Charging device and method for manufacturing a charging device

Abstract

The present invention provides a charging device in which a connector is located on the lid, and a method for manufacturing the charging device. [Solution] In the charging device 100, the third busbar 633 and the second busbar 632 are fixedly connected by a fixing member 661. The fixing member 661 is positioned in the through hole 612C when viewed from the direction normal to the second surface 612B of the lid 611.

Description

Technical Field

[0001] The present disclosure relates to a charging device and a method for manufacturing the charging device.

Background Art

[0002] International Publication No. 2013-073491 (Patent Document 1) discloses a charging device for charging a battery of a vehicle. The charging device is mounted in the motor room (also referred to as the engine room) of this vehicle. The charging device has a housing and an inverter etc. disposed inside the housing. A connector is disposed on the side wall of the housing of this charging device. A cable is connected to this connector.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As described above, the charging device is mounted in the motor room of the vehicle. Other components are also mounted in the motor room in addition to the charging device. Also, as described above, the connector is disposed on the side wall of the housing. Therefore, considering the presence of other components, the designer may want to dispose the connector on the lid of the charging device. However, in the conventional charging device, the configuration of disposing the connector on the lid has not been considered.

[0005] The present disclosure has been made to solve the above-described problems, and an object in one aspect is to provide a charging device in which a connector is disposed on a lid and a method for manufacturing the charging device.

Means for Solving the Problems

[0006] The charging device of this disclosure is mounted on a vehicle. The charging device comprises a connector into which a cable connector of a cable supplied with voltage from an external charger of the vehicle is inserted, a supply circuit that supplies power supplied to the connector to the vehicle's battery, a connector terminal that is conductive to the connector, a first busbar for supplying voltage to the supply circuit, a housing having an opening, and a lid that closes the opening. The lid closes the opening to form a housing space. The housing space houses the supply circuit, the first busbar, and the connector terminal, and the lid has a first surface facing the housing space, a second surface opposite the first surface, and a through hole. The connector is fixed to the second surface. The first busbar and the connector terminal are fixedly connected by a fixing member. The fixing member is positioned in the through hole when viewed from the direction normal to the second surface.

[0007] The manufacturing method of the present disclosure is a manufacturing method for manufacturing a charging device to be mounted on a vehicle. The manufacturing method comprises preparing a lid unit and preparing a housing unit. The lid unit has a lid having a first surface, a second surface opposite to the first surface, and a through hole, a connector into which a cable connector of a cable supplied with voltage from an external charger of the vehicle is inserted and fixed to the second surface, and a connector terminal that is conductive to the connector. The housing unit has a supply circuit that supplies power supplied to the connector to the vehicle's battery, a busbar for supplying voltage to the supply circuit, and a housing having an opening. The manufacturing method further comprises positioning the lid unit on the housing unit such that the first surface faces the housing unit and the lid closes the opening. By positioning the lid unit on the housing unit, a housing space is formed. The housing space accommodates the supply circuit, the busbar, and the connector terminal. The manufacturing method further comprises passing a fixing member through the through hole and fixing the connector terminal and the busbar with the fixing member. [Effects of the Invention]

[0008] According to this disclosure, a power control device having a connector arranged on a lid, and a method for manufacturing the power control device can be provided. [Brief explanation of the drawing]

[0009] [Figure 1] This diagram illustrates the state in which the charging device of this embodiment is mounted on a vehicle. [Figure 2] This is a perspective view of the charging device of the comparative example. [Figure 3] This is a perspective view of the charging device of this embodiment. [Figure 4] This is a perspective view of a charging device having a pair of harnesses. [Figure 5] This is a diagram illustrating the internal components of the charging device according to this embodiment. [Figure 6] This is a diagram showing the charging device viewed from directly above. [Figure 7] This diagram shows the main components of the charging device attached to the cable connector 689 and the first connector. [Figure 8] This is a block diagram of the inside of the charging device. [Figure 9] This flowchart shows the main steps in the manufacturing process of a charging device. [Figure 10] This is a diagram showing a connector device. [Figure 11] This is a diagram showing the base device. [Figure 12] This diagram shows the connector device attached to the base device. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure will be described in detail below with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals, and their descriptions will not be repeated.

[0011] [Vehicles and charging equipment] FIG. 1 is a diagram for explaining a state where the charging device 100 of the present embodiment is mounted on the vehicle 10. The vehicle 10 is an electric vehicle. The vehicle 10 mainly includes a charging port 12, a pair of cables 160, an engine room 10A, wheels 10B, a battery 106, and the like. When the vehicle 10 is an electric vehicle, there is no engine, but the engine room 10A is formally called an engine room in the present embodiment. Further, the charging device 100 is mounted in the engine room 10A. The charging device 100 is electrically connected to a pair of cables 160, a battery 106, and the like.

[0012] In the present embodiment, the height direction of the vehicle 10 is the Z-axis direction. The Z-axis direction is the direction of gravity acting on the charging device 100 (hereinafter, also referred to as the "gravity direction"). Also, the front-rear direction of the vehicle 10 is the Y-axis direction. In particular, the front direction of the vehicle 10 is the Y1-axis direction, and the rear direction of the vehicle 10 is the Y2-axis direction. Also, the left-right direction of the vehicle 10 is the X-axis direction. In particular, the right direction of the vehicle 10 is the X1-axis direction, and the left direction of the vehicle 10 is the X2-axis direction. Further, in a state where the charging device 100 is mounted on the vehicle 10, the Z-axis direction is the height direction of the charging device 100.

