Junction box

Abstract

This can prevent the connector from being damaged by external force. [Solution] The junction box used in connection with a fuel cell comprises a housing, a connector protruding from the outer surface of the housing, and a protective part that protects the connector by covering at least a part of the connector, the protective part having a first protective part facing at least a part of the upper part of the connector and a second protective part facing at least a part of the side of the connector.

Description

Technical Field

[0001] The present disclosure relates to a junction box used in connection with a fuel cell.

Background Art

[0002] Patent Document 1 discloses a high-voltage cable connected to an in-vehicle fuel cell stack. Such a high-voltage cable may be connected to a junction box that distributes power to electrical devices mounted on a vehicle.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The junction box is provided with a connector that is electrically connected to electrical devices. Since such a connector is often applied with a high voltage, a technique that can suppress the occurrence of an event in which the connector is damaged by an unexpected external force is desired.

Means for Solving the Problems

[0005] The present disclosure can be realized in the following forms.

[0006] (1) According to one embodiment of the present disclosure, a junction box is provided for use in connection with a fuel cell. The junction box comprises a housing, a connector protruding from the outer surface of the housing, and a protective portion that protects the connector by covering at least a portion of the connector, wherein the protective portion has a first protective portion facing at least a portion of the upper part of the connector and a second protective portion facing at least a portion of the side of the connector. According to this embodiment, since the first protective portion faces at least a portion of the upper part of the connector, it is possible to suppress the connector from receiving external forces from the side facing the upper part of the connector. Also, since the second protective portion faces at least a portion of the side of the connector, it is possible to suppress the connector from receiving external forces from the side facing the side of the connector. Therefore, it is possible to suppress the event of the connector being damaged by external forces. (2) In the above embodiment, the protective portion may have a third protective portion that faces at least a portion of the connector end portion in the protruding direction from which the connector protrudes. In this embodiment, since the third protective portion faces at least a portion of the connector end portion in the protruding direction from which the connector protrudes, it is possible to suppress the connector from receiving external force from the side facing the connector end portion. (3) In the above embodiment, the first protective part, the second protective part, and the third protective part may be configured to cover a part of the electrical wiring connected to the connector, including the part that connects to the connector. In this embodiment, since the first protective part, the second protective part, and the third protective part are configured to cover a part of the electrical wiring connected to the connector, including the part that connects to the connector, the part of the electrical wiring including the part that connects to the connector can be protected by the first protective part, the second protective part, and the third protective part. This prevents damage to a part of the electrical wiring connected to the connector due to external force. Furthermore, in a configuration where a covering material made of insulating material is not provided on a part of the electrical wiring including the part that connects to the connector, and the strands of the electrical wiring are exposed, it is possible to prevent other parts from coming into contact with the exposed strands. (4) In the above embodiment, the housing may have a projection on its outer surface that protrudes from a position different from the position from which the connector protrudes, and the protective part may have a fastening portion fastened to the projection. In this embodiment, since the protective part has a fastening portion fastened to the projection, when the protective part is subjected to an external force, the protective part can flexibly deform starting from the projection, thereby effectively absorbing the external force. For this reason, the protective part can properly protect the connector. (5) In the above configuration, the protective part and the housing may be electrically connected via the fastening part. In this configuration, since the protective part and the housing are electrically connected via the fastening part, if the connector is damaged and the damaged connector comes into contact with the protective part, the current that flows from the connector to the protective part can be passed to the housing via the fastening part. [Brief explanation of the drawing]

[0007] [Figure 1] This is a top view of the junction box mounted on the vehicle in this embodiment. [Figure 2] This is a perspective view of the connector attached to the housing in this embodiment. [Figure 3] This is a perspective view of the protective part in this embodiment. [Figure 4] Figure 3 is a cross-sectional view of the protective section cut along line AA. [Figure 5] This is a side view of the protective part in this embodiment. [Figure 6] Figure 3 shows a cross-sectional view of the protective section cut along the BB line. [Modes for carrying out the invention]

[0008] A. Embodiments: A1. Overall configuration of junction box 100: Figure 1 is a top view of the junction box 100 mounted on the vehicle VC in this embodiment. For the sake of explaining this embodiment, the direction along the direction of travel of the vehicle VC will be referred to as the "forward-backward direction," the vertical direction as seen from the perspective of the driver in the vehicle VC will be referred to as the "up-down direction," and the left-right direction as seen from the perspective of the driver in the vehicle VC will be referred to as the "left-right direction." The "forward-backward direction," "up-down direction," and "left-right direction" are orthogonal to each other.

