Cable routing material, electrical connection unit, and method for manufacturing cable routing material

Abstract

One embodiment provides a cable routing material, an electrical connection unit, and a method for manufacturing the cable routing material that can improve thermal properties. [Solution] The cable routing material in one embodiment includes a busbar and a heat storage member. The heat storage member is attached to the busbar by a fixing portion formed by crimping.

Description

Technical Field

[0008] ,

[0001] Embodiments of the present invention relate to a wiring material, an electrical connection unit, and a method for manufacturing the wiring material.

Background Art

[0002] An electrical connection unit having an electronic component and a bus bar electrically connected to the electronic component is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0009] According to one embodiment, it is possible to improve the thermal properties. [Brief explanation of the drawing]

[0010] [Figure 1] A cross-sectional view showing the electrical connection unit of the first embodiment. [Figure 2] A perspective view showing the cable routing material of the first embodiment. [Figure 3] A diagram illustrating the fixing part of the first embodiment. [Figure 4] A diagram illustrating the manufacturing method of the cable material according to the first embodiment. [Figure 5] A cross-sectional view illustrating the manufacturing method of the cable material according to the first embodiment. [Figure 6] A diagram illustrating the fixing part of the second embodiment. [Figure 7] A cross-sectional view illustrating the manufacturing method of the cable guide material according to the second embodiment. [Figure 8] A perspective view showing the cable routing material of a first modified embodiment. [Figure 9] A cross-sectional view showing an electrical connection unit of a second modified embodiment. [Figure 10] A perspective view illustrating a heat storage member of a second modified embodiment. [Modes for carrying out the invention]

[0011] The embodiments will be described below with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numerals. Duplication of these components may be omitted. The components described below do not limit the scope of the embodiments.

[0012] In this disclosure, terms are defined as follows: “Connection” may include electrical connections, not just mechanical ones. That is, “Connection” may include cases where two elements to be connected are directly connected, not just cases where two elements to be connected are connected with another element in between. “Facing” means that the virtual projections of two objects overlap when viewed from a particular direction. That is, “Facing” may include cases where two objects face each other with another member present between them, not just cases where two objects face each other. “Parallel,” “orthogonal,” or “same” may include cases where they are “approximately parallel,” “approximately orthogonal,” or “approximately the same,” respectively.

[0013] In this disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows: The +X direction is, for example, the extension direction of at least a portion of the extension portion 63 of the busbar 60 described later (see Figure 2). The -X direction is the direction opposite to the +X direction. Hereinafter, when the +X direction and the -X direction are not distinguished, they will simply be referred to as the "X direction". The +Y direction and the -Y direction are directions that intersect (e.g., are orthogonal to) the X direction. The +Y direction is, for example, the width direction of the extension portion 63 of the busbar 60 (see Figure 2). The -Y direction is the direction opposite to the +Y direction. Hereinafter, when the +Y direction and the -Y direction are not distinguished, they will simply be referred to as the "Y direction". The +Z direction and the -Z direction are directions that intersect (e.g., are orthogonal to) the X direction and the Y direction. The +Z direction is the direction from the extension portion 63 of the busbar 60 toward the heat storage member 70 described later (see Figure 2). The -Z direction is the opposite direction to the +Z direction. In the following, when the +Z and -Z directions are not distinguished, they will simply be referred to as the "Z direction".

[0014] (First Embodiment) <1. Configuration of the Electrical Connection Unit> FIG. 1 is a cross-sectional view showing an electrical connection unit 1 according to the first embodiment. The electrical connection unit 1 is an in-vehicle device mounted on a vehicle such as an EV (Electric Vehicle), HEV (Hybrid Electric Vehicle), or PHEV (Plug-in Hybrid Electric Vehicle). The electrical connection unit 1 may be referred to as, for example, an "electrical connection box" or a "junction box". However, the electrical connection unit 1 is not limited to a box-shaped device. The electrical connection unit 1 has, for example, a housing 5 and a main body unit MU.

[0015] The housing 5 is a member that forms the outer shell of the electrical connection unit 1. The housing 5 is made of, for example, a synthetic resin and has insulating properties. The housing 5 houses the main body unit MU. The housing 5 has, for example, an opening 5h that exposes a connection component 20 for external connection. Note that the housing 5 may be omitted.

[0016] The main body unit MU is a part that performs the main functions of the electrical connection unit 1 (for example, switching the electrical connection state or overcurrent protection). The main body unit MU may be referred to as a "circuit configuration body". The main body unit MU includes, for example, one or more electronic components 10, connection components 20, a base member 30, a plurality of fixing parts 40, and one or more wiring materials 50.

[0017] <2. Electronic Components> First, the electronic component 10 will be described. The electronic component 10 is an electronic component mounted according to the functions required for the main body unit MU. The electronic component 10 is, for example, a connector, a fuse, a relay (for example, a mechanical relay or a semiconductor relay), a capacitor, a branching component, various sensors (for example, a current sensor or a voltage sensor), an electronic control unit, or an electronic component unit formed by unitizing two or more of these. However, the types of the electronic component 10 are not limited to the above examples. The electronic component 10 is, for example, a heat-generating component that generates heat when energized. The electronic component 10 has, for example, a case 11, a component main body part 12, and a plurality of terminals 13.

[0018] The case 11 is an outer casing that forms most of the external shape of the electronic component 10. The case 11 is made of, for example, synthetic resin and has insulating properties. The case 11 houses the component body 12. The case 11 and the component body 12 may be formed as a single unit.