[0013] When the vehicle 10 is charged at a charging facility or the like, a stand-side connector extending from a charging stand 从充电架14作为车辆10外部的充电器插入充电口12。从充电架14到充电口12施加交流(AC:Alternating Current)电压和直流(DC:Direct Current)电压。 [[ID=IO]]

[0014] The voltage from the charging stand 14 is supplied to the charging device 100 via the charging port 12 and a pair of cables 160. The charging device 100 includes a first connector 601, a second connector 602, a third connector 603, a fourth connector 604, a pair of harnesses 152, and the like.

[0015] It should be noted that in the original text of item , there is an incomplete expression "从充电架14作为车辆10外部的充电器插入充电口12", which may affect the understanding of the full meaning. The above translation is based on the existing text as accurately as possible.The first connector 601 is inserted with the cable connectors 689 of a pair of cables 160 to which the voltage from the charging stand 14 is supplied. The first connector 601 corresponds to the "connector" of the present disclosure. When a DC voltage is input to the first connector 601, a voltage greater than 0V and not exceeding 1000V is supplied. Also, when an AC voltage is input to the first connector 601, a voltage greater than 0Vrms (Voltage Root-Mean-Square) and not exceeding 293Vrms is supplied.

[0016] When the voltage input to the first connector 601 is an AC voltage, the AC voltage is supplied to the second connector 602. Then, the AC voltage is input from the second connector 602 to the third connector 603 via the harness 152. The AC voltage is input from the third connector 603 to the conversion circuit 180 (see FIG. 4).

[0017] The conversion circuit 180 converts the voltage supplied to the first connector 601 and supplies the converted voltage to the battery 106. For example, when the voltage supplied from the charging stand 14 is an AC voltage, the conversion circuit 180 converts the AC voltage to a DC voltage and supplies the DC voltage from the fourth connector 604 to the battery 106. The conversion circuit 180 typically includes an on-board charger.

[0018] Also, when the voltage supplied from the charging stand 14 is a DC voltage, the charging device 100 supplies the DC voltage from the fourth connector 604 to the battery 106. As a modification, the conversion circuit 180 of the charging device 100 may adjust the voltage value of the DC voltage from the charging stand 14 and supply the adjusted DC voltage to the battery 106.

[0019] The pair of power lines in this embodiment includes a high-voltage wiring for carrying high-voltage current and a low-voltage wiring for carrying low-voltage current. Similarly, the pair of harnesses 152 includes a high-voltage harness for carrying high-voltage current and a low-voltage harness for carrying low-voltage current. Furthermore, the busbars, which will be described later, also include a pair of busbars, and this pair of busbars includes a high-voltage busbar and a low-voltage busbar.

[0020] [Comparative example charging device] Figure 2 is a perspective view of the comparative example charging device 100X. The comparative example charging device 100X is a charging device that supports only AC charging and does not support DC charging. Furthermore, the charging device 100X does not house the supply circuit described later. The charging device 100X has a side surface 100A, and a connector 603X is located on this side surface 100A.

[0021] Here, the charging device 100X is mounted in the vehicle's engine compartment. In addition to the charging device 100X, other components are also mounted in the engine compartment. Also, in the example in Figure 2, the connector 603X is located on side 100A. When the connector 603X is located on side 100A, the worker passes the wiring of the connector 603X through a through hole (not shown) formed in side 100A from the outside of the charging device 100X. The worker then screws (not shown) the flange portion of the connector 603X to side 100A. This allows the worker to connect the wiring of the connector 603X to the components inside the charging device 100X through the opening before closing the lid (top surface) of the charging device 100X.

[0022] Incidentally, the presence of these other components can create problems, such as making it cumbersome to insert a cable into the connector 603X located on side 100A. Taking the presence of such other components into consideration, the designer may want to place the connector on the lid (top surface) of the charging device 100X.

[0023] Therefore, a configuration in which the connector 603X is placed on the lid (top surface) of the charging device 100X can be considered. However, in the comparative example charging device 100X, if the connector 603X is simply placed on the lid (top surface), after fixing the connector 603X to the lid, it will be necessary to connect the connector's wiring to the internal components of the charging device 100X before closing the lid. This would necessitate using long cables for the wiring, and the connection work would need to be performed while holding the lid, potentially resulting in significant manufacturing costs.

[0024] Therefore, in this embodiment, a charging device 100 is provided in which the connector is fixed to the lid, while suppressing manufacturing costs by using the comparative example charging device 100X.

[0025] [Perspective view of the charging device of this embodiment] Figure 3 is a perspective view of the charging device 100 of this embodiment. The charging device 100 is a device to which a connector device 100S has been added to a base device 100N. The base device 100N may be an existing charging device, for example, it may correspond to the charging device 100X of the comparative example. The connector device 100S corresponds to the "lid unit" of this disclosure. The base device 100N corresponds to the "housing unit" of this disclosure.

[0026] As described above, the charging device 100 has a first connector 601, a second connector 602, and a third connector 603. The first connector 601 and the second connector 602 are provided on the connector device 100S, and the third connector 603 is provided on the base device 100N.

[0027] Furthermore, in the connector device 100S, the area of ​​the surface on which the first connector 601 is located (the second surface 612B of the cover 611, described later) is larger than the area of ​​the side surface of the connector device 100S.

[0028] Figure 4 is a perspective view of the charging device 100 having a pair of harnesses 152. As described above, one end of the pair of harnesses 152 is connected to the second connector 602, and the other end of the pair of harnesses 152 is connected to the third connector 603.

