Relay unit

Abstract

To provide a relay unit that reduces a risk of electrical short circuit caused by bus bar deformation due to an external force.SOLUTION: A high voltage JB2 being a relay unit comprises a positive electrode bus bar 20p, a negative electrode bus bar 20n, electrical components, and a JB case 10. The electrical components are at least one of a positive electrode SMR30p, a negative electrode SMR30n, a positive electrode charging relay 40p, a negative electrode charging relay 40n, a precharge relay 50, a pyro-fuse 80, a precharge resistor 60, and a current sensor 70. Each of the relays is an electromagnetic relay for switching output current from a battery between flowing and blocking. The pyro-fuse 80 is a fuse for blocking output current from the battery. The precharge resistor 60 is a resistor to be electrical resistance of output current from the battery. The current sensor 70 detects a size of output current from the battery. Then, between the positive electrode bus bar 20p and the negative electrode bus bar 20n, at least a part of the electrical components is interposed.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The disclosure according to this specification relates to a relay unit.

Background Art

[0002] Patent Document 1 discloses a relay unit electrically connected between a battery and an inverter. This relay unit has a plurality of relays that are electromagnetic relays, a plurality of bus bars, and a plurality of connection terminals.

[0003] The connection terminals include battery terminals connected to each of the positive and negative sides of the battery, and inverter terminals connected to each of the positive and negative sides of the inverter. The bus bars include a positive bus bar and a negative bus bar that form a current path between the battery terminal and the inverter terminal. The relays include a positive relay provided in the current path by the positive bus bar and a negative relay provided in the current path by the negative bus bar.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In Patent Document 1, the positive bus bar and the negative bus bar are formed in a shape that connects the battery terminal and the inverter terminal by the shortest path. As a result, the positive bus bar and the negative bus bar are in a shape that extends while adjacent to each other.

[0006] Here, when an external force such as a collision is applied to the relay unit, it is assumed that the bus bar will deform. However, if the bus bars of both poles extend while adjacent to each other as described above, there is a concern that the bus bars of both poles will come into contact with each other and cause an electrical short circuit.

[0007] An object of the present disclosure is to provide a relay unit that reduces the risk of an electrical short circuit due to deformation of the bus bar by an external force.

Means for Solving the Problems

[0008] To achieve the above object, one disclosed aspect is a positive electrode bus bar (20p) that forms a current path between the positive electrode side of the battery (3) and the inverter (4), a negative electrode bus bar (20n) that forms a current path between the negative electrode side of the battery and the inverter, an electrical component that is at least one of a relay (30p, 30n, 40p, 40n, 50) that is an electromagnetic relay for switching the energization and interruption of the output current from the battery, a fuse (80) that interrupts the output current, a resistor (60) that serves as the electrical resistance of the output current, and a current sensor (70) that detects the magnitude of the output current, a case (10) that houses the positive electrode bus bar, the negative electrode bus bar, and the electrical component inside, a relay unit in which at least a part of the electrical component is interposed between the positive electrode bus bar and the negative electrode bus bar.

[0009] In this aspect, at least a part of the electrical component is interposed between the positive electrode bus bar and the negative electrode bus bar. Therefore, even when at least one of the two bus bars is deformed by an impact or the like, the electrical component functions as a buffer between the two bus bars. Thus, the risk of the two bus bars coming into contact and short-circuiting can be reduced. Also, the fact that an electrical component is interposed between the two bus bars means that the distance between the two bus bars is increased by the amount of the mounting space of the electrical component. Thus, the risk of the two bus bars coming into contact and short-circuiting can be reduced.

[0010] Note that the reference numbers in parentheses in the above and the claims only show an example of the correspondence with the specific configurations in the embodiments described later, and do not limit the technical scope in any way. Also, combinations of claims not explicitly stated in the claims are possible as long as there is no problem with the combination in particular.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0012] Hereinafter, a plurality of embodiments will be described with reference to the drawings. In each embodiment, the same reference numerals may be assigned to corresponding components, and redundant explanations may be omitted. When only a part of the configuration is described in each embodiment, the configuration of other embodiments described previously can be applied to other parts of the said configuration. Also, not only the combinations of configurations explicitly stated in the description of each embodiment, but also the configurations of a plurality of embodiments can be partially combined as long as there is no problem with the combination in particular, even if not explicitly stated.

[0013] (First Embodiment) The high-voltage junction box (hereinafter referred to as high-voltage JB) according to the first embodiment of the present disclosure shown in FIG. 1 is used in an electric vehicle such as a BEV (Battery Electric Vehicle). The high-voltage JB 2 is mounted on an electric vehicle together with a battery 3, an inverter 4, a charging inlet 5, and the like. The high-voltage JB 2 is electrically connected to the battery 3, the inverter 4, the charging inlet 5, and the like.

[0014] The battery 3 is a power storage device that stores electric power for driving the electric vehicle. The battery 3 includes a rechargeable secondary battery such as a lithium-ion battery or a nickel-metal hydride battery. The inverter 4 is electrically connected to a motor generator 6 for driving. The motor generator 6 is a permanent magnet type or wound field type synchronous motor, or an induction motor or the like.

[0015] The inverter 4 controls the rotational speed and torque of the motor generator 6. A smoothing capacitor 4C is connected in parallel to the inverter 4. The smoothing capacitor 4C smooths the current from the battery 3 supplied to the inverter 4 through the high-voltage JB 2. A charging cable of a charging stand provided outside the vehicle is connected to the charging inlet 5. DC power for rapidly charging the battery 3 is applied to the charging inlet 5. The charging inlet 5 supplies the DC power input from the charging stand to the high-voltage JB 2.

[0016] The high-voltage JB 2 includes a power control circuit 10a and a JB case 10 (see FIG. 2) that protects the power control circuit 10a. The power control circuit 10a includes a plurality of current paths. The power control circuit 10a switches the plurality of current paths.

[0017] The power control circuit 10a includes a pair of battery terminals (hereinafter referred to as BAT terminals) 11p, 11n, a pair of inverter terminals (hereinafter referred to as INV terminals) 12p, 12n, and a pair of charging terminals 13p, 13n, respectively. Note that elements with the symbol "p" attached are positive electrode side configurations. Elements with the symbol "n" attached are negative electrode side (ground side) configurations.

