Electric device

Abstract

An electric device 1 comprises: a heat-generating component; a bus bar 20 connected to the heat-generating component; and a holding member 10 holding the heat-generating component and the bus bar 20. The bus bar 20 includes a conductor portion CP and an insulating member NP having a higher emissivity than the conductor portion CP and covering at least a portion of an outer surface of the conductor portion CP. The bus bar 20 has a shape shorter in a short-side direction and bent at least at one portion. A bent edge BE of the bus bar 20 extends in the short-side direction.

Description

Electrical Equipment

[0001] The present disclosure relates to electrical equipment.

[0002] Electrical equipment installed in vehicles such as electric vehicles and hybrid vehicles includes components that easily generate heat, such as relays, and is provided with a structure for dissipating heat from these components. A known example of such electrical equipment is the circuit assembly described in Japanese Patent Laid-Open No. 2020-88087 (Patent Document 1). The circuit assembly described in Patent Document 1 includes a main relay as a heat-generating component, a first bus bar, a base member on which the main relay and the first bus bar are disposed, an insulating plate superimposed on the underside of the base member, and a metal heat dissipation plate superimposed on the underside of the insulating plate. The first bus bar includes a first electrical connection portion electrically connected to the main relay, a first thermally conductive connection portion, and a first bypass portion connecting the first electrical connection portion and the first thermally conductive connection portion. The first thermally conductive connection portion contacts the insulating plate through a first through-hole provided in the base member. As a result, the first thermally conductive connection portion is thermally connected to the heat dissipation member via the insulating plate. By providing the first detour portion, the first thermally conductive connection portion can be provided at a position separated from the main relay, thereby enabling heat from the main relay to be dissipated.

[0003] Japanese Patent Application Laid-Open No. 2020-88087

[0004] In the above-described configuration, an insulating plate is provided to prevent electrical conduction between the bus bar and the heat dissipation member. Furthermore, a separate upper case or the like must be provided to cover the bus bar from above so that the upper surface of the bus bar is not exposed to the outside. Thus, a structure for insulating the bus bar must be provided in the circuit assembly, which tends to increase the number of components.

[0005] Furthermore, in the above configuration, the first bus bar is provided with the first thermally conductive connection portion and the first detour portion in order to dissipate heat from the main relay, which may increase the size of the first bus bar.

[0006] The electrical device disclosed herein includes a heat-generating component, a bus bar connected to the heat-generating component, and a holding member that holds the heat-generating component and the bus bar, wherein the bus bar includes a conductor portion and an insulating member that has a higher emissivity than the conductor portion and covers at least a portion of an outer surface of the conductor portion, the bus bar is short in the short side direction and has a shape that is bent at at least one point, and all of the bent edges of the bus bar extend in the short side direction.

[0007] According to the present disclosure, in an electrical device, it is possible to reduce the number of components for insulating bus bars, and to dissipate heat from heat-generating components while preventing the bus bars from becoming larger.

[0008] FIG. 1 is a plan view of the electrical device according to the first embodiment. FIG. 2 is a bottom view of the electrical device. FIG. 3 is a perspective view of the electrical device attached to a metal housing. FIG. 4 is a perspective view of the electrical device attached to the metal housing, with a holding member omitted. FIG. 5 is a schematic diagram of the circuit configuration of the electrical device. FIG. 6 is a perspective view of the holding member. FIG. 7 is a perspective view of a first bus bar. FIG. 8 is a perspective view of the first bus bar seen from a different direction than FIG. 7. FIG. 9 is a perspective view of a second bus bar. FIG. 10 is a cross-sectional view taken along line A-A in FIG. 1. FIG. 11 is a perspective view of a fifth bus bar. FIG. 12 is a cross-sectional view taken along line B-B in FIG. 2. FIG. 13 is a perspective view of a sixth bus bar. FIG. 14 is a diagram illustrating the connection between the sixth bus bar and a precharge resistor. FIG. 15 is a perspective view of an eighth bus bar. FIG. 16 is a perspective view illustrating the arrangement of the eighth and ninth bus bars. FIG. 17 is an explanatory diagram illustrating a manufacturing process of the first bus bar. Fig. 18 is a plan view of the electric device according to the second embodiment. Fig. 19 is a bottom view of the electric device. Fig. 20 is a cross-sectional view taken along CC in Fig. 18. Fig. 21 is a perspective view of the electric device attached to a metal housing. Fig. 22 is a perspective view of the electric device attached to a metal housing, with the holding member omitted.

[0009] [Description of Embodiments of the Present Disclosure] First, embodiments of the present disclosure will be listed and described. [1] An electric device of the present disclosure includes a heat-generating component, a bus bar connected to the heat-generating component, and a holding member that holds the heat-generating component and the bus bar, the bus bar including a conductor portion and an insulating member that has a higher emissivity than the conductor portion and covers at least a portion of an outer surface of the conductor portion, the bus bar being short in a short-side direction and having at least one bent shape, and all bent edges of the bus bar extending in the short-side direction.

[0010] With this configuration, at least a portion of the outer surface of the conductor portion of the bus bar is covered with the insulating material, which makes it easier to ensure insulation of the bus bar from the outside. Furthermore, because the insulating material has a higher emissivity than the conductor portion, heat transferred from the heat-generating component to the bus bar can be easily dissipated to the outside by radiation. In other words, heat dissipation from the heat-generating component is facilitated. Therefore, heat can be dissipated from the heat-generating component without requiring a large bus bar.

[0011] Because the bent edges of the busbar all extend in the short-side direction, the conductor portion of the busbar can be made of a strip-shaped metal plate. This allows an extruder to be used to form the insulating member on the outside of the metal plate, making it easy to form the busbar.

[0012] [2] In the above [1], it is preferable that the bus bar includes a tuning fork terminal connected to a terminal portion of the heat-generating component.

[0013] With this configuration, even if the terminal portion of the heat-generating component and the bus bar are arranged so as to intersect at right angles, the terminal portion and the bus bar can be connected to each other.

[0014] [3] Preferably, the electrical device of [1] or [2] above further includes an intermediate terminal connecting the heat-generating component and the bus bar, and the intermediate terminal includes a connecting tube portion into which a terminal portion of the heat-generating component and an end portion of the bus bar are inserted, a first contact portion connected to the terminal portion of the heat-generating component within the connecting tube portion, and a second contact portion connected to the end portion of the bus bar within the connecting tube portion.

