Bent busbar, electrical connection unit, and method for manufacturing a bent busbar

Abstract

One embodiment provides a bendable busbar that facilitates flexible cable routing, an electrical connection unit, and a method for manufacturing a bendable busbar. [Solution] A bent busbar of one embodiment comprises a first busbar element having a first extension portion extending in a first extension direction within the cable routing surface and a first connecting portion continuous with the first extension portion, wherein the first connecting portion has a first connecting surface along the cable routing surface and a first through hole penetrating from the first connecting surface in a thickness direction intersecting the cable routing surface; and a second busbar element having a second extension portion extending in a second extension direction different from the first extension direction within the cable routing surface and a second connecting portion continuous with the second extension portion, wherein the second connecting portion has a second connecting surface in contact with the first connecting surface, and the second connecting portion has a first projection that projects continuously from the second connecting surface and extends through the first through hole, and is fastened to the first connecting portion.

Description

Technical Field

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

Background Art

[0002] In an electrical connection unit, it is known that a bus bar is used for wiring with electronic components such as relays and resistors.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in an electrical connection unit, the wiring path may be different for each product. However, with wiring using a bus bar, it may be difficult to perform free wiring.

[0005] One embodiment provides a flexible bus bar that is easy to perform free wiring, an electrical connection unit, and a method for manufacturing a flexible bus bar.

Means for Solving the Problems

[0006] A bent busbar in one embodiment comprises a first busbar element having a first extension portion extending in a first extension direction within the cable routing surface and a first connecting portion continuous with the first extension portion, wherein the first connecting portion has a first connecting surface along the cable routing surface and a first through hole penetrating from the first connecting surface in a thickness direction intersecting the cable routing surface; and a second busbar element having a second extension portion extending in a second extension direction different from the first extension direction within the cable routing surface and a second connecting portion continuous with the second extension portion, wherein the second connecting portion has a second connecting surface in contact with the first connecting surface, and the second connecting portion has a first projection that projects continuously from the second connecting surface and extends through the first through hole, and is fastened to the first connecting portion.

[0007] A method for manufacturing a bent busbar according to one embodiment involves determining the layout of a first busbar element comprising: a first busbar element comprising: a first extended portion extending in a first extending direction within the cable routing surface; and a first connecting portion continuous with the first extended portion, wherein the first connecting portion has a first connecting surface along the cable routing surface; and a first through hole penetrating from the first connecting surface in a thickness direction intersecting the cable routing surface; and a second busbar element comprising: a second extended portion extending in a second extending direction different from the first extending direction within the cable routing surface; and a second connecting portion continuous with the second extended portion, wherein the second connecting portion has a second connecting surface in contact with the first connecting surface; and the second connecting portion has a first projection that projects continuously from the second connecting surface and extends through the first through hole; and fastening the second connecting portion to the first connecting portion. [Effects of the Invention]

[0008] According to one embodiment, flexible cable routing is possible. [Brief explanation of the drawing]

[0009] [Figure 1] A perspective view showing an electrical connection unit of an embodiment. [Figure 2] A perspective view showing a relay module of an embodiment. [Figure 3] A perspective view showing a fuse module of an embodiment. [Figure 4]A perspective view showing the terminal module of the embodiment. [Figure 5] A perspective view showing a refraction busbar of an embodiment. [Figure 6] View in the direction of arrow VI in Figure 5. [Figure 7] View taken in the direction of arrow VII in Figure 5. [Figure 8] Front views of the second and third busbar elements before fastening in the embodiment. [Figure 9] A perspective view illustrating the manufacturing method of a refraction busbar according to an embodiment. [Figure 10] A perspective view illustrating the manufacturing method of a refraction busbar according to an embodiment. [Figure 11] A perspective view illustrating the manufacturing method of a refraction busbar according to an embodiment. [Figure 12] A front view illustrating the manufacturing method of an articulated busbar. [Figure 13] A front view illustrating the manufacturing method of an articulated busbar. [Figure 14] A front view illustrating the manufacturing method of an articulated busbar. [Figure 15] A perspective view of a refraction busbar of a first modified embodiment. [Figure 16] A partial side view of a retractable busbar of a second modified embodiment. [Figure 17] Front view of the second busbar element and the third busbar element before fastening in a second modified example of the embodiment. [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 the present disclosure, terms are defined as follows. "Connection" is not limited to mechanical connection and may include electrical connection. That is, "connection" is not limited to the case where two elements to be connected are directly connected, and may include the case where two elements to be connected are connected with another element intervening therebetween. "Containment" is not limited to the case where the whole of a component is contained, and may include the case where only a part of the component is contained (with the remaining part of the component protruding). "Covering" is not limited to the case of covering the whole of an object, and may include the case of covering only a part of the object. "Facing" means that the virtual projection images of two objects overlap when viewed from a specific direction. That is, "facing" is not limited to the case where two objects directly face each other, and may include the case where two objects face each other with another member existing between them. "Parallel", "orthogonal", or "the same" may each include the case of being "substantially parallel", "substantially orthogonal", or "substantially the same".

[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 the plane along the base plate 2 described later. The +X direction is one of the directions in the X direction. The -X direction is the 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 that intersects (for example, is orthogonal to) the X direction in the plane along the base plate 2 described later. The +Y direction is one of the directions in the Y direction. The -Y direction is the 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 that intersect (for example, are orthogonal to) the X direction and the Y direction. The +Z direction is the direction from the base plate 2 described later toward each first module 3 described later (see FIG. 1). The -Z direction is the 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 Z direction is an example of the "first direction". The X direction is an example of the "second direction". Note that the "second direction" is not limited to the X direction, and may be the Y direction or another direction.

