring material 50. The base member 30 is made of, for example, synthetic resin and has insulating properties. In this embodiment, fastening members 41 and 44, which will be described later, are fixed to the base member 30.

[0045] <5. Fixing Part>

[0046] The fixing part 40 is used to fix the wiring material 50 and the connection object. Multiple fixing parts 40 may include, for example, a first fixing part 40A and a second fixing part 40B.

[0047] <5.1 First Fixing Part>

[0048] The first fixing part 40A is a fixing part that fixes the first connecting part 61 and the first connecting object of the wiring material 50 described later. The first fixing part 40A includes, for example, a fastening member 41 (e.g., a bolt or screw), a locking member 42 (e.g., a nut), and a washer 43.

[0049] The fastening member 41 is, for example, a bolt having a shaft portion 41a and a head 41b. The circumferential surface of the shaft portion 41a has threads. The shaft portion 41a is engaged by a washer 43 and by a locking member 42. The head 41b has a larger diameter than the shaft portion 41a. In this embodiment, the fastening member 41 is fixed to the base member 30 with the shaft portion 41a protruding from the base member 30 in the +Z direction. The fastening member 41 is an example of a "first fastening member". Furthermore, the first fixing portion 40A is not limited to the above example. The first fixing portion 40A can be any structure that fixes the first connecting portion 61 of the wiring material 50 and the first connecting object, and is not limited to a specific structure.

[0050] <5.2 Second Fixing Part>

[0051] The second fixing part 40B is a fixing part that fixes the second connecting part 62 of the wiring material 50 and the second connecting object. The second fixing part 40B includes, for example, a fastening member 44 (e.g., a bolt or screw), a locking member 45 (e.g., a nut), and a washer 46.

[0052] The fastening member 44 is, for example, a bolt having a shaft portion 44a and a head 44b. The circumferential surface of the shaft portion 44a has threads. The shaft portion 44a is engaged by a washer 46 and by a locking member 45. The head 44b has a larger diameter than the shaft portion 44a. In this embodiment, the fastening member 44 is fixed to the base member 30 with the shaft portion 44a protruding from the base member 30 in the +Z direction. The fastening member 44 is an example of a "second fastening member". Furthermore, the second fixing portion 40B is not limited to the above example. The second fixing portion 40B can be any structure that fixes the second connecting portion 62 of the wiring material 50 and the second connecting object, and is not limited to a specific structure.

[0053] <6. Cabling Materials>

[0054] Next, the wiring material 50 will be explained.

[0055] Figure 2This is a perspective view of the wiring material 50. The wiring material 50 includes, for example, a busbar 60 (a busbar for power transmission) and a heat storage component 70 (e.g., a busbar 70A for heat storage).

[0056] <6.1 Busbar for Power Supply>

[0057] Busbar 60 is a wiring component that electrically connects multiple connection objects. Busbar 60 is made of metal (e.g., copper, copper alloy, aluminum, or aluminum alloy) and is conductive. Busbar 60 electrically connects a first connection object to a second connection object. For example, busbar 60 electrically connects electronic component 10 to connection component 20. Electronic component 10 is an example of a "first connection object." Connection component 20 is an example of a "second connection object."

[0058] However, the first and second connection objects are not limited to the examples described above. For example, the first connection object can be any one of an electronic component, a connecting component, another busbar within the electrical connection unit 1 (e.g., a typical busbar 8 or a busbar 60 included in another wiring material 50), or a busbar 9 for external connection. For example, the second connection object can be any one of an electronic component, a connecting component, another busbar within the electrical connection unit 1 (e.g., a typical busbar 8 or a busbar 60 included in another wiring material 50), or a busbar 9 for external connection. For example, busbar 60 may electrically connect electronic component 10 (the first connection object) to another electronic component 10 (the second connection object). Busbar 60 may also electrically connect connecting component 20 (the first connection object) to another connecting component 20 (the second connection object).

[0059] Hereinafter, as an example of a busbar 60, a busbar 60 that electrically connects an electronic component 10 (the first connection object) to a connecting component 20 (the second connection object) will be described. However, in the following description, the terms "electronic component 10" and "connecting component 20" can be appropriately replaced with other components based on the above-mentioned purpose.

[0060] like Figure 2 As shown, the busbar 60 has, for example, a first connecting portion 61, a second connecting portion 62, and an extension portion 63.

