Method for manufacturing electrical connection unit, and metal component

Abstract

This method for manufacturing an electrical connection unit includes: forming an assembly in which a connection object component and a metal component are integrated by fixing the metal component to the connection object component by using a first fastening member; and electrically connecting the connection object component and a bus bar by fixing the metal component included in the assembly to the bus bar by using a second fastening member after forming the assembly.

Description

Electrical connection unit manufacturing method and metal part

[0001]

[0001] This application claims priority to Japanese Patent Application No. 2024-062275, filed on April 8, 2024, the contents of which are incorporated herein by reference.

[0002] 2. Description of the Related Art An electrical connection unit including an electronic component and a bus bar connected to the electronic component is used as one type of in-vehicle device.

[0003] International Publication No. 2021 / 059767 Japanese Patent Application Laid-Open No. 2018-093711

[0004] It is expected that the assembly of the electrical connection unit will be improved.

[0005] One embodiment provides a method for manufacturing an electrical connection unit and a metal part that can improve assembly efficiency.

[0006] In one embodiment, a method for manufacturing an electrical connection unit includes using a first fastening member to fasten a metal component to a component to be connected to form an assembly in which the component to be connected and the metal component are integrated, and after forming the assembly, using a second fastening member to fasten the metal component included in the assembly to a bus bar, thereby electrically connecting the component to be connected to the bus bar.

[0007] In one embodiment, the metal component is a metal component used in an electrical connection unit. The metal component has a first portion and a second portion. The first portion is fixed to an electronic component using a first fastening member. The second portion is fixed to a bus bar using a second fastening member after the electronic component and the metal component are integrated using the first fastening member. The metal component electrically connects the electronic component and the bus bar. The width of the metal component in the longitudinal direction of the electronic component is smaller than the width of the electronic component in the longitudinal direction.

[0008] According to one embodiment, the assembly of the electrical connection unit can be improved.

[0009] 1 is a cross-sectional view showing an electrical connection unit of a first embodiment; a perspective view showing a portion of the electrical connection unit of the first embodiment; an exploded perspective view showing a portion of the electrical connection unit of the first embodiment; a plan view showing a first electronic component and a metal component of the first embodiment; a cross-sectional view for explaining a method of manufacturing the electrical connection unit of the first embodiment; a cross-sectional view for explaining a method of manufacturing the electrical connection unit of the first embodiment; a cross-sectional view for explaining a method of manufacturing the electrical connection unit of the first embodiment; a cross-sectional view for explaining the operation of the electrical connection unit of the first embodiment; a cross-sectional view showing an electrical connection unit of a first modified example of the first embodiment; a cross-sectional view showing an electrical connection unit of a second modified example of the first embodiment; a cross-sectional view showing an electrical connection unit of a third modified example of the first embodiment; a perspective view showing a portion of the electrical connection unit of a third modified example of the first embodiment; a cross-sectional view showing a portion of the electrical connection unit of a second embodiment; a perspective view showing a portion of the electrical connection unit of the second embodiment; a cross-sectional view for explaining a method of manufacturing the electrical connection unit of the second embodiment; a cross-sectional view for explaining a method of manufacturing the electrical connection unit of the second embodiment; a cross-sectional view for explaining a method of manufacturing the electrical connection unit of the second embodiment; a perspective view showing a portion of the electrical connection unit of a third embodiment.

[0010] Hereinafter, embodiments will be described with reference to the drawings. In the following description, components having the same or similar functions will be assigned the same reference numerals. Duplicate descriptions of these components may be omitted. In this disclosure, terms are defined as follows: "Connection" is not limited to mechanical connection, but may also include electrical connection. That is, "connection" is not limited to a direct connection between two elements to be connected, but may also include a connection between two elements to be connected via another element interposed therebetween. "Parallel," "orthogonal," or "same" may include the cases of "substantially parallel," "substantially orthogonal," or "substantially the same," respectively.

