Method of manufacturing electrical devices
The electrical device design addresses misalignment stress and heat management by using intersecting plate-shaped busbar members fixed to relay terminals, ensuring secure and efficient electrical and thermal connections.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- DENSO CORP
- Filing Date
- 2023-06-27
- Publication Date
- 2026-06-30
Smart Images
Figure 0007882170000001 
Figure 0007882170000002 
Figure 0007882170000003
Abstract
Description
Technical Field
[0001] electric It relates to a method for manufacturing an electrical device.
Background Art
[0002] An electrical device including an electrical device such as a relay and a bus bar connected to a terminal of the electrical device is known. When such an electrical device is installed in a circuit through which a large current such as a charge and discharge path flows, a large current flows through the relay and the bus bar, and Joule heat proportional to the square of the current amount is generated, and the amount of heat generation also increases. For this reason, a technique for actively dissipating heat from the bus bar by contacting a cooler or a heat radiating member with the bus bar is known. Patent Document 1 describes an electrical device including a relay having terminals, a bus bar, and a joint plate. The bus bar described in Patent Document 1 is substantially L-shaped and has a portion parallel to the base plate and a portion perpendicular thereto. The bus bar is fixed so as to be pressed against the base plate with a heat transfer material sandwiched therebetween in its parallel portion. Since the heat of the bus bar is diffused to the base plate through the heat transfer material, the temperature rise of the bus bar is suppressed. The bus bar is fastened to the relay terminal through a joint plate in its perpendicular portion. The joint plate has a hole for fastening to the relay terminal at one end and a hole for fastening to the bus bar at the other end. The hole for fastening to the relay terminal of the joint plate is formed in an elongated shape with a margin in the longitudinal size of the joint plate. Therefore, even if the position of the joint plate is displaced in the longitudinal direction by being fastened to the bus bar, the joint plate can be fastened to the relay terminal.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] Busbars, which can carry large currents, tend to use metal plates (such as copper plates) with a large cross-sectional area in the direction of the current to reduce electrical and thermal resistance. However, metal plates with a large cross-sectional area are highly rigid and difficult to bend, so if the positions of the busbar and relay terminals are misaligned from the intended positions when fastening them, fastening becomes difficult. Furthermore, forcibly bending the busbar during fastening can generate significant stress at the fastening point between the busbar and the terminal.
[0005] According to Patent Document 1, if the joint plate is misaligned in the longitudinal direction, it is possible to suppress the stress that may occur when fastening the joint plate to the relay terminal. However, if the joint plate is misaligned in the transverse direction perpendicular to the longitudinal direction or in the thickness direction, it is difficult to suppress the stress. If one attempts to accommodate misalignment of the joint plate in both the longitudinal and transverse directions, the size of the hole must have to be larger in both the longitudinal and transverse directions, making it difficult to fasten the joint plate to the relay terminal. In other words, the method of providing a larger hole size for fastening conductive members such as joint plates to the terminals of electrical equipment such as relays, as in Patent Document 1, can suppress the stress that may occur due to misalignment in one specific direction, but it is difficult to suppress the stress that may occur due to misalignment in other directions as well.
[0006] In view of the above, the present disclosure aims to provide a method different from conventional methods that can suppress the stress that may occur when fixing the terminals of electrical equipment to the busbar. [Means for solving the problem]
[0007] This disclosure provides an electrical device comprising an electrical device and a busbar connected to the terminals of the electrical device. The busbar comprises a plate-shaped first member fixed to the terminals provided on the outer circumferential surface of the electrical device by a fastener, and a plate-shaped second member extending in a direction intersecting the first member and dissipating heat by a heat dissipation mechanism. The first member and the second member are joined at a position where they intersect each other.
[0008] According to the above electrical device, the busbar comprises a first member fixed to a terminal provided on the outer surface of the electrical equipment by a fastener, and a second member that dissipates heat by a heat dissipation mechanism, and the first member and the second member are joined at positions where they intersect with each other. With this configuration, after fixing the first member to the terminal of the electrical equipment while the first member and the second member are not joined, the busbar can be fixed to the terminal of the electrical equipment by joining the first member and the second member. When the busbar is subjected to heat dissipation by a heat dissipation mechanism due to reasons such as a large current flowing through it, there is a tendency to use a busbar that is highly rigid and difficult to bend. However, with the above electrical device, since the first member can be fixed to the terminal of the electrical equipment while the first member and the second member are not joined, even if the position of the first member relative to the second member is misaligned when the first member is fixed to the terminal of the electrical equipment, the busbar can be fixed to the terminal of the electrical equipment without bending the first member and the second member. Therefore, it is possible to suppress the stress that may occur when fixing the terminals of electrical equipment to the busbar. In other words, the above-described electrical device can suppress the stress that may occur when fixing the terminals of electrical equipment to the busbar by a method different from the conventional method of leaving a margin in the size of the hole for fastening to the terminals of electrical equipment.
[0009] This disclosure provides a method for manufacturing an electrical device comprising an electrical device and a busbar connected to the terminals of the electrical device. In this electrical device, the busbar comprises a plate-shaped first member and a plate-shaped second member. The manufacturing method includes an arrangement step of arranging the first member and the second member at positions where they intersect each other, a fixing step of fixing the first member to the terminals provided on the outer circumferential surface of the electrical device using a fixing device, and a joining step after the fixing step of joining the first member and the second member at positions where they intersect each other.
[0010] In the above method for manufacturing an electrical device, in the placement step, the first and second members of the busbar are positioned at mutually intersecting locations, and in the fixing step, the first member is fixed to the terminals provided on the outer surface of the electrical equipment using a fixing device. The joining step is performed after the fixing step, and the first and second members are joined at mutually intersecting locations. Because the joining step is performed after the fixing step, the first member is fixed to the terminals of the electrical equipment while the first and second members are not joined, and then the first and second members are joined, thereby achieving a state in which the busbar is fixed to the terminals of the electrical equipment. According to the above method for manufacturing an electrical device, since the first member can be fixed to the terminals of the electrical equipment while the first and second members are not joined, and then the first and second members can be joined, even if the position of the first member relative to the second member shifts when the first member is fixed to the terminals of the electrical equipment, a state in which the busbar is fixed to the terminals of the electrical equipment can be achieved without bending the first and second members. Therefore, the stress that may occur when fixing the terminals of the electrical equipment to the busbar can be suppressed. In other words, the above method of manufacturing electrical equipment suppresses the stress that may occur when fixing the terminals of the electrical equipment to the busbar by a method different from the conventional method of leaving a margin in the size of the hole for fastening to the terminals of the electrical equipment. [Brief explanation of the drawing]
[0011] [Figure 1] A perspective view of an electrical device according to an embodiment. [Figure 2] Cross-sectional view along line II-II in Figure 2. [Figure 3] Figure 1 illustrates the manufacturing method of the electrical device shown in Figure 1. [Figure 4] Figure 1 illustrates the manufacturing method of the electrical device shown in Figure 1. [Figure 5] Figure 1 illustrates the manufacturing method of the electrical device shown in Figure 1. [Figure 6] Figure 1 illustrates the manufacturing method of the electrical device shown in Figure 1. [Figure 7] Figure 1 illustrates the manufacturing method of the electrical device shown in Figure 1. [Figure 8] A diagram showing a part of the busbar of an electrical device relating to a modified example. [Figure 9] A longitudinal cross-sectional view of an electrical device relating to a modified example. [Figure 10] A longitudinal cross-sectional view of an electrical device relating to a modified example. [Figure 11] Top view of the electrical device in a modified form. [Modes for carrying out the invention]
[0012] (Electrical equipment) Figure 1 shows a relay unit 10 according to an embodiment. The relay unit 10 comprises a relay 20, a first pole busbar 30 and a second pole busbar 40, a base member 50, and a heat dissipation sheet 70. The relay 20 is an example of an electrical device according to the embodiment, and the relay unit 10 is an example of an electrical device according to the embodiment.
