Electrical connection unit and assembly

Abstract

One embodiment provides an electrical connection unit and assembly that can improve ease of assembly. [Solution] An electrical connection unit according to one embodiment comprises a plurality of first modules, each having an electronic component and a first rigid member on which the electronic component is mounted; a second rigid member on which the plurality of first modules are mounted; a support portion formed separately from the plurality of first modules and mounted on the second rigid member; and a connector supported by the support portion and electrically connectable.

Description

Technical Field

[0001] Embodiments of the present invention relate to an electrical connection unit and an assembly.

Background Art

[0002] In an electrical connection unit, it is known that electronic components such as relays and resistors are mounted on the mounting surface of a housing.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, an assembly including an electrical connection unit may not have a structure for stably supporting, for example, a connector for wiring materials. In such a case, the work of attaching the wiring materials becomes complicated.

[0005] One embodiment provides an electrical connection unit and an assembly that can improve the assemblability.

Means for Solving the Problems

[0006] An electrical connection unit according to one embodiment includes a plurality of first modules each including an electronic component and a first rigid member on which the electronic component is mounted, a second rigid member on which the plurality of first modules are mounted, a support portion formed separately from the plurality of first modules and mounted on the second rigid member, and a connector supported by the support portion and electrically connectable.

[0007] An assembly according to one embodiment includes the above electrical connection unit and a wiring material connected to the connector.

Effects of the Invention

[0008] According to one embodiment, assembly can be improved. [Brief explanation of the drawing]

[0009] [Figure 1] A perspective view showing the electrical connection unit and assembly of the embodiment. [Figure 2] A plan view showing the electrical connection unit and assembly of the embodiment. [Figure 3] A perspective view showing a relay module of an embodiment. [Figure 4] A perspective view showing a fuse module of an embodiment. [Figure 5] A perspective view showing the terminal module of the embodiment. [Figure 6] A perspective view showing the support and connector of the embodiment. [Figure 7] A perspective view illustrating the cover and cable routing of the embodiment. [Figure 8] A plan view illustrating the cover of the embodiment. [Figure 9] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 10] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 11] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 12] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 13] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 14] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 15] A perspective view illustrating the manufacturing method of the electrical connection unit and assembly according to the embodiment. [Figure 16] A perspective view showing the base plate of the first modified example. [Modes for carrying out the invention]

[0010] 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. Note that the components described below do not limit the scope of the embodiments.

[0011] 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 connected with another element in between, not just directly connected. “Accommodate” may include cases where only a part of a part is accommodated (with the remaining part protruding), not just the entire part. “Cover” may include cases where only a part of an object is covered, not just the entire object. “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 directly facing each other. “Parallel,” “orthogonal,” or “same” may include cases where they are “approximately parallel,” “approximately orthogonal,” or “approximately the same,” respectively.

[0012] In the present disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows. The X direction is a direction in a plane along a base plate 2 to be described later. The +X direction is one of the directions in the X direction. The -X direction is a direction opposite to the +X direction. Hereinafter, when the +X direction and the -X direction are not distinguished, they are simply referred to as the "X direction". The Y direction is a direction (e.g., orthogonal) intersecting the X direction in a plane along the base plate 2 to be described later. The +Y direction is one of the directions in the Y direction. The -Y direction is a direction opposite to the +Y direction. Hereinafter, when the +Y direction and the -Y direction are not distinguished, they are simply referred to as the "Y direction". The +Z direction and the -Z direction are directions (e.g., orthogonal) intersecting the X direction and the Y direction. The +Z direction is a direction from the base plate 2 to be described later toward each first module 3 to be described later (see FIG. 1). The -Z direction is a direction opposite to the +Z direction. Hereinafter, when the +Z direction and the -Z direction are not distinguished, they are simply referred to as the "Z direction". The X direction is an example of the "first direction". The Y direction is an example of the "second direction". The Z direction is an example of the "third direction".

[0013] Hereinafter, when the X direction and the Y direction are not distinguished, they may be referred to as the "horizontal direction". Hereinafter, the Z direction may be referred to as the "vertical direction". Also hereinafter, the +Z direction side may be referred to as "up" and the -Z direction side may be referred to as "down". However, these expressions are for convenience of explanation and do not limit the gravitational direction (installation posture of the electrical connection unit 1) of the electrical connection unit 1.

[0014] (First Embodiment) <1. Configuration of Electrical Connection Unit and Assembly> The electrical connection unit 1 is an in-vehicle device installed in vehicles such as EVs (Electric Vehicles), HEVs (Hybrid Electric Vehicles), or PHEVs (Plug-in Hybrid Electric Vehicles). The electrical connection unit 1 is connected to multiple external devices located outside the vehicle. The electrical connection unit 1 mediates the connections between the multiple external devices. For example, the external devices may include a battery pack, a load, a charger, etc. The battery pack is installed in the vehicle. The load is a device including an inverter for driving the vehicle's motor, which is powered by the electricity stored in the battery pack. The charger is a device for supplying power to charge the battery pack. The electrical connection unit 1 may be referred to as, for example, an "electrical connection box" or "junction box." However, the electrical connection unit 1 is not limited to a box-shaped device.

