Manufacturing method of energy storage device

Abstract

The objective of this invention is to provide a method for manufacturing an energy storage device in which the junction box can be easily and reliably fastened even in a structure where a junction box is mounted on a heat sink. The solution is as follows: A method for manufacturing an energy storage device includes: a mounting step in which bolts from a plurality of bases respectively disposed on the energy storage device are inserted into a plurality of sleeve components disposed on the junction box, and the junction box is mounted on a heat sink placed in an area surrounded by the plurality of bases; and a first fastening step in which a nut is screwed onto a first bolt to fasten a first sleeve component to the base, wherein in the first fastening step, the junction box avoids the reaction force from the heat sink by tilting relative to the first sleeve component.

Description

Technical Field

[0001] This invention relates to a method for manufacturing an energy storage device. Background Technology

[0002] The structure of fastening the housing of the junction box containing the relay device to the base component is well known (for example, see Patent Document 1).

[0003] Patent Document 1: Japanese Patent Application Publication No. 2015-012627 Summary of the Invention

[0004] Junction boxes are sometimes secured with multiple bolts and nuts when mounted on a heat sink. However, if the junction box is lightweight, the reaction force from the heat sink when securing it with the first bolt and nut may cause excessive rotational torque on the first bolt or nut, making it difficult to secure it reliably.

[0005] Therefore, the object of the present invention is to provide a method for manufacturing an energy storage device in which the junction box can be easily and reliably fastened even in a structure in which the junction box is arranged on the heat sink.

[0006] To achieve the above objectives, the manufacturing method of the energy storage device according to the first aspect of the present invention includes: a configuration step in which bolts respectively disposed on a plurality of bases of the energy storage device are inserted into a plurality of sleeve components disposed on a junction box, and the junction box is disposed on a heat sink placed in an area surrounded by the plurality of said bases; and a first fastening step in which a nut is screwed onto a first bolt to fasten a first sleeve component to the base, wherein in the first fastening step, the junction box avoids the reaction force from the heat sink by tilting relative to the first sleeve component.

[0007] According to the invention of the first aspect, in the configuration step, bolts respectively disposed on multiple bases of the energy storage device are inserted into multiple sleeve components disposed on the junction box, and the junction box is disposed on a heat sink placed in the area surrounded by the multiple bases. Then, in the first fastening step, a nut is screwed onto the first bolt to fasten the first sleeve component to the base.

[0008] Here, in this first fastening step, the junction box avoids the reaction force from the heat sink by tilting relative to the first sleeve component. Therefore, the rotational torque when screwing the nut onto the first bolt will not become excessive. That is, even in a structure where the junction box is arranged on the heat sink, the junction box can be easily and reliably fastened.

[0009] Furthermore, the manufacturing method of the energy storage device according to the second aspect of the present invention is, in the manufacturing method of the energy storage device according to the first aspect, a second fastening step is included, in which a nut is screwed into the second or subsequent bolts to fasten the second or subsequent sleeve components to the base.

[0010] According to the second embodiment of the invention, in the second fastening step, the nut is screwed onto the second or subsequent bolts to fasten the second or subsequent sleeve components to the base. Here, when screwing the nut onto the second or subsequent bolts, the screwing can be performed simultaneously by pressing the heat sink from above through the junction box, thus preventing excessive rotational torque. Therefore, even in structures where a junction box is mounted on the heat sink, the junction box can be easily and reliably fastened.

[0011] Furthermore, the method for manufacturing the energy storage device according to the third aspect of the present invention is such that, in the method for manufacturing the energy storage device according to the first or second aspect, the sleeve component is configured to be axially rotatable in a direction orthogonal to the axial direction of the bolt.

[0012] According to the invention of the third aspect, the sleeve component is configured to rotate axially in a direction orthogonal to the axis of the bolt. Therefore, in the first fastening step, the junction box can smoothly tilt relative to the sleeve component, thereby smoothly avoiding the reaction force from the heat sink.

[0013] Furthermore, the method for manufacturing the energy storage device according to the fourth aspect of the present invention is that, in the method for manufacturing the energy storage device according to the first or second aspect, a hinge portion is formed on the junction box on the side closer to the region than the sleeve component.

[0014] According to the fourth aspect of the invention, a hinge portion is formed on the junction box located further from the aforementioned region than the sleeve component. Therefore, during the first fastening process, the junction box can smoothly tilt relative to the sleeve component, thereby smoothly avoiding the reaction force from the heat sink.

[0015] Invention Effects

[0016] As described above, according to the present invention, even in a structure in which a junction box is disposed on a heat sink, the junction box can be easily and reliably fastened and fixed. Attached Figure Description

[0017] Figure 1 This is a schematic side view showing the state in which the nut is first screwed into the first bolt provided on the base of the energy storage device according to the first embodiment.

[0018] Figure 2 This is a schematic side view showing the state before the nut is screwed into the first bolt on the base of the energy storage device according to the first embodiment and before the nut is screwed into the second bolt.

[0019] Figure 3 It is an enlarged representation Figure 2 A schematic side view of the structure near the first sleeve component.

[0020] Figure 4 This is a schematic side view showing the state in which the nut is screwed into the second bolt provided on the base of the energy storage device according to the first embodiment.

[0021] Figure 5 This is a schematic side view showing the state in which the nut is first screwed into the first bolt located on the base of the energy storage device according to the second embodiment.

[0022] Figure 6 This is a schematic side view showing the state in which the nut is first screwed into the first bolt located on the base of the energy storage device involved in the comparative example. Detailed Implementation

[0023] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. For ease of explanation, in each figure, arrow UP is shown as the upward direction of the energy storage device, and arrow LH is shown as the leftward direction of the energy storage device. Furthermore, in the following description, when up / down and left / right directions are mentioned unless otherwise specified, they refer to the up / down and left / right directions within the energy storage device. However, since the energy storage device is installed in vehicles such as battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs), they also refer to the up / down and left / right directions within the vehicle.

[0024] <First Embodiment>

[0025] First, the first embodiment will be described. Figure 1 , Figure 2 As shown, the energy storage device 10 according to the first embodiment has a generally rectangular box-shaped metal housing 12, inside which is housed an energy storage module (not shown). Then, a junction box 20 is housed at the front or rear end of the housing 12.

[0026] That is, multiple (e.g., four) bases 14 are provided at predetermined positions inside the housing 12. Each base 14 is provided with a bolt (welding bolt) 16, and a nut (flange nut) 18 is screwed onto each bolt 16. The junction box 20 is installed inside the housing 12 via the bolts 16 and nuts 18 in each base 14.

[0027] Furthermore, the junction box 20 is used for connecting and disconnecting high-voltage circuits, and therefore a large current is energized in the junction box 20. Therefore, in order to cool the junction box 20 (to dissipate heat to a cooler not shown), a heat sink 40 of a predetermined thickness is disposed in region E of the housing 12 surrounded by multiple bases 14. That is, the junction box 20 is disposed on its heat sink 40.

[0028] Furthermore, the thickness of the heat sink 40, for example, when viewed from the side, is such that the height of its upper surface is slightly (a few mm) lower than the height of the upper surface of the base 14. Also, the heat sink 40 is configured to be elastically deformable at least in the vertical direction, and its upper surface is pressed against the lower surface of the junction box 20 (described later as housing 22) by the fastened junction box 20 from above.

[0029] The junction box 20 has a generally rectangular, box-shaped resin housing 22, which is miniaturized and lightweight. Protrusions 24, approximately half the thickness of the housing 22, protrude integrally outward from the upper sides of the four corners of the housing 22. Through holes 24A are formed in the protrusions 24, and a generally cylindrical sleeve member 30 is disposed within the through holes 24A. That is, the sleeve member 30 is made of metal (cold casting) and is integrally disposed within the through holes 24A of the protrusions 24 in the housing 22, formed by insert molding.

[0030] like Figure 3 As shown, the sleeve component 30 is formed into a so-called barrel shape, with its outer peripheral surface expanding into a roughly semi-circular cross-section at approximately its axial center, and its two axial ends are respectively formed into cylindrical shapes of a specified thickness. Hereinafter, the axial center of the sleeve component 30 will be referred to as the expansion portion 32, and the two axial ends of the sleeve component 30 will be referred to as the cylindrical portions 34.

[0031] During insert molding, a groove 26 with a generally semi-circular cross-section is formed annularly on the inner circumferential surface of the axial center portion of the through hole 24A in the protrusion 24 via the expansion portion 32 of the sleeve component 30. The expansion portion 32 of the sleeve component 30 is slidably held on the inner surface of the groove 26 via this groove 26. Then, a predetermined gap S is formed between the inner circumferential surface of the peripheral portion 28, which serves as both axial ends of the through hole 24A, and the outer circumferential surface of the cylindrical portion 34 of the sleeve component 30.

[0032] Therefore, the sleeve component 30 is configured to be able to swing vertically relative to the housing 22. In other words, the sleeve component 30 is configured to be able to rotate axially relative to the housing 22 in a direction orthogonal to the axis of the bolt 16. Additionally, around the through hole 24A of the protrusion 24 (in... Figure 3The area (indicated by the dashed line) has shear strength that allows the sleeve component 30 to be slidably maintained. Furthermore, the sleeve component 30 is configured such that the outer peripheral surface of its cylindrical portion 34 abuts against the inner peripheral surface of its peripheral portion 28, thereby limiting its rotation (swing) range.

[0033] In the energy storage device 10 according to the first embodiment constructed as described above, its operation (manufacturing method) will be explained next.

[0034] First of all, Figure 6 The energy storage device 100 involved in the comparative example shown will be described. For example... Figure 6 As shown, in this comparative example, the sleeve component 130 is fixedly disposed in the through hole 124A formed by the protrusion 124 of the housing 122 of the junction box 120. That is, the sleeve component 130 will not rotate (swing) relative to the housing 122.

[0035] like Figure 6 As shown, the first of the bolts 116 of the housing 112 of the energy storage device 100, which are respectively provided on the plurality of bases 114, is inserted into one of the plurality of sleeve components 130 provided on the housing 122 of the junction box 120, and the junction box 120 (housing 122) is disposed on the heat sink 140 in the area E surrounded by the plurality of bases 114.

[0036] Here, if the nut 118 is screwed onto the first bolt 116 to secure the first sleeve component 130 to the base 114, the housing 122 will tilt due to the reaction force from the heat sink 140, and thus the sleeve component 130 will also tilt. Therefore, the rotational torque on the nut 118 screwed onto the first bolt 116 becomes too large, making it difficult to secure reliably.

[0037] In contrast, the sleeve member 30 in the energy storage device 10 according to the first embodiment is configured to be able to swing vertically relative to the housing 22 of the junction box 20; in other words, it can rotate axially in a direction orthogonal to the axis of the bolt 16. Therefore, the rotational torque on the nut 18 screwed to the first bolt 16 will not become excessive, and reliable fastening can be achieved. This will be explained below.

[0038] like Figure 1 As shown, one of the multiple sleeve components 30 of the housing 22 of the junction box 20 is inserted through the first of the bolts 16 respectively provided on the multiple bases 14 of the housing 12, and the junction box 20 (housing 22) is placed on the heat sink 40 in the area E surrounded by the multiple bases 14 (configuration process).

[0039] Then, the nut 18 is screwed onto the first bolt 16 to secure the first sleeve component 30 to the first base 14 (first fastening step). Here, in this first fastening step, the housing 22 of the junction box 20 avoids the reaction force from the heat sink 40 by tilting relative to the first sleeve component 30 fastened by the nut 18.

[0040] That is, the sleeve component 30 is configured to be able to swing in the vertical direction relative to the housing 22 of the junction box 20, in other words, it can rotate axially in a direction orthogonal to the axis of the bolt 16. Therefore, if the first sleeve component 30 is fastened from above by the nut 18, the housing 22 is pushed upward relative to the heat sink 40, thereby tilting relative to the first sleeve component 30.

[0041] That is, even in the structure where the junction box 20 (housing 22) is arranged on the heat sink 40, the first sleeve component 30 is always arranged parallel to the base 14 when tightened with the nut 18. Therefore, the rotational torque on the nut 18 screwed to the first bolt 16 will not become too large, and the first sleeve component 30 can be easily and reliably tightened to the first base 14.

[0042] Thus, if the nut 18 is screwed onto the first bolt 16 to secure the first sleeve component 30 to the first base 14, then as Figure 2 , Figure 4 As shown, the nut 18 is screwed into the bolt 16 that is inserted into the second and subsequent sleeve components 30, thereby securing the second and subsequent sleeve components 30 to the second and subsequent base 14 (second fastening step).

[0043] Here, when screwing the nut 18 onto the second and subsequent bolts 16, the screwing can be performed simultaneously by pressing the heat sink 40 from above through the housing 22. Therefore, when tightening with the nut 18, the second and subsequent sleeve components 30 are always arranged parallel to the base 14. Thus, the rotational torque on the nut 18 screwed onto the second and subsequent bolts 16 is not made excessive, and the second and subsequent sleeve components 30 can be easily and reliably tightened and fixed to the second and subsequent base 14.

[0044] That is, even in the structure in which the junction box 20 (housing 22) is arranged on the heat sink 40 with a specified thickness as described above, the junction box 20 can be easily and reliably fastened to the base 14 of the housing 12 in the energy storage device 10.

[0045] Furthermore, the sleeve component 30 in this first embodiment is configured to rotate axially in a direction orthogonal to the axis of the bolt 16. Therefore, in the first fastening process, the housing 22 of the junction box 20 can smoothly tilt relative to the sleeve component 30, thereby smoothly avoiding the reaction force from the heat sink 40.

[0046] <Second Implementation>

[0047] Next, the second embodiment will be described. Furthermore, the same symbols will be used to mark the same parts as in the first embodiment, and detailed descriptions will be omitted where appropriate.

[0048] like Figure 5 As shown, in this second embodiment, the only difference from the first embodiment is that the cylindrical sleeve component 36 is fixedly disposed on the protrusion 24 of the housing 22 in the junction box 20, and a thin plate-shaped hinge portion 38 is formed between the protrusion 24 (heat sink 40 side) which is further from the sleeve component 36 in region E and the housing body 23 of the housing 22.

[0049] A hinge portion 38 is formed with a predetermined thickness between the upper surface of the protrusion 24 and the upper surface of the housing body 23, and integrally connects the protrusion 24 and the housing body 23. Furthermore, a notch-shaped recess 24B is formed on the lower half of the side surface on the region E side of the protrusion 24, and a protrusion 23A is integrally formed on the side surface of the housing body 23 on the protrusion 24 side in the height direction, protruding outwards. Then, the housing 22 is normally in a state where the protrusion 23A fits into the recess 24B.

[0050] In the energy storage device 10 according to the second embodiment constructed as described above, its operation (manufacturing method) will be explained next.

[0051] like Figure 5 As shown, one of the multiple sleeve components 36 provided in the housing 22 of the junction box 20 is inserted through the first of the bolts 16 respectively provided in the multiple bases 14 of the housing 12, and the junction box 20 (housing 22) is placed on the heat sink 40 in the area E surrounded by the multiple bases 14 (configuration process).

[0052] Then, the nut 18 is screwed onto the first bolt 16 to secure the first sleeve component 36 to the first base 14 (first fastening step). Here, in this first fastening step, the housing 22 (housing body 23) of the junction box 20 avoids the reaction force from the heat sink 40 by tilting relative to the first sleeve component 36 fastened by the nut 18.

[0053] That is, the protrusion 24 to which the sleeve component 36 is fixed is integrally connected to the housing body 23 of the housing 22 via the hinge portion 38. Therefore, if the first sleeve component 36 is tightened from above by the nut 18, the housing body 23 is pushed upward relative to the heat sink 40 (the protrusion 23A separates from the recess 24B), thereby tilting relative to the first sleeve component 36 (protrusion 24).

[0054] That is, even in the structure where the junction box 20 (housing 22) is arranged on the heat sink 40, the first sleeve component 36 (protrusion 24) is always arranged parallel to the base 14 when tightened with the nut 18. Therefore, the rotational torque on the nut 18 screwed to the first bolt 16 will not become too large, and the first sleeve component 36 can be easily and reliably tightened to the first base 14.

[0055] Thus, if the nut 18 is screwed onto the first bolt 16 to fasten the first sleeve component 36 to the first base 14, then the nut 18 is screwed onto the second and subsequent bolts 16 that are respectively inserted into the second and subsequent sleeve components 36 to fasten the second and subsequent sleeve components 36 to the second and subsequent base 14 (second fastening process).

[0056] Here, when screwing the nut 18 onto the second and subsequent bolts 16, the screwing can be performed simultaneously by pressing the heat sink 40 from above through the housing body 23 of the housing 22. Therefore, when tightening with the nut 18, the second and subsequent sleeve components 36 (protrusions 24) are always arranged parallel to the base 14. Thus, the rotational torque on the nut 18 screwed onto the second and subsequent bolts 16 is not made too large, and the second and subsequent sleeve components 36 can be easily and reliably tightened and fixed to the second and subsequent base 14.

[0057] That is, even in the structure in which the junction box 20 (the housing body 23 of the housing 22) is arranged on the heat sink 40 with a specified thickness as described above, the junction box 20 can be easily and reliably fastened to the base 14 of the housing 12 in the energy storage device 10.

[0058] Furthermore, in this second embodiment, a hinge portion 38 is formed in the housing 22 (between the protrusion 24 and the housing body 23) of the junction box 20, which is located further to region E than the sleeve member 36. Therefore, during the first fastening process, the housing 22 (housing body 23) of the junction box 20 can smoothly tilt relative to the sleeve member 36 (protrusion 24), thereby smoothly avoiding the reaction force from the heat sink 40.

[0059] The manufacturing method of the energy storage device 10 according to this embodiment has been described above with reference to the accompanying drawings. However, the manufacturing method of the energy storage device 10 according to this embodiment is not limited to the drawings, and appropriate design changes can be made without departing from the spirit of the present invention. For example, the number of base 14 (bolt 16) provided on the housing 12 of the energy storage device 10 is not particularly limited as long as there are multiple bases 14.

[0060] Furthermore, the junction box 20 is not limited to a structure located inside the housing 12 of the energy storage device 10, but can also be located outside the housing 12, for example, on the upper wall of the housing 12. In the second embodiment, the hinge portion 38 can also be constructed by additionally providing a hinge component such as a butterfly hinge (not shown).

[0061] Symbol Explanation

[0062] 10-Energy storage device, 14-Base, 16-Bolt, 18-Nut, 20-Junction box, 30-Sleeve assembly, 38-Hinge, 40-Heat sink, E-Area.

Claims

1. A method for manufacturing an electrical storage device, characterized by comprising: have: The configuration process involves inserting bolts from multiple bases respectively located on the energy storage device into multiple sleeve components located on the junction box, and configuring the junction box on a heat sink placed in the area surrounded by the multiple bases; and In the first fastening step, the nut is screwed onto the first bolt to fasten the first sleeve component to the base. In the first fastening step, the junction box avoids the reaction force from the heat sink by tilting relative to the first sleeve component.

2. The method for manufacturing the power storage device according to claim 1, characterized by have: The second fastening step involves screwing a nut onto the second or subsequent bolts to fasten the second or subsequent sleeve components to the base.

3. The method for manufacturing the energy storage device according to claim 1 or 2, characterized in that, The sleeve component is configured to rotate axially in a direction orthogonal to the axis of the bolt.

4. The method for manufacturing the energy storage device according to claim 1 or 2, characterized in that, A hinge portion is formed on the junction box on the side closer to the region than the sleeve component.

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