[0029] [Internal components of the charging device] Figure 5 is a diagram illustrating the internal components of the main part of the charging device 100 of this embodiment. Figure 6 is a top-down view of the connector device 100S of the charging device 100. Figure 5 is a schematic cross-sectional view along line AA in Figure 6, showing only one of the pair of busbars.

[0030] As shown in Figure 5, the charging device 100 comprises a lid 611 and a housing 660. The outer wall of the connector device 100S becomes the lid 611, and the outer wall of the base device 100N becomes the housing 660. The lid 611 has a top plate portion 612, a side wall 613, and a flange 681 formed on the side wall 613.

[0031] The top plate portion 612 has a first surface 612A, a second surface 612B, and a through hole 612C. The first surface 612A and the second surface 612B face each other. The first surface 612A is the surface facing the storage space 670, which will be described later. The second surface 612B is the surface opposite to the first surface 612A.

[0032] The housing 660 has an opening 660A and a side wall 660B. Furthermore, the housing 660 has a flange 682 formed on the side wall 660B. The lid 611 is installed on the housing 660 so as to close the opening 660A, and flanges 681 and 682 are fixed to a fixing member 672. In this embodiment, the fixing member is a screw. Note that the fixing member may be any other member that can be fixed.

[0033] The fixing member 672 secures the lid 611 to the housing 660, forming a housing space 670. The housing space 670 accommodates the supply circuit 190, the first busbar 631, the third busbar 633, the connector terminal 635, and the connector frame 651, among other things. The first busbar 631 corresponds to the "busbar" in this disclosure.

[0034] The first connector 601 is fixed to the second surface 612B of the top plate portion 612. The first connector 601, the connector frame 651, and the flange 671 are integrally formed. The connector frame 651 insulates the connection between the connector terminal body 640 and the first connector 601 from the outside. In the example shown in Figure 5, the flange 671 is fixed to the lid 611 by a fixing member 663, thereby fixing the first connector 601 to the second surface 612B.

[0035] The second connector 602 is fixed to the side wall 613. The second connector 602, the connector frame 652, and the flange 673 are integrally formed. The connector frame 652 insulates the connection between the third busbar 633 and the second connector 602 from the outside. In the example in Figure 5, the flange 673 is fixed to the side wall 613 by a fixing member 665, thereby fixing the second connector 602 to the side wall 613.

[0036] The connector terminal 635 comprises a connector terminal body 640 and a second busbar 632. The connector terminal body 640 has an elongated shape. In Figure 6, the connector terminal body 640 is elongated in the Z-axis direction. The connector terminal body 640 is conductive to the first connector 601.

[0037] The second busbar 632 has an elongated shape. The second busbar 632 has one end 632A and the other end 632B in the elongation direction. The other end 632B and the connector terminal body 640 are fixedly connected by a fixing member 662. In the example of Figure 5, the fixing member 662 is fixed in the Z-axis direction. Furthermore, in the example of Figure 5, the second busbar 632 has a bent portion 632C.

[0038] The first bus bar 631 has an elongated shape. The first bus bar 631 has one end 631A and the other end 631B in the elongation direction.

[0039] The third busbar 633 has an elongated shape. The third busbar 633 has one end 633A and the other end 633B in the direction of extension.

[0040] Furthermore, the first busbar 631, the second busbar 632, and the third busbar 633 are fixed by the first terminal block 641, the second terminal block 642, and the third terminal block 643, respectively.

[0041] The first terminal block 641 is fixed to a predetermined part (not shown) of the housing 660 (base device 100N). The second terminal block 642 and the third terminal block 643 are fixed to a predetermined part of the connector device 100S (in the example of Figure 6, the first surface 612A of the top plate portion 612).

[0042] One end 631A of the first busbar 631, one end 632A of the second busbar 632, and one end 633A of the third busbar 633 are fixedly connected by a fixing member 661. "Fixed connection" means that the connection is both fixed and electrically connected.

[0043] The other end 631B of the first busbar 631 is connected to the power supply circuit 190. The other end 633B of the third busbar 633 is connected to the second connector 602. As described above, the power input from the second connector 602 is supplied to the conversion circuit 180 via a pair of harnesses 152. Therefore, the third busbar 633 is a busbar for supplying voltage to the conversion circuit 180.

[0044] Furthermore, the charging device 100 includes a closing member 730 for closing the through hole 612C. The closing member 730 is fixed to the lid 611 by a fixing member 664.

[0045] Figure 6 shows the connector device 100S of the charging device 100 as viewed from the normal direction (Z-axis direction) of the second surface 612B of the cover 611. In other words, Figure 6 shows the charging device 100 as viewed from the direction of gravity of the charging device 100. "Viewing from the normal direction" is also referred to as "viewing from above." Note that the closing member 730, fixing member 664, flange 681, and fixing member 672 are not shown in Figure 6.

[0046] In Figure 6, exposed parts are shown with solid lines, and parts concealed by the cover 611 are shown with dashed lines. As shown in Figure 6, the fixing member 661 is positioned in the through hole 612C when viewed from the direction normal to the second surface 612B. In other words, the fixing member 661 is positioned inside the through hole 612C when viewed from the direction normal to the second surface 612B.

[0047] Note that the cover 611 in Figure 6 is the cover of the connector device 100S. The housing space 670 of the connector device 100S may be in communication with the housing space of the base device 100N. Alternatively, the housing space 670 of the connector device 100S and the housing space of the base device 100N may be separate spaces. In other words, a partition may be provided between the housing space 670 of the connector device 100S and the housing space of the base device 100N.