[0013] Figures 1 and 2 show the relay unit 10, and Figures 3 to 7 show the manufacturing process of the relay unit 10. The relay 20 is a mechanical relay and, as shown in Figures 1 and 2, has a resin casing that is approximately rectangular in shape, with the z-axis direction being vertical, the x-axis direction being horizontal, and the y-axis direction being depth. Hereinafter, in this specification, the positive z-axis direction may be referred to as the upward direction, the negative z-axis direction as the downward direction, the positive x-axis direction as the rightward direction, the negative x-axis direction as the leftward direction, the positive y-axis direction as the backward direction, and the negative y-axis direction as the forward direction.
[0014] The relay 20 has a contact section and a coil section (not shown) inside its resin casing. A pair of terminals are provided on the front surface of the relay 20 (the negative y-axis side in Figure 1), spaced apart from each other in the left-right direction. As shown in Figure 1, the first pole terminal 27 is the right-hand terminal, and the second pole terminal 28 is the left-hand terminal.
[0015] As shown in FIG. 2, FIG. 3, etc., the first pole terminal 27 and the second pole terminal 28 are ring-shaped contact portions provided on the front surface of the relay 20 (the surface in the negative direction of the y-axis). Inside the relay 20, a bolt fastening hole extending in the y-axis direction is provided at the central portion of the first pole terminal 27. The first pole bus bar 30 is fixed to the first pole terminal 27 by a first pole terminal fixing bolt 63 that passes through a through hole 37 to be described later and is fastened to the first pole side bolt fastening hole while being in contact with the first pole terminal 27 from the front. Thereby, the first pole terminal 27 and the first pole bus bar 30 are electrically and thermally connected to each other.
[0016] Similarly, although not shown, a bolt fastening hole extending in the y-axis direction is provided at the central portion of the second pole terminal 28 inside the relay 20. The second pole bus bar 40 is fixed to the second pole terminal 28 by a second pole terminal fixing bolt 64 that passes through a through hole 47 to be described later and is fastened to the second pole side bolt fastening hole while being in contact with the second pole terminal 28 from the front. Thereby, the second pole terminal 28 and the second pole bus bar 40 are electrically and thermally connected to each other. Hereinafter, in this specification, the first pole terminal 27, the second pole terminal 28, the first pole bus bar 30, the second pole bus bar 40, the first pole terminal fixing bolt 63, and the second pole terminal fixing bolt 64 may be abbreviated as terminal 27, 28, bus bar 30, 40, terminal fixing bolts 63, 64, respectively.
[0017] Between the first pole terminal 27 and the second pole terminal 28, a partition plate 21 protruding in the front direction (the negative direction of the y-axis) is formed over substantially the entire length in the vertical direction of the relay 20. The partition plate 21 prevents the first pole bus bar 30 connected to the first pole terminal 27 and the second pole bus bar 40 connected to the second pole terminal 28 from coming into contact and short-circuiting.
[0018] The relay 20 is controlled to be turned on / off by a control circuit not shown. When the relay 20 is turned on, a current flows between the first pole terminal 27 and the second pole terminal 28 through the contact portion inside the relay 20. When the relay 20 is turned off, no current flows between the first pole terminal 27 and the second pole terminal 28.
[0019] The relay 20 has two legs at its lower end that protrude to the left and right (positive and negative x-axis directions as shown in Figure 1, etc.). In Figure 2, etc., the first pole side leg 23, which is located on the first pole side (to the right), is shown, but the second pole side leg, which is located on the second pole side (to the left), is not shown. Bolt insertion holes are formed in each of the two legs.
[0020] As shown in Figure 3, the base member 50 is a holding member that holds the relay 20, and includes a mounting portion 53 on which the relay 20 is placed, and a first pole-side portion 51 and a second pole-side portion 52 provided to the right and left of the mounting portion 53. The first pole-side portion 51 and the second pole-side portion 52 are higher than the mounting portion 53, and the first pole-side portion 51, the second pole-side portion 52 and the mounting portion 53 form a recess for housing the relay 20.
[0021] The mounting portion 53 is provided with a first pole-side through hole 56 on the side closest to the first pole-side side portion 51, and a second pole-side through hole 58 on the side closest to the second pole-side side portion 52. The first pole-side through hole 56 is located in the forward direction (negative direction of the y-axis) of the mounting portion 53, and the second pole-side through hole 58 is located in the rear direction (positive direction of the y-axis) of the mounting portion 53. The first pole-side through hole 56 and the second pole-side through hole 58 are located at diagonal positions in the mounting portion 53, which has a rectangular shape when viewed from above.
[0022] The first pole side relay fixing bolt 61 is fastened from above, passing through the first pole side through hole 56 and the bolt insertion hole of the first pole side leg portion 23. Similarly, on the second pole side, the second pole side relay fixing bolt 62 is fastened by passing through the second pole side through hole 58 and the bolt insertion hole of the second pole side leg portion (not shown). By fastening the first pole side relay fixing bolt 61 and the second pole side relay fixing bolt 62, the relay 20 is attached to and fixed to the base member 50.
[0023] The first pole busbar 30 comprises a first member 31 and a second member 32. The second pole busbar 40 comprises a first member 41 and a second member 42. The first members 31, 41 and the second members 32, 42 are each formed by processing a conductive metal plate. In this embodiment, the first members 31, 41 and the second members 32, 42 are formed from the same metal plate (for example, copper).
[0024] The first members 31 and 41 are substantially rectangular plate-shaped members, and as shown in Figure 4, when the plate surface of the first member 41 is inverted around the z-axis as shown in Figure 1, it is formed to have the same shape as the first member 31. The first members 31 and 41 each have through holes 37 and 47 that penetrate in the thickness direction (y-axis direction as shown in Figure 1, etc.).