[0018] The BAT terminals 11p and 11n are terminal portions used for the electrical connection between the high-voltage JB2 and the battery 3. The BAT terminal 11p is connected to the positive electrode side of the battery 3. The BAT terminal 11n is connected to the negative electrode side of the battery 3. The INV terminals 12p and 12n are terminal portions used for the electrical connection between the high-voltage JB2 and the inverter 4. The INV terminal 12p is connected to the positive electrode side of the inverter 4. The INV terminal 12n is connected to the negative electrode side of the inverter 4.

[0019] The charging terminals 13p and 13n are terminal portions used for the electrical connection between the high-voltage JB2 and the charging inlet 5. The charging terminal 13p is connected to the positive electrode side of the charging inlet 5. The charging terminal 13n is connected to the negative electrode side of the charging inlet 5. Electric power for charging the battery 3 is supplied to the charging terminals 13p and 13n.

[0020] Furthermore, the power control circuit 10a includes a positive electrode bus bar 20p, a negative electrode bus bar 20n, a positive electrode system main relay (hereinafter referred to as positive electrode SMR) 30p, a negative electrode system main relay (hereinafter referred to as negative electrode SMR) 30n, a positive electrode charging relay 40p, and a negative electrode charging relay 40n. Furthermore, the power control circuit 10a includes a precharge relay 50, a precharge resistor 60, a current sensor 70, and a pyro fuse 80.

[0021] <Bus bar> As shown in FIG. 1, the positive electrode bus bar 20p forms a current path between the positive electrode side of the battery 3 and the inverter 4. The negative electrode bus bar 20n forms a current path between the negative electrode side of the battery 3 and the inverter 4. The positive electrode bus bar 20p and the negative electrode bus bar 20n are conductive members formed of a metal material having excellent conductivity such as copper and are in a plate shape. These bus bars can conduct a large current sufficient to cause the vehicle's driving force to be exerted on the motor generator 6 and form a plurality of current paths of the power control circuit 10a.

[0022] The positive electrode bus bar 20p includes a positive electrode inverter bus bar (hereinafter referred to as the positive electrode INV bus bar) 21p, a positive electrode charging bus bar 22p, and a positive electrode battery bus bar (hereinafter referred to as the positive electrode BAT bus bar) 23p. That is, these multiple bus bars are electrically connected to form part of the current path by the positive electrode bus bar 20p. The negative electrode bus bar 20n includes a negative electrode inverter bus bar (hereinafter referred to as the negative electrode INV bus bar) 21n, a negative electrode charging bus bar 22n, and a negative electrode battery bus bar (hereinafter referred to as the negative electrode BAT bus bar) 23n.

[0023] The positive electrode INV bus bar 21p forms the current path between the inverter 4 and the positive electrode SMR 30p. Specifically, one end of the positive electrode INV bus bar 21p is connected to the INV terminal 12p, and the other end is connected to the positive electrode SMR 30p. The negative electrode INV bus bar 21n forms the current path between the inverter 4 and the negative electrode SMR 30n. Specifically, one end of the negative electrode INV bus bar 21n is connected to the INV terminal 12n, and the other end is connected to the negative electrode SMR 30n.

[0024] The positive electrode charging bus bar 22p forms the current path between the charging inlet 5 and the positive electrode charging relay 40p. Specifically, one end of the positive electrode charging bus bar 22p is connected to the charging terminal 13p, and the other end is connected to the positive electrode charging relay 40p. The negative electrode charging bus bar 22n forms the current path between the charging inlet 5 and the negative electrode charging relay 40n. Specifically, one end of the negative electrode charging bus bar 22n is connected to the charging terminal 13n, and the other end is connected to the negative electrode charging relay 40n. The positive electrode charging bus bar 22p and the negative electrode charging bus bar 22n

[0025] The positive electrode BAT bus bar 23p forms the current path between the battery 3 and the positive electrode SMR 30p. Specifically, one end of the positive electrode BAT bus bar 23p is connected to the BAT terminal 11p, and the other end is connected to the positive electrode SMR 30p. The negative electrode BAT bus bar 23n forms the current path between the battery 3 and the negative electrode SMR 30n. Specifically, one end of the negative electrode BAT bus bar 23n is connected to the BAT terminal 11n, and the other end is connected to the negative electrode SMR 30n.

[0026] <Relay> The positive SMR30p corresponds to the "positive relay" and is located between the positive BAT bus bar 23p and the positive INV bus bar 21p. The negative SMR30n corresponds to the "negative relay" and is located between the negative BAT bus bar 23n and the negative INV bus bar 21n. The pre-charge relay 50 is connected in parallel to the negative SMR30n. The positive SMR30p, the negative SMR30n, and the pre-charge relay 50 switch the state of the current path between the battery 3 and the inverter 4 between an energized state (on) and a non-energized state (off).

[0027] The positive charge relay 40p is located between the positive SMR30p and the positive charge bus bar 22p. The positive charge relay 40p is connected in parallel to the positive SMR30p. The negative charge relay 40n is located between the negative SMR30n and the negative charge bus bar 22n. The negative charge relay 40n is connected in parallel to the negative SMR30n. The positive charge relay 40p and the negative charge relay 40n switch the state of the current path between the battery 3 and the charge inlet 5 between an energized state (on) and a non-energized state (off).

[0028] The operations of these positive SMR30p, negative SMR30n, pre-charge relay 50, positive charge relay 40p, and negative charge relay 40n are individually controlled by a control device 90 (see FIG. 2) mounted on the vehicle. The control device 90 includes an arithmetic processing circuit including a processor, a RAM (Random Access Memory), and a storage, etc. For example, the control device 90 has a control board 91 and a microcomputer (hereinafter, μC) 92. The μC 92 provides the above-mentioned processor, RAM, and storage, etc. The above-mentioned arithmetic processing circuit is provided by the control board 91 and the μC 92 and various electronic components mounted on the control board 91.

[0029] The arithmetic processing circuit in the control device 90 outputs a control signal for controlling the on / off switching to each of the above-described various relays. In short, each of these various relays is a plurality of current paths including the above-described various busbars, and switches the current path through which a large DC current of several tens to several hundreds of amperes flows according to the control signal obtained from the control device 90.