[0061] (First connecting part)

[0062] The first connecting portion 61 is the portion connected to the first connected object (e.g., electronic component 10). The first connecting portion 61 is located midway through the busbar 60 or at the first end of the busbar 60. The first connecting portion 61 is the portion facing the first fixing portion 40A when viewed from the Z direction (e.g., the portion facing the fastening member 41, the engaging member 42, or the washer 43). In this embodiment, the first connecting portion 61 is defined as a square area tangent to the first fixing portion 40A when viewed from the Z direction (see reference). Figure 2 ).

[0063] The first connecting portion 61 has a first mounting hole 61h for inserting the fastening member 41. The mounting hole 61h does not have a threaded groove, for example. The mounting hole 61h is, for example, a through hole that passes through the first connecting portion 61 in the Z direction. The mounting hole 61h is an example of a "first mounting hole".

[0064] The mounting hole 61h of the first connecting portion 61 overlaps with the mounting hole 13h of the electronic component 10 in the Z direction. The fastening member 41 is inserted along the Z direction into the mounting hole 61h of the first connecting portion 61 and the mounting hole 13h of the electronic component 10. The engaging member 42 engages with the front end of the fastening member 41 passing through the mounting hole 61h of the first connecting portion 61 and the mounting hole 13h of the electronic component 10. With this configuration, the terminal 13 of the electronic component 10 and the first connecting portion 61 are fixed. Alternatively, instead of the above example, either the mounting hole 61h of the first connecting portion 61 or the mounting hole 13h of the electronic component 10 may have a threaded groove for engaging with the fastening member 41. In this case, the engaging member 42 may be omitted.

[0065] (Second connecting part)

[0066] The second connecting portion 62 is the portion connected to the second connecting object (e.g., connecting member 20). The second connecting portion 62 is located midway through the busbar 60 or at the second end of the busbar 60. The second connecting portion 62 is the portion facing the second fixing portion 40B when viewed from the Z direction (e.g., facing the fastening member 44, the engaging member 45, or the washer 46). In this embodiment, the second connecting portion 62 is defined as a square region tangent to the second fixing portion 40B when viewed from the Z direction (see reference). Figure 2 ).

[0067] The second connecting portion 62 has a second mounting hole 62h for inserting the fastening member 44. The mounting hole 62h, for example, does not have a threaded groove. The mounting hole 62h is, for example, a through hole that penetrates the second connecting portion 62 along the Z direction. The mounting hole 62h is an example of a "second mounting hole".

[0068] The mounting hole 62h of the second connecting portion 62 overlaps with the mounting hole 20h of the connecting member 20 in the Z direction. The fastening member 44 is inserted along the Z direction into both the mounting hole 62h of the second connecting portion 62 and the mounting hole 20h of the connecting member 20. The engaging member 45 engages with the front end of the fastening member 44 passing through both the mounting hole 62h of the second connecting portion 62 and the mounting hole 20h of the connecting member 20. With this configuration, the connecting member 20 and the second connecting portion 62 are fixed. Alternatively, instead of the above example, either the mounting hole 62h of the second connecting portion 62 or the mounting hole 20h of the connecting member 20 may have a threaded groove for engaging with the fastening member 44. In this case, the engaging member 45 may be omitted.

[0069] (Extension)

[0070] An extension 63 is disposed between the connecting portion 61 and the connecting portion 62. The extension 63 extends through both the connecting portion 61 and the connecting portion 62. The extension 63 connects the connecting portion 61 and the connecting portion 62. Figure 2 In the example shown, the extension 63 extends linearly along the X direction. However, the extension 63 may also include a portion that bends and extends along the Y or Z direction. In this case, the "extension direction of the extension" refers to the direction along the extension 63 while bending. The extension 63 is formed, for example, in a plate shape. The Z direction is the thickness direction (plate thickness direction) of the extension 63. In this embodiment, the entire busbar 60, including the first connecting portion 61, the second connecting portion 62, and the extension 63, is formed in a plate shape.

[0071] <6.2 Thermal storage components (busbars for thermal storage)>

[0072] Next, the heat storage component 70 will be described. The heat storage component 70 is a metal component installed on the busbar 60. The heat storage component 70 is, for example, a component that stores (absorbs) at least a portion of the heat emitted by the first or second connected object and / or at least a portion of the heat emitted by the busbar 60 itself. Instead of the above examples / in addition to the above examples, the heat storage component 70 may also be a component that reduces thermal interference from external devices (external connection busbar 9) corresponding to the electronic component 10. The heat storage component 70 may be, for example, made of copper, copper alloy, aluminum, or aluminum alloy, but is not limited to these examples.