[0019] The main body of the component 12 is the part that performs the main function of the electronic component 10. For example, if the electronic component 10 is a relay, the main body of the component 12 includes a switching part (e.g., a contact part) that switches between a conductive state and a non-conductive state. For example, if the electronic component 10 is a fuse, the main body of the component 12 includes a fuse that melts when an overcurrent flows. For example, if the electronic component 10 is a capacitor, the main body of the component 12 includes a part that stores electric charge.

[0020] Terminal 13 is an electrical connection part exposed to the outside of the case 11. Terminal 13 is electrically connected to the component body 12 inside the case 11. In this embodiment, the electronic component 10 includes terminals 13A and terminal 13B as a plurality of terminals 13. One of terminals 13A and terminal 13B is the positive terminal. The other of terminals 13A and terminal 13B is the negative terminal. One of terminals 13A and terminal 13B is an example of a "first terminal". The other of terminals 13A and terminal 13B is an example of a "second terminal".

[0021] Each terminal 13 has a mounting hole 13h into which a fastening member 41 (e.g., a screw or bolt), described later, is inserted. The mounting hole 13h does not have a screw thread, for example. The mounting hole 13h is, for example, a through hole that penetrates the terminal 13 in the Z direction. In this disclosure, "mounting hole" is not limited to a hole without a screw thread, but may also be a hole with a screw thread into which the fastening member 41 engages. Also in this disclosure, "mounting hole" is not limited to a through hole, but may also be a hole with a bottom. For example, the mounting hole 13h may be a hole with a screw thread into which the fastening member 44 engages, or it may be a hole with a bottom.

[0022] <3. Connecting parts> Next, the connecting component 20 will be described. The connecting component 20 is a component for electrically connecting multiple members. The connecting component 20 forms part of the electrical circuit in the electrical connection unit 1. The connecting component 20 is made of metal (for example, copper, copper alloy, aluminum, or aluminum alloy). The connecting component 20 has a mounting hole 20h into which the fastening member 44, which will be described later, is inserted. The mounting hole 20h does not have screw threads, for example. The mounting hole 20h is, for example, a through hole that penetrates the connecting component 20 in the Z direction. The mounting hole 20h may have screw threads or may be a bottomed hole.

[0023] In this embodiment, the connecting component 20 is positioned between the cable routing member 50 and the bus bar 9 for external connection, electrically connecting the cable routing member 50 and the bus bar 9. The bus bar 9 is a bus bar for electrically connecting the electrical connection unit 1 and external equipment. In this disclosure, "external equipment" refers to electrical equipment located outside the electrical connection unit 1. External equipment includes, but is not limited to, a battery unit mounted on a vehicle or an inverter for driving the vehicle's motor.

[0024] In this disclosure, "connecting component" is not limited to the examples above. A connecting component (e.g., connecting component 20) may be a member that is placed between the terminal 13 of another electronic component 10 and the cable 50, and electrically connects the other electronic component 10 and the cable 50. Alternatively, a connecting component (e.g., connecting component 20) may be a member that is placed between two cable 50, and electrically connects the two cable 50. Furthermore, a connecting component (e.g., connecting component 20) may be a member that is placed between a normal busbar in the electrical connection unit 1 (e.g., busbar 8 described later, see Figure 9) and the cable 50, and electrically connects the normal busbar and the cable 50.

[0025] <4. Base components> Next, the base member 30 will be described. The base member 30 is a support member that supports one or more of the electronic components 10, connecting components 20, and wiring members 50. The base member 30 is made of, for example, synthetic resin and has insulating properties. In this embodiment, fastening members 41 and 44, which will be described later, are fixed to the base member 30.

[0026] <5. Fixed part> The fixing part 40 is a fixing part for fixing the cable material 50 to the object to be connected. The plurality of fixing parts 40 include, for example, a first fixing part 40A and a second fixing part 40B.

[0027] <5.1 1st fixed part> The first fixing part 40A is a fixing part that fixes the first connection part 61 of the cable member 50 (described later) to the first connection target. The first fixing part 40A includes, for example, a fastening member 41 (e.g., a bolt or screw), an engaging member 42 (e.g., a nut), and a washer 43.

[0028] The fastening member 41 is, for example, a bolt having a shaft portion 41a and a head portion 41b. The circumferential surface of the shaft portion 41a has screw threads. The shaft portion 41a is passed through a washer 43 and engages with an engaging member 42. The head portion 41b has a larger diameter than the shaft portion 41a. In this embodiment, the fastening member 41 is fixed to the base member 30 in a position where the shaft portion 41a protrudes from the base member 30 in the +Z direction. The fastening member 41 is an example of a "first fastening member". The first fixing portion 40A is not limited to the above example. The first fixing portion 40A can be any structure that fixes the first connection portion 61 of the cable material 50 to the first connection target, and is not limited to a specific structure.

[0029] <5.2 Second fixed part> The second fixing portion 40B is a fixing portion that fixes the second connection portion 62 of the cable member 50 to the second connection target. The second fixing portion 40B includes, for example, a fastening member 44 (e.g., a bolt or screw), an engaging member 45 (e.g., a nut), and a washer 46.

[0030] The fastening member 44 is, for example, a bolt having a shaft portion 44a and a head portion 44b. The circumferential surface of the shaft portion 44a has screw threads. The shaft portion 44a is passed through a washer 46 and engages with an engaging member 45. The head portion 44b has a larger diameter than the shaft portion 44a. In this embodiment, the fastening member 44 is fixed to the base member 30 in a position where the shaft portion 44a protrudes from the base member 30 in the +Z direction. The fastening member 44 is an example of a "second fastening member". The second fixing portion 40B is not limited to the above example. The second fixing portion 40B can be any structure that fixes the second connection portion 62 of the cable material 50 to the second connection target, and is not limited to a specific structure.

[0031] <6. Routing material> Next, we will explain the cable routing member 50. Figure 2 is a perspective view showing the wiring harness 50. The wiring harness 50 includes, for example, a bus bar 60 (a bus bar for conducting electricity) and a heat storage member 70 (for example, a bus bar 70A for heat storage).

[0032] <6.1 Busbars for power supply> The busbar 60 is a wiring member that electrically connects multiple connection targets. The busbar 60 is made of metal (for example, copper, copper alloy, aluminum, or aluminum alloy) and is conductive. The busbar 60 electrically connects a first connection target and a second connection target. For example, the busbar 60 electrically connects an electronic component 10 and a connecting component 20. The electronic component 10 is an example of a "first connection target". The connecting component 20 is an example of a "second connection target".

[0033] However, the first and second connection targets are not limited to the examples above. For example, the first connection target is any one of the following: an electronic component, a connecting component, another busbar in the electrical connection unit 1 (e.g., a normal busbar 8 or a busbar 60 included in another wiring material 50), or a busbar 9 for external connection. For example, the second connection target is any one of the following: an electronic component, a connecting component, another busbar in the electrical connection unit 1 (e.g., a normal busbar 8 or a busbar 60 included in another wiring material 50), or a busbar 9 for external connection. For example, busbar 60 may electrically connect electronic component 10 (first connection target) to another electronic component 10 (second connection target). Busbar 60 may electrically connect connecting component 20 (first connection target) to another connecting component 20 (second connection target).

[0034] In the following, as an example of a busbar 60, a busbar 60 that electrically connects an electronic component 10 (first connection target) and a connecting component 20 (second connection target) will be described. However, in the following description, the terms "electronic component 10" and "connecting component 20" may be appropriately replaced with other components based on the above-mentioned purpose.

[0035] As shown in Figure 2, the busbar 60 has, for example, a first connecting portion 61, a second connecting portion 62, and an extension portion 63.

[0036] (First connection section) The first connection portion 61 is the portion that connects to the first connection target (e.g., electronic component 10). The first connection portion 61 is located in the middle of the bus bar 60 or at the first end of the bus bar 60. When viewed from the Z direction, the first connection portion 61 is the portion that faces the first fixing portion 40A (e.g., the portion that faces the fastening member 41, the engaging member 42, or the washer 43). In this embodiment, the first connection portion 61 is defined as a rectangular region that circumscribes the first fixing portion 40A when viewed from the Z direction (see Figure 2).

[0037] The first connecting portion 61 has a first mounting hole 61h into which the fastening member 41 is inserted. The mounting hole 61h does not have, for example, a screw thread. The mounting hole 61h is, for example, a through hole that penetrates the first connecting portion 61 in the Z direction. The mounting hole 61h is an example of the "first mounting hole".

[0038] The mounting hole 61h of the first connecting portion 61 is aligned with the mounting hole 13h of the electronic component 10 in the Z direction. A fastening member 41 is inserted along the Z direction into the mounting hole 61h of the first connecting portion 61 and the mounting hole 13h of the electronic component 10. An engaging member 42 is engaged with the tip of the fastening member 41 that has passed through the mounting hole 61h of the first connecting portion 61 and the mounting hole 13h of the electronic component 10. This configuration fixes the terminal 13 of the electronic component 10 to the first connecting portion 61. Alternatively, either the mounting hole 61h of the first connecting portion 61 or the mounting hole 13h of the electronic component 10 may have a screw thread for the fastening member 41 to engage. In this case, the engaging member 42 may be omitted.

[0039] (Second connection point) The second connecting portion 62 is the portion that connects to the second connection target (for example, the connecting component 20). The second connecting portion 62 is located in the middle of the busbar 60 or at the second end of the busbar 60. When viewed from the Z direction, the second connecting portion 62 is the portion that faces the second fixing portion 40B (for example, the portion that faces the fastening member 44, the engaging member 45, or the washer 46). In this embodiment, the second connecting portion 62 is defined as a rectangular region that circumscribes the second fixing portion 40B when viewed from the Z direction (see Figure 2).

[0040] The second connecting portion 62 has a second mounting hole 62h into which the fastening member 44 is inserted. The mounting hole 62h does not have, for example, a screw thread. The mounting hole 62h is, for example, a through hole that penetrates the second connecting portion 62 in the Z direction. The mounting hole 62h is an example of a "second mounting hole".

[0041] The mounting hole 62h of the second connecting portion 62 is aligned with the mounting hole 20h of the connecting component 20 in the Z direction. A fastening member 44 is inserted along the Z direction through the mounting hole 62h of the second connecting portion 62 and the mounting hole 20h of the connecting component 20. An engaging member 45 is engaged with the tip of the fastening member 44 that has passed through the mounting hole 62h of the second connecting portion 62 and the mounting hole 20h of the connecting component 20. This configuration fixes the connecting component 20 and the second connecting portion 62. Alternatively, either the mounting hole 62h of the second connecting portion 62 or the mounting hole 20h of the connecting component 20 may have a screw thread for the fastening member 44 to engage. In this case, the engaging member 45 may be omitted.

[0042] (extension part) The extension portion 63 is provided between the connecting portion 61 and the connecting portion 62. The extension portion 63 extends across the connecting portion 61 and the connecting portion 62. The extension portion 63 connects the connecting portion 61 and the connecting portion 62. In the example shown in Figure 2, the extension portion 63 extends linearly in the X direction. However, the extension portion 63 may include a portion that bends and extends in the Y direction or the Z direction. In this case, the "extension direction of the extension portion" is the direction along the extension portion 63 while bending. The extension portion 63 is formed, for example, in the shape of a plate. The Z direction is the thickness direction (plate thickness direction) of the extension portion 63. In this embodiment, the entire busbar 60, including the first connecting portion 61, the second connecting portion 62, and the extension portion 63, is formed in the shape of a plate.

[0043] <6.2 Heat Storage Components (Busbars for Heat Storage)> Next, the heat storage member 70 will be described. The heat storage member 70 is a metal member attached to the busbar 60. The heat storage member 70 is a member that stores (absorbs) at least a portion of the heat emitted by the first connection target or the second connection target, and at least a portion of the heat emitted by the busbar 60 itself. In addition to the above example, the heat storage member 70 may also be a member that reduces thermal interference from external equipment (external connection busbar 9) to the electronic component 10. The heat storage member 70 is made of copper, copper alloy, aluminum, or aluminum alloy, but is not limited to these examples.

[0044] In this embodiment, the heat storage member 70 is attached to the extended portion 63 of the busbar 60. For example, the heat storage member 70 is provided detached from the first connection portion 61 and the second connection portion 62 of the busbar 60. That is, when viewed from the Z direction, the heat storage member 70 is provided in a region that does not overlap with the first fixing portion 40A and the second fixing portion 40B.

[0045] In this embodiment, a heat storage bus bar 70A is provided as an example of a heat storage member 70. The heat storage bus bar 70A is a metal plate member arranged along the energizing bus bar 60. The heat storage bus bar 70A is arranged overlapping the energizing bus bar 60 from the Z direction.

[0046] In this embodiment, a heat storage member 70 that satisfies the following conditions is defined as a heat storage bus bar 70A. That is, the heat storage member 70 has a thickness T70 as the thickness in the direction (Z direction) in which it overlaps with the extended portion 63 of the bus bar 60. The heat storage member 70 has a length L70 as the length in the extension direction of the extended portion 63 of the bus bar 60 (for example, the X direction, hereinafter simply referred to as the "extension direction"). The heat storage member 70 also has a width W70 as the width in the direction perpendicular to the extension direction (for example, the Y direction, hereinafter simply referred to as the "width direction"). In this embodiment, a heat storage member 70 in which the length L70 and width W70 are greater than the thickness T70, and the length L70 is greater than the width W70, is defined as a heat storage bus bar 70A.

[0047] For example, the heat storage member 70 (heat storage bus bar 70A) is formed in a plate-like (flat) shape along the extended portion 63 of the bus bar 60. For example, the thickness T70 of the heat storage member 70 in the Z direction is smaller than the length L70 of the heat storage member 70 in the extension direction. In this embodiment, the thickness T70 of the heat storage member 70 in the Z direction is smaller than half the length L70 of the heat storage member 70 in the extension direction. Also, the width W70 of the heat storage member 70 in the Y direction is smaller than the length L70 of the heat storage member 70 in the extension direction. In this embodiment, the width W70 of the heat storage member 70 in the Y direction is smaller than half the length L70 of the heat storage member 70 in the extension direction.

[0048] The shape of the heat storage member 70 is not limited to the above example. For example, the width W70 of the heat storage member 70 in the Y direction may be greater than the length L70 of the heat storage member 70 in the extension direction. For example, the thickness T70 of the heat storage member 70 in the Z direction may be greater than at least one of the width W70 of the heat storage member 70 in the Y direction and the length L70 of the heat storage member 70 in the extension direction.

[0049] In this embodiment, the heat storage member 70 is provided over more than half the length of the extended portion 63 of the busbar 60 in the extending direction. For example, the length L70 of the heat storage member 70 in the extending direction is greater than half the length L63 of the extended portion 63 of the busbar 60 in the extending direction.

[0050] In this embodiment, the width W70 of the heat storage member 70 in the Y direction is greater than half the width W63 of the extended portion 63 of the busbar 60 in the Y direction. In this embodiment, the width W70 of the heat storage member 70 in the Y direction is the same as the width W63 of the extended portion 63 of the busbar 60 in the Y direction. Note that the width W70 of the heat storage member 70 in the Y direction may be greater than the same as the width W63 of the extended portion 63 of the busbar 60 in the Y direction.

[0051] In this embodiment, the thickness T70 of the heat storage member 70 in the Z direction is greater than the thickness T63 of the extended portion 63 of the busbar 60 in the Z direction. With this configuration, it is easier to increase the heat capacity of the heat storage member 70 compared to the case where the thickness T70 of the heat storage member 70 in the Z direction is smaller than the thickness T63 of the extended portion 63 of the busbar 60 in the Z direction.

[0052] The thickness T70 of the heat storage member 70 in the Z direction may be the same as or smaller than the thickness T63 of the extended portion 63 of the busbar 60 in the Z direction. If the thickness T70 of the heat storage member 70 in the Z direction is smaller than the thickness T63 of the extended portion 63 of the busbar 60 in the Z direction, it is easier to miniaturize (reduce the height of) the electrical connection unit 1.

[0053] <6.3 Fixed part> Next, the fixing portion 80 will be described. The fixing portion 80 is a fixing portion that fixes the bus bar 60 and the heat storage member 70. When viewed from the Z direction, the fixing portion 80 is located in the region that overlaps with the extended portion 63 of the bus bar 60. In other words, when viewed from the Z direction, the fixing portion 80 is located in the region that is outside the first fixing portion 40A and the second fixing portion 40B.

[0054] Figure 3 is a diagram illustrating the fixing portion 80. In this embodiment, the fixing portion 80 is a fixing portion that fixes the bus bar 60 and the heat storage member 70 by crimping. The fixing portion 80 is formed, for example, by a part of the bus bar 60 and a part of the heat storage member 70. The fixing portion 80 includes, for example, a fixing hole 60h formed in the extended portion 63 of the bus bar 60 and an insertion portion 92 provided in the heat storage member 70.

[0055] In this embodiment, the extended portion 63 of the busbar 60 has a first surface 60s1, a second surface 60s2, and a fixing hole 60h. The first surface 60s1 is the surface facing the +Z direction. The first surface 60s1 faces the heat storage member 70. The second surface 60s2 is the surface facing the -Z direction. The second surface 60s2 is located on the opposite side from the first surface 60s1.

[0056] The fixing hole 60h is, for example, a through hole that penetrates the busbar 60 in the Z direction. The fixing hole 60h spans the first surface 60s1 and the second surface 60s2. However, the fixing hole 60h is not limited to the above example. The fixing hole 60h may also be a bottomed recess that is recessed in the -Z direction from the first surface 60s1. Also, the fixing hole 60h is, for example, circular, but may also be polygonal or elliptical.

[0057] On the other hand, the heat storage member 70 has a main body portion 91 and an insertion portion 92. The main body portion 91 is a plate portion that follows the first surface 60s1 of the bus bar 60. The main body portion 91 is arranged overlapping the first surface 60s1 of the bus bar 60 from the +Z direction side.

[0058] The insertion portion 92 protrudes from the main body portion 91 in the -Z direction and is inserted into the fixing hole 60h of the bus bar 60. The insertion portion 92 is in contact with the inner circumferential surface of the fixing hole 60h of the bus bar 60 and is fitted into the fixing hole 60h of the bus bar 60. In this embodiment, the contact area between the bus bar 60 and the heat storage member 70 is increased by the insertion portion 92 being in contact with the inner circumferential surface of the fixing hole 60h of the bus bar 60 (see arrow AR in Figure 3). For example, the insertion portion 92 protrudes from inside the fixing hole 60h beyond the second surface 60s2 of the bus bar 60 in the -Z direction.

[0059] In this embodiment, the insertion portion 92 has a bulge portion 92a located on the -Z side of the minimum inner diameter portion 60ha of the fixing hole 60h. The bulge portion 92a bulges out in the X or Y direction from the minimum inner diameter portion 60ha of the fixing hole 60h. In the Z direction, the bulge portion 92a is located on the opposite side of the main body portion 91 from a portion of the bus bar 60. In the Z direction, a portion of the bus bar 60 is sandwiched between the main body portion 91 and the bulge portion 92a of the heat storage member 70.

[0060] In this embodiment, the insertion portion 92 is part of the heat storage member 70. The insertion portion 92 is formed, for example, by deforming a part of the heat storage member 70, which is a plate member. The insertion portion 92 is formed, for example, by pressing a part of the heat storage member 70 toward the fixing hole 60h of the bus bar 60 and deforming it to conform to the inner circumferential surface of the fixing hole 60h. In this embodiment, the fixing portion 80 is formed by crimping and fixing when the insertion portion 92 is fitted into the fixing hole 60h of the bus bar 60.

[0061] <6. Manufacturing method of the cable material 50> Next, a method for manufacturing the cable material 50 will be described. Figure 4 is a diagram illustrating the manufacturing method of the cable guide 50. In this embodiment, the busbar 60 is an example of a "first component". The heat storage component 70 is an example of a "second component".

[0062] First, fixing holes 60h are formed in the busbar 60 (step S1). The fixing holes 60 are formed, for example, by press working. In this disclosure, "forming fixing holes in the busbar" may include cases where the fixing holes are formed simultaneously with the formation of the busbar.

[0063] Next, the bus bar 60 and the heat storage member 70 (heat storage bus bar 70A) are placed on top of each other (step S2). Then, a portion of the heat storage member 70 is deformed by pressurization and inserted into the fixing hole 60h of the bus bar 60, thereby fixing the bus bar 60 and the heat storage member 70 together by crimping (step S3). This process completes the cable rigging member 50.

[0064] Figure 5 is a cross-sectional view illustrating the manufacturing method of the cable material 50. Figure 5 shows the process of step S3 described above. In this embodiment, a die 101 and a punch 102 are used in the process of step S3.

[0065] The die 101 is positioned on the opposite side (-Z direction side) from the heat storage member 70 relative to the bus bar 60. The die 101 has a recess 101a in the portion corresponding to the fixing hole 60h of the bus bar 60. The dimensions of the recess 101a in the X and Y directions are larger than the fixing hole 60h of the bus bar 60. The recess 101a forms a space S between the bus bar 60 and the die 101, from which the heat storage member 70 can deform.

[0066] The punch 102 is positioned on the opposite side of the die 101 from the bus bar 60 and the heat storage member 70. The punch 102 is positioned corresponding to the fixing hole 60h of the bus bar 60. The punch 102 has an outer shape (e.g., diameter) smaller than the fixing hole 60h of the bus bar 60. As the punch 102 moves toward the die 101, a portion of the heat storage member 70 is deformed by pressure and inserted into the fixing hole 60h of the bus bar 60, forming an insertion portion 92. In this process, a portion of the heat storage member 70 that has passed through the smallest inner diameter portion 60ha of the fixing hole 60h bulges in the X or Y direction, forming a bulge portion 92a. In this process, a fixing portion 80 is formed, and the bus bar 60 and the heat storage member 70 are fixed together by crimping.

[0067] <7. Examples> Next, an example relating to the material combination of the busbar 60 and the heat storage member 70 will be described.

[0068] <7.1 First Example> In the first embodiment, the busbar 60 is made of aluminum or an aluminum alloy. The heat storage member 70 is made of copper or a copper alloy. Here, the specific heat of copper is lower than that of aluminum. With the above configuration, since the material of the busbar 60 is aluminum or an aluminum alloy, while the material of the heat storage member 70 is copper or a copper alloy, it is possible to reduce the volume of the cable 50 and make it smaller (e.g., lower profile) while ensuring the heat storage capacity of the cable 50. With this configuration, it is possible to improve the thermal characteristics of the electrical connection unit 1 while making the electrical connection unit 1 smaller (e.g., lower profile).

[0069] <7.2 Second Example> In the second embodiment, the busbar 60 is made of aluminum or an aluminum alloy. The heat storage member 70 is made of aluminum or an aluminum alloy. Here, the specific gravity of aluminum is lower than that of copper. With this configuration, since the material of the busbar 60 is aluminum or an aluminum alloy, while the material of the heat storage member 70 is aluminum or an aluminum alloy, it is possible to reduce the weight of the cable material 50 while ensuring the heat storage capacity of the cable material 50. With this configuration, it is possible to improve the thermal properties of the electrical connection unit 1 while reducing the weight of the electrical connection unit 1.

[0070] <8. Advantages> As a first comparative example, consider a structure in which the heat storage member 70 does not exist. In such a structure, if sufficient heat capacity is not secured within the electrical connection unit, a large temperature rise may occur in a part of the electrical connection unit, and / or thermal interference with the first or second connection target may increase. For example, when a transient large current flows, a large temperature rise may occur in a part of the electrical connection unit, and / or thermal interference with the first or second connection target may increase. As a result, it may become difficult to improve the thermal characteristics of the electrical connection unit.

[0071] On the other hand, in this embodiment, the cable routing member 50 includes a bus bar 60 and a heat storage member 70. The bus bar 60 has a first connecting portion 61 connected to a first connection target, a second connecting portion 62 connected to a second connection target, and an extension portion 63 extending between the first connecting portion 61 and the second connecting portion 62. The heat storage member 70 is attached to the extension portion 63 of the bus bar 60.

[0072] With this configuration, the heat storage member 70 increases the heat capacity of the busbar 60. By increasing the heat capacity of the busbar 60 in this way, a portion of the heat transmitted through the busbar 60 can be stored (absorbed) by the heat storage member 70, at least temporarily. This structure makes it possible to suppress a large temperature rise in a part of the electrical connection unit 1 and / or large thermal interference with the first or second connection target. This action makes it possible to improve the thermal characteristics of the electrical connection unit 1 (e.g., heat dissipation or heat storage).

[0073] As a second comparative example, consider a structure in which the busbar 60 and the heat storage member 70 are fixed together by a fastening member such as a bolt. In this comparative example, the contact area between the busbar 60 and the heat storage member 70 at the fixing point is small, and there is room for improvement in terms of thermal characteristics.

[0074] Therefore, in this embodiment, the cable routing member 50 has a bus bar 60 and a heat storage member 70 attached to the bus bar 60 by a crimping fixing part 80. With this configuration, it is much easier to secure a larger contact area between the bus bar 60 and the heat storage member 70 compared to the structure of the comparative example above. With this structure, the bus bar 60 and the heat storage member 70 can be thermally firmly connected. This action makes it possible to improve the thermal characteristics of the electrical connection unit 1.

[0075] In this embodiment, the heat storage member 70 is a plate member that runs along the bus bar 60. With this configuration, the heat storage member 70 is easy to deform, and the bus bar 60 and the heat storage member 70 are easy to fix together by crimping. With this configuration, the manufacturability of the cable guide material 50 can be improved.

[0076] In this embodiment, the fixing portion 80 has a fixing hole 60h formed in the busbar 60 and an insertion portion 92 which is a part of the heat storage member 70 and is inserted into the fixing hole 60h of the busbar 60. With this configuration, the busbar 60 and the heat storage member 70 can be fixed by crimping while ensuring a large volume (heat capacity) of the heat storage member 70. This makes it possible to further improve the thermal characteristics of the electrical connection unit 1 by further improving the heat dissipation performance of the heat storage member 70.

[0077] In this embodiment, the busbar 60 has a first surface 60s1 facing the heat storage member 70 and a second surface 60s2 located on the opposite side of the first surface 60s1. The fixing hole 60h of the busbar 60 is a through hole extending from the first surface 60s1 to the second surface 60s2. The insertion portion 92 of the heat storage member 70 protrudes from inside the fixing hole 60h of the busbar 60 beyond the second surface 60s2 of the busbar 60. With this configuration, because the fixing hole 60h of the busbar 60 is a through hole, the insertion portion 92 of the heat storage member 70 is easily deformed through the fixing hole 60h during crimping. Due to this action, for example, compared to the case where the fixing hole 60h is a bottomed hole, the heat storage member 70 can be deformed with a relatively small force and the busbar 60 and the heat storage member 70 can be fixed by crimping. This structure makes it possible to further improve the manufacturability of the cable 50.

[0078] (Second Embodiment) Next, a second embodiment will be described. The second embodiment differs from the first embodiment in that a fixing hole 70h is formed in the heat storage member 70 and an insertion portion 92 is provided in the bus bar 60. Other than what is described below, the configuration is the same as that of the first embodiment.

[0079] Figure 6 is a diagram illustrating the fixing part 80 of the second embodiment. In this embodiment, the fixing part 80 is a fixing part that fixes the bus bar 60 and the heat storage member 70 by crimping. The fixing part 80 includes, for example, a fixing hole 70h formed in the heat storage member 70 (heat storage bus bar 70A) and an insertion part 92 provided in the extended part 63 of the bus bar 60.

[0080] In this embodiment, the heat storage member 70 (heat storage bus bar 70A) has a first surface 70s1, a second surface 70s2, and a fixing hole 70h. The first surface 70s1 is the surface facing the -Z direction. The first surface 70s1 faces the extended portion 63 of the bus bar 60. The second surface 70s2 is the surface facing the +Z direction. The second surface 70s2 is located on the opposite side from the first surface 70s1.

[0081] The fixing hole 70h is, for example, a through hole that penetrates the heat storage member 70 (heat storage bus bar 70A) in the Z direction. The fixing hole 70h extends from the first surface 70s1 to the second surface 70s2. However, the fixing hole 70h is not limited to the above example. The fixing hole 70h may also be a bottomed recess that is recessed in the +Z direction from the first surface 70s1. Also, the fixing hole 70h is, for example, circular, but may also be polygonal or elliptical.

[0082] On the other hand, the extension portion 63 of the busbar 60 has a main body portion 91 and an insertion portion 92. The main body portion 91 is a plate portion that follows the first surface 70s1 of the heat storage member 70. The main body portion 91 is arranged overlapping the first surface 70s1 of the heat storage member 70 from the -Z direction side.

[0083] The insertion portion 92 protrudes from the main body portion 91 in the +Z direction and is inserted into the fixing hole 70h of the heat storage member 70. The insertion portion 92 is in contact with the inner circumferential surface of the fixing hole 70h of the heat storage member 70 and is fitted into the fixing hole 70h of the heat storage member 70. In this embodiment, the contact area between the busbar 60 and the heat storage member 70 is increased by the insertion portion 92 being in contact with the inner circumferential surface of the fixing hole 70h of the heat storage member 70. For example, the insertion portion 92 protrudes from inside the fixing hole 70h beyond the second surface 70s2 of the heat storage member 70 in the +Z direction.

[0084] In this embodiment, the insertion portion 92 has a bulge portion 92a located on the +Z side of the minimum inner diameter portion 70ha of the fixing hole 70h. The bulge portion 92a bulges out in the X or Y direction from the minimum inner diameter portion 70ha of the fixing hole 70h. In the Z direction, the bulge portion 92a is located on the opposite side of the main body portion 91 from a portion of the heat storage member 70. In the Z direction, a portion of the heat storage member 70 is sandwiched between the main body portion 91 and the bulge portion 92a of the busbar 60.

[0085] In this embodiment, the insertion portion 92 is a part of the extended portion 63 of the busbar 60. The insertion portion 92 is formed, for example, by deforming a part of the extended portion 63 of the busbar 60, which is a plate member. The insertion portion 92 is formed, for example, by pressing a part of the extended portion 63 of the busbar 60 toward the fixing hole 70h of the heat storage member 70 and deforming it to conform to the inner circumferential surface of the fixing hole 70h. In this embodiment, the fixing portion 80 is formed by crimping and fixing when the insertion portion 92 is fitted into the fixing hole 70h of the heat storage member 70.

[0086] Figure 7 is a cross-sectional view illustrating the manufacturing method of the cable guide 50 of this embodiment. The manufacturing method of the cable guide 50 of this embodiment is the same as that of the cable guide 50 of the first embodiment. The explanation of the manufacturing method of the cable guide 50 of this embodiment can be explained by replacing "bus bar 60" and "extension portion 63" with "heat storage member 70", "fixing hole 60h" with "fixing hole 70h", and "heat storage member 70" with "extension portion 63 of bus bar 60" in the explanation of the manufacturing method of the cable guide 50 of the first embodiment described above. In this embodiment, the heat storage member 70 is an example of a "first member". The bus bar 60 is an example of a "second member".

[0087] In the second embodiment, the fixing portion 80 has a fixing hole 70h formed in the heat storage member 70 and an insertion portion 92 which is a part of the extended portion 63 of the busbar 60 and is inserted into the fixing hole 70h of the heat storage member 70. With this configuration, the busbar 60 and the heat storage member 70 can be fixed by crimping while ensuring a large current-carrying area of ​​the extended portion 63 of the busbar 60. This improves the electrical characteristics of the electrical connection unit 1 by improving the electrical characteristics of the wiring material 50. In addition, by not providing a fixing hole 60h in the busbar 60, the amount of heat generated by the busbar 60 itself can be reduced compared to, for example, the case in which a fixing hole 60h is provided in the busbar 60. This effect further improves the thermal characteristics of the electrical connection unit 1.

[0088] In this embodiment, the heat storage member 70 has a first surface 70s1 facing the extended portion 63 of the busbar 60 and a second surface 70s2 located on the opposite side of the first surface 70s1. The fixing hole 70h of the heat storage member 70 is a through hole extending from the first surface 70s1 to the second surface 70s2. The insertion portion 92 of the extended portion 63 of the busbar 60 protrudes from inside the fixing hole 70h of the heat storage member 70 beyond the second surface 70s2 of the heat storage member 70. With this configuration, because the fixing hole 70h of the heat storage member 70 is a through hole, the insertion portion 92 of the busbar 60 is easily deformed through the fixing hole 70h during crimping. Due to this action, for example, compared to the case where the fixing hole 70h is a bottomed hole, the busbar 60 can be deformed with a relatively small force and the busbar 60 and the heat storage member 70 can be fixed by crimping. This structure makes it possible to further improve the manufacturability of the cable 50.