[0030] All of the above-described various relays have the same structure and the same specifications. Hereinafter, the structure of the relay will be described taking the positive electrode SMR30p as an example. The positive electrode SMR30p includes a fixed core, a movable core, a rod, an exciting coil, a pressing spring, a movable terminal 33p (see FIG. 1), a pair of fixed terminals 31pH, 31pL, a relay case 32p, etc. Inside the relay case 32p, a fixed core, a movable core, a rod, an exciting coil, a pressing spring, a movable terminal, and a pair of fixed terminals 31pH, 31pL are accommodated. A part of the pair of fixed terminals 31pH, 31pL is exposed from the relay case 32p and is connected to the above-described positive electrode busbar 20p.

[0031] When the electromagnetic coil is excited by the control signal output from the control device 90, the movable core is attracted to the fixed core and operates. A rod is attached to the movable core, and a movable terminal is attached to the rod. The movable terminal that has moved with the operation of the movable core abuts against the pair of fixed terminals 31pH, 31pL. As a result, the pair of fixed terminals 31pH, 31pL are electrically connected by the movable terminal and enter the energized state (on). When the output of the control signal stops and the excitation of the electromagnetic coil disappears, the movable core is pushed back to its original position before excitation by the pressing spring, and the movable terminal separates from the pair of fixed terminals 31pH, 31pL. As a result, the pair of fixed terminals 31pH, 31pL enter the non-energized state (off).

[0032] Of the pair of fixed terminals 31pH, 31pL that the positive electrode SMR30p has, the fixed terminal 31pH is the terminal on the high voltage side, and the fixed terminal 31pL is the terminal on the low voltage side. In addition, elements with "H" attached to the symbol are configurations on the high voltage side. Elements with "L" attached to the symbol are configurations on the low voltage side.

[0033] In this embodiment, the pair of fixed terminals 31pH and 31pL accommodated in the relay case 32p of the positive electrode SMR30p correspond to the "positive electrode terminals". The pair of fixed terminals 31nH and 31nL accommodated in the relay case 32n of the negative electrode SMR30n correspond to the "negative electrode terminals". The pair of fixed terminals 41pH and 41pL accommodated in the relay case 42p of the positive electrode charging relay 40p correspond to the "positive electrode charging terminals". The pair of fixed terminals 41nH and 41nL accommodated in the relay case 42n of the negative electrode charging relay 40n correspond to the "negative electrode charging terminals". As shown in FIG. 1, the positive electrode terminals and the positive electrode charging terminals are connected to the positive electrode bus bar 20p. The negative electrode terminals and the negative electrode charging terminals are connected to the negative electrode bus bar 20n.

[0034] The connection relationship between the bus bar and the relay will be described in more detail below with reference to FIGS. 2 to 6. The fixed terminal 31pH of the positive electrode SMR30p is connected to the connection portion 23p1 of the positive electrode BAT bus bar 23p. The fixed terminal 31pL is connected to the connection portion 21p1 of the positive electrode INV bus bar 21p. The fixed terminal 41pH of the positive electrode charging relay 40p is connected to the connection portion 23p2 of the positive electrode BAT bus bar 23p. The fixed terminal 41pL is connected to the connection portion 22p1 of the positive electrode charging bus bar 22p.

[0035] The fixed terminal 31nH of the negative electrode SMR30n is connected to the connection portion 23n1 of the negative electrode BAT bus bar 23n. The fixed terminal 31nL is connected to the connection portion 21n1 of the negative electrode INV bus bar 21n. The fixed terminal 41nH of the negative electrode charging relay 40n is connected to the connection portion 23n2 of the negative electrode BAT bus bar 23n. The fixed terminal 41nL is connected to the connection portion 22n1 of the negative electrode charging bus bar 22n.

[0036] In this embodiment, bolts are used for connecting the terminals of various relays to the bus bar. However, the above connection is not limited to bolts, and for example, it may be connected by caulking, riveting, crimping, or welding.

[0037] As shown in FIG. 4, a positive electrode insulating plate 35p is provided in the relay case 32p of the positive electrode SMR30p. The positive electrode insulating plate 35p is made of a resin having electrical insulation properties and is integrally resin-molded with the relay case 32p. The positive electrode insulating plate 35p is disposed between a pair of fixed terminals 31pL and 31pH. The positive electrode insulating plate 35p has a plate shape and is disposed so as to partition the pair of fixed terminals 31pL and 31pH.

[0038] As shown in FIGS. 4 and 2, a negative electrode insulating plate 35n is provided in the relay case 32n of the negative electrode SMR30n. The negative electrode insulating plate 35n is made of a resin having electrical insulation properties and is integrally resin-molded with the relay case 32n. The negative electrode insulating plate 35n is disposed between a pair of fixed terminals 31nL and 31nH. The negative electrode insulating plate 35n has a plate shape and is disposed so as to partition the pair of fixed terminals 31nL and 31nH.

[0039] As shown in FIG. 4, a positive electrode insulating plate 45p is provided in the relay case 42p of the positive electrode charging relay 40p. The positive electrode insulating plate 45p is made of a resin having electrical insulation properties and is integrally resin-molded with the relay case 42p. The positive electrode insulating plate 45p is disposed between a pair of fixed terminals 41pL and 41pH. The positive electrode insulating plate 45p has a plate shape and is disposed so as to partition the pair of fixed terminals 41pL and 41pH.

[0040] As shown in FIGS. 4 and 2, a negative electrode insulating plate 45n is provided in the relay case 42n of the negative electrode charging relay 40n. The negative electrode insulating plate 45n is made of a resin having electrical insulation properties and is integrally resin-molded with the relay case 42n. The negative electrode insulating plate 45n is disposed between a pair of fixed terminals 41nL and 41nH. The negative electrode insulating plate 45n has a plate shape and is disposed so as to partition the pair of fixed terminals 41nL and 41nH.

[0041] The precharge resistor 60 is a resistor connected in series with the precharge relay 50. The precharge resistor 60 and the precharge relay 50 form a current path that bypasses the negative SMR 30n between the negative BAT bus bar 23n and the negative INV bus bar 21n. The precharge resistor 60 reduces the charging current (inrush current) flowing through the smoothing capacitor 4C when switching the precharge relay 50 to the energized state (on state).