[0009] The junction box 100 is used in connection with a fuel cell (not shown). The junction box 100 distributes the power supplied from the fuel cell to electrical equipment (not shown) mounted on the vehicle VC, such as an air compressor, motor, and battery. The vehicle VC runs using the power supplied from the fuel cell.

[0010] As shown in Figure 1, the junction box 100 is mounted inside the front room FM located at the front of the vehicle VC. Numerous components are arranged in layers in the vertical direction within the front room FM. The junction box 100 is located in the center of the front room FM in the horizontal direction and is positioned on the uppermost layer of the front room FM. The fuel cell is mounted below the junction box 100. The dash panel DP is located behind the junction box 100.

[0011] Figure 2 is a perspective view of the connector 20 attached to the housing 10 in this embodiment. Figure 3 is a perspective view of the protective section 30 in this embodiment. As shown in Figures 2 and 3, the junction box 100 comprises the housing 10, the connector 20, and the protective section 30. Note that the protective section 30 is omitted in Figure 2.

[0012] <Enclosure 10> The housing 10 is constructed from a material primarily composed of aluminum. The housing 10 includes fuses and busbar wiring (not shown) for distributing the power supplied from the fuel cell. The power supplied from the fuel cell is delivered to electrical equipment mounted on the vehicle VC via the busbar wiring.

[0013] <Connector 20> A high voltage is applied to the connector 20 in order to supply power to the electrical equipment mounted on the vehicle VC. As shown in Figure 2, the connector 20 protrudes backward from the rear outer surface 12 of the housing 10. In this embodiment, two connectors 20 are arranged in parallel in the left-right direction, and each connector 20 protrudes backward from the outer surface 12. Of the two connectors 20, the connector 20 located on the left is called the "first connector 20a," and the connector 20 located on the right is called the "second connector 20b."

[0014] The connector 20 has an upper part 21 facing upward, a pair of side parts 22 consisting of a left side part 22 and a right side part 22, and a rear part 23 facing backward. In this embodiment, the "rear part 23" corresponds to the connector end part 23 in the protruding direction from which the connector 20 protrudes. As shown in Figure 2, electrical wiring EW is connected to the rear part 23 of each connector 20. Details of the electrical wiring EW connected to the connector 20 will be described later.

[0015] In this embodiment, the upper part 21 is the portion visible when the connector 20 is viewed from above. Similarly, the side portion 22 is the portion visible when the connector 20 is viewed from the left or right, and the rear portion 23 is the portion visible when the connector 20 is viewed from behind. Therefore, in a connector 20 that is partially rounded as in this embodiment, the upper part 21 and the side portion 22 partially overlap in their respective areas.

[0016] <Protection Department 30> The protection part 30 protects the connector 20 by covering at least a part of the connector 20. The protection part 30 is provided as a member separate from the housing 10. The protection part 30 is formed, for example, by making a metal material excellent in toughness and ductility such as steel into a plate shape. The ductility and toughness of the material constituting the protection part 30 are superior to those of the material constituting the housing 10.

[0017] As shown in FIG. 3, the protection part 30 has a first protection part 31, a second protection part 32, and a third protection part 33. The first protection part 31, the second protection part 32, and the third protection part 33 form a smooth shape that is continuous with each other. The first protection part 31 is located above the upper part 21 of each connector 20 and faces the upper part 21. The second protection part 32 is located to the left of the left side part 22 of the first connector 20a and faces the left side part 22. Also, the second protection part 32 is located to the right of the right side part 22 of the second connector 20b and faces the right side part 22. The third protection part 33 is located behind the rear part 23 of each connector 20 and faces the rear part 23.