[0025] The first members 31 and 41 are arranged such that their plate surfaces are substantially parallel to and opposite the front surface of the relay 20. Since the front surface of the relay 20 is generally parallel to the z-axis and x-axis directions, the first members 31 and 41 are arranged such that their plate surfaces are generally parallel to the z-axis and x-axis directions and perpendicular to the y-axis direction. The first members 31 and 41 are arranged to be substantially symmetrical with respect to the axis of symmetry in the z-axis direction. The surfaces of the first members 31 and 41 facing the relay 20 (rear surfaces) are in contact with terminals 27 and 28 provided on the front surface of the relay 20, respectively, and the first members 31 and 41 are fastened to terminals 27 and 28 by terminal fixing bolts 63 and 64. By being fastened with terminal fixing bolts 63 and 64, the first members 31 and 41 are electrically and thermally connected to the first pole terminal 27 and the second pole terminal 28 of the relay 20.
[0026] As shown in Figures 2 and 4, the second members 32 and 42 are plate-shaped members with a roughly rectangular plate material bent at two points. The second member 32 and the second member 42 are processed to be roughly the same shape. The second member 32 has a flat plate portion 32a, a stepped portion 32b, and a fastening portion 32c arranged in this order from the negative y-axis to the positive y-axis. Similarly, the second member 42 has a flat plate portion 42a, a stepped portion 42b, and a fastening portion 42c arranged in this order from the negative y-axis to the positive y-axis.
[0027] The flat plate portions 32a and 42a extend in the y-axis direction below the mounting portion 53. Parts of the flat plate portions 32a and 42a are embedded and fixed in the base member 50, while their lower surfaces are exposed downward relative to the lower surface of the base member 50. A heat dissipation sheet 70, described later, is provided so as to be in contact with the lower surfaces of the flat plate portions 32a and 42a that are exposed from the base member 50. The ends of the flat plate portions 32a and 42a in the negative y-axis direction protrude from the base member 50 in the y-axis direction. The ends of the flat plate portions 32a and 42a in the positive y-axis direction are connected to the negative y-axis ends of the stepped portions 32b and 42b, respectively.
[0028] The stepped portions 32b and 42b are bent at both ends and have a step in the z-axis direction. The positive y-axis ends of the stepped portions 32b and 42b are connected to the negative y-axis ends of the fastening portions 32c and 42c, respectively. The fastening portions 32c and 42c are exposed on the upper surface side of the base member 50. Through holes 35 and 45 are provided in the fastening portions 32c and 42c, respectively. As shown in Figure 2, a bolt fastening hole 55 is provided in the base member 50 at a position below the through hole 35. For example, the first pole busbar 30 can be connected to the external wiring by placing an external busbar that connects to the external wiring of the relay unit 10 on the upper surface side of the fastening portion 32c, aligning the through hole in the external busbar with the through hole 35 in the fastening portion 32c, and then bolting them together. Although not shown in the diagram, the base member 50 is also provided with a bolt fastening hole having the same structure as the bolt fastening hole 55, located below the through hole 45. By aligning the through hole in the external busbar with the through hole 45 in the fastening portion 42c and fastening them together with bolts, the second pole busbar 40 can be connected to the external wiring.
[0029] The first member 31 and the second member 32 are positioned in a positional relationship that intersects with each other, and are joined to each other by welding at the intersection. As shown in Figures 2 and 3, the flat plate portion 32a of the second member 32 protrudes from the base member 50 at positions y1 to y4. Position y1 is the front surface of the mounting portion 53 of the base member 50, and position y4 is the front surface of the second member 32. The relay 20 is fixed to the base member 50 such that the position of its front surface is at position y2, which is shifted forward from position y1. The flat plate portion 32a of the second member 32 protrudes from the front surface of the relay 20 at positions y2 to y4. The joining surface 31a of the first member 31 is joined to the upper surface (the surface facing the relay 20) of the second member 32 at positions y2 to y3. The joining surface 31a is the surface (downward surface) opposite the upward surface in which the through hole 37 is provided nearby. Position y3 is a position shifted backward from position y4. As shown in Figures 1 and 2, the first pole busbar 30 is formed in an overall L-shape by joining the first member 31 and the second member 32 in a state where the second member 32 is dominant and the two members are approximately perpendicular to each other (more specifically, the first member 31 is approximately upright with respect to the plate surface of the second member 32).
[0030] Similarly, the first member 41 and the second member 42 are positioned in a positional relationship that intersects with each other, and are joined to each other by welding at the intersection. As shown in Figure 3, the flat plate portion 42a of the second member 42 protrudes from the base member 50 at positions y1 to y4. Position y1 is the position of the front surface of the mounting portion 53 of the base member 50, and position y4 is the position of the front surface of the second member 42. The relay 20 is fixed to the base member 50 such that the position of its front surface is at position y2, which is shifted forward from position y1. The flat plate portion 42a of the second member 42 protrudes from the front surface of the relay 20 at positions y2 to y4. The joining surface 41a of the first member 41 is joined to the upper surface (the surface facing the relay 20) of the second member 42 at positions y2 to y3. The joining surface 41a is the surface (downward surface) opposite the upward surface in which the through hole 47 is provided nearby. Position y3 is a position shifted backward from position y4. Although not shown in the figures, similar to the first pole busbar 30, the second pole busbar 40 is formed in an overall approximate L-shape by joining the first member 41 and the second member 42 in a state where the second member 42 is dominant and the two members are approximately perpendicular to each other (more specifically, the first member 41 is approximately upright with respect to the plate surface of the second member 42).
[0031] In this embodiment, in the first pole busbar 30 and the second pole busbar 40, the second members 32 and 42 are in a dominant position, and the first members 31 and 41 and the second member 42 are joined to each other. That is, the joint portion where the first member 31 and the second member 32 are joined to each other is the portion where the end face (the surface adjacent to the plate surface) of the first member 31 and the plate surface of the second member 32 are joined to each other. The joint portions where the first member 41 and the second member 42 are joined to each other are the portions where the end face of the first member 41 and the plate surface of the second member 42 are joined to each other.
[0032] The position of the joint-side end of the second members 32, 42 (the front end shown in Figure 1, etc.) is position y4, and the position of the front surface of the first members 31, 41 is position y3, which is shifted backward from position y4. In other words, the joint-side end of the second members 32, 42 (the front end shown in Figure 1, etc.) protrudes from the plate surface of the first members 31, 41. Because positions y3 and y4 are designed in this way, even if the y-axis position of the first members 31, 41 is misaligned, the end faces of the first members 31, 41 can remain positioned on the plate surface of the second members 32, 42. Furthermore, since position y2, which is the front surface of the relay 20, is shifted forward from position y1, which is the front surface of the mounting portion 53 of the base member 50, the first members 31, 41 can be brought into contact with the terminals 27, 28 while their end faces are positioned on the plate surface of the second members 32, 42.