[0089] <Variation> Several modifications of the first or second embodiment are described below. Note that, apart from the configurations described below, the configurations of each modification are the same as those of the first or second embodiment. In each modification described below, the fixing part 80 may be the same as the fixing part 80 in the first embodiment, or the same as the fixing part 80 in the second embodiment.

[0090] <First variation> Figure 8 is a perspective view showing the wiring member 50 of the first modified example. In the first modified example, the length L70 of the heat storage member 70 in the extension direction is less than half the length L63 of the extension portion 63 of the bus bar 60 in the extension direction. The heat storage member 70 is provided corresponding to only a part of the extension portion 63 of the bus bar 60. Even with this configuration, the thermal characteristics of the electrical connection unit 1 can be improved.

[0091] <Second variation> Figure 9 is a perspective view showing the electrical connection unit 1 of a second modified example. In this embodiment, the busbar 60 electrically connects the electronic component 10 to another busbar 9 included in the electrical connection unit 1. The electronic component 10 is an example of a "first connection target". The busbar 9 is an example of a "second connection target".

[0092] In this modified example, the extended portion 63 includes a first extended portion 63a (first part) and a second extended portion 63b (second part).

[0093] The first extension portion 63a is adjacent to the first connecting portion 61 and extends from the first connecting portion 61. In this modified example, the first connecting portion 61 is a plate portion that runs along the Z and Y directions. The first extension portion 63a extends, for example, from the first connecting portion 61 in the -Z direction. The first extension portion 63a is, for example, a plate portion that runs along the Z and Y directions.

[0094] The second extension 63b is located on the opposite side of the first connection 61 from the first extension 63a. The second extension 63b is located between the first extension 63a and the second connection 62. The second extension 63b extends bent from the first connection 61. The second extension 63b extends in the +X direction from, for example, the -Z direction end of the first extension 63a. The second extension 63b is, for example, a plate portion along the X and Y directions.

[0095] Figure 10 is a perspective view illustrating the heat storage member 70 of the second modified example. In this modified example, the heat storage member 70 (heat storage bus bar 70A) is attached to the first extension portion 63a. The heat storage member 70 (heat storage bus bar 70A) is formed in a plate-like (flat) shape along the first extension portion 63a of the bus bar 60. The heat storage member 70 is provided over more than half the length of the first extension portion 63a of the bus bar 60 in the extension direction. That is, the length L70 of the heat storage member 70 in the extension direction is greater than half the length L63a of the first extension portion 63a of the bus bar 60 in the extension direction.

[0096] In this modified example, the heat storage member 70 is not attached to the second extension portion 63b. In other words, the heat storage member 70 is positioned closer to the electronic component 10 (e.g., the heat-generating object) than the boundary between the first extension portion 63a and the second extension portion 63b.

[0097] With the configuration of the second modified example described above, the thermal characteristics of the electrical connection unit 1 can be improved, similar to the first or second embodiment.

[0098] Several embodiments and modifications have been described above. However, the embodiments and modifications are not limited to the examples described above. For example, the modifications described above may be implemented in combination with each other. [Explanation of Symbols]

[0099] 1…Electrical connection unit 10…Electronic components 20…Connecting parts 40…Fixed part 40A…1st fixed part 40B…Second fixed part 41…Fastening member (first fastening member) 44…Fastening member (second fastening member) 50...Routing material 60... Busbar (busbar for power supply) 60h…Fixing hole 61...First connection section 61h…Mounting holes 62...Second connection section 62h…Mounting holes 63…Extension part 63a...First extension part (first part) 63b...Second extension part (second part) 70…Heat storage components 70A... Busbar for heat storage 70h…Fixing hole 91...Main body 92... Insertion part

Claims

1. Bus bar and, A heat storage member attached to the busbar by a crimped fixing portion, A cable routing material equipped with the following features.

2. The heat storage member is a plate member along the busbar. The cable routing material according to claim 1.

3. The aforementioned fixing part is The fixing holes formed in the busbar, A part of the heat storage member, which is an insertion portion inserted into the fixing hole, including, The cable routing material according to claim 2.

4. The busbar has a first surface facing the heat storage member and a second surface located on the opposite side of the first surface, and the fixing hole is a through hole extending from the first surface to the second surface. The insertion portion protrudes from the inside of the fixing hole beyond the second surface. The cable routing material according to claim 3.

5. The aforementioned fixing part is The fixing holes formed in the heat storage member, A part of the busbar, an insertion portion inserted into the fixing hole, including, The cable routing material according to claim 2.

6. The heat storage member has a first surface facing the busbar and a second surface located on the opposite side of the first surface, and the fixing hole is a through hole extending from the first surface to the second surface. The insertion portion protrudes from the inside of the fixing hole beyond the second surface. The cable routing material according to claim 5.

7. A cable routing material according to claim 1 or claim 2, The connection target connected to the aforementioned cable material, An electrical connection unit equipped with [a specific feature].

8. A fixing hole is formed in the first member, which is one of the busbar and the heat storage member. The second member, which is the other of the busbar and the heat storage member, is placed on top of the first member. The busbar and the heat storage member are fixed together by crimping by deforming a part of the second member by pressurizing and inserting it into the fixing hole. A method for manufacturing a cable material, including the following.

Images