[0015] The assembly 100 comprises an electrical connection unit 1 and a wiring member 7 (details of which will be described later). The assembly 100 is mounted, for example, on a vehicle. Figures 1 and 2 show the assembly 100 with the wiring member 7 and the cover 6 (Figure 7), which will be described later, visible through it. Specifically, Figures 1 and 2 show the electrical connection unit 1 with the cover 6 visible through it.

[0016] As shown in Figures 1 and 2, the electrical connection unit 1 comprises a base plate 2, a plurality of first modules 3, a plurality of terminal modules 4, a plurality of bus bars 5, a plurality of support parts 8, and a plurality of connectors 9. The base plate 2 is an example of a second rigid member. Each bus bar 5 is an example of a wiring member. Each terminal module 4 is an example of a second module. The electrical connection unit 1 may further comprise a cover 6. In the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, the plurality of bus bars 5, the plurality of support parts 8, and the plurality of connectors 9 are covered by the base plate 2 from the -Z direction and covered by the cover 6 from the +Z direction. That is, in the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, the plurality of bus bars 5, the plurality of support parts 8, and the plurality of connectors 9 are housed in a housing which is a combination structure of the cover 6 and the base plate 2.

[0017] <2. Configuration of the second rigid member> Let's explain base plate 2. The base plate 2 is a holding member that integrally holds a plurality of first modules 3, a plurality of terminal modules 4, and a plurality of support parts 8. The base plate 2 has a plate shape that extends in a planar manner in the X and Y directions. The base plate 2 is a metal product formed of, for example, metal, and has thermal conductivity. The base plate 2 is a plate-shaped member that is aligned horizontally. The base plate 2 may be made of a metal such as copper or aluminum.

[0018] The base plate 2 has a front and back surface, which is a pair of plate surfaces: a first surface 2a and a second surface 2b. The first surface 2a is a horizontal plane facing the +Z direction. The second surface 2b is a horizontal plane facing the -Z direction. The first surface 2a and the second surface 2b may be, for example, smooth planes.

[0019] <3. Configuration of Module 1> Multiple versions of Module 3 will be described. The multiple first modules 3 are units, each divided into functional units, with each module performing one of the smallest units of circuit function in the electrical connection unit 1 (such as interruption, switching, resistance, charging, sensing, conversion, etc.). The multiple first modules 3 are arranged along the first surface 2a of the base plate 2. Each first module 3 is placed on the base plate 2 with its bottom surface 3b facing the first surface 2a. Each first module 3 is provided on the first surface 2a side of the base plate 2. Each first module 3 may, for example, be mounted on the first surface 2a.

[0020] Among the multiple first modules 3, each of some first modules 3 may have a gap between it and other adjacent first modules 3 in the X direction, for example. Among the multiple first modules 3, each of some first modules 3 may have a gap between it and other adjacent first modules 3 in the Y direction, for example.

[0021] Each first module 3 comprises an electronic component 31 and a first rigid member 32. One electronic component 31 is mounted on each first rigid member 32. That is, each of the multiple electronic components 31 provided in the electrical connection unit 1 is individually mounted on the corresponding first rigid member 32. Each first module 3 may, for example, comprise only one electronic component 31 and one first rigid member 32 corresponding to (this one electronic component 31) from among the multiple electronic components 31 and multiple first rigid members 32 included in the electrical connection unit 1.

[0022] Each electronic component 31 is an electronic component mounted in accordance with the function required of the electrical connection unit 1. As shown in Figures 1 and 2, each electronic component 31 may be fixed to the corresponding first rigid member 32 by fastening to the corresponding first rigid member 32, for example. The electronic components 31 include fuses, relays (e.g., mechanical relays or semiconductor relays), resistors (e.g., pre-charge resistors), capacitors, various sensors (e.g., current sensors or voltage sensors), ferrite cores, etc. As shown in Figures 3 and 4, each electronic component 31 may have, for example, a pair of component terminals 39.

[0023] The first rigid member 32 is fixed to the base plate 2. The first rigid member 32 may be bonded to the base plate 2, for example. The first rigid member 32 may have, for example, a first bonding surface 32b. The first bonding surface 32b is a plane facing the -Z direction. The first bonding surface 32b corresponds to the bottom surface 3b of the first module 3. The first bonding surface 32b may be bonded to the first surface 2a, for example, by adhesive, thermocompression bonding, laser welding, etc., so that the first rigid member 32 is bonded to the base plate 2.

