Vehicle charger mounting structure

Abstract

The objective is to provide a mounting structure that has sufficient rigidity or strength, while also being able to be made small and lightweight. [Solution] A vehicle charger mounting structure for fixing a charger on a mounting section 6 provided inside a predetermined housing section in a vehicle, comprising a bracket 12 for connecting the charger to the mounting section 6, the bracket 12 having a first fastening section 13 attached to the charger, and a second fastening section 14 and a third fastening section 15 connected to the mounting section 6, the third fastening section 15 being provided at a position off the straight line L1 passing through the first fastening section 13 and the second fastening section 14.

Description

Technical Field

[0001] This invention relates to a charger mounting structure for fixing a charger inside a vehicle equipped with a charger such as an electric vehicle.

Background Art

[0002] An example of a structure for mounting a charger on a vehicle is described in Patent Document 1. The structure described in Patent Document 1 is a structure mainly aimed at protecting the charger as an auxiliary machine when the vehicle collides. The charger is mounted in a storage location on the front side of the vehicle. A bracket attached to the cross member is provided in that storage location. The bracket is for holding a power control unit (PCU) and has legs standing on the bracket. The charger is arranged between those legs. The charger is provided with flanges protruding from both its left and right sides. The flanges are fixed to the legs. The charger protrudes forward of the PCU in the vehicle-mounted state. Therefore, when the vehicle collides and the front part of the vehicle is deformed toward the storage location side, the charger is pushed backward inside the storage location. Due to the collision load, the flange detaches from the leg, and the charger moves backward inside the storage location. As a result, the load applied to the charger is alleviated, and the charger is protected.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As described in Patent Document 1 above, the bracket and flange are components that fix the charger or power control unit (PCU) to the vehicle body. Loads due to collisions, etc., act on the bracket and flange either through electrical equipment such as the charger or directly. In the configuration described in Patent Document 1, the load on the charger is mitigated by causing the flange to break under collision load.

[0005] However, if there is insufficient space to move the electrical equipment that needs protection, it is necessary to increase the rigidity of the electrical equipment itself, as well as the rigidity or strength of the bracket that secures it, in order to reliably withstand loads from collisions, etc. Making the bracket larger and thicker will improve its rigidity or strength. However, the bracket, electrical equipment, and its support members are separate components, and fasteners such as bolts are required for attachment. While making the bracket larger, including these fasteners, can reliably hold the electrical equipment, it also means that the bracket and fasteners used to support and secure the electrical equipment will become larger, potentially increasing the weight of the vehicle or raising costs.

[0006] This invention was made against the background described above, and its purpose is to provide a mounting structure that has sufficient rigidity or strength and can be made small and lightweight. [Means for solving the problem]

[0007] To achieve the above objective, this invention provides a vehicle charger mounting structure for which a charger is fixed on a mounting portion provided inside a predetermined housing portion in a vehicle, comprising a bracket for connecting the charger to the mounting portion, wherein the bracket has a first fastening portion attached to the charger, and a second fastening portion and a third fastening portion connected to the mounting portion, and the third fastening portion is provided at a position deviating from the straight line passing through the first fastening portion and the second fastening portion.

[0008] In this invention, the bracket has a first flat plate portion attached to the charger, a second flat plate portion that is offset vertically from the first flat plate portion and attached to the mounting portion, and an inclined connecting portion between the first flat plate portion and the second flat plate portion, the first fastening portion is provided on the first flat plate portion, and the second fastening portion and the third fastening portion may be provided on the second flat plate portion.

[0009] In this invention, the bracket may be arranged at an inclination such that the second and third fastening portions are lower than the first fastening portion.

[0010] In this invention, the bracket may have a first extension portion located on the extension toward the second fastening portion of the straight line connecting the first fastening portion and the second fastening portion and in contact with the upper surface of the mounting portion, and a second extension portion located on the extension toward the third fastening portion of the straight line connecting the first fastening portion and the third fastening portion and in contact with the upper surface of the mounting portion.

[0011] In this invention, the first fastening portion, the second fastening portion, and the third fastening portion may be configured to connect the bracket by bolts that pass through the bracket.

[0012] In this invention, the charger has a main body and a retaining frame provided on the outside of the main body, and the bracket may be connected to the retaining frame by the second fastening portion.

