Electrical connection unit

Abstract

One embodiment provides an electrical connection unit that can be miniaturized. [Solution] An electrical connection unit according to one embodiment comprises a relay having terminals and a circuit module. The circuit module includes a substrate, a precharge resistor, a precharge relay, wiring material, and a protective member for protecting the substrate. The precharge relay is connected in series with the precharge resistor. The precharge resistor and the precharge relay are mounted on the substrate and enclosed within the protective member. The wiring material extends from the substrate toward the terminals and is electrically connected to the terminals.

Description

Technical Field

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

Background Art

[0002] A power distribution device (hereinafter, also referred to as an “electrical connection unit”) including a main relay, a precharge resistor, and a precharge relay is known.

[0003] For example, Patent Document 1 discloses a power distribution device including “a precharge resistor mounted on a circuit board after being modularized and a part of a modularized precharge relay”.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, further miniaturization of an electrical connection unit including a main relay, a precharge resistor, and a precharge relay is desired.

[0006] One embodiment is to provide an electrical connection unit capable of achieving miniaturization.

Means for Solving the Problems

[0007] An electrical connection unit in one embodiment comprises a relay having terminals and a circuit module. The circuit module includes a substrate, a precharge resistor, a precharge relay, wiring material, and a protective member for protecting the substrate. The precharge relay is connected in series with the precharge resistor and mounted on the substrate. The precharge resistor and the precharge relay are enclosed within the protective member. The wiring material extends from the substrate toward the terminals and is electrically connected to the terminals. [Effects of the Invention]

[0008] According to one embodiment, the electrical connection unit can be easily miniaturized. [Brief explanation of the drawing]

[0009] [Figure 1] A perspective view showing the electrical connection unit of the first embodiment. [Figure 2] A perspective view showing a disassembled portion of the electrical connection unit shown in Figure 1. [Figure 3] Figure 1 is a perspective view showing the circuit module. [Figure 4] A perspective view showing the installation of the circuit module shown in Figure 1. [Figure 5] A perspective view showing the electrical connection unit of the comparative example. [Figure 6] Circuit diagram of the electrical connection unit in the comparative example. [Figure 7] A perspective view showing the electrical connection unit of the second embodiment. [Figure 8] Figure 7 is a perspective view showing the circuit module. [Figure 9] A perspective view showing the installation of the circuit module shown in Figure 7. [Figure 10] A perspective view showing the circuit module of the third embodiment. [Figure 11] Figure 10 is a perspective view showing the installation of the circuit module. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure will be described below with reference to the drawings. The drawings and specific configurations used in each embodiment should not be used to interpret the disclosure. In all drawings, identical or corresponding components are denoted by the same reference numerals, and common descriptions are omitted.

[0011] In this disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows: The -Y direction is the direction in which terminal 13 faces. The +Y direction is the opposite direction to the -Y direction. Hereinafter, when the +Y direction and the -Y direction are not distinguished, they will simply be referred to as the "Y direction". The +X direction is the direction in which terminal 13B aligns with terminal 13A. The -X direction is the opposite direction to the +X direction. Hereinafter, when the +X direction and the -X direction are not distinguished, they will simply be referred to as the "X direction". The -Z direction is the direction in which at least a portion of the busbar 30 of the circuit module 20 extends. The +Z direction is the opposite direction to the -Z direction. The +Z direction and the -Z direction are directions that intersect (e.g., are orthogonal to) the X direction and the Y direction. Hereinafter, when the +Z direction and the -Z direction are not distinguished, they will simply be referred to as the "Z direction". The Y direction is an example of a "first direction". The Z direction is an example of a "second direction." The X direction is an example of a "third direction."

[0012] In the following, when the X and Y directions are not distinguished, they may be referred to as the "horizontal direction." However, these expressions are for explanatory convenience only and do not limit the arrangement of the circuit module 20.

[0013] (First Embodiment) <1. Configuration of the electrical connection unit> The electrical connection unit 100 of the first embodiment will be described below with reference to the figures. FIG. 1 is a cross-sectional view showing an electrical connection unit 100 according to the first embodiment. The electrical connection unit 100 is an in-vehicle device mounted on a vehicle such as an EV (Electric Vehicle), HEV (Hybrid Electric Vehicle), or PHEV (Plug-in Hybrid Electric Vehicle). The electrical connection unit 100 may be referred to as, for example, an "electrical connection box" or a "junction box". However, the electrical connection unit 100 is not limited to a box-shaped device. The electrical connection unit 100 includes, for example, a relay 10, a circuit module 20, a bus bar 40, and a plurality of fastening members 51. Further, the electrical connection unit 100 may include a plurality of connection members 60 as needed. The electrical connection unit 100 in the present embodiment includes a plurality of connection members 60. Note that in FIGS. 1 and 4, the relay 10 and the connection members 60 are shown in a simplified manner.

[0014] <2. Relay> First, the relay 10 will be described. The relay 10 is mounted according to the functions required for the electrical connection unit 100. The relay 10 may be a mechanical relay or a semiconductor relay.

[0015] FIG. 2 is a perspective view showing a partially disassembled electrical connection unit 100. FIG. 3 is a perspective view showing a part of the electrical connection unit 100. The relay 10 has, for example, a case 11, a component body portion 12, and a terminal 13. The relay 10 has the terminal 13 at one end of the relay 10 in the horizontal direction (for example, the Y direction).