[0042] For example, when energizing the positive SMR 30p and the negative SMR 30n, if energization is performed in a state where the charge stored in the smoothing capacitor 4C is small, there is a concern that the above inrush current may occur and cause damage to the device. Therefore, when the charge of the smoothing capacitor 4C is small, such as at startup, the precharge relay 50 is energized and turned on prior to the positive SMR 30p and the negative SMR 30n. Thereby, the charge of the smoothing capacitor 4C can be increased through the current path via the precharge resistor 60. Thereafter, the positive SMR 30p and the negative SMR 30n are energized and turned on, and power is supplied to the inverter 4 without passing through the precharge resistor 60.

[0043] The current sensor 70 is provided on the negative BAT bus bar 23n and detects the magnitude of the current (output current) output from the battery 3. The current sensor 70 has a magnetic core and a Hall element (not shown). The magnetic core is formed in an annular shape and is arranged so as to surround the negative BAT bus bar 23n to be measured. The Hall element detects the magnetic flux generated in the magnetic core by the current flowing through the negative BAT bus bar 23n. The current sensor 70 measures the current flowing through the negative BAT bus bar 23n by detecting a change in the output voltage of the Hall element.

[0044] The pyro fuse 80 is provided on the negative electrode BAT bus bar 23n and functions as a current breaker. When an abnormally large current occurs in the negative electrode BAT bus bar 23n, the pyro fuse 80 automatically breaks the wire. By interrupting the connection with the battery 3, the pyro fuse 80 protects other components of the power control circuit 10a and the inverter 4 etc. from overcurrent. The pyro fuse 80 has an igniter 81, a piston (not shown), and a cut-off bus bar 82.

[0045] For example, when the current value detected by the current sensor 70 exceeds a predetermined threshold value, the microcomputer 92 outputs an ignition current to the igniter 81. The igniter 81 into which the ignition current is input burns to generate gas. The piston is pushed down by the pressure of the gas generated by the igniter 81 to cut the cut-off bus bar 82. The cut-off bus bar 82 is connected to the negative electrode BAT bus bar 23n so as to constitute a part of the current path by the negative electrode BAT bus bar 23n. Therefore, when the cut-off bus bar 82 is cut by the piston as described above, the current path of the negative electrode BAT bus bar 23n is interrupted. Thereby, when an abnormally large current occurs, the current path of the negative bus bar 20n is interrupted.

[0046] <Positional relationship of each component> The high-voltage JB2 corresponds to a "relay unit". The positive electrode SMR30p, the negative electrode SMR30n, the positive electrode charging relay 40p, the negative electrode charging relay 40n, the pre-charge relay 50, the pyro fuse 80, the pre-charge resistor 60, and the current sensor 70 correspond to "electrical components". These electrical components are housed in the JB case 10. The JB case 10 has a resin base plate 11 and a resin cover 12. Each of the electrical components is fixed to the base plate 11 by screws or the like. Note that FIGS. 3 and 4 show the high-voltage JB2 with the cover 12 removed from the base plate 11.

[0047] As shown in FIG. 4, the positive electrode SMR30p and the positive electrode charging relay 40p are arranged adjacent to each other along a predetermined first direction (X direction). The positive electrode SMR30p and the negative electrode SMR30n are arranged adjacent to each other along a second direction (Y direction) orthogonal to the first direction. The Z direction indicated by the arrow in the figure is a direction orthogonal to the X direction and the Y direction. Note that the vertical direction in the state where the high-voltage JB2 is mounted on the vehicle coincides with the Z direction. The positive electrode SMR30p and the positive electrode charging relay 40p are arranged at the same position in the Z direction.

[0048] As shown in FIG. 5, the fixed terminal 31pL of the positive electrode SMR30p and the fixed terminal 41pL of the positive electrode charging relay 40p are arranged adjacent to each other along the X direction. These fixed terminals 31pL and 41pL are arranged at the same position in the Y direction and the Z direction. The fixed terminal 31pH of the positive electrode SMR30p and the fixed terminal 41pH of the positive electrode charging relay 40p are arranged adjacent to each other along the X direction. These fixed terminals 31pH and 41pH are arranged at the same position in the Y direction and the Z direction.

[0049] As shown in FIG. 4, the negative electrode SMR30n and the negative electrode charging relay 40n are arranged adjacent to each other along a predetermined first direction (X direction). As shown in FIG. 2, the fixed terminal 31nL of the negative electrode SMR30n and the fixed terminal 41nL of the negative electrode charging relay 40n are arranged adjacent to each other along the X direction. These fixed terminals 31nL and 41nL are arranged at the same position in the Y direction and the Z direction. The fixed terminal 31nH of the negative electrode SMR30n and the fixed terminal 41nH of the negative electrode charging relay 40n are arranged adjacent to each other along the X direction. These fixed terminals 31nH and 41nH are arranged at the same position in the Y direction and the Z direction.

[0050] In other words, the positive electrode SMR30p is attached to the base plate 11 such that a pair of fixed terminals 31pL and 31pH of the positive electrode SMR30p are arranged in the Z direction. The negative electrode SMR30n is attached to the base plate 11 such that a pair of fixed terminals 31nL and 31nH of the negative electrode SMR30n are arranged in the Z direction. Also, the positive electrode charging relay 40p is attached to the base plate 11 such that a pair of fixed terminals 41pL and 41pH of the positive electrode charging relay 40p are arranged in the Z direction. The negative electrode charging relay 40n is attached to the base plate 11 such that a pair of fixed terminals 41nL and 41nH of the negative electrode charging relay 40n are arranged in the Z direction.

[0051] Also, the positive electrode SMR30p and the negative electrode SMR30n are attached to the base plate 11 such that the fixed terminals 31pL and 31pH of the positive electrode SMR30p and the fixed terminals 31nL and 31nH of the negative electrode SMR30n face opposite sides. That is, the fixed terminals 31pL and 31pH face the side opposite to the negative electrode SMR30n in the Y direction. The fixed terminals 31nL and 31nH face the side opposite to the positive electrode SMR30p in the Y direction.

[0052] Also, the positive electrode charging relay 40p and the negative electrode charging relay 40n are attached to the base plate 11 such that the fixed terminals 41pL and 41pH of the positive electrode charging relay 40p and the fixed terminals 41nL and 41nH of the negative electrode charging relay 40n face opposite sides. That is, the fixed terminals 41pL and 41pH face the side opposite to the negative electrode charging relay 40n in the Y direction. The fixed terminals 41nL and 41nH face the side opposite to the positive electrode charging relay 40p in the Y direction.

[0053] The positive electrode SMR30p, the negative electrode SMR30n, the positive electrode charging relay 40p, and the negative electrode charging relay 40n are arranged between the positive electrode bus bar 20p and the negative electrode bus bar 20n. Similarly, the pre-charge relay 50, the pyro fuse 80, the pre-charge resistor 60, and the current sensor 70 are also arranged between the positive electrode bus bar 20p and the negative electrode bus bar 20n. Hereinafter, these arrangements will be described in more detail.

[0054] <Wall-facing portion> As shown in FIG. 6, the positive electrode bus bar 20p has a plurality of positive electrode wall-facing portions p1 to p6. The negative electrode bus bar 20n has a plurality of negative electrode wall-facing portions n1 to n7. The portion marked with dots in FIG. 6 corresponds to the positive electrode wall-facing portions p1 to p6 and the negative electrode wall-facing portions n1 to n7. These wall-facing portions are the portions of the plate surface of the bus bar that face the wall surface of the case 10. The plate surface of the wall-facing portion is parallel to the plate surface of the case 10 that extends perpendicular to the Y direction. And the positive electrode SMR 30p, the negative electrode SMR 30n, the positive electrode charging relay 40p, and the negative electrode charging relay 40n are arranged between the positive electrode wall-facing portions p1 to p6 and the negative electrode wall-facing portions n1 to n7.

[0055] The positive electrode charging bus bar 22p has positive electrode wall-facing portions p1, p2, and p3, and the negative electrode charging bus bar 22n has negative electrode wall-facing portions n1, n2, and n3. The positive electrode INV bus bar 21p has a positive electrode wall-facing portion p4, and the negative electrode INV bus bar 21n has a negative electrode wall-facing portion n4. The positive electrode BAT bus bar 23p has positive electrode wall-facing portions p5 and p6, and the negative electrode BAT bus bar 23n has negative electrode wall-facing portions n5, n6, and n7.

[0056] The positive electrode charging relay 40p and the negative electrode charging relay 40n are located at positions sandwiched between the positive electrode wall-facing portions p2, p3, p5 and the negative electrode wall-facing portions n2, n3, n5. The positive electrode SMR 30p and the negative electrode SMR 30n are located at positions sandwiched between the positive electrode wall-facing portions p2, p4, p5 and the negative electrode wall-facing portions n2, n4, n5.

[0057] The pre-charge relay 50 is located at a position sandwiched between the positive electrode wall-facing portion p1 and the negative electrode wall-facing portion n1. The pyro fuse 80 is located at a position sandwiched between the positive electrode wall-facing portion p6 and the negative electrode wall-facing portion n7. The pre-charge resistor 60 is located at a position sandwiched between the positive electrode wall-facing portion p6 and the negative electrode wall-facing portion n6. The current sensor 70 is located at a position sandwiched between the positive electrode wall-facing portion p6 and the negative electrode wall-facing portion n7.

[0058] Note that, as described so far, "an electrical component is disposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n" means that at least a part of the electrical component is located in the region between the positive electrode bus bar 20p and the negative electrode bus bar 20n. The "region between the positive electrode bus bar 20p and the negative electrode bus bar 20n" means the range obtained by projecting the positive electrode bus bar 20p onto the negative electrode bus bar 20n, or the range obtained by projecting the negative electrode bus bar 20n onto the positive electrode bus bar 20p. Also, a part of one electrical component may be located in the above region, or the whole of one electrical component may be located in the above region.

[0059] (Summary of the First Embodiment) Here, an external force may be applied to the high-voltage JB2 due to a collision of a vehicle equipped with the high-voltage JB2 or the like. For example, when an external force is applied in the direction indicated by the dotted arrow in FIG. 4, the negative electrode charging bus bar 22n deforms toward the inside of the JB case 10 as shown by the dashed-dotted line. Therefore, if the positive electrode bus bar 20p and the negative electrode bus bar 20n extend while being adjacent to each other, there is a concern that the positive electrode bus bar 20p and the negative electrode bus bar 20n may come into contact with each other and cause an electrical short circuit.

[0060] In response to this concern, in the present embodiment, at least a part of an electrical component is interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n. Therefore, even when at least one of the positive electrode bus bar 20p and the negative electrode bus bar 20n is deformed by an external force such as an impact, the electrical component functions as a buffer between the two bus bars. Thus, the risk of the two bus bars coming into contact and short-circuiting can be reduced. Also, the fact that an electrical component is interposed between the two bus bars means that the distance between the two bus bars becomes longer by the amount of the mounting space of the electrical component. Thus, the risk of the two bus bars coming into contact and short-circuiting can be reduced.

[0061] Furthermore, in the present embodiment, both the positive electrode SMR30p and the negative electrode SMR30n are interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n. Thus, the function of the SMR (electrical component) as a buffer between the two bus bars can be improved.

[0062] Furthermore, in the present embodiment, the positive electrode SMR30p and the negative electrode SMR30n are arranged such that the fixed terminals 31pH and 31pL (positive electrode terminals) and 31nH and 31nL (negative electrode terminals) face opposite sides to each other. According to this, the positive electrode terminal and the negative electrode terminal are in a positional relationship where they are separated from each other. As a result, the portion of the positive electrode bus bar 20p connected to the positive electrode terminal and the portion of the negative electrode bus bar 20n connected to the negative electrode terminal are in a positional relationship where they are separated from each other. Therefore, when the bus bar is deformed by an external force, the risk of the two bus bars coming into contact and short-circuiting can be further reduced.

[0063] Furthermore, in the present embodiment, the positive electrode SMR30p has a positive electrode insulating plate 35p disposed between the pair of fixed terminals 31pL and 31pH (positive electrode terminals). Therefore, when the bus bar is deformed by an external force, the risk of the portion of the positive electrode bus bar 20p connected to the fixed terminal 31pL and the portion connected to the fixed terminal 31pH coming into contact and short-circuiting can be reduced. Thus, the risk of the positive electrode SMR30p being energized contrary to the intention can be reduced.

[0064] Furthermore, in the present embodiment, the negative electrode SMR30n has a negative electrode insulating plate 35n disposed between the pair of fixed terminals 31nL and 31nH (negative electrode terminals). Therefore, when the bus bar is deformed by an external force, the risk of the portion of the negative electrode bus bar 20n connected to the fixed terminal 31nL and the portion connected to the fixed terminal 31nH coming into contact and short-circuiting can be reduced. Thus, the risk of the negative electrode SMR30n being energized contrary to the intention can be reduced.

[0065] Furthermore, in the present embodiment, both the positive electrode charging relay 40p and the negative electrode charging relay 40n are interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n. Therefore, the function as a buffer material between the two bus bars by the charging relay (electrical component) can be improved.

[0066] Furthermore, in the present embodiment, the positive charging relay 40p and the negative charging relay 40n are arranged such that the fixed terminals 41pH and 41pL (positive charging terminals) and the fixed terminals 41nH and 41nL (negative charging terminals) face opposite sides. According to this, the positive charging terminal and the negative charging terminal are in a positional relationship where they are far from each other. As a result, the portion of the positive bus bar 20p connected to the positive charging terminal and the portion of the negative bus bar 20n connected to the negative charging terminal are in a positional relationship where they are far from each other. Therefore, when at least one of the positive bus bar 20p and the negative bus bar 20n is deformed by an external force, the risk of the two bus bars coming into contact and short-circuiting can be further reduced.

[0067] Furthermore, in the present embodiment, the fixed terminal 31pH on the high voltage side among the pair of positive terminals of the positive SMR 30p and the fixed terminal 41pH on the high voltage side among the pair of positive charging terminals of the positive charging relay 40p are arranged to be aligned in the first direction (X direction). Also, the fixed terminal 31pL on the low voltage side among the pair of positive terminals and the fixed terminal 41pL on the low voltage side among the pair of positive charging terminals are arranged to be aligned in the first direction. Therefore, when the positive bus bar 20p connects the terminals aligned in the first direction, the positive bus bar 20p has more portions extending in the first direction.

[0068] Also, the fixed terminal 31nH on the high voltage side among the pair of negative terminals of the negative SMR 30n and the fixed terminal 41nH on the high voltage side among the pair of negative charging terminals of the negative charging relay 40n are arranged to be aligned in the first direction. Also, the fixed terminal 31nL on the low voltage side among the pair of negative terminals and the fixed terminal 41nL on the low voltage side among the pair of negative charging terminals are arranged to be aligned in the first direction. Therefore, when the negative bus bar 20n connects the terminals aligned in the first direction, the negative bus bar 20n has more portions extending in the first direction.

[0069] In short, according to the arrangement of the fixed terminals described above, both the positive electrode bus bar 20p and the negative electrode bus bar 20n have more portions extending in the first direction. That is, the region sandwiched between the two bus bars can be made large efficiently. Therefore, while adopting a layout with shorter lengths of both bus bars, it is easily possible to interpose an electrical component between the positive electrode bus bar 20p and the negative electrode bus bar 20n. Moreover, since it becomes easier to concentrate and arrange a plurality of electrical components interposed between the two bus bars in a space-saving manner, miniaturization of the high-voltage JB2 can also be achieved.

[0070] Here, since the positive electrode bus bar 20p and the negative electrode bus bar 20n carry a large current, they generate heat when energized. As a result, there are concerns about problems such as thermal damage to electronic components such as the microcomputer 92 and an increase in electrical resistance. In view of this point, in the present embodiment, the positive electrode bus bar 20p has positive electrode wall surface facing portions p1, p2, p3, p4, p5, p6 that are portions facing the wall surface of the case 10. The negative electrode bus bar 20n has negative electrode wall surface facing portions n1, n2, n3, n4, n5, n6, n7 that are portions facing the wall surface of the case 10. And at least an electrical component is interposed between the positive electrode wall surface facing portion and the negative electrode wall surface facing portion. Therefore, heat of the bus bar can be promoted to be radiated from the wall surface facing portion to the case 10. Note that the case 10 can be expected to be cooled by outside air. As described above, the above concerns can be reduced.

[0071] (Other embodiments) As described above, a plurality of embodiments according to the present disclosure have been described. However, the present disclosure is not construed as being limited to the above embodiments, and can be applied to various embodiments and combinations without departing from the gist of the present disclosure.

[0072] In the above embodiment, the positive electrode charging relay 40p is connected in parallel to the positive electrode SMR 30p, but it may be connected in series. In the above embodiment, the negative electrode charging relay 40n is connected in parallel to the negative electrode SMR 30n, but it may be connected in series.

[0073] In the above-described embodiment, electrical components are interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n. These electrical components include all of the positive electrode SMR 30p, the negative electrode SMR 30n, the positive electrode charging relay 40p, the negative electrode charging relay 40n, the pre-charge relay 50, the pyro fuse 80, the pre-charge resistor 60, and the current sensor 70. In contrast, at least one of these electrical components may be interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n.

[0074] In the above-described embodiment, both the positive electrode SMR 30p and the negative electrode SMR 30n are interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n, but a layout in which either one of them is interposed may also be used. Also, in the above-described embodiment, both the positive electrode charging relay 40p and the negative electrode charging relay 40n are interposed between the positive electrode bus bar 20p and the negative electrode bus bar 20n, but a layout in which either one of them is interposed may also be used.

[0075] In the above-described embodiment, the positive electrode SMR 30p and the negative electrode SMR 30n are arranged in the same direction as the direction (Y direction) in which the positive electrode bus bar 20p and the negative electrode bus bar 20n are arranged. In contrast, the positive electrode SMR 30p and the negative electrode SMR 30n may be arranged in the X direction or in the Z direction. Also, in the above-described embodiment, the positive electrode charging relay 40p and the negative electrode charging relay 40n are arranged in the same direction as the direction (Y direction) in which the positive electrode bus bar 20p and the negative electrode bus bar 20n are arranged. In contrast, the positive electrode charging relay 40p and the negative electrode charging relay 40n may be arranged in the X direction or in the Z direction.