[0073] In this embodiment, the heat storage member 70 is installed on the extension 63 of the busbar 60. For example, the heat storage member 70 is positioned away from the first connecting portion 61 and the second connecting portion 62 of the busbar 60. That is, the heat storage member 70 is positioned in an area where the first fixing portion 40A and the second fixing portion 40B do not overlap when viewed from the Z direction.

[0074] In this embodiment, as an example of the heat storage member 70, a heat storage busbar 70A is provided. The heat storage busbar 70A is a metal plate member arranged along the energizing busbar 60. The heat storage busbar 70A is arranged overlapping the energizing busbar 60 in the Z direction.

[0075] In this embodiment, a heat storage member 70 that satisfies the following conditions is defined as a heat storage manifold 70A. Specifically, the heat storage member 70 has a thickness T70 as its thickness in the direction (Z direction) overlapping the extension 63 of the manifold 60. The heat storage member 70 has a length L70 as its length in the extension direction (e.g., the X direction, hereinafter simply referred to as the "extension direction") of the extension 63 of the manifold 60. Furthermore, the heat storage member 70 has a width W70 as its width in the direction orthogonal to the aforementioned extension direction (e.g., the Y direction, hereinafter simply referred to as the "width direction"). In this embodiment, a heat storage member 70 whose length L70 and width W70 are both greater than the thickness T70, and whose length L70 is greater than its width W70, is defined as a heat storage manifold 70A.

[0076] For example, the heat storage member 70 (heat storage manifold 70A) is formed as a plate (flat shape) along the extension 63 of the manifold 60. For example, the thickness T70 of the heat storage member 70 in the Z direction is smaller than the length L70 of the heat storage member 70 in the aforementioned extension direction. In this embodiment, the thickness T70 of the heat storage member 70 in the Z direction is smaller than half of the length L70 of the heat storage member 70 in the aforementioned extension direction. Furthermore, the width W70 of the heat storage member 70 in the Y direction is smaller than the length L70 of the heat storage member 70 in the aforementioned extension direction. In this embodiment, the width W70 of the heat storage member 70 in the Y direction is smaller than half of the length L70 of the heat storage member 70 in the aforementioned extension direction.

[0077] Furthermore, the shape of the heat storage member 70 is not limited to the examples described above. For example, the width W70 in the Y direction of the heat storage member 70 may be greater than the length L70 in the aforementioned extending direction. For example, the thickness T70 in the Z direction of the heat storage member 70 may be greater than at least one of the width W70 in the Y direction and the length L70 in the aforementioned extending direction.

[0078] In this embodiment, the heat storage member 70 is configured to extend for more than half its length in the extending direction of the extension 63 of the busbar 60. For example, the length L70 of the heat storage member 70 in the extending direction is greater than half of the length L63 of the extension 63 of the busbar 60 in the extending direction.

[0079] In this embodiment, the width W70 of the heat storage member 70 in the Y direction is greater than half the width W63 of the extension 63 of the busbar 60 in the Y direction. In this embodiment, the width W70 of the heat storage member 70 in the Y direction is the same as the width W63 of the extension 63 of the busbar 60 in the Y direction. Alternatively, the width W70 of the heat storage member 70 in the Y direction may be greater than, but not the same as, the width W63 of the extension 63 of the busbar 60 in the Y direction.

[0080] In this embodiment, the thickness T70 in the Z direction of the heat storage member 70 is greater than the thickness T63 in the Z direction of the extension 63 of the busbar 60. With this configuration, it is easier to increase the heat capacity of the heat storage member 70 compared to the case where the thickness T70 in the Z direction of the heat storage member 70 is smaller than the thickness T63 in the Z direction of the extension 63 of the busbar 60.

[0081] Furthermore, the thickness T70 in the Z direction of the heat storage member 70 can be the same as or smaller than the thickness T63 in the Z direction of the extension 63 of the busbar 60. When the thickness T70 in the Z direction of the heat storage member 70 is smaller than the thickness T63 in the Z direction of the extension 63 of the busbar 60, it is easier to achieve miniaturization (thinning) of the electrical connection unit 1.

[0082] <6.3 Fixing Part>

[0083] Next, the fixing part 80 will be described. The fixing part 80 is a fixing part for fixing the busbar 60 and the heat storage member 70. The fixing part 80 is arranged in the area that overlaps with the extension 63 of the busbar 60 when viewed from the Z direction. That is, the fixing part 80 is provided in the area that is separate from the first fixing part 40A and the second fixing part 40B when viewed from the Z direction.

