Vehicle Power Supply

Abstract

To absorb misalignment between a DC connector and a bus bar inside a housing of a device while suppressing the increase in size of the DC connector.SOLUTION: A vehicle power supply device includes a device and a DC connector. The device is arranged on an electrical path leading to a DC inlet of an electric vehicle. The DC connector is arranged on the electrical path. The DC connector includes a first connector attached to the housing of the device. The first connector includes a terminal arranged inside the housing, and a bus bar fastening portion provided at the tip of a terminal. The device includes a bus bar which is arranged inside the housing and has one end connected to a component of the device. The bus bar includes a connector fastening portion fastened to the bus bar fastening portion via a fastening tool, and a Z-shaped metal spring which is interposed between the other end of the bus bar and the connector fastening portion or interposed midway through the bus bar at an end portion on the other end side of the bus bar, and extends in a direction parallel to an extending direction of the bus bar at the end portion on the other end side.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a vehicle power supply device in which a DC connector is used for connection between devices. [Background technology]

[0002] Patent Document 1 discloses a connector used for electrical connections in electric vehicles such as battery electric vehicles. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-087580 Summary of the Invention [Problem to be solved by the invention]

[0004] When the system voltage of an electric vehicle is increased to 800V or higher, it becomes necessary to increase the size of the DC connector, for example by using thicker wires to withstand heat buildup.One connector of the DC connector (the first connector) is attached to the housing of the equipment included in the vehicle power supply unit, but the internal space of this housing is limited.

[0005] Regarding the connection between the first connector and the bus bar within the housing, one possible approach is to use a braided wire as an electric wire connected to the inside of the first connector to absorb misalignment between the first connector and the bus bar. However, using a braided wire increases the size of the first connector, which may make it difficult to establish a structure that absorbs the misalignment in the limited space within the housing.

[0006] The present disclosure has been made in consideration of the above-described problems, and aims to provide a vehicle power supply device that can absorb misalignment between the DC connector and the bus bar within the device housing while suppressing an increase in size of the DC connector. [Means for solving the problem]

[0007] A vehicle power supply device according to the present disclosure includes a device and a DC connector. The device is arranged on an electrical path connected to a DC inlet of an electric vehicle. The DC connector is arranged on the electrical path. The DC connector includes a first connector attached to a housing of the device and a second connector assembled to the first connector. The first connector includes a terminal arranged inside the housing and a bus bar fastening portion provided at a tip of the terminal. The device includes a bus bar arranged inside the housing and having one end connected to a component of the device. The bus bar includes a connector fastening portion fastened to the bus bar fastening portion via a fastener, and a metal Z-shaped spring interposed between the other end of the bus bar and the connector fastening portion or interposed midway along the bus bar at an end on the other end side of the bus bar, and expands and contracts in a direction parallel to the extension direction of the bus bar at the end on the other end side.

[0008] The device may be a battery pack that supplies power to a drive motor of an electric vehicle.

[0009] The device may be a buck-boost converter arranged on an electrical path between a battery pack that supplies power to a drive motor of an electric vehicle and a DC inlet. [Effects of the Invention]

[0010] According to the vehicle power supply device of the present disclosure, by using the Z-shaped spring arranged as described above, it is possible to absorb the misalignment between the DC connector (first connector) and the bus bar while preventing the DC connector from becoming larger, compared to an example in which a braided wire is used to absorb the misalignment. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a diagram illustrating an example of the configuration of a vehicle power supply device according to an embodiment; [Figure 2] 2 is a diagram schematically illustrating a structure around the first connector shown in FIG. 1. FIG. [Figure 3] 3 is a diagram schematically illustrating a structure around the first connector as viewed from the direction of arrow A in FIG. 2. FIG. [Figure 4] 10A and 10B are diagrams illustrating other examples of arrangement of Z-shaped springs according to the embodiment. [Figure 5] 10A and 10B are diagrams illustrating still another example of arrangement of Z-shaped springs according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, a vehicle power supply device according to an embodiment of the present disclosure will be described with reference to the accompanying drawings. Note that common elements in the drawings will be assigned the same reference numerals, and redundant explanations will be omitted or simplified.

[0013] 1. Vehicle power supply system configuration 1 is a diagram illustrating an example of the configuration of a vehicle power supply device 10 according to an embodiment. The vehicle power supply device 10 is mounted on an electric vehicle such as a battery electric vehicle (BEV) or a plug-in hybrid electric vehicle (PHEV).

[0014] The vehicle power supply device 10 includes a DC (direct current) inlet 12, a battery pack 14, and a buck-boost converter 16. The battery pack 14 and the buck-boost converter 16 are each an example of a "device" arranged on an electrical path connected to the DC inlet 12. Specifically, the DC inlet 12 and the buck-boost converter 16 are connected via a pair of positive and negative power lines 18. The buck-boost converter 16 and the battery pack 14 are also connected via a pair of positive and negative power lines 20.

[0015] Vehicle power supply device 10 can receive power from an external DC power supply via DC inlet 12. The voltage applied to vehicle power supply device 10 from the external DC power supply is a high voltage such as 800V.

[0016] The battery pack 14 includes a housing 22. The housing 22 accommodates a battery stack as well as battery peripheral components (for example, a relay and a fuse) connected to the battery stack.

[0017] The buck-boost converter (buck-boost DC / DC converter) 16 includes a housing 24. The housing 24 contains, for example, a buck-boost circuit, a high-voltage interruption circuit, and a DC relay. The buck-boost converter 16 (boost-boost circuit) is configured to have a step-down function of stepping down the voltage (e.g., 800 V) supplied from the DC inlet 12 to the battery pack 14 to a predetermined voltage (e.g., 400 V). The buck-boost converter 16 is also configured to have a step-up function of stepping up the voltage (e.g., 400 V) supplied from the battery pack 14 to a predetermined voltage (e.g., 800 V). The high voltage boosted by the buck-boost converter 16 is supplied to an inverter (not shown) to drive, for example, a drive motor (not shown) of an electric vehicle.

[0018] The vehicle power supply device 10 includes a DC (direct current) connector 30 disposed on an electrical path connected to the DC inlet 12. Specifically, as shown in FIG. 1, the connection between the DC inlet 12 and the buck-boost converter 16 using the power line 18 is made via the DC connector 30. The DC connector 30 is also used to connect the buck-boost converter 16 to one end of the power line 20. The DC connector 30 is also used to connect the other end of the power line 20 to the battery pack 14. Each DC connector 30 is composed of a first connector 32 and a second connector 34 assembled to the first connector 32. Note that reference numeral 36 in FIG. 1 indicates a mating portion where these connectors 32 and 34 are mated with each other. The first connector 32 is one of a male connector and a female connector, and the second connector 34 is the other of the male connector and the female connector.

[0019] Fig. 2 is a diagram schematically illustrating the structure around the first connector 32 shown in Fig. 1. Fig. 3 is a diagram schematically illustrating the structure around the first connector 32 as viewed from the direction of arrow A in Fig. 2.

[0020] 2 and 3 illustrate the structure around the first connector 32 attached to the housing 22 of the battery pack 14, but the structure around the first connector 32 attached to the housing 24 of the boost / buck converter 16 is similar. Note that the second connector 34 and the fitting portion 36 are not shown in FIGS.

[0021] The first connector 32 includes a resin housing 38, a pair of positive and negative terminals 40, and a pair of bus bar fastening portions 42. Each terminal 40 is made of metal and attached to the housing 38. Each terminal 40 is disposed inside the housing 22 of the battery pack 14. A bus bar fastening portion 42 is fixed to the tip of each terminal 40 (the end opposite the housing 38). Each bus bar fastening portion 42 is made of metal and has a fastening hole 42a for a bolt 44 (see FIG. 3 ). Note that the bus bar fastening portion 42 may be formed integrally with the terminal 40.

[0022] The battery pack 14 includes a pair of positive and negative bus bars 50 arranged inside the housing 22. 2 and 3 show the end of the bus bar 50 on the first connector 32 side. Each bus bar 50 is made of metal and has one end (not shown) connected to a component of the battery pack 14 (e.g., a relay). In the example of the first connector 32 attached to the housing 24 of the boost / buck converter 16, the bus bar corresponding to the first connector 32 has one end connected to the component of the boost / buck converter 16.

[0023] Each bus bar 50 includes a connector fastening portion 52 (see FIG. 3 ) and a metal Z-shaped spring 54. Each connector fastening portion 52 is made of metal and has a fastening hole 52a for a bolt 44. Each connector fastening portion 52 is fastened to the bus bar fastening portion 42 via the bolt 44 and a nut 46, which are an example of a fastener, in a state where the connector fastening portion 52 is overlapped with the bus bar fastening portion 42. Note that the nut 46 may be fixed to the connector fastening portion 52 in advance, or, conversely to the example shown in FIG. 3 , the nut 46 may be fixed to the bus bar fastening portion 42 in advance.

[0024] The Z-shaped spring 54 is interposed between the other end 50a of the bus bar 50 and the connector fastening portion 52. The Z-shaped spring 54 is provided so as to expand and contract in a direction parallel to the extension direction D of the bus bar 50 at the end on the other end 50a side. The Z-shaped spring 54 is formed, for example, by bending a plate-shaped member.

[0025] More specifically, for example, one end of the Z-shaped spring 54 is fixed to a metal nut 56 by welding or other methods. The nut 56 is fixed to the other end 50a of the bus bar 50 by screwing or other methods. The other end of the Z-shaped spring 54 is fixed to the connector fastening portion 52 by welding or other methods. The bus bar 50 and the connector fastening portion 52 are connected by an electric wire 58 via the nut 56.

[0026] 2.Effects There is a limit to the internal space of the housings (e.g., housings 22 and 24) of the devices of the vehicle power supply device 10, such as the battery pack 14 and the step-up / step-down converter 16. More specifically, since various components of the devices are arranged inside the housings, the bus bar connected to the first connector is arranged by utilizing the limited space inside the housing while avoiding the components.

[0027] In order to absorb misalignment between the terminals 40 of the first connector 32 and the bus bar 50 when the first connector 32 is disposed in the above-described environment, the vehicle power supply device 10 according to this embodiment includes a Z-shaped spring 54 interposed between the other end 50a of the bus bar 50 and the connector fastening portion 52. The Z-shaped spring 54 can be mounted in a small space. By providing the Z-shaped spring 54 disposed as described above, it becomes possible to absorb the misalignment in a small space by utilizing the expansion and contraction of the Z-shaped spring 54. Therefore, compared to an example in which a braided wire is used to absorb the misalignment, it is possible to absorb the misalignment while suppressing an increase in the size of the first connector 32 (DC connector 30).

[0028] 3. Other examples of Z-type spring arrangement Fig. 4 is a diagram illustrating another example of the arrangement of the Z-shaped spring 54 according to the embodiment. Fig. 4 and Fig. 5, which will be described later, are diagrams illustrating the structure around the first connector as viewed from the same direction as Fig. 3.

[0029] 4, each of the pair of positive and negative bus bars 60 arranged inside the housing 22 includes a connector fastening portion 62 and a Z-shaped spring 54. The connector fastening portion 62 is fixed to the other end 60a of the bus bar 60 (the end of the bus bar 60 on the first connector 32 side shown in FIG. 4). The connector fastening portion 62 may be formed integrally with the bus bar 60. In this example, the Z-shaped spring 54 is provided so as to expand and contract in a direction parallel to the extension direction D of the bus bar 60 at the end on the other end 60a side.

[0030] 4 also makes it possible to absorb misalignment between the first connector 32 and the bus bar 60 in a small space by utilizing the expansion and contraction of the Z-shaped spring 54. Therefore, compared to an example in which a braided wire is used to absorb the misalignment, it is possible to achieve absorption of the misalignment while suppressing an increase in size of the first connector 32 (DC connector).

[0031] Fig. 5 is a diagram illustrating yet another example of the arrangement of the Z-shaped spring 54 according to the embodiment. In the example shown in Fig. 5, a first connector 70 of a DC connector includes a resin housing 38, a pair of positive and negative terminals 72, and a pair of bus bar fastening portions 74. The terminals 72 are bent midway from the housing 38 toward the bus bar fastening portions 74.

[0032] Meanwhile, each of the pair of positive and negative bus bars 80 arranged inside the housing 22 includes a connector fastening portion 82 and a Z-shaped spring 54. The connector fastening portion 82 is fixed to the other end 80a of the bus bar 80 (the end of the bus bar 80 on the first connector 70 side shown in FIG. 5). The connector fastening portion 82 may be formed integrally with the other end 80a. Also in this example, similar to the example shown in FIG. 4, the Z-shaped spring 54 is provided so as to expand and contract in a direction parallel to the extension direction D of the bus bar 80 at the end on the other end 80a side. This structure also provides the same effects as the example shown in FIG. 4.

[0033] 4. Other examples of equipment In the above-described embodiment, the battery pack 14 and the buck-boost converter 16 are exemplified as "devices arranged on an electrical path connected to a DC inlet of an electric vehicle." However, the "device" may also include, for example, an electric supply unit (ESU; not shown) connected to the battery pack 14 via a pair of positive and negative power lines. The ESU is a unit that integrates the functions of AC (alternating current) charging, power conversion, and power distribution. The "DC connector" according to the present disclosure may be arranged on an electrical path located between the ESU and the battery pack 14 in a vehicle power supply device equipped with such an ESU. [Explanation of symbols]

[0034] 10 Vehicle power supply unit 12 DC inlet 14 Battery pack 16 Buck-boost converter 18, 20 Power lines 22 Battery pack housing 24 Buck-boost converter housing 30 DC connector 32, 70 DC connector 1st connector 38 Housing of first connector 40, 72 Terminals of the first connector 42, 74 Busbar fastening portion of first connector 50, 60, 80 bus bar 50a, 60a, 80a Other end of bus bar 52, 62, 82 Busbar connector fastening part 54 Z-shaped spring

Claims

1. A device disposed on an electrical path connected to a DC inlet of an electric vehicle; a DC connector disposed on the electrical path; A vehicle power supply device comprising: The DC connector is a first connector attached to a housing of the device; a second connector assembled to the first connector; Including, the first connector includes a terminal disposed inside the housing and a bus bar fastening portion provided at a tip of the terminal, the device includes a bus bar disposed within the housing and having one end connected to a component of the device; The bus bar includes: a connector fastening portion fastened to the bus bar fastening portion via a fastener; a metal Z-shaped spring that is interposed between the other end of the bus bar and the connector fastening portion, or that is interposed in the middle of the bus bar at an end portion on the other end side of the bus bar, and that expands and contracts in a direction parallel to an extension direction of the bus bar at the end portion on the other end side; Including, One end of the Z-shaped spring is fixed to a nut fixed to the bus bar, The device further includes an electric wire that connects the portion of the bus bar where the one end is located and the connector fastening portion via the nut. Vehicle power supply.

2. The device is a battery pack that supplies power to a drive motor of the electric vehicle.

2. The vehicle power supply device according to claim 1.

3. The device is a step-up / step-down converter that is disposed on the electrical path between a battery pack that supplies power to a drive motor of the electric vehicle and the DC inlet.

2. The vehicle power supply device according to claim 1.

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