[0016] (Case) The case 11 is an outer member that forms most of the outer shape of the relay 10. The case 11 is made of, for example, synthetic resin and has insulating properties. The case 11 houses the component body portion 12. Note that the case 11 and the component body portion 12 may be integrally formed.

[0017] (Body portion) The main component part 12 is the part that performs the main function of the relay 10. For example, the main component part 12 includes a switching part (e.g., a contact part) that switches between a conductive state and a non-conductive state.

[0018] (Terminals) Terminal 13 is an electrical connection part exposed to the outside of case 11. Terminal 13 is electrically connected to the component body 12 inside case 11. Terminal 13 includes terminal 13A and terminal 13B. One of terminals 13A and 13B is the positive terminal. The other of terminals 13A and 13B is the negative terminal. One of terminals 13A and 13B is an example of a "first terminal". The other of terminals 13A and 13B is an example of a "second terminal".

[0019] In this embodiment, terminals 13A and 13B are provided at one end of the relay 10 in the horizontal direction (e.g., the Y direction). For example, when viewed from the Z direction, terminal 13B is aligned with terminal 13A in the X direction. For example, in this embodiment, terminals 13A and 13B are arranged side by side in the horizontal direction (e.g., the X direction). Each of terminals 13A and 13B faces the horizontal direction (e.g., the Y direction). Note that when viewed from the X direction, the position of terminal 13A in the Z direction and the position of terminal 13B in the Z direction may be different. In other words, terminals 13A and 13B do not have to be arranged side by side in the horizontal direction (e.g., the X direction).

[0020] The terminal 13 has a mounting hole 13h into which a fastening member 51 (e.g., a screw or bolt), described later, is inserted. The mounting hole 13h opens horizontally (e.g., in the -Y direction). The inner circumferential surface of the mounting hole 13h of the relay 10 has a screw groove. The mounting hole 13h is a bottomed hole provided in the relay 10. Note that the mounting hole 13h is not limited to a hole with a screw groove, and may be a hole without a screw groove. Also, if the terminal 13 is plate-shaped, the mounting hole 13h may be a through hole that penetrates the terminal 13 in the direction of the plate thickness of the terminal 13.

[0021] (others) The relay 10 may have multiple mounting parts 14 (only one is shown in Figure 2). The mounting portion 14 is a part for fixing the relay 10. For example, the mounting portion 14 is a part for fixing the relay 10 to another component. For example, each mounting portion 14 is positioned to protrude from both sides of the case 11 in the horizontal direction.

[0022] Case 11 may have insulating ribs 11a that protrude horizontally (e.g., in the -Y direction) and extend in the Z direction, as shown in Figure 2. In all figures except Figure 2, the insulating ribs 11a are omitted. The insulating ribs 11a are, for example, plate-shaped and aligned along the Y and Z directions. The insulating ribs 11a extend, for example, along the entire length of case 11 in the Z direction. The insulating ribs 11a are positioned between terminals 13A and 13B. The insulating ribs 11a electrically insulate terminals 13A and 13B. In addition, a portion of the insulating ribs 11a may be positioned between two connecting members 60. The insulating ribs 11a electrically insulate, for example, between two connecting members 60.

[0023] <3. Connecting Members> Next, the connecting members 60 will be described. In this embodiment, the electrical connection unit 100 includes two connecting members 60.

[0024] The connecting member 60 is a metal member attached to the busbar 30 of the circuit module 20. The connecting member 60 electrically connects the relay 10, the circuit module 20, and the busbar 40 (see Figure 1). The connecting member 60 has, for example, a first part 61 and a second part 62. The connecting member 60 is made of, for example, copper, a copper alloy, aluminum, or an aluminum alloy, but is not limited to these examples.

[0025] Furthermore, the connecting member 60 may also have the function of increasing the heat capacity of the current-carrying path of the electrical connection unit 100. For example, the connecting member 60 stores (absorbs) at least a portion of the heat generated by the connected object (at least one of the relay 10, busbar 30, and busbar 40).

[0026] (first part) The first portion 61 of the connecting member 60 is the portion that connects to the terminal 13 of the relay 10. The first portion 61 is a plate-shaped or rectangular parallelepiped portion that extends in the Z direction. The first portion 61 extends in the Z direction along one end of the relay 10 (for example, the end in the Y direction). The first portion 61 is an upright portion that stands upright in the Z direction relative to the busbar 40. The first portion 61 is adjacent to the relay 10 in the horizontal direction (for example, the Y direction). For example, the first portion 61 is adjacent to the terminal 13 of the relay 10 in the horizontal direction (for example, the Y direction) and is connected to the terminal 13 of the relay 10 from the horizontal direction (for example, the Y direction).

[0027] The first portion 61 of the connecting member 60 has a first mounting hole 61h through which a fastening member 51 (e.g., a screw or bolt) passes. The connecting member 60 in this embodiment is fastened together with the first busbar 30A by fastening the fastening member 51 through the first through hole 32h and the first mounting hole 61h. The connecting member 60 may also be fastened together with the second busbar 30B. The first mounting hole 61h opens horizontally (e.g., in the X direction). The first portion 61 also has a recess 65 around the first mounting hole 61h. The recess 65 is a housing portion that accommodates the head of the fastening member 51 inserted into the first mounting hole 61h. The first portion 61 is physically and electrically connected to the terminal 13 of the relay 10 by the fastening member 51 passed through the first mounting hole 61h engaging with the mounting hole 13h of the terminal 13 of the relay 10. The first portion 61 does not necessarily have to have a recess 65. The first mounting hole 61h is an example of either the "first mounting hole" or the "third mounting hole".

[0028] (Second part) The second portion 62 of the connecting member 60 is the portion that connects to the busbar 40 (see Figure 1). This connection electrically connects the relay 10 and the busbar 40. The second portion 62 protrudes horizontally (e.g., in the Y direction) from the -Z direction end of the first portion 61. The second portion 62 is a plate portion that runs horizontally. The second portion 62 is adjacent to the busbar 40 in the Z direction and connects to the busbar 40 from the Z direction. The second portion 62 of the connecting member 60 is attached from the Z direction to a fastening member 43 (e.g., a screw or bolt) that protrudes from the busbar 40 in the +Z direction, and is physically and electrically connected to the busbar 40. In this embodiment, the second portion 62 of the connecting member 60 has a second mounting hole 62h through which the fastening member 43 passes. The second mounting hole 62h is open in the Z direction. The fastening member 43 passes through the second mounting hole 62h of the second portion 62. Then, the second portion 62 is fixed to the busbar 40 by engaging an engaging member (e.g., a nut) with the tip of the fastening member 43 that has been passed through the second mounting hole 62h. In this embodiment, the first portion 61 and the second portion 62 form an L-shaped single connecting member 60. The second mounting hole 62h is an example of a "second mounting hole".

[0029] The connecting member 60 may be formed by bending, cutting, or casting. If the connecting member 60 is formed by bending, the connecting member 60 may be a plate-shaped member. That is, the thickness of the first portion 61 in the axial direction of the first mounting hole 61h and the thickness of the second portion 62 in the axial direction of the second mounting hole 62h may be the same.

[0030] <4. Circuit Modules> Next, the circuit module 20 will be described. Figure 3 is a perspective view showing a part of the electrical connection unit 100. The circuit module 20 is a modularized unit comprising a precharge resistor 22 and a precharge relay 23 connected in series with the precharge resistor 22 (see Figure 6). The circuit module 20 is electrically connected to terminals 13 (terminals 13A and 13B) and forms a bypass circuit to divert the current flowing through the relay 10 to the bypass circuit. The circuit module 20 is electrically connected in parallel to the main circuit formed by the relay 10 and the busbar 40. The circuit module 20 includes a circuit board 21, a precharge resistor 22, a precharge relay 23, two busbars 30, a control circuit 24, and a protective member 25. The precharge resistor 22, the precharge relay 23, and the control circuit 24 are mounted on the circuit board 21 and enclosed together with the circuit board 21 in the protective member 25.

[0031] The protective member 25 is a member that protects the substrate 21 in the circuit module 20 and is an outer shell member that forms most of the outer shape of the circuit module 20. The protective member 25 is made of, for example, synthetic resin and has insulating properties. In this embodiment, the protective member 25 is molded resin. For example, in the circuit module 20 in this embodiment, the substrate 21, the precharge resistor 22, the precharge relay 23, the two busbars 30, the control circuit 24, and the protective member 25 are integrated by molded resin. The protective member 25 may also be an outer shell member that covers the substrate 21.

[0032] In this embodiment, the substrate 21 is arranged along a plane that includes the Y direction (XY plane, ZY plane). In other words, in this embodiment, the circuit module 20 is located on the upper side (+Z direction), lower side (-Z direction), right side (+X direction), or left side (-X direction) of the relay 10, with the end of the relay 10 on which the terminal 13 is provided facing forward. An example in which the circuit module 20 is located on the front side (-Y direction) or the back side (+Z direction) of the relay 10 will be described later in the third embodiment. In this embodiment, the precharge resistor 22 and precharge relay 23 mounted on the substrate 21 overlap the relay 10 when viewed from the Z direction.

[0033] The precharge relay 23 includes a coil 231 and a switch 232. The switch 232 operates in response to the energization of the coil 231. The switch 232 operates in response to the energization of the coil 231 as shown below, for example.

[0034] (Control circuits, coils, switches) The control circuit 24 in this disclosure controls the conduction state of the coil 231. Switching the conduction of the coil 231 switches between excitation and demagnetization, and the switch 232 switches in accordance with the generation and disappearance of the magnetic field. For example, the switch 232 includes a movable contact and a fixed contact. For example, the movable contact is connected to a movable element via a transmission unit, and the transmission unit moves the movable contact in accordance with the movement of the movable element. The movement of the movable contact is performed as follows: First, when the control circuit 24 energizes the coil 231, the magnetic field generated by the coil 231 attracts the movable element. Next, the transmission unit moves the movable contact in accordance with the attraction of the movable element. The movement of the movable contact causes the movable contact to contact the fixed contact, thereby opening and closing the switch 232. When the switch 232 switches from the "closed position" to the "open position", current flows in the bypass circuit and gradually charges the capacitor in the main circuit via the precharge resistor 22. When the capacitor has finished charging, the control circuit 24 cuts off the power to the coil 231. When the power to the coil 231 is cut off, the movable element does not attract, and the switch 232 switches from the "open position" to the "closed position". In this way, the current flow in the electrical connection unit 100 switches from the bypass circuit to the main circuit. For example, in this embodiment, the "closed position" is the position of the movable contact when the bypass circuit is a closed circuit. Note that the above is merely an example, and the switch 232 in the bypass circuit can be either normally open or normally closed.

[0035] (Bus bar 30) The busbar 30 is a wiring member (electrical connection member) included in the circuit module 20. The busbar 30 is a wiring member for electrically connecting the precharge resistor 22 and the precharge relay 23 in parallel to the relay 10. The busbar 30 is made of metal (e.g., copper or copper alloy) and is conductive. The busbar 30 is an example of a "first wiring member". The busbar 30 extends from the substrate 21 toward the terminal 13 and is electrically connected to the terminal 13 (see Figure 4).

[0036] The busbar 30 has a connecting portion 31 and an extension portion 32. The connecting portion 31 is the part that is electrically connected to the substrate 21. The connecting portion 31 may penetrate the substrate 21. The extension portion 32 extends from the substrate 21 toward the terminal 13 and is the part that is electrically connected to the relay 10 via a fastening member 51 (e.g., a screw or bolt).

[0037] Here, the busbar 30 includes a first busbar 30A electrically connected to terminal 13A via a first through-hole 32h, and a second busbar 30B electrically connected to terminal 13B. As mentioned above, terminals 13A and 13B do not have to be arranged side by side in the horizontal direction (for example, the X direction), so the length of the extension portion 32 electrically connected to terminal 13A and the extension portion 32 electrically connected to terminal 13B may differ.

[0038] The specific routing of the busbar 30 is described below. The extension portion 32 extends continuously from the end of the connection portion 31. For example, in this embodiment, the extension portion 32 extends continuously from the end of the connection portion 31 on the -Z direction side. At least a portion of the extension portion 32 is plate-shaped along the vertical direction. Also, at least a portion of the extension portion 32 extends in the Z direction along one end of the relay 10. For example, in this embodiment, a portion of the busbar 30 extends in the Z direction (for example, the -Z direction) along the end of the relay 10 in the Y direction (see Figure 4).

[0039] The first busbar 30A has a first through-hole 32h in the extension portion 32 that penetrates the first busbar 30A in the Y direction. In this embodiment, the extension portion 32 is adjacent to the connecting member 60 in the Y direction at the first through-hole 32h. In the Y direction, the first busbar 30A is connected to the connecting member 60 from the -Y direction by a fastening member 51 (e.g., a screw or bolt) passing through the first through-hole 32h and the first mounting hole 61h (see Figure 4). Here, the second busbar 30B may have the same configuration as the first busbar 30A. For example, the second busbar 30B in this embodiment has a first through-hole 32h in the extension portion 32 that penetrates the second busbar 30B in the Y direction.

[0040] <5. Busbar 40> Next, we will describe the busbar 40. Figure 4 is a perspective view showing the mounting of the circuit module 20. The busbar 40 is a wiring member for electrically connecting the relay 10. Together with the relay 10, the busbar 40 forms the main circuit of the electrical connection unit 100. The busbar 40 comprises a connecting portion 41 and an extension portion 42. The busbar 40 is made of metal (e.g., copper or a copper alloy) and is conductive. The busbar 40 is an example of a "second wiring member". The busbar 40 is electrically connected to the terminal 13 via the connecting portion 60 or the extension portion 32.

[0041] The busbar 40 has a connecting portion 41 and an extension portion 42. The connecting portion 41 is the part that is electrically connected to the relay 10 and is the part that contacts the connecting member 60 or the extension portion 32. When viewed from the Z direction in the busbar 40, the connecting portion 41 is the part that overlaps with the second portion 62 of the connecting member 60 or the extension portion 32 of the busbar 30. In this embodiment, the connecting portion 41 is adjacent to the second portion 62 of the connecting member 60 in the Z direction and connects to the first portion 61 from the Z direction.

[0042] The specific routing of the busbar 40 will be described below. The extension portion 42 extends continuously from the end of the connecting portion 41. For example, in this embodiment, the extension portion 42 extends continuously from one end of the connecting portion 41 in the horizontal direction (for example, the X direction). The extension portion 42 is plate-shaped and oriented horizontally.

[0043] (Fastening member) Next, the fastening member 43 will be described. The fastening member 43 is a component for fixing the bus bar 40 to the component to which the bus bar 40 is connected (connecting member 60 or bus bar 30). The fastening member 43 is, for example, a crimping bolt fixed to the bus bar 40. The fastening member 43 is an example of a "fastening part".

[0044] In this embodiment, the connection portion 41 of the busbar 40 has a through hole 40h. The through hole 40h penetrates the busbar 40 in the Z direction. The fastening member 43 is, for example, a bolt having a shaft portion 43a and a head. The circumferential surface of the shaft portion 43a has screw grooves. For example, the head has a larger diameter than the shaft portion 43a. For example, the fastening member 43 is crimped to the busbar 40 with the shaft portion 43a passing through the through hole 40h of the busbar 40. With this fixing, the fastening member 43 is electrically and physically connected to the busbar 40 with the shaft portion 43a protruding from the through hole 40h of the busbar 40 in the +Z direction. Note that the fastening member 43 is not limited to crimping, and may be fixed to the busbar 40 by welding or other methods.