[0076] In the above embodiment, the positive electrode SMR30p and the positive electrode charging relay 40p are arranged in the same direction as the longitudinal direction (X direction) in which the positive electrode wall surface facing portions p1 to p6 of the positive electrode bus bar 20p extend. In contrast, the positive electrode SMR30p and the positive electrode charging relay 40p may be arranged in the Y direction or may be arranged in the Z direction. Further, in the above embodiment, the negative electrode SMR30n and the negative electrode charging relay 40n are arranged in the same direction as the longitudinal direction (X direction) in which the negative electrode wall surface facing portions n1 to n7 of the negative electrode bus bar 20n extend. In contrast, the negative electrode SMR30n and the negative electrode charging relay 40n may be arranged in the Y direction or may be arranged in the Z direction.

[0077] In the above embodiment, a form in which the relay unit of the present disclosure is adopted in the high-voltage JB2 mounted on the electric vehicle has been described. However, the relay unit can also be adopted for applications different from electric vehicles. For example, the relay unit according to the present disclosure may be mounted on various moving bodies such as railway vehicles, trams, drones, and electric aircraft such as eVTOL.

[0078] (Disclosure of Technical Idea) This specification discloses a plurality of technical ideas described in a plurality of items listed below. Some items may be described in a multiple dependent form in which a preceding item is alternatively cited in a subsequent item. Further, some items may be described in a multiple dependent form that cites another multiple dependent form item. The items described in these multiple dependent forms define a plurality of technical ideas. (Technical Idea 1) A positive electrode bus bar (20p) that forms a current path between the positive electrode side of the battery (3) and the inverter (4), A negative electrode bus bar (20n) that forms a current path between the negative electrode side of the battery and the inverter, A relay (30p, 30n, 40p, 40n, 50) which is an electromagnetic relay for switching the energization and interruption of the output current from the battery, a fuse (80) for interrupting the output current, a resistor (60) serving as the electrical resistance of the output current, and an electrical component which is at least one of a current sensor (70) for detecting the magnitude of the output current, A case (10) which houses the positive electrode bus bar, the negative electrode bus bar, and the electrical component inside, A relay unit in which at least a part of the electrical component is interposed between the positive electrode bus bar and the negative electrode bus bar.

[0079] (Technical idea 2) The electrical component includes the relay, The relay includes a positive electrode relay (30p) having a pair of positive electrode terminals (31pH, 31pL) connected to the positive electrode bus bar, and a negative electrode relay (30n) having a pair of negative electrode terminals (31nH, 31nL) connected to the negative electrode bus bar, The relay unit according to Technical Idea 1, in which both the positive electrode relay and the negative electrode relay are interposed between the positive electrode bus bar and the negative electrode bus bar.

[0080] (Technical idea 3) The relay unit according to Technical Idea 2, in which the positive electrode relay and the negative electrode relay are arranged such that the positive electrode terminals and the negative electrode terminals face opposite sides.

[0081] (Technical idea 4) The positive electrode relay has a positive electrode insulating plate (35p) which is an electrically insulating member arranged between the pair of positive electrode terminals, The relay unit according to Technical Idea 2 or 3, in which the negative electrode relay has a negative electrode insulating plate (35n) which is an electrically insulating member arranged between the pair of negative electrode terminals.

[0082] (Technical idea 5) The electrical component includes a charging relay (40p, 40n) that switches the energization and interruption of the charging current flowing between the battery and the charging inlet (9). The charging relay includes a positive charging relay (40p) having a pair of positive charging terminals (41pH, 41pL) connected to the positive bus bar, and a negative charging relay (40n) having a pair of negative charging terminals (41nH, 41nL) connected to the negative bus bar. Both the positive charging relay and the negative charging relay are interposed between the positive bus bar and the negative bus bar, and are the relay units according to any one of Technical Ideas 1 to 4.

[0083] (Technical Idea 6) The positive charging relay and the negative charging relay are the relay units according to Technical Idea 5, in which the positive charging terminals and the negative charging terminals are arranged so as to face opposite sides to each other.

[0084] (Technical Idea 7) The electrical component includes a charging relay (40p, 40n) that switches the energization and interruption of the charging current flowing between the battery and the charging inlet (9). The charging relay includes a positive charging relay (40p) having a pair of positive charging terminals (41pH, 41pL) connected to the positive bus bar, and a negative charging relay (40n) having a pair of negative charging terminals (41nH, 41nL) connected to the negative bus bar. The positive charging relay and the negative charging relay are arranged such that the positive charging terminals and the negative charging terminals face opposite sides to each other. The positive bus bar includes a positive inverter bus bar (21p) that forms a current path between the inverter and the positive relay, a positive charging bus bar (22p) that forms a current path between the charging inlet and the positive charging relay, and a positive battery bus bar (23p) that forms a current path between the battery and the positive relay. The negative electrode bus bar includes a negative electrode inverter bus bar (21n) that forms a current path between the inverter and the negative electrode relay, a negative electrode charging bus bar (22n) that forms a current path between the charging inlet and the negative electrode charging relay, and a negative electrode battery bus bar (23n) that forms a current path between the battery and the negative electrode relay. The positive electrode relay and the positive electrode charging relay are arranged to be aligned in a predetermined first direction. The negative electrode relay and the negative electrode charging relay are arranged to be aligned in a predetermined second direction. The terminal on the high voltage side among the pair of positive electrode terminals and the terminal on the high voltage side among the pair of positive electrode charging terminals are arranged to be aligned in the first direction. The terminal on the low voltage side among the pair of positive electrode terminals and the terminal on the low voltage side among the pair of positive electrode charging terminals are arranged to be aligned in the first direction. The terminal on the high voltage side among the pair of negative electrode terminals and the terminal on the high voltage side among the pair of negative electrode charging terminals are arranged to be aligned in the second direction. The terminal on the low voltage side among the pair of negative electrode terminals and the terminal on the low voltage side among the pair of negative electrode charging terminals are arranged to be aligned in the second direction, which is the relay unit described in Technical Idea 3.

[0085] (Technical Idea 8) The positive electrode bus bar has positive electrode wall surface facing portions (p1, p2, p3, p4, p5, p6) that are portions facing the wall surface of the case. The negative electrode bus bar has negative electrode wall surface facing portions (n1, n2, n3, n4, n5, n6, n7) that are portions facing the wall surface of the case. The relay unit according to any one of Technical Ideas 1 to 7, wherein at least the electrical component is interposed between the positive electrode wall surface facing portion and the negative electrode wall surface facing portion.