[0015] With this configuration, the terminal portion of the heat-generating component and the bus bar can be easily connected.

[0016] [4] The electrical device of any one of [1] to [3] above further includes a bolt for fixing the bus bar, and the bolt preferably includes a head having at least an insulated surface.

[0017] With this configuration, it is possible to prevent the bus bar from being electrically connected to the outside via the bolt.

[0018] [Details of the Embodiments of the Present Disclosure] The following describes embodiments of the present disclosure. The present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims. In the drawings, for the convenience of explanation, some components may be exaggerated or simplified. Furthermore, the dimensional ratios of each part may differ between drawings. In this specification, "orthogonal" does not only refer to a strict orthogonal relationship, but also includes a roughly orthogonal relationship within the scope of the operation and effect of this embodiment.

[0019] First Embodiment A first embodiment of the present disclosure will be described with reference to FIGS. 1 to 17 . An electrical device 1 according to this embodiment is mounted on a vehicle such as an electric vehicle or a hybrid vehicle, and is disposed in a power supply path connecting a power source such as a battery and a load such as a motor. The electrical device 1 can be disposed in any orientation, but in the following description, the direction indicated by arrow Z will be referred to as upward, the direction indicated by arrow X as forward, and the direction indicated by arrow Y as leftward. Note that, for multiple identical components, only some of the components may be designated by reference numerals, and the reference numerals for the other components may be omitted.

[0020] 1 and 3 , the electric device 1 includes a main relay 2 (an example of a heat-generating component), a pre-charge relay 3 (an example of a heat-generating component), a pre-charge resistor 4 (an example of a heat-generating component), a plurality of bus bars 20, and a holding member 10. The holding member 10 holds the main relay 2, the pre-charge relay 3, the pre-charge resistor 4, and the plurality of bus bars 20. As shown in Fig. 4 , the plurality of bus bars 20 include a first bus bar 21, a second bus bar 22, a third bus bar 23, a fourth bus bar 24, a fifth bus bar 25, a sixth bus bar 26, a seventh bus bar 27, an eighth bus bar 28, and a ninth bus bar 29.

[0021] (Holding member 10) The holding member 10 is made of insulating synthetic resin. As shown in FIG. 6 , the holding member 10 has an overall shape that is flat in the vertical direction. A main relay housing 11 is formed in the left-right center of the holding member 10. The main relay housing 11 is generally frame-shaped. Nut attachment portions 11A, on which nuts N1 (see FIG. 4 ) are disposed, are formed in the front right corner and the rear left corner of the main relay housing 11. As shown in FIG. 1 , the main relay 2 is housed in the main relay housing 11. A mounting bolt B1 is inserted into a mounting hole in a mounting piece 2C provided on the main relay 2 and fastened to the nut N1 (see FIG. 4 ) of the nut attachment portion 11A of the main relay housing 11, thereby fixing the main relay 2 to the main relay housing 11.

[0022] As shown in FIG. 6 , the holding member 10 has a precharge relay housing 12. The precharge relay housing 12 is disposed in front of the main relay housing 11. The precharge relay housing 12 is generally frame-shaped. A flexible lock receiving portion 12A is formed on the side wall of the precharge relay housing 12. A first insertion hole 12B and a second insertion hole 12C are formed on the bottom of the precharge relay housing 12. As shown in FIG. 3 , the precharge relay 3 is housed in the precharge relay housing 12, and the lock receiving portion 12A is adapted to engage with a lock portion 3D of the precharge relay 3. As shown in FIG. 12 , the first terminal 3B of the precharge relay 3 is inserted into the first insertion hole 12B. Although not shown in detail, the second terminal 3C of the precharge relay 3 is inserted into the second insertion hole 12C.

[0023] As shown in Fig. 6, the holding member 10 has a connector fitting portion 13. The connector fitting portion 13 is disposed in front of the precharge relay housing portion 12. The connector fitting portion 13 is generally cylindrical and has a bottom. A terminal hole 13A is formed at the bottom of the connector fitting portion 13. As shown in Fig. 3, the connector 5 is adapted to fit into the connector fitting portion 13. Although not shown in detail, an end of the eighth bus bar 28 and an end of the ninth bus bar 29 are inserted into the terminal hole 13A.

[0024] As shown in FIG. 6 , the holding member 10 has a pre-charge resistor housing 14. The pre-charge resistor housing 14 is disposed to the left of the main relay housing 11 and the pre-charge relay housing 12. The pre-charge resistor housing 14 is elongated in the front-to-rear direction and is generally frame-shaped. Deformable locking portions 14A are formed on the front and rear walls of the pre-charge resistor housing 14. A third insertion hole 14B is formed in the bottom of the pre-charge resistor housing 14. As shown in FIG. 3 , the pre-charge resistor 4 is housed in the pre-charge resistor housing 14, and the locking portion 14A is adapted to lock onto the main body 4A of the pre-charge resistor 4. Although not shown in detail, the terminal portion 4B of the pre-charge resistor 4 is inserted into the third insertion hole 14B.

[0025] As shown in FIG. 6 , busbar engagement holes 15A, 15B are formed at both left and right ends of the holding member 10. As shown in FIG. 3 , the second busbar 22 is inserted into the left busbar engagement hole 15A. The fourth busbar 24 is inserted into the right busbar engagement hole 15B. The second busbar 22 and the fourth busbar 24 are positioned relative to the holding member 10 by the busbar engagement holes 15A, 15B. As shown in FIG. 6 , the holding member 10 has nut attachment portions 16 formed by recessing from the top surface. The nut attachment portions 16 are located to the right of the busbar engagement hole 15A and to the left of the busbar engagement hole 15B. As shown in FIG. 10 , nuts N2 are disposed in the nut attachment portions 16.

[0026] As shown in FIG. 6 , the holding member 10 includes mounting posts 17A, 17B, 17C, and 17D extending upward from the top surface of the holding member 10. The mounting post 17B is disposed between the precharge resistor housing 14 and the nut mounting portion 16 on the left side in the left-right direction. The mounting post 17A is disposed in front of the mounting post 17B. The mounting post 17C is disposed between the main relay housing 11 and the nut mounting portion 16 on the right side in the left-right direction. The mounting post 17D is disposed behind the mounting post 17C. The mounting posts 17A, 17B, 17C, and 17D have nut mounting portions 17A1, 17B1, 17C1, and 17D1, respectively, on which the nut N3 (see FIG. 10) is disposed. A busbar insertion hole 18 is formed near the base end of each of the mounting posts 17A and 17D in the holding member 10.

