Electrical connection unit

Abstract

An electrical connection unit includes a sandwiching portion, a first circuit, and a second circuit, the first circuit includes a first electronic component and is disposed on a first side in a first direction with respect to the sandwiching portion, and the second circuit includes a second electronic component and is disposed on a second side in the first direction with respect to the sandwiching portion.

Description

Technical Field

[0001] Embodiments of the present invention relate to an electrical connection unit. Background Technology

[0002] In electrical connection units, electronic components such as relays and resistors are known to be mounted on the mounting surface of the housing.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Unexamined Patent Application, First Publication No. 2018-113184 Summary of the Invention

[0006] In electrical connection units, a specific structure may be required depending on the product to be connected. Due to this specific structure, it may be difficult to adapt the electrical connection unit to different products.

[0007] One embodiment provides an electrical connection unit that can be easily applied to different products.

[0008] An electrical connection unit according to one embodiment includes: a clamping portion; a first circuit including a first electronic component and disposed on a first side in a first direction relative to the clamping portion; and a second circuit including a second electronic component and disposed on a second side in the first direction relative to the clamping portion.

[0009] An electrical connection unit according to one embodiment includes: a clamping portion; a first circuit including a first electronic component and disposed on a first side in a first direction relative to the clamping portion; and a relay busbar including a first connecting portion, a second connecting portion, and an extension portion, the first connecting portion being electrically connected to the first circuit, the second connecting portion being electrically connected to a second circuit including a second electronic component, the second circuit being disposed on a second side in the first direction relative to the clamping portion, and the extension portion extending between the first connecting portion and the second connecting portion.

[0010] According to one embodiment, the electrical connection unit can be easily applied to different products. Attached Figure Description

[0011] Figure 1 This is a perspective view showing the electrical connection unit according to an embodiment;

[0012] Figure 2 This is an exploded perspective view showing the metal cover and the first structure according to an embodiment;

[0013] Figure 3This is an exploded perspective view showing a portion of the first structure, relay bus, and external connection bus according to an embodiment;

[0014] Figure 4 This is an exploded perspective view showing the electrical connection unit according to an embodiment;

[0015] Figure 5 This is a plan view showing the electrical connection unit according to an embodiment;

[0016] Figure 6 This is a plan view showing the electrical connection unit according to the embodiment, as viewed through the second cover;

[0017] Figure 7 This is a perspective view showing a relay bus bar according to an embodiment;

[0018] Figure 8 It is further observed through the first cover. Figure 6 Enlarged 3D view of section VIII;

[0019] Figure 9 This is a perspective view showing an electrical connection unit according to a modified embodiment; and

[0020] Figure 10 This is a perspective view showing an electrical connection unit according to a modified embodiment.

[0021] Reference tag list

[0022] 1 Electrical connection unit

[0023] 3 First Structure

[0024] 4 Second Structure

[0025] 5. Metal base (support body, clamping structure)

[0026] 5q opening

[0027] 6. Relay busbar

[0028] 7 External connection busbar

[0029] 8. Auxiliary base components

[0030] 30 First Circuit

[0031] 31 Wiring Board

[0032] 32. Busbar (First Busbar)

[0033] 33 First Electronic Components

[0034] 34 Connecting components

[0035] 35. Substrate (base component)

[0036] 36 Flat surface section

[0037] 37 claws

[0038] 40 Second Circuit

[0039] 41 First Cover

[0040] 41q Open

[0041] 42. Busbar (Second Busbar)

[0042] 42A Busbar

[0043] 43 Second electronic components

[0044] 45 Locking section

[0045] 45AR Arm

[0046] 45PR protrusion

[0047] 46 Second cover

[0048] 46q Open

[0049] 47 Fourth connecting part

[0050] 48 Third Extension

[0051] 49 Signal Connector

[0052] 51 Support part (clamping part)

[0053] 51s support surface

[0054] 52 Zhou Bi

[0055] 53 First Maintenance Department

[0056] 53RS recess

[0057] 54 Second Maintenance Section

[0058] 61 First connecting part

[0059] 62 Second connecting part

[0060] 62s flat surface

[0061] 62h Fastening Hole

[0062] 63 First extension (extension)

[0063] 64 Third connecting part

[0064] 65 Second Extension

[0065] 71 Fifth connecting part

[0066] 72 Sixth connecting part

[0067] 73 Fourth Extension

[0068] 91 Insulating sheet

[0069] 91A First Insulating Sheet

[0070] 91B Second Insulating Sheet

[0071] 92 Heat transfer components

[0072] 92A First Heat Transfer Component

[0073] 92B Second Heat Transfer Component

[0074] 98 Cooler

[0075] 101 Electrical Connection Unit

[0076] 105 Clamping Structure

[0077] 151 Clamping section

[0078] U-shaped space Detailed Implementation

[0079] The embodiments will now be described with reference to the accompanying drawings. In the following description, constructions having the same or similar functions are identified by the same reference numerals. Redundant descriptions of these constructions may be omitted. The constructions described below do not limit the scope of the embodiments.

[0080] In this disclosure, the terms are defined as follows: The term "connection" is not limited to mechanical connections and may also include electrical connections. That is, the term "connection" is not limited to the case where two components are directly connected, but may include the case where two components are connected by another component between them. The term "accommodate" is not limited to the case where the entire component is accommodated, but may also include the case where only a part of the component is accommodated (the remaining part of the component protrudes). The term "cover" is not limited to the case where the entire target is covered, but may include the case where only a part of the target is covered. The term "facing" indicates that when viewed from a specific direction, the virtual projected images of two objects overlap each other. That is, the term "facing" is not limited to the case where two objects directly face each other, but may include the case where the two objects face each other with another component between them. The terms "orthogonal" or "identical" may respectively include "substantially orthogonal" or "substantially identical". The terms "sheet" or "sheet material" are not limited to components with a thickness of 1 mm or more, but may be components with a thickness of less than 1 mm (so-called thin films).

