Electrical connection box

Abstract

Disclosed is an electrical connection box capable of being downsized in the XY direction of a housing body. The electrical connection box (10) is provided with: a housing body (12); a relay terminal (14); bus bar housing portions (42a to 42c, 44) that house a plurality of bus bars (16a to 16k); upper side element mounting portions (59, 72a to 72d, 74) on which upper side elements (18, 20) that are connected to the bus bars (16a to 16k) are mounted from above; and lower side element mounting portions (36a to 36d) on which lower side elements (22, 24, 26, 28) that are connected to the bus bars (16a to 16k) are mounted from below, the upper side element mounting portions (59, 72a to 72d) and the lower side element mounting portions (36a to 36d) are arranged in a superposed manner in the vertical direction, and the bus bars (16a to 16k) and tab terminals (30) of the lower side elements (22, 24, 26, 28) are connected to the relay terminal (14), whereby the lower side elements (22, 24, 26, 28) are connected in conduction to the bus bars (16a to 16g).

Description

Technical Field

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

[0002] Patent Document 1 discloses an electrical connection box (terminal block) that forms part of a power supply device mounted in a vehicle, enabling the connection and disconnection between a battery and a load. In such an electrical connection box, multiple busbars forming a power path are assembled relative to a synthetic resin housing body. Multiple electrical components, such as contactors and fuses, are assembled in multiple component housings protruding from the upper surface of the housing body and connected to the busbars. Furthermore, the busbars have external connection portions for connecting external power-conducting components such as wiring harnesses; these external connection portions are also located on the upper surface of the housing body to allow for the secure connection of external power-conducting components to the external connection portions.

[0003] Existing technical documents

[0004] Patent Document 1: Japanese Patent Application Publication No. 2020-195235 Summary of the Invention

[0005] The problem that the invention aims to solve

[0006] However, with the increasing current in vehicles and the high density of onboard components in recent years, the electrical connection box also requires miniaturization. However, in the electrical connection box described in Patent Document 1, multiple component housings and external connection portions of the busbars are separately provided at multiple locations on the upper surface of the housing body, allowing for the assembly of electrical components and external energized parts from above. Therefore, there is a limit to the reduction in size in the direction orthogonal to the vertical direction (Z-direction) of the housing body (XY direction).

[0007] Therefore, an electrical connection box capable of being miniaturized in the XY direction of the housing body is disclosed.

[0008] Methods for solving problems

[0009] The electrical connection box disclosed herein comprises: a housing body; a relay terminal receiving portion having an upper opening and a lower opening opening above and below the housing body, and receiving a relay terminal assembled by inserting into the upper opening; a busbar receiving portion opening above the housing body, and receiving a plurality of busbars assembled from above to form a power conduction path; an upper side element mounting portion opening above the housing body, and mounting an upper side element assembled from above and connected to the busbars in the upper side element mounting portion; and a lower side element mounting portion opening below the housing body, and mounting a lower side element assembled from below and connected to the busbars in the lower side element mounting portion. The upper side element mounting portion and the lower side element mounting portion are arranged overlapping in the vertical direction of the housing body. A portion of the busbars is connected to the relay terminal. The lower side element has a contact terminal, and the contact terminal is inserted through the lower opening of the relay terminal receiving portion and connected to the relay terminal, thereby conducting a connection between the lower side element and the busbars.

[0010] Invention Effects

[0011] According to the electrical connection box disclosed herein, miniaturization of the housing body in the XY direction can be achieved. Attached Figure Description

[0012] Figure 1 This is a top perspective view showing the electrical connection box of Embodiment 1.

[0013] Figure 2 yes Figure 1 The bottom 3D view of the electrical connection box shown.

[0014] Figure 3 It shows from Figure 1 The diagram shown is a perspective view of the electrical connection box after the main body and top cover have been removed.

[0015] Figure 4 yes Figure 1 The top view of the electrical connection box shown.

[0016] Figure 5 yes Figure 4 VV sectional view.

[0017] Figure 6 yes Figure 4 Sectional view VI-VI.

[0018] Figure 7 yes Figure 1 An exploded perspective view of the electrical connection box shown.

[0019] Figure 8 Viewed from below Figure 1A partially enlarged perspective view of the top cover of the electrical connection box shown. Detailed Implementation

[0020] <Description of embodiments of this disclosure>

[0021] First, embodiments of this disclosure will be described.

[0022] (1) The electrical connection box of this disclosure comprises: a housing body; a relay terminal receiving portion having an upper opening and a lower opening opening to the upper and lower parts of the housing body, and receiving a relay terminal assembled by inserting into the upper opening; a busbar receiving portion opening to the upper part of the housing body, and receiving a plurality of busbars assembled from the upper part to form a power conduction path; an upper side element mounting portion opening to the upper part of the housing body, and mounting an upper side element assembled from the upper part and connected to the busbars in the upper side element mounting portion; and a lower side element mounting portion opening to the lower part of the housing body, and mounting a lower side element assembled from the lower part and connected to the busbars in the lower side element mounting portion, wherein the upper side element mounting portion and the lower side element mounting portion are arranged overlapping in the vertical direction of the housing body, a portion of the busbars is connected to the relay terminal, and the lower side element has a contact terminal, the contact terminal being inserted through the lower opening of the relay terminal receiving portion and connected to the relay terminal, thereby making the lower side element and the busbars electrically connected.