[0027] (Main Relay 2) The main relay 2 is a mechanical relay having a contact portion and a coil portion therein. As shown in FIG. 1 , the main relay 2 has a rectangular parallelepiped main body 2A, a terminal portion (not shown) and a partition wall 2B disposed on the rear surface of the main body 2A, a mounting piece 2C protruding from the main body 2A, and a connector fitting portion 2D (see FIG. 4 ) disposed on the left surface of the main body 2A. The terminal portion of the main relay 2 is nut-shaped to which a bolt B2 is fastened. The partition wall 2B is disposed between the two terminal portions. The partition wall 2B determines the creepage distance between the two terminal portions. The mounting piece 2C has a mounting hole (not shown) through which a mounting bolt B1 is inserted. The main relay 2 is turned on and off by a signal transmitted from an external device via a connector (not shown) fitted into the connector fitting portion 2D.

[0028] (Precharge Relay 3, Precharge Resistor 4) The precharge relay 3 is a mechanical relay smaller than the main relay 2 and has a contact portion and a coil portion therein. The precharge relay 3 has a rectangular parallelepiped main body 3A, a first terminal portion 3B (see FIG. 12) and a second terminal portion 3C (see FIG. 16) protruding from the bottom surface of the main body 3A, and a lock portion 3D (see FIG. 4) protruding from the main body 3A. Here, the first terminal portion 3B and the second terminal portion 3C are examples of terminal portions. As shown in FIG. 4, the precharge resistor 4 has a rectangular parallelepiped main body 4A and a terminal portion 4B protruding from the bottom surface of the main body 4A. The precharge relay 3 and the precharge resistor 4 are components of a precharge circuit.

[0029] 5 is a schematic diagram of the circuit configuration of the electrical device 1, showing the electrical connections between each component and each bus bar 20. The precharge circuit is connected in parallel to the main relay 2. The precharge relay 3 is turned on and off by a signal transmitted from outside via a connector 5 (see FIG. 3) fitted into the connector fitting portion 13. The second terminal portion 3C is connected to this connector 5 via an eighth bus bar 28 and a ninth bus bar 29 (see FIG. 16). When the main relay 2 is turned on after the precharge relay 3 is turned on, an inrush current is prevented from flowing through the main relay 2.

[0030] (Bus bars 20) Each of the multiple bus bars 20 has the following common characteristics. As shown in Fig. 4 , each bus bar 20 is connected directly to components that generate heat when energized (main relay 2, pre-charge relay 3, pre-charge resistor 4) or indirectly via another bus bar 20. This allows heat to be transferred from the heat-generating components to each bus bar 20.

[0031] Each bus bar 20 includes a conductor portion CP and an insulating member NP that covers at least a portion of the outer surface of the conductor portion CP (see, for example, the first bus bar 21 in FIG. 7 ). The insulating member NP has a thickness (e.g., several tens of μm) that ensures insulation from the conductor portion CP, which is connected to a battery or the like, even when the insulating member NP comes into contact with the surface of the insulating member NP. In the drawings, the insulating member NP corresponds to the shaded area. The conductor portion CP is made of a metal such as copper, copper alloy, aluminum, or aluminum alloy, and has a plate shape. The insulating member NP has a higher emissivity than the conductor portion CP. For example, an insulating resin material such as polyimide, fluororesin, or epoxy resin can be used as the insulating member NP.

[0032] The insulating member NP preferably covers a portion of the outer surface of the conductor portion CP that is not hidden by other members (such as the holding member 10), thereby making it possible to prevent contact with the conductor portion CP from the outside.

[0033] Each bus bar 20 is short in the short-side direction and has a shape that is bent at at least one location. The bent edges BE of each bus bar 20 extend in the short-side direction. The above are the common features of the bus bars 20, and the configuration of each bus bar 20 will be described in detail below. In the following description, the same reference numerals are used for the conductor portions CP, insulating members NP, and bent edges BE. However, the shape of the conductor portions CP, the area where the insulating members NP are formed relative to the conductor portions CP, the number of bent edges BE, etc. may differ between bus bars 20.

[0034] (First bus bar 21) As shown in Fig. 1, the first bus bar 21 is generally L-shaped in a plan view. As shown in Figs. 7 and 8, the first bus bar 21 includes a first portion 21A and a second portion 21B bent relative to the first portion 21A. The first portion 21A extends in the left-right direction. The second portion 21B extends in the front-rear direction. A bent edge BE is formed between the left end of the first portion 21A and the rear end of the second portion 21B. The bent edge BE of the first bus bar 21 extends in the direction of the short side of the first bus bar 21 (the up-down direction).

[0035] As shown in FIG. 7 , the outer surface of the conductor portion CP of the first bus bar 21 is covered with an insulating member NP, except for two cut surfaces 21C and 21D and three connection portions 21E, 21F, and 21G. In other words, the conductor portion CP is exposed to the outside at the cut surfaces 21C and 21D and the connection portions 21E, 21F, and 21G. The cut surfaces 21C and 21D are located on the right end surface of the first portion 21A and the front end surface of the second portion 21B, respectively. As shown in FIG. 1 , the cut surface 21C is located adjacent to and facing the partition wall 2B of the main relay 2. The cut surface 21D is accommodated in a groove 17A2 provided in the mounting post 17A of the holding member 10. This prevents contact with the cut surfaces 21C and 21D from the outside.

[0036] As shown in FIG. 7 , the first portion 21A has a connection portion 21E at its right end. The connection portion 21E has a through hole 21E1 that penetrates the conductor portion CP in the front-rear direction and a connection surface 21E2 formed on the edge of the through hole 21E1. Although not shown in detail, a bolt B2 (see FIG. 1 ) is inserted into the through hole 21E1 and fastened to a terminal portion of the main relay 2, thereby bringing the connection surface 21E2 into contact with the terminal portion of the main relay 2. This electrically connects the main relay 2 and the first bus bar 21. The bolt B2 has a similar structure to the bolt B3, which will be described later.

[0037] 7, the second portion 21B has a connection portion 21F in the center between the front and rear of the second portion 21B. The connection portion 21F is connected to a second bus bar 22, which will be described later. The connection portion 21F has a through hole 21F1 that passes through the conductor portion CP in the left-right direction, and a connection surface 21F2 formed on the edge of the through hole 21F1. The right connection surface 21F2 provided on the connection portion 21F has a rectangular shape that matches the size of the second bus bar 22, which will be described later.

