Electrical device and manufacturing method for electrical device

Abstract

An electrical device (10) comprises an electrical instrument (20) and bus bars (30, 40) that are connected to terminals of the electrical instrument. The bus bars each comprise: a plate-like first member (31, 41) that is fixed by a fixture to a terminal provided on an outer peripheral surface of the electrical instrument; and a plate-like second member (32, 42) which extends in a direction intersecting the first member and from which heat is dissipated by a heat dissipation mechanism. The first member and the second member are joined at a position where the two intersect each other.

Description

Electrical device and method for manufacturing the same CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on Japanese Application No. 2023-105074, filed on June 27, 2023, the contents of which are incorporated herein by reference.

[0002] The present invention relates to electrical devices and methods for manufacturing electrical devices.

[0003] Electrical devices are known that include an electrical device such as a relay and a bus bar connected to the terminals of the electrical device. When such electrical devices are installed in a circuit through which a large current flows, such as a charging / discharging path, a large current flows through the relay or bus bar, generating Joule heat proportional to the square of the current amount, resulting in a large amount of heat. For this reason, a technique for actively dissipating heat from the bus bar by, for example, abutting a cooler or a heat dissipation member on the bus bar is known. Patent Document 1 (Patent Document 1) describes an electrical device that includes a relay having terminals, a bus bar, and a joint plate. The bus bar described in Patent Document 1 is approximately L-shaped and has a portion parallel to a base plate and a portion perpendicular to the base plate. The bus bar is fixed at the parallel portion so as to be pressed against the base plate with a heat transfer material sandwiched therebetween. Heat from the bus bar is diffused to the base plate via the heat transfer material, thereby suppressing a temperature rise of the bus bar. The bus bar is fastened to a relay terminal at its vertical portion via a joint plate. The joint plate has a hole at one end for fastening to the relay terminal and a hole at the other end for fastening to the bus bar. The holes in the joint plate that fasten to the relay terminals are elongated to allow for a certain margin in the longitudinal size of the joint plate, so that the joint plate can be fastened to the relay terminals even if the joint plate is displaced longitudinally due to being fastened to the bus bar.

[0004] Patent No. 7139938

[0005] Bus bars, through which large currents can flow, tend to be made of metal plates (e.g., copper plates) with a large cross-sectional area in the direction of the current in order to reduce electrical and thermal resistance. Metal plates with large cross-sectional areas are highly rigid and difficult to bend, making fastening difficult if the positions of the bus bar and the terminal of the relay deviate from the intended positions. Furthermore, forcibly bending the bus bar to fasten it can cause large stresses at the fastening points between the bus bar and the terminal.

[0006] According to Patent Document 1, when the position of a joint plate is misaligned in the longitudinal direction, stress that may occur when fastening the joint plate to a relay terminal can be suppressed. However, when the position of the joint plate is misaligned in the transverse direction or thickness direction, which are perpendicular to the longitudinal direction, it is difficult to suppress stress. To accommodate misalignment of the joint plate in both the longitudinal and transverse directions, the hole size must be increased in both the longitudinal and transverse directions, making it difficult to fasten the joint plate to the relay terminal. In other words, while the technique of Patent Document 1, which increases the size of the hole for fastening a current-carrying member such as a joint plate to a terminal of an electrical device such as a relay, can suppress stress that may occur due to misalignment in one specific direction, it is difficult to suppress stress that may occur due to misalignment in other directions.

[0007] In view of the above, an object of the present disclosure is to provide a method that differs from conventional methods and that can suppress stress that may occur when fixing a terminal of an electrical device to a bus bar.

[0008] The present disclosure provides an electric device including an electric device and a bus bar connected to a terminal of the electric device. The bus bar includes a first plate-like member fixed to the terminal provided on the outer peripheral surface of the electric device by a fastener, and a second plate-like 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 with each other.

[0009] According to the above-described electric device, the bus bar includes a first member fixed to a terminal provided on an outer peripheral surface of the electric device by a fastener and a second member for dissipating heat by a heat dissipation mechanism, the first member and the second member being joined at a position where they intersect. With this configuration, the first member and the second member are fixed to the terminal of the electric device in a state where they are not joined, and then the first member and the second member are joined, thereby achieving a state in which the bus bar is fixed to the terminal of the electric device. In cases where heat is dissipated from the bus bar by a heat dissipation mechanism due to reasons such as a large current flowing through the bus bar, bus bars that are highly rigid and difficult to bend tend to be used. However, according to the above-described electric device, the first member and the second member can be fixed to the terminal of the electric device in a state where they are not joined, and then the first member and the second member can be joined. Therefore, even if the position of the first member relative to the second member is misaligned when the terminal of the electric device and the first member are fixed, the bus bar can be fixed to the terminal of the electric device without bending the first member and the second member. Therefore, stress that may occur when fastening the terminals of the electrical device to the bus bars can be suppressed. That is, the electrical device described above uses a method that differs from the conventional method of providing a margin in the size of the holes used for fastening the terminals of the electrical device, thereby suppressing stress that may occur when fastening the terminals of the electrical device to the bus bars.

[0010] The present disclosure provides a method for manufacturing an electric device including an electric device and a bus bar connected to a terminal of the electric device. In the electric device, the bus bar includes a first plate-shaped member and a second plate-shaped member. The manufacturing method includes an arrangement step of arranging the first member and the second member at a mutually intersecting position, a fixing step of fixing the first member to the terminal provided on the outer peripheral surface of the electric device using a fixing device, and a joining step of joining the first member and the second member at the mutually intersecting position after the fixing step.

[0011] In the above-described method for manufacturing an electric device, the arrangement step includes arranging a first member and a second member provided on the bus bar at a position where they intersect with each other, and the fixing step includes fixing the first member to a terminal provided on an outer peripheral surface of the electric device using a fastener. The joining step is performed after the fixing step, and joins the first member and the second member at the position where they intersect with each other. Since the joining step is performed after the fixing step, the first member is fixed to the terminal of the electric device in a state where the first member and the second member are not joined, and then the first member and the second member are joined, thereby achieving a state in which the bus bar is fixed to the terminal of the electric device. According to the above-described method for manufacturing an electric device, the first member can be fixed to the terminal of the electric device in a state in which the first member and the second member are not joined, and then the first member and the second member can be joined. Therefore, even if the position of the first member relative to the second member is misaligned when the terminal of the electric device and the first member are fixed, the bus bar can be fixed to the terminal of the electric device without bending the first member and the second member. Therefore, the stress that may occur when fastening the terminals of the electrical device to the bus bars can be suppressed. That is, according to the manufacturing method of the electrical device described above, the stress that may occur when fastening the terminals of the electrical device to the bus bars can be suppressed by using a method that differs from the conventional method of providing a margin in the size of the holes for fastening the terminals of the electrical device.