[0045] <6. Circuit Module Installation Procedure> Next, the installation procedure for the circuit module 20 will be described.

[0046] First, the relay 10 is placed on the busbar 40 (Figure 4:4-1). Next, the connecting member 60 is placed on the bus bar 40 such that, when viewed from the Z direction, the second portion 62 of the connecting member 60 overlaps with the connecting portion 41 of the bus bar 40. More specifically, the connecting member 60 is placed on the bus bar 40 by inserting the fastening member 43 vertically into the second mounting hole 62h of the connecting member 60. Next, an engaging member (e.g., a nut) is engaged with the upper end of the fastening member 43 from the vertical direction. This fixes the connecting member 60 to the bus bar 40 (Figure 4: 4-2).

[0047] Next, with the circuit module 20 in close proximity to the terminal 13 (Figure 4:4-3), it is electrically connected to the terminal 13 via a fastening member 51 (for example, a screw or bolt) (Figure 4:4-5). At this time, the connecting member 60 is fixed to the terminal 13A together with the first busbar 30A by the fastening member 51 passing through the first through hole 32h and the first mounting hole 61h (Figure 4:4-4). In this embodiment, the second busbar 30B is similarly fixed to the terminal 13B together with the second busbar 30B. In this way, the circuit module 20 is electrically connected to the relay 10, and the bypass circuit is electrically connected in parallel to the main circuit.

[0048] <7. Advantages> First, let's describe the comparative example electrical connection unit 700. Figure 5 is a perspective view of the comparative example electrical connection unit 700. Figure 6 is a circuit diagram of the comparative example electrical connection unit 700.

[0049] For example, if the electrical connection unit 100 includes a circuit that stores electricity in a capacitor, such as an inverter circuit, a large current (inrush current) may flow through the circuit when the power supply to the electrical connection unit 100 is turned ON. To prevent damage to the circuit due to the inrush current, it is necessary to provide a current path (bypass circuit) incorporating a precharge resistor 22 separately from the main circuit, and configure it so that current flows through the precharge resistor 22 until electricity is stored in the capacitor. The electrical connection unit 700 shown in the comparative example differs from the electrical connection unit 100 in that it includes a precharge resistor 22, a precharge relay 23, and a busbar 90 instead of a circuit module 20. The busbar 90 forms a bypass circuit by being electrically connected to the busbar 40. In the electrical connection unit 700 of the comparative example, the busbar 90 connects bypass circuits upstream and downstream of the relay 10. In the electrical connection unit 700 of the comparative example, space is required for the bypass circuit in order to provide the bypass circuit. Furthermore, since the bypass circuit is connected to both the upstream and downstream of the relay 10, layout constraints are required to electrically connect the bypass circuit in parallel with the relay 10.

[0050] On the other hand, the electrical connection unit 100 in this embodiment includes a relay 10 having terminals 13 and a circuit module 20. The circuit module 20 includes a substrate 21, a precharge resistor 22, a precharge relay 23, wiring (e.g., busbars 30), and a protective member 25 that protects the substrate 21. The precharge relay 23 is connected in series with the precharge resistor 22. The precharge resistor 22 and the precharge relay 23 are mounted on the substrate 21 and enclosed within the protective member 25. The wiring extends from the substrate 21 toward terminals 13 and is electrically connected to terminals 13.

[0051] In the electrical connection unit 100 of this embodiment, a circuit module 20 including a precharge resistor 22 and a precharge relay 23 is electrically connected to the relay 10, thereby providing bypass circuits upstream and downstream of the relay 10. The bypass circuits protect the relay 10 by preventing inrush current from flowing through it. In this embodiment, the precharge resistor 22 and precharge relay 23 that form the bypass circuits are enclosed within a protective member 25, thus being less subject to layout constraints. Compared to the comparative example electrical connection unit 700, the area occupied by the precharge resistor 22 and precharge relay 23 can be reduced in the electrical connection unit 100 of this embodiment. For example, with the end of the relay 10 on which the terminal 13 is provided facing forward, the precharge resistor 22 and precharge relay 23 and the relay 10 can be easily stacked so that the circuit module 20 is positioned above (+Z direction) or below (-Z direction) the relay 10. As described above, the electrical connection unit 100 of this embodiment is easily miniaturized.

[0052] Furthermore, in this embodiment, terminal 13 is located at one end of relay 10 in a first direction (for example, the Y direction). The substrate 21 is arranged along a plane that includes the first direction. When viewed from a second direction (for example, the Z direction) that intersects the first direction, the precharge resistor 22 and precharge relay 23 overlap with relay 10. With this configuration, the area occupied by the precharge resistor 22 and precharge relay 23 within the electrical connection unit 100 can be reduced. Therefore, the electrical connection unit 100 in this embodiment is easily miniaturized.

[0053] In this embodiment, the electrical connection unit 100 further includes a fastening member 51. The terminal 13 includes a first terminal (e.g., terminal 13A) and a second terminal (e.g., terminal 13B). When viewed from the second direction, the second terminal is aligned with respect to the first terminal in a third direction (e.g., the X direction) that intersects the first and second directions. The wiring material includes a first busbar 30A electrically connected to the first terminal and a second busbar 30B electrically connected to the second terminal. The first busbar 30A extends in the second direction and has a first through-hole 32h through which the fastening member 51 passes. The first through-hole 32h penetrates the first busbar in the first direction. In the first direction, the first busbar is fixed to the first terminal. With this configuration, the wiring path of the wiring material can be shortened while reducing the area occupied by the precharge resistor 22 and precharge relay 23 within the electrical connection unit 100. Based on the above, the electrical connection unit 100 in this embodiment is easily miniaturized.

[0054] In this embodiment, the electrical connection unit 100 further comprises a connecting member 60. The connecting member 60 has a first mounting hole 61h. The fastening member 51 of the connecting member 60 is fastened together with the first busbar 30A through the first through hole 32h and the first mounting hole 61h. With this configuration, at least a portion of the heat generated by the relay 10 or the first busbar 30A is transferred to the connecting member 60, which facilitates the cooling of the electrical connection unit 100's current-carrying circuit.

[0055] (Second embodiment) <8. Configuration of the electrical connection unit> The electrical connection unit 200 of the second embodiment will be described below with reference to the figures. Figure 7 is a perspective view showing the electrical connection unit 200 of the second embodiment. Figure 8 is a perspective view showing the circuit module 20 in the second embodiment. Figure 9 is a perspective view showing the mounting of the circuit module 20B in the second embodiment.

[0056] The second embodiment differs from the first embodiment in the respects described below. However, the configuration is the same as that of the first embodiment, except for the features described below.

[0057] Figure 7 shows the electrical connection unit 200 and the circuit module 20B. The electrical connection unit 200 does not require a connecting member 60. In the electrical connection unit 200, the extension portion 32-2 of the circuit module 20B electrically connects the relay 10 and the busbar 40 (see Figure 9). The circuit module 20B includes a busbar 30, which includes a first busbar 30A2 and a second busbar 30B. As shown in Figure 8, the first busbar 30A2 of the circuit module 20B has a connecting portion 31 and an extension portion 32-2.

[0058] The first busbar 30A2 differs from the first busbar 30A in that the first busbar 30A further has a second through-hole 32h2 in the extension portion 32. The extension portion 32-2 differs from the extension portion 32 in that the cable routing path of the extension portion 32 is different.

[0059] In this embodiment, the substrate 21 is arranged along a plane that includes the Y direction (XY plane, ZY plane). In other words, in this embodiment, the circuit module 20B is located above (+Z direction), below (-Z direction), to the right (+X direction), or to the left (-X direction) of the relay 10, with the end of the relay 10 on which the terminal 13 is provided facing forward. Similarly in this embodiment, the precharge resistor 22 and precharge relay 23 mounted on the substrate 21 overlap the relay 10 when viewed from the Z direction.

[0060] The extension portion 32-2 extends continuously from the end of the connection portion 31 described above. For example, in this embodiment, the extension portion 32-2 extends continuously from the end of the connection portion 31 on the -Z direction side. At least a portion of the extension portion 32-2 is plate-shaped along the vertical direction. Also, at least a portion of the extension portion 32-2 extends in the Z direction along one end of the relay 10. For example, a portion of the busbar 30 in this embodiment extends in the Z direction (e.g., the -Z direction) along the end of the relay 10 in the Y direction (see Figure 9).

[0061] The following describes the specific wiring configuration for the first busbar 30A2. For example, the extension portion 32-2 of the first busbar 30A2 extends in the Z direction (e.g., the -Z direction), then bends, and extends in the Y direction (e.g., the -Y direction).

[0062] The first busbar 30A2 has a first through hole 32h and a second through hole 32h2 in its extension portion 32-2. Similarly in this embodiment, the extension portion 32-2 is adjacent to the terminal 13A in the Y direction at the first through hole 32h. In the Y direction, the first busbar 30A2 is connected to the terminal 13A from the -Y direction by a fastening member 51 (e.g., a screw or bolt) passing through the first through hole 32h.

[0063] The second through-hole 32h2 is a through-hole that penetrates the first busbar 30A2 in the Z direction. In this embodiment, the extension portion 32-2 is adjacent to the connection portion 41 of the busbar 40 in the Z direction at the second through-hole 32h2. In the Z direction, the first busbar 30A2 is connected to the busbar 40 from the -Z direction by a fastening member 43 that passes through the second through-hole 32h2.

[0064] Here, the second busbar 30B may have the same configuration as the first busbar 30A2. For example, in this embodiment, the second busbar 30B has a first through-hole 32h in the extension portion 32-2 that penetrates the second busbar 30B in the Y direction. In the Y direction, the second busbar 30B is connected to the terminal 13B from the -Y direction by a fastening member 51 (e.g., a screw or bolt) passing through the first through-hole 32h.

[0065] Next, the installation procedure for the circuit module 20B in this embodiment will be described using Figure 9.

[0066] First, the relay 10 is placed on the busbar 40 (Figure 9:9-1). Next, the circuit module 20B is placed on the bus bar 40 such that the extension portion 32-2 overlaps the connection portion 41 of the bus bar 40 when viewed from the Z direction. More specifically, the circuit module 20B is placed on the bus bar 40 by inserting the fastening member 43 vertically into the second through hole 32h2 located in the extension portion 32-2. Next, the engaging member (e.g., a nut) is engaged with the upper end of the fastening member 43 from the vertical direction. This fixes the connecting member 60 to the bus bar 40 (Figure 9:9-2).

[0067] Next, with the circuit module 20B in close proximity to the terminal 13 (Figure 9:9-2), it is electrically connected to the terminal 13 via a fastening member 51 (for example, a screw or bolt) (Figure 9:9-4). At this time, the first busbar 30A2 is fixed to the terminal 13A by the fastening member 51 passing through the first through-hole 32h (Figure 9:9-4). In this embodiment, the second busbar 30B is similarly fixed to the terminal 13B together with the second busbar 30B. In this way, the circuit module 20B is electrically connected to the relay 10, and the bypass circuit is electrically connected in parallel to the main circuit.

[0068] In the circuit module 20B of this embodiment, the relay 10, the circuit module 20B, and the busbar 40 are electrically and / or thermally connected by the bent extension portion 32-2. In the electrical connection unit 200 of this embodiment, a connection member 60 is not required, and therefore a reduction in the number of parts in the electrical connection unit is expected.

[0069] (Third embodiment) <9. Configuration of the electrical connection unit> Next, a third embodiment will be described. Except for the configuration described below, the configuration is the same as that of the embodiments described above. Figure 10 is a perspective view showing the circuit module 20C in the embodiment. Figure 11 is a perspective view showing the mounting of the circuit module 20C in the second embodiment.

[0070] In this embodiment, an electrical connection unit 300 and a circuit module 20C are shown. The electrical connection unit 300 requires a connecting member 60, similar to the electrical connection unit 100. In the electrical connection unit 300, the extension portion 32-3 of the circuit module 20C is electrically connected to the bus bar 40. The circuit module 20C includes a bus bar 30, which includes a first bus bar 30A3 and a second bus bar 30B. As shown in Figure 10, the first bus bar 30A3 of the circuit module 20C has a connecting portion 31 and an extension portion 32-3. In this embodiment, the connecting portion 31 penetrates the substrate 21.

[0071] The first busbar 30A3 differs from the first busbar 30A in that the direction in which the first through-hole 32h penetrates the first busbar 30A is different. The extension 32-3 differs from the extension 32 in that the routing path of the extension 32 is different.

[0072] In this embodiment as well, terminals 13 (terminals 13A and 13B) are located at one end of the relay 10 in the Y direction. For example, when viewed from the Z direction, terminal 13B is aligned with terminal 13A in the X direction.

[0073] In this embodiment, the substrate 21 is arranged, for example, along a plane (ZX plane) that intersects the Y direction. In other words, in this embodiment, the circuit module 20C is located either on the front side (-Y direction side) or the back side (+Z direction side) of the relay 10, with the end of the relay 10 on which the terminal 13 is provided facing forward. In this embodiment, the precharge resistor 22 and precharge relay 23 mounted on the substrate 21 overlap the relay 10 when viewed from the Y direction.

[0074] The extension portion 32-3 extends continuously from the end of the connection portion 31 described above. For example, in this embodiment, the extension portion 32-3 extends continuously from the end of the connection portion 31 on the -Z direction side. At least a portion of the extension portion 32-3 is plate-shaped along the vertical direction. Also, at least a portion of the extension portion 32-3 extends in the Z direction along one end of the relay 10. For example, a portion of the busbar 30 in this embodiment extends in the Z direction (e.g., the -Z direction) along the end of the relay 10 in the Y direction (see Figure 11).

[0075] The following describes the specific wiring configuration for the first busbar 30A3. For example, the extension portion 32-3 of the first busbar 30A3 extends in the Z direction (e.g., the -Z direction), then bends, and extends in the Y direction (e.g., the +Y direction).

[0076] The first busbar 30A3 has a first through-hole 32h in its extension portion 32-3. Here, the first through-hole 32h penetrates the first busbar 30A3 in the Z direction. At the first through-hole 32h, the extension portion 32-3 is adjacent to the connection portion 41 of the busbar 40 in the Z direction. In the Z direction, the first busbar 30A3 is connected to the connection member 60 from the -Z direction by a fastening member 43 that passes through the first through-hole 32h (see Figure 11).

[0077] Here, the second busbar 30B may have the same configuration as the first busbar 30A3. For example, in this embodiment, the second busbar 30B has a first through hole 32h in the extension portion 32-3 that penetrates the second busbar 30B in the Z direction. In the Z direction, the second busbar 30B is connected to the connecting member 60 from the -Z direction by a fastening member 43 that passes through the first through hole 32h and the second mounting hole 62h.

[0078] Next, the installation procedure for the circuit module 20C in this embodiment will be described using Figure 11.