[0038] The second portion 21B has a connection portion 21G at its front end. The connection portion 21G is connected to a fifth bus bar 25, which will be described later. The connection portion 21G has a configuration substantially similar to that of the connection portion 21F, and has a through-hole 21G1 and a connection surface 21G2. The right connection surface 21G2 provided on the connection portion 21G has a rectangular shape that matches the size of the fifth bus bar 25.

[0039] (Second Bus Bar 22) As shown in FIG. 10 , the second bus bar 22 has a crank shape when viewed from the front-rear direction. As shown in FIG. 9 , the second bus bar 22 includes a first portion 22A, a second portion 22B bent relative to the first portion 22A, and a third portion 22C bent relative to the second portion 22B. The first portion 22A extends in the up-down direction. The second portion 22B extends in the left-right direction. The third portion 22C extends in the up-down direction. The bent edge BE of the second bus bar 22 includes a first bent edge BE1 and a second bent edge BE2. The first bent edge BE1 is formed between the bottom end of the first portion 22A and the right end of the second portion 22B. The second bent edge BE2 is formed between the left end of the second portion 22B and the top end of the third portion 22C. The bent edges BE (first bent edge BE1 and second bent edge BE2) of the second bus bar 22 extend in the short side direction (front-rear direction) of the second bus bar 22.

[0040] The outer surface of the conductor portion CP of the second bus bar 22 is covered with an insulating member NP, except for two cut surfaces 22D and 22E and two connection portions 22F and 22G. In other words, the conductor portion CP is exposed to the outside at the cut surfaces 22D and 22E and the connection portions 22F and 22G. The cut surfaces 22D and 22E are located on the upper end surface of the first portion 22A and the lower end surface of the third portion 22C, respectively. As shown in FIG. 10 , the third portion 22C is inserted into the bus bar engagement hole 15A of the holding member 10. As a result, the cut surface 22E on the lower end surface of the third portion 22C is located inside the bus bar engagement hole 15A. Furthermore, the first portion 22A is connected to the first bus bar 21, and the cut surface 22D on the upper end surface of the first portion 22A is located below the upper end surface of the first bus bar 21 and the upper end of the mounting post 17B. In this way, the cut surfaces 22D and 22E are arranged at positions that make it difficult to contact them from the outside.

[0041] As shown in Fig. 9, the first portion 22A has a connection portion 22F. The connection portion 22F has a through hole 22F1 that passes through the conductor portion CP in the left-right direction and a connection surface 22F2 formed on the edge of the through hole 22F1. As shown in Fig. 10, a bolt B3 is inserted through the through hole 22F1 and the through hole 21F1 of the first bus bar 21, and the bolt B3 is fastened to a nut N3 of the nut mounting portion 17B1 of the mounting column 17B, thereby bringing the connection surface 22F2 into contact with the connection surface 21F2 of the first bus bar 21. This electrically connects the second bus bar 22 and the first bus bar 21.

[0042] The bolt B3 has a head that is large enough to hide the connection surface 21F2 (see FIG. 8 ) that comes into contact with the bolt B3. The head is a portion formed at the end of the shank that is inserted into the through holes 21F1 and 22F1 and that expands in diameter from the shank. The bolt B3 has a head with at least an insulated surface. For example, the portion of the bolt B3 other than the surface of the head may be made of metal. Alternatively, the entire bolt B3 may be made of insulating resin. This prevents electrical connection with the conductor portions CP of the first bus bar 21 and the second bus bar 22 when the head of the bolt B3 is contacted from the outside.

[0043] As shown in FIG. 9 , the second portion 22B has a connection portion 22G. The connection portion 22G has a through hole 22G1 that passes through the conductor portion CP in the vertical direction and a connection surface 22G2 formed on the edge of the through hole 22G1. The connection portion 22G is connected to a first external connection bus bar (not shown). The first external connection bus bar is electrically connected to a load, such as a motor. As shown in FIG. 10 , a bolt (not shown) is inserted through the through hole 22G1 and the through hole of the first external connection bus bar (not shown). The bolt is then fastened to a nut N2 of the nut mounting portion 16, whereby the connection surface 22G2 and the first external connection bus bar come into contact. This electrically connects the second bus bar 22 and the first external connection bus bar.

[0044] 1, the third bus bar 23 is generally L-shaped in a plan view, and is configured in a manner similar to that of the first bus bar 21. A bent edge BE of the third bus bar 23 extends in the direction of the short side (vertical direction) of the third bus bar 23. Although not shown in detail, the third bus bar 23 includes a connection portion connected to a terminal portion of the main relay 2, a connection portion connected to the fourth bus bar 24, and a connection portion connected to the seventh bus bar 27 (see FIG. 4).

[0045] (Fourth Bus Bar 24) As shown in Fig. 4, the fourth bus bar 24 is crank-shaped when viewed in the front-rear direction and is configured substantially similarly to the second bus bar 22. The bent edge BE of the fourth bus bar 24 includes a first bent edge BE1 and a second bent edge BE2 and extends in the short-side direction (front-rear direction) of the fourth bus bar 24. The fourth bus bar 24 has a connection portion (not shown) connected to the third bus bar 23 and a connection portion 24A connected to a second external connection bus bar (not shown). This second external connection bus bar is electrically connected to a power source such as a battery.

[0046] (Fifth Bus Bar 25) As shown in FIG. 11 , the fifth bus bar 25 has a generally angular U-shape when viewed from the front-to-rear direction. The fifth bus bar 25 includes a first portion 25A, a second portion 25B bent relative to the first portion 25A, and a third portion 25C bent relative to the second portion 25B. The first portion 25A extends in the vertical direction. The second portion 25B extends in the horizontal direction. The third portion 25C extends in the vertical direction. The bent edge BE of the fifth bus bar 25 includes a first bent edge BE1 and a second bent edge BE2. The first bent edge BE1 is formed between the lower end of the first portion 25A and the right end of the second portion 25B. The second bent edge BE2 is formed between the left end of the second portion 25B and the lower end of the third portion 25C. The bent edges BE (first bent edge BE1 and second bent edge BE2) of the fifth bus bar 25 extend in the short side direction (front-rear direction) of the fifth bus bar 25.