[0012] The above and other objects, features, and advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which Fig. 1 is a perspective view of an electric device according to an embodiment, Fig. 2 is a cross-sectional view taken along line II-II in Fig. 1, Fig. 3 is a diagram illustrating a method for manufacturing the electric device shown in Fig. 1, Fig. 4 is a diagram illustrating a method for manufacturing the electric device shown in Fig. 1, Fig. 5 is a diagram illustrating a method for manufacturing the electric device shown in Fig. 1, Fig. 6 is a diagram illustrating a method for manufacturing the electric device shown in Fig. 1, Fig. 7 is a diagram illustrating a method for manufacturing the electric device shown in Fig. 1, Fig. 8 is a diagram illustrating a portion of a bus bar of an electric device according to a modified example, Fig. 9 is a longitudinal cross-sectional view of an electric device according to a modified example, Fig. 10 is a longitudinal cross-sectional view of an electric device according to a modified example, and Fig. 11 is a top view of an electric device according to a modified example.

[0013] 1 shows a relay unit 10 according to an embodiment. The relay unit 10 includes a relay 20, a first pole bus bar 30, a second pole bus bar 40, a base member 50, and a heat dissipation sheet 70. The relay 20 is an example of an electric device according to an embodiment, and the relay unit 10 is an example of an electric device according to an embodiment.

[0014] 1 and 2 show relay unit 10, and Figures 3 to 7 show a manufacturing process for relay unit 10. Relay 20 is a mechanical relay, and as shown in Figures 1 and 2, etc., has a resin exterior that is approximately rectangular parallelepiped overall, with the z-axis direction as the vertical direction, the x-axis direction as the horizontal direction, and the y-axis direction as the depth direction. Hereinafter, in this specification, the positive direction of the z-axis may be referred to as the upward direction, the negative direction of the z-axis as the downward direction, the positive direction of the x-axis as the rightward direction, the negative direction of the x-axis as the leftward direction, the positive direction of the y-axis as the backward direction, and the negative direction of the y-axis as the forward direction.

[0015] The relay 20 has a contact portion and a coil portion (not shown) inside a resin exterior. A pair of terminals are provided on the front surface of the relay 20 (the surface facing the negative y-axis in FIG. 1 ) and spaced apart from each other in the left-right direction. As shown in FIG. 3 and other figures, the first pole terminal 27 is the right-side terminal, and the second pole terminal 28 is the left-side terminal.

[0016] 2 and 3 , the first pole terminal 27 and the second pole terminal 28 are ring-shaped contact portions provided on the front surface (the surface facing the negative y-axis) of the relay 20. A bolt fastening hole extending in the y-axis direction through the center of the first pole terminal 27 is provided inside the relay 20. The first pole bus bar 30 is fixed to the first pole terminal 27 in a state of abutting against the first pole terminal 27 from the front by a first pole terminal fixing bolt 63 that passes through a through hole 37 (described later) and is fastened to a bolt fastening hole on the first pole side. This electrically and thermally connects the first pole terminal 27 and the first pole bus bar 30 to each other.

[0017] Similarly, a bolt fastening hole (not shown) is provided inside the relay 20, extending in the y-axis direction through the center of the second pole terminal 28. The second pole bus bar 40 is fixed to the second pole terminal 28 in a state where it abuts against the second pole terminal 28 from the front direction by a second pole terminal fixing bolt 64 that passes through a through hole 47 (described later) and is fastened to a bolt fastening hole on the second pole side. This electrically and thermally connects the second pole terminal 28 and the second pole bus bar 40 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 to terminals 27, 28, bus bars 30, 40, and terminal fixing bolts 63, 64, respectively.

[0018] A partition plate 21 that protrudes forward (in the negative direction of the y-axis) is formed between the first pole terminal 27 and the second pole terminal 28, extending 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 with each other and causing a short circuit.

[0019] The relay 20 is controlled to be turned on and 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 via a 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.

[0020] Two legs are provided at the bottom of relay 20, protruding on both the left and right sides (positive and negative directions of the x-axis shown in Figure 1, etc.). Figure 2, etc. shows the first-pole-side leg 23 provided on the first-pole side, which is the right side, but does not show the second-pole-side leg provided on the second-pole side, which is the left side. A bolt insertion hole is formed in each of the two legs.

[0021] 3 and other figures, 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 mounted, and a first pole-side side surface portion 51 and a second pole-side side surface portion 52 provided to the right and left of the mounting portion 53. The first pole-side side surface portion 51 and the second pole-side side surface portion 52 are higher than the mounting portion 53, and the first pole-side side surface portion 51, the second pole-side side surface portion 52, and the mounting portion 53 form a recess that accommodates the relay 20.

[0022] A first-pole-side through-hole 56 is provided in the mounting portion 53 on a side closer to the first-pole-side side surface portion 51, and a second-pole-side through-hole 58 is provided on a side closer to the second-pole-side side surface portion 52. The first-pole-side through-hole 56 is provided in the front direction (negative direction of the y-axis) of the mounting portion 53, and the second-pole-side through-hole 58 is provided 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 provided at diagonal positions on the mounting portion 53, which has a rectangular shape when viewed from above.

[0023] 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 23. Similarly, on the second-pole side, the second-pole side relay fixing bolt 62 is fastened, passing through the second-pole side through-hole 58 and the bolt insertion hole of the second-pole side leg (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 and fixed to the base member 50.

[0024] The first pole bus bar 30 includes a first member 31 and a second member 32. The second pole bus bar 40 includes 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 material. In this embodiment, the first members 31, 41 and the second members 32, 42 are formed from the same metal plate material (e.g., copper material).

[0025] 4, the first members 31 and 41 are substantially rectangular plate-like members, and are formed so that when the plate surface of the first member 41 is inverted around the z-axis in FIG. 1, etc., it has 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 plate thickness direction (the y-axis direction shown in FIG. 1, etc.).

[0026] The first members 31 and 41 are disposed so that their plate surfaces face substantially parallel to the front surface of the relay 20. Because 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 disposed so 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 disposed so that they are 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) abut against terminals 27 and 28, respectively, provided on the front surface of the relay 20, and the first members 31 and 41 are fastened to the terminals 27 and 28 by terminal fixing bolts 63 and 64. Fastening the first members 31 and 41 with the terminal fixing bolts 63 and 64 electrically and thermally connects the first and second pole terminals 27 and 28 of the relay 20.