[0024] The first rigid member 32 comprises a pair of first flanges 33, a housing portion 34, and a plurality of first reinforcing ribs 37. The first rigid member 32 is an integrally molded product in which the pair of first flanges 33, the housing portion 34, and the plurality of first reinforcing ribs 37 are all integrated. The first rigid member 32 is a synthetic resin product formed from synthetic resin.

[0025] The housing section 34 comprises a peripheral wall 35 and a bottom 36. The peripheral wall 35 protrudes upright from the bottom 36 in the +Z direction. The peripheral wall 35 may have a plurality of notches 35n cut out in the -Z direction from the +Z side edge 35t in a portion of the periphery of the electronic component 31.

[0026] The housing section 34 has a housing space 34s that houses at least a portion of the electronic components 31. The housing space 34s is a space defined by the contour of the inner surface of the peripheral wall 35 and the surface of the bottom 36 facing the +Z direction. The housing space 34s may, for example, have a roughly rectangular parallelepiped contour.

[0027] The pair of first flanges 33 extend from the -Z direction end of the housing portion 34 to both ends in one horizontal direction. The -Z direction facing surface of the bottom 36 and the -Z direction facing surfaces of the pair of first flanges 33 may, for example, be flush with each other, thereby forming the first bonding surface 32b as a whole.

[0028] Multiple first reinforcing ribs 37 support the circumferential wall 35 from its outer circumference. Each first reinforcing rib 37 may be a triangular rib fitted into the corner (concave angle) between the circumferential wall 35 and each first flange 33.

[0029] The multiple first modules 3 may include, for example, relay modules 3R. In this case, as shown in Figure 3, the relay module 3R includes a relay 31R as an electronic component 31.

[0030] In the relay module 3R, at least one of the multiple notches 35n in the peripheral wall 35 is cut out such that a pair of component terminals 39 are exposed from between the peripheral wall 35 toward the outside of the first rigid member 32. That is, in the relay module 3R, at least one of the multiple notches 35n in the peripheral wall 35 may be cut out such that a busbar 5 connected to the component terminals 39 can pass through the notch 35n between the inside and outside of the first rigid member 32.

[0031] In each relay module 3R, for example, a pair of component terminals 39 of the electronic component 31 may face outward from the electrical connection unit 1 via the cover 6. In each relay module 3R, for example, the electronic component 31 may be arranged such that one or both of the pair of component terminals 39 of the electronic component 31 face and are exposed to the inner surface of the cover 6 in the horizontal direction.

[0032] The multiple first modules 3 may include, for example, a fuse module 3F. In this case, as shown in Figure 4, the fuse module 3F includes a fuse 31F as an electronic component 31.

[0033] In the fuse module 3F, at least one pair of notches 35n of the peripheral wall 35 is cut out so that a pair of component terminals 39 can protrude beyond the peripheral wall 35. The fuse module 3F may also include, for example, a pair of fixed terminals 38 that are fastened to the pair of component terminals 39. Each fixed terminal 38 is fastened to a corresponding component terminal 39.

[0034] <4. Configuration of Module 2> Multiple terminal modules 4 will be described below. The multiple terminal modules 4 are divided into multiple units, each of which is responsible for one of the smallest units of connection terminal function in the electrical connection unit 1. The multiple terminal modules 4 may include, for example, a terminal module 4 for connecting to external devices. As shown in Figure 5, each terminal module 4 is equipped with a connection terminal 41 and a terminal block 42.

[0035] Each terminal module 4 may, for example, comprise only one connection terminal 41 and one terminal block 42 corresponding to this one connection terminal 41, out of the multiple connection terminals 41 and multiple terminal blocks 42 included in the electrical connection unit 1.

[0036] The connection terminal 41 extends from the end face 42a on the +Z side of the terminal block 42, protruding in the +Z direction. The connection terminal 41 is electrically connected to at least one of the multiple first modules 3 via a bus bar 5, other terminal modules 4, etc.

[0037] The terminal block 42 comprises a main body 43, a pair of second flanges 44, and a plurality of second reinforcing ribs 45. The terminal block 42 is a single-piece molded product in which the main body 43, the pair of second flanges 44, and the plurality of second reinforcing ribs 45 are integrated. The terminal block 42 is a synthetic resin product formed from synthetic resin.

[0038] The terminal block 42 is fixed to the base plate 2. The terminal block 42 may be bonded to the base plate 2, for example. The terminal block 42 may have, for example, a second bonding surface 42b. The second bonding surface 42b is a plane facing the -Z direction. The second bonding surface 42b corresponds to the flush bottom surface of the terminal block 42 extending from the main body 43 to the pair of second flanges 44. The second bonding surface 42b may be bonded to the first surface 2a, for example, by adhesive, thermocompression, laser welding, etc., so that the connection terminals 41 are bonded to the base plate 2.