[0047] The outer surface of the conductor portion CP of the fifth bus bar 25 is covered with an insulating member NP, except for one cut surface 25D and two connection portions 25E and 25F. In other words, the conductor portion CP is exposed to the outside at the cut surface 25D and the connection portions 25E and 25F. The cut surface 25D is located on the upper end surface of the third portion 25C. The third portion 25C is connected to the first bus bar 21. Although not shown in detail, the cut surface 25D is located below the upper end surface of the first bus bar 21 and the upper end of the mounting post 17A. In this way, the cut surface 25D is located in a position that makes it difficult to contact from the outside. The first portion 25A has a tab-shaped connection portion 25E at its upper end. The conductor portion CP is exposed on the entire outer surface of the connection portion 25E. The connection portion 25E is electrically connected to the first terminal portion 3B of the precharge relay 3 via an intermediate terminal 30, which will be described below.

[0048] (Intermediate terminal 30) As shown in Figure 12, the intermediate terminal 30 includes a connecting tubular portion 31 (see Figure 4), a first contact portion 32, and a second contact portion 33. The connecting tubular portion 31 is rectangular and opens upward and downward. The first contact portion 32 and the second contact portion 33 are disposed inside the connecting tubular portion 31. The first contact portion 32 is an elastic piece that extends obliquely downward from the upper end of the right wall portion of the connecting tubular portion 31. The second contact portion 33 is an elastic piece that extends obliquely upward from the lower end of the first contact portion 32. The second contact portion 33 is disposed between the first contact portion 32 and the right wall portion of the connecting tubular portion 31.

[0049] The first terminal 3B of the pre-charge relay 3 is inserted into the connecting tubular portion 31 from above and comes into contact with the first contact portion 32. The connecting portion 25E of the fifth bus bar 25 is inserted into the connecting tubular portion 31 from below and comes into contact with the second contact portion 33. This electrically connects the first terminal 3B of the pre-charge relay 3 and the fifth bus bar 25.

[0050] As shown in FIG. 11 , the connection portion 25F of the third portion 25C has a through-hole 25F1 that passes through the conductor portion CP in the left-right direction and a connection surface 25F2 formed on the edge of the through-hole 25F1. The left connection surface 25F2 provided on the connection portion 25F has a rectangular shape that matches the size of the first bus bar 21. The third portion 25C is inserted into the bus bar insertion hole 18 (see FIG. 6 ) of the holding member 10 and is disposed so as to overlap the first bus bar 21. The fifth bus bar 25 and the first bus bar 21 are electrically connected in a manner similar to the connection between the second bus bar 22 and the first bus bar 21 (see FIG. 10 ). That is, bolt B4 (see FIG. 1) is inserted through through hole 25F1 and through hole 21G1 of first bus bar 21, and this bolt B4 is fastened to nut N3 of nut attachment portion 17A1 of mounting post 17A, thereby bringing connection surface 25F2 into contact with connection surface 21G2 of first bus bar 21. Bolt B4 has the same configuration as bolt B3 described above.

[0051] (Sixth Bus Bar 26) As shown in FIG. 13 , the sixth bus bar 26 has a generally angular U-shape when viewed from the front-to-rear direction. The sixth bus bar 26 includes a first portion 26A, a second portion 26B bent relative to the first portion 26A, and a third portion 26C bent relative to the second portion 26B. The first portion 26A extends in the vertical direction. The second portion 26B extends in the horizontal direction. The third portion 26C extends in the vertical direction. The bent edge BE of the sixth bus bar 26 includes a first bent edge BE1 and a second bent edge BE2. The first bent edge BE1 is formed between the lower end of the first portion 26A and the right end of the second portion 26B. The second bent edge BE2 is formed between the left end of the second portion 26B and the lower end of the third portion 26C. The bent edges BE (first bent edge BE1 and second bent edge BE2) of the sixth bus bar 26 extend in the short side direction (front-rear direction) of the sixth bus bar 26.

[0052] The outer surface of the conductor portion CP of the sixth bus bar 26 is covered with an insulating member NP, except for the cut surface 26D and the connection portion 26E. In other words, the conductor portion CP is exposed to the outside at the cut surface 26D and the connection portion 26E. The cut surface 26D includes the end surface of the tuning fork terminal 40, which will be described below. The first portion 26A has a tab-shaped connection portion 26E at its upper end. The conductor portion CP is exposed over the entire outer surface of the connection portion 26E. The connection portion 26E is electrically connected to the first terminal portion 3B of the pre-charge relay 3 via the intermediate terminal 30 (see FIG. 4).

[0053] (Tuning Fork Terminal 40) The third portion 26C includes a tuning fork terminal 40. The tuning fork terminal 40 is generally U-shaped when viewed from the left and right. The tuning fork terminal 40 includes a base 41 and a pair of clamping pieces 42 extending upward from the front and rear ends of the base 41. A protrusion 43 is formed at the tip (upper end) of the clamping piece 42. Each protrusion 43 protrudes from the clamping piece 42 in a direction that narrows the space between the pair of clamping pieces 42. The left and right surfaces of the tuning fork terminal 40 are covered with an insulating member NP. On the other hand, the cut surface 26D created during the formation of the tuning fork terminal 40 is not covered with the insulating member NP, and the conductor portion CP is exposed. As a result, when the terminal portion 4B of the pre-charge resistor 4 is inserted between the pair of clamping pieces 42 of the tuning fork terminal 40, the terminal portion 4B of the pre-charge resistor 4 is clamped by the pair of protrusions 43, as shown in FIG. 14 . The cut surface 26D arranged on the protrusion 43 comes into contact with the terminal portion 4B of the pre-charge resistor 4. This electrically connects the sixth bus bar 26 and the pre-charge resistor 4. By providing the tuning fork terminal 40 in this manner, it is possible to easily connect the end of the sixth bus bar 26, whose plate thickness directions are perpendicular to each other, to the terminal portion 4B of the pre-charge resistor 4. Furthermore, because the cut surface 26D of the third portion 26C is arranged inside the holding member 10, it is possible to prevent external contact with the conductor portion CP of the sixth bus bar 26.

[0054] 4 , the seventh bus bar 27 has a generally angular U-shape when viewed from the front-to-rear direction. The bent edge BE of the seventh bus bar 27 includes a first bent edge BE1 and a second bent edge BE2, and extends in the direction of the short side of the seventh bus bar 27 (the front-to-rear direction). The seventh bus bar 27 is configured generally similarly to the connection portion 25F of the fifth bus bar 25, and includes a connection portion (not shown) connected to the third bus bar 23 and a tuning fork terminal 40 connected to the terminal portion 4B of the pre-charge resistor 4.