[0027] 2 and 4, the second members 32 and 42 are plate-like members formed by bending a substantially rectangular plate material at two locations. The second members 32 and 42 are machined to have substantially the same shape. The second member 32 includes a flat portion 32a, a stepped portion 32b, and a fastening portion 32c, which are arranged in this order from the negative side to the positive side of the y-axis. Similarly, the second member 42 includes a flat portion 42a, a stepped portion 42b, and a fastening portion 42c, which are arranged in this order from the negative side to the positive side of the y-axis.

[0028] The flat plate portions 32a, 42a extend in the y-axis direction below the mounting portion 53. While portions of the flat plate portions 32a, 42a are embedded and fixed in the base member 50, their lower surfaces are exposed downward from the lower surface of the base member 50. A heat dissipation sheet 70, which will be described later, is provided so as to contact the lower surfaces of the flat plate portions 32a, 42a exposed from the base member 50. The ends of the flat plate portions 32a, 42a facing the negative y-axis protrude from the base member 50 in the y-axis direction. The ends of the flat plate portions 32a, 42a facing the positive y-axis are connected to the ends of the stepped portions 32b, 42b facing the negative y-axis, respectively.

[0029] The stepped portions 32b, 42b are bent at both ends, forming a step in the z-axis direction. The positive y-axis ends of the stepped portions 32b, 42b are connected to the negative y-axis ends of the fastening portions 32c, 42c, respectively. The fastening portions 32c, 42c are exposed on the upper surface of the base member 50. The fastening portions 32c, 42c are provided with through holes 35, 45, respectively. As shown in FIG. 2 , a bolt fastening hole 55 is provided in the base member 50 below the through hole 35. For example, an external bus bar connected to external wiring of the relay unit 10 is disposed on the upper surface of the fastening portion 32c, and the first-pole bus bar 30 can be connected to external wiring by aligning the through hole of the external bus bar with the through hole 35 of the fastening portion 32c and fastening them together with a bolt. Although not shown, the base member 50 also has a bolt fastening hole having a structure similar to that of the bolt fastening hole 55 at a position below the through hole 45, and the second pole bus bar 40 can be connected to external wiring by aligning the through hole provided in the external bus bar with the through hole 45 of the fastening portion 42c and fastening them together with a bolt.

[0030] The first member 31 and the second member 32 are disposed in a mutually intersecting positional relationship and are joined to each other by welding at the intersecting portion. As shown in FIGS. 2 and 3 , the flat portion 32a of the second member 32 protrudes from the base member 50 at positions y1 to y4. Position y1 is the front position of the mounting portion 53 of the base member 50, and position y4 is the front position of the second member 32. The relay 20 is fixed to the base member 50 so that its front position is position y2, which is shifted forward from position y1. The flat 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 a surface (lower surface) that faces an upper surface near which the through-hole 37 is provided. Position y3 is a position shifted rearward from position y4. As shown in Figures 1 and 2, the first pole bus bar 30 is formed into a substantially L-shape overall by joining the first member 31 and the second member 32 to each other in a substantially orthogonal state (more specifically, a state in which the first member 31 is substantially upright with respect to the plate surface of the second member 32) with the second member 32 in a leading state.

[0031] Similarly, the first member 41 and the second member 42 are disposed in a mutually intersecting positional relationship and are joined to each other by welding at the intersecting portion. As shown in FIG. 3 , the flat portion 42a of the second member 42 protrudes from the base member 50 at positions y1 to y4. Position y1 is the front position of the mounting portion 53 of the base member 50, and position y4 is the front position of the second member 42. The relay 20 is fixed to the base member 50 so that its front position is position y2, which is shifted forward from position y1. The flat 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 a surface (lower surface) that faces an upper surface near which the through-hole 47 is provided. Position y3 is a position shifted rearward from position y4. Although not shown, similar to the first pole bus bar 30, the second pole bus bar 40 is formed into a substantially L-shape overall by joining the first member 41 and the second member 42 to each other in a substantially orthogonal state (more specifically, a state in which the first member 41 is substantially upright with respect to the plate surface of the second member 42) with the second member 42 in a leading state.

[0032] In this embodiment, in the first pole bus bar 30 and the second pole bus bar 40, the second members 32, 42 are in a leading state, and the first members 31, 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 face adjacent to the plate face) of the first member 31 and the plate face of the second member 32 are joined to each other. The joint portion where the first member 41 and the second member 42 are joined to each other is the portion where the end face of the first member 41 and the plate face of the second member 42 are joined to each other.

[0033] The position of the joint-side end of the second members 32, 42 (the front-side end shown in FIG. 1 and other figures) is position y4, and the position of the front of the first members 31, 41 is position y3, which is shifted rearward from position y4. That is, the joint-side end of the second members 32, 42 (the front-side end shown in FIG. 1 and other figures) protrudes from the plate surfaces of the first members 31, 41. Because positions y3 and y4 are designed in this manner, even if the first members 31, 41 are misaligned in the y-axis direction, the end faces of the first members 31, 41 can remain positioned on the plate surfaces of the second members 32, 42. Furthermore, because position y2, which is the position of the front face of the relay 20, is shifted forward from position y1, which is the position of the front face of the mounting portion 53 of the base member 50, the first members 31, 41 can be abutted against the terminals 27, 28 with the end faces of the first members 31, 41 positioned on the plate surfaces of the second members 32, 42.

[0034] A weld 33 is provided at the position where the first member 31 and the second member 32 are joined. The weld 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 side of the y-axis and the positive side of the z-axis). A weld 43 is provided at the position where the first member 41 and the second member 42 are joined. The weld 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 side of the y-axis and the positive side of the z-axis).

[0035] In this embodiment, fillet welding is used to form welds 33, 43 as a means for joining the first members 31, 41 and the second members 32, 42. The weld 33 is a joint where the first member 31 and the second member 32 are joined to each other. The weld 43 is a joint 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 of components provided in the electrical device, the application, etc. As a means for joining the first member and the second member, various joining means such as welding, brazing, pressure welding, fusion welding, solder bonding, crimping, and ultrasonic welding can be used, and a combination of multiple joining means may also be used.