[0013] Hereinafter, when the X direction and the Y direction are not distinguished, it 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). The horizontal plane is an example of the wiring plane of the bending bus bar 6 described later. The Z direction is an example of the thickness direction of the bending bus bar 6 described later.

[0014] (Embodiment) <1. Configuration of Electrical Connection Unit> The electrical connection unit 1 is, for example, 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 is connected to a plurality of external devices existing outside. The electrical connection unit 1 mediates the connection between the plurality of external devices. For example, the external devices may include a battery pack, a load, a charger, etc. The battery pack is mounted on the vehicle. The load is a device including an inverter for driving a motor of the vehicle that is driven using the power charged in the battery pack. The charger is a device for supplying power for charging the battery pack. 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.

[0015] As shown in Figure 1, the electrical connection unit 1 comprises a base plate 2, a plurality of first modules 3, a plurality of terminal modules 4, and a plurality of busbars 5. The base plate 2 is an example of a second rigid member. Each busbar 5 is an example of a wiring member. Each terminal module 4 is an example of a second module. In the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, and the plurality of busbars 5 are covered by the base plate 2 from the -Z direction and covered by a cover from the +Z direction. That is, in the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, and the plurality of busbars 5 are housed in a housing which is a combination structure of a cover and a base plate 2. Note that Figure 1 shows the electrical connection unit 1 with the cover visible through it.

[0016] <2. Configuration of the second rigid member> Let's explain base plate 2. The base plate 2 is a holding member that integrally holds multiple first modules 3 and multiple terminal modules 4. 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, for example, a metal product 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.

[0017] The base plate 2 has a front and back surface, which consists of 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.

[0018] <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.

[0019] 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.

[0020] As shown in Figures 2 and 3, 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.

[0021] In this embodiment, each of several of the multiple first modules 3 may further comprise a pair of auxiliary busbars 30. Each auxiliary busbar 30 is an example of an auxiliary cable routing member.

[0022] Each first module 3 may, for example, comprise only one electronic component 31, a pair of auxiliary busbars 30 corresponding to this one electronic component 31, and one first rigid member 32 corresponding to this one electronic component 31, from among the plurality of electronic components 31, plurality of first rigid members 32, and plurality of auxiliary busbars 30 included in the electrical connection unit 1.

[0023] Each electronic component 31 is an electronic component mounted in accordance with the function required of the electrical connection unit 1. 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. Examples of 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. Each electronic component 31 may have, for example, a pair of component terminals 39.

[0024] The partial rigid member 32 is fixed to the corresponding 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.

[0025] 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 a single molded product in which the pair of first flanges 33, the housing portion 34, and the plurality of first reinforcing ribs 37 are integrated. The first rigid member 32 is a synthetic resin product.

[0026] 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.

[0027] 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.

[0028] 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 and continuous planes, thereby forming the first bonding surface 32b as a whole.

[0029] 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.

[0030] The multiple first modules 3 may include, for example, relay modules 3R. In this case, as shown in Figure 2, the relay module 3R includes a relay 31R as an electronic component 31.

[0031] 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 pair of component terminals 39 are exposed from between the peripheral wall 35 toward the outside of the first rigid member 32. In the relay module 3R, each of at least one pair of the multiple notches 35n in the peripheral wall 35 may be cut out such that one end of the corresponding auxiliary busbar 30 (the second end 30b described later) can protrude beyond the peripheral wall 35.

[0032] 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 through the cover. That is, 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 in the horizontal direction.

[0033] The multiple first modules 3 may include, for example, a fuse module 3F. In this case, as shown in Figure 3, the fuse module 3F includes a fuse 31F as an electronic component 31.

[0034] In the fuse module 3F, at least one pair of notches 35n in the peripheral wall 35 is cut out such that the corresponding component terminal 39 can protrude beyond the peripheral wall 35. The fuse module 3F may also include 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.

[0035] Each auxiliary busbar 30 is an auxiliary wiring member (electrical connection member) for electrically connecting the component terminal 39 and the busbar 5. Each auxiliary busbar 30 extends between the component terminal 39 and the busbar 5. Each auxiliary busbar 30 is a metal product and is conductive. Each auxiliary busbar 30 may be made of a metal such as copper or aluminum.

[0036] Each auxiliary busbar 30 has a first end 30a and a second end 30b. The first end 30a of each auxiliary busbar 30 is electrically connected to the corresponding component terminal 39 by being fastened to the corresponding component terminal 39. The second end 30b of each auxiliary busbar 30 protrudes horizontally from the outer circumference of the first rigid member 32. The second end 30b is electrically connected to the busbar 5 to which the first module 3 is to be connected. The second end 30b faces the connection portion of the busbar 5 to which it is to be connected from the -Z direction or the +Z direction. The second end 30b may be fastened to the connection portion of the busbar 5 to which it is to be connected. The second end 30b may be electrically connected to the busbar 5 by fastening members such as bolts, or by fastening to the busbar 5 by a mating structure.

[0037] Each auxiliary busbar 30 has a shape corresponding to the first module 3 between its first end 30a and second end 30b. As shown in Figure 2, in the relay module 3R, each auxiliary busbar 30 may be, for example, a curved plate extending from the first end 30a to the second end 30b. As shown in Figure 3, in the fuse module 3F, each auxiliary busbar 30 may be, for example, a flat plate extending straight horizontally from the first end 30a to the second end 30b.