[0055] 15 , the eighth bus bar 28 includes a first portion 28A, a second portion 28B bent relative to the first portion 28A, a third portion 28C bent relative to the second portion 28B, a fourth portion 28D bent relative to the third portion 28C, and a fifth portion 28E bent relative to the fourth portion 28D. The first portion 28A extends in the vertical direction. The second portion 28B extends in the front-rear direction. The third portion 28C extends in the vertical direction. The fourth portion 28D extends diagonally forward and upward from the third portion 28C. The fifth portion 28E extends in the vertical direction. The third portion 28C includes a wide portion 28C1 connected to the second portion 28B, and a narrow portion 28C2 extending upward from the wide portion 28C1 and formed narrower than the wide portion 28C1. The narrow portion 28C2 is disposed to the left of the center of the wide portion 28C1. The narrow portion 28C2 is connected to the fourth portion 28D. The fourth portion 28D and the fifth portion 28E are configured to have substantially the same width dimension (dimension in the left-right direction) as the narrow portion 28C2.

[0056] The bending edges BE of the eighth bus bar 28 include a first bending edge BE1, a second bending edge BE2, a third bending edge BE3, and a fourth bending edge BE4. The first bending edge BE1 is formed between the lower end of the first portion 28A and the rear end of the second portion 28B. The second bending edge BE2 is formed between the front end of the second portion 28B and the lower end of the third portion 28C (wide portion 28C1). The third bending edge BE3 is formed between the upper end of the third portion 28C (narrow portion 28C2) and the lower end of the fourth portion 28D. The fourth bending edge BE4 is formed between the upper end of the fourth portion 28D and the lower end of the fifth portion 28E. The bending edges BE of the eighth bus bar 28 (the first bending edge BE1, the second bending edge BE2, the third bending edge BE3, and the fourth bending edge BE4) extend in the short-side direction (left-right direction) of the eighth bus bar 28.

[0057] The first portion 28A includes a tuning fork terminal 40. The fifth portion 28E includes a tab-shaped connecting portion 28F at its upper end. The conductor portion CP is exposed on the entire outer surface of the connecting portion 28F. As shown in FIG. 16 , the tuning fork terminal 40 is connected to the second terminal 3C of the precharge relay 3. The connecting portion 28F is inserted into the terminal hole 13A of the connector fitting portion 13 of the holding member 10 and is disposed within the connector fitting portion 13 (see FIG. 6 ). The connecting portion 28F is connected to the connector 5 fitted into the connector fitting portion 13.

[0058] (Ninth Bus Bar 29) The ninth bus bar 29 is configured substantially similarly to the eighth bus bar 28. As shown in FIG. 4 , the ninth bus bar 29 includes a first portion 29A, a second portion 29B bent relative to the first portion 29A, and a third portion 29C bent relative to the second portion 29B. The first portion 29A extends in the vertical direction and includes a tuning fork terminal 40. The second portion 29B extends in the front-rear direction. The third portion 29C extends in the vertical direction. The bent edge BE of the ninth bus bar 29 includes only a first bent edge BE1 and a second bent edge BE2. The first bent edge BE1 is formed between the lower end of the first portion 29A and the rear end of the second portion 29B. The second bent edge BE2 is formed between the front end of the second portion 29B and the lower end of the third portion 29C.

[0059] As shown in FIG. 16 , the second portion 29B is longer in the front-to-rear direction than the second portion 28B of the eighth bus bar 28. The third portion 29C includes a wide portion 29C1 connected to the second portion 29B and a narrow portion 29C2 extending upward from the wide portion 29C1 and narrower than the wide portion 29C1. The narrow portion 29C2 is located to the right of the center of the wide portion 29C1. A tab-shaped connection portion 29D is formed at the upper end of the narrow portion 29C2. The connection portion 29D is configured to be connected to the connector 5.

[0060] The second portion 28B of the eighth bus bar 28 is arranged overlapping the second portion 29B of the ninth bus bar 29. The connection portion 28F of the eighth bus bar 28 and the connection portion 29D of the ninth bus bar 29 are arranged side by side in the left-right direction. Cut surfaces 28G and 29E that appear due to the formation of the connection portions 28F and 29D, respectively, expose the conductor portions CP, but these cut surfaces 28G and 29E are arranged at a spatial distance that allows insulation from each other. By arranging the eighth bus bar 28 and the ninth bus bar 29 overlapping in this manner, the installation space for the eighth bus bar 28 and the ninth bus bar 29 can be reduced.

[0061] In this embodiment, as shown in FIG. 3 , at least a portion of each of the first bus bar 21, the second bus bar 22, the third bus bar 23, and the fourth bus bar 24 is exposed to the outside on the upper surface of the holding member 10. The bus bar 20 includes the insulating member NP, so that the bus bar 20 is insulated from the outside even when a portion of the bus bar 20 is exposed to the outside in the electric device 1. Therefore, the electric device 1 does not need an insulating member to entirely cover the bus bar 20, thereby reducing the number of components of the electric device 1. Furthermore, because the bus bar 20 is not entirely covered in the electric device 1, heat buildup in the bus bar 20 within the electric device 1 can be reduced. Furthermore, the exposed portion of the bus bar 20 is covered with the insulating member NP, which has a higher emissivity than the conductor portion CP, so heat from the bus bar 20 can be efficiently radiated to the outside. This improves the heat dissipation of the bus bar 20.

[0062] The electric device 1 of this embodiment is attached to a metal housing 6. Note that only a portion of the metal housing 6 where the electric device 1 is installed is illustrated. The metal housing 6 may house, for example, a battery inside. As shown in FIG. 2 , in the electric device 1, the fifth bus bar 25, the sixth bus bar 26, the seventh bus bar 27, the eighth bus bar 28, and the ninth bus bar 29 are attached to the underside of the holding member 10. When the electric device 1 is attached to the metal housing 6, the fifth bus bar 25, the sixth bus bar 26, the seventh bus bar 27, the eighth bus bar 28, and the ninth bus bar 29 are not exposed to the outside but contact the metal housing 6 inside the holding member 10 (see FIGS. 3 and 4 ). Note that the eighth bus bar 28 is connected to the metal housing 6 via the ninth bus bar 29. The portions of these bus bars 20 that contact the metal housing 6 are insulating members NP, preventing electrical conduction between the bus bars 20 and the metal housing 6. When the bus bar 20 comes into contact with the metal housing 6, the heat of the bus bar 20 can be transferred to the metal housing 6. Therefore, the heat dissipation property of the bus bar 20 can be improved.