[0033] A welded joint 33 is provided at the position where the first member 31 and the second member 32 are joined. The welded joint 33 is formed by fillet welding the position where the first member 31 and the second member 32 are joined from the side where the relay 20 is not present (the negative y-axis side and the positive z-axis side). A welded joint 43 is provided at the position where the first member 41 and the second member 42 are joined. The welded joint 43 is formed by fillet welding the position where the first member 41 and the second member 42 are joined from the side where the relay 20 is not present (the negative y-axis side and the positive z-axis side).
[0034] In this embodiment, fillet welding is used as a means to join the first members 31, 41 and the second members 32, 42 to form welded portions 33, 43. Welded portion 33 is the joint portion where the first member 31 and the second member 32 are joined to each other. Welded portion 43 is the joint portion where the first member 41 and the second member 42 are joined to each other. The means for joining the first member and the second member is not limited to welding and can be appropriately selected depending on the type and application of each component of the electrical device. Various joining means can be used to join the first member and the second member, such as welding, brazing, pressure welding, fusion welding, soldering, crimping, and ultrasonic welding, and furthermore, multiple joining means may be used in combination.
[0035] The welded joints 33 and 43 are formed in positions that do not face the relay 20. In the relay unit 10, a position facing the relay 20 means a position included in the region (referred to as the relay projection region for convenience of explanation) obtained by projecting the region where the relay 20 is located in the x-axis, y-axis, and z-axis directions. Specifically, as shown in Figure 2, this refers to a position included in the region where positions z0 to z1 are in the z-axis direction and positions y0 to y2 are in the y-axis direction. A position not facing the relay 20 means a position not included in the relay projection region. Specifically, as shown in Figure 2, this refers to a position included in the region where positions z1 to z2 are in the z-axis direction and positions y2 to y4 are in the y-axis direction. Here, positions z0, z1, y0, and y1 are the top, bottom, back, and front positions of the relay 20, respectively. Positions z2 and y4 are the bottom and front positions of the second members 32 and 42, respectively. In other words, it is preferable that the welds 33 and 43 are formed in a region that is below the lower surface of the relay 20 and in front of the front surface of the relay 20. If the positions where the welds 33 and 43 are formed are not opposite the relay 20, it is possible to suppress the heating of the relay 20 by the heat generated when forming the welds 33 and 43.
[0036] As shown in Figure 2, a heat dissipation sheet 70 is provided on the lower surface of the second members 32 and 42 as a heat dissipation mechanism. For example, a heat dissipation sheet 70 can be made of silicone rubber filled with a thermally conductive filler such as aluminum oxide or iron oxide. A heat dissipation sheet 70 made of silicone rubber, like the heat dissipation sheet 70, is easily deformable and has high thermal conductivity and electrical insulation properties. A highly adhesive heat dissipation sheet 70 may be used and attached to the lower surface of the second members 32 and 42, or the heat dissipation sheet 70 may be pressed against the lower surface of the second members 32 and 42 using other materials. Alternatively, a paste-like heat dissipation material may be used as a heat dissipation mechanism and applied to the lower surface of the second members 32 and 42. Note that the heat dissipation mechanism may use means other than heat dissipation materials. For example, a cooling mechanism that cools the second members 32 and 42 by providing a heat exchanger through which a refrigerant passes on the lower surface of the second members 32 and 42 may be used as a heat dissipation mechanism.
[0037] The welded joints 33 and 43 are positioned so as not to reach the lower surfaces of the second members 32 and 42. Therefore, the flatness of the lower surfaces of the second members 32 and 42 is not impaired by welding. Since the heat dissipation sheet 70 is provided on the flat lower surfaces of the second members 32 and 42, good adhesion between the lower surfaces of the second members 32 and 42 and the heat dissipation sheet 70 can be ensured, and heat conductivity between the lower surfaces of the second members 32 and 42 and the heat dissipation sheet 70 can be ensured.
[0038] In this embodiment, the heat dissipation sheet 70, which corresponds to the heat dissipation mechanism, is in contact with the lower surface of the second members 32 and 42, which corresponds to the heat dissipation surface. However, the heat dissipation sheet 70 may be provided so as not to be in contact with the heat dissipation surface of the second members 32 and 42. The heat dissipation surface of the second members 32 and 42 may be any surface facing the heat dissipation mechanism. In this embodiment, other members may be provided between the heat dissipation surface of the second members 32 and 42 and the heat dissipation mechanism, so that the second members 32 and 42 dissipate heat indirectly through the heat dissipation mechanism.
[0039] (Manufacturing methods for electrical equipment) The method for manufacturing the relay unit 10 includes an arrangement step, a fixing step, and a joining step. The arrangement step is to arrange the first members 31 and 41 and the second members 32 and 42 at positions where they intersect each other. The fixing step is to fix the first members 31 and 41 to the terminals 27 and 28 of the relay 20, respectively, using terminal fixing bolts 63 and 64. The joining step is to join the first members 31 and 41 and the second members 32 and 42 at positions where they intersect each other, and is performed after the fixing step. After the joining step, the relay unit 10 can be manufactured by further performing a heat dissipation mechanism installation step in which a heat dissipation mechanism is installed.
[0040] The arrangement step includes a first step and a second step. The first step is to prepare a base member 50 to which the second members 32 and 42 are fixed. Hereinafter, for convenience of explanation, the base member 50 to which the second members 32 and 42 are fixed may be referred to as the fixed base member. The second step is to fix the relay 20 to the fixed base member.
[0041] (Placement step) First, as shown in Figure 3, a base member 50 (fixed base member) is prepared, to which the second members 32 and 42 are fixed by insert molding (first step). The second members 32 and 42 are fixed by being roughly embedded in the lower part of the mounting portion 53 of the base member 50, with the lower surfaces of their flat portions 32a and 42a exposed from the lower surface of the mounting portion 53 of the base member 50. In addition, the flat portions 32a and 42a protrude forward relative to the base member 50 at positions y1 to y4. The distance from positions y1 to y4 is designed to be greater than the thickness of the first members 31 and 41.
[0042] Next, as shown in Figure 3, the relay 20 is positioned so that its lower surface faces the upper surface of the mounting portion 53 of the base member 50, and the relay 20 is fixed to the base member 50 by fastening the relay fixing bolts 61 and 62 (second step). The relay 20 is positioned so that the first pole terminal 27 side is upward relative to the second member 32, and the second pole terminal 28 side is upward relative to the second member 42. Through the first and second steps, the relay 20, the base member 50, and the second members 32 and 42 are fixed to each other with the flat plate portions 32a and 42a positioned opposite the lower surface of the relay 20.