[0013] In this invention, the mounting portion may be the upper surface portion of a predetermined electrical device fixed inside the housing portion.

[0014] In this invention, the housing is provided in the front portion of the vehicle, a part of the charger protrudes rearward from the electrical equipment in the longitudinal direction of the vehicle, the bracket is positioned such that the first fastening portion is located rearward in the longitudinal direction of the vehicle relative to the second fastening portion and the third fastening portion, the second fastening portion and the third fastening portion are fastened to the rear end of the electrical equipment, and the first fastening portion is fastened to the charger. [Effects of the Invention]

[0015] In this invention, when a load is applied to the charger in a pushing direction, the bracket is connected to the mounting part at two points, the second fastening part and the third fastening part. Therefore, the load applied to the charger is divided into a load in the direction of the straight line connecting the first fastening part and the second fastening part, and a load in the direction of the straight line connecting the first fastening part and the third fastening part, and these loads are applied to the second fastening part and the third fastening part. In other words, since the load is distributed, the maximum stress acting on any one point can be reduced, the required rigidity or strength can be decreased, and the overall structure of the bracket, including each fastening part, can be made smaller and lighter.

[0016] In this invention, if the bracket is configured to include a first flat plate portion and a second flat plate portion connected by an inclined connecting portion, a load that brings the first fastening portion closer to the second and third fastening portions may act as a load that lifts the bracket. In that case, the load that lifts the bracket is received at two locations, the second and third fastening portions, so the load or stress at each location becomes smaller, and the rigidity or strength of each fastening portion can be reduced.

[0017] Furthermore, in this invention, even when the bracket is positioned such that the second and third fastening parts are lower than the first fastening part, a load may act in a direction that lifts the second and third fastening parts. In this case as well, the lifting load is distributed to two locations, so the load or stress at each location becomes smaller, and the rigidity or strength of each fastening part can be reduced.

[0018] For example, if the second fastening part and the third fastening part are configured to connect the bracket to the mounting part by bolts, two bolts can function effectively, so that the size increase of each bolt can be avoided or suppressed.

[0019] In this invention, the bracket is connected to the upper surface of a predetermined electrical device by the second fastening part and the third fastening part, and the charger is supported by the bracket, so that electrical components such as the charger and the predetermined electrical device can be mounted inside the accommodating part in a state where they are stacked vertically.

[0020] When the charger protrudes rearward from the predetermined electrical device in this stacked state, if the electrical device and the charger drop rearward due to the load from the front side of the vehicle, the charger will hit another member before the electrical device. In that case, a load is applied to the bracket toward the front side, but since this load is dispersed and received by the second fastening part and the third fastening part, the required maximum rigidity or maximum strength is reduced, and the overall configuration including the bracket can be made smaller and lighter.

Brief Description of the Drawings

[0021] [Figure 1] FIG. 1 is a schematic diagram showing the mounting position and posture of the charger in an embodiment of this invention. [Figure 2] FIG. 2 is a perspective view showing a PCU upper cover, a bracket for attaching the charger, and an intermediate bracket. [Figure 3] FIG. 3 is a side view showing the state where the charger is attached on the PCU upper cover. [Figure 4] FIG. 4 is a plan view of the intermediate bracket. [Figure 5] FIG. 5 is a side view of the intermediate bracket. [Figure 6]FIG. 6 is a diagram showing the measurement results of the tensile load acting on the bolt, (A) shows the measurement results of the tensile load of the bolt in the second fastening part, and (B) shows the measurement results of the tensile load of the bolt in the third fastening part.

BEST MODE FOR CARRYING OUT THE INVENTION

[0022] Next, embodiments of the present invention will be described with reference to the accompanying drawings. Note that the embodiments described below are merely examples of implementing the present invention and do not limit the present invention.

[0023] This invention is a structure for mounting a charger used in a vehicle on the vehicle. FIG. 1 schematically shows an example of the mounting structure. The vehicle 1 includes a housing portion 2 on the front side. This housing portion 2 corresponds to a portion equivalent to the engine compartment in a conventional engine vehicle. The charger 3 is disposed on top of electrical devices such as a DC-DC converter 4 and a power control unit (PCU) 5. In the example shown in FIG. 1, the charger 3 is attached on top of the PCU 5. These electrical devices and the charger 3 are inclined such that the front side in the longitudinal direction of the vehicle 1 is lower in a state of being stacked vertically. This is a mounting posture adapted to the shape of the housing portion 2. Note that the PCU 5 or its upper cover corresponds to the mounting portion in the embodiment of the present invention.