[0036] The welds 33, 43 are formed at positions that do not face the relay 20. In the relay unit 10, a position facing the relay 20 refers to a position included in the region where the relay 20 is present, projected in the x-axis direction, y-axis direction, and z-axis direction (for convenience of explanation, referred to as the relay projection region). Specifically, as shown in FIG. 2, it refers to a position included in the region between positions z0 and z1 in the z-axis direction and positions y0 and y2 in the y-axis direction. A position that does not face the relay 20 refers to a position not included in the relay projection region. Specifically, as shown in FIG. 2, it refers to a position included in the region between positions z1 and z2 in the z-axis direction and positions y2 to y4 in the y-axis direction. Here, positions z0, z1, y0, and y1 are positions on the top, bottom, back, and front surfaces of the relay 20, respectively. Positions z2 and y4 are positions on the bottom and front surfaces of the second members 32, 42, respectively. That is, it is preferable that the welds 33, 43 are formed in a region that is below the bottom surface of the relay 20 and forward of the front surface of the relay 20. If the positions at which the welds 33, 43 are formed are not opposite the relay 20, it is possible to prevent the relay 20 from being heated by the heat generated when the welds 33, 43 are formed.

[0037] As shown in FIG. 2 , a heat dissipation sheet 70 is provided on the underside of the second members 32 and 42 as a heat dissipation mechanism. The heat dissipation sheet 70 can be, for example, silicone rubber filled with a thermally conductive filler such as aluminum oxide or iron oxide. A heat dissipation sheet 70 made of a silicone rubber heat dissipation material, like the heat dissipation sheet 70, is easily deformable and has high thermal conductivity and electrical insulation. A highly adhesive heat dissipation sheet 70 may be attached to the underside of the second members 32 and 42, or another material may be used to press the heat dissipation sheet 70 against the underside of the second members 32 and 42. Alternatively, a paste-like heat dissipation material may be applied to the underside of the second members 32 and 42. The heat dissipation mechanism may use a means other than a heat dissipation material. 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 underside of the second members 32 and 42 may be used as the heat dissipation mechanism.

[0038] The welded portions 33, 43 are provided at positions that do not reach the undersides of the second members 32, 42, respectively. Therefore, welding does not impair the flatness of the undersides of the second members 32, 42. Because the heat dissipation sheet 70 is provided on the undersides of the second members 32, 42, which have ensured flatness, it is possible to ensure adhesion between the undersides of the second members 32, 42 and the heat dissipation sheet 70, and it is also possible to ensure thermal conductivity between the undersides of the second members 32, 42 and the heat dissipation sheet 70.

[0039] In the present embodiment, the heat dissipation sheet 70, which corresponds to the heat dissipation mechanism, is in contact with the underside of the second member 32, 42, which corresponds to the heat dissipation surface, but the heat dissipation sheet 70 may be provided so as not to be in contact with the heat dissipation surface of the second member 32, 42. The heat dissipation surface of the second member 32, 42 may be the surface facing the heat dissipation mechanism, and another member may be provided between the heat dissipation surface of the second member 32, 42 and the heat dissipation mechanism, so that the second member 32, 42 dissipates heat indirectly via the heat dissipation mechanism.

[0040] (Method of Manufacturing Electrical Device) The method of manufacturing the relay unit 10 includes an arrangement step, a fixing step, and a joining step. The arrangement step is a step of arranging the first members 31, 41 and the second members 32, 42 at positions where they intersect with each other. The fixing step is a step of fixing the first members 31, 41 to the terminals 27, 28 of the relay 20 with terminal fixing bolts 63, 64, respectively. The joining step is a step of joining the first members 31, 41 and the second members 32, 42 at positions where they intersect with each other, and is performed after the fixing step. After the joining step, a heat dissipation mechanism installation step of installing a heat dissipation mechanism is further performed, thereby manufacturing the relay unit 10.

[0041] The placement step includes a first step and a second step. The first step is a step of preparing a base member 50 to which the second members 32, 42 are fixed. Hereinafter, for convenience of explanation, the base member 50 to which the second members 32, 42 are fixed may be referred to as a fixed base member in this specification. The second step is a step of fixing the relay 20 to the fixed base member.

[0042] (Placement Step) First, as shown in Figure 3, a base member 50 (fixed base member) to which the second members 32, 42 are fixed by insert molding is prepared (first step). The second members 32, 42 are fixed by being substantially embedded in the lower part of the mounting portion 53 of the base member 50, with the lower surfaces of the flat portions 32a, 42a exposed from the lower surface of the mounting portion 53. Furthermore, the flat portions 32a, 42a protrude forward from 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, 41.

[0043] 3 , the relay 20 is placed so that its underside 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, 62 (second step). The relay 20 is placed so that the first pole terminal 27 faces upward relative to the second member 32, and the second pole terminal 28 faces 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, 42 are fixed to one another with the flat plate portions 32a, 42a positioned to face the underside of the relay 20.

[0044] Next, as shown in Figures 4 and 5, the first members 31, 41 are arranged in front of the front surface of the relay 20. As shown in Figure 5, the first members 31, 41 are arranged so that their plate surfaces face the front surface of the relay 20 in a manner substantially parallel to the front surface. The first member 31 is placed over the first terminal 27 from the front side by aligning the through hole 37 with a bolt fastening hole provided in the center of the first terminal 27. The first member 41 is placed over the second terminal 28 from the front side by aligning the through hole 47 with a bolt fastening hole provided in the center of the second terminal 28. As a result, as shown in Figure 5, the first members 31, 41 are placed in a substantially upright state relative to the second members 32, 42, respectively, and are held by magnetic force or electrostatic force by the chucks 81, 82 abutting against them from above. The through holes 37, 47 are formed in positions such that the joint surfaces 31a, 41a come into contact with the upper surfaces of the portions of the flat plate portions 32a, 42a at positions y1 to y4 when the through holes 37, 47 are aligned with the bolt fastening holes provided in the centers of the terminals 27, 28. The chucks 81, 82 hold the first members 31, 41 while maintaining the joint surfaces 31a, 41a of the first members 31, 41 in contact with the upper surfaces of the second members 32, 42, respectively, while allowing the first members 31, 41 to move in directions parallel to the joint surfaces 31a, 41a.

[0045] 5 and 6 , with the first members 31, 41 held by the chucks 81, 82, the terminal fixing bolts 63, 64 are inserted from the front of the first members 31, 41 into the through holes 37, 47 and fastened to bolt fastening holes provided in the centers of the terminals 27, 28. In the fixing step, the first members 31, 41 and the second members 32, 42 are not joined to each other, and the first members 31, 41 are held by the chucks 81, 82. Therefore, the first members 31, 41 can be fixed in contact with the terminals 27, 28 of the relay 20 while allowing movement in directions parallel to the joining surfaces 31 a, 41 a of the first members 31, 41 (the x-axis and y-axis directions shown in FIG. 6 ). Even if the first members 31, 41 move in a direction parallel to their joint surfaces 31 a, 41 a before and after fixing the first members 31, 41 to the terminals 27, 28 of the relay 20, the first members 31, 41 and the second members 32, 42 do not bend, thereby suppressing stress that may occur when fixing the terminals 27, 28 of the relay 20 to the first members 31, 41. Furthermore, the terminals 27, 28 of the relay 20 can be fixed to the first members 31, 41 with the rear surfaces of the first members 31, 41 securely in contact with the terminals 27, 28.