[0043] Next, as shown in Figures 4 and 5, the first members 31 and 41 are positioned in the front direction of the front surface of the relay 20. As shown in Figure 5, the first members 31 and 41 are positioned so that their plate surfaces are substantially parallel to and facing the front surface of the relay 20. Aligning the through hole 37 with the bolt fastening hole provided in the center of the first pole terminal 27, the first member 31 is superimposed on the first pole terminal 27 from the front. Aligning the through hole 47 with the bolt fastening hole provided in the center of the second pole terminal 28, the first member 41 is superimposed on the second pole terminal 28 from the front. As a result, as shown in Figure 5, the first members 31 and 41 are positioned substantially upright relative to the second members 32 and 42, and are held in place by magnetic or electrostatic force by chucks 81 and 82 that contact them from above. The through holes 37 and 47 are formed in such a position that, when aligned with the bolt fastening holes provided in the center of the terminals 27 and 28, the joint surfaces 31a and 41a and the upper surfaces of the flat plate portions 32a and 42a at positions y1 to y4 come into contact with each other. The chucks 81 and 82 hold the first members 31 and 41 while maintaining the state in which the joint surfaces 31a and 41a of the first members 31 and 41 are in contact with the upper surfaces of the second members 32 and 42, respectively, while allowing the first members 31 and 41 to move in a direction parallel to the joint surfaces 31a and 41a.
[0044] (Fixed step) Next, as shown in Figures 5 and 6, with the first members 31 and 41 held by the chucks 81 and 82, terminal fixing bolts 63 and 64 are inserted through the through holes 37 and 47 from the front of the first members 31 and 41 and fixed by fastening to the bolt fastening holes provided in the center of the terminals 27 and 28. In the fixing step, the first members 31 and 41 and the second members 32 and 42 are not joined to each other, and the first members 31 and 41 are held by the chucks 81 and 82. Therefore, the first members 31 and 41 can be brought into contact with the terminals 27 and 28 of the relay 20 and fixed, while allowing movement in directions parallel to the joining surfaces 31a and 41a of the first members 31 and 41 (the x-axis and y-axis directions shown in Figure 6). Even if the first members 31 and 41 move in a direction parallel to their joint surfaces 31a and 41a before and after fixing the first members 31 and 41 to the terminals 27 and 28 of the relay 20, the first members 31 and 41 and the second members 32 and 42 do not bend, thus suppressing the stress that may occur when fixing the terminals 27 and 28 of the relay 20 to the first members 31 and 41. Furthermore, the terminals 27 and 28 of the relay 20 and the first members 31 and 41 can be fixed with the rear surfaces of the first members 31 and 41 in secure contact with the terminals 27 and 28.
[0045] (Joining step) Next, the first members 31, 41 and the second members 32, 42 are joined at positions where they intersect. By fillet welding the positions where the first members 31, 41 and the second members 32, 42 intersect, from the side of the first members 31, 41 that does not face the relay 20 (the front side), the heat generated during welding can suppress the heating of the relay 20, and the welded parts 33, 43 can be formed. Fillet welding is just one example of a joining method, and the joining step can be performed using various joining methods such as welding, brazing, pressure welding, fusion welding, soldering, crimping, and ultrasonic welding. Furthermore, multiple joining methods may be used in combination to perform the joining step. In this embodiment, the chucks 81 and 82 are described as maintaining a state in which the joining surfaces 31a and 41a of the first members 31 and 41 are in contact with the upper surfaces of the second members 32 and 42, respectively. However, even if a small gap is created between the joining surfaces 31a and 41a of the first members 31 and 41 and the plate surfaces of the second members 32 and 42 after the fixing step, if a means of melting metal material such as welding or brazing is used in the joining step, the gap can be filled with molten metal, and the electrical resistance and thermal resistance at the joint can be prevented from increasing.
[0046] In the joining step, it is preferable to set the welding conditions such that the positions where the welds 33 and 43 are formed do not face the relay 20. That is, it is preferable to set the welding conditions so that the welds 33 and 43 are formed in a region that is below the lower surface of the relay 20 and in front of the front surface of the relay 20. If the positions where the welds 33 and 43 are formed do not face the relay 20, it is possible to suppress the heating of the relay 20 by the heat generated when forming the welds 33 and 43.
[0047] In the joining step, it is preferable to set the welding conditions so that welded joints 33 and 43 are not formed on the lower surfaces of the second members 32 and 42. As will be described later, the heat dissipation sheet 70 is installed in contact with the lower surfaces of the second members 32 and 42. If welded joints 33 and 43 are formed, the flatness of the lower surfaces of the second members 32 and 42 will be impaired, and there is a concern that the adhesion with the heat dissipation sheet 70 will decrease. By setting the welding conditions in the joining step so that welded joints 33 and 43 are not formed on the lower surfaces of the second members 32 and 42, adhesion between the lower surfaces of the second members 32 and 42 and the heat dissipation sheet 70 can be ensured, and heat conductivity between the lower surfaces of the second members 32 and 42 and the heat dissipation sheet 70 can be ensured.
[0048] (Heat dissipation mechanism installation step) After the joining step, a heat dissipation sheet 70 is installed on the lower surface of the second members 32 and 42. For example, a highly adhesive heat dissipation sheet 70 is used and installed by directly attaching it to the lower surface of the second members 32 and 42. Since no welded joints 33 and 43 are formed on the lower surface of the second members 32 and 42, the heat dissipation sheet 70 can be attached to the flat second members 32 and 42. This ensures that thermal conductivity is maintained between the lower surface of the second members 32 and 42 and the heat dissipation sheet 70. The relay unit 10 can be manufactured by each of the manufacturing processes described above.
[0049] As described above, if the fixing step is performed after the placement step, the joint surfaces 31a and 41a of the first members 31 and 41 can be maintained in contact with the upper surfaces of the second members 32 and 42, respectively, by using simple holders such as chucks 81 and 82, thereby fixing the first members 31 and 41 to the terminals 27 and 28 of the relay 20. However, the manufacturing method of the relay unit 10 is not limited to the order in which the fixing step is performed after the placement step. For example, after fixing the first members 31 and 41 to the terminals 27 and 28 of the relay 20 by the fixing step, a base member 50 to which the second members 32 and 42 are fixed by the first step in the placement step is prepared. Then, the relay 20 to which the first members 31 and 41 are fixed is fixed to the base member 50 to which the second members 32 and 42 are fixed. The placement step and the fixing step may be performed in this order.
[0050] As described above, the relay unit 10 and its manufacturing method have been explained, and the relay unit 10 is suitably used, for example, to connect or disconnect the electrical connection between an on-board battery and an external charging device. In this case, for example, when the relay 20 is closed with the first-pole busbar 30 connected to the external charging device side and the second-pole busbar 40 connected to the on-board battery side, a charging current is supplied to the relay 20, the first-pole busbar 30 and the second-pole busbar 40. When the charging current is supplied, heat is generated in the relay 20, the first-pole busbar 30 and the second-pole busbar 40.