[0024] FIGS. 2 and 3 show a mechanism for fixing the charger 3 to a PCU upper cover (hereinafter simply referred to as an upper cover) 6. The upper cover 6 has a substantially rectangular shape and is disposed with the front left side in FIG. 2 facing the front of the vehicle 1. The charger 3 has a substantially rectangular shape with a width substantially the same as that of the upper cover 6 and is slightly longer than the upper cover 6. As shown in FIG. 3, the charger 3 has a main body portion 7 and a pair of front and rear brackets 8 and 9. The brackets 8 and 9 are for attaching the main body portion 7 to the upper cover 6 and correspond to the holding frame portion in the embodiment of the present invention.

[0025] One bracket 8 has a bottom portion 8a fixed to the upper surface of the upper cover 6, and a wall portion 8b rising from the bottom portion 8a and facing the front end surface of the main body 7. The bracket 8 is connected to the main body 7 via a bush 10 that passes through its wall portion 8b. The other bracket 9 has a pair of side wall portions 9a facing the left and right sides of the rear end of the main body 7, and a bottom portion 9b that connects and integrates these side wall portions 9a at the bottom. This bracket 9 is connected to the main body 7 via a bush 11 that passes through its side wall portions 9a.

[0026] The rear end of the charger 3 is connected to the upper cover 6 by an intermediate bracket 12. This intermediate bracket 12 corresponds to the bracket in the embodiment of this invention. Details of the intermediate bracket 12 are shown in Figures 4 and 5. The intermediate bracket 12 is made of metal such as steel and has a first flat plate portion 12a that is tightly connected to the lower part of the bracket 9 on the charger 3, a second flat plate portion 12b that is tightly connected to the upper surface of the upper cover 6, and a connecting portion 12c that connects these flat plate portions 12a and 12b. The first flat plate portion 12a and the second flat plate portion 12b are offset in the vertical direction or in the thickness direction, as shown in Figure 5. Therefore, the connecting portion 12c is inclined, as shown in Figure 5. This connecting portion 12c corresponds to the inclined connecting portion in the embodiment of this invention. Furthermore, the width gradually increases from the first flat plate portion 12a to the second flat plate portion 12b. Therefore, the intermediate bracket 12 has a roughly triangular shape in plan view.

[0027] A first fastening portion 13 is provided at one location on the first flat plate portion 12a. For example, the first fastening portion 13 is composed of a bolt hole 13a that penetrates the first flat plate portion 12a in the thickness direction and a bolt 13b inserted into the bolt hole 13a. In addition, other fastening portions are provided at two locations on the wider second flat plate portion 12b. Specifically, a second fastening portion 14 and a third fastening portion 15 are provided on the second flat plate portion 12b. For example, each of these second fastening portions 14 and 3rd fastening portions 15 is composed of bolt holes 14a and 15a that penetrate in the thickness direction and bolts 14b and 15b inserted into the bolt holes 14a and 15a, similar to the first fastening portion 13.

[0028] These three fastening parts 13, 14, and 15 are located at positions corresponding to the vertices of a triangle, as shown in Figure 4. In other words, one fastening part is positioned off the straight line passing through any two of the fastening parts. In the embodiment described here, as shown in Figure 4, the first fastening part 13 and the second fastening part 14 are aligned in the front-rear direction of the vehicle 1 or along the long side of the upper cover 6. In contrast, the third fastening part 15 is located closer to the center in the width direction of the upper cover 6, which is the vertical direction in Figure 4. Therefore, the straight line passing through the first fastening part 13 and the third fastening part 15 points diagonally forward to the right in the vehicle 1.