[0046] (Joining Step) Next, the first members 31, 41 and the second members 32, 42 are joined at their intersecting positions. Fillet welding is performed at the intersecting positions of the first members 31, 41 and the second members 32, 42 from the surfaces of the first members 31, 41 that do not face the relay 20 (the front surfaces), thereby forming the welded portions 33, 43 while preventing the relay 20 from being heated by the heat generated during welding. Note that fillet welding is an example of a joining method, and the joining step can be performed using various joining methods such as welding, brazing, pressure welding, fusion welding, solder bonding, crimping, and ultrasonic welding. Furthermore, the joining step may be performed using a combination of multiple joining methods. In this embodiment, the chucks 81, 82 are described as an example in which the joining surfaces 31a, 41a of the first members 31, 41 maintain a state in which they are in contact with the upper surfaces of the second members 32, 42, respectively. However, even if a small gap is left between the joining surfaces 31a, 41a of the first members 31, 41 and the plate surfaces of the second members 32, 42 after the fixing step, if a means of melting a metal material such as welding or brazing is used in the joining step, the gap can be filled with the molten metal, and the electrical resistance and thermal resistance at the joint portion can be prevented from becoming high.

[0047] In the joining step, the welding conditions are preferably set so that the positions where the welds 33, 43 are formed are not opposite the relay 20. In other words, the welding conditions are preferably set so that the welds 33, 43 are formed in a region below the bottom surface of the relay 20 and forward of the front surface of the relay 20. If the positions where the welds 33, 43 are formed are not opposite the relay 20, heating of the relay 20 due to heat generated when the welds 33, 43 are formed can be suppressed.

[0048] In the joining step, it is preferable to set welding conditions so that welds 33, 43 are not formed on the undersides of the second members 32, 42. As described below, a heat dissipation sheet 70 is placed in contact with the undersides of the second members 32, 42. If welds 33, 43 are formed, there is a concern that the flatness of the undersides of the second members 32, 42 will be impaired, reducing adhesion to the heat dissipation sheet 70. By setting the welding conditions in the joining step so that welds 33, 43 are not formed on the undersides of the second members 32, 42, adhesion between the undersides of the second members 32, 42 and the heat dissipation sheet 70 is ensured, and thermal conductivity between the undersides of the second members 32, 42 and the heat dissipation sheet 70 can be ensured.

[0049] (Heat Dissipation Mechanism Installation Step) After the joining step, the heat dissipation sheet 70 is installed on the underside of the second members 32, 42. For example, a highly adhesive heat dissipation sheet 70 is used and installed by directly adhering it to the underside of the second members 32, 42. Because the welded portions 33, 43 are not formed on the underside of the second members 32, 42, the heat dissipation sheet 70 can be attached to the second members 32, 42, which ensures flatness. This ensures thermal conductivity between the underside of the second members 32, 42 and the heat dissipation sheet 70. The relay unit 10 can be manufactured through the manufacturing processes described above.

[0050] As described above, when the fixing step is performed after the arranging step, the joint surfaces 31 a, 41 a of the first members 31, 41 can be maintained in contact with the upper surfaces of the second members 32, 42, respectively, by using simple holders such as chucks 81, 82, thereby fixing the first members 31, 41 to the terminals 27, 28 of the relay 20, respectively. However, the method for manufacturing the relay unit 10 is not limited to the order in which the fixing step is performed after the arranging step. For example, after fixing the first members 31, 41 to the terminals 27, 28 of the relay 20, respectively, in the fixing step, the base member 50 to which the second members 32, 42 are fixed is prepared in the first step of the arranging step. Then, the relay 20 to which the first members 31, 41 are fixed is fixed to the base member 50 to which the second members 32, 42 are fixed. The arranging step and the fixing step may be performed in this order.

[0051] As described above, the relay unit 10 and its manufacturing method have been described. The relay unit 10 is suitable for use in applications such as establishing or breaking an electrical connection between an in-vehicle battery and an external charging device. In this case, for example, when the first pole bus bar 30 is connected to the external charging device and the second pole bus bar 40 is connected to the in-vehicle battery, and the relay 20 is closed, a charging current flows through the relay 20, the first pole bus bar 30, and the second pole bus bar 40. The flow of the charging current causes heat to be generated in the relay 20, the first pole bus bar 30, and the second pole bus bar 40.

[0052] According to the relay unit 10, the first and second pole bus bars 30 and 40 dissipate heat through the heat dissipation sheet 70 that contacts the lower surfaces of the second members 32 and 42. The first and second pole bus bars 30 and 40 are thermally connected to the first and second pole terminals 27 and 28 of the relay 20 at their first members 31 and 41. Therefore, the relay 20 dissipates heat through the first and second pole bus bars 30 and 40. The bus bars 30 and 40 are connected to the terminals 27 and 28 of the relay 20 that are prone to heat generation, so heat generated near the terminals 27 and 28 can be effectively dissipated. According to the relay unit 10, heat dissipation through the first and second pole bus bars 30 and 40 allows heat generated in the relay 20 due to the flow of charging current to be dissipated through the first and second pole bus bars 30 and 40. Therefore, a temperature rise in the relay 20 can be suppressed. Furthermore, according to the relay unit 10, by dissipating heat from the first pole bus bar 30 and the second pole bus bar 40, it is possible to prevent heat generated in the first pole bus bar 30 and the second pole bus bar 40 due to the flow of charging current from being conducted to the relay 20. As a result, it is possible to prevent a temperature rise in the relay 20.

[0053] In a situation where the temperature of the relay 20 increases over time due to the passage of a charging current, the temperature of the relay 20 reaches the upper limit of its operating temperature, and the charging current must be reduced. This increases the charging time of the power storage device. If an attempt were made to address this problem by increasing the heat resistance temperature of the relay 20, other problems would arise, such as an increase in the size and cost of the relay 20. The relay unit 10 dissipates heat from the first pole bus bar 30 and the second pole bus bar 40 using a heat dissipation mechanism, thereby suppressing the temperature rise of the relay 20 due to the passage of a charging current, and thus suppressing an increase in the size and cost of the relay 20.