[0038] <4. Configuration of Module 2> Multiple terminal modules 4 will be described below. The multiple terminal modules 4 are divided 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 4, each terminal module 4 is equipped with a connection terminal 41 and a terminal block 42.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] The terminal block 42 is fixed to the corresponding 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.

[0043] 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.

[0044] 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 flush with each other, thereby forming a second bonding surface 42b as a whole.

[0045] 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.

[0046] <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, or to the first module 3 and the terminal module 4. Each busbar 5 extends between the first module 3 and the first module 3, or between the first module 3 and the terminal module 4. Each busbar 5 is a metal product and is conductive. Each busbar 5 may be made of a metal such as copper or aluminum.

[0047] Of the ends of each busbar 5, the end connected to the first module 3 may be fastened to, for example, an auxiliary busbar 30. 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] As shown in Figure 1, some of the busbars 5 are bent busbars 6. Some of the busbars 5 other than the bent busbars 6 may be, for example, flat plates having a rectangular surface oriented vertically.

[0049] <6. Configuration of the curved busbar> Let's explain the bent busbar 6. The bent busbar 6 is curved in the horizontal plane. The bent busbar 6 as a whole may have, for example, a U-shape when viewed from the Z direction.

[0050] As shown in Figure 5, the bent busbar 6 comprises a first busbar element 7, a second busbar element 8, and a third busbar element 9. The bent busbar 6 is constructed by a combination of the first busbar element 7, the second busbar element 8, and the third busbar element 9. With this configuration, the bent busbar 6 may, for example, bend in the horizontal plane between the first busbar element 7 and the second busbar element 8, and bend in the horizontal plane between the second busbar element 8 and the third busbar element 9.

[0051] <6.1 Structure of the First Busbar Element> The first busbar element 7 comprises a first extension portion 71, a first connecting portion 72, and a fifth connecting portion 73. The first connecting portion 72 extends continuously from one end of the first extension portion 71. The fifth connecting portion 73 extends continuously from the other end of the first extension portion 71. The first extension portion 71, the first connecting portion 72, and the fifth connecting portion 73 may, for example, be integrally molded.

[0052] The first busbar element 7 has a first plane 7a and a second plane 7b as a pair of planes facing the Z direction. The first plane 7a faces the +Z direction. The first plane 7a may be, for example, a plane extending in the +Z direction from the first extension 71 to the first connection 72. The second plane 7b faces the -Z direction. The second plane 7b may be, for example, a plane extending in the -Z direction from the first extension 71 to the fifth connection 73.

[0053] The first extension portion 71 extends in the first extension direction DE1 in the horizontal plane. The first extension portion 71 has a thick plate shape that extends straight in the first extension direction DE1.

[0054] The first connecting portion 72 extends from the first extending portion 71 in one direction of the first extending direction DE1. The outer circumference of the first connecting portion 72, facing horizontally, has an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction. As shown in Figure 6, the first connecting portion 72 has a first connecting surface 72a and a first through hole 72h. The first connecting surface 72a is aligned with the horizontal plane. The first connecting surface 72a faces the same direction (-Z direction) as the second plane 7b. The first connecting surface 72a is a plane that is recessed in the +Z direction from the second plane 7b. The recess in the first connecting surface 72a is created by machining such as cutting or pressing so that flatness can be maintained when connected to other busbars. The first through hole 72h penetrates from the first connecting surface 72a in the Z direction.

[0055] The fifth connecting portion 73 extends from the first extending portion 71 in the other direction of the first extending direction DE1 (opposite to the direction in which the first connecting portion 72 extends). As shown in Figure 5, the outer circumference of the fifth connecting portion 73 facing horizontally has an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction. The fifth connecting portion 73 has a fifth connecting surface 73a. The fifth connecting surface 73a is aligned with the horizontal plane. The fifth connecting surface 73a faces the same direction as the first plane 7a (+Z direction). The fifth connecting surface 73a is a plane that is recessed in the -Z direction from the first plane 7a. The recess in the fifth connecting surface 73a is created by processing such as cutting or pressing so that flatness can be maintained when connected to other busbars. The fifth connecting surface 73a is in contact with one surface of the auxiliary busbar 30.

[0056] The fifth connecting portion 73 includes a third projection 731. The third projection 731 extends from the fifth connecting surface 73a in the +Z direction. The third projection 731 projects continuously from the fifth connecting surface 73a. The third projection 731 and the fifth connecting surface 73a may be part of an integrally molded product. The third projection 731 may be, for example, a rivet portion.

[0057] The fifth connecting portion 73 may be fastened to, for example, the auxiliary busbar 30. In this case, the third projection 731 may extend through a through hole in the auxiliary busbar 30. Alternatively, the tip of the third projection 731 that has passed through the through hole may be pressed against the auxiliary busbar 30, thereby fastening the fifth connecting portion 73 to the auxiliary busbar 30. Furthermore, the outer circumference of the tip of the pressed third projection 731 on the auxiliary busbar 30 may be welded or joined to the surface of the auxiliary busbar 30 in the +Z direction by welding, laser processing, or the like.

[0058] <6.2 Configuration of the second busbar element> The second busbar element 8 comprises a second extension portion 81, a second connecting portion 83, and a fourth connecting portion 82. The second connecting portion 83 extends continuously from one end of the second extension portion 81. The fourth connecting portion 82 extends continuously from the other end of the second extension portion 81. The second extension portion 81, the second connecting portion 83, and the fourth connecting portion 82 may, for example, be integrally molded.

[0059] The second busbar element 8 has a third plane 8a and a fourth plane 8b as a pair of planes facing the Z direction. The third plane 8a faces the +Z direction. The third plane 8a may be, for example, a plane extending in the +Z direction from the second extension 81 to the fourth connection 82. The first plane 7a and the third plane 8a may be, for example, flush with each other. The fourth plane 8b faces the -Z direction. The fourth plane 8b may be, for example, a plane extending in the -Z direction from the second extension 81 to the second connection 83. The second plane 7b and the fourth plane 8b may be, for example, flush with each other.

[0060] The second extension portion 81 extends in the second extension direction DE2 in the horizontal plane. The second extension direction DE2 is a different direction from the first extension direction DE1. The second extension portion 81 has a thick plate shape that extends straight in the second extension direction DE2.

[0061] The second connecting portion 83 extends from the second extending portion 81 in one direction of the second extending direction DE2. The outer circumference of the second connecting portion 83, facing horizontally, has an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction. As shown in Figure 6, the second connecting portion 83 has a second connecting surface 83a. The second connecting surface 83a is aligned with the horizontal plane. The second connecting surface 83a faces the same direction (+Z direction) as the third plane 8a. The second connecting surface 83a is a plane that is recessed in the -Z direction from the third plane 8a. The recess in the second connecting surface 83a is created by machining such as cutting or pressing so that flatness can be maintained when connected to other busbars. The second connecting surface 83a is in contact with the first connecting surface 72a. At that time, the first busbar element 7 and the second busbar element 8 are combined such that the first connecting portion 72 fits into the recess of the second connecting surface 83a, and the second connecting portion 83 fits into the recess of the first connecting surface 72a.

[0062] The second connecting portion 83 includes a first rivet portion 831. The first rivet portion 831 is an example of a first projection. The first rivet portion 831 extends from the second connecting surface 83a in the +Z direction. The first rivet portion 831 projects continuously from the second connecting surface 83a. The first rivet portion 831 and the second connecting surface 83a may be part of an integrally molded product.

[0063] The second connecting portion 83 is fastened to the first connecting portion 72. In this case, the first rivet portion 831 extends through the first through hole 72h. Alternatively, the tip of the first rivet portion 831 that has passed through the first through hole 72h may be pressed against the first connecting portion 72, thereby fastening the second connecting portion 83 to the first connecting portion 72. Furthermore, the outer circumference of the tip of the first rivet portion 831 that has been pressed against the first connecting portion 72 may be welded or joined to the first plane 7a surrounding the tip of the first rivet portion 831 by welding, laser processing, or the like.

[0064] As shown in Figure 5, the fourth connecting portion 82 extends from the second extending portion 81 in the other direction of the second extending direction DE2 (opposite to the direction in which the second connecting portion 83 extends). The outer circumference of the fourth connecting portion 82, facing horizontally, has an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction. As shown in Figure 7, the fourth connecting portion 82 has a fourth connecting surface 82a and a second through hole 82h. The fourth connecting surface 82a is aligned with the horizontal plane. The fourth connecting surface 82a faces the same direction as the fourth plane 8b (-Z direction). The fourth connecting surface 82a is a plane that is recessed in the +Z direction from the fourth plane 8b. The recess in the fourth connecting surface 82a is created by machining such as cutting or pressing so that flatness can be maintained when connected to other busbars. The second through hole 82h penetrates from the fourth connecting surface 82a in the Z direction.

[0065] <6.3 Configuration of the third busbar element> As shown in Figure 5, the third busbar element 9 comprises a third extension portion 91, a third connecting portion 93, and a sixth connecting portion 92. The third connecting portion 93 extends continuously from one end of the third extension portion 91. The sixth connecting portion 92 extends continuously from the other end of the third extension portion 91. The third extension portion 91, the third connecting portion 93, and the sixth connecting portion 92 may be, for example, a single molded product.

[0066] The third busbar element 9 has a fifth plane 9a and a sixth plane 9b as a pair of planes facing the Z direction. The fifth plane 9a faces the +Z direction. The fifth plane 9a may be, for example, a plane extending in the +Z direction from the third extension 91 to the sixth connection 92. The third plane 8a and the fifth plane 9a may be, for example, flush with each other. The sixth plane 9b faces the -Z direction. The sixth plane 9b may be, for example, a plane extending in the -Z direction from the third extension 91 to the third connection 93. The fourth plane 8b and the sixth plane 9b may be, for example, flush with each other.

[0067] The third extension portion 91 extends in the third extension direction DE3 in the horizontal plane. The third extension direction DE3 is different from the second extension direction DE2. The third extension direction DE3 may be, for example, the same direction as the first extension direction DE1. The third extension portion 91 has a thick plate shape that extends straight in the third extension direction DE3.

[0068] The third connecting portion 93 extends from the third extending portion 91 in one direction of the third extending direction DE3. The outer circumference of the third connecting portion 93, facing horizontally, has an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction. As shown in Figure 7, the third connecting portion 93 has a third connecting surface 93a. The third connecting surface 93a is aligned with the horizontal plane. The third connecting surface 93a faces the same direction (+Z direction) as the fifth plane 9a. The third connecting surface 93a is a plane that is recessed in the -Z direction from the fifth plane 9a. The recess in the third connecting surface 93a is created by machining such as cutting or pressing so that flatness can be maintained when connected to other busbars. The third connecting surface 93a is in contact with the fourth connecting surface 82a. At that time, the second busbar element 8 and the third busbar element 9 are combined such that the fourth connecting portion 82 fits into the recess of the third connecting surface 93a, and the third connecting portion 93 fits into the recess of the fourth connecting surface 82a.

[0069] The third connecting portion 93 includes a second rivet portion 931. The second rivet portion 931 is an example of a second projection. The second rivet portion 931 extends from the third connecting surface 93a in the +Z direction. The second rivet portion 931 protrudes continuously from the third connecting surface 93a. The second rivet portion 931 and the third connecting surface 93a may be part of an integrally molded product.

[0070] The third connecting portion 93 is fastened to the fourth connecting portion 82. In this case, the second rivet portion 931 extends through the second through hole 82h. Alternatively, the tip of the second rivet portion 931 that has passed through the second through hole 82h may be pressed against the fourth connecting portion 82, thereby fastening the third connecting portion 93 to the fourth connecting portion 82. Furthermore, the outer circumference of the tip of the pressed second rivet portion 931 of the third connecting portion 93 may be welded or joined to the third plane 8a surrounding the tip of the second rivet portion 931 by welding, laser processing, or the like.

[0071] As shown in Figure 5, the sixth connecting portion 92 extends from the third extending portion 91 in the other direction of the third extending direction DE3 (opposite to the direction in which the third connecting portion 93 extends). The outer circumference of the sixth connecting portion 92, facing horizontally, has an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction. The sixth connecting portion 92 has a sixth connecting surface 92a and a third through hole 92h. The sixth connecting surface 92a is aligned with the horizontal plane. The sixth connecting surface 92a faces the same direction (-Z direction) as the sixth plane 9b. The sixth connecting surface 92a is a plane that is recessed in the +Z direction from the sixth plane 9b. The recess in the sixth connecting surface 92a is created by machining such as cutting or pressing so that flatness can be maintained when connected to other busbars. The sixth connecting surface 92a is in contact with one surface of the auxiliary busbar 30. The third through-hole 92h penetrates from the sixth connecting surface 92a in the Z direction.

[0072] The sixth connecting portion 92 may be fastened to, for example, an auxiliary bus bar 30 (a different auxiliary bus bar 30 from the one to which the fifth connecting portion 73 is connected). In this case, the rivet portion of the auxiliary bus bar 30 may be passed through the third through hole 92h and crimped, thereby fastening the sixth connecting portion 92 to the auxiliary bus bar 30. Furthermore, the outer circumference of the tip of the crimped rivet portion of the auxiliary bus bar 30 may be welded or joined to the -Z direction surface of the auxiliary bus bar 30 by welding, laser processing, or the like.

[0073] <7. Manufacturing method for a bent busbar> A method for manufacturing the bent busbar 6 will be described. The manufacturer produces the bent busbar 6 by carrying out the following steps.

[0074] (1st step) In the first step, the manufacturer prepares the first busbar element 7, the second busbar element 8, and the third busbar element 9.

[0075] Here, as shown in Figure 8, the second busbar element 8 includes a first rivet portion 831A before it is processed into the first rivet portion 831. The first rivet portion 831A extends to a position higher by a height dH than the height of the third plane 8a.

[0076] Similarly, the third busbar element 9 includes a second rivet portion 931A before it is machined into the second rivet portion 931. The second rivet portion 931A also extends to a position higher by a height dH than the height of the fifth plane 9a.

[0077] (2nd process) As shown in Figure 9, in the second step, the manufacturer combines the first busbar element 7, the second busbar element 8, and the third busbar element 9.

[0078] In the second step, the manufacturer combines the first busbar element 7 and the second busbar element 8 such that the first connecting portion 72 fits into the recess of the second connecting surface 83a, and the second connecting portion 83 fits into the recess of the first connecting surface 72a. At that time, the manufacturer combines the first busbar element 7 and the second busbar element 8 such that the first rivet portion 831A passes through the first through hole 72h.

[0079] In the second step, the manufacturer combines the second busbar element 8 and the third busbar element 9 such that the fourth connecting portion 82 fits into the recess of the third connecting surface 93a, and the third connecting portion 93 fits into the recess of the fourth connecting surface 82a. At the same time, the manufacturer combines the first busbar element 7 and the second busbar element 8 such that the second rivet portion 931A passes through the second through hole 82h.

[0080] (3rd step) As shown in Figure 10, in the third step, the manufacturer determines the layout of the first busbar element 7, the second busbar element 8, and the third busbar element 9. In the third step, the first rivet portion 831A passes through the first through hole 72h, and the second rivet portion 931A passes through the second through hole 82h. Due to this configuration, the layout in the horizontal plane is not fixed, and the worker can freely determine the angle of the layout in the horizontal plane.

[0081] In the third step, the manufacturer may, for example, determine the layout of the first busbar element 7 and the second busbar element 8 by rotating the first busbar element 7 in the horizontal plane around the first through-hole 72h through which the first rivet portion 831A passes. Here, in order to facilitate the rotation of the first busbar element 7 relative to the second busbar element 8, the outer circumference of the first connecting portion 72 and the outer circumference of the second connecting portion 83, both facing horizontally, have an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction.

[0082] Similarly, in the third step, the manufacturer may, for example, determine the layout of the second busbar element 8 and the third busbar element 9 by rotating the third busbar element 9 in the horizontal plane around the second rivet portion 931A passing through the second through hole 82h relative to the second busbar element 8. Here, in order to facilitate the rotation of the third busbar element 9 relative to the second busbar element 8, the outer circumference of the third connector portion 93 facing horizontally and the outer circumference of the fourth connector portion 82 facing horizontally each have an R shape (a shape with a semicircular circumference in its contour) when viewed from the Z direction.

[0083] (4th step) As shown in Figure 11, in the fourth step, the manufacturer fastens the second connecting part 83 to the first connecting part 72 and the third connecting part 93 to the fourth connecting part 82 to complete the bent busbar 6.

[0084] In the fourth step, as shown in Figures 12 and 13, the manufacturer may, for example, use a press machine PS to press the tip of the first rivet portion 831A passing through the first through hole 72h to form the first rivet portion 831, and then fasten the second connecting portion 83 to the first connecting portion 72.

[0085] Similarly, in the fourth step, as shown in Figures 12 and 13, the manufacturer may, for example, use a press machine PS to press the tip of the second rivet portion 931A passing through the second through hole 82h to form the second rivet portion 931, and fasten the third connecting portion 93 to the fourth connecting portion 82.

[0086] (5th step) Furthermore, depending on the structural strength and electrical resistance of the bent busbar 6, the manufacturer may perform a fifth step if necessary. In the fifth step, as shown in Figure 14, the manufacturer may weld or join the periphery AR around the tip (each crimped portion) of the first rivet portion 831 to the first plane 7a by welding, laser processing, etc. Similarly, the manufacturer may weld or join the periphery AR around the tip (crimped portion) of the second rivet portion 931 to the third plane 8a by welding, laser processing, etc. Note that in the fifth step, the tips of the first rivet portion 831 and the second rivet portion 931 are facing in the +Z direction (for example, upward), making it easier for the manufacturer to perform the fifth step.

[0087] Subsequently, the manufacturer places the completed bent busbar 6 onto the base plate 2, connects it to the auxiliary busbar 30, and completes the electrical connection unit 1.

[0088] <8. Advantages> In this embodiment of the bent busbar 6, the second connecting portion 83 is fastened to the first connecting portion 72. This configuration allows for the creation of various layouts of the bent busbar 6 by combining the first busbar element 7 and the second busbar element 8, which have different shapes or lengths. Furthermore, this configuration allows for flexible routing and simple connections. Therefore, it facilitates flexible routing.

[0089] Furthermore, with the bent busbar 6 of this embodiment, various bent busbar layouts can be created by combining a standard first busbar element 7 and a standard second busbar element 8. Therefore, costs can be reduced. In addition, if it can be assembled with standard busbar elements, automation is also easier.

[0090] As a comparative example, in a busbar structure that is bent by pressing or the like so that it can be routed into the internal structure of a product, it is difficult to freely change the shape. Also, in the comparative example, the shape is tailored to the internal structure of each individual product, so standardization is not possible. In contrast, with the bent busbar 6 of this embodiment, as described above, various layouts of bent busbars 6 can be created by combining the first busbar element 7 and the second busbar element 8 which have different shapes or lengths. Therefore, the shape can be freely changed and standardization is easy.

[0091] Furthermore, in the bent busbar 6 of this embodiment, the first rivet portion 831 extends through the first through hole 72h. With this configuration, the bending angle can be adjusted and fastened to one of the busbar elements, the first busbar element 7 and the second busbar element 8, while rotating the other busbar element. Therefore, it is easier to absorb variations in the bending direction of the bent busbar. In addition, if it can be assembled with standard busbar elements, automation is also easier.

[0092] In particular, in the electrical connection unit 1 of this embodiment, each electronic component 31 is mounted on the base plate 2 via a first rigid member 32. With this configuration, the arrangement of multiple electronic components 31 on the base plate 2 can be freely set. On the other hand, by applying the bendable busbar 6 to such an electrical connection unit 1, the bendable busbar can flexibly accommodate the first module 3 which is freely arranged on the base plate 2. For example, if the bendable busbar 6 is used for the electrical connection between the first module 3 and the first module 3, or between the first module 3 and the terminal module 4, the bending angle of the bendable busbar can be adjusted with respect to the first module 3 as described above. Therefore, the bendable busbar 6 can flexibly accommodate the freely set configuration of the first module 3.

[0093] Furthermore, in the bent busbar 6 of this embodiment, the second busbar element 8 is an integrally molded product. This configuration reduces the number of parts. As a comparative example, consider a case in a bent busbar where the first busbar element and the second busbar element have bolt holes and are fastened with bolts. In the configuration of this comparative example, it is necessary to fasten them with bolts and nuts at least. Therefore, the number of parts is large in the comparative example. In contrast to this comparative example, the second busbar element 8 of this embodiment is an integrally molded product including the first rivet portion 831 as described above. Therefore, the number of parts can be reduced. In addition, since the first rivet portion 831 has a rivet structure, the number of parts can be reduced even further.

[0094] Furthermore, in the bent busbar 6 of this embodiment, the third connecting portion 93 is fastened to the fourth connecting portion 82. This configuration allows for the creation of various layouts of the bent busbar 6 by combining the second busbar element 8 and the third busbar element 9, which have different shapes or lengths. Therefore, flexible routing is easily achieved.

[0095] Furthermore, with the bent busbar 6 of this embodiment, various layouts of the bent busbar 6 can be created by combining a standard second busbar element 8 and a standard third busbar element 9. Therefore, costs can be reduced. In addition, if it can be assembled with standard busbar elements, automation is also easier.

[0096] Furthermore, in the bent busbar 6 of this embodiment, the second rivet portion 931 extends through the second through hole 82h. With this configuration, the bending angle can be adjusted and fastened to one of the busbar elements, the second busbar element 8 and the third busbar element 9, while rotating the other busbar element. Therefore, variations in the bending direction of the bent busbar can be absorbed.

[0097] Furthermore, in the bent busbar 6 of this embodiment, the first plane 7a and the third plane 8a are flush, and the second plane 7b and the fourth plane 8b are flush. This configuration makes it possible to reduce the height of the bent busbar 6. Therefore, space-saving cable routing is easier.

[0098] Furthermore, in the manufacturing method of the bent busbar 6 of this embodiment, the worker determines the layout of the first busbar element 7 and the second busbar element 8, and fastens the second connecting part 83 to the first connecting part 72. Through this process, various layouts of bent busbars 6 can be created by combining the first busbar element 7 and the second busbar element 8 which have different shapes or lengths. Therefore, flexible routing is possible.

[0099] Furthermore, according to the manufacturing method of the bent busbar 6 of this embodiment, various layouts of the bent busbar 6 can be created by combining a standard first busbar element 7 and a standard second busbar element 8 through this process. Therefore, costs can be reduced. In addition, if it can be assembled with standard busbar elements, automation is also easier.

[0100] Furthermore, according to the manufacturing method of the bent busbar 6 of this embodiment, this process allows the bending angle to be adjusted and fastened while rotating one of the busbar elements, the first busbar element 7 and the second busbar element 8. Therefore, it is easier to absorb variations in the bending direction of the bent busbar 6.

[0101] As described above, the electrical connection unit 1 of this embodiment allows for the free arrangement of multiple electronic components 31 on the base plate 2. With such an electrical connection unit 1, each first module 3, which is an elemental module at the electronic component level, can be arranged on the base plate 2 in a free layout according to the functions required by the product. In addition, with such an 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. Therefore, the development period can be shortened.

[0102] 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.

[0103] 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.

[0104] 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 for other products and are difficult to adapt.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] (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.

[0117] (First variation) In each busbar element of the above embodiment, the length and shape other than the connection portion may be freely set. Also, in the above-described bent busbar 6, several busbar elements having several standard busbar shapes and lengths may be crimped together with rivets after the layout is determined and processed into the required wiring shape. For example, in the above-described bent busbar 6, the extension portion of each busbar element extends straight in the extension direction. However, as long as the bent busbar is bent in the horizontal plane, it may be composed of any number of busbar elements. As a modified example, the bent busbar 106, in contrast to the bent busbar 6, includes a third busbar element 109 instead of the third busbar element 9. The third busbar element 109 includes a third extension portion 191, a third connection portion 93, and a sixth connection portion 92. As shown in Figure 15, the third extension portion 191 extends in the third extension direction DE3, then bends in the second extension direction DE2, and extends in the second extension direction DE2. This modified example offers the same advantages as those of the embodiments described above.

[0118] (Second variation) In the above-described embodiment, the first plane 7a and the third plane 8a are flush. However, the configuration can be any way as long as the tip of the first rivet portion 831 is crimped to the first connecting portion 72. As a modification, in the first busbar element 7 and the second busbar element 8, as shown in Figure 16, the surface of the first busbar element 7 facing the +Z direction may be recessed around the first through hole 72h. This recess allows, for example, the tip of the crimped first rivet portion 831 to be flush with or recessed with respect to the first plane 7a facing the +Z direction and the third plane 8a facing the Z direction. The second busbar element 8 and the third busbar element 9 may also be configured similarly. According to this modification, the tips of each crimped rivet portion can be flush with or recessed. This configuration makes it possible to reduce the profile. Therefore, it is easy to route in a space-saving manner.

[0119] Furthermore, in the manufacturing method of the bent busbar 6 in this modified example, in the first step, a second busbar element 8 and a third busbar element 9 may be prepared as shown in Figure 17. In this case, the height of the tip of the first rivet portion 831A before crimping may be aligned with, for example, the third plane 8a. Also, the height of the tip of the second rivet portion 931A before crimping may be aligned with, for example, the fifth plane 9a. According to this modified example, material loss is reduced and processing from plates and strips is possible. As a comparative example, when processing each busbar element from a plate or strip, if the rivet portion is extruded, there will be a lot of material loss or it will become necessary to join separate parts. In contrast, according to this modified example, as described above, material loss is reduced and processing from plates and strips is possible.

[0120] (Third 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.

[0121] (Fourth variation) In the above embodiment, the electrical connection unit 1 includes busbars 5 other than the bent busbar 6 as routing members. However, the electrical connection unit 1 may include any routing members as long as they can be routed to multiple first modules 3. As a modification, the electrical connection unit 1 may include wiring as routing members instead of busbars 5 other than the bent busbar 6.

[0122] (Fifth variation) In the above-described embodiment, each of several of the multiple first modules 3 is equipped with an auxiliary busbar 30 as an auxiliary wiring member. However, each first module 3 may be equipped with any auxiliary wiring member as long as it can be wired to the component terminals 39 and the busbar 5. As a modification, each first module 3 may be equipped with auxiliary wiring as an auxiliary wiring member instead of the auxiliary busbar 30.

[0123] (Sixth 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.

[0124] (Seventh 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.

[0125] (Variation 8) In the embodiment described above, some of the busbars 5 are bent busbars 6. However, the configuration can be any way as long as it allows for routing of the multiple first modules 3 and the multiple terminal modules 4. As a modification, many of the busbars 5 may be bent busbars 6. As another modification, all of the busbars 5 may be bent busbars 6.

[0126] (9th variation) In the above-described embodiment, the bent busbars 6 and 106 are applied to the electrical connection unit 1. However, if the product requires cable routing, the bent busbars 6 and 106 may be applied to flat cable routing materials or other products.