Explanation of Reference Numerals

[0086] 2 High-voltage JB (Relay Unit), 5 Charging Inlet, 10 Case, 20n Negative Busbar, 20p Positive Busbar, 21n Negative Inverter Busbar, 21p Positive Inverter Busbar, 22n Negative Charging Busbar, 22p Positive Charging Busbar, 23n Negative Battery Busbar, 23p Positive Battery Busbar, 3 Battery, 30n Relay, 30n Negative Relay, 30p Relay, 30p Positive Relay, 31nH, 31nL Negative Terminals, 31pH, 31pL Positive Terminals, 35n Negative Insulating Plate, 35p Positive Insulating Plate, 4 Inverter, 40n Relay, 40n Charging Relay, 40n Negative Charging Relay, 40n Charging Relay, 40n Negative Charging Relay, 40p Relay, 40p Charging Relay, 40p Positive Charging Relay, 40p Charging Relay, 40p Positive Charging Relay, 41nH, 41nL Negative Charging Terminals, 41pH, 41pL Positive Charging Terminals, 50 Relay, 60 Resistor, 70 Current Sensor, 80 Fuse, n1, n2, n3, n4, n5, n6, n7 Negative Wall Opposing Parts, p1, p2, p3, p4, p5, p6 Positive Wall Opposing Parts.

Claims

1. A positive electrode bus bar (20p) that forms a current path between the positive electrode side of the battery (3) and the inverter (4), A negative electrode bus bar (20n) that forms a current path between the negative electrode side of the battery and the inverter, Relays (30p, 30n, 40p, 40n, 50) which are electromagnetic relays for switching on and off the energization of the output current from the battery, a fuse (80) for interrupting the output current, a resistor (60) serving as the electrical resistance of the output current, and an electrical component which is at least one of a current sensor (70) for detecting the magnitude of the output current, A case (10) that houses the positive electrode bus bar, the negative electrode bus bar, and the electrical component inside, A relay unit in which at least a part of the electrical component is interposed between the positive electrode bus bar and the negative electrode bus bar.

2. The electrical component includes the relay, The relay includes a positive electrode relay (30p) having a pair of positive electrode terminals (31pH, 31pL) connected to the positive electrode bus bar, and a negative electrode relay (30n) having a pair of negative electrode terminals (31nH, 31nL) connected to the negative electrode bus bar, The relay unit according to claim 1, wherein both the positive electrode relay and the negative electrode relay are interposed between the positive electrode bus bar and the negative electrode bus bar.

3. The relay unit according to claim 2, wherein the positive electrode relay and the negative electrode relay are arranged such that the positive electrode terminal and the negative electrode terminal face opposite sides.

4. The positive electrode relay has a positive electrode insulating plate (35p) which is an electrically insulating member arranged between the pair of positive electrode terminals, The relay unit according to claim 2 or 3, wherein the negative electrode relay has a negative electrode insulating plate (35n) which is an electrically insulating member arranged between the pair of negative electrode terminals.

5. The electrical component includes a charging relay (40p, 40n) for switching on and off the energization of the charging current flowing between the battery and the charging inlet (5), The charging relay includes a positive electrode charging relay (40p) having a pair of positive electrode charging terminals (41pH, 41pL) connected to the positive electrode bus bar, and a negative electrode charging relay (40n) having a pair of negative electrode charging terminals (41nH, 41nL) connected to the negative electrode bus bar, The relay unit according to any one of claims 1 to 3, wherein both the positive electrode charging relay and the negative electrode charging relay are interposed between the positive electrode bus bar and the negative electrode bus bar.

6. The relay unit according to claim 5, wherein the positive electrode charging relay and the negative electrode charging relay are arranged such that the positive electrode charging terminal and the negative electrode charging terminal face opposite sides.

7. The electrical component includes a charging relay (40p, 40n) that switches the energization and interruption of the charging current flowing between the battery and the charging inlet (5). The charging relay includes a positive electrode charging relay (40p) having a pair of positive electrode charging terminals (41pH, 41pL) connected to the positive electrode bus bar, and a negative electrode charging relay (40n) having a pair of negative electrode charging terminals (41nH, 41nL) connected to the negative electrode bus bar. The positive electrode charging relay and the negative electrode charging relay are arranged such that the positive electrode charging terminal and the negative electrode charging terminal face opposite sides. The positive electrode bus bar includes a positive electrode inverter bus bar (21p) that forms a current path between the inverter and the positive electrode relay, a positive electrode charging bus bar (22p) that forms a current path between the charging inlet and the positive electrode charging relay, and a positive electrode battery bus bar (23p) that forms a current path between the battery and the positive electrode relay. The negative electrode bus bar includes a negative electrode inverter bus bar (21n) that forms a current path between the inverter and the negative electrode relay, a negative electrode charging bus bar (22n) that forms a current path between the charging inlet and the negative electrode charging relay, and a negative electrode battery bus bar (23n) that forms a current path between the battery and the negative electrode relay. The positive electrode relay and the positive electrode charging relay are arranged side by side in a predetermined first direction. The negative electrode relay and the negative electrode charging relay are arranged side by side in a predetermined second direction. The terminal on the high voltage side of the pair of positive electrode terminals and the terminal on the high voltage side of the pair of positive electrode charging terminals are arranged side by side in the first direction. The terminal on the low voltage side of the pair of positive electrode terminals and the terminal on the low voltage side of the pair of positive electrode charging terminals are arranged side by side in the first direction. The terminal on the high voltage side of the pair of negative electrode terminals and the terminal on the high voltage side of the pair of negative electrode charging terminals are arranged side by side in the second direction. The relay unit according to claim 3, wherein the terminal on the low voltage side among the pair of negative terminal electrodes and the terminal on the low voltage side among the pair of negative charging terminal electrodes are arranged side by side in the second direction.

8. The positive electrode bus bar has a positive electrode wall surface facing portion (p1, p2, p3, p4, p5, p6) which is a portion facing the wall surface of the case. The negative electrode bus bar has a negative electrode wall surface facing portion (n1, n2, n3, n4, n5, n6, n7) which is a portion facing the wall surface of the case. The relay unit according to any one of claims 1, 2, 3, and 7, wherein the electrical component is interposed at least between the positive electrode wall surface facing portion and the negative electrode wall surface facing portion.

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