[0054] According to the relay unit 10 and its manufacturing method, the first pole bus bar 30 and the second pole bus bar 40 include first members 31, 41 fixed to the terminals 27, 28 of the relay 20 by terminal fixing bolts 63, 64, and second members 32, 42 from which heat is dissipated by a heat dissipation mechanism. The first pole bus bar 30 is manufactured by joining the first member 31 and the second member 32 at a position where they intersect with each other. The second pole bus bar 40 is manufactured by joining the first member 41 and the second member 42 at a position where they intersect with each other.

[0055] According to this configuration, the first member 31 is fixed to the terminal 27 of the relay 20 in a state where the first member 31 and the second member 32 are not joined, and then the first member 31 and the second member 32 are joined, thereby achieving a state in which the first-pole bus bar 30 is fixed to the terminal 27 of the relay 20. Similarly, the first member 41 is fixed to the terminal 28 of the relay 20 in a state where the first member 41 and the second member 42 are not joined, and then the first member 41 and the second member 42 are joined, thereby achieving a state in which the second-pole bus bar 40 is fixed to the terminal 28 of the relay 20.

[0056] In cases where a heat dissipation mechanism is used to dissipate heat from a bus bar due to, for example, a large current flowing through the bus bar, a bus bar that is highly rigid and difficult to flex tends to be used. As described above, according to 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. This allows the first member 31 to move relative to the second member 32 during fixation, eliminating the need to flex 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. This allows the first member 41 to move relative to the second member 42 during fixation, eliminating the need to flex the first member 41 and the second member 42. In other words, according to the relay unit 10, stress that may occur when the first pole bus bar 30 and the second pole bus bar 40 are fixed to the terminals 27 and 28 of the relay 20 can be suppressed.

[0057] Increasing the cross-sectional area of ​​the bus bar perpendicular to the current-carrying direction to reduce electrical resistance and thermal resistance increases rigidity and makes it difficult to flex, raising concerns about difficulty in connecting the bus bar to the relay terminals. According to the relay unit 10, the first and second pole bus bars 30 and 40 can be fixed to the terminals 27 and 28 of the relay 20 without flexing, thereby increasing the cross-sectional area of ​​the first and second pole bus bars 30 and 40 perpendicular to the current-carrying direction. This more effectively suppresses temperature rise in the relay 20, thereby more effectively suppressing increases in the size and cost of the relay 20.

[0058] For example, if a series of L-shaped bus bars are forcibly bent and then fastened to relay terminals by tightening terminal fixing bolts, misalignment between the relay terminals and the bus bars can cause significant stress at the fastening points between the bus bars and the relay terminals. If the terminal fixing bolts are fastened to fasten the bus bars to the relay terminals while such stress is present, removing the fastened terminal fixing bolts can result in a relatively large gap between the fastening points of the bus bars and the relay terminals, or scratches at the fastening points of the bus bars. In contrast, the relay unit 10 allows the first members 31, 41 to move relative to the second members 32, 42 when fastening the bus bars to the terminals 27, 28 of the relay 20, thereby suppressing such stress. Therefore, removing the terminal fixing bolts 63, 64 of the relay unit 10 rarely results in a gap between the first members 31, 41 and the terminals 27, 28 of the relay 20, or scratches at the fastening points of the bus bars 30, 40.

[0059] Gaps between the first members 31, 41 and the terminals 27, 28 of the relay 20 and scratches at the fastening portions of the bus bars 30, 40 can increase the electrical resistance and thermal resistance between the first members 31, 41 and the terminals 27, 28 of the relay 20. The relay unit 10 substantially eliminates such gaps and scratches, thereby reducing the electrical resistance and thermal resistance between the first members 31, 41 and the terminals 27, 28 of the relay 20 compared to conventional cases where gaps and scratches may occur. Even if the relay unit 10 increases the electrical resistance and thermal resistance at the joints between the first members 31, 41 and the second members 32, 42, the reduction in the electrical resistance and thermal resistance between the first members 31, 41 and the terminals 27, 28 of the relay 20 is sufficiently greater than the increase in the electrical resistance and thermal resistance at the joints. This more effectively suppresses temperature rise in the relay 20, thereby more effectively suppressing increases in the size and cost of the relay 20.

[0060] Furthermore, with the relay unit 10, the first members 31, 41 can be fixed to the terminals 27, 28 of the relay 20 while allowing movement in directions parallel to the joint surfaces 31 a, 41 a of the first members 31, 41. That is, in directions parallel to the joint surfaces 31 a, 41 a of the first members 31, 41 (the x-axis direction and y-axis direction shown in FIG. 1 , etc.), stress that may be generated due to misalignment between the first members 31, 41 and the second members 32, 42 can be suppressed without relying on the conventional method of providing a margin in the size of the through holes 37, 47. With the relay unit 10, stress that may be generated when fixing the terminals 27, 28 of the relay 20 to the bus bars 30, 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, 28 of the relay 20.

[0061] The method of fixing the first members 31, 41 to the terminals 27, 28 of the relay 20 while allowing movement parallel to the joint surfaces 31a, 41a provided by the relay unit 10 may be used in conjunction with a conventional method of increasing the size of the holes used for fastening to the terminals 27, 28 of the relay 20, as shown in FIG. 8 . The through-hole 37a of the first member 31 shown in FIG. 8 is formed so that its length in the z direction is longer than its length in the x direction to allow for a certain size in the z direction. This allows the first members 31, 41 to be fixed to the terminals 27, 28 of the relay 20 while allowing for movement in directions parallel to the joint surfaces 31a, 41a (x-axis and y-axis directions) as well as movement perpendicular to the joint surfaces 31a, 41a (z-axis direction). As shown in FIG. 8 , it is preferable that the direction in which the hole size is increased is not parallel to the joint surfaces 31a, 41a. As shown in FIG. 8 , by providing through holes 37a with larger hole sizes in the z-axis direction, which is not parallel to the joining surfaces 31a and 41a, stress that may occur when fixing first members 31 and 41 to terminals 27 and 28 of relay 20, respectively, can be suppressed without increasing material costs, even if misalignment occurs in any of the x-axis direction, y-axis direction, and z-axis direction.

[0062] Furthermore, in the relay 20, the outer peripheral surface on which the terminals 27, 28 are provided is the front surface shown in Fig. 1 and the outer peripheral surface opposite to the second members 32, 42 is the bottom surface intersecting 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, the side of the second members 32, 42 opposite to the side facing the second surface 20b of the relay 20 (surface 32u side) (surface 32d side) serves as a heat dissipation surface that dissipates heat from the second members 32, 42. Because the second members 32, 42 can be disposed below the relay 20, the area of ​​the relay unit 10 shown in Fig. 1 in the x-axis direction and the y-axis direction can be prevented from increasing.