[0051] In the relay unit 10, the first pole busbar 30 and the second pole busbar 40 dissipate heat through the heat dissipation sheet 70 that is in contact with the lower surfaces of the second members 32 and 42. In addition, the first pole busbar 30 and the second pole busbar 40 are thermally connected to the first pole terminal 27 and the second pole terminal 28 of the relay 20 at their first members 31 and 41. Therefore, heat is dissipated from the relay 20 via the first pole busbar 30 and the second pole busbar 40. Since the busbars 30 and 40 are connected to the terminals 27 and 28 of the relay 20, which are prone to generating heat, the heat generated near the terminals 27 and 28 can be effectively dissipated. In the relay unit 10, by dissipating heat from the first pole busbar 30 and the second pole busbar 40, the heat generated in the relay 20 due to the flow of charging current can be dissipated via the first pole busbar 30 and the second pole busbar 40. Therefore, the temperature rise of the relay 20 can be suppressed. Furthermore, the relay unit 10 dissipates heat from the first pole busbar 30 and the second pole busbar 40, thereby suppressing the conduction of heat generated in the first pole busbar 30 and the second pole busbar 40 due to the flow of charging current to the relay 20. This suppresses the temperature rise of the relay 20.
[0052] In situations where the temperature of relay 20 rises over time due to the flow of charging current, the temperature of relay 20 may reach its upper limit temperature, forcing a reduction in the charging current. This increases the charging time of the energy storage device. Attempting to address this problem by increasing the heat resistance temperature of relay 20 could lead to other problems, such as an increase in the size of relay 20 or an increase in its cost. Relay unit 10, however, uses a heat dissipation mechanism to dissipate heat from the first pole busbar 30 and the second pole busbar 40, thereby suppressing the temperature rise of relay 20 caused by the flow of charging current, and thus preventing an increase in the size and cost of relay 20.
[0053] According to the relay unit 10 and its manufacturing method, the first pole busbar 30 and the second pole busbar 40 each comprise a first member 31, 41 fixed to terminals 27, 28 of the relay 20 by terminal fixing bolts 63, 64, and a second member 32, 42 that dissipates heat by a heat dissipation mechanism. The first pole busbar 30 is manufactured by joining the first member 31 and the second member 32 at positions where they intersect each other. The second pole busbar 40 is manufactured by joining the first member 41 and the second member 42 at positions where they intersect each other.
[0054] With this configuration, after fixing the first member 31 to the terminal 27 of the relay 20 while the first member 31 and the second member 32 are not joined, the first member 31 and the second member 32 are joined together to obtain a state in which the first pole busbar 30 is fixed to the terminal 27 of the relay 20. Similarly, after fixing the first member 41 to the terminal 28 of the relay 20 while the first member 41 and the second member 42 are not joined, the first member 41 and the second member 42 are joined together to obtain a state in which the second pole busbar 40 is fixed to the terminal 28 of the relay 20.
[0055] In cases where a busbar is subjected to high current flow and heat is dissipated by a heat dissipation mechanism, a busbar with high rigidity and difficulty in bending is tended to be used. As described above, with the relay unit 10, the first member 31 can be fixed to the terminal 27 of the relay 20 without the first member 31 and the second member 32 being joined together, so the first member 31 is allowed to move relative to the second member 32 during fixing, and there is no need to bend the first member 31 and the second member 32. Similarly, the first member 41 can be fixed to the terminal 28 of the relay 20 without the first member 31 and the second member 42 being joined together, so the first member 41 is allowed to move relative to the second member 42 during fixing, and there is no need to bend the first member 41 and the second member 42. In other words, with the relay unit 10, the stress that may occur when fixing the first pole busbar 30 and the second pole busbar 40 to the terminals 27 and 28 of the relay 20 can be suppressed.
[0056] Increasing the cross-sectional area perpendicular to the direction of current flow of the busbars to reduce electrical and thermal resistance raises concerns that the high rigidity and difficulty in bending them will make it difficult to connect them to the relay terminals. With the relay unit 10, the first pole busbar 30 and the second pole busbar 40 can be fixed to the terminals 27 and 28 of the relay 20, respectively, without bending them, thus allowing for a larger cross-sectional area perpendicular to the direction of current flow of the first pole busbar 30 and the second pole busbar 40. As a result, the temperature rise of the relay 20 can be suppressed more effectively, and the increase in the size and cost of the relay 20 can be suppressed more effectively.
[0057] For example, if a pre-formed L-shaped busbar is forcibly bent and then fixed to a relay terminal by fastening terminal fixing bolts, a large stress may be generated at the fastening point between the busbar and the relay terminal if there is a misalignment between the relay terminal and the busbar. If the terminal fixing bolts are fastened and the busbar is fixed to the relay terminal under such stress, when the fastened terminal fixing bolts are removed, a relatively large gap may be created between the fastening point of the busbar and the relay terminal, or scratches may occur on the fastening point of the busbar. In contrast, in the relay unit 10, the first members 31 and 41 are allowed to move relative to the second members 32 and 42 when fixed to the terminals 27 and 28 of the relay 20, thereby suppressing such stress. As a result, when the terminal fixing bolts 63 and 64 of the relay unit 10 are removed, there is almost no gap between the first members 31 and 41 and the terminals 27 and 28 of the relay 20, nor is there any scratching of the fastening points of the busbars 30 and 40.
[0058] The presence of gaps between the first members 31, 41 and the terminals 27, 28 of the relay 20, and scratches on the fastening portions of the busbars 30, 40, can increase the electrical and thermal resistance between the first members 31, 41 and the terminals 27, 28 of the relay 20. With the relay unit 10, such gaps and scratches rarely occur, thus reducing the electrical and thermal resistance between the first members 31, 41 and the terminals 27, 28 of the relay 20 compared to conventional designs where gaps and scratches may occur. With the relay unit 10, even if the electrical and thermal resistance at the joint between the first members 31, 41 and the second members 32, 42 increases, the reduction in electrical and thermal resistance between the first members 31, 41 and the terminals 27, 28 of the relay 20 is sufficiently large compared to the increase in electrical and thermal resistance at the joint. Therefore, the temperature rise of the relay 20 can be suppressed more effectively, and the increase in the size and cost of the relay 20 can be suppressed more effectively.
[0059] Furthermore, with the relay unit 10, the first members 31 and 41 can be fixed to the terminals 27 and 28 of the relay 20, respectively, while allowing movement in a direction parallel to the joint surfaces 31a and 41a of the first members 31 and 41. In other words, in the direction parallel to the joint surfaces 31a and 41a of the first members 31 and 41 (the x-axis and y-axis directions shown in Figure 1, etc.), stress that may occur due to misalignment between the first members 31 and 41 and the second members 32 and 42 can be suppressed without relying on the conventional method of providing a margin in the size of the through holes 37 and 47. With the relay unit 10, stress that may occur when fixing the terminals 27 and 28 of the relay 20 to the busbars 30 and 40 can be suppressed by a method different from the conventional method of providing a margin in the size of the holes for fastening to the terminals 27 and 28 of the relay 20.