[0081] In this disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows. For example... Figure 1 As shown, the X direction is a direction within the plane of the support surface 51s of the support portion 51, which will be described below. The +X direction is a direction within the X direction. The -X direction is the opposite direction to the +X direction. Hereinafter, when the +X and -X directions are not distinguished from each other, they will be simply referred to as the "X direction". The Y direction is a direction that intersects (e.g., is orthogonal) the X direction within the plane of the support surface 51s of the support portion 51, which will be described below. The +Y direction is a direction within the Y direction. The -Y direction is the opposite direction to the +Y direction. Hereinafter, when the +Y and -Y directions are not distinguished from each other, they 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 facing the support surface 51s of the support portion 51, which will be described below. The -Z direction is the opposite direction to the +Z direction. Hereinafter, when the +Z and -Z directions are not distinguished from each other, these directions will be simply referred to as the "Z direction". The Z direction is an example of a "first direction". The -Z direction side is an example of a "first side of the first direction". The +Z direction is an example of "the second side in the first direction". The X direction is an example of "the second direction". The Y direction is an example of "the third direction".

[0082] In the following text, without distinguishing between the X and Y directions, these directions may be referred to as "horizontal directions". The Z direction may be referred to as "vertical directions". Furthermore, the +Z direction may be referred to as "up", and the -Z direction may be referred to as "down". However, these expressions are for ease of description and do not limit the direction of gravity relative to the electrical connection unit 1 (the mounting orientation of the electrical connection unit 1).

[0083] (Example)

[0084] <1. Construction of Electrical Connection Unit>

[0085] Electrical connection unit 1 is an on-board device, for example, installed on a vehicle such as an electric vehicle (EV), a hybrid electric vehicle (HEV), or a plug-in hybrid electric vehicle (PHEV). Electrical connection unit 1 connects to multiple external devices. Electrical connection unit 1 facilitates connections between multiple external devices (hereinafter also referred to as "products"). For example, external devices may include a battery pack, a load, a charger, etc. The battery pack is installed on the vehicle. The load is a device including an inverter or similar device used to drive a vehicle motor that uses electricity stored in the battery pack. The charger is a device that provides power to charge the battery pack. For example, electrical connection unit 1 may be referred to as an "electrical connection box" or a "junction box." However, electrical connection unit 1 is not limited to a box-shaped device.

[0086] The electrical connection unit 1 includes a first structure 3, a second structure 4, a metal base 5, a relay busbar 6, multiple external connection busbars 7, and multiple auxiliary base components 8. The electrical connection unit 1 also includes an insulating sheet 91 and a heat transfer component 92 (see...). Figure 2 and Figure 4 The second structure 4 is supported by a metal base 5. The second structure 4 is stacked on top of the first structure 3, with the metal base 5 sandwiched between the second structure 4 and the first structure 3 in the +Z direction. Through this stacking, the electrical connection unit 1 has at least a two-layer hierarchical structure. For example, the electrical connection unit 1 can be configured to contact the cooling surface of the external cooler 98 from the -Z side. The external cooler 98 can be, for example, a water jacket. The metal base 5 is an example of a "sandwich structure". The metal base 5 is an example of a "support".

[0087] <2. Construction of the First Structure>

[0088] like Figure 2 As shown, the first structure 3 includes a first circuit 30. The first circuit 30 includes a wiring board 31, a plurality of first electronic components 33, and a plurality of connecting components 34. Figure 3 As shown, the wiring board 31 includes a plurality of busbars 32 and a substrate 35. The substrate 35 is an example of a base component. Each busbar 32 is an example of a first busbar. The first structure 3 may be a unit included in the first layer of a two-layer hierarchical structure, for example, the electrical connection unit 1.

[0089] (First electronic component)

[0090] Among the electronic components included in the electrical connection unit 1, each first electronic component 33 is a crucial component for performing the function of connecting multiple external devices. Each first electronic component 33 may be a common electronic component required by the electrical connection unit 1, for example, in different products using the electrical connection unit 1. The plurality of first electronic components 33 may include, for example, relays (e.g., mechanical relays or semiconductor relays). The plurality of first electronic components 33 may include, for example, relays installed in the electrical connection unit 1 that are capable of switching between on and off at maximum current. Each first electronic component 33 is electrically connected to at least one of the plurality of busbars 32. For example, each first electronic component 33 may be electrically connected to a busbar 32 via a pair of connecting members 34.

[0091] (Wiring board)

[0092] The wiring board 31 is a board used to form at least a portion of a power-conducting path connected to the first electronic component 33. In this disclosure, "wiring board" refers to the wiring structure of a board shape. "Board shape" refers to a board-like shape along a plane when viewed as a whole, without considering minute details. In this disclosure, "board-like shape" is not limited to a completely flat shape and may include cases where there are localized fixing structures, ribs, etc., protruding in the Z-direction. In this embodiment, the wiring board 31 is a board-like shape formed in both the X and Y directions.

[0093] In the wiring board 31, multiple busbars 32 and the substrate 35 are integrated by insert molding. The wiring board 31 is formed as a single component by insert molding the busbars 32 and the substrate 35. That is, the busbars 32 are integrated with the substrate 35 without the use of fastening components such as screws or bolts. Note that instead of insert molding, the wiring board 31 can be formed by other structures.

[0094] (Substrate)

[0095] The substrate 35 is a holding member for integrally holding a plurality of busbars 32 spaced apart in a horizontal direction. The substrate 35 is made of, for example, synthetic resin and has insulating properties. The substrate 35 electrically insulates the plurality of busbars 32 from each other. The substrate 35 includes a flat surface portion 36 and a plurality of claw portions 37. The substrate 35 is an example of a "base member". The substrate 35 may be referred to as an "insulating substrate".