[0063] (Method for Manufacturing Electrical Device 1) The above describes the configuration of the electrical device 1. Below, we will explain one example of a method for manufacturing the electrical device 1. The method for manufacturing the electrical device 1 includes a manufacturing process for the busbars 20, a manufacturing process for the holding members 10, and a process for assembling each component.

[0064] (Manufacturing Process of Busbar 20) An example of a manufacturing process of busbar 20 will be described below with reference to FIG. 17 . Here, a manufacturing process (manufacturing method) of first busbar 21 will be described as a representative of busbar 20. First, a strip-shaped metal plate 50 extending in one direction is prepared (first process). This metal plate 50 will become the conductor portion CP of busbar 20. The short-side direction of metal plate 50 (the vertical direction in FIG. 17 ) corresponds to the short-side direction of busbar 20.

[0065] Next, the outer surface of the metal plate 50 is coated with an insulating material NP to obtain a coated plate 51 (second step). Because the metal plate 50 has a strip shape extending in one direction, in the second step, the insulating material NP can be formed on the outer surface of the metal plate 50 using an extruder. That is, the insulating material NP can be attached to the outer surface of the metal plate 50 while the extruder feeds the metal plate 50 in its extension direction (long side direction). The short side direction of the metal plate 50 is perpendicular to the direction in which the extruder feeds the metal plate 50. Using an extruder can improve the work efficiency of the second step and reduce the manufacturing cost of the bus bar 20.

[0066] The covering plate 51 is cut and holes are drilled to obtain a first formed body 52 (third step). When manufacturing the first bus bar 21, the cutting line is straight, but the cutting line may be changed as appropriate depending on the shape of the bus bar 20 to be manufactured. For example, when manufacturing the sixth bus bar 26, the portion corresponding to the tuning fork terminal 40 is formed using a curved cutting line. Furthermore, depending on the shape of the bus bar 20, drilling holes may not be performed.

[0067] Subsequently, a part (a part surrounded by a dashed line) of the insulating member NP of the first molded body 52 is removed to obtain the second molded body 53 (fourth step), thereby forming the connection portions 21E, 21F, and 21G.

[0068] Finally, the second molded body 53 is bent at the bending lines 54 indicated by the dashed lines to obtain the first bus bar 21 (see FIG. 7 ) (step 5). In step 5, the second molded body 53 is bent so that the bending edges BE of the first bus bar 21 extend in the direction of the short sides of the first bus bar 21. The bending lines 54 correspond to the bending edges BE. By specifying the direction of the bending lines 54 in this manner, the bending process of the second molded body 53 becomes easier. Furthermore, the insulating member NP is less likely to be damaged at the bending edges BE. This completes the manufacturing of the first bus bar 21.

[0069] The holding member 10 can be formed by injection molding or the like. As described above, the holding member 10 has holes for accommodating and engaging each component. The assembly process of each component is carried out by placing each component on the holding member 10 and connecting the components by bolts or the like. This completes the manufacturing of the electrical device 1.

[0070] (Effects and Functions of First Embodiment) (1) The electrical device 1 according to the first embodiment includes heat-generating components (a main relay 2, a precharge relay 3, and a precharge resistor 4), a bus bar 20 connected to the heat-generating components, and a holding member 10 that holds the heat-generating components and the bus bar 20. The bus bar 20 includes a conductor portion CP and an insulating member NP that has a higher emissivity than the conductor portion CP and covers at least a portion of the outer surface of the conductor portion CP. The bus bar 20 is short in the short side direction and has a shape that is bent at at least one point, and all of the bent edges BE of the bus bar 20 extend in the short side direction.

[0071] With this configuration, at least a portion of the outer surface of the conductor portion CP of the bus bar 20 is covered with the insulating member NP, which makes it easier to ensure insulation of the bus bar 20 from the outside. Furthermore, because the insulating member NP has a higher emissivity than the conductor portion CP, heat transferred from the heat-generating components to the bus bar 20 can be more easily dissipated to the outside by radiation. In other words, heat dissipation from the heat-generating components is easier. Therefore, heat can be dissipated from the heat-generating components without the need to make the bus bar 20 large.

[0072] Because the bent edges BE of the busbar 20 all extend in the short-side direction, the conductor portion CP of the busbar 20 can be formed from a strip-shaped metal plate 50. Therefore, an extruder can be used to form the insulating member NP on the outside of the metal plate 50. This allows the busbar 20 to be formed easily.

[0073] (2) In the first embodiment, the bus bars 20 (the sixth bus bar 26, the seventh bus bar 27, the eighth bus bar 28, and the ninth bus bar 29) include tuning fork terminals 40. The tuning fork terminals 40 of the sixth bus bar 26 and the seventh bus bar 27 are connected to the terminal 4B of the precharge resistor 4. The tuning fork terminals 40 of the eighth bus bar 28 and the ninth bus bar 29 are connected to the second terminal 3C of the precharge relay 3.

[0074] With this configuration, even if the terminal portion of the heat-generating component and the bus bar 20 are arranged so as to intersect at right angles, the terminal portion and the bus bar 20 can be connected to each other.

[0075] (3) The electrical device 1 according to the first embodiment further includes an intermediate terminal 30 that connects the heat-generating component (pre-charge relay 3) and the busbar 20 (fifth busbar 25, sixth busbar 26). The intermediate terminal 30 includes a connecting tube portion 31 into which the terminal portion (first terminal portion 3B) of the heat-generating component and the end portion (connection portions 25E, 26E) of the busbar 20 are inserted, a first contact portion 32 that is connected to the terminal portion of the heat-generating component within the connecting tube portion 31, and a second contact portion 33 that is connected to the end portion of the busbar 20 within the connecting tube portion 31.

[0076] With this configuration, the terminal portion of the heat-generating component and the bus bar 20 can be easily connected.

[0077] (4) The electric device 1 according to the first embodiment further includes bolts B2, B3, and B4 for fixing the bus bar 20, and the bolts B2, B3, and B4 include heads whose surfaces are at least insulated.

[0078] This configuration can prevent the bus bar 20 from being electrically connected to the outside via the bolts B2, B3, and B4.