[0048] Furthermore, the lid 611 may be integrated with the lid of the base device 100N, or it may be a separate lid from the lid of the base device 100N.

[0049] Figure 7 shows the main part of the charging device 100 with the cable connector 689 of cable 160 (see Figure 1) attached (inserted) into the first connector 601. Figure 7(A) is a top-down view of the charging device 100 in this case, and Figure 7(B) is the main part of the charging device 100 in this case corresponding to the diagram in Figure 5. In Figure 7(A), the second connector 602, flange 673, and fixing member 665 shown in Figure 6 are not shown. Also, although a closing member 730 is attached, the fixing member 664 is not shown in Figure 7(A).

[0050] As shown in Figure 7(B), the insertion direction of the cable connector 689 into the first connector 601 is the same as the normal direction (Z-axis direction) described above. In the example in Figure 7(B), the insertion direction is indicated by arrow A. Also, when the charging device 100 is mounted on the vehicle 10 (see Figure 1), this normal direction is the height direction (Z-axis direction) of the vehicle 10.

[0051] Furthermore, in the example of Figure 7(B), the extension direction of the cable 160 is the Y-axis direction. In the example of Figure 7(B), the extension direction is indicated by arrow B. As shown by arrows A and B, the insertion direction of the cable connector 689 into the first connector 601 is different from the extension direction of the cable 160. More specifically, the angle between the insertion direction (arrow A) and the extension direction (arrow B) is 90 degrees, as shown at location R.

[0052] Furthermore, as shown in Figure 7(A), when the charging device 100 is viewed from the normal direction, the cable 160 overlaps with at least a portion of the through-hole 612C. In other words, the cable 160 may overlap with the entire through-hole 612C. Alternatively, the cable 160 may overlap with only a portion of the through-hole 612C.

[0053] Furthermore, as shown in Figure 7(B), the pair of cables 160 are fixed by a fixing base 162 (clamp). More specifically, the pair of cables 160 are fixed between one end and the other end of the pair of cables 160 by the fixing base 162.

[0054] [Circuit configuration of the charging device] Figure 8 is a block diagram of the inside of the charging device 100. Figure 8 shows the first connector 601, the second connector 602, the third connector 603, the first busbar 631, the connector terminal 635 (connector terminal body 640, second busbar 632), the third busbar 633, and a pair of harnesses 152. Furthermore, the charging device 100 includes a first node 102A, a first switchgear 301, an ECU (Electronic Control Unit) 320, a conversion circuit 180, and a supply circuit 190. The vehicle 10 also includes a battery 106 (see Figure 1) and an electrical load 104. The fourth connector 604 is not shown in Figure 8.

[0055] The first node 102A corresponds to the location fixed by the fixing member 661 (see Figure 5), that is, the location where the first busbar 631, the second busbar 632, and the third busbar 633 are electrically connected.

[0056] The first busbar 631 is a busbar from the first node 102A to the supply circuit 190. In other words, it is a busbar for supplying voltage to the supply circuit 190. Connector terminal 635 (second busbar 632) is a busbar from the first connector 601 to the first node 102A. The third busbar 633 is a busbar from the first node 102A to the second connector 602.

[0057] The ECU320 can determine whether the voltage input from the charging station 14 to the first connector 601 is AC voltage or DC voltage. For example, the charging station 14 transmits a voltage type signal to the ECU320 indicating whether it is AC voltage or DC voltage. Based on this voltage type signal, the ECU320 can determine whether it is AC voltage or DC voltage.

[0058] The supply circuit 190 includes a pair of power lines 350, a second node 102B, a third node 102C, a second switchgear 302, and a third switchgear 303. The pair of power lines 350 consists of a high-voltage power line 350H carrying high-voltage current and a low-voltage power line 350L carrying low-voltage current. One end of the pair of power lines 350 included in the supply circuit 190 is connected to the other end 631B of the first busbar 631 (see Figure 5). In other words, the first connector 601 and the battery 106 are electrically connected by the connector terminal 635, the first busbar 631, and the pair of power lines 350.

[0059] The second node 102B is located closer to the battery 106 than the first node 102A. The third node 102C is located closer to the battery 106 than the second node 102B.

[0060] At the second node 102B, a power line branches off from a pair of power lines 350. This branched power line is connected to an electrical load 104. The electrical load 104 is a load that generates the driving force for the vehicle 10 using the power from the battery 106. The electrical load 104 is, for example, a traction inverter.

[0061] At the third node 102C, a power line branches off from a pair of power lines 350. This branched power line 351 is connected to the output side of the conversion circuit 180.

[0062] Furthermore, one switchgear includes a high-voltage relay provided on the high-voltage power line and a low-voltage relay provided on the low-voltage power line. For example, the first switchgear 301 includes a high-voltage relay 301H and a low-voltage relay 301L. The first switchgear 301 is located between a pair of power lines 350 and the output side of the conversion circuit 180. The second switchgear 302 is located between the first node 102A and the second node 102B. The third switchgear 303 is located between the second node 102B and the third node 102C.

[0063] Furthermore, in this disclosure, "opening a switchgear" means "opening both the high-voltage relay and the low-voltage relay included in the switchgear." By opening the switchgear, electricity becomes non-conductive (cannot conduct) at the location of the switchgear. On the other hand, "closing a switchgear" means "closing both the high-voltage relay and the low-voltage relay included in the switchgear." By closing the switchgear, electricity becomes conductive (can conduct) at the location of the switchgear.