[0039] The main body portion 43 occupies most of the terminal block 42. The end face of the main body portion 43 on the +Z direction side may correspond to, for example, the end face 42a. The main body portion 43 supports the connection terminal 41.

[0040] The pair of second flanges 44 extend from the -Z-direction end of the main body 43 to both ends in one horizontal direction. The surface of the main body 43 facing the -Z direction and the surface of the pair of second flanges 44 facing the -Z direction may, for example, be a continuous plane that is flush with the surface, thereby forming a second bonding surface 42b as a whole.

[0041] Multiple second reinforcing ribs 45 support the main body 43 from its outer circumference. Each second reinforcing rib 45 may be a triangular rib that fits into the corner (concave angle) between the outer circumference 43a and each second flange 44 of the main body 43.

[0042] <5. Configuration of cable routing members> This section describes multiple busbars 5. Each busbar 5 is a wiring member (electrical connection member) for electrically connecting the first module 3 to the first module 3, the first module 3 to the terminal module 4, or the terminal module 4 to the terminal module 4. Each busbar 5 extends between the first module 3 to the first module 3, between the first module 3 to the terminal module 4, or between the terminal module 4 to the terminal module 4. Each busbar 5 is a metal product formed of metal and is conductive. Each busbar 5 may be made of a metal such as copper or aluminum.

[0043] At least a portion of each busbar 5 is plate-shaped. As shown in Figures 1 and 2, some of the busbars 5 may be, for example, curved plates throughout.

[0044] Some of the busbars 5 may be forming busbars, for example, that are curved in a horizontal plane and whose orientation changes continuously from vertical to horizontal (or from horizontal to vertical). In this case, the forming busbars 5 may be pre-formed into the shape to be routed before being combined with the first module 3 or terminal module 4.

[0045] Some of the multiple busbars 5 may branch off into multiple paths, for example, towards different routes along the way. Some of the multiple busbars 5 may be structures in which multiple forming busbars are connected in such a way that they branch off into multiple paths. In this case, the multiple forming busbars to be combined may be connected in advance before being combined with the first module 3 or terminal module 4.

[0046] Some of the busbars 5 may be flat plates with a rectangular surface oriented vertically. Some of the busbars 5 may be flat plates with an L-shaped surface oriented vertically.

[0047] Of the ends of each busbar 5, the end connected to the first module 3 may be fastened to, for example, a component terminal 39. Of the ends of each busbar 5, the end connected to the terminal module 4 may be fastened to, for example, a connection terminal 41.

[0048] <6. Support structure> The multiple support parts 8 will now be described. Each support portion 8 is capable of supporting a connector 9. The support portions 8 are formed separately from the first module 3. That is, the support portions 8 are formed as independent modules. In this embodiment, the support portions 8 are arranged to be in contact with the first rigid member 32 as part of their outer shape when viewed from the +Z direction. However, the support portions 8 and the first rigid member 32 are arranged so as not to overlap when viewed from the +Z direction. Multiple support members 8 are mounted on the base plate 2. Each support member 8 may, for example, be placed on the first surface 2a.

[0049] As shown in Figure 6, each support portion 8 has a base portion 81 and a support body 82. The support portion 8 is a one-piece molded product in which the entire structure, including the base portion 81 and the support body 82, is formed as a single unit. The support portion 8 is a synthetic resin product, for example, made of synthetic resin.

[0050] The base portion 81 is formed in a rectangular shape that extends in the X and Y directions. The base portion 81 is formed so that one side in the X and Y directions is longer than the other side. The base portion 81 has a connecting surface 81a facing the -Z direction. That is, the base portion 81 is formed in a rectangular shape so that one side in the X and Y directions is longer than the other.

[0051] The base portion 81 is positioned on the base plate 2 with its connecting surface 81a facing the first surface 2a. The connecting surface 81a may be bonded to the first surface 2a by means of adhesive, thermocompression, laser welding, etc., so that the base portion 81 is bonded to the base plate 2. Furthermore, the base portion 81 is connected to the support body 82 on a surface facing the +Z direction. In this embodiment, the base portion 81 is formed to extend further in the X and Y directions than the support body 82 when viewed from the +Z direction.

[0052] The support body 82 is formed to protrude from the base portion 81 in the +Z direction. The support body 82 is connected to the base portion 81 at an end face facing the -Z direction. The support body 82 has an extended portion 83 and a plurality of third reinforcing ribs 84.

[0053] The extended portion 83 constitutes the majority of the support body 82. The extended portion 83 is formed in a substantially rectangular parallelepiped shape. In this embodiment, the extended portion 83 has an upper surface 83a, a main surface 83b, and a side surface 83c.