[0096] The flat surface portion 36 is a plate-shaped portion formed in the substrate 35. The flat surface portion 36 is plate-shaped along the horizontal direction. The flat surface portion 36 forms the main part of the substrate 35. The flat surface portion 36 forms the base (insulating base) of the substrate 35. In this embodiment, except for the four corners of the substrate 35, the flat surface portion 36 extends across the entire width of the substrate 35 in the X direction and across the entire width of the substrate 35 in the Y direction. A first electronic component 33 is placed on the flat surface portion 36 from the +Z direction side. That is, the first electronic component 33 is disposed on the +Z direction side relative to the flat surface portion 36. A plurality of claw portions 37 are located on the outer periphery of the flat surface portion 36. Each claw portion 37 protrudes from the flat surface portion 36 in the +Z direction.

[0097] (First busbar)

[0098] Each busbar 32 is a wiring component (electrical connection component) included in the wiring board 31. Each busbar 32 is, for example, a wiring component that forms at least a portion of a power path electrically connected to the first electronic component 33. Each busbar 32 may be, for example, a wiring component that electrically connects the first electronic component 33 to an external device of the second circuit 40 or the electrical connection unit 1. The busbar 32 is made of metal (e.g., copper or copper alloy) and is conductive. At least a portion of each busbar 32 is held by a substrate 35. A plurality of busbars 32 may include portions disposed, for example, on the same plane.

[0099] At least a portion of each busbar 32 is plate-shaped in a horizontal direction. At least a portion of each busbar 32 extends along a flat surface portion 36. In this embodiment, each busbar 32 is plate-shaped in a horizontal direction along its entire length. The busbar 32 is a component that forms a power path in the horizontal direction.

[0100] <3. Construction of the Second Structure>

[0101] like Figures 4 to 6 As shown, the second structure 4 includes a second circuit 40, a first cover 41, multiple locking parts 45, and a second cover 46. The second circuit 40 is supported by a support part 51 (see...). Figure 8 The second circuit 40 includes a plurality of second electronic components 43 and a plurality of busbars 42. Each busbar 42 is an example of a "second busbar". The second structure 4 may be a part included in the second layer of a two-layer hierarchical structure, for example, the electrical connection unit 1.

[0102] (Second electronic component)

[0103] Each second electronic component 43, compared to the first electronic component 33, requires greater design freedom and component replacement capabilities depending on the product used in the electrical connection unit 1. The second electronic component 43 may, for example, prioritize ease of wiring for each product used in the electrical connection unit 1, and may be an electronic component whose component positions within the electrical connection unit 1 are easily changeable. The second electronic component 43 may, for example, have component specifications easily adaptable to each product used in the electrical connection unit 1. The second electronic component 43 may, for example, be installed or not installed in the electrical connection unit 1 depending on the component specifications of different products used in the electrical connection unit 1. The second electronic component 43 may, for example, be easily replaceable due to component deterioration or periodic maintenance of the electrical connection unit 1.

[0104] The second electronic component 43 may be, for example, various sensors (e.g., current sensors or voltage sensors), fuses, or control circuits (e.g., microcontroller units (MCUs), microprocessor units (MPUs), etc.). The second electronic component 43 may be, for example, one of a plurality of relays mounted on the electrical connection unit 1, excluding the relay controlling the on and off of the maximum current. Each of the plurality of second electronic components 43 is electrically connected to at least one of the plurality of busbars 42. The second electronic component 43 may include a signal connector 49.

[0105] Signal connector 49 is a connector capable of inputting and outputting signals related to the second electronic component 43. For example, when the second electronic component 43 is a current sensor, signal connector 49 can send a detection signal related to the current flowing through the second electronic component 43 to the outside of electrical connection unit 1. For example, when the second electronic component 43 is a fuse, signal connector 49 can send an alarm signal to the outside of electrical connection unit 1 to notify the second electronic component 43 of its failure. For example, when the second electronic component 43 is a relay, signal connector 49 can receive control signals for the on and off states of the second electronic component 43 from the outside of electrical connection unit 1.

[0106] (Second busbar)

[0107] Each busbar 42 is a wiring component used to form a power path in the second circuit 40. Each busbar 42 can form a power path, for example, connected to a second electronic component 43. At least a portion of each busbar 42 extends in a horizontal direction. The busbar 42 is made of metal (e.g., copper or a copper alloy) and is conductive. The ends of each busbar 42 can be fastened to terminals of the second electronic component 43, relay busbar 6, or another busbar 42 by means of fastening components such as screws or bolts.

[0108] Multiple busbars 42 may include, for example, busbar 42A. For instance, busbar 42A may intersect with an external connecting busbar 7. Busbar 42A includes a pair of fourth connectors 47 and a third extension 48. One of the pair of fourth connectors 47 is electrically connected to a second connector 62 using a fastening member such as a screw or bolt. The other fourth connector 47 of the pair of fourth connectors 47 is electrically connected to a second electronic component 43 via another busbar 42. This other fourth connector 47 is fastened to the connection end of the other busbar 42 by a fastening member such as a screw or bolt. The third extension 48 extends across the pair of fourth connectors 47. The third extension 48 is continuous with each of the pair of fourth connectors 47. The third extension 48 is disposed between the pair of fourth connectors 47. The third extension 48 connects the pair of fourth connectors 47. The third extension 48 extends while bending. The third extension 48 extends from the +Y direction side of one of the fourth connecting portions 47 in the +Y direction, and extends in the +X direction while bending in the XY plane. The third extension 48 has a step in the +Z direction as it extends in the +X direction, and thus extends to the -X direction side of the other fourth connecting portion 47.

[0109] (First cap and second cap)

[0110] Each of the first cover 41 and the second cover 46 is tray-shaped, in which most of the outer periphery (except for a portion) is upright. The first cover 41 and the second cover 46 are combined such that the upright directions of the outer peripheries face each other. The first cover 41 has a plurality of openings 41q. The portion of the first cover 41, excluding the plurality of openings 41q, covers the second circuit 40 from the -Z direction side. The second cover 46 has a plurality of openings 46q. The portion of the second cover 46, excluding the plurality of openings 46q, covers the second circuit 40 from the +Z direction side. The first cover 41 and the second cover 46 are combined to accommodate most of the second circuit 40 (e.g., the portion of the busbar 42 except for the portion to be fastened to the relay busbar 6 and the signal connector 49). For example, each of the first cover 41 and the second cover 46 can be detached from or in contact with the plurality of busbars 42 and the plurality of second electronic components 43. Each of the first cover 41 and the second cover 46 can be made of, for example, synthetic resin.