[0029] The intermediate bracket 12 described above is positioned in the front-rear direction of the vehicle 1, at the left corner of the rear end of the upper cover 6. The intermediate bracket 12 is connected to and fixed to the upper cover 6 by screwing a bolt 14b inserted into the bolt hole 14a of the second fastening part 14 into the upper cover 6, and by screwing a bolt 15b inserted into the bolt hole 15a of the third fastening part 15 into the upper cover 6. Furthermore, the intermediate bracket 12 is connected to and fixed to the charger 3 by placing the first flat plate part 12a on the bottom surface 9b of the bracket 9 of the charger 3 and making it tightly attached, and then screwing a bolt 13b inserted into the bolt hole 13a of the first fastening part 13 into the charger 3 or its bracket 9. In this way, the rear end portion of the charger 3 is connected to and fixed to the upper cover 6 via the intermediate bracket 12.

[0030] Figure 3 shows the charger 3 mounted on the upper surface of the upper cover 6. As mentioned above, the charger 3 is somewhat elongated by the upper cover 6, making it rectangular or cuboid in shape. Therefore, the rear end of the charger 3 protrudes further rearward than the upper cover 6, as shown in Figure 3. Although not specifically shown, the housing 2 contains numerous other components required for the vehicle 1, and one of these components is close to the rear end of the charger 3. Therefore, if the DCDC converter 4 or PCU 5 moves towards the rear of the vehicle 1 due to a load such as a frontal collision, the rear end of the charger 3 will strike one of the other components close to it, pushing the charger 3 forward of the vehicle 1. The intermediate bracket 12 receives such a load directed towards the front of the vehicle.

[0031] Here, we consider the load on the intermediate bracket 12 when the charger 3 retracts during a collision with vehicle 1, and is consequently pushed forward by other parts. Assuming that a collision load is applied to vehicle 1 from its right front, a load acts on the intermediate bracket 12 in the direction of a straight line L3 that passes between the straight line L1 connecting the first fastening part 13 and the second fastening part 14 and the straight line L2 connecting the first fastening part 13 and the third fastening part 15, as shown in Figure 4. As mentioned above, the charger 3 is positioned at an angle so that it is lower towards the front of vehicle 1. Also, as shown in Figures 3 and 5, the first fastening part 13 on the charger 3 side of the intermediate bracket 12 is at a higher position than the second fastening part 14 and the third fastening part 15. In contrast, the load from the right front of vehicle 1 and the stress on it act almost horizontally.

[0032] Therefore, the intermediate bracket 12 functions as a lever, with the first extension P1 and the second extension P2 on the side of the second fastening portion 14 and the third fastening portion 15 being supported from below by the upper cover 6, the first fastening portion 13 acting as the point of force application, and the second fastening portion 14 and the third fastening portion 15 acting as the points of application. Consequently, tensile loads in the axial direction act on the bolts 14b and 15b in the second fastening portion 14 and the third fastening portion 15. The magnitude of the tensile load is determined by the ratio of the distance from the first fastening part 13 to each extension P1, P2 of the intermediate bracket 12 on the straight line L1 passing through the first fastening part 13 and the second fastening part 14 to each extension P1, P2, and the ratio of the distance from the first fastening part 13 to the tip of the intermediate bracket 12 on the straight line L2 passing through the first fastening part 13 and the third fastening part 15 to each extension P1, P2.

[0033] In this embodiment of the invention, as shown in Figure 4, the above dimensions or ratios on the second fastening portion 14 side and the third fastening portion 15 side are approximately equal. Therefore, the loads acting on the bolts 14b and 15b in the second fastening portion 14 and the third fastening portion 15 are approximately equal. The magnitude of the loads acting on these bolts 14b and 15b is shown in Figures 6(A) and (B). In Figure 6, the horizontal axis represents the impact load due to collision, etc., and the vertical axis represents the load acting on the bolts 14B and 15b. Since the intermediate bracket 12 tends to move along the upper surface of the upper cover 6, shear forces act on the bolts 14b of the second fastening portion 14 and the bolts 15b of the third fastening portion 15. In the embodiment shown in Figure 4, the relative positions of the second fastening portion 14 and the third fastening portion 15 with respect to the first fastening portion 13 are approximate, so the shear forces acting on each bolt 14b and 15b are approximately equal.