[0084] Figure 3 This is a diagram used to explain the fixing part 80. In this embodiment, the fixing part 80 is a fixing part that fixes the busbar 60 and the heat storage member 70 by riveting. The fixing part 80 is formed, for example, a part of the busbar 60 and a part of the heat storage member 70. The fixing part 80 includes, for example, a fixing hole 60h formed in the extension 63 of the busbar 60; and an insertion part 92 provided in the heat storage member 70.

[0085] In this embodiment, the extension 63 of the busbar 60 has a first surface 60s1, a second surface 60s2, and a fixing hole 60h. The first surface 60s1 is the surface facing the +Z direction side. The first surface 60s1 faces the heat storage member 70. The second surface 60s2 is the surface facing the -Z direction side. The second surface 60s2 is located on the opposite side of the first surface 60s1.

[0086] The fixing hole 60h is, for example, a through hole penetrating the busbar 60 along the Z direction. The fixing hole 60h penetrates the first surface 60s1 and the second surface 60s2. However, the fixing hole 60h is not limited to the above example. The fixing hole 60h may also be a bottomed recess that is recessed from the first surface 60s1 in the -Z direction. Furthermore, the fixing hole 60h may be circular for example, but may also be polygonal or elliptical, etc.

[0087] On the other hand, the heat storage member 70 has a main body portion 91 and an insertion portion 92. The main body portion 91 is a plate portion along the first surface 60s1 of the busbar 60. The main body portion 91 is disposed overlapping the first surface 60s1 of the busbar 60 from the +Z direction side.

[0088] The insertion part 92 protrudes from the main body 91 in the -Z direction and is inserted into the fixing hole 60h of the busbar 60. The insertion part 92 contacts the inner peripheral surface of the fixing hole 60h of the busbar 60 and fits into the fixing hole 60h of the busbar 60. In this embodiment, the insertion part 92 contacts the inner peripheral surface of the fixing hole 60h of the busbar 60, thereby increasing the contact area between the busbar 60 and the heat storage member 70 (see reference). Figure 3 (Arrow AR in the image). For example, the insertion part 92 protrudes from the inside of the fixing hole 60h beyond the second surface 60s2 of the busbar 60 in the -Z direction.

[0089] In this embodiment, the insertion portion 92 has a bulge 92a located on the -Z direction side relative to the minimum inner diameter portion 60ha of the fixing hole 60h. The bulge 92a bulges in the X or Y direction compared to the minimum inner diameter portion 60ha of the fixing hole 60h. In the Z direction, the bulge 92a is located on the opposite side of the main body portion 91 relative to a portion of the manifold 60. A portion of the manifold 60 is sandwiched between the main body portion 91 of the heat storage member 70 and the bulge 92a in the Z direction.

[0090] In this embodiment, the insertion portion 92 is part of the heat storage member 70. The insertion portion 92 is formed, for example, by deforming a portion of the heat storage member 70, which is a plate member. The insertion portion 92 is formed, for example, by pressing a portion of the heat storage member 70 into the fixing hole 60h of the busbar 60 and deforming it in a manner mimicking the inner circumferential surface of the fixing hole 60h. In this embodiment, the insertion portion 92 fits into the fixing hole 60h of the busbar 60, thereby forming a fixing portion 80 based on riveting.

[0091] <6. Manufacturing method of wiring material 50>

[0092] Next, the manufacturing method of the wiring material 50 will be explained.

[0093] Figure 4This diagram illustrates the manufacturing method of the wiring material 50. In this embodiment, the busbar 60 is an example of a "first component." The heat storage component 70 is an example of a "second component."

[0094] First, a fixing hole 60h is formed in the busbar 60 (step S1). The fixing hole 60h is formed, for example, by stamping. Furthermore, in this disclosure, "forming a fixing hole in the busbar" can include the case where the fixing hole is formed simultaneously with the formation of the busbar.

[0095] Next, the busbar 60 and the heat storage member 70 (heat storage busbar 70A) are arranged overlappingly (step S2). Then, a portion of the heat storage member 70 is deformed by applying pressure, causing it to be inserted into the fixing hole 60h of the busbar 60, thereby fixing the busbar 60 and the heat storage member 70 by riveting (step S3). Through this process, the wiring material 50 is completed.

[0096] Figure 5 This is a cross-sectional view used to illustrate the manufacturing method of the wiring material 50. Figure 5 This indicates the process of step S3 described above. In this embodiment, in the process of step S3, a die head 101 and a punch 102 are used.

[0097] The die head 101 is disposed on the opposite side (-Z direction side) of the heat storage member 70 relative to the busbar 60. The die head 101 has a recess 101a in the portion corresponding to the fixing hole 60h of the busbar 60. The dimensions of the recess 101a in the X and Y directions are larger than those of the fixing hole 60h of the busbar 60. The recess 101a forms a deformable space S for the heat storage member 70 between the busbar 60 and the die head 101.

[0098] The punch 102 is disposed on the opposite side of the die head 101 relative to the busbar 60 and the heat storage member 70. The punch 102 is disposed corresponding to the fixing hole 60h of the busbar 60. The punch 102 has, for example, a smaller profile (e.g., diameter) than the fixing hole 60h of the busbar 60. The punch 102 is moved toward the die head 101, thereby deforming a portion of the heat storage member 70 by applying pressure and inserting it into the fixing hole 60h of the busbar 60, forming an insertion portion 92. Furthermore, through this process, a portion of the heat storage member 70 passing through the minimum inner diameter portion 60ha of the fixing hole 60h bulges out in the X or Y direction, forming a bulge portion 92a. Through this process, a fixing portion 80 is formed, and the busbar 60 and the heat storage member 70 are fixed by riveting.

[0099] <7. Example>

[0100] Next, an embodiment relating to the combination of materials of the busbar 60 and the heat storage component 70 will be described.

[0101] <7.1 First Embodiment>

[0102] In the first embodiment, the busbar 60 is made of aluminum or an aluminum alloy. The heat storage member 70 is made of copper or a copper alloy. Here, copper has a lower specific heat than aluminum. According to the above configuration, the busbar 60 is made of aluminum or an aluminum alloy, while the heat storage member 70 is made of copper or a copper alloy. Therefore, the volume of the wiring material 50 can be reduced to achieve miniaturization (e.g., thinning), and the heat storage capacity of the wiring material 50 can be ensured. With this configuration, the thermal characteristics of the electrical connection unit 1 can be improved, and the electrical connection unit 1 can be miniaturized (e.g., thinned).

[0103] <7.2 Second Embodiment>

[0104] In the second embodiment, the busbar 60 is made of aluminum or an aluminum alloy. The heat storage member 70 is also made of aluminum or an aluminum alloy. Here, aluminum has a lower specific gravity than copper. According to this configuration, the busbar 60 is made of aluminum or an aluminum alloy, while the heat storage member 70 is made of aluminum or an aluminum alloy. Therefore, the weight of the wiring material 50 can be reduced, and the heat storage capacity of the wiring material 50 can be ensured. With this configuration, the thermal characteristics of the electrical connection unit 1 can be improved, and the electrical connection unit 1 can be made lighter.

[0105] <8. Advantages>

[0106] As a first comparative example, a structure without the heat storage component 70 is considered. In such a structure, if sufficient heat capacity is not ensured within the electrical connection unit, a significant temperature rise may occur in a portion of the electrical connection unit, and / or thermal interference to the first or second connected object may increase. For example, when a large transient current flows through, a significant temperature rise may occur in a portion of the electrical connection unit, and / or thermal interference to the first or second connected object may increase. Therefore, it can sometimes be difficult to improve the thermal characteristics of the electrical connection unit.

[0107] On the other hand, in this embodiment, the wiring material 50 has a busbar 60 and a heat storage member 70. The busbar 60 has: a first connecting portion 61 connected to a first connecting object; a second connecting portion 62 connected to a second connecting object; and an extension portion 63 extending between the first connecting portion 61 and the second connecting portion 62. The heat storage member 70 is mounted on the extension portion 63 of the busbar 60.

[0108] According to this configuration, the heat capacity of the busbar 60 is amplified by the heat storage member 70. Thus, the heat capacity of the busbar 60 is amplified by the heat storage member 70, thereby enabling at least temporary heat storage (heat absorption) of a portion of the heat transferred in the busbar 60. With this structure, it is possible to suppress large temperature rises and / or increased thermal interference to the first or second connected object within a portion of the electrical connection unit 1. Through this effect, the thermal characteristics (e.g., heat release or heat storage) of the electrical connection unit 1 can be improved.

[0109] As a second comparative example, a structure in which the busbar 60 and the heat storage member 70 are fixed by a fastening member such as a bolt is considered. In the structure of this comparative example, the contact area between the busbar 60 and the heat storage member 70 in the fixing part is small, which leaves room for improvement from the viewpoint of thermal characteristics.

[0110] Therefore, in this embodiment, the wiring material 50 includes a busbar 60 and a heat storage member 70, which is mounted to the busbar 60 by a riveting-based fixing part 80. With this configuration, compared to the structure of the comparative example described above, it is easier to ensure a larger contact area between the busbar 60 and the heat storage member 70. With this structure, the busbar 60 and the heat storage member 70 can be securely thermally connected. Through this effect, the thermal characteristics of the electrical connection unit 1 can be improved.

[0111] In this embodiment, the heat storage member 70 is a plate member along the busbar 60. This configuration facilitates the deformation of the heat storage member 70 and allows for easy fixing of the busbar 60 and the heat storage member 70 by riveting. This configuration also improves the manufacturability of the wiring material 50.

[0112] In this embodiment, the fixing part 80 includes: a fixing hole 60h formed in the busbar 60; and an insertion part 92, which is part of the heat storage member 70 and is inserted into the fixing hole 60h of the busbar 60. With this configuration, the volume (heat capacity) of the heat storage member 70 can be largely ensured, and the busbar 60 and the heat storage member 70 are fixed by riveting. Therefore, by further improving the heat dissipation performance based on the heat storage member 70, the thermal characteristics of the electrical connection unit 1 can be further improved.

[0113] In this embodiment, the busbar 60 has a first surface 60s1 facing the heat storage member 70, and a second surface 60s2 located on the opposite side of the first surface 60s1. The fixing hole 60h of the busbar 60 is a through hole penetrating both the first surface 60s1 and the second surface 60s2. The insertion portion 92 of the heat storage member 70 protrudes beyond the second surface 60s2 of the busbar 60 from inside the fixing hole 60h. Due to this configuration, the fixing hole 60h of the busbar 60 is a through hole, so during riveting, the insertion portion 92 of the heat storage member 70 easily passes through and deforms through the fixing hole 60h. Through this effect, for example, compared to a bottomed hole, the heat storage member 70 can be deformed even with a smaller force, and the busbar 60 and the heat storage member 70 can be fixed by riveting. This structure allows for further improvement in the manufacturability of the wiring material 50.

[0114] (Second Implementation)

[0115] Next, the second embodiment will be described. The second embodiment differs from the first embodiment in the following aspects: a fixing hole 70h is formed in the heating member 70, and an insertion portion 92 is provided in the busbar 60. Otherwise, the configuration is the same as that of the first embodiment, except as described below.

[0116] Figure 6 This is a diagram used to explain the fixing part 80 of the second embodiment. In this embodiment, the fixing part 80 is a fixing part that fixes the busbar 60 and the heat storage member 70 by riveting. The fixing part 80 includes, for example, a fixing hole 70h formed in the heat storage member 70 (heat storage busbar 70A); and an insertion part 92 provided in the extension 63 of the busbar 60.

[0117] In this embodiment, the heat storage member 70 (heat storage manifold 70A) has a first surface 70s1, a second surface 70s2, and a fixing hole 70h. The first surface 70s1 is the surface facing the -Z direction side. The first surface 70s1 faces the extension 63 of the manifold 60. The second surface 70s2 is the surface facing the +Z direction side. The second surface 70s2 is located on the opposite side of the first surface 70s1.

[0118] The fixing hole 70h is, for example, a through hole penetrating the heat storage member 70 (heat storage manifold 70A) along the Z direction. The fixing hole 70h penetrates the first surface 70s1 and the second surface 70s2. However, the fixing hole 70h is not limited to the above example. The fixing hole 70h may also be a bottomed recess that is recessed from the first surface 70s1+Z direction. Furthermore, the fixing hole 70h may be circular for example, but may also be polygonal or elliptical, etc.

[0119] On the other hand, the extension 63 of the busbar 60 has a main body 91 and an insertion part 92. The main body 91 is a plate portion along the first surface 70s1 of the heat storage member 70. The main body 91 is disposed overlapping the first surface 70s1 of the heat storage member 70 from the -Z direction side.

[0120] The insertion portion 92 protrudes from the main body portion 91 in the +Z direction and is inserted into the fixing hole 70h of the heat storage member 70. The insertion portion 92 contacts the inner peripheral surface of the fixing hole 70h of the heat storage member 70 and fits into the fixing hole 70h of the heat storage member 70. In this embodiment, the insertion portion 92 contacts the inner peripheral surface of the fixing hole 70h of the heat storage member 70, thereby increasing the contact area between the busbar 60 and the heat storage member 70. For example, the insertion portion 92 protrudes from the inside of the fixing hole 70h beyond the second surface 70s2 of the heat storage member 70 in the +Z direction.

[0121] In this embodiment, the insertion portion 92 has a bulge 92a located on the +Z direction side of the minimum inner diameter portion 70ha of the fixing hole 70h. The bulge 92a bulges out in the X or Y direction than the minimum inner diameter portion 70ha of the fixing hole 70h. In the Z direction, the bulge 92a is located on the opposite side of the main body portion 91 relative to a part of the heat storage member 70. A part of the heat storage member 70 is sandwiched between the main body portion 91 of the manifold 60 and the bulge 92a in the Z direction.

[0122] In this embodiment, the insertion portion 92 is a part of the extension 63 of the busbar 60. The insertion portion 92 is formed, for example, by deforming a part of the extension 63 of the busbar 60, which is a plate member. The insertion portion 92 is also formed, for example, by pressing a part of the extension 63 of the busbar 60 into the fixing hole 70h of the heat storage member 70, and deforming it in a manner mimicking the inner circumferential surface of the fixing hole 70h. In this embodiment, the insertion portion 92 fits into the fixing hole 70h of the heat storage member 70, thereby forming a fixing portion 80 based on riveting.

[0123] Figure 7 This is a cross-sectional view used to explain the manufacturing method of the wiring material 50 in this embodiment. The manufacturing method of the wiring material 50 in this embodiment is the same as that of the wiring material 50 in the first embodiment. Regarding the description related to the manufacturing method of the wiring material 50 in this embodiment, in the description related to the manufacturing method of the wiring material 50 in the first embodiment described above, "busbar 60" and "extension 63" are replaced with "heat storage member 70", "fixing hole 60h" is replaced with "fixing hole 70h", and "heat storage member 70" is replaced with "extension 63 of busbar 60". In this embodiment, the heat storage member 70 is an example of a "first member". The busbar 60 is an example of a "second member".

[0124] In the second embodiment, the fixing part 80 includes: a fixing hole 70h formed in the heat storage member 70; and an insertion part 92, which is part of the extension 63 of the busbar 60 and is inserted into the fixing hole 70h of the heat storage member 70. With this configuration, the conductive area of ​​the extension 63 of the busbar 60 can be maximized, and the busbar 60 and the heat storage member 70 can be fixed by riveting. Therefore, the electrical characteristics of the electrical connection unit 1 can be improved by improving the electrical characteristics of the wiring material 50. Furthermore, by not providing the fixing hole 60h in the busbar 60, for example, compared to the case where the fixing hole 60h is provided in the busbar 60, the heat generation of the busbar 60 itself can be reduced. Through this effect, the thermal characteristics of the electrical connection unit 1 can be further improved.

[0125] In this embodiment, the heat storage member 70 has a first surface 70s1 facing the extension 63 of the busbar 60, and a second surface 70s2 located on the opposite side of the first surface 70s1. The fixing hole 70h of the heat storage member 70 is a through hole penetrating both the first surface 70s1 and the second surface 70s2. The insertion portion 92 of the extension 63 of the busbar 60 protrudes beyond the second surface 70s2 of the heat storage member 70 from inside the fixing hole 70h. Due to this configuration, the fixing hole 70h of the heat storage member 70 is a through hole, so during riveting, the insertion portion 92 of the busbar 60 easily passes through the fixing hole 70h and deforms. Through this effect, for example, compared to the case where the fixing hole 70h is a bottomed hole, the busbar 60 can be deformed even with a smaller force, and the busbar 60 and the heat storage member 70 can be fixed by riveting. This structure allows for further improvements in the manufacturability of the wiring material 50.

[0126] <Variation Example>

[0127] Hereinafter, some variations of the first embodiment or the second embodiment will be described. Furthermore, in each variation, the configuration other than that described below is the same as that of the first embodiment or the second embodiment. Additionally, in each variation described below, the fixing part 80 can be either the same fixing part 80 as in the first embodiment or the same fixing part 80 as in the second embodiment.

[0128] <Example 1>

[0129] Figure 8 This is a perspective view showing the wiring material 50 in the first modification. In the first modification, the length L70 of the heat storage member 70 in the aforementioned extending direction is less than half the length L63 of the extension portion 63 of the busbar 60 in the aforementioned extending direction. The heat storage member 70 is only correspondingly provided on a portion of the extension portion 63 of the busbar 60. With this configuration, it is also possible to improve the thermal characteristics of the electrical connection unit 1.

[0130] <Second Variation>

[0131] Figure 9 This is a perspective view showing the electrical connection unit 1 in the second variation. In this embodiment, the busbar 60 electrically connects the electronic component 10 to another busbar 9 included in the electrical connection unit 1. The electronic component 10 is an example of a "first connection object". The busbar 9 is an example of a "second connection object".

[0132] In this modified example, the extension 63 includes a first extension 63a (first part) and a second extension 63b (second part).

[0133] The first extension 63a is adjacent to and extends from the first connecting portion 61. In this modified example, the first connecting portion 61 is a plate portion along the Z and Y directions. The first extension 63a extends from the first connecting portion 61 along the -Z direction, for example. The first extension 63a is, for example, a plate portion along the Z and Y directions.

[0134] The second extension 63b is located on the opposite side of the first connecting portion 61 relative to the first extension 63a. The second extension 63b is located between the first extension 63a and the second connecting portion 62. The second extension 63b extends from the first connecting portion 61 by bending. For example, the second extension 63b extends along the +X direction from the end of the first extension 63a on the -Z direction side. The second extension 63b is, for example, a plate portion along both the X and Y directions.

[0135] Figure 10 This is a perspective view illustrating the heat storage member 70 of the second modification. In this modification, the heat storage member 70 (heat storage manifold 70A) is mounted on the first extension 63a. The heat storage member 70 (heat storage manifold 70A) is formed in a plate-like (flat) shape along the first extension 63a of the manifold 60. The heat storage member 70 is configured to have a length greater than half of the length of the first extension 63a of the manifold 60 in the extending direction. That is, the length L70 of the heat storage member 70 in the extending direction is greater than half of the length L63a of the first extension 63a of the manifold 60 in the extending direction.

[0136] In this variation, the heat storage member 70 is not installed in the second extension 63b. In other words, the heat storage member 70 is located near the electronic component 10 (e.g., the heat-generating object) at a location closer to the boundary between the first extension 63a and the second extension 63b.

[0137] Based on the configuration of the second variation described above, the thermal characteristics of the electrical connection unit 1 can be improved in the same way as in the first or second embodiment.

[0138] The above describes some implementation methods and variations. However, the implementation methods and variations are not limited to the examples described above. For example, the various variations described above can also be implemented by combining each other.

[0139] Explanation of reference numerals in the attached figures

[0140] 1…Electrical connection unit

[0141] 10… Electronic components

[0142] 20…Connecting parts

[0143] 40…Fixed part

[0144] 40A…First Fixing Part

[0145] 40B…Second Fixing Part

[0146] 41… Fastening component (first fastening component)

[0147] 44… Fastening component (Second fastening component)

[0148] 50… Wiring materials

[0149] 60… Busbar (busbar for power supply)

[0150] 60h…fixed hole

[0151] 61…First connecting part

[0152] 61h…Mounting hole

[0153] 62…Second connecting part

[0154] 62h… mounting holes

[0155] 63… Extension

[0156] 63a… First extension (Part 1)

[0157] 63b…Second Extension (Part 2)

[0158] 70…Heat storage components

[0159] 70A… Busbar for thermal storage

[0160] 70h…fixed hole

[0161] 91…Main Body

[0162] 92… Insertion section

Claims

1. A wiring material comprising: a bus bar, and a heat storage member installed to the bus bar based on a riveted fixing portion.

2. The wiring material according to claim 1, wherein the heat storage member is a plate member along the bus bar.

3. The wiring material according to claim 2, wherein the fixing portion includes: a fixing hole formed in the bus bar, and an insertion portion that is a part of the heat storage member and is inserted into the fixing hole.

4. The wiring material according to claim 3, wherein the bus bar has a first surface facing the heat storage member and a second surface located on the opposite side of the first surface, and the fixing hole is a through hole that penetrates the first surface and the second surface; the insertion portion protrudes from the inside of the fixing hole beyond the second surface.

5. The wiring material according to claim 2, wherein the fixing portion includes: a fixing hole formed in the heat storage member, and an insertion portion that is a part of the bus bar and is inserted into the fixing hole.

6. The wiring material according to claim 5, wherein the heat storage member has a first surface facing the bus bar and a second surface located on the opposite side of the first surface, and the fixing hole is a through hole that penetrates the first surface and the second surface; the insertion portion protrudes from the inside of the fixing hole beyond the second surface.

7. An electrical connection unit comprising: the wiring material according to claim 1 or claim 2, and a connection object connected to the wiring material.

8. A manufacturing method of a wiring material, comprising: forming a fixing hole in a first member that is one of a bus bar and a heat storage member; overlapping a second member that is the other of the bus bar and the heat storage member on the first member; deforming a part of the second member by pressurization so as to be inserted into the fixing hole, thereby fixing the bus bar and the heat storage member by riveting.

Images