[0111] (Locking section)

[0112] Multiple locking portions 45 are located at the ends of the second structure 4 on the +X, -X, +Y, and -Y directions. The multiple locking portions 45 are integrally formed with the second cover 46. The locking portions 45 can be, for example, snap-fit ​​components. The second structure 4 is fixed to the support portion 51 by the multiple locking portions 45.

[0113] Each locking portion 45 includes an arm 45AR and a protrusion 45PR. The arm 45AR extends toward the first retaining portion 53, which will be described below. The arm 45AR extends from the upper outer periphery of the first cover 41 toward the first retaining portion 53. The arm 45AR is deformable and capable of warping in a horizontal direction from an orientation extending in the Z direction. The arm 45AR has a restoring force in a direction opposite to the direction of deformation. The protrusion 45PR protrudes from the arm 45AR toward the first retaining portion 53 in a direction intersecting the extending direction of the arm 45AR.

[0114] <4. Construction of the Support (Clamping Structure)>

[0115] The metal base 5 includes a support portion 51, a peripheral wall 52, a plurality of first retaining portions 53, and a plurality of second retaining portions 54. The metal base 5 has a plurality of openings 5q. Each opening 5q extends from the external opening of the electrical connection unit 1 to the receiving space U (see below). Figure 2 The portion of the metal base 5, excluding the plurality of openings 5q, covers the first structure 3 from the +Z direction side. At least a portion of the metal base 5 is made of metal (e.g., aluminum or an aluminum alloy). The support portion 51, the peripheral wall 52, and the first retaining portion 53 can be integrally formed using, for example, a metallic material. The support portion 51 is an example of a clamping portion.

[0116] (Support part (clamping part))

[0117] The support portion 51 supports the second structure 4 from the -Z direction side. The first circuit 30 is disposed on the -Z direction side relative to the support portion 51. The second circuit 40 is disposed on the +Z direction side relative to the support portion 51. The support portion 51 is sandwiched between the first circuit 30 and the second circuit 40. The support portion 51 has a support surface 51s facing the +Z direction. The support surface 51s can be, for example, a flat surface.

[0118] (Zhou Bi)

[0119] The peripheral wall 52 extends from the outer edge of the support portion 51 in the -Z direction to the outer edge of the substrate 35. The peripheral wall 52, excluding the plurality of openings 5q and the plurality of second retaining portions 54, encloses the outer periphery of the space sandwiched between the support portion 51 and the substrate 35. The peripheral wall 52 covers at least a plurality of first electronic components 33 from the +X direction side, -X direction side, +Y direction side, and -Y direction side. With this configuration, the plurality of first electronic components 33 are accommodated in the accommodating space U defined by the metal base 5 and the wiring board 31 (see...). Figure 2 )middle.

[0120] (Maintenance Department)

[0121] Each first retaining portion 53 protrudes from the support portion 51 in the +Z direction. Each first retaining portion 53 has a recess 53RS. The recess 53RS is formed by the horizontally protruding edge of the first retaining portion 53. The recess 53RS is recessed in the direction in which the protrusion 45PR extends from the arm portion 45AR. When the first cover 41 approaches the support portion 51 in the -Z direction, the protrusion 45PR crosses the edge of the first retaining portion 53 surrounding the recess 53RS and engages with the recess 53RS. As a result, the second structure 4 is held in a state where it is mounted on the metal base 5.

[0122] Each second retaining portion 54 is located closer to the peripheral wall 52 on the -Z direction side. Each second retaining portion 54 is engaged by the end of the associated claw portion 37. Through this engagement, the metal base 5 holds the substrate 35. The second retaining portion 54 may be, for example, an opening in the peripheral wall 52 in the horizontal direction. Each second retaining portion 54 is not limited to an opening, and may also be a recess from the inner peripheral surface of the peripheral wall 52. On the other hand, each claw portion 37 may have any locking structure, as long as it can be engaged by the associated second retaining portion 54.

[0123] (Opening)

[0124] Of the plurality of openings 5q, the opening 5q associated with the relay bus 6 is positioned to electrically connect the first circuit 30 and the second circuit 40. The opening 5q associated with the relay bus 6 may be positioned, for example, so that the relay bus 6 protrudes from the metal base 5 in the +Z direction. Of the plurality of openings 5q, the opening 5q associated with the external connection bus 7 is positioned to allow the external connection bus 7 to pass between the -Z direction side and the +Z direction side of the support portion 51.

[0125] <5. Construction of relay busbars>

[0126] The relay busbar 6 is electrically connected to busbars 32 and 42 to relay power to them. The relay busbar 6 is a component that forms a vertical power path. For example... Figure 3 and Figure 7 As shown, the relay bus 6 includes a first connecting portion 61, a second connecting portion 62, a first extension portion 63, a third connecting portion 64, and a second extension portion 65. As will be described below, for example, a portion of the relay bus 6 may protrude from the support surface 51s toward the +Z direction side (see...). Figure 4 The relay bus 6 can be connected to the second circuit 40, for example, on the +Z direction side of the support surface 51s. The first extension 63 is an example of an "extension".

[0127] (First connecting part)

[0128] The first connecting portion 61 is a portion of the relay busbar 6 that extends continuously from the -Z direction side of the first extension portion 63 in the -X direction. The first connecting portion 61 is electrically connected to the busbar 32. For example, the first connecting portion 61 can be fastened to one end of the busbar 32 in a manner that enables electrical connection using fastening components such as screws or bolts.

[0129] (Second connecting part)

[0130] The second connecting portion 62 is disposed on the +Z direction side relative to the first connecting portion 61. The second connecting portion 62 is a portion of the relay busbar 6 that extends continuously from the +Z direction side of the first extension portion 63 in the +X direction.