[0034] In short, in the embodiments of this invention described above, the second fastening portion 14 and the third fastening portion 15, which receive the load on the upper cover 6 side, are subjected to substantially equal tensile and shear loads. That is, each of these fastening portions 14 and 15 effectively performs its fastening function. In other words, it is not necessary to make either of these fastening portions 14 or 15 highly rigid or highly strong, and as a result, according to the embodiments of this invention, it is possible to avoid increasing the size and weight due to partially increasing the rigidity or strength of the fastening portion.

[0035] Furthermore, this invention is not limited to the embodiments described above and can be implemented with appropriate modifications. In this invention, the charger may be arranged horizontally. Also, the bracket may be formed entirely in a flat shape without having the inclined connecting portion described above. Moreover, the contour shape of the bracket is not limited to a substantially triangular shape and may be an appropriate contour shape as needed. The housing portion in this invention may be provided on the rear side of the vehicle instead of the front side. Furthermore, the bracket in this invention is not limited to the intermediate bracket shown in the embodiments, and may be configured to connect the charger to a mounting portion such as an upper cover at multiple points, or it may be provided on the front side of the vehicle instead of the rear side of the charger in the longitudinal direction of the vehicle. [Explanation of Symbols]

[0036] 1 vehicle 2. Storage area 3 charger 4 DC-DC converters 5. Power Control Unit (PCU) 6 Upper cover 7 Main body 8,9 Bracket 8a,9b Bottom part 8b Wall section 9a Side wall section 10,11 Bush 12 Intermediate bracket 12a 1st flat plate part 12b 2nd flat plate part 12c connection part 13 1st fastening part 13a, 14a, 15a Bolt holes 13b, 14b, 15b bolts 14 Second fastening part 15 Third fastening section L1,L2,L3 straight line P1,P2 extension part

Claims

1. A vehicle charger mounting structure in which a charger is fixed on a mounting part provided inside a predetermined housing part in the vehicle, The charger is provided with a bracket that connects to the mounting portion, The bracket has a first fastening portion that is attached to the charger, and a second fastening portion and a third fastening portion that are connected to the mounting portion. The third fastening portion is provided at a position that is off the straight line passing through the first fastening portion and the second fastening portion. A vehicle charger mounting structure characterized by the following features.

2. A vehicle charger mounting structure according to claim 1, The bracket has a first flat plate portion attached to the charger, a second flat plate portion that is offset vertically from the first flat plate portion and attached to the mounting portion, and an inclined connecting portion between the first flat plate portion and the second flat plate portion. The first fastening portion is provided on the first flat plate portion, The second fastening portion and the third fastening portion are provided on the second flat plate portion. A vehicle charger mounting structure characterized by the following features.

3. A vehicle charger mounting structure according to claim 1 or 2, The bracket is positioned at an angle such that the second and third fastening portions are lower than the first fastening portion. A vehicle charger mounting structure characterized by the following features.

4. A vehicle charger mounting structure according to claim 3, The bracket has a first extension portion located on the extension toward the second fastening portion of the straight line connecting the first fastening portion and the second fastening portion and in contact with the upper surface of the mounting portion, and a second extension portion located on the extension toward the third fastening portion of the straight line connecting the first fastening portion and the third fastening portion and in contact with the upper surface of the mounting portion. A vehicle charger mounting structure characterized by the following features.

5. A vehicle charger mounting structure according to claim 3, The first fastening portion, the second fastening portion, and the third fastening portion are configured to connect the bracket by bolts that pass through the bracket. A vehicle charger mounting structure characterized by the following features.

6. A vehicle charger mounting structure according to claim 3, The charger comprises a main body and a retaining frame provided on the outside of the main body. The bracket is connected to the retaining frame by the second fastening portion. A vehicle charger mounting structure characterized by the following features.

7. A vehicle charger mounting structure according to claim 6, The mounting portion is the upper surface portion of a predetermined electrical device fixed inside the housing portion. A vehicle charger mounting structure characterized by the following features.

8. A vehicle charger mounting structure according to claim 7, The aforementioned storage section is provided in the front part of the vehicle, A portion of the charger protrudes rearward from the electrical equipment in the longitudinal direction of the vehicle. The bracket is positioned such that the first fastening portion is located on the rearward side in the longitudinal direction of the vehicle relative to the second and third fastening portions, the second and third fastening portions are fastened to the rear end of the electrical equipment, and the first fastening portion is fastened to the charger. A vehicle charger mounting structure characterized by the following features.

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