[0064] The third switchgear 303 includes relays 303H and 303L, as well as relay 303P connected to a resistor. For example, when the charging device 100 pre-charges the capacitor of the electrical load 104 during vehicle startup, it closes relays 303H and 303P. This reduces the current flowing through the resistor connected to relay 303P, thereby suppressing inrush current flowing through the capacitor.

[0065] The ECU320 controls charging via an external power supply, and controls the opening and closing of multiple switchgear devices. The ECU320 is also referred to as a "control circuit."

[0066] [Control of ECU320] Next, the control of the ECU320 will be explained. As mentioned above, the ECU320 performs actions such as controlling the opening and closing of multiple switchgears. This allows the state of the vehicle 10 (charging device 100) to be switched to one of several states. These states include a battery discharge state, an AC charging state, and a DC charging state.

[0067] First, let's explain the battery discharge state. The battery discharge state is a state in which the battery 106 is being discharged, for example, when the vehicle 10 is being driven (running). The ECU 320 sets the state of the charging device 100 to the battery discharge state by closing the first switchgear 301, opening the second switchgear 302, and closing the third switchgear 303.

[0068] In the battery discharge state, power from battery 106 is supplied to the electrical load 104.

[0069] Next, the AC charging state will be described. The AC charging state is a state in which AC voltage is supplied from the first connector 601 and the battery 106 is charged. When the ECU 320 detects that AC voltage is being applied from the charging station 14, it opens the second switchgear 302 and closes the first switchgear 301 and the third switchgear 303.

[0070] Furthermore, it is sufficient for either the second switchgear 302 or the third switchgear 303 to be open. Moreover, if both the second switchgear 302 and the third switchgear 303 are open, it is possible to prevent unintentional power supply to the electrical load 104.

[0071] In the AC charging state, AC power supplied from the first connector 601 is input to the conversion circuit 180 via the second connector 602 and the third connector 603. The conversion circuit 180 converts the AC power to DC power and supplies it to the battery 106.

[0072] Next, the DC charging state will be described. When the ECU 320 performs DC charging, it opens the first switchgear 301 and closes the second switchgear 302 and the third switchgear 303. As a result, the DC power supplied from the first connector is supplied to the battery 106.

[0073] Thus, the ECU 320 opens the second switchgear 302 (switching circuit) when AC charging is enabled and closes the second switchgear 302 when DC charging is enabled. With this control, the charging device 100 of this embodiment can charge the battery 106 regardless of whether AC power or DC power is input to the first connector 601.

[0074] [Manufacturing method] Next, the main steps of the manufacturing method for the charging device 100 will be described. Figure 9 is a flowchart showing the main steps of the manufacturing method for the charging device 100. This process is performed by at least one of a manufacturer (human) and a robot. Hereinafter, this at least one will also be referred to as "manufacturer, etc."

[0075] First, in step S2, the manufacturer or the like prepares the connector device 100S (Figure 10, described later) and the base device 100N (Figure 11, described later). Next, in step S4, the manufacturer or the like places the connector device 100S on the base device 100N. Next, in step S6, the manufacturer or the like passes the fixing member 661 through the through hole 612C and fixes one end 631A of the first busbar 631, one end 632A of the second busbar 632, and one end 631A of the third busbar 633 with the fixing member 661.

[0076] Figure 10 shows the connector device 100S corresponding to cross-section AA in Figure 6. Figure 11 shows the base device 100N corresponding to cross-section AA in Figure 6.

[0077] The connector device 100S in Figure 10 mainly comprises a cover 611, a first connector 601, a second connector 602, a third busbar 633, a connector terminal 635, and a connector frame 651. As described in Figure 6, the cover 611 has a first surface 612A, a second surface 612B, and a through hole 612C. The first connector 601 is fixed to the second surface 612B. The second busbar 632 and the third busbar 633 are fixed to the second terminal block 642 and the third terminal block 643, respectively. The second terminal block 642 and the third terminal block 643 are fixed to the cover 611. Through holes are formed at one end 632A of the second busbar 632 and at one end 633A of the third busbar 633.

[0078] The base device 100N in Figure 11 includes a housing 660, a supply circuit 190, a first busbar 631, and a first terminal block 641. The housing 660 has an opening 660A and a side wall 60B.

[0079] The first busbar 631 is fixed to the first terminal block 641. A through hole is formed in one end 633A of the first busbar 631. Furthermore, the first terminal block 641 has an engagement hole into which the tip of the fixing member 661 engages.

[0080] Furthermore, the manufacturing process for the connector device 100S and the manufacturing process for the base device 100N may be any process. Also, the third connector 603 and the fourth connector 604 are fixed to the base device 100N in advance.

[0081] Figure 12 is a diagram illustrating steps S4 and S6 of Figure 9. As shown in Figure 12, in step S4, the connector device 100S is positioned on the base device 100N such that the first surface 612A of the cover 611 faces the housing space 670 and the cover 611 closes the opening 660A. Also, in the example of Figure 12, engagement holes 691 into which the fixing member 661 engages are formed by the through holes of the first busbar 631, the second busbar 632, the third busbar 633, and the engagement holes of the first terminal block 641.

[0082] Then, in step S6, as shown by arrow C in Figure 11, the fixing member 661 is passed through the through hole 612C and engages with the engagement hole 691. The engagement of the fixing member 661 with the engagement hole 691 fixes the first busbar 631, the second busbar 632, and the third busbar 633. Subsequently, fixing is performed by the fixing member 672 and closing is performed by the closing member 730.

[0083] [Summary] (1) Generally, the charging device is mounted in the engine compartment of the vehicle. In addition to the charging device, other components are also mounted in the engine compartment. Furthermore, as shown in Figure 2, the connector 603X of the comparative example charging device 100X is located on the side 100A of the charging device 100X. Therefore, the presence of other components in the engine compartment may cause problems, such as the process of inserting a cable into the connector being cumbersome. Taking the presence of such other components into consideration, the designer may want to place the connector on the cover of the charging device.

[0084] However, conventionally, the manufacture of a charging device in which the connector is fixed to the lid has not been considered. In contrast, in the charging device 100 of this embodiment, as shown in Figure 5, the fixing member 661 is positioned inside the through hole 612C when viewed from the direction normal to the second surface 612B of the lid 611. Therefore, a charging device 100 in which the first connector 601 is positioned on the second surface 612B of the lid 611 can be manufactured, for example, by the process described in Figures 9 to 12. Specifically, the charging device 100 is configured so that the fixing member 661 can be used to connect to the internal components after the lid 611 has been closed. In the charging device 100, there is no need to make internal connections before closing the lid 611, so there is no need for long cables, and manufacturing becomes easier.

[0085] (2) As shown in Figure 7, the insertion direction of the cable connector 689 into the first connector 601 (see arrow A) is the same as the normal direction (Z-axis direction) described above.

[0086] With this configuration, the operator can insert the cable connector 689 into the first connector 601 from above the charging device 100. Therefore, the operator can easily insert the cable connector 689 into the first connector 601.

[0087] In this disclosure, the term "identical" between any direction (hereinafter also referred to as the "first direction") and another direction (hereinafter also referred to as the "second direction") may include both being completely identical and being substantially identical. "Substantially identical" may include the first and second directions being different to the extent that they produce the effects relating to the first and second directions. For example, the insertion direction (see arrow A) and the normal direction (Z-axis direction) being substantially identical means that the insertion direction and the normal direction are different to the extent that they produce the effect of "the worker being able to easily insert the cable connector 689 into the first connector 601."

[0088] (3) As shown in Figure 1, with the charging device 100 mounted on the vehicle 10, the above normal direction is the same as the height direction (Z-axis direction) of the vehicle 10.

[0089] As described above, the charging device 100 is mounted in the engine room 10A, where other components are also installed. In conventional charging devices, the operator needs to insert the cable connector into a connector located on the side of the charging device. In this case, the process of inserting the cable connector into the connector becomes complicated due to obstruction by other components, etc. In contrast, according to the configuration of the present disclosure, the operator can insert the cable connector 689 into the first connector 601 from above the charging device 100. Therefore, the operator can easily insert the cable connector 689 into the first connector 601.

[0090] (4) As shown in Figure 7(B), the insertion direction (arrow A) is different from the extension direction of the cable 160 (arrow B).

[0091] With this configuration, even if the cable 160 is pulled while the cable connector 689 is inserted into the first connector 601, it is possible to prevent the cable connector 689 from being unintentionally pulled out of the first connector 601.

[0092] Furthermore, as shown at location R in Figure 7(B), the angle between the insertion direction (arrow A) and the extension direction (arrow B) is 90 degrees.

[0093] With this configuration, even if the cable 160 is pulled while the cable connector 689 is inserted into the first connector 601, it is possible to prevent the cable connector 689 from being unintentionally pulled out of the first connector 601.

[0094] In this disclosure, "the angle between the insertion direction and the extension direction is 90 degrees" means that the angle between the insertion direction and the extension direction is not only exactly 90 degrees, but may also include angles that fall outside the 90-degree range (for example, 80 degrees or more and 100 degrees or less). For example, the angle between the insertion direction and the extension direction may fall outside the 90-degree range to the extent that it prevents the cable connector 689 from being unintentionally pulled out of the first connector 601.

[0095] (5) As shown in Figure 7(A), when the charging device 100 is viewed from the normal direction, the cable 160 overlaps with at least a portion of the through hole 612C.

[0096] With this configuration, a fail-safe structure can be established in which, when power can be supplied from the charging station via the cable 160, workers cannot access the fixing members 661 (first busbars 631 to third busbars 633). In other words, in order for workers to access the fixing members 661, they must disconnect the cable 160. Therefore, it is possible to prevent workers from inadvertently coming into contact with the fixing members 661 (first busbars 631 to third busbars 633).

[0097] (6) As shown in Figure 5, the connector terminal 635 includes the connector terminal body 640 and the second busbar 632.

[0098] With this configuration, since the connector terminal 635 includes the connector terminal body 640 and the second busbar 632, the connector terminal 635 can be manufactured for each component separately.

[0099] (7) As shown in Figure 5, the second terminal block 642 is fixed to the cover 611. With this configuration, even if the second busbar 632 is long, the second busbar 632 can be stably held to the lid side.

[0100] (8) The pair of cables 160 are fixed by a mounting base 162 (clamp). With this configuration, for example, even if a force is applied in the direction of cable extension (see arrow B), the impact of this force on the first connector 601 can be reduced.

[0101] (9) As explained in Figure 8, the charging device 100 has a second switch 302 that switches between a state in which the DC voltage supplied to the first connector 601 is applied to the first busbar 631 and a state in which the AC voltage supplied to the first connector 601 is applied to the third busbar 633. The first busbar 631 supplies the DC voltage supplied to the first connector 601 to the supply circuit 190. The third busbar 633 supplies the AC voltage supplied to the first connector 601 to the conversion circuit 180.

[0102] With this configuration, whether the power from the charging stand 14 is AC power or DC power, only one first connector 601 is needed as the charging port, and the wiring to the charging device 100 can also be shortened.

[0103] (10) When DC power is supplied to the first connector 601, a voltage greater than 0V and less than or equal to 1000V is supplied, and when AC power is supplied, a voltage greater than 0Vrms and less than or equal to 293Vrms is supplied.

[0104] With this configuration, the battery 106 can be properly charged even when the above-mentioned voltage is supplied to the first connector 601.

[0105] [Differentiation] In the above-described connector terminal 635, a configuration was described in which the connector terminal body 640 and the second busbar 632 are separate components. However, the connector terminal body 640 and the second busbar 632 may be formed integrally.

[0106] [Note] (Section 1) The charging device of the present disclosure is mounted on a vehicle. The charging device comprises a connector into which a cable connector of a cable supplied with voltage from an external charger of the vehicle is inserted, a supply circuit that supplies power supplied to the connector to the vehicle's battery, a connector terminal that is conductive to the connector, a first busbar for supplying voltage to the supply circuit, a housing having an opening, and a lid that closes the opening. The lid closes the opening to form a housing space. The housing space houses the supply circuit, the first busbar, and the connector terminal, and the lid has a first surface facing the housing space, a second surface opposite the first surface, and a through hole. The connector is fixed to the second surface. The first busbar and the connector terminal are fixedly connected by a fixing member. The fixing member is positioned in the through hole when viewed from the direction normal to the second surface.

[0107] With this configuration, during the manufacturing stage of the charging device, the first busbar and the connector member can be fixedly connected via a fixing member through a through-hole. Therefore, a charging device can be manufactured in which the connector is located on the second surface of the lid.

[0108] (Paragraph 2) The charging device described in Paragraph 1, wherein the direction of insertion of the cable connector into the connector is the normal direction.

[0109] With this configuration, the operator can insert the cable connector into the connector from above the charging device.

[0110] (Article 3) The charging device described in Article 2, wherein when the charging device is mounted on a vehicle, the normal direction is the direction of the vehicle's height.

[0111] The charging device is mounted in the engine compartment, where other components are also installed. In conventional charging devices, the operator needs to insert the cable connector into a connector located on the side of the charging device. In this case, the process of inserting the cable connector into the connector can be complicated due to obstruction by other components. In contrast, according to the configuration of this disclosure, the operator can insert the cable connector into the connector from above the charging device. Therefore, the complexity of the process of inserting the cable connector into the connector can be reduced.

[0112] (Clause 4) A charging device as described in paragraph 2 or 3, wherein the insertion direction is different from the cable's extension direction.

[0113] With this configuration, even if the cable is pulled while the cable connector is inserted into the connector, it is possible to prevent the cable connector from being unintentionally pulled out of the connector.

[0114] (Clause 5) A charging device as described in any one of paragraphs 1 to 4, wherein when the charging device is viewed from the normal direction, the cable overlaps with at least a portion of the through hole.

[0115] With this configuration, a fail-safe structure can be implemented where workers cannot access the fixed components when power is supplied via the cable.

[0116] (Clause 6) A charging device according to any one of paragraphs 1 to 5, wherein the connector terminal further comprises a second busbar. The charging device comprises a terminal block for fixing the second busbar. The housing space houses the supply circuit, the first busbar, and the second busbar. The first busbar and the second busbar are fixedly connected by a fixing member.

[0117] With this configuration, since the connector terminal includes the second busbar and other components, the connector terminal can be manufactured for each component separately.

[0118] (Clause 7) The charging device described in paragraph 6, wherein the terminal block is fixed to the cover. With this configuration, for example, even if the second busbar is long, the second busbar can be stably held in place by the lid.

[0119] (Clause 8) A charging device as described in any one of paragraphs 1 to 7, wherein the cable is secured by a mounting base.

[0120] With this configuration, for example, even if a force is applied in the direction of cable extension, the impact of this force on the connector can be reduced.

[0121] (Section 9) A charging device according to any one of Sections 1 to 8, wherein the connector is supplied with a DC voltage and an AC voltage from a charger. A first busbar supplies the DC voltage supplied to the connector to a supply circuit. The supply circuit supplies the DC voltage supplied by the first busbar to the battery. The charging device further includes a conversion circuit that converts the AC voltage to a DC voltage, a third busbar that supplies the AC voltage supplied to the connector to the conversion circuit, and a switching circuit that switches between a state in which the DC voltage supplied to the connector is applied to the first busbar and a state in which the AC voltage supplied to the connector is applied to the third busbar. The housing space houses the supply circuit, the first busbar, and the third busbar. The first busbar and the third busbar are fixedly connected by a fixing member.

[0122] With this configuration, whether the power from the charging station is AC or DC voltage, only one connector is needed for the charging port, and the wiring from the vehicle's charging port to the charging device can be shortened.

[0123] (Item 10) A charging device as described in any one of items 1 to 9, wherein the connector is supplied with a voltage greater than 0V and less than or equal to 1000V when DC power is supplied, and with a voltage greater than 0Vrms and less than or equal to 293Vrms when AC power is supplied.

[0124] With this configuration, the battery can be properly charged even if the voltages mentioned above are supplied to the connector.