[0054] The upper surface 83a is the surface facing the +Z direction. The upper surface 83a is the +Z end of the support portion 8. For example, when the support portion 8 is fixed to the base plate 2, the upper surface 83a is positioned away from the base plate 2 relative to the upper surface (the surface facing the +Z direction) of the electronic component 31 fixed to the base plate 2. In other words, the upper surface 83a is positioned higher in the +Z direction relative to the upper surface of the electronic component 31.

[0055] The main surface 83b and the side surface 83c are surfaces facing horizontally. The main surface 83b is a surface that extends horizontally along one of the shorter sides of the base portion 81. The main surface 83b is connectable to the connector 9. The main surface 83b may have projections or the like formed on it that engage with the connector 9. The side surface 83c is a surface that extends horizontally along one of the longer sides of the base portion 81.

[0056] Multiple third reinforcing ribs 84 support the extended portion 83 from its outer circumference. The third reinforcing ribs 84 extend outward to enlarge the side surface 83c. Furthermore, the third reinforcing ribs 84 are formed flush with the side surface 83c. In other words, the third reinforcing ribs 84 are formed to protrude from the main surface 83b. The third reinforcing ribs 84 may be triangular ribs formed to move away from the main surface 83b from the +Z direction to the -Z direction.

[0057] <7. Connector Configuration> Multiple connectors 9 will be described. Each connector 9 is supported and positioned on each support portion 8. Each connector 9 can be electrically connected to a desired location such as the first module 3 or the terminal module 4. Each connector 9 can be detachably connected to an external connector 71, which will be described later. Each connector 9 is either a so-called male connector or a female connector. In this embodiment, the connector 9 is, for example, a female connector. Each connector 9 has a connector body 91 and a connector connection portion 92.

[0058] The connector body 91 is the outer shell of the connector 9. The connector body 91 is formed, for example, in the shape of a rectangular parallelepiped. The connector body 91 can be fixed to the support part 8 by a part of it (for example, one of its surfaces). The connector body 91 is a synthetic resin product, for example, made of synthetic resin, and has insulating properties. The connector body 91 has an upper surface 91a at the end in the +Z direction.

[0059] The connector connection portion 92 is the part that can be connected to the external connector 71. In this embodiment, the connector connection portion 92 is formed recessed in the -Z direction from the upper surface 91a of the connector body 91. In other words, the connector 9 is positioned with the connector connection portion 92 facing the +Z direction. That is, the connector 9 can be connected to the external connector 71 from the +Z direction.

[0060] Furthermore, in this embodiment, the connector 9 is positioned such that its upper surface 91a is above the upper surface 83a of the support portion 8 (support body 82). In other words, the support portion 8 supports the connector 9 such that the upper surface 91a of the connector 9 is further away from the base plate 2 than the upper surface 83a of the support portion 8. That is, the connector 9 is positioned to protrude in the +Z direction from the support portion 8. Moreover, the connector 9 may be positioned to protrude in the +Z direction from, for example, other components mounted on the base plate 2 (such as the first module 3 or the terminal module 4).

[0061] <8. Cover composition> Let's explain cover 6. As shown in Figures 7 and 8, the cover 6 is a component capable of housing multiple first modules 3, multiple terminal modules 4, multiple busbars 5, multiple support parts 8, and multiple connectors 9 in combination with the base plate 2. That is, the cover 6 can cover the multiple first modules 3, multiple terminal modules 4, multiple busbars 5, multiple support parts 8, and multiple connectors 9 from the +Z direction. The cover 6 is formed, for example, to form a rectangular parallelepiped when combined with the base plate 2. The cover 6 is a synthetic resin product, for example, made of synthetic resin. The cover 6 has a top surface portion 61 and side portions 62.

[0062] The upper surface portion 61 is a plate-shaped section that extends horizontally. The upper surface portion 61 has through holes 61a that penetrate in the Z direction. The through holes 61a are formed so that the connector 9 is exposed when viewed from the +Z direction with the cover 6 attached to the base plate 2. That is, the through holes 61a are formed to be larger than the size of the connector 9 in the horizontal direction. In addition, multiple through holes 61a are formed at positions corresponding to multiple connectors 9. The upper surface portion 61 is connected to the side portions 62 at all of its horizontal ends.

[0063] The side portion 62 is a plate-shaped part that extends in the -Z direction from the horizontal end of the top portion 61. The side portion 62 can contact the base plate 2 at its end in the -Z direction.

[0064] <9. Composition of Cable Distribution Materials> Let me explain the cable routing member 7. The wiring material 7 is a component that connects the electrical connection unit 1 to external equipment. The wiring material 7 can be connected to the connector 9. The wiring material 7 is, for example, a wire harness or an FPC (Flexible Printed Circuits). The wiring material 7 has an external connector 71 and a cable portion 72.

[0065] The external connector 71 is detachable from the connector 9. By connecting the external connector 71 to the connector 9, the electrical connection unit 1 and the external device can be electrically connected. The external connector 71 is either a so-called male connector or a female connector. In this embodiment, the external connector 71 is a male connector. The external connector 71 is connected to a cable 72. The cable 72 is a conductive part, such as a conductive cable. The cable 72 connects the external connector 71 to the external device.

[0066] <10. Manufacturing method for electrical connection units and assemblies> A method for manufacturing the electrical connection unit 1 and the assembly 100 will be described. The manufacturer carries out the following steps 1 through 7 to produce the electrical connection unit 1 and assembly 100.

[0067] (1st step) As shown in Figure 9, in the first step, the manufacturer prepares the base plate 2.

[0068] (2nd process) As shown in Figure 10, in the second step, the manufacturer attaches the multiple first rigid members 32, the multiple terminal modules 4, and the multiple support parts 8 to the base plate 2. The manufacturer may also bond the multiple first rigid members 32 and the multiple terminal modules 4 to the base plate 2. The manufacturer also attaches the multiple connectors 9 to the multiple support parts 8.

[0069] (3rd step) As shown in Figure 11, in the third step, the manufacturer mounts some of the electronic components 31 to be mounted on the first rigid member 32 onto the corresponding first rigid member 32. The manufacturer may fasten and fix the electronic components 31 to each first rigid member 32. As shown in Figure 11, in the third step, the manufacturer may mount, for example, a relay module 3R from among the multiple electronic components 31 onto the corresponding first rigid member 32.

[0070] (4th step) As shown in Figure 12, in the fourth step, the manufacturer places multiple busbars 5 on multiple first modules 3 and multiple terminal modules 4. For example, in the fourth step, the manufacturer may mount some of the remaining electronic components 31 to be mounted on the corresponding first rigid member 32. For example, as shown in Figure 12, in the fourth step, the manufacturer may mount a fuse module 3F from among the multiple electronic components 31 on the corresponding first rigid member 32. Furthermore, in the fourth step, the manufacturer may mount a portion 31T of the remaining electronic components 31 to be mounted on the corresponding first rigid member 32.

[0071] (5th step) In the fifth step, the manufacturer fastens multiple busbars 5 to multiple first modules 3 and multiple terminal modules 4. For example, as shown in Figure 13, in the fifth step, the manufacturer may mount the remaining parts of the electronic components 31 to be mounted onto the corresponding first rigid member 32.

[0072] (6th step) As shown in Figure 14, in the sixth step, the manufacturer attaches the cover 6 to the structure on which multiple first modules 3, multiple terminal modules 4, multiple busbars 5, and multiple support parts 8 are attached to the base plate 2.

[0073] (7th step) As shown in Figure 15, in the seventh step, the manufacturer connects the external connector 71 to the connector 9. However, the timing of connecting the connector 9 and the external connector 71 is not limited to this. For example, the connector 9 and the external connector 71 may be connected in advance before attaching the cover 6 to the base plate 2 in the sixth step.

[0074] <11. Advantages> In the electrical connection unit 1 and assembly 100 of this embodiment, the support portion 8 is mounted on the base plate 2. The connector 9 is supported and positioned by the support portion 8. With this configuration, the position of the support portion 8 and the connector 9 on the base plate 2 can be freely set. Furthermore, since the support portion 8 is formed separately from the first module 3 and the terminal module 4, it becomes easy to position the support portion 8 and the connector 9 on the base plate. With this electrical connection unit 1 and assembly 100, it becomes easy to position the connector 9 in a position where the wiring material 7 can be easily attached. In addition, the connector 9 can be stably supported by the support portion 8. Therefore, the ease of assembly of the electrical connection unit 1 and assembly 100 can be improved.

[0075] Furthermore, the connection surface 81a (base portion 81) of this embodiment is formed in a rectangular shape, with one side in the horizontal direction being longer than the other. This configuration makes it easier to position the support portion 8 at any position outside the area on the base plate 2 where the electronic components 31 are mounted. In other words, it makes it easier to position the support portion 8 in the dead space of the base plate 2. Therefore, with this electrical connection unit 1 and assembly 100, it becomes easier to position the connector 9 in a position where the wiring material 7 can be easily attached. Thus, the ease of assembly of the electrical connection unit 1 and assembly 100 can be further improved.

[0076] Furthermore, the upper surface 91a of the connector 9 in this embodiment is positioned to protrude in the +Z direction more than the upper surface 83a of the support portion 8. With this configuration, the support portion 8 is less likely to get in the way when connecting the cable 7 (external connector 71) to the connector 9. In other words, it is possible to connect the cable 7 to the connector 9 more easily. Therefore, the ease of assembly of the assembly body 100 can be further improved.

[0077] In this embodiment of the electrical connection unit 1, each electronic component 31 is mounted on the base plate 2 via a first rigid member 32. This configuration allows for the free arrangement of multiple electronic components 31 on the base plate 2. With this electrical connection unit 1, each first module 3, which is an element-based module of electronic components, can be arranged on the base plate 2 in a free layout according to the functions required by the product. In addition, with this electrical connection unit 1, the electronic components 31 can be flexibly arranged on the base plate 2 in response to changes or modifications in the layout, for example. Therefore, the development period can be shortened.

[0078] As a comparative example, consider an electrical connection unit in which a resin component holds multiple electronic components together. In such a comparative example, the designer needs to design the arrangement of the multiple electronic components on the resin component. When such a design is required, the arrangement of the multiple electronic components on the resin component must be designed for each electrical connection unit with different specifications. Therefore, in such a comparative example, the design of the electrical connection unit is time-consuming.

[0079] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each first module 3 to be freely arranged according to the functions required for the product. Therefore, as described above, the development period can be shortened.

[0080] Furthermore, in the comparative examples described above, the electrical connection unit may have a unique design for the product to which it is applied. Therefore, the comparative examples have low versatility to other products and are difficult to adapt.

[0081] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each first module 3 to be constructed from standard components. Therefore, it offers high versatility for use in other products and is easily adaptable to other applications.

[0082] Furthermore, in the electrical connection unit 1 of this embodiment, one of the electronic components used is mounted on one first rigid member 32. This configuration allows the first modules 3 to be reused among multiple electrical connection units 1 with different arrangements of the first modules 3, or within an electrical connection unit 1. Therefore, the quality and reliability of the electrical connection unit 1 can be improved.

[0083] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to use standard unit modules as multiple first modules 3. Therefore, lead time and cost can be reduced.

[0084] Furthermore, with the electrical connection unit 1 of this embodiment, existing modules can be utilized as each first module 3. Therefore, the time and cost required for design and manufacturing can be reduced.

[0085] Furthermore, according to the electrical connection unit 1 of this embodiment, if improvements are needed in a specific set of first modules 3, efficient modifications can be made focusing on those specific modules 3. Therefore, this can contribute to improving the efficiency of maintenance work.

[0086] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to create a layout in which, for example, multiple first modules 3 are arranged on a base plate 2 of a specified size. Therefore, the electrical connection unit 1 can be configured freely, flexibly, and quickly.

[0087] Furthermore, according to the electrical connection unit 1 of this embodiment, the first rigid member 32 is made of synthetic resin, which makes the electrical connection unit 1 lighter. On the other hand, because the base plate 2 is made of metal, deformation of the base plate 2 caused by the weight of the multiple first modules 3 is suppressed.

[0088] Furthermore, according to the electrical connection unit 1 of this embodiment, the first rigid member 32 is equipped with a housing portion 34, thereby protecting the electronic component 31. Therefore, the electrical connection unit 1 can be made more robust.

[0089] Furthermore, according to the electrical connection unit 1 of this embodiment, the terminal module 4 is equipped with connection terminals 41, which allows for flexible adaptation to the connection specifications of the electrical connection unit 1. For example, if the connection terminals 41 for connecting to external devices are modularized as individual terminals, such as in the terminal module 4, then flexible adaptation to the specifications of external devices becomes possible.

[0090] Furthermore, in the electrical connection unit 1 of this embodiment, the first rigid member 32 is bonded to the base plate 2. This configuration allows for the free arrangement of each first rigid member 32 relative to the base plate 2. Therefore, the manufacturer can freely set the arrangement layout of multiple first modules 3.

[0091] Furthermore, according to the electrical connection unit 1 of this embodiment, multiple first modules 3 can be arranged on one side of the base plate 2. Therefore, the electrical connection unit 1 can be made lower in profile.

[0092] Furthermore, according to the electrical connection unit 1 of this embodiment, the busbar 5 is fastened to the component terminal 39. This configuration reduces the number of wiring members that electrically connect the multiple first modules 3.

[0093] (Various variations) Next, we will describe some variations. Note that, apart from the configurations described below, the configurations in each variation are the same as those of the embodiments described above.

[0094] (First variation) In the embodiments described above, the first surface 2a and the second surface 2b of the base plate 2 are smooth planes relative to each other. However, the first surface of the base plate 2 may be configured in any way as long as each first module 3 can be placed on it. As a modification, the electrical connection unit 1 may include a base plate 102 instead of the base plate 2. In the base plate 102, for example, as shown in Figure 13, the surface roughness of the first surface 102a is rougher than that of the second surface 102b by applying a surface treatment that creates minute bumps and irregularities to the first surface 102a. The second surface 102b is a smooth plane similar to the second surface 2b of the base plate 2. Due to the high surface roughness of the first surface 102a, the base plate 102 can exert a fixing anchor effect on the first module 3, terminal module 4, and support part 8 on which it is placed. In this case, each first module 3 may be bonded to the first surface 102a of the base plate 102, for example, as in the embodiments described above. As a result of this effect, the first module 3, terminal module 4, and support portion 8 are less likely to detach from the base plate 102. Therefore, the electrical connection unit 1 can be made more robust. As another modification, a minute uneven surface treatment may be applied only to the area of ​​the first surface 102a of the base plate 102 on which the first module 3, terminal module 4, and support portion 8 are placed.

[0095] (Second variation) In the above-described embodiment, the electrical connection unit 1 includes a base plate 2 as a second rigid member. However, the second rigid member may be configured in any way as long as multiple first modules 3 can be mounted on it. As a modification, the second rigid member may be a block, a box, or the like instead of the base plate 2.

[0096] (Third variation) In the above-described embodiment, the electrical connection unit 1 includes a busbar 5 as a wiring member. However, the electrical connection unit 1 may include any wiring member as long as it can be wired to multiple first modules 3. As a modification, the electrical connection unit 1 may include wiring as a wiring member instead of the busbar 5.

[0097] (Fourth variation) In the above-described embodiment, the multiple first rigid members 32 are bonded to the base plate 2. However, the first rigid members 32 may be fixed in any way as long as the electronic components 31 can be arranged on the base plate 2 in a free layout. As a modified example, the multiple first rigid members 32 may be fastened to the base plate 2.

[0098] (Fifth variation) In the embodiment described above, the multiple terminal modules 4 are bonded to the base plate 2. However, the multiple terminal modules 4 may be fixed in any way as long as they can be arranged on the base plate 2 in a free layout. As a modified example, the multiple terminal modules 4 may be fastened to the base plate 2.

[0099] (Sixth variation) In the embodiment described above, the multiple support parts 8 are bonded to the base plate 2. However, the multiple support parts 8 can be fixed in any way as long as they can be arranged on the base plate 2 in a free layout. As a variation, the multiple support parts 8 may be fastened to the base plate 2.

[0100] (Seventh variation) In the embodiment described above, the electrical connection unit 1 comprises a plurality of support parts 8 and a plurality of connectors 9. However, it is not limited to this configuration, and at least one of the support parts 8 and connectors 9 may be provided. Furthermore, the electrical connection unit 1 is not limited to a configuration in which the same number of support parts 8 and connectors 9 are provided. For example, it may be configured so that two connectors 9 are supported by one support part 8.

[0101] Several embodiments and modifications have been described above. However, the embodiments and modifications are not limited to the examples described above. For example, multiple embodiments may be implemented in combination with each other. [Explanation of symbols]

[0102] 100 assemblies 1. Electrical connection unit 2. Base plate (second rigid member) 2a 1st page 2b 2nd side 3. Module 1 3b Bottom 3F Fuse Module 3R Relay Module 4-terminal module (second module) 5. Busbar (rope routing member) 6 Covers 7 Routing material 8 Support part 9 connectors 31 Electronic Components 31F Fuse 31R Relay 31T part 32 First rigid member 32b 1st adhesive surface 33. First Flange 34 Storage Unit 34s Containment space 35 Peripheral wall 35n notch 35t edge 36 bottom 37. First reinforcing rib 38 Fixed terminal 39 Component terminals 41 Connection terminals 42 Terminal block 42a End face 42b 2nd adhesive surface 43 Main body 43a Outer perimeter 44. Second flange 45. Second reinforcing rib 61 Top part 61a Through hole 62 Side part 71 External connectors 72 Cable section 81 Base 81a Connection surface 82 Support body 83 Stretching section 83a top surface 83b Main surface 83c side 84 Third reinforcing rib 91 Connector body 91a Top side 92 Connector connection section 102 Base plate (second rigid member) 102a 1st page 102b 2nd side

Claims

1. A plurality of first modules each comprising an electronic component and a first rigid member on which the electronic component is mounted, The plurality of first modules are mounted on a second rigid member that extends in a first direction and in a second direction intersecting the first direction, A support portion formed separately from the plurality of first modules and mounted on the second rigid member, A connector supported by the aforementioned support and electrically connectable, Equipped with, Electrical connection unit.

2. The support portion has a connecting surface that contacts the second rigid member, The connecting surface is rectangular in shape, with one of the first or second directions being longer than the other. The electrical connection unit according to claim 1.

3. The support portion is bonded to the second rigid member. The electrical connection unit according to claim 1.

4. The support portion supports the connector such that the upper surface of the connector is further away from the upper surface of the support portion than the upper surface of the support portion relative to the second rigid member. The electrical connection unit according to claim 1.

5. The first rigid member is made of synthetic resin, The second rigid member is made of metal, The support portion is made of synthetic resin. The electrical connection unit according to claim 1.

6. An electrical connection unit according to any one of claims 1 to 5, The cable material connected to the aforementioned connector, Equipped with, assembly.

7. The connector is arranged so that the cable material can be connected from a third direction intersecting the first and second directions. The assembly according to claim 6.

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