[0127] (10th variation) In the above-described embodiment, the bent busbars 6 and 106 are composed of a combination of a first busbar element 7, a second busbar element 8, and a third busbar element 9. However, they may be configured in any way as long as a plurality of first modules 3 and a plurality of terminal modules 4 can be routed. As a modification, the bent busbars 6 and 106 may further include one or more other busbar elements in addition to the first busbar element 7, the second busbar element 8, and the third busbar element 9.

[0128] (11th variation) In the above-described embodiment, the fifth connecting portion 73 includes a third projection 731. The sixth connecting portion 92 has a sixth connecting surface 92a and a third through hole 92h. However, the configuration may be any way, regardless of the presence or absence of the third projection 731 or the third through hole 92h, as long as the bent busbar 6 can be connected to the auxiliary busbar 30.

[0129] (12th variation) In the above-described embodiment, the manufacturer performs each step of the manufacturing process for the bent busbars 6 and 106. However, any entity may perform each step of the manufacturing process for the bent busbar 6, as long as it is capable of doing so. As a variation, the manufacturing process for the bent busbar 6 may be performed by a processing device, robot, or the like.

[0130] (13th variation) In the bent busbars 6 and 106 of the above-described embodiment, the busbar elements are fastened together by rivet portions. However, the busbar elements may be fastened together in any way as long as they are connected. As a modification, each rivet portion may be a projection with a male thread at its tip, and fastened with a nut having a female thread.

[0131] (14th variation) In the above-described embodiment, the bent busbars 6 and 106 are fastened to the auxiliary busbar 30. However, the configuration may be any way as long as the bent busbars 6 and 106 and the electronic component 31 are electrically connected. As a modified example, the bent busbars 6 and 106 may be directly fastened to the component terminals 39 of the electronic component 31.

[0132] 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]

[0133] 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 (Riding Member) 6. 106 Bent Busbar 6. Flexible busbar 7. First bus bar element 7a 1st plane 7b 2nd plane 8. Second bus bar element 8a 3rd plane 8b 4th plane 9. Third bus bar element 9a 5th plane 9b 6th plane 30 Auxiliary busbar (auxiliary cable routing member) 30a 1st end 30b 2nd end 31 Electronic Components 31F Fuse 31R Relay 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 71 1st extension section 72 First connection section 72a First connection surface 72h 1st through hole 73 Fifth connection section 73a Fifth connection surface 81 2nd extension section 82 Fourth Connection Section 82a Fourth connection surface 82h 2nd through hole 83 Second connection section 83a Second connection surface 91 Third extension section 92 Sixth connection section 92a Sixth connection surface 92h 3rd through hole 93 Third connection section 93a Third connection surface 106 Bent busbar 109 Third bus bar element 191 Third extension section 731 Third protrusion 831 First rivet section (first projection) 831A First rivet section (first projection) 931 Second rivet section (second projection) 931A Second rivet section (second projection) AR surroundings PS press machine

Claims

1. A first busbar element comprising: a first extension portion extending in a first extension direction within the cable routing surface; and a first connecting portion continuous with the first extension portion, wherein the first connecting portion has a first connecting surface along the cable routing surface and a first through hole penetrating from the first connecting surface in a thickness direction intersecting the cable routing surface; The second busbar element comprises a second extension portion extending in a second extension direction different from the first extension direction within the cable routing surface, and a second connecting portion continuous with the second extension portion, wherein the second connecting portion has a second connecting surface in contact with the first connecting surface. Equipped with, The second connecting portion includes a first projection that protrudes continuously from the second connecting surface and extends through the first through hole, and is fastened to the first connecting portion. Curved busbar.

2. The second busbar element is a single molded product. The curved bus bar according to claim 1.

3. The third busbar element comprises a third extending portion extending in a third extending direction different from the second extending direction within the cable routing surface, and a third connecting portion continuous with the third extending portion, wherein the third connecting portion has a third connecting surface along the cable routing surface. The second busbar element further comprises a fourth connecting portion continuous with the second extension portion, The fourth connecting portion has a fourth connecting surface in contact with the third connecting surface and a second through hole extending from the fourth connecting surface in the thickness direction. The third connecting portion includes a second projection that protrudes continuously from the third connecting surface and extends through the second through hole, and is fastened to the fourth connecting portion. The curved bus bar according to claim 1 or 2.

4. The first busbar element has a first plane facing one direction in the thickness direction and extending from the first extension portion to the first connection portion, and a second plane facing the other direction in the thickness direction and extending across the first extension portion. The second busbar element has a third plane facing one direction in the thickness direction and extending across the second extension, and a fourth plane facing the other direction in the thickness direction and extending from the second extension to the second connection, The first plane and the third plane are flush, The second plane and the fourth plane are flush. The curved bus bar according to claim 1 or 2.

5. The surface of the first busbar element facing one of the thickness directions is recessed around the first through hole. The curved bus bar according to claim 1 or 2.

6. A bent busbar according to claim 1 or 2, An electronic component electrically connected to the aforementioned bent busbar, Equipped with, Electrical connection unit.

7. A first busbar element comprising: a first extension portion extending in a first extension direction within the cable routing surface; and a first connecting portion continuous with the first extension portion, wherein the first connecting portion has a first connecting surface along the cable routing surface and a first through hole penetrating from the first connecting surface in a thickness direction intersecting the cable routing surface; A second busbar element comprising: a second extending portion extending in a second extending direction different from the first extending direction within the cable routing surface; and a second connecting portion continuous with the second extending portion, wherein the second connecting portion has a second connecting surface in contact with the first connecting surface; and the second connecting portion has a first projection that projects continuously from the second connecting surface and extends through the first through hole; Decide on the layout, The second connecting portion is fastened to the first connecting portion. A method for manufacturing a bent busbar.

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