[0125] (Section 11) A manufacturing method of the present disclosure is a manufacturing method for manufacturing a charging device to be mounted on a vehicle. The manufacturing method comprises preparing a lid unit and preparing a housing unit. The lid unit has a lid having a first surface, a second surface opposite to the first surface, and a through hole, a connector into which a cable connector of a cable supplied with voltage from an external charger of the vehicle is inserted and fixed to the second surface, and a connector terminal that is conductive to the connector. The housing unit has a supply circuit that supplies power supplied to the connector to the vehicle's battery, a busbar for supplying voltage to the supply circuit, and a housing having an opening. The manufacturing method further comprises positioning the lid unit on the housing unit such that the first surface faces the housing unit and the lid closes the opening. By positioning the lid unit on the housing unit, a housing space is formed. The housing space accommodates the supply circuit, the busbar, and the connector terminal. The manufacturing method further comprises passing a fixing member through the through hole and fixing the connector terminal and the busbar with the fixing member.

[0126] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The scope of this disclosure is indicated by the claims rather than by the description of the embodiments above, and all modifications within the meaning and scope equivalent to the claims are intended to be included. [Explanation of Symbols]

[0127] 10 Vehicle, 10A Engine room, 10B Wheels, 12 Charging port, 14 Charging stand, 100 Charging device, 100A Side, 100N Base device, 100S Connector device, 102A First node, 102B Second node, 102C Third node, 104 Electrical load, 106 Battery, 152 Harness, 160 Cable, 162 Fixing base, 180 Conversion circuit, 190 Supply circuit, 301 First switch, 302 Second switch, 303 Third switch, 601 First connector, 602 Second connector, 603 Third connector, 604 Fourth connector, 611 Cover, 612 Top plate, 612A First surface, 612B Second surface, 612C Through hole, 631 First busbar, 632 Second busbar, 633 Third busbar, 635 Connector terminal, 640 Connector terminal body, 641 First terminal block, 642 Second terminal block, 643 Third terminal block, 660 Enclosure, 689 Cable connector 691 Engagement hole, 730 Closure member.

Claims

1. A charging device installed in a vehicle, A connector into which the cable connector of the cable that receives voltage from an external charger for the vehicle is inserted, A power supply circuit that supplies the power supplied to the connector to the vehicle's battery, A connector terminal having conductivity to the aforementioned connector, A first busbar for supplying voltage to the aforementioned supply circuit, A housing having an opening, It comprises a lid that closes the aforementioned opening, The lid closes the opening, thereby forming a storage space. The aforementioned housing space houses the supply circuit, the first busbar, and the connector terminals. The aforementioned lid is The first surface on the side of the accommodation space, The second surface opposite to the first surface, Having a through hole, The connector is fixed to the second surface, The first busbar and the connector terminal are fixedly connected by a fixing member. The fixing member is a charging device positioned in the through hole when viewed from the direction normal to the second surface.

2. The charging device according to claim 1, wherein the insertion direction of the cable connector into the connector is the normal direction.

3. The charging device according to claim 2, wherein, when the charging device is mounted on the vehicle, the normal direction is the height direction of the vehicle.

4. The charging device according to claim 2 or claim 3, wherein the insertion direction is different from the cable's extension direction.

5. When the charging device is viewed from the normal direction, The charging device according to any one of claims 1 to 3, wherein the cable overlaps with at least a portion of the through hole.

6. The aforementioned connector terminal further comprises a second busbar, The charging device includes a terminal block for fixing the second busbar, The aforementioned housing space houses the supply circuit, the first busbar, and the second busbar. The charging device according to any one of claims 1 to 3, wherein the first busbar and the second busbar are fixedly connected by the fixing member.

7. The charging device according to claim 6, wherein the terminal block is fixed to the cover.

8. The charging device according to any one of claims 1 to 3, wherein the cable is fixed by a fixing base.

9. The connector receives DC voltage and AC voltage from the charger. The first busbar supplies the DC voltage supplied to the connector to the supply circuit. The supply circuit supplies the DC voltage supplied by the first busbar to the battery. The charging device further includes, A conversion circuit that converts AC voltage to DC voltage, A third busbar that supplies the AC voltage supplied to the connector to the conversion circuit, The system includes a switching circuit that switches between a state in which a DC voltage supplied to the connector is applied to the first busbar and a state in which an AC voltage supplied to the connector is applied to the third busbar. The aforementioned housing space houses the supply circuit, the first busbar, and the third busbar. The charging device according to any one of claims 1 to 3, wherein the first busbar and the third busbar are fixedly connected by the fixing member.

10. To the aforementioned connector, When DC power is supplied, a voltage greater than 0V and less than or equal to 1000V is supplied. A charging device according to any one of claims 1 to 3, wherein when AC power is supplied, a voltage greater than 0 Vrms (Voltage Root-Mean-Square) and less than or equal to 293 Vrms is supplied.

11. A manufacturing method for producing a charging device to be installed in a vehicle, Prepare the lid unit, This includes preparing the enclosure unit, The aforementioned lid unit is A lid having a first surface, a second surface opposite to the first surface, and a through hole, A cable connector of a cable that receives voltage from an external charger of the vehicle is inserted into a connector that is fixed to the second surface, The connector has conductive connector terminals, The aforementioned housing unit is A power supply circuit that supplies the power supplied to the connector to the vehicle's battery, A busbar for supplying voltage to the aforementioned supply circuit, It has a housing that has an opening, The aforementioned manufacturing method further includes, The lid unit is positioned on the housing unit such that its first surface faces the housing unit and its lid closes the opening. The lid unit is placed on the housing unit to form a storage space. The aforementioned housing space houses the supply circuit, the busbar, and the connector terminals. The aforementioned manufacturing method further includes, A manufacturing method comprising passing a fixing member through the through hole and fixing the connector terminal and the busbar with the fixing member.

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