[0063] The relay unit 10 also includes a base member 50 to which the second members 32 and 42 are fixed. The relay 20 is attached to the base member 50 with the second surface 20b facing the base member 50 and the second members 32 and 42 facing 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 the protruding portions. In this configuration, the base member 50, the relay 20, and the second members 32 and 42 are fixed to one another. In the relay unit 10, the first members 31 and 41 are fixed to the terminals 27 and 28 of the relay 20 without the first members 31 and 41 and the second members 32 and 42 being joined to one another. Therefore, by adjusting the positions 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.

[0064] (Modification) Instead of the bus bars 30, 40 shown in Fig. 1 etc., a bus bar 130 as shown in Fig. 9 may be employed. The bus bar 130 is formed by joining the first member 131 and the second member 132 in a state where the first member 131 is in a leading position relative to the second member 132 and the first member 131 and the second member 132 are substantially perpendicular to each other. The welded portion 133 is formed by fillet welding the position where the first member 131 and the second member 132 are joined from the side where the relay 120 is not present (the negative side of the y-axis and the negative side of the z-axis).

[0065] Even when using bus bar 130, first member 131 and second member 132 are not joined together, and terminal fixing bolt 163 is fastened to fix first member 131 to the terminal of relay 120, and then first member 131 and second member 132 are joined together, thereby achieving a state in which bus bar 130 is fixed to the terminal of relay 120. According to the configuration of bus bar 130, first member 131 can be fixed to the terminal of relay 120 while allowing movement in the x-axis direction and z-axis direction, which are directions parallel to the joining surface of first member 131.

[0066] As shown in FIG. 10 , a large portion of the second member 232 may be disposed in a position that does not face the relay 220. In the relay unit shown in FIG. 10 , similar to FIG. 1 and the like, the second member 232 is in a leading position, and the first member 231 and the second member 232 are joined to each other in a substantially perpendicular state, thereby forming the bus bar 230. 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 is not present (the positive side of the y-axis and the positive side of the z-axis). Even when the bus bar 230 is used, the first member 231 and the second member 232 are not joined, and the first member 231 is fixed to the terminal of the relay 220 by fastening the terminal fixing bolt 263. Then, the first member 231 and the second member 232 are joined to each other, thereby achieving a state in which the bus bar 230 is fixed to the terminal of the relay 220.

[0067] 1 and the like, the configuration of bus bar 230 allows first member 231 to be fixed to the terminal of relay 220 while allowing movement in the x-axis direction and the y-axis direction, which are directions parallel to the joint surface of first member 231. Therefore, by providing through hole 237 with a margin in size in the z-axis direction as in FIG. 8, stress that may occur when first member 231 is fixed to the terminal of relay 220 in the x-axis direction, the y-axis direction, and the z-axis direction can be suppressed without increasing material costs.

[0068] 11 , second members 332 and 342 may be arranged on both sides of the relay 320 in the x-axis direction (horizontal direction), which is the direction in which the terminals of the relay 320 are arranged. As in FIG. 1 and other figures, the relay 320 is placed in the positive direction of the z-axis on a base member (not shown). The first-pole bus bar 330 includes a first member 331 and a second member 332. The second-pole bus bar 340 includes a first member 341 and a second member 342.

[0069] 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 direction of the x-axis from the fastening position of the terminal fixing bolt 363, and its end face on the positive side of the x-axis is joined to the plate surface of the second member 332 on the relay 320 side (the surface on the negative side of the x-axis). The weld 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 side of the x-axis and the negative side of the y-axis). The surface of the second member 332 that does not face the relay 320 (the surface on the positive side of the x-axis) is a heat dissipation surface, and a heat dissipation sheet 371 is provided in contact with this heat dissipation surface.

[0070] 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 position of the terminal fixing bolt 364, and its end face on the negative x-axis side is joined to the plate surface of the second member 342 on the relay 320 side (the surface on the positive x-axis). The weld 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 side and the negative y-axis side). The surface of the second member 342 that does not face the relay 320 (the surface on the negative x-axis side) is a heat dissipation surface, and a heat dissipation sheet 372 is provided in contact with this heat dissipation surface.

[0071] According to the configuration of the bus bars 330, 340, the first members 331, 341 can be fixed to the terminals of the relay 320 while allowing movement in the y-axis and z-axis directions, which are directions parallel to the joint surfaces of the first members 331, 341. For this reason, the first members 331, 341 are preferably provided with through holes that have a sizable margin in the x-axis direction as through holes through which the terminal fixing bolts 363, 364 are inserted. This makes it possible to suppress stress that may occur when fixing the first members 331, 341 to the terminals of the relay 320 in the x-axis, y-axis, and z-axis directions, respectively, without increasing material costs.

[0072] As explained using Figures 1, 8, and 11, when the method provided by relay unit 10 or the like (a method in which the first member is fixed to the terminals of the relay while allowing movement in a direction parallel to the joint surface between the first member and the second member) is used in combination with the conventional method as shown in Figure 8 (a method in which the size of the hole for fastening to the relay terminal is provided with a margin), it is preferable that the direction in which the size of the through hole provided in the first member for fastening to the relay terminal is provided with a margin is a direction non-parallel to the joint surface between the first member and the second member.

[0073] In the above embodiments, the electrical device is the relay 20 and the electrical apparatus is a relay unit, but this is not a limitation. The electrical device may be any device configured to allow a bus bar to be fixed to a terminal on its outer circumferential surface using a fastener. The above-described configuration of the electrical apparatus according to the present application is particularly suitable for use in electrical devices used in applications where a large current flows and where heat generation due to the large current is a concern. For example, the electrical apparatus may include a charger / discharger, a power converter, or the like. In the above embodiments, the fastener is a bolt, but this is not a limitation. The fastener may be a screw-like member other than a bolt, or a pin-like member without a thread.