[0079] <Embodiment 2> Embodiment 2 of the present disclosure will be described with reference to Fig. 18 to Fig. 22. An electric device 101 according to embodiment 2 is configured substantially similarly to the electric device 1 of embodiment 1. Therefore, hereinafter, substantially the same members as those of embodiment 1 will be assigned the same reference numerals, and descriptions thereof may be omitted.

[0080] Each bus bar 20 in embodiment 2 may differ from each bus bar 20 in embodiment 1 in terms of the shape of the conductor portion CP, the area in which the insulating member NP is formed relative to the conductor portion CP, the number of bending edges BE, etc., but is configured in approximately the same way as each bus bar 20 in embodiment 1.

[0081] As shown in Fig. 19 , the holding member 110 according to the second embodiment differs from the holding member 10 according to the first embodiment in that the holding member 110 holds the main relay 2, the first bus bar 21, and the third bus bar 23 on the lower surface side of the holding member 110. The main relay 2, the first bus bar 21, and the third bus bar 23 are disposed inside the holding member 110 and are not exposed to the outside (see Figs. 21 and 22 ). As shown in Figs. 18 and 21 , the pre-charge relay 3, the pre-charge resistor 4, the second bus bar 22, and the fourth bus bar 24 are held on the upper surface side of the holding member 110. As shown in Figs. 20 and 22 , when the electrical device 101 is attached to the metal housing 6, the first bus bar 21 and the third bus bar 23 are in contact with the metal housing 6. Therefore, in the second embodiment, unlike the first embodiment, heat transfer from the first bus bar 21 and the third bus bar 23 to the metal housing 6 is possible.

[0082] As shown in Fig. 20 , the holding member 110 has a tool hole 119 that penetrates its right wall in the left-right direction. A tool (not shown) can be inserted into the tool hole 119 to bolt the connection portion of the first bus bar 21 to the terminal portion of the main relay 2 from the outside. As shown in Fig. 19 , the holding member 110 is also provided with a tool hole 119 for bolting the connection portion of the third bus bar 23 to the terminal portion of the main relay 2.

[0083] The effects of the second embodiment are substantially the same as those of the first embodiment, and therefore a description thereof will be omitted.

[0084] Other Embodiments The above-described first and second embodiments can be modified as follows: The above-described first and second embodiments and the following modifications can be combined and implemented within the scope of technical compatibility.

[0085] In the first and second embodiments, the main relay 2, the precharge relay 3, and the precharge resistor 4 are exemplified as heat-generating components, but the heat-generating components include any component that can generate heat when energized. The heat-generating components may be, for example, resistors, coils, capacitors, fuses, diodes, ICs (Integrated Circuits), switching elements such as FETs (Field Effect Transistors), and the like.

[0086] In the first and second embodiments, the electric device 1, 101 includes nine bus bars 20. However, the electric device may include at least one bus bar.

[0087] 1: Electrical equipment 2: Main relay 2A: Main body 2B: Partition wall 2C: Mounting piece 2D: Connector fitting portion 3: Pre-charge relay 3A: Main body 3B: First terminal portion 3C: Second terminal portion 3D: Lock portion 4: Pre-charge resistor 4A: Main body 4B: Terminal portion 5: Connector 6: Metal housing 10: Holding member 11: Main relay accommodating portion 11A: Nut mounting portion 12: Pre-charge relay accommodating portion 12A: Lock receiving portion 12B: First insertion hole 12C: Second insertion hole 13: Connector fitting portion 13A: Terminal hole 14: Pre-charge resistor accommodating portion 14A: Locking portion 14B: Third insertion hole 15A, 15B: Bus bar engagement holes 16: Nut mounting portion 17A, 17B, 17C, 17D: Mounting post 18: Busbar insertion hole 20: Busbar 21: First busbar 21A: First portion 21B: Second portion 21C, 21D: Cut surface 21E: Connection portion 21E1: Through hole 21E2: Connection surface 21F: Connection portion 21F1: Through hole 21F2: Connection surface 21G: Connection portion 21G1: Through hole 21G2: Connection surface 22: Second busbar 22A: First portion 22B: Second portion 22C: Third portion 22D,22E: Cut surface 22F: Connection portion 22F1: Through hole 22F2: Connection surface 22G: Connection portion 22G1: Through hole 22G2: Connection surface 23: Third bus bar 24: Fourth bus bar 24A: Connection portion 25: Fifth bus bar 25A: First portion 25B: Second portion 25C: Third portion 25D: Cut surface 25E: Connection portion 25F: Connection portion 25F1: Through hole 25F2: Connection surface 26: Sixth bus bar 26A: First portion 26B: Second portion 26C: Third portion 26D: Cut surface 26E: Connection portion 27: Seventh bus bar 28: Eighth bus bar 28A: First portion 28B: Second portion 28C: Third portion 28C1: Wide portion 28C2: Narrow width portion 28D: Fourth portion 28E: Fifth portion 28F: Connection portion 28G: Cut surface 29: Ninth bus bar 29A: First portion 29B: Second portion 29C: Third portion 29C1: Wide width portion 29C2: Narrow width portion 29D: Connection portion 29E: Cut surface 30: Intermediate terminal 31: Connection tube portion 32: First contact portion 33: Second contact portion 40: Tuning fork terminal 41: Base portion 42: Clamping piece 43: Projection portion 50: Metal plate material 51: Covering plate material 52: First molded body 53: Second molded body 54: Bending line 101: Electrical equipment B1: Mounting bolt B2, B3, B4: Bolt BE: Bending edge BE1: First bending edge BE2: Second bending edge BE3: Third bending edge BE4: Fourth bending edge CP: Conductor part N1, N2, N3: Nut NP: Insulating member

Claims

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5. A method for manufacturing an electric device, comprising: a manufacturing step of a bus bar; a manufacturing step of a holding member that holds the bus bar; and an assembling step of assembling the bus bar to the holding member, The manufacturing process of the bus bar includes: A first step of preparing a strip-shaped metal plate material extending in one direction; a second step of adhering an insulating member to an outer surface of the metal plate while feeding the metal plate in its extension direction using an extruder, thereby obtaining a coated plate; a third step of cutting and drilling the coated plate material to obtain a first molded body; a fourth step of obtaining a second molded body by removing a portion of the insulating member of the first molded body; a fifth step of bending the second molded body to obtain a bus bar; A method for manufacturing an electrical device, comprising: