DC-DC converter integrated structure

Abstract

This invention provides a DC-DC converter mounting structure for electric vehicles that allows for efficient use of space while mounting a DC-DC converter, and also simplifies the structure. [Solution] The DCDC converter mounting structure 2 is for mounting a DCDC converter 1 below the cross member 103 in a vehicle 100 having a pair of side rails 101, 102 arranged in the Y direction and a cross member 103 provided to span across the pair of side rails 101, 102. The DCDC converter mounting structure 2 comprises retaining members 21 to 23 positioned below the cross member 103 while holding the DCDC converter 1, and brackets 30 for fixing the retaining members 21 to 23 to the side rails 101, 102 and / or the cross member 103.

Description

TECHNICAL FIELD

[0001] The present invention relates to a DCDC converter mounting structure.

BACKGROUND ART

[0002] Patent Document 1 describes a mounting structure for mounting electronic equipment on a vehicle. The vehicle includes a pair of side members that extend in the front-rear direction and are spaced apart from each other in the vehicle width direction, and a first cross member and a second cross member that connect the pair of side members to each other. The first cross member is located forward of the second cross member. The electronic equipment is disposed between the first cross member and the second cross member.

PRIOR ART DOCUMENTS

PATENT DOCUMENTS

[0003]

PATENT DOCUMENT 1

SUMMARY OF INVENTION

PROBLEM TO BE SOLVED BY THE INVENTION

[0004] By the way, in general, an electric vehicle has a plurality of electronic devices including a DCDC converter and a plurality of wire harnesses that electrically connect the plurality of electronic devices to each other, so it is necessary to mount the DCDC converter while effectively utilizing space. In addition, in consideration of structural design that minimizes damage to the DCDC converter as much as possible due to requirements for mounting vibration specifications (such as G-resistance performance), it has been difficult to simplify the structure.

[0005] Accordingly, an object of the present invention is to provide a DCDC converter mounting structure that allows a DCDC converter to be mounted in an electric vehicle while effectively utilizing space, and that allows the structure to be simplified.

MEANS FOR SOLVING PROBLEM

[0006] The DC-DC converter mounting structure according to the present invention is [1] "a DC-DC converter mounting structure for mounting a DC-DC converter below a cross member in an electric vehicle having a pair of side rails arranged in the width direction of the vehicle and a cross member provided so as to span across the pair of side rails, comprising a holding member disposed below the cross member in a state in which the DC-DC converter is held, and a bracket for fixing the holding member to the side rails and / or cross member."

[0007] In this DC-DC converter mounting structure, a holding member that holds the DC-DC converter is positioned below the cross member, and this holding member is fixed to the side rail and / or cross member by a bracket. This allows the DC-DC converter to be mounted below the cross member. Thus, this DC-DC converter mounting structure allows for the effective use of the space below the cross member to mount the DC-DC converter. Furthermore, in this DC-DC converter mounting structure, the DC-DC converter is positioned at the mounting portion of the cross member on a pair of relatively rigid side rails. As a result, the input to the DC-DC converter is reduced, which is advantageous in terms of mounting vibration requirements and allows for structural simplification.

[0008] The DC-DC converter mounting structure according to the present invention may also be [2] "the DC-DC converter mounting structure according to [1] above, wherein the electric vehicle has a plurality of cross members, and the holding member is positioned below the cross member that is located furthest forward and behind the front wheels of the electric vehicle, while holding the DC-DC converter." In this case, the DC-DC converter can be positioned below the cross member that is located furthest forward and behind the front wheels of the electric vehicle. Therefore, the distance between the electrical elements located at the front of the electric vehicle and the DC-DC converter is shortened, making it easier to connect the elements to the DC-DC converter.

[0009] The DC-DC converter mounting structure according to the present invention may also be [3] "the DC-DC converter mounting structure according to [1] or [2] above, comprising a plurality of holding members, wherein the plurality of holding members are stacked vertically and integrated with each other and arranged below the cross member, each holding the DC-DC converter." In this case, since each of the plurality of holding members holds a DC-DC converter, a plurality of DC-DC converters can be mounted below the cross member. Furthermore, by stacking the plurality of DC-DC converters vertically, the space below the cross member can be utilized more effectively.

[0010] The DC-DC converter mounting structure according to the present invention may also be [4] "the DC-DC converter mounting structure according to [3] above, wherein one of the plurality of holding members located at the lowest position has a U-shape that is open upward when viewed from the front-rear direction of the electric vehicle and includes a first holding portion that holds one DC-DC converter, and another of the plurality of holding members located at the highest position has a U-shape that is open downward when viewed from the front-rear direction and includes a second holding portion that holds another DC-DC converter." In this case, the plurality of DC-DC converters can be held more efficiently in the space defined by the U-shaped first holding portion of the lowest holding member and the U-shaped second holding portion of the uppermost holding member.