[0131] The second connection portion 62 is electrically connected to the second circuit 40. The second connection portion 62 is exposed toward the second structure 4. For example, the second connection portion 62 can be exposed in the +Z direction from the opening 5q (see...). Figure 1 and Figure 6 For example, the second connecting portion 62 may protrude slightly from the metal base 5 in the +Z direction (see...). Figure 1 and Figure 4 However, the second connecting portion 62 may also be flush with the support portion 51 on the +Z direction side.

[0132] The second connection part 62 is electrically connected to the bus bar 42 (see...) Figure 6 For example, the second connecting portion 62 can be electrically fastened to one end of the busbar 42 using a fastening member such as a screw or bolt. For example, the second connecting portion 62 can have a flat surface 62s that can contact the busbar 42 and faces the +Z direction. For example, the second connecting portion 62 can have a fastening hole 62h for inserting a fastening member such as a screw or bolt. For example, the fastening hole 62h can extend through the second connecting portion 62 in the Z direction.

[0133] (First extension)

[0134] A first extension 63 extends across a first connecting portion 61 and a second connecting portion 62. The first extension 63 is disposed between the first connecting portion 61 and the second connecting portion 62. The first extension 63 connects the first connecting portion 61 and the second connecting portion 62. The first extension 63 extends continuously from the +X direction side of the first connecting portion 61, which extends in the X direction. The first extension 63 bends gently from the first connecting portion 61 in the +Z direction and extends in the +Z direction. The first extension 63 extends continuously from the -X direction side of the second connecting portion 62, which extends in the X direction. The first extension 63 extends in the -Z direction and bends gently in the -Z direction from the second connecting portion 62.

[0135] (Third connecting part)

[0136] The third connecting portion 64 is the part of the relay busbar 6 that extends laterally from the second extension portion 65 in the -Z direction toward the +X direction. For example, the third connecting portion 64 can be exposed from the second structure 4 and the metal base 5 in the +Z direction (see...). Figure 5 The third connection portion 64 is electrically connected to a device outside the electrical connection unit 1. For example, the third connection portion 64 can be fastened to one end of a wiring component (e.g., a busbar) extending from the device outside the electrical connection unit 1 in a manner that allows for electrical connection with each other using fastening components such as screws or bolts.

[0137] (Second extension)

[0138] The second extension 65 extends across the second connecting portion 62 and the third connecting portion 64. The second extension 65 is disposed between the second connecting portion 62 and the third connecting portion 64. The second extension 65 connects the second connecting portion 62 and the third connecting portion 64. The second extension 65 extends continuously from the +X direction side of the second connecting portion 62, which extends in the X direction. The second extension 65 bends gently from the second connecting portion 62 in the -Z direction and extends in the -Z direction. The second extension 65 extends continuously from the -X direction side of the third connecting portion 64, which extends in the X direction. The second extension 65 bends gently from the third connecting portion 64 in the +Z direction and extends in the +Z direction.

[0139] <6. Construction of External Connection Busbar>

[0140] Multiple external connection busbars 7 are busbars used to electrically connect external devices to the first circuit 30 or the second circuit 40. For example... Figure 3 and Figure 4 As shown, each external connection busbar 7 includes a fifth connection portion 71, a sixth connection portion 72, and a fourth extension portion 73. For example, similar to the fifth connection portion 71 or the sixth connection portion 72 described below, some busbar portions of the external connection busbar 7 may be disposed on the +Z direction side relative to the support portion 51.

[0141] (Fifth connecting part)

[0142] The fifth connecting portion 71 is the portion of the external connecting busbar 7 that extends horizontally from one end of the fourth extension 73. The fifth connecting portion 71 is electrically connected to busbar 32 or busbar 42. For example, the fifth connecting portion 71 can be fastened to one end of busbar 32 or busbar 42 in an electrically connected manner using fastening components such as screws or bolts. In at least one external connecting busbar 7, the fifth connecting portion 71 may, for example, be disposed on the +Z direction side relative to the support surface 51s (see...). Figure 4 ).

[0143] (Sixth connecting part)

[0144] The sixth connection portion 72 is electrically connected to a wiring component (e.g., a busbar) extending from an external device. The sixth connection portion 72 is disposed on the +Z direction side or the -Z direction side relative to the fifth connection portion 71. The sixth connection portion 72 is the portion of the external connection busbar 7 that extends horizontally from the other end of the fourth extension portion 73. In at least some of the external connection busbars 7, the sixth connection portion 72 may, for example, be disposed on the +Z direction side relative to the support surface 51s (see...). Figure 4 ).

[0145] like Figure 5 As shown, the sixth connection portion 72 protrudes from the opening 5q of the metal base 5 in the +Z direction. For example, the sixth connection portion 72 may protrude from the second structure 4 and the metal base 5 in the +Z direction to electrically connect to a wiring component (e.g., a busbar) extending from an external device.

[0146] Some of the sixth connection portions 72 may be fastened to wiring components (e.g., busbars) extending from external devices using fastening components such as screws or bolts. For example, some of the sixth connection portions 72 may also be soldered to wiring components (e.g., busbars) extending from external devices.

[0147] (Fourth extension)

[0148] like Figure 3 and Figure 4 As shown, the fourth extension 73 extends across the fifth connecting portion 71 and the sixth connecting portion 72. The fourth extension 73 is disposed between the fifth connecting portion 71 and the sixth connecting portion 72. The fourth extension 73 connects the fifth connecting portion 71 and the sixth connecting portion 72. The fourth extension 73 extends continuously from one end of the fifth connecting portion 71, which extends horizontally. The fourth extension 73 bends gently from the fifth connecting portion 71 in the +Z direction (or -Z direction) and extends in the +Z direction (or -Z direction). The fourth extension 73 extends continuously from one end of the sixth connecting portion 72, which extends horizontally. The fourth extension 73 bends gently from the sixth connecting portion 72 in the -Z direction (or +Z direction) and extends in the -Z direction (or +Z direction).