[0079] First, the relay 10 is placed on the busbar 40 (Figure 11:11-1). Next, the connecting member 60 is placed on the bus bar 40 such that, when viewed from the Z direction, the second portion 62 of the connecting member 60 overlaps with the connection portion 41 of the bus bar 40. More specifically, the connecting member 60 is placed on the bus bar 40 by inserting the fastening member 43 vertically into the second mounting hole 62h of the connecting member 60. Next, an engaging member (e.g., a nut) is engaged with the upper end of the fastening member 43 from the vertical direction. This fixes the connecting member 60 to the bus bar 40 (Figure 11:11-2).

[0080] Next, in the Y direction, the connecting member 60 is fixed to the terminal 13A (in this embodiment, the same applies to terminal 13B) by a fastening member 51 (Figure 11:11-3) passing through the first mounting hole 61h (Figure 11:11-4). Next, when viewed from the Z direction, the circuit module 20C is placed on the connecting member 60 such that the extension portion 32-3 overlaps the second portion 62 of the connecting member 60. More specifically, the circuit module 20C is placed on the already placed connecting member 60 by inserting the fastening member 43 vertically into the first through hole 32h located in the extension portion 32-3 (Figure 11:11-5). Next, in the Z direction, the first bus bar 30A3 is fixed to the connecting member 60 by a fastening member 43 passing through the first through hole 32h and the second mounting hole 62h. In this embodiment, the second bus bar 30B is similarly fixed to the connecting member 60. In this way, the circuit module 20C is electrically connected to the relay 10, and the bypass circuit is electrically connected in parallel to the main circuit (Figure 11:11-6).

[0081] In the circuit module 20C of this embodiment, a bypass circuit is formed in the relay 10 by the connection between the bent extension portion 32-3 and the connecting member 60. In the electrical connection unit 300 of this embodiment, it is easy to increase the distance between the circuit module 20C and the relay 10. Therefore, in the electrical connection unit 300 of this embodiment, the circuit module 20C is prone to initiating thermal interference with the relay 10.

[0082] One embodiment has been described above. However, the embodiments are not limited to the example described above. For example, multiple embodiments may be implemented by combining them with one another. [Explanation of symbols]

[0083] 100 Electrical Connection Units 200 Electrical Connection Unit 300 Electrical Connection Unit 10 Relays 11 cases 13 terminals 13A terminal 13B terminal 13h mounting holes 20 circuit modules 20B Circuit Module 20C Circuit Module 21 circuit boards 22 Precharge resistors 23 Pre-charge relay 231 coil 232 switches 24 Control circuits 25 Protective component 30 Busbars (Riding Material) 30A First Busbar 30A2 First Bus Bar 30A3 First Bus Bar 30B Second Bus Bar 31 Connection part 32 Stretching section 32-2 Extension section 32-3 Extension section 32h First through hole 32h2 Second through hole 40 Bus Bar 40h through hole 41 Connection part 42 Stretching section 43 Fastening members 43a Shaft 51 Fastening member 60 Connecting Member 61 Part 1 61h First mounting hole 62 Second part 62h Second mounting hole 700 Electrical Connection Unit 90 Bus Bar

Claims

1. A relay having terminals, A circuit module comprising a circuit board, a precharge resistor, a precharge relay connected in series with the precharge resistor, wiring material, and a protective member for protecting the circuit board, Equipped with, The precharge resistor and the precharge relay are mounted on the substrate and enclosed within the protective member. The aforementioned wiring material extends from the substrate toward the terminal and is electrically connected to the terminal. Electrical connection unit.

2. The terminal is located at one end of the relay in the first direction. The substrate is arranged along a plane including the first direction, When viewed from a second direction intersecting the first direction, the precharge resistor and the precharge relay overlap the relay. The electrical connection unit according to claim 1.

3. Further comprising fastening members, The aforementioned terminal includes a first terminal and a second terminal, When viewed from the second direction, the second terminal is aligned with respect to the first terminal in a third direction that intersects the first and second directions. The cable routing member includes a first busbar electrically connected to the first terminal and a second busbar electrically connected to the second terminal. The first bus bar extends in the second direction and has a first through hole through which the fastening member passes, The first through-hole penetrates the first busbar in the first direction, In the first direction, the first busbar is fixed to the first terminal. The electrical connection unit according to claim 2.

4. The system further comprises a connecting member having a first mounting hole, the fastening member passing through the first through hole and the first mounting hole and fastening together with the first busbar, The electrical connection unit according to claim 3.

5. The terminal is located at one end of the relay in the first direction. The substrate is arranged along a plane that intersects the first direction, When viewed from the first direction, the precharge resistor and the precharge relay overlap the relay. The electrical connection unit according to claim 1.

6. Further comprising fastening members, The connecting member further comprises a second mounting hole and a third mounting hole, The aforementioned terminal includes a first terminal and a second terminal, When viewed from a second direction intersecting the first direction, the second terminal is aligned with respect to the first terminal in a third direction intersecting both the first and second directions. The cable routing member includes a first busbar electrically connected to the first terminal and a second busbar electrically connected to the second terminal. The first busbar extends in the second direction and then bends, and extends in the first direction, The first bus bar has a first through hole through which the fastening member passes, The first through-hole penetrates the first busbar in the second direction, In the first direction, the connecting member is fixed to the first terminal via the third mounting hole. In the second direction, the first busbar is fixed to the connecting member. The electrical connection unit according to claim 5.

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