[0023] According to this method, the electrical connection box has an upper-side component mounting section that opens to the top of the housing body, and a lower-side component mounting section that opens to the bottom of the housing body. These sections are arranged overlapping in the vertical direction of the housing body. Therefore, in the XY direction (orthogonal to the vertical direction of the housing, i.e., the Z-direction), it is not necessary to separate the upper-side component mounting section from the lower-side main mounting section, enabling miniaturization of the housing body in the XY direction. Specifically, a lower-side component with a contact terminal is mounted on the lower-side component mounting section. The contact terminal of the lower-side component passes through the lower opening of the relay terminal receiving section and connects to the relay terminal, thereby establishing a conductive connection between the lower-side component and the busbar. Therefore, even without assembling the lower-side component from the top side of the housing body, a conductive connection with the busbar housed in the housing body is possible. As a result, by arranging the lower-side component mounting section in a configuration that overlaps with the upper-side component mounting section in the vertical direction of the housing body, miniaturization of the housing body in the XY direction can be achieved. Furthermore, since the connector terminals of the lower side components can be connected to the busbar via the relay terminals housed in the relay terminal housing of the housing body, even if the upper side component mounting portion can be stacked in the vertical direction, the advantage of reducing the length of the busbar can still be enjoyed.

[0024] (2) Based on (1) above, it is preferable that the upper component mounting portion includes an external conductor fastening portion, which holds the external connection portion provided on the busbar and allows the external energized component to be fastened from above to the external connection portion. This is because, for ease of operation, it is preferable for the operator to fasten the external energized component from above to the external connection portion when fastening the external energized component relative to the external connection portion provided on the busbar. Even when such an external conductor fastening portion is provided as the upper component mounting portion, it can be provided overlappingly above the lower component mounting portion in the vertical direction of the housing body, thus enabling miniaturization of the housing body in the XY direction.

[0025] (3) Based on (2) above, it is preferable to provide a positive electrode side circuit at one end of the housing body and a negative electrode side circuit at the other end of the housing body, and to provide the external conductor fastening part at the central part of the housing body. This is because, compared to the case where the external conductor fastening part is provided at the periphery of the housing body, the wiring length of the busbar can be shortened.

[0026] (4) Based on any one of (1) to (3) above, it is preferable that the upper component mounting portion includes an electrical component fastening portion, the electrical component fastening portion holds an electrical component including a fastening terminal portion, the fastening terminal portion is bolted to a bolt fastening portion provided on the busbar, and the electrical component fastening portion allows the fastening terminal portion to be bolted from above to the bolt fastening portion. This is because, from an operational point of view, it is preferable to fasten the electrical component including the fastening terminal portion bolted to the bolt fastening portion of the busbar from above. Even when such an electrical component fastening portion is provided as an upper component mounting portion, it can be provided overlapping above the lower component mounting portion in the vertical direction of the housing body, thus enabling miniaturization of the housing body in the XY direction.

[0027] (5) Based on any one of (1) to (4) above, it is preferable that the lower side element mounting portion includes a plurality of lower side element mounting portions arranged overlapping in the vertical direction. This is because, by arranging the lower side element mounting portions overlapping in the vertical direction, further miniaturization of the housing body in the XY direction can be achieved. For example, in the case of providing two lower side element mounting portions arranged overlapping in the vertical direction, by arranging the contact terminals of the lower side element mounted on one of them and the lower side element mounted on the other at different positions in the XY direction, the plurality of lower side element mounting portions can be arranged overlapping in the vertical direction.

[0028] (6) Based on any one of (1) to (5) above, it is preferable that the lower side component mounting portion has a locking portion that engages with the lower side component to keep the lower side component in a connected state with the busbar and prevent the lower side component from falling off the lower side component mounting portion. This is because it can prevent the lower side component from accidentally falling off the lower side component mounting portion due to vibrations during the handling of the electrical connection box or during vehicle operation.

[0029] (7) Based on any one of (1) to (6) above, preferably, the electrical connection box has a cover covering the upper surface of the housing body. The cover has: a connector mounting portion opening upwards; a contact insertion hole through which the connector mounting portion passes; and a guide tube portion protruding downwards around the connector mounting portion. The busbar has a connecting contact, which is inserted through the contact insertion hole of the connector mounting portion and disposed in the connector mounting portion. The housing body has: a connecting contact mounting portion disposed on the upper surface; and a positioning protrusion protruding upwards around the connecting contact mounting portion. When assembling the cover to the housing body, before the connecting contact is inserted through the contact insertion hole, the positioning protrusion is inserted into the guide tube portion to position the connecting contact in the contact insertion hole. By covering the upper surface of the housing body with the cover, it is possible to prevent the components from accidentally detaching from the housing body and to ensure insulation. In particular, even when the connector mounting part for mounting external connectors is located on the top cover, the positioning protrusion of the housing body can be inserted into the guide tube of the top cover, and the contact insertion hole of the connector mounting part and the connecting contact of the busbar protruding from the side of the housing body can be pre-positioned, enabling the assembly of the top cover to the housing body with good workability.

[0030] <Detailed description of the embodiments of this disclosure>

[0031] 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, but is shown in the claims and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0032] <Implementation Method 1>

[0033] The following uses Figures 1 to 8The electrical connection box 10 of Embodiment 1 of this disclosure will now be described. This electrical connection box 10 connects to a vehicle power source and a load, such as the interior of a battery pack in an electric vehicle or hybrid vehicle. In Embodiment 1, the electrical connection box 10 connects to a battery (not shown) and an converter (not shown) as an example of a load. Furthermore, in a vehicle, the electrical connection box 10 can be configured in any orientation, but in the following description... Figures 1 to 8 In the explanation, Figure 1 The vertical direction of the electrical connection box 10 and Figure 7 The vertical direction of the shell body 12 is set as either the vertical direction or the Z direction. Figure 1 The left and right directions of the electrical connection box 10 and Figure 7 The left and right directions of the main body 12 of the shell are set to either the left and right direction or the X direction. Figure 1 The front and rear directions of the electrical connection box 10 and Figure 7 The front-back direction of the housing body 12 is described as either the front-back direction or the Y direction. Furthermore, for multiple identical components, sometimes only some components are labeled with reference numerals, while reference numerals are omitted for other components.

[0034] <Electrical Connection Box 10>

[0035] like Figure 7 As shown, the electrical connection box 10 includes: a housing body 12, a plurality of relay terminals 14 and a plurality of busbars 16a-16k assembled from the top of the housing body 12. The relay terminals 14 and the busbars 16a-16k are formed by stamping and punching metal plates, and a portion of the plurality of busbars 16a-16k is connected to the relay terminals 14 to form a power path. Furthermore, the electrical connection box 10 has a fuse 18 and a current sensor 20 as upper-side components assembled from the top of the housing body 12 and connected to the busbars 16d-16g, and a positive-side main contactor 22, a negative-side main contactor 24, a pre-charge contactor 26 and a pre-charge resistor 28 as lower-side components assembled from the bottom of the housing body 12 and connected to the busbars 16a-16g. Furthermore, the positive-side main contactor 22, the negative-side main contactor 24, the pre-charge contactor 26, and the pre-charge resistor 28 each have a contact terminal 30, which is connected to the relay terminal 14, thereby enabling the positive-side main contactor 22, the negative-side main contactor 24, the pre-charge contactor 26, and the pre-charge resistor 28 to be electrically connected to the busbars 16a-16g via the relay terminal 14. Moreover, the electrical connection box 10 has a cover 31 made of insulating material that covers the upper surface of the housing body 12.

[0036] <Main body 12 / Lower side component mounting parts 36a~36d>

[0037] The main body 12 of the housing is formed of an insulating material such as synthetic resin, and is generally shaped as a rectangular block that is longer in the X direction. More specifically, the main body 12 of the housing has a generally rectangular plate-shaped base plate portion 32 and a plurality of support feet 34a to 34c protruding upward from the upper surface of the base plate portion 32. Figure 7 As shown, support foot 34a is disposed on the left side of the housing body 12 in the left-right direction (X direction), support foot 34c is disposed on the right side, and support foot 34b is disposed between them. Furthermore, the housing body 12 has lower-side component mounting portions 36a~36d that protrude downwards in a frame-like manner from the lower surface of the base plate portion 32 and open downwards towards the lower part of the housing body 12 (see reference). Figure 5 The positive-side main contactor 22, the negative-side main contactor 24, the pre-charge contactor 26, and the pre-charge resistor 28, which are lower-side components, are respectively installed in the lower-side component mounting sections 36a to 36d. In addition, bolt fixing parts 40 for mounting fastening bolts 38 are provided at the four corners of the base plate section 32, and the electrical connection box 10 is fastened to the battery pack housing (not shown).

[0038] <Convergence Bar Containment Sections 42a~42c, 44>

[0039] like Figure 7 As shown, the protruding end faces of the support feet 34a-34c are provided with multiple busbar receiving portions 42a-42c, divided by ribs protruding at appropriate locations on the periphery. The upper surface of the base plate 32 is also provided with multiple busbar receiving portions 44, divided by ribs or grooves protruding at appropriate positions. These busbar receiving portions 42a-42c and busbar receiving portions 44 are all open upwards, accommodating busbars 16a-16k assembled from above.

[0040] <Relay Terminal Housing Section 45>

[0041] like Figure 5 , 6As shown, in the area of ​​the bottom wall forming the lower-side component mounting portions 36a-36d in the base plate portion 32, at a position facing the respective contact terminals 30 of the positive-side main contactor 22, negative-side main contactor 24, pre-charge contactor 26, and pre-charge resistor 28, which are respectively mounted as lower-side components, there is a relay terminal receiving portion 45, each of which houses a cylindrical relay terminal 14. Each relay terminal receiving portion 45 has an upper opening 46 opening upwards towards the housing body 12 and a lower opening 48 opening downwards. The upper opening 46 is sized to allow the relay terminal 14 to be inserted, and the relay terminal 14 is assembled into the relay terminal receiving portion 45 by inserting it through the upper opening 46. The lower opening 48 is sized to allow the contact terminal 30 to be inserted but not the relay terminal 14. Therefore, the terminals 30 of the positive side main contactor 22, the negative side main contactor 24, the pre-charge contactor 26, and the pre-charge resistor 28 are inserted through the lower opening 48 and connected to the relay terminal 14.

[0042] Furthermore, the connecting portion 50, which is a part of the busbars 16a to 16g, is inserted into the upper opening 46 of each relay terminal receiving portion 45 and connected to the relay terminal 14. As a result, the positive-side main contactor 22, the negative-side main contactor 24, the pre-charge contactor 26, and the pre-charge resistor 28, which are respectively installed in the lower-side component mounting portions 36a to 36d, are connected to the busbars 16a to 16g via the relay terminal 14.

[0043] <Busbars 16a~16c>

[0044] like Figure 3 , 7As shown, busbars 16a, 16b, and 16c constitute the input / output circuit to the positive-side main contactor 22 and the pre-charge circuit bypassing the positive-side main contactor 22. An external connection portion 52a on the input side is provided at one end of busbar 16a. A connection portion 50a protrudes from the downward-extending portion of the external connection portion 52a and connects to the contact terminal 30 on the input side of the positive-side main contactor 22 via a relay terminal 14. A downward-protruding connection portion 50b is provided at the other end of busbar 16a extending towards the pre-charge resistor 28 and connects to the contact terminal 30 on the input side of the pre-charge resistor 28 via a relay terminal 14. The lower end connection portion 50c of busbar 16b connects to the output side contact terminal 30 of the pre-charge resistor 28 via a relay terminal 14, and the upper end connection portion 50d connects to the input side contact terminal 30 of the pre-charge contactor 26 via a relay terminal 14. The output-side contact terminal 30 of the pre-charge contactor 26 is connected to the connection portion 50e provided at the end of the busbar 16c on the pre-charge contactor 26 side via the relay terminal 14. At the other end of the busbar 16c, there is an output-side external connection portion 52b arranged parallel to the input-side external connection portion 52a. The busbar 16c has a connection portion 50f protruding from the downwardly extending portion of the external connection portion 52b, which is connected to the output-side contact terminal 30 of the positive-side main contactor 22 via the relay terminal 14.

[0045] <Fuse 16d~16g>

[0046] like Figure 3 , 7 As shown, the input / output circuit of the main contactor 24 on the negative side is composed of busbars 16d, 16e, 16f, and 16g. An external connection portion 52c on the input side is provided at one end of busbar 16d. The other end of busbar 16d... Figure 3 , 7 The right inner side is bolted with bolt 57 and connected to the input terminal 56 of the current sensor 20 (see reference). Figure 4The output terminal 58 of the current sensor 20 is bolted to one end 60 of the busbar 16e using a bolt 57. Additionally, a current sensor mounting portion 59, which serves as an upper-side component mounting portion, is provided on the right side end of the base plate portion 32 of the housing body 12, opening upwards. A nut 61 for fastening the bolt 57 is housed on the bottom surface of the current sensor mounting portion 59. The busbar 16d and input terminal 56, and the busbar 16e and output terminal 58, are respectively clamped between the bolt 57 and the nut 61 in a manner that allows energization. Next, a downwardly extending connecting portion 50g is provided at the other end of the busbar 16e, which is connected to the input-side contact terminal 30 of the negative-side main contactor 24 via a relay terminal 14. The output-side contact terminal 30 of the negative-side main contactor 24 is connected to the connecting portion 50h located at one end of the busbar 16f via the relay terminal 14. A bolt fastening portion 62a is provided at the other end of the busbar 16f, and is fastened to the fastening terminal portion 66a provided on the input side of the fuse 18 by using a fastening bolt 68. The fastening terminal portion 66b on the output side of the fuse 18 is fastened to the bolt fastening portion 62b provided at one end of the busbar 16g by using a fastening bolt 68. An external connection portion 52d on the output side is provided at the other end of the busbar 16g.

[0047] <Busbar 16i~16k>

[0048] The control circuit for controlling the opening and closing of the positive-side main contactor 22, the negative-side main contactor 24, and the pre-charge contactor 26 is composed of busbars 16i-16k. Busbars 16i-16k are narrower than busbars 16a-16h. A connecting tab 70 is provided at one end of each busbar 16i-16k, and the connecting tab 70 is inserted into the tab insertion hole 98 of the connector mounting portion 96 (described later) and disposed in the connector mounting portion 96. These multiple connecting tabs 70 are arranged in a generally central position in the X direction on the upper surface of the base plate portion 32, and are positioned in a busbar receiving portion 44 located at the front side in the Y direction, protruding upwards from the upper surface of the base plate portion 32. The other ends of the busbars 16i-16k are connected to the corresponding tab terminals 30 of the positive-side main contactor 22, the negative-side main contactor 24, and the pre-charge contactor 26 via relay terminals 14.

[0049] <Upper side component mounting section (current sensor mounting section 59, external conductor fastening sections 72a~72d and electrical component fastening section 74)>

[0050] In the housing body 12, in addition to the aforementioned current sensor mounting part 59, there are also external conductor fastening parts 72a-72d and electrical component fastening parts 74 serving as upper-side component mounting parts. External energized components (not shown) are bolted to the external conductor fastening parts 72a-72d, and the fuses are installed in a connected state to the busbars 16a-16c. The fastening terminals 66a and 66b of the fuse 18 are bolted to the bolt fastening parts 62a and 62b of the busbars 16f and 16g via fastening bolts 68, and are installed in a connected state to the busbars 16f and 16g in the electrical component fastening part 74.

[0051] External conductor fastening portions 72a-72d are provided at the protruding ends of the support leg portion 34b. At the protruding end of the support leg portion 34b, four nut receiving portions 76 are provided, opening upwards and extending into the bottom surface of the busbar receiving portion 42b. Nuts 78 (see reference) are respectively received in the nut receiving portions 76. Figure 5 , 7 External connecting portions 52a-52d, respectively, are disposed above the nut receiving portion 76 and located on the busbars 16a, 16c, 16d, and 16g, and are held by the busbar receiving portion 42b. The nut receiving portion 76, the nut 78, the external connecting portions 52a-52d, and the busbar receiving portion 42b, arranged in this manner, constitute the external conductor fastening portions 72a-72d.

[0052] like Figure 1 , 4 As shown, even when the housing body 12 is covered by the top cover 31, the external conductor fastening portions 72a-72d are exposed to the outside through the opening window 80 provided on the top cover 31, opening towards the top of the housing body 12. Thus, the external conductor fastening portions 72a-72d have a structure that allows external energized components (such as wiring harnesses or busbars, not shown) to be fastened from the top of the housing body 12 and the top cover 31 relative to the external connection portions 52a-52d provided on the busbars 16a, 16c, 16d, and 16g.

[0053] An electrical component fastening part 74 is provided at the protruding end of the support leg 34c. At the protruding end of the support leg 34c, a pair of nut receiving parts 82 are provided, opening upwards and extending into the bottom surface of the busbar receiving part 42c. Nuts 84 (see reference) are respectively received in the nut receiving parts 82. Figure 7Bolt fastening portions 62a and 62b, respectively, provided on the busbars 16f and 16g, are respectively disposed above the nut receiving portion 82 and held by the busbar receiving portion 42c. Each fastening terminal portion 66a and 66b of the fuse 18 is mounted on these bolt fastening portions 62a and 62b, thus holding the fuse 18. The nut receiving portion 82, nut 84, bolt fastening portions 62a and 62b, and busbar receiving portion 42c, arranged in this manner, constitute the electrical component fastening portion 74.

[0054] like Figure 1 , 4 As shown, even when the housing body 12 is covered by the top cover 31, the electrical component fastening part 74 is exposed to the outside through the through hole 86 provided in the top cover 31 and opens to the top of the housing body 12. In this way, the electrical component fastening part 74 has a structure that allows the following operation: the fastening terminals 66a and 66b of the fuse 18 overlap with the bolt fastening parts 62a and 62b provided on the busbars 16f and 16g from the top of the housing body 12 and the top cover 31, and are fastened by the fastening bolts 68.

[0055] <Top Cover 31>

[0056] The top cover 31 has a generally integral shape covering the upper surface of the base plate portion 32 in the housing body 12, and is made of an insulating material such as synthetic resin. By covering the upper surface of the housing body 12 with the top cover 31, accidental detachment of components from the housing body 12 can be prevented, ensuring insulation. Figure 1 , 4 As shown in Figure 7, a positive electrode side cover 88 is provided on the left end of the upper cover 31. The positive electrode side cover 88 is connected to the positive electrode side main contactor 22, the pre-charge contactor 26, and the pre-charge resistor 28 to form a positive electrode side circuit 89a, covering the busbars 16a, 16b, and 16c held in the support foot 34a. A negative electrode side cover 90 is provided on the right end of the upper cover 31. The negative electrode side cover 90 is connected to the negative electrode side main contactor 24, the fuse 18, and the current sensor 20 to form a negative electrode side circuit 89b, covering the busbars 16d to 16g held in the support foot 34c. In addition, the negative electrode side cover 90 of the upper cover has a through hole 86 that exposes the electrical component fastening part 74 that fastens the fuse 18 to the outside and a through hole 91 that exposes the current sensor mounting part 59 to the outside. Thus, the following operations can be performed: with the housing body 12 covered by the top cover 31, the fuse 18 is installed on the electrical component fastening part 74 from the outside and above of the electrical connection box 10, and the current sensor 20 is installed on the current sensor mounting part 59, and they are connected to the negative side circuit 89b by bolts.

[0057] In the left-right direction of the top cover 31, a central cover 92 is provided between the positive electrode side cover 88 and the negative electrode side cover 90. The central cover 92 is arranged facing the support leg 34b, and in the area corresponding to the outer conductor fastening parts 72a-72d of the busbar receiving part 42b housed in the support leg 34b, four opening windows 80 are provided, each penetrating through the central cover 92. Thus, in the central part of the top cover 31 in the left-right direction, i.e., the central cover 92, the outer conductor fastening parts 72a-72d are inserted through the opening windows 80 and exposed to the outside. As a result, with the top cover 31 covering the housing body 12, it is possible to perform the operation of bolting external energized components such as wire harnesses (not shown) to the outer conductor fastening parts 72a-72d from outside and above the electrical connection box 10 to connect to the positive electrode side circuit 89a and the negative electrode side circuit 89b. In Embodiment 1, a positive electrode side circuit 89a is provided at one end of the housing body 12, and a negative electrode side circuit 89b is provided at the other end. An external conductor fastening portion 72a-72d is provided in the central part of the housing body 12. As a result, compared with the case where the external conductor fastening portions 72a-72d are provided at the periphery of the housing body 12, the wiring length of the busbars 16a-16k can be shortened.

[0058] like Figure 1 , 7 As shown, in the negative electrode side cover portion 90 of the upper cover 31, a connector cover portion 94 is provided protruding outward from the front peripheral wall in the front direction (Y direction) to cover the top and surrounding area of ​​the connector contacts 70 of the busbars 16i~16k. A connector mounting portion 96 is provided on the upper wall of the connector cover portion 94, protruding upward in a rectangular cylindrical shape and having an opening. (See diagram below.) Figure 8As shown in the magnified view, four through holes 98 extending vertically are provided on the bottom wall of the connector mounting portion 96. The front end of the connecting tab 70 is inserted through the through holes 98 and disposed within the connector mounting portion 96. On the bottom wall of the connector mounting portion 96, a pair of downwardly protruding guide tube portions 100 are provided around the through holes 98. On the upper surface of the base plate portion 32, which faces the upper wall of the connecting tab cover portion 94 in the Z direction, a region including a groove-shaped busbar receiving portion 44 constitutes a connecting tab placement portion 102, and the connecting tabs 70 held in the busbar receiving portion 44 are placed in an arranged state. Around this connecting tab placement portion 102, a pair of positioning protrusions 104 are provided upwardly at the portion facing the pair of guide tube portions 100. Furthermore, when assembling the upper cover 31 to the housing body 12, before the connecting tab 70 is inserted into the tab insertion hole 98, the positioning protrusion 104 is inserted into the guide tube portion 100, and the connecting tab 70 is positioned in the tab insertion hole 98. This reduces the risk of deformation of the connecting tab 70 and facilitates the assembly of the upper cover 31 to the housing body 12. Additionally, an external connector for connecting to external control circuitry (not shown) is installed in the connector mounting portion 96.

[0059] Assembly of Electrical Connection Box 10

[0060] The following describes a specific example of the assembly method for the electrical connection box 10. However, the assembly method for the electrical connection box 10 is not limited to the method described below.

[0061] First, the relay terminal 14 is inserted through the upper opening 46 from the top of the housing body 12 into the relay terminal receiving portion 45 located at an appropriate position on the housing body 12. Nuts 78 and 84 are received in nut receiving portions 76 and 82 located at appropriate positions on the housing body. Next, multiple busbars 16a to 16k are arranged at predetermined positions from the top of the housing body 12, and received and held in busbar receiving portions 42a to 42c and 44 located at appropriate positions on the housing body 12. A top cover 31 covering the upper surface of the housing body 12 is assembled from the top of the housing body relative to the housing body 12 with the busbars 16a to 16k assembled thereon.

[0062] Next, the housing body 12 is flipped upside down so that the upper cover 31 faces downwards. In this state, the positive-side main contactor 22, the negative-side main contactor 24, the pre-charge contactor 26, and the pre-charge resistor 28 are sequentially installed on the lower-side component mounting portions 36a-36d. Figure 2As shown, each of the lower side component mounting portions 36a to 36d is provided with a locking portion 106 that can be elastically deformed. For example, by each locking portion 106 engaging with a locking protrusion (not shown) that protrudes from the housing of the positive side main contactor 22, the negative side main contactor 24, and the pre-charge contactor 26, and the housing of the pre-charge resistor 28, the lower side component can be prevented from falling off or detaching from the lower side component mounting portions 36a to 36d.

[0063] Then, the housing body 12 is flipped up and down so that the top cover 31 is facing upwards. In this state, the fuse 18 is installed from above and bolted to the electrical component fastening part 74 exposed to the outside through the through hole 86 of the top cover 31. In addition, the current sensor 20 is installed from above and bolted to the current sensor mounting part 59 exposed to the outside through the through hole 91 of the top cover 31. Thus, the electrical connection box 10 of Embodiment 1 is completed.

[0064] According to the electrical connection box 10 of Embodiment 1 configured in this way, in addition to the upper-side component mounting portions (i.e., external conductor fastening portions 72a-72d, electrical component fastening portion 74, and current sensor mounting portion 59) opening upwards towards the housing body 12, it also has lower-side component mounting portions 36a-36d opening downwards towards the housing body. Furthermore, the external conductor fastening portions 72a-72d and the lower-side component mounting portion 36a, which mounts the positive-side main contactor 22, are arranged to completely overlap in the vertical direction (Z-direction) of the housing body 12. Similarly, the electrical component fastening portion 74 and the lower-side component mounting portion 36b, which mounts the negative-side main contactor 24, are also arranged to completely overlap in the vertical direction (Z-direction) of the housing body 12. Therefore, in the XY direction, which is orthogonal to the vertical direction (Z-direction) of the housing body 12, it is not necessary to separate the upper-side component mounting portions and the lower-side main mounting portions, thus enabling miniaturization of the housing body 12 in the XY direction.

[0065] The lower component mounting portions 36a-36d are respectively equipped with a positive-side main contactor 22, a negative-side main contactor 24, a pre-charge contactor 26, and a pre-charge resistor 28, which are lower component elements having contact terminals 30. These contact terminals 30 are inserted through the lower opening 48 of the relay terminal receiving portion 45 and connected to the relay terminal 14, thereby making the lower component conductively connected to the busbars 16a-16k. By using the relay terminal 14 housed in such a relay terminal receiving portion 45, it is possible to make conductively connected to the busbars 16a-16k housed in the housing body 12 even without assembling the lower component from the upper side of the housing body. Therefore, it is possible to assemble the lower side components to the lower side component mounting portions 36a~36b, and the lower side component mounting portions 36a~36b can overlap with the external conductor fastening portions 72a~72d and the electrical component fastening portions 74 in the vertical direction without deterioration of assembly workability, and miniaturization of the housing body 12 and the electrical connection box 10 in the XY direction can be achieved.

[0066] Furthermore, in the vertical direction of the housing body 12, the connection between the upper component mounting parts (especially the external conductor fastening parts 72a~72d and the electrical component fastening part 74) and the lower component mounting parts 36a, 36b is achieved by using relay terminals 14, which can advantageously reduce the wiring length of the busbars 16a~16k.

[0067] In addition, as the upper-side component mounting section, each is provided with an external conductor fastening section 72a~72d, an electrical component fastening section 74, and a current sensor mounting section 59 that require bolt tightening operations, so that assembly operations can be easily performed from the top of the housing body 12.

[0068] like Figure 5 , 6 As shown, the lower-side component mounting portions 36c and 36d are arranged overlappingly in the vertical direction of the housing body 12. Specifically, the lower-side component mounting portion 36c is positioned above the lower-side component mounting portion 36d in the vertical direction of the housing body 12. Figure 6It is known that the two ends of the lower component mounting portion 36d in the Y direction protrude to both sides beyond the two ends of the lower component mounting portion 36c in the Y direction. Furthermore, the contact terminals 30 of the pre-charge resistor 28 mounted on the lower component mounting portion 36d are located at a position that does not overlap with the lower component mounting portion 36c in the vertical direction. Therefore, by positioning the relay terminal 14 connecting the contact terminals 30 of the pre-charge resistor 28 at a position offset outward in the Y direction from the two ends of the lower component mounting portion 36c, the lower component mounting portions 36c and 36d can be arranged to overlap in the vertical direction of the housing body 12. Thus, by having multiple lower component mounting portions 36c and 36d also overlap in the vertical direction of the housing body 12, miniaturization in the XY direction of the housing body 12 and the electrical connection box 10 can be achieved more advantageously.

[0069] <Variation Example>

[0070] The above detailed description of Embodiment 1 is provided as a specific example of this disclosure, but this disclosure is not limited to this specific description. Modifications and improvements within the scope of achieving the purpose of this disclosure are included in this disclosure. For example, the following modifications of the embodiment are also included within the technical scope of this disclosure.

[0071] (1) In the above embodiment, the upper side component mounting parts (external conductor fastening parts 72a~72d and electrical component fastening parts 74) and the lower side component mounting parts 36a and 36b are arranged to completely overlap in the vertical direction (Z direction) of the housing body 12, but they can also be arranged to partially overlap. Even in this case, miniaturization of the housing body 12 and the electrical connection box 10 in the XY direction can be achieved.

[0072] (2) In the above embodiment, the upper side component mounting part is exemplified by a structure in which bolts are fastened to the busbar, but it is not limited to this. As a structure for connecting to the busbar, a structure with any structure such as relay terminal or welding can be adopted.

[0073] (3) In the above embodiment, an example is shown in which two lower side component mounting portions 36c and 36d are arranged overlapping in the vertical direction of the housing body 12, but it is also possible to have three or more lower side component mounting portions overlapping in the vertical direction. In addition, it is not necessary to have multiple lower side component mounting portions overlapping in the vertical direction, and miniaturization of the electrical connection box 10 in the XY direction can also be achieved by adding upper side component mounting portions that overlap with the lower side component mounting portions in the vertical direction.