[0060] Furthermore, the method of fixing the first members 31 and 41 to the terminals 27 and 28 of the relay 20, respectively, while allowing movement in a direction parallel to the joining surfaces 31a and 41a provided by the relay unit 10, may be used in conjunction with the conventional method of providing extra size in the holes for fastening to the terminals 27 and 28 of the relay 20, as shown in Figure 8. The through hole 37a of the first member 31 shown in Figure 8 is formed so that the length in the z direction is longer than the length in the x direction, in order to provide extra size in the z direction. Therefore, the first members 31 and 41 can be fixed to the terminals 27 and 28 of the relay 20, respectively, while allowing movement in a direction perpendicular to the joining surfaces 31a and 41a (in the z direction) in addition to movement in the directions parallel to the joining surfaces 31a and 41a (in the x and y directions). As shown in Figure 8, it is preferable that the direction in which the size of the hole is increased is not parallel to the joining surfaces 31a and 41a. As shown in Figure 8, by providing a through-hole 37a with a larger size in the z-axis direction that is not parallel to the joint surfaces 31a and 41a, it is possible to suppress the stress that may occur when fixing the first members 31 and 41 to the terminals 27 and 28 of the relay 20, regardless of whether a positional displacement occurs in the x-axis, y-axis, or z-axis direction, without increasing the cost of the components.
[0061] Furthermore, in the relay 20, the outer surface on which terminals 27 and 28 are provided is the front surface as shown in Figure 1, etc., and the outer surface on which the second members 32 and 42 are arranged opposite each other is the bottom surface that intersects the front surface. If the front surface of the relay 20 is the first surface 20a and the bottom surface is the second surface 20b, then the side of the second members 32 and 42 opposite to the side facing the second surface 20b of the relay 20 (surface 32u side) (surface 32d side) is a heat dissipation surface that allows heat to be dissipated from the second members 32 and 42. Because the second members 32 and 42 can be positioned below the relay 20, it is possible to suppress an increase in the area of the relay unit 10 in the x-axis and y-axis directions as shown in Figure 1.
[0062] Furthermore, the relay unit 10 includes a base member 50 to which the second members 32 and 42 are fixed. The relay 20 is mounted on the base member 50 with its second surface 20b facing the base member 50 and the second members 32 and 42 positioned opposite the second surface 20b. The second members 32 and 42 protrude from the base member 50 toward the first surface 20a, and the first members 31 and 41 are joined to these protruding portions. In this configuration, the base member 50, the relay 20, and the second members 32 and 42 are fixed to each other. In the relay unit 10, the first members 31 and 41 are fixed to the terminals 27 and 28 of the relay 20 without bending the first members 31 and 41 and the second members 32 and 42, respectively, by adjusting the position of the first members 31 and 41 according to the position of the relay 20, the first members 31 and 41 can be fixed to the terminals 27 and 28 of the relay 20 without bending.
[0063] (modified version) Instead of the busbars 30 and 40 shown in Figure 1, etc., a busbar 130 as shown in Figure 9 may be used. The busbar 130 is formed when the first member 131 is superior to the second member 132, and the first member 131 and the second member 132 are joined to each other in a substantially orthogonal manner. The welded joint 133 is formed by fillet welding the joint between the first member 131 and the second member 132 from the side where the relay 120 does not exist (the negative y-axis side and the negative z-axis side).
[0064] Even when using the busbar 130, the first member 131 is fixed to the terminals of the relay 120 by fastening the terminal fixing bolt 163 to the first member 131 and the second member 132 while they are not joined together, and then the first member 131 and the second member 132 are joined together to obtain a state in which the busbar 130 is fixed to the terminals of the relay 120. With the configuration of the busbar 130, the first member 131 can be fixed to the terminals of the relay 120 while allowing movement in the x-axis and z-axis directions, which are parallel to the joining surface of the first member 131.
[0065] As shown in Figure 10, the majority of the second member 232 may be positioned so as not to face the relay 220. In the relay unit shown in Figure 10, as in Figure 1, the busbar 230 is formed by joining the first member 231 and the second member 232 to each other in a substantially orthogonal position, with the second member 232 in a dominant position. The welded portion 233 is formed by fillet welding the joint between the first member 231 and the second member 232 from the side where the relay 220 does not exist (the positive y-axis side and the positive z-axis side). Even when using the busbar 230, the first member 231 can be fixed to the terminals of the relay 220 by fastening terminal fixing bolts 263 to the terminals of the relay 220 with the first member 231 and the second member 232 not yet joined, and then the busbar 230 can be fixed to the terminals of the relay 220 by joining the first member 231 and the second member 232.
[0066] According to the configuration of the busbar 230, as in Figure 1, the first member 131 can be fixed to the terminals of the relay 220 while allowing movement in the x-axis and y-axis directions, which are parallel to the joint surface of the first member 231. Therefore, by providing a through hole 237 with a margin in the z-axis direction, as in Figure 8, it is possible to suppress the stress that may occur when fixing the first member 231 to the terminals of the relay 220 in the x-axis, y-axis, and z-axis directions, respectively, without increasing the cost of the components.
[0067] As shown in Figure 11, the second members 332 and 342 may be arranged on both sides of the relay 320 in the x-axis direction (lateral direction), which is the direction in which the terminals of the relay 320 are aligned. The relay 320 is mounted on a base member (not shown) in the positive z-axis direction, as in Figure 1, etc. The first pole busbar 330 comprises a first member 331 and a second member 332. The second pole busbar 340 comprises a first member 341 and a second member 342.
[0068] The first member 331 is fixed to a first pole terminal (not shown) by fastening a terminal fixing bolt 363. The first member 331 extends in the positive x-axis direction from the fastening portion by the terminal fixing bolt 363 and is joined to the plate surface of the second member 332 on the relay 320 side (the negative x-axis side) at its end face on the positive x-axis side. The welded portion 333 is formed by fillet welding the joint between the first member 331 and the second member 332 from the side where the relay 320 is not present (the negative x-axis and negative y-axis side). The side of the second member 332 that does not face the relay 320 (the positive x-axis side) is a heat dissipation surface, and a heat dissipation sheet 371 is provided so as to be in contact with this heat dissipation surface.
[0069] The first member 341 is fixed to a second pole terminal (not shown) by fastening a terminal fixing bolt 364. The first member 341 extends in the negative x-axis direction from the fastening portion by the terminal fixing bolt 364 and is joined to the plate surface of the second member 342 on the relay 320 side (the positive x-axis direction surface) at its end face on the negative x-axis side. The welded portion 343 is formed by fillet welding the joint between the first member 341 and the second member 342 from the side where the relay 320 is not present (the positive x-axis direction side and the negative y-axis direction side). The side of the second member 342 that does not face the relay 320 (the negative x-axis direction side) is a heat dissipation surface, and a heat dissipation sheet 372 is provided so as to be in contact with this heat dissipation surface.
[0070] The configuration of the busbars 330 and 340 allows the first members 331 and 341 to be fixed to the terminals of the relay 320 while allowing movement in the y-axis and z-axis directions, which are parallel to the joint surface of the first members 331 and 341. For this reason, it is preferable that the first members 331 and 341 are provided with through holes that have a margin in the x-axis direction for inserting the terminal fixing bolts 363 and 364. This suppresses the stress that may occur when fixing the first members 331 and 341 to the terminals of the relay 320 in the x-axis, y-axis, and z-axis directions, respectively, without increasing the cost of the components.