[0018] As shown in FIG. 3, the upper part 21 of the connector 20 is configured to be invisible from above by the first protection part 31. Similarly, the left side part 22 of the first connector 20a is configured to be invisible from the left, and the right side part 22 of the second connector 20b is configured to be invisible from the right. The rear part 23 of the connector 20 is configured to be invisible from behind by the third protection part 33.

[0019] Note that the first protection part 31 does not have to face the entire upper part 21, and it only needs to face at least a part. Similarly, the second protection part 32 only needs to face at least a part of the left side part 22 of the first connector 20a or the right side part 22 of the second connector 20b, and the third protection part 33 only needs to face at least a part of the rear part 23.

[0020] For example, if a moving vehicle VC collides with an obstacle in front of it, in a configuration without the protective part 30, the connector 20 is expected to receive force from the dash panel DP. This is because, when the connector 20 is viewed from above or behind, the dash panel DP has a portion that overlaps with the connector 20. In contrast, in this embodiment, the connector 20 is protected by the protective part 30 covering it, thus suppressing the event that the connector 20 is damaged by force from the dash panel DP. The configuration of the protective part 30 and the surrounding area for properly protecting the connector 20 will be described in detail below.

[0021] A2. Detailed configuration of the protective section 30 and its surroundings: <Protective structure of electrical wiring EW> Figure 4 is a cross-sectional view of the protective section 30 cut along line AA in Figure 3. As shown in Figure 4, the electrical wiring EW connected to the rear portion 23 of each connector 20 extends downward from the rear portion 23 of each connector 20. High voltage is applied to each electrical wiring EW, just like to the connector 20. Therefore, it is preferable that each electrical wiring EW is protected together with each connector 20. In this regard, as shown in Figures 2 and 4, the outer circumference of the electrical wiring EW is covered with a covering material CM made of insulating material. The covering material CM is fixed to the electrical wiring EW with insulating tape, thereby protecting the outer circumference of the electrical wiring EW. On the other hand, it may be difficult to completely cover a part of the electrical wiring EW, including the portion connected to the connector 20, with the covering material CM. In this case, as in this embodiment, a part of the electrical wiring EW, including the portion connected to the connector 20, is exposed as a single wire BW that is not covered with the covering material CM.

[0022] The first protective section 31, the second protective section 32, and the third protective section 33 are configured to cover not only the connector 20, but also a portion of the electrical wiring EW, including the connection portion to the connector 20, that is, the portion of the individual wires BW that are not covered with the insulation material CM. More specifically, the individual wires BW of the electrical wiring EW connected to each connector 20 are covered by the first protective section 31 so that they cannot be seen from above, and are covered by the third protective section 33 so that they cannot be seen from behind. Similarly, the individual wires BW of the electrical wiring EW connected to the first connector 20a are covered by the second protective section 32 so that they cannot be seen from the left. In addition, the individual wires BW of the electrical wiring EW connected to the second connector 20b are covered by the second protective section 32 so that they cannot be seen from the right.

[0023] As shown in Figure 4, the third protective section 33 is provided with a bent portion 37 at the end 36 opposite to the connection portion between the first protective section 31 and the third protective section 33, which bends away from the electrical wiring EW. In the event of a collision with a vehicle VC, if the protective section 30 deforms downward, in a configuration without the bent portion 37, the end 38 of the end 36 of the third protective section 33 may come into contact with the electrical wiring EW. On the other hand, in this embodiment, the provision of the bent portion 37 prevents the end 38 of the end 36 of the third protective section 33 from coming into contact with the electrical wiring EW. Therefore, damage to the electrical wiring EW can be suppressed, and the electrical wiring EW connected to the connector 20 can be properly protected.

[0024] <Structure of fastening portion 35> As shown in Figure 4, the housing 10 has a projection 14 that protrudes rearward from the rear outer surface 12 of the housing 10. More specifically, the projection 14 protrudes rearward from a position on the outer surface 12 that is above the position from which the connector 20 protrudes.

[0025] The protective part 30 has a fastening portion 35 that is fastened to the projection 14. As shown in Figures 3 and 4, the protective part 30 is fastened to the housing 10 by inserting two screws SW from behind the projection 14. The protective part 30 and the housing 10 are electrically connected via the fastening portion 35. In this regard, if the surface of the protective part 30 or the housing 10 is painted with an insulating material, the protective part 30 and the housing 10 can be electrically connected by removing the paint from the part that comes into contact with the fastening portion 35.

[0026] <Structure of the lower layer of the protective section 30> Figure 5 is a side view of the protective part 30 in this embodiment. As shown in Figure 5, a space TS is provided between the protective part 30 and any lower component LP mounted on the lower side of the protective part 30. This prevents the protective part 30 from being damaged or the lower component LP from being damaged by contact with the lower component LP, even if the protective part 30 deforms downward during a collision with a vehicle VC. Therefore, the protective part 30 can properly protect the connector 20. It is preferable to set lower and upper limits for the distance DT between the protective part 30 and the lower component LP in the space TS. The lower limit can be set, for example, based on the amount of downward deformation of the protective part 30 expected during a collision with a vehicle VC.

[0027] The upper limit can be set, for example, based on the amount of downward deformation of the protective part 30 expected during a collision of the vehicle VC, plus the diameter of an average human finger. This prevents workers repairing the vehicle VC from inserting their fingers between the protective part 30 and the lower part LP when the protective part 30 deforms downward during a collision of the vehicle VC.

[0028] Figure 6 is a cross-sectional view of the protective section 30 cut along the line BB in Figure 3. As shown in Figure 6, the second protective section 32 extends away from the connector 20 as it moves away from the connection point between the second protective section 32 and the first protective section 31. That is, the left side of the second protective section 32 extends away from the connector 20 to the left as it moves downward. Similarly, the right side of the second protective section 32 extends away from the connector 20 to the right as it moves downward. As a result, even if the protective section 30 comes into contact with the lower component LP during a collision with the vehicle VC, the second protective section 32 will deform and spread out away from each connector 20. Therefore, it is possible to more effectively suppress damage to the protective section 30 or damage to the lower component LP caused by contact between the protective section 30 and the lower component LP.

[0029] As described above, the junction box 100 has a first protective section 31 that faces at least a portion of the upper part 21 of the connector 20, thus preventing the connector 20 from receiving external forces from the side facing the upper part 21. The second protective section 32 also faces at least a portion of the side part 22 of the connector 20, thus preventing the connector 20 from receiving external forces from the side facing the side part 22. Therefore, damage to the connector 20 due to external forces can be suppressed. Furthermore, the presence of the second protective section 32 in the protective section 30 increases the rigidity of the protective section 30. Therefore, when the protective section 30 is subjected to an impact, it can be prevented from deforming significantly and coming into contact with the connector 20.

[0030] Furthermore, in order to suppress impact on the connector 20, a configuration in which ribs, which are part of the housing 10, are provided around the connector 20 instead of the protective part 30 is also conceivable. However, in such a configuration, the external force received by the ribs is directly transmitted to the housing 10, which may cause the housing 10 to deform. On the other hand, in this embodiment, since the protective part 30 is provided as a separate component from the housing 10, even if an external force is applied to the protective part 30, deformation of the housing 10 can be suppressed.

[0031] Furthermore, since the third protective portion 33 faces at least a part of the connector end portion 23 in the protruding direction from which the connector 20 protrudes, it is possible to suppress the connector 20 from receiving external force from the side facing the connector end portion 23.

[0032] The first protective section 31, the second protective section 32, and the third protective section 33 are configured to cover a portion of the electrical wiring EW connected to the connector 20, including the portion connected to the connector 20. Therefore, a portion of the electrical wiring EW, including the portion connected to the connector 20, can be protected by the first protective section 31, the second protective section 32, and the third protective section 33. This prevents damage to a portion of the electrical wiring EW connected to the connector 20 due to external force. Furthermore, in this embodiment, where a covering material CM made of insulating material is not provided on a portion of the electrical wiring EW, including the portion connected to the connector 20, and the individual wires BW of the electrical wiring EW are exposed, contact between the exposed wires BW and other components can also be prevented.

[0033] Furthermore, since the protective part 30 has a fastening portion 35 fastened to the protrusion 14, when the protective part 30 is subjected to an external force, the protective part 30 can flexibly deform starting from the protrusion 14, thereby effectively absorbing the external force. For this reason, the protective part 30 can properly protect the connector 20.

[0034] Furthermore, a collision with the vehicle VC may damage the connector 20, and the damaged connector 20 may come into contact with the protective part 30. Even in this case, the protective part 30 and the housing 10 are electrically connected via the fastening part 35, and the housing 10 is made of a metal material such as aluminum with low electrical resistance, so the current flowing from the connector 20 to the protective part 30 can be passed to the housing 10 via the fastening part 35.

[0035] B. Other embodiments: (B1) In this embodiment, the junction box 100 was located in the center of the front room FM in the left-right direction and on the uppermost layer of the front room FM, but the disclosure is not limited thereto. The junction box 100 may be mounted on the lower layer of the front room FM, or it may be mounted under the vehicle body instead of the front room FM. Furthermore, the junction box 100 is not limited to being mounted on the vehicle VC, and can be used for various purposes such as branching electrical wiring EW.

[0036] (B2) In this embodiment, the connector 20 was positioned to protrude rearward from the rear outer surface 12 of the housing 10, but the disclosure is not limited thereto. The connector 20 may be positioned to protrude from the right, left, front, top, or bottom of the housing 10.

[0037] (B3) In this embodiment, two connectors 20 protruded in parallel from the outer surface 12 of the housing 10 in the left-right direction, but the disclosure is not limited thereto. For example, one or more connectors 20 may protrude from the housing 10. Also, the housing 10 may have multiple connectors 20 protruding in different directions, such as one connector 20 protruding from the rear of the housing 10 while another connector 20 protrudes from the right side of the housing 10.

[0038] (B4) In this embodiment, the connector 20 was partially rounded such that the upper part 21 and the side part 22 partially overlapped, but the disclosure is not limited thereto. The connector 20 can take on various shapes, such as a prism shape or a cylindrical shape. For example, in the case of a cylindrical connector 20, the left half of the upper part 21 overlaps with the upper half of the side part 22 facing left. Similarly, the right half of the upper part 21 overlaps with the upper half of the side part 22 facing right. In addition, in a cylindrical connector 20, the upper part 21 and the side part 22 may be defined so that their ranges do not overlap with each other. For example, the connector 20 may be divided into four equal parts such that the central angle of the cylindrical connector 20 is 90 degrees, and parts of these divided parts may be defined as the upper part 21 and the side part 22.

[0039] (B5) In this embodiment, the connector 20 was assumed to receive force from the dash panel DP located behind and above the connector 20 when a moving vehicle VC collides with an obstacle in front of it, but the disclosure is not limited thereto. For example, if the vehicle VC is hit from the side, the connector 20 is assumed to receive force from components located to the side of the connector 20. The second protective part 32 can appropriately protect the connector 20 by suppressing external force from being received from the side of the connector 20. The disclosure is applicable to various situations in which the junction box 100 may be subjected to impact.

[0040] (B6) In this embodiment, the first protective portion 31, the second protective portion 32, and the third protective portion 33 form a continuous and smooth shape with respect to each other, but the disclosure is not limited thereto. The first protective portion 31, the second protective portion 32, and the third protective portion 33 may each be formed independently. In this case, for example, the first protective portion 31, the second protective portion 32, and the third protective portion 33 may each be fastened to a part of the housing 10.

[0041] (B7) In this embodiment, the second protective portion 32 covered the first connector 20a from the left and the second connector 20b from the right. That is, the second protective portion 32 covered the connector 20 from either the left or the right, but the disclosure is not limited thereto. The second protective portion 32 may cover the connector 20 from both the left and the right.