[0074] Characteristic configurations extracted from the above-described embodiments are described below. [Configuration 1] An electric device (10) comprising an electric device (20, 120, 220, 320) and a bus bar (30, 40, 130, 230, 330, 340) connected to a terminal of the electric device, wherein the bus bar comprises: a plate-shaped first member (31, 41, 131, 231, 331, 341) fixed by a fastener to the terminal provided on the outer peripheral surface of the electric device; and a plate-shaped second member (32, 42, 132, 232, 332, 342) extending in a direction intersecting the first member and dissipating heat by a heat dissipation mechanism, wherein the first member and the second member are joined at a position where they intersect with each other. [Configuration 2] The electric device according to Configuration 1, wherein a joint portion where the first member and the second member are joined to each other is located in a position that does not face the electric device. [Configuration 3] The electric device of Configuration 1 or 2, wherein the joint portion where the first member and the second member are joined to each other is located at a position that does not reach the heat dissipation surface, which is the surface of the second member that faces the heat dissipation mechanism. [Configuration 4] The electric device of any of Configurations 1 to 3, wherein the joint portion where the first member and the second member are joined to each other is a state in which an end face of the first member and a plate surface of the second member are joined to each other, and an end of the second member on the joint portion side protrudes from the plate surface of the first member. [Configuration 5] The electric device of any of Configurations 1 to 4, wherein the outer peripheral surface on which the terminals are provided of the electric device is a first surface, the second member is disposed opposite a second surface of the electric device that intersects with the first surface, and the side of the second member opposite the side facing the second surface of the electric device is a heat dissipation surface that allows heat to be dissipated from the second member. [Configuration 6] An electric device according to any one of configurations 1 to 5, further comprising a holding member to which the second member is fixed, wherein the outer peripheral surface of the electric device on which the terminals are provided is a first surface, the electric device is attached to the holding member with a second surface intersecting the first surface facing the holding member, and the second member is disposed opposite the second surface, and the second member protrudes from the holding member toward the first surface, and the first member is joined to the protruding portion.[Configuration 7] A manufacturing method for an electric device (10) including an electric device (20, 120, 220, 320) and a bus bar (30, 40, 130, 230, 330, 340) connected to a terminal of the electric device, wherein the bus bar includes a plate-shaped first member (31, 41, 131, 231, 331, 341) and a plate-shaped second member (32, 42, 132, 232, 332, 342), the manufacturing method for the electric device including: an arrangement step of arranging the first member and the second member at a position where they intersect with each other; a fixing step of fixing the first member to the terminal provided on the outer peripheral surface of the electric device with a fixing device; and a joining step of joining the first member and the second member at the position where they intersect with each other after the fixing step. [Configuration 8] The method for manufacturing an electric device according to Configuration 7, wherein the disposing step includes: a first step of preparing a holding member to which the second member is fixed; and a second step of fixing the electric device to the holding member to which the second member is fixed. [Configuration 9] The method for manufacturing an electric device according to Configuration 8, wherein the second member is fixed to the holding member with a portion on which the first member is to be disposed protruding from the holding member. [Configuration 10] The method for manufacturing an electric device according to any one of Configurations 7 to 9, wherein in the fixing step, the first member is fixed to the terminal of the electric device while being held so as to contact the second member at a position where the first member intersects with the second member. [Configuration 11] The method for manufacturing an electric 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 sides of the first member and the second member that do not face the electric device. [Configuration 12] The method for manufacturing an electric device according to any one of Configurations 7 to 11, further including, after the joining step, a step of installing a heat dissipation mechanism that dissipates heat from the second member.

[0075] Although the present disclosure has been described with reference to the embodiments, it is understood that the present disclosure is not limited to the embodiments or structures. The present disclosure also encompasses various modifications and equivalent modifications. In addition, various combinations and forms, including only one element, more than one element, or less than one element, are also within the scope and spirit of the present disclosure.

Claims

1. An electric device (10) comprising an electric device (20, 120, 220, 320) and a bus bar (30, 40, 130, 230, 330, 340) connected to a terminal of the electric device, wherein the bus bar comprises: a plate-shaped first member (31, 41, 131, 231, 331, 341) fixed by a fastener to the terminal provided on the outer peripheral surface of the electric device; and a plate-shaped second member (32, 42, 132, 232, 332, 342) extending in a direction intersecting the first member and from which heat is dissipated by a heat dissipation mechanism, wherein the first member and the second member are joined at a position where they intersect each other.

2. The electric device according to claim 1, wherein the joint portion where the first member and the second member are joined together is provided at a position that does not face the electric device.

3. An electrical device as described in claim 1 or 2, wherein the joint portion where the first member and the second member are joined to each other is provided at a position that does not reach the heat dissipation surface, which is the surface of the second member facing the heat dissipation mechanism.

4. An electrical device as described in claim 1 or 2, wherein the joint portion where the first member and the second member are joined together is a state in which an end face of the first member and a plate surface of the second member are joined together, and an end portion of the second member on the joint portion side protrudes beyond the plate surface of the first member.

5. An electrical device as described in claim 1 or 2, wherein the outer peripheral surface on which the terminals are provided in the electrical device is a first surface, the second member is disposed opposite a second surface of the electrical device which intersects with the first surface, and the side of the second member opposite to the side facing the second surface of the electrical device is a heat dissipation surface which dissipates heat from the second member.

6. An electrical device as described in claim 1 or 2, further comprising a retaining member to which the second member is fixed, wherein the outer peripheral surface of the electrical device on which the terminals are provided is a first surface, the electrical device is attached to the retaining member with a second surface that intersects with the first surface facing the retaining member, and the second member is disposed opposite the second surface, and the second member protrudes from the retaining member towards the first surface, and the first member is joined to the protruding portion.

7. A method for manufacturing an electric device (10) comprising an electric device (20, 120, 220, 320) and a bus bar (30, 40, 130, 230, 330, 340) connected to a terminal of the electric device, wherein the bus bar comprises a plate-shaped first member (31, 41, 131, 231, 331, 341) and a plate-shaped second member (32, 42, 132, 232, 332, 342), the method including: an arrangement step of arranging the first member and the second member at a position where they intersect with each other; a fixing step of fixing the first member to the terminal provided on the outer peripheral surface of the electric device with a fixing device; and a joining step of joining the first member and the second member at the position where they intersect with each other after the fixing step.

8. A method for manufacturing an electrical device as described in claim 7, wherein the positioning step includes a first step of preparing a holding member to which the second member is fixed, and a second step of fixing the electrical equipment to the holding member to which the second member is fixed.

9. A method for manufacturing an electric device as set forth in claim 8, wherein said second member is fixed to said holding member in a state where a portion on which said first member is disposed projects from said holding member.

10. A method for manufacturing an electrical device as described in claim 7 or 8, wherein in the fixing step, the first member is fixed to the terminal of the electrical equipment while being held in contact with the second member at a position intersecting the second member.

11. A method for manufacturing an electrical device as described in claim 7 or 8, wherein in the joining step, the position where the first member and the second member intersect are welded from the side of the first member and the second member that does not face the electrical equipment.

12. The method for manufacturing an electric device according to claim 7 or 8, further comprising the step of providing a heat dissipation mechanism for dissipating heat from said second member after said joining step.

Images