[0071] As explained using Figures 1, 8, and 11, when the method provided by the relay unit 10, etc. (a method of fixing the first member to the relay terminals while allowing movement in a direction parallel to the joint surface of the first member and the second member) is used in conjunction with the conventional method shown in Figure 8 (a method of providing a margin in the size of the hole for fastening to the relay terminals), it is preferable that the direction in which the size of the through hole provided in the first member for fastening to the relay terminals is provided is a direction non-parallel to the joint surface of the first member and the second member.
[0072] In the embodiments described above, the electrical equipment is a relay 20 and the electrical device is a relay unit, but the invention is not limited to this. The electrical equipment can be any device that has a configuration on which a busbar can be fixed to terminals provided on its outer surface by a fixing device. In the case of an electrical device used for applications in which a large current flows and in which there is concern about heat generation that may occur due to the flow of a large current, the configuration of the electrical device according to the present invention described above can be used particularly suitably. For example, the electrical device may include a charger / discharger, a power converter, etc., as electrical equipment. Also, in the embodiments described above, the fixing device is a bolt, but the invention is not limited to this. The fixing device may be a screw-shaped member other than a bolt, or a pin-shaped member without threads.
[0073] The following describes the characteristic configurations extracted from each of the embodiments described above. [Configuration 1] An electrical device (10) comprising electrical equipment (20, 120, 220, 320) and busbars (30, 40, 130, 230, 330, 340) connected to the terminals of the electrical equipment, The aforementioned bus bar is A plate-shaped first member (31, 41, 131, 231, 331, 341) is fixed to the terminals provided on the outer surface of the electrical equipment by a fastener, The device comprises a plate-shaped second member (32, 42, 132, 232, 332, 342) extending in a direction intersecting the first member and having heat dissipated by a heat dissipation mechanism, An electrical device in which the first member and the second member are joined at positions where they intersect with each other. [Configuration 2] The electrical device according to configuration 1, wherein the joint portion to which the first member and the second member are joined is provided in a position that does not face the electrical equipment. [Configuration 3] The electrical device according to configuration 1 or 2, wherein the joint portion to which the first member and the second member are joined is provided at a position that does not reach the heat dissipation surface, which is the heat dissipation mechanism side of the second member. [Structure 4] The joint portion in which the first member and the second member are joined to each other is a state in which the end face of the first member and the plate surface of the second member are joined to each other. The electrical device according to any one of configurations 1 to 3, wherein the end of the second member on the joint side protrudes from the plate surface of the first member. [Composition 5] In the aforementioned electrical device, the outer surface on which the terminals are provided is the first surface. The second member is positioned opposite the second surface that intersects the first surface in the electrical device. The electrical device according to any one of configurations 1 to 4, wherein the side of the second member opposite to the side facing the second surface of the electrical equipment is a heat dissipation surface that allows heat to be dissipated from the second member. [Composition 6] The second member further comprises a retaining member to which the second member is fixed, In the aforementioned electrical device, the outer surface on which the terminals are provided is the first surface. The electrical device is attached to the holding member such that the second surface intersecting the first surface is on the side of the holding member, and the second member is positioned opposite the second surface. The electrical device according to any one of configurations 1 to 5, wherein the second member protrudes from the holding member toward the first surface, and the first member is joined to the protruding portion. [Composition 7] A method for manufacturing an electrical device (10) comprising electrical equipment (20, 120, 220, 320) and busbars (30, 40, 130, 230, 330, 340) connected to the terminals of the electrical equipment, The busbar comprises a plate-shaped first member (31, 41, 131, 231, 331, 341) and a plate-shaped second member (32, 42, 132, 232, 332, 342), Arrangement step of positioning the first member and the second member at positions where they intersect each other, A fixing step for fixing the first member to the terminals provided on the outer surface of the electrical equipment using a fixing device, A method for manufacturing an electrical device, comprising, after the fixing step, a joining step of joining the first member and the second member at positions where they intersect each other. [Structure 8] The aforementioned placement step is, The first step is to prepare a retaining member to which the second member is fixed, A method for manufacturing an electrical device according to configuration 7, comprising a second step of fixing the electrical device to the holding member to which the second member is fixed. [Composition 9] The method for manufacturing an electrical device according to configuration 8, wherein the second member is fixed to the holding member such that the portion on which the first member is placed protrudes from the holding member. [Configuration 10] A method for manufacturing an electrical device according to any one of configurations 7 to 9, wherein in the fixing step, the first member is held so as to be in contact with the second member at a position intersecting with the second member, and is fixed to the terminal of the electrical device. [Composition 11] A method for manufacturing an electrical device according to any one of configurations 7 to 10, wherein in the joining step, the position where the first member and the second member intersect is welded from the side of the first member and the second member that does not face the electrical device. [Composition 12] A method for manufacturing an electrical device according to any one of configurations 7 to 11, further comprising the step of installing a heat dissipation mechanism for dissipating heat from the second member after the joining step. [Explanation of symbols]
[0074] 10…Relay unit, 20, 120, 220, 320…Relays, 30, 40, 130, 230, 330, 340…Bus bars, 31, 41, 131, 231, 331, 341…First component, 32, 42, 132, 232, 332, 342…Second component
Claims
1. A method for manufacturing an electrical device (10) comprising electrical equipment (20, 120, 220, 320) and busbars (30, 40, 130, 230, 330, 340) connected to the terminals of the electrical equipment, The busbar comprises a plate-shaped first member (31, 41, 131, 231, 331, 341) and a plate-shaped second member (32, 42, 132, 232, 332, 342), Arrangement step of positioning the first member and the second member at positions where they intersect each other, A fixing step for fixing the first member to the terminals provided on the outer surface of the electrical equipment using a fixing device, A method for manufacturing an electrical device, comprising, after the fixing step, a joining step of joining the first member and the second member at positions where they intersect each other.
2. The aforementioned arrangement step is, The first step is to prepare a retaining member to which the second member is fixed, A method for manufacturing an electrical device according to claim 1, comprising a second step of fixing the electrical device to the holding member to which the second member is fixed.
3. The method for manufacturing an electrical device according to claim 2, wherein the second member is fixed to the holding member such that the portion on which the first member is placed protrudes from the holding member.
4. The method for manufacturing an electrical device according to claim 1 or 2, wherein in the fixing step, the first member is held so as to be in contact with the second member at a position intersecting with the second member, and is fixed to the terminal of the electrical device.
5. The method for manufacturing an electrical device according to claim 1 or 2, wherein in the joining step, the position where the first member and the second member intersect is welded from the side of the first member and the second member that does not face the electrical device.
6. A method for manufacturing an electrical device according to claim 1 or 2, further comprising the step of installing a heat dissipation mechanism for dissipating heat from the second member after the joining step.