[0074] Explanation of reference numerals in the attached figures

[0075] 10 Electrical connection box

[0076] 12. Shell Body

[0077] 14 relay terminals

[0078] 16a~16k Busbars

[0079] 18. Fuse (top-side component)

[0080] 20 Current sensor (top side element)

[0081] 22 Positive side main contactor (bottom side component)

[0082] 24 Negative side main contactor (bottom side component)

[0083] 26 Pre-charge contactor (bottom side element)

[0084] 28 Pre-charge resistor (bottom side component)

[0085] 30 lug terminals

[0086] 31 Top Cover

[0087] 32 Base plate

[0088] 34a~34c Support feet

[0089] 36a~36d Lower side component mounting section

[0090] 38 Fastening bolts

[0091] 40 Bolt fixing part

[0092] 42a-42c Busbar Containment Unit

[0093] 44 Convergence Line Containment Department

[0094] 45. Relay terminal housing section

[0095] 46. ​​Upper opening

[0096] 48. Lower opening

[0097] 50a~50h Connecting section (part of the busbar)

[0098] 52a~52d External connection parts

[0099] 56 Input Terminals

[0100] 57 bolts

[0101] 58 Output Terminals

[0102] 59 Current sensor mounting section

[0103] 60 One end

[0104] 61 Nuts

[0105] 62a, 62b Bolt fastening parts

[0106] 66a, 66b Fastening terminal section

[0107] 68 Fastening bolts

[0108] 70 Connecting Piece

[0109] 72a~72d External conductor fastening part (top side component mounting part)

[0110] 74 Electrical component fastening part (top side component mounting part)

[0111] 76 Nut Receiving Section

[0112] 78 nuts

[0113] 80 Opening window

[0114] 82 Nut Receiving Part

[0115] 84 Nut

[0116] 86 Through Holes

[0117] 88 Positive electrode side cover

[0118] 90 Negative electrode side cover

[0119] 91 Through Hole

[0120] 92 Central cover

[0121] 94 Connecting tab cover

[0122] 96 Connector Mounting Section

[0123] 98 Connector Through Hole

[0124] 100 Guide tube section

[0125] 102 Connecting tab mounting section

[0126] 104 Positioning Protrusion

[0127] 106 Locking section.

Claims

1. An electrical connection box, comprising: Shell body; The relay terminal receiving part has an upper opening and a lower opening that open to the top and bottom of the housing body, and receives a relay terminal assembled by inserting it through the upper opening; The busbar receiving section opens towards the upper part of the housing body and receives multiple busbars assembled from the upper part to form a power conduction path; The upper side component mounting portion opens to the upper part of the housing body, and the upper side component assembled from the upper part and connected to the busbar is mounted in the upper side component mounting portion; and The lower side component mounting portion opens to the lower part of the housing body, and the lower side component, which is assembled from the lower part and connected to the busbar, is mounted in the lower side component mounting portion. The upper side component mounting portion and the lower side component mounting portion are arranged overlappingly in the vertical direction of the housing body. A portion of the busbar is connected to the relay terminal. The lower side element has a contact terminal, which is inserted through the lower opening of the relay terminal receiving part and connected to the relay terminal, thereby making the lower side element conductively connected to the bus bar.

2. The electrical connection box according to claim 1, wherein, The upper component mounting portion includes an external conductor fastening portion, which holds the external connection portion provided on the busbar and allows external energized components to be fastened from the upper side to the external connection portion.

3. The electrical connection box according to claim 2, wherein, A positive electrode circuit is provided at one end of the housing body, and a negative electrode circuit is provided at the other end of the housing body. The external conductor fastening part is provided in the central part of the housing body.

4. The electrical connection box according to claim 1 or 2, wherein, The upper component mounting portion includes an electrical component fastening portion, which holds an electrical component including a fastening terminal portion. The fastening terminal portion is bolted to a bolt fastening portion provided on the busbar. The electrical component fastening portion allows the fastening terminal portion to be bolted from above to the bolt fastening portion.

5. The electrical connection box according to claim 1 or 2, wherein, The lower side element mounting portion includes a plurality of lower side element mounting portions arranged overlapping in the vertical direction.

6. The electrical connection box according to claim 1 or 2, wherein, The lower side element mounting portion has a locking portion that engages with the lower side element to keep the lower side element in a connected state with the busbar and prevent the lower side element from being removed from the lower side element mounting portion.

7. The electrical connection box according to claim 1 or 2, wherein, The electrical connection box has a top cover that covers the upper surface of the main body of the housing. The top cover has: a connector mounting portion that opens upwards; a contact insertion hole that penetrates the bottom wall of the connector mounting portion; and a guide tube portion that protrudes downwards around the connector mounting portion. The busbar has a connecting tab, which is inserted into the connecting tab insertion hole of the connector mounting portion and is disposed in the connector mounting portion. The housing body has: a connecting tab mounting portion disposed on the upper surface; and a positioning protrusion protruding upward around the connecting tab mounting portion. When assembling the top cover to the housing body, before the connecting piece is inserted into the connecting piece insertion hole, the positioning protrusion is inserted into the guide tube to position the connecting piece in the connecting piece insertion hole.

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