[0149] <7. Construction of Auxiliary Base Components>

[0150] Multiple auxiliary base components 8 are support components for three-dimensional cabling of various busbars. Each of the multiple auxiliary base components 8 supports a trunk busbar 6 from the -Z direction side or an external connection busbar 7 from the -Z direction side. The auxiliary base component 8 can support, for example, two external connection busbars 7. The auxiliary base component 8 is disposed in the Z direction between the cabling board 31 and the corresponding busbars in the trunk busbar 6 and the external connection busbar 7. The auxiliary base component 8 is made of, for example, synthetic resin and has insulating properties. The auxiliary base component 8 is an example of an "auxiliary support" or "third support".

[0151] <8. Construction of Insulating Sheets>

[0152] Multiple insulating sheets 91 are insulating components used to insulate the first circuit 30 from the second circuit 40. For example... Figure 2 As shown, each insulating sheet 91 is sheet-shaped in a horizontal direction. Each insulating sheet 91 is insulating. Each insulating sheet 91 is made of a synthetic resin such as polyester or polyimide. The plurality of insulating sheets 91 includes a first insulating sheet 91A and a pair of second insulating sheets 91B.

[0153] The first insulating sheet 91A is disposed on the -Z direction side of the first circuit 30. For example, the first insulating sheet 91A is configured to contact the surface of the wiring board 31 on the -Z direction side. The first insulating sheet 91A may be disposed, for example, between the wiring board 31 and a pair of first heat transfer components 92A described later.

[0154] like Figure 4 As shown, a pair of second insulating sheets 91B are disposed on the -Z direction side of the second circuit 40. For example, the pair of second insulating sheets 91B face the support surface 51s. For example, the pair of second insulating sheets 91B are configured to contact the support surface 51s. Each second insulating sheet 91B may be disposed, for example, between the support surface 51s and a corresponding pair of the two pairs of second heat transfer components 92B described later.

[0155] <9. Construction of heat transfer components>

[0156] Multiple heat transfer components 92 are components used to transfer the heat (Joule heat) generated by the first circuit 30 and the second circuit 40 when energized to the outside of the first circuit 30 and the second circuit 40. Each heat transfer component 92 is, for example, a resilient heat transfer sheet (e.g., a thermally conductive silicone sheet). Each heat transfer component 92 can be made of, for example, a material with a higher thermal conductivity than the substrate 35. However, each heat transfer component 92 is not limited to the above examples and can be a heat transfer component made of thermally conductive gel or other materials. Figure 2 As shown, the plurality of heat transfer components 92 include a pair of first heat transfer components 92A and two pairs of second heat transfer components 92B.

[0157] A pair of first heat transfer elements 92A are disposed on the cooling surface of the external cooler 98 (see Figure 1 Between the first heat transfer component 92A and the first insulating sheet 91A. For example, when viewed in the Z direction, each of the first heat transfer components 92A may be positioned at a location overlapping with the associated first electronic component 33.

[0158] like Figure 4 As shown, two pairs of second heat transfer components 92B are disposed between a pair of second insulating sheets 91B and the second circuit 40. Each pair of second heat transfer components 92B faces the +Z-oriented surface of the associated second insulating sheet 91B. Each pair of second heat transfer components 92B also faces the -Z-oriented surface of the associated second electronic component 43. Figure 8 As shown, when viewed in the Z direction, each pair of second heat transfer components 92B can be positioned at a location overlapping with the associated second electronic component 43. For example, each second electronic component 43 can be placed on the support 51 via a busbar 42 or an externally connected busbar 7, a pair of second heat transfer components 92B, and a second insulating sheet 91B.

[0159] <10. Advantages related to layout>

[0160] (First advantage)

[0161] According to the electrical connection unit 1 of this embodiment, the first circuit 30 is disposed on the -Z direction side relative to the support portion 51. On the other hand, according to the electrical connection unit 1, the second circuit 40 is disposed on the +Z direction side relative to the support portion 51. With these configurations, components whose layout may change depending on the product to be connected to the electrical connection unit 1 and their peripheral circuits can be concentrated in the second circuit 40. This concentration makes it easy to change the layout regardless of the first circuit 30. Therefore, according to the electrical connection unit 1, the electrical connection unit can be easily applied to different products.

[0162] For example, even if there is an optional component among the multiple second electronic components 43 of the second circuit 40 depending on the product to be connected to the electrical connection unit 1, the second circuit 40 can be changed according to the presence or absence of the optional component without changing the first circuit 30.

[0163] For example, even if the optional components among the multiple second electronic components 43 of the second circuit 40 are changed depending on the product to be connected to the electrical connection unit 1, the second circuit 40 can be changed according to the change of the optional components without changing the first circuit 30.

[0164] Furthermore, among the electronic components included in the electrical connection unit 1, components requiring maintenance and those most likely to be replaced can be concentrated in the second circuit 40. Therefore, maintenance of the electrical connection unit is easy according to the electrical connection unit 1.

[0165] (Second advantage)

[0166] According to the electrical connection unit 1 of this embodiment, the support portion 51 supports the second circuit 40. With this configuration, the first circuit 30 and the second circuit 40 can be stacked in a space-saving manner. Therefore, the electrical connection unit 1 can be miniaturized.

[0167] (Third advantage)

[0168] According to the electrical connection unit 1 of this embodiment, the relay bus 6 connects the first circuit 30 and the second circuit 40. With such a relay bus 6, components requiring centralized access and their peripheral circuits can be flexibly concentrated in the second circuit 40. Therefore, the layout can be easily changed regardless of the first circuit 30.