[0042] (B8) In this embodiment, the protective part 30 had a third protective part 33, but this disclosure may omit it. For example, if the connector 20 is expected to be subjected to external forces mainly from above, the third protective part 33 that covers the connector 20 from the rear can be omitted.

[0043] (B9) In this embodiment, a portion of the electrical wiring EW, including the portion connected to the connector 20, was exposed as uncovered strands BW, but the disclosure is not limited thereto. The electrical wiring EW may be configured such that a portion, including the portion connected to the connector 20, is completely covered with the covering material CM, so that the strands BW are not exposed.

[0044] (B10) In this embodiment, the first protective part 31, the second protective part 32, and the third protective part 33 covered the strands BW that were not covered by the covering material CM, but the disclosure is not limited thereto. For example, if the covering material CM completely covers a portion including the connection portion with the connector 20, and the strands BW are not exposed, then the first protective part 31, the second protective part 32, and the third protective part 33 do not need to cover a portion of the electrical wiring EW.

[0045] (B11) In this embodiment, the housing 10 has a projection 14 that protrudes rearward from the rear outer surface 12 of the housing 10, and the protective part 30 has a fastening part 35 fastened to the projection 14, but the disclosure is not limited thereto. The protective part 30 may be fixed to the housing 10 by any fastening means without going through the projection 14. The protective part 30 may also be fixed to a component other than the housing 10 that is arranged around the housing 10.

[0046] (B12) In this embodiment, the protective part 30 and the housing 10 are electrically connected via the fastening part 35, but the disclosure is not limited thereto. For example, if the area around the protective part 30 is covered with an insulating material, the protective part 30 and the housing 10 do not need to be electrically connected.

[0047] (B13) In this embodiment, the projection 14 protrudes from above the connector 20 toward the rear on the outer surface 12, but the disclosure is not limited thereto. The projection 14 may protrude from a position on the outer surface 12 different from the position where the connector 20 protrudes, for example, it may protrude toward the rear from below, to the right, or to the left of the connector 20 on the outer surface 12. Even in this case, the protective part 30 can effectively absorb the external force it receives by flexibly deforming with the projection 14 as the starting point. Therefore, the protective part 30 can properly protect the connector 20.

[0048] This disclosure is not limited to the embodiments described above, and can be implemented in various configurations without departing from its spirit. For example, the technical features in the embodiments corresponding to the technical features in each form described in the summary of the invention can be replaced or combined as appropriate in order to solve some or all of the above-described problems, or to achieve some or all of the above-described effects. Furthermore, if a technical feature is not described as essential in this specification, it can be deleted as appropriate. [Explanation of Symbols]

[0049] 10…Housing, 12…Outer surface, 14…Protrusion, 20…Connector, 20a…First connector, 20b…Second connector, 21…Top, 22…Side, 23…Connector end (rear), 30…Protective part, 31…First protective part, 32…Second protective part, 33…Third protective part, 35…Fastening part, 36…End, 37…Bent part, 38…End, 100…Junction box, BW…Wire strand, CM…Insulation material, DP…Dash panel, DT…Distance, EW…Electrical wiring, FM…Front room, LP…Lower layer component, SW…Screw, TS…Space, VC…Vehicle

Claims

1. A junction box used in connection with a fuel cell, The casing and A connector protruding from the outer surface of the aforementioned housing, A protective part that covers at least a portion of the connector to protect the connector, Equipped with, The aforementioned protective part is A first protective portion facing at least a portion of the upper part of the connector, A junction box having a second protective portion facing at least a portion of the side of the connector.

2. A junction box according to claim 1, The protective portion is a junction box having a third protective portion that faces at least a portion of the connector end portion in the protruding direction from which the connector protrudes.

3. A junction box according to claim 2, The first protective section, the second protective section, and the third protective section are configured to cover a portion of the electrical wiring connected to the connector, including the portion connected to the connector, in a junction box.

4. A junction box according to claim 1, The housing has a projection on its outer surface that protrudes from a position different from the position from which the connector protrudes, The protective portion is a junction box having a fastening portion fastened to the projection.

5. A junction box according to claim 4, A junction box in which the protective part and the housing are electrically connected via the fastening part.

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