[0011] The DC-DC converter mounting structure according to the present invention may also be the DC-DC converter mounting structure according to any one of [1] to [4] above, wherein the bracket fixes the retaining member to the side rail and the cross member. In this case, the fixing of the retaining member becomes more secure. [Effects of the Invention]

[0012] According to the present invention, it is possible to provide a DC-DC converter mounting structure for electric vehicles that allows for efficient use of space while mounting a DC-DC converter, and also simplifies the structure. [Brief explanation of the drawing]

[0013] [Figure 1] Figure 1 is a schematic plan view showing a part of a vehicle equipped with a DC-DC converter mounting structure according to this embodiment. [Figure 2] Figure 2 is a schematic perspective view showing an enlarged portion of Figure 1. [Figure 3] Figure 3 is a perspective view showing the DC-DC converter and DC-DC converter mounting structure shown in Figure 2. [Figure 4] Figure 4 is a perspective view showing the DC-DC converter mounting structure shown in Figure 3. [Modes for carrying out the invention]

[0014] The following describes a DC-DC converter mounting structure according to one embodiment, with reference to the drawings. In the description of each figure, the same or equivalent elements are denoted by the same reference numeral, and redundant explanations may be omitted. In addition, each figure may illustrate a Cartesian coordinate system defined by the X-axis, the Y-axis intersecting the X-axis, and the Z-axis intersecting the X-axis and Y-axis.

[0015] Figure 1 is a schematic plan view showing a part of a vehicle equipped with a DC-DC converter mounting structure according to this embodiment. Vehicle 100 is, for example, a large vehicle such as a truck, cargo vehicle, or bus. Vehicle 100 is also, for example, an electric vehicle. Electric vehicles include, for example, hybrid vehicles (HEV), plug-in hybrid vehicles (PHEV), fuel cell vehicles (FCEV), and battery electric vehicles (BEV). For example, the X direction indicates the longitudinal direction of vehicle 100, the Y direction indicates the vehicle width direction of vehicle 100, and the Z direction indicates the vertical up and down direction.

[0016] Vehicle 100 comprises a DC-DC converter 1, a DC-DC converter mounting structure 2, a pair of side rails 101 and 102, a plurality of cross members 103, and electrical elements 104. The pair of side rails 101 and 102 are arranged spaced apart from each other along the Y direction and extend along the X direction. The plurality of cross members 103 are arranged spaced apart from each other along the X direction and are provided to span across the pair of side rails 101 and 102. The electrical elements 104 are any elements that can be electrically connected to the DC-DC converter, such as a fuel cell (FC stack) or a battery. The electrical elements 104 are located at the front of vehicle 100.

[0017] The DC-DC converter 1 has the function of receiving DC power input from electrical element 104 or other electrical elements, converting the voltage of said DC power, and outputting it to another electrical element. As will be described later, the DC-DC converter 1 is mounted on the lower part of the cross member 103 by the DC-DC converter mounting structure 2. More specifically, the DC-DC converter 1 is mounted on the lower part of the cross member 103A, which is located behind the front wheel 110 and closest to the front wheel 110, among the multiple cross members 103.

[0018] The space below the cross member 103A is a space where, if the vehicle 100 were driven by an internal combustion engine, a transmission, propeller shaft, etc., connected to the internal combustion engine could be located. Therefore, if the vehicle 100 is an electric vehicle and does not have a transmission or propeller shaft, the space below the cross member 103A is relatively large and can be effectively utilized for mounting the DCDC converter 1. Even if the vehicle 100 is an electric vehicle and has a transmission and propeller shaft, it is conceivable to mount the DCDC converter 1 in the space below the cross member 103A or other cross members 103 in order to effectively utilize that space.

[0019] As described above, the DCDC converter mounting structure 2 is configured to mount the DCDC converter 1 below the cross member 103 (in the present embodiment, cross member 103A). Hereinafter, the DCDC converter mounting structure 2 will be described more specifically.

[0020] FIG. 2 is a schematic perspective view showing an enlarged part of FIG. 1, FIG. 3 is a perspective view showing the DCDC converter and the DCDC converter mounting structure shown in FIG. 2, and FIG. 4 is a perspective view showing the DCDC converter mounting structure shown in FIG. 3. As shown in FIGS. 2 to 4, the DCDC converter mounting structure 2 includes a plurality of (three in this case) holding members 21 to 23 and a pair of brackets 30.

[0021] The holding members 21 to 23 are respectively disposed below the cross member 103A in a state where the DCDC converter 1 is held. Therefore, in the present embodiment, the vehicle 100 includes a plurality of (the same number as the holding members, three in this case) DCDC converters 1. As described above, the holding members 21 to 30, and the brackets 30 fix the holding members 21 to 23 to the side rails 101, 102 and the cross member 103A.

[0022] The holding members 21 to 23 are stacked in this order from the lower side to the upper side in the Z direction. Therefore, the holding member 21 (one holding member) is located at the lowermost position in the Z direction among the holding members 21 to 23, and the holding member 23 (another holding member) is located at the uppermost position in the Z direction among the holding members 21 to 23. The holding member 22 is interposed between the holding member 21 and the holding member 23 in the Z direction.

[0023] The retaining member 21 includes a retaining portion (first retaining portion) 21a and a pair of flange portions 21b. The retaining portion 21a has a U-shape that is open upward when viewed from the X direction, and holds one DC-DC converter 1 on its bottom portion 21c. The bottom portion 21c has a plurality (two in this case) of openings 21d arranged along the Y direction. The pair of flange portions 21b are provided so as to protrude outward in the Y direction from both ends of the retaining portion 21a in the Y direction.

[0024] The retaining member 23 includes a retaining portion (second retaining portion) 23a and a pair of flange portions 23b. The retaining portion 23a has a U-shape that is open downward when viewed from the X direction, and holds another DCDC converter 1 on its bottom portion 23c (on the upward-facing surface of the bottom portion 23c). The bottom portion 23c has a plurality (in this case, two) of openings 23d arranged along the Y direction. The pair of flange portions 23b are provided so as to protrude outward in the Y direction from both ends of the retaining portion 23a in the Y direction.

[0025] The retaining member 22 includes a retaining portion 22a and a pair of leg portions 22b. The retaining portion 22a is plate-shaped and holds another DCDC converter 1 on its upper surface. The retaining portion 22a has a plurality (two in this case) of openings 22d arranged along the Y direction. The pair of leg portions 22b are erected at both ends of the retaining portion 22a in the Y direction and extend upward to the retaining portion 23a. The leg portions 22b are fixed to the retaining portions 22a and 23a, thereby fixing the retaining member 22 and the retaining member 23 to each other while maintaining a space between the retaining portions 22a and 23a.

[0026] Furthermore, the flange portion 21b of the retaining member 21 is fixed to both ends of the retaining portion 22a in the Y direction, thereby fixing the retaining member 21 and the retaining member 22 to each other. As a result, the retaining members 21 to 23 are fixed to each other and integrated. In this state, the DC-DC converter 1 is stacked along the Z direction by being held between the retaining member 21 and the retaining member 22, between the retaining member 22 and the retaining member 23, and on the retaining member 23. The bottom portion 21c of the retaining portion 21a, the retaining portion 22a, and the bottom portion 23c of the retaining portion 23a extend along the X and Y directions and are substantially parallel to each other.

[0027] The bracket 30 includes a first fixing portion 31 that extends along the X and Y directions and overlaps with the flange portion 23b of the retaining member 23, and a second fixing portion 32 that extends along the X and Z directions and overlaps with the side rails 101 and 102, respectively. The bracket 30 is fixed to the flange portion 23b of the retaining member 23 at the first fixing portion 31 and to the side rails 101 and 102 at the second fixing portion 32, thereby fixing the retaining members 21 to 23 to the side rails 101 and 102.

[0028] In this embodiment, the cross member 103A includes a first portion 105 stretched across a pair of side rails 101 and 102, and a second portion 106 that overlaps the first portion 105 below it and is also stretched across the pair of side rails 101 and 102. The first portion 105 and the second portion 106 are in contact (e.g., joined) with each other at the center portion of the cross member 103A in the Y direction, and are spaced apart from each other in the Z direction at both ends of the cross member 103A in the Y direction, and are fixed to different Z-direction positions of the side rails 101 and 102.

[0029] The second fixing portion 32 of the bracket 30 is fixed to the fixing portion with respect to the side rails 101 and 102 in the second portion 106 (for example, the bracket 30 and the cross member 103A are fastened together to the side rails 101 and 102). As a result, the bracket 30 fixes the retaining members 21 to 23 to both the side rails 101 and 102 and the cross member 103A.

[0030] As described above, in the DC-DC converter mounting structure 2 according to this embodiment, holding members 21 to 23 that hold the DC-DC converter 1 are arranged below the cross member 103, and these holding members 21 to 23 are fixed to at least the side rails 101 and 102 by brackets 30. This allows the DC-DC converter 1 to be mounted below the cross member 103.

[0031] Thus, the DC-DC converter mounting structure 2 allows the DC-DC converter 1 to be mounted by effectively utilizing the space below the cross member 103. Furthermore, in the DC-DC converter mounting structure 2, the DC-DC converter 1 is positioned on the mounting portion of the cross member 103 on a pair of relatively rigid side rails 101 and 102. As a result, the input to the DC-DC converter 1 is reduced, which is advantageous for mounting vibration requirements and allows for structural simplification.

[0032] Furthermore, in the DCDC converter mounting structure 2 according to this embodiment, the vehicle 100 has a plurality of cross members 103, and the holding members 21 to 23 are positioned below the cross member 103A that is located behind the front wheels 110 of the vehicle 100 and furthest forward, when the DCDC converter 1 is being held. Therefore, the DCDC converter 1 can be positioned below the cross member 103A that is located behind the front wheels of the vehicle 100 and furthest forward. As a result, the distance between the electrical element 104 located at the front of the vehicle 100 and the DCDC converter 1 is shortened, making it easier to connect the electrical element 104 and the DCDC converter 1.

[0033] Furthermore, the DC-DC converter mounting structure 2 according to this embodiment includes a plurality of holding members 21 to 23, and the plurality of holding members 21 to 23, each holding a DC-DC converter 1, are stacked vertically (Z-direction) and integrated with each other, and are positioned below the cross member 103. In this way, in the DC-DC converter mounting structure 2, each of the plurality of holding members 21 to 23 holds a DC-DC converter 1, so multiple DC-DC converters 1 can be mounted below the cross member 103. In addition, by stacking the multiple DC-DC converters 1 vertically, the space below the cross member 103 can be utilized more effectively.

[0034] Furthermore, in the DCDC converter mounting structure 2 according to this embodiment, the lowermost holding member 21 of the plurality of holding members 21 to 23 has a U-shape that is open upward when viewed from the front-to-back direction (X direction) and includes a holding portion 21a for holding one DCDC converter 1. The uppermost holding member 23 of the plurality of holding members 21 to 23 has a U-shape that is open downward when viewed from the X direction and includes a holding portion 23a for holding another DCDC converter 1. Therefore, multiple DCDC converters 1 can be held more efficiently in the space defined by the U-shaped holding portion 21a of the holding member 21 and the U-shaped holding portion 23a of the holding member 23.

[0035] Furthermore, in the DC-DC converter mounting structure 2 according to this embodiment, the bracket 30 fixes the retaining members 21 to 23 to the side rails 101 and 102 and the cross member 103. As a result, the fixing of the retaining members 21 to 23 becomes more secure.

[0036] The above embodiments describe one aspect of the present invention. Therefore, the present invention is not limited to the DC-DC converter mounting structure 2 according to the above embodiment, and the DC-DC converter mounting structure 2 can be modified as desired.

[0037] For example, in the above embodiment, the case in which the bracket 30 fixes the retaining members 21 to 23 to both the side rails 101 and 102 and the cross member 103 was described. However, the bracket 30 only needs to fix the retaining members 21 to 23 to at least one of the side rails 101 and 102 and the cross member 103.

[0038] Furthermore, the above embodiment illustrates a case where the DCDC converter mounting structure 2 includes a plurality of retaining members 21 to 23. However, the DCDC converter mounting structure 2 may have only one retaining member, in which case the number of DCDC converters 1 may also be one.

[0039] Furthermore, the shape of the holding portions 21a and 23a of the holding members 21 and 23 when viewed from the X direction is not limited to a U shape but can be any shape. [Explanation of Symbols]

[0040] 1...DC-DC converter, 2...DC-DC converter mounting structure, 21, 22, 23...Retaining members, 21a...Retaining part (first retaining part), 23a...Retaining part (second retaining part), 30...Bracket, 100...Vehicle (electric vehicle), 101, 102...Side rails, 103, 103A...Cross member, 104...Electrical element (electrical component), 110...Front wheel.

Claims

1. A DC-DC converter mounting structure for a DC-DC converter mounted below the cross member in an electric vehicle having a pair of side rails arranged in the width direction of the vehicle and a cross member provided to span across the pair of side rails, A holding member positioned below the cross member while the DCDC converter is being held, A bracket for fixing the retaining member to the side rail and / or cross member, Equipped with, Features a DC-DC converter.

2. The electric vehicle has a plurality of the cross members, The holding member is positioned below the cross member that is located furthest forward and behind the front wheels of the electric vehicle among the plurality of cross members, when the DC-DC converter is being held. The DC-DC converter mounting structure according to claim 1.

3. The facility comprises a plurality of the aforementioned retaining members, The multiple holding members, each holding the DC-DC converter, are stacked vertically and integrated with each other, and are positioned below the cross member. The DC-DC converter mounting structure according to claim 1.

4. The lowermost of the plurality of retaining members has a U-shape that is open upward when viewed from the front-rear direction of the electric vehicle and includes a first retaining portion that holds one of the DC-DC converters. Another retaining member, located at the uppermost position among the plurality of retaining members, has a U-shape that is open downward when viewed from the front-rear direction and includes a second retaining portion that holds another DCDC converter. The DC-DC converter mounting structure according to claim 3.

5. The bracket secures the retaining member to the side rail and the cross member. A DC-DC converter mounting structure according to any one of claims 1 to 4.

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