[0169] (Fourth advantage)

[0170] According to the electrical connection unit 1 of this embodiment, the substrate 35 is disposed on the -Z direction side relative to the support portion 51. Furthermore, the first circuit 30 includes a busbar 32 and a first electronic component 33. Furthermore, the second circuit 40 includes a busbar 42 and a second electronic component 43. With these configurations, the layout of the busbar 42 and the second electronic component 43 can be easily changed regardless of the presence or absence of the busbar 32, the first electronic component 33, and the substrate 35. Therefore, according to the electrical connection unit 1, the electrical connection unit can be easily applied to different products.

[0171] (Fifth advantage)

[0172] According to the electrical connection unit 1 of this embodiment, the first electronic component 33 includes a relay. With this configuration, the relay, being a component that changes relatively little depending on the product to be connected to the electrical connection unit 1, allows the circuitry associated with the relay to be positioned on the -Z direction side relative to the support portion 51. Therefore, according to the electrical connection unit 1, the space on the -Z direction side of the support portion 51 can be utilized effectively.

[0173] (Sixth Advantage)

[0174] According to the electrical connection unit 1 of this embodiment, the second electronic component 43 includes a sensor, a fuse, or a control circuit. With this configuration, the circuitry associated with the sensor, fuse, or control circuitry, which frequently changes depending on the product to be connected to the electrical connection unit 1, can be positioned relative to the support portion 51 on the +Z direction side. Therefore, according to the electrical connection unit 1, it is easy to apply the electrical connection unit to different products.

[0175] <11. Advantages related to wiring freedom>

[0176] (Seventh Advantage)

[0177] According to the electrical connection unit 1 of this embodiment, the first circuit 30 is disposed on the -Z direction side relative to the support portion 51. On the other hand, according to the electrical connection unit 1, the second circuit 40 includes a busbar 42 disposed on the +Z direction side relative to the support portion 51. With these configurations, regardless of the first circuit 30, the direction and length of the busbar 42 can be freely changed according to the product to be connected to the electrical connection unit 1. With this degree of freedom, the position of the connection portion of the product to be connected can be easily addressed. Therefore, according to the electrical connection unit 1, the electrical connection unit can be easily applied to different products.

[0178] (Eighth Advantage)

[0179] According to the electrical connection unit 1 of this embodiment, the relay busbar 6 connects the first circuit 30 and the second circuit 40. With such a relay busbar 6, busbars whose direction and length may change can be flexibly concentrated in the second circuit 40. Therefore, regardless of the first circuit 30, the position of the connection part of the product to be connected can be easily accommodated. Therefore, according to the electrical connection unit 1, the electrical connection unit can be easily applied to different products.

[0180] (Ninth Advantage)

[0181] According to the electrical connection unit 1 of this embodiment, the second electronic component 43 includes a sensor, a fuse, and a control circuit. With this configuration, the positions of the sensor, fuse, and control circuit—which are components located close to the connection portion of the product to be connected—among the electronic components included in the electrical connection unit 1 can be freely changed. This degree of freedom makes it easy to adapt to the position of the connection portion of the product to be connected. Therefore, according to the electrical connection unit 1, it is easy to apply the electrical connection unit to different products.

[0182] (Tenth Advantage)

[0183] According to the electrical connection unit 1 of this embodiment, a portion of the busbar portion of the external connection busbar 7 is disposed on the +Z direction side relative to the support portion 51. With these configurations, regardless of the first circuit 30, the direction and length of the external connection busbar 7 can be freely changed according to the product to be connected to the electrical connection unit 1. This degree of freedom makes it easy to address the position of the connection portion of the product to be connected. Therefore, according to the electrical connection unit 1, the electrical connection unit can be easily applied to different products.

[0184] (Variation example)

[0185] Next, several variations will be described. Note that, except for those described in the various variations below, the construction is the same as that of the embodiments described above.

[0186] (First variation)

[0187] In the above embodiment, since the second structure 4 is stacked on the first structure 3, the electrical connection unit 1 has a two-layer structure. However, the electrical connection unit 1 can be configured in any way, as long as it has a hierarchical structure. As a variation, the electrical connection unit 1 can have a three-layer structure, a four-layer structure, etc., by further including a third structure, a fourth structure, etc.

[0188] (Second variation)

[0189] In the above embodiment, the metal base 5 is sandwiched between the second structure 4 and the first structure 3, with the second structure 4 stacked on top of the first structure 3. However, the electrical connection unit 1 can be configured in any way, as long as it has a layered structure. As a variation, in the electrical connection unit 1, in addition to the metal base 5, another structure is sandwiched between the second structure 4 and the first structure 3, with the second structure 4 stacked on top of the first structure 3.

[0190] (Third variation)

[0191] In the above embodiment, the electrical connection unit 1 includes a metal base 5 serving as a support. However, the electrical connection unit 1 may include any support, as long as it is a support. As a variation, instead of the metal base 5, the electrical connection unit 1 may include a support made of synthetic resin. For example, when the support is made of resin, at least a portion of the support may be made of synthetic resin. When the support is made of synthetic resin, for example, the support portion, the peripheral wall, and the retaining portion may be integrally formed from synthetic resin material.

[0192] (Fourth variation)

[0193] In the above embodiments, the first circuit 30 includes a wiring board 31. However, the wiring structure can be any wiring structure, as long as it forms at least a portion of the power-conducting path connected to the first electronic component 33. As a variation, the first circuit 30 may not include a substrate 35. As another variation, instead of a substrate 35, the first circuit 30 may include a base component in the shape of a block, a box, or the like.

[0194] (Fifth variation)

[0195] In the above embodiment, the electrical connection unit 1 includes a relay busbar 6. However, the electrical connection unit 1 may include any relay wiring component, as long as it can connect the first circuit 30 and the second circuit 40. As a variation, instead of the relay busbar 6, the electrical connection unit 1 may include a relay wire.

[0196] (Sixth variation)

[0197] In the above embodiment, the first circuit 30 includes a busbar 32. However, the first circuit 30 may include any wiring component, as long as it can form at least a portion of a power path electrically connected to the first electronic component 33. As a variation, instead of the busbar 32, the first circuit 30 may include wires.

[0198] (Seventh variation)

[0199] In the above embodiment, the second circuit 40 includes a busbar 42. However, the second circuit 40 may include any wiring component, as long as it can form at least a portion of a power path electrically connected to the first electronic component 33. As a variation, instead of the busbar 32, the second circuit 40 may include wires as wiring components.

[0200] (Eighth variation)

[0201] In the above embodiments, the electrical connection unit 1 includes an external connection busbar 7. However, the electrical connection unit 1 may include any wiring component, as long as it can electrically connect an external device to the first circuit 30 or the second circuit. As a variation, instead of the external connection busbar 7, the electrical connection unit 1 may include an external connection wire.

[0202] (Ninth variation)

[0203] In the above embodiment, the second connecting portion 62 is exposed from the opening 5q in the +Z direction. However, the second connecting portion 62 can be constructed in any manner, as long as it can be electrically connected to the second circuit 40. As a variation, such as Figure 9As shown, the second connecting portion 62 may protrude from the notch 5p in the +Z direction. The second connecting portion 62 may protrude slightly from the metal base 5 in the +Z direction, for example, so that the relay bus 6 passes through the notch 5p. However, the second connecting portion 62 may also be flush with the metal base 5 on the +Z direction side.

[0204] (Tenth variation)

[0205] In the above embodiment, the second circuit 40 includes a busbar 42 connected to the second electronic component 43. However, the second circuit 40 may include any wiring component, as long as it can be wired relative to the support portion 51 on the +Z direction side. As a variation, the second circuit 40 may include a busbar portion of the external connection busbar 7 disposed on the +Z direction side relative to the support portion 51, which is electrically connected to the second electronic component 43. As another variation, the second circuit 40 may include a busbar portion of the external connection busbar 7 disposed on the +Z direction side relative to the support portion 51, which is not electrically connected to the second electronic component 43.

[0206] (Eleventh variation)

[0207] In the above embodiment, the second circuit 40 is supported by the support portion 51 of the metal base 5. However, the electrical connection unit 1 can be constructed in any manner, as long as the components whose layout may be changed and their peripheral circuits can be concentrated in the second circuit 40. As a variation, in the electrical connection unit 1, the support portion 51 is not necessarily required to support the second circuit 40. In this variation, instead of the metal base 5, the electrical connection unit 1 may include, for example, a support body made of synthetic resin.

[0208] (Twelfth variation)

[0209] In the above embodiment, the second circuit 40 is supported by the support portion 51 of the metal base 5. However, the electrical connection unit 1 can be constructed in any manner, as long as its components, whose layout may be altered, and their peripheral circuits can be concentrated in the second circuit 40. As a variation, the electrical connection unit 1 can be as follows: Figure 10The electrical connection unit 101 is shown. Compared to electrical connection unit 1, electrical connection unit 101 includes a clamping structure 105 having a clamping portion 151 that does not support the second circuit 40, instead of the metal base 5 (which has a support portion 51 supporting the second circuit 40). In this variation, the clamping structure 105 may be made of, for example, synthetic resin. Similar to electrical connection unit 1, electrical connection unit 101 includes a first structure 3, a relay bus 6, and an external connection bus 7 (except for a portion thereof). Furthermore, similar to the metal base 5, the clamping structure 105 has a plurality of openings 5q. Additionally, the relay bus 6 includes a second connection portion 62 that can be electrically connected to the bus 42 of the second circuit 40 located on the +Z side relative to the clamping portion 151. The second circuit 40 and the second connection portion 62 can be fastened together, thereby enabling electrical connection.

[0210] Even using these modified constructions, components whose layout may change depending on the product to be connected to electrical connection units 1 and 101, along with their peripheral circuits, can be concentrated in the second circuit 40. This concentration allows for easy changes to the layout regardless of the first circuit 30. Therefore, electrical connection units 1 and 101 can be easily applied to different products.

[0211] Even with these modified constructions, the direction and length of the busbar 42 can be freely changed regardless of the first circuit 30. This freedom allows for easy adjustment of the position of the connection portion of the products to be connected. Therefore, based on electrical connection units 1 and 101, the electrical connection units can be easily applied to different products.

[0212] Several embodiments and variations have been described above. However, the embodiments and variations are not limited to the examples described above. For example, multiple embodiments can be implemented by combining them with each other.

Claims

1. An electrical connection unit, the electrical connection unit comprising: Clamping part; A first circuit, the first circuit including a first electronic component and disposed on a first side in a first direction relative to the clamping portion; as well as The second circuit includes a second electronic component and is disposed on a second side in the first direction relative to the clamping portion.

2. The electrical connection unit according to claim 1, wherein, The clamping part supports the second circuit.

3. The electrical connection unit according to claim 1 or 2 further includes a relay busbar, the relay busbar including a first connection portion, a second connection portion and an extension portion, the first connection portion being electrically connected to the first circuit, the second connection portion being electrically connected to the second circuit, and the extension portion extending between the first connection portion and the second connection portion.

4. The electrical connection unit according to claim 3, wherein, The first circuit includes a first busbar and a base component, the first busbar being fastened to the first connection portion, and the base component holding the first busbar. The second circuit includes a second busbar, which is fastened to the second connection portion. The first electronic component is electrically connected to the first busbar, and The second electronic component is electrically connected to the second busbar.

5. The electrical connection unit according to claim 1 or 2, wherein, The first electronic component includes a relay.

6. The electrical connection unit according to claim 1 or 2, wherein, The second electronic component includes a sensor, a fuse, or a control circuit.

7. An electrical connection unit, the electrical connection unit comprising: Clamping part; A first circuit, the first circuit including a first electronic component and disposed on a first side in a first direction relative to the clamping portion; as well as A relay busbar includes a first connecting portion, a second connecting portion, and an extension portion. The first connecting portion is electrically connected to a first circuit, the second connecting portion is electrically connected to a second circuit including a second electronic component, the second circuit is disposed on a second side in the first direction relative to the clamping portion, and the extension portion extends between the first connecting portion and the second connecting portion.

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