[0011] In the present disclosure, the +X direction, the −X direction, the +Y direction, the −Y direction, the +Z direction, and the −Z direction are defined as follows: The +X direction is the direction from the first electronic component 20 described later toward the first metal component 60 (see FIG. 1). The −X direction is the direction opposite to the +X direction. Hereinafter, when the +X direction and the −X direction are not distinguished, they will simply be referred to as the “X direction.” The +Y direction is the direction from the first terminal portion 23A toward the second terminal portion 23B of the first electronic component 20 (see FIG. 3). The −Y direction is the direction opposite to the +Y direction. Hereinafter, when the +Y direction and the −Y direction are not distinguished, they will simply be referred to as the “Y direction.” The +Z direction is the direction from the base member 11 described later toward the bus bar 40 (see FIG. 1). The −Z direction is the direction opposite to the +Z direction. Hereinafter, when the +Z direction and the −Z direction are not distinguished, they will simply be referred to as the “Z direction.”

[0012] First Embodiment First, a first embodiment will be described. In the first embodiment, the X direction is an example of a "first direction," and the Z direction is an example of a "second direction."

[0013] <A1. Configuration of Electrical Connection Unit> Fig. 1 is a cross-sectional view showing an electrical connection unit 1 according to a first embodiment. The electrical connection unit 1 is used in vehicles such as electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (PHEVs). The electrical connection unit 1 is a component known as an electrical connection box or junction box, for example.

[0014] 1 is a cross-sectional view showing an electrical connection unit 1. The electrical connection unit 1 includes, for example, a housing 10, a plurality of electronic components 20 and 30, a plurality of bus bars 40 (only one of which is shown in FIG. 1 ), and a plurality of metal components 60 and 70.

[0015] <A1.1 Housing> The housing 10 is an outer shell member that forms the outer shape of the electrical connection unit 1. The housing 10 houses a plurality of electronic components 20, 30, a plurality of bus bars 40, and a plurality of metal components 60, 70. The housing 10 has, for example, a base member 11 and a cover member 12.

[0016] The base member 11 is, for example, a member that forms the bottom of the housing 10. The base member 11 is made of, for example, synthetic resin and has insulating properties. The base member 11 has a support surface 11a that is exposed inside the housing 10. At least a portion of the support surface 11a has, for example, a flat surface 11s that extends along the X direction and the Y direction.

[0017] In the present embodiment, a plurality of fastening members 51 (e.g., screws) are fixed to the base member 11. For example, the fastening members 51 are fixed to the base member 11 by being insert molded into the base member 11. For example, the heads of the fastening members 51 are embedded in the base member 11. The shanks of the fastening members 51 protrude in the +Z direction from the plane 11s of the base member 11 and extend in the +Z direction. The shanks of the fastening members 51 have threads. Note that the fastening members 51 may be fixed to the base member 11 by means other than insert molding. In the present embodiment, a plurality of bus bars 40, which will be described later, are fixed to the base member 11. The base member 11 is an example of a "support body."

[0018] The cover member 12 is, for example, a member that forms a lid portion of the housing 10. In this embodiment, the housing 10 is formed by combining the base member 11 and the cover member 12. The cover member 12 is made of, for example, a synthetic resin and has insulating properties. The bus bar 40 may be fixed to the cover member 12 instead of the base member 11. The cover member 12 is another example of a "support body."

[0019] <A1.2 Electronic Components> The multiple electronic components 20, 30 are electronic components mounted on the electrical connection unit 1 according to the functions or applications required. The electronic components 20, 30 are, for example, connectors, fuses, relays (e.g., mechanical relays or semiconductor relays), capacitors, branching components, electronic control units, or electronic component units that combine two or more of these. Note that the types of electronic components 20, 30 are not limited to the above examples. The electronic components 20 and 30 may be the same type of component or different types of components. The electronic components 20, 30 are, for example, heat-generating components that generate heat when power is applied.

[0020] For ease of explanation, the electronic component 20 may be referred to as the "first electronic component 20" below. The electronic component 30 may be referred to as the "second electronic component 30" below. Note that the electrical connection unit 1 may have only one electronic component (for example, only one of the electronic components 20 and 30) instead of having multiple electronic components 20 and 30. The first electronic component 20 is an example of a "component to be connected." The second electronic component 30 is another example of a "component to be connected."

[0021] <A1.2.1 First Electronic Component> The first electronic component 20 has, for example, a case 21, a main body 22, a plurality of terminals 23 (see FIG. 3), and a plurality of attachment portions 24 (see FIG. 4).

[0022] (Case) The case 21 is an outer casing member that forms most of the outer shape of the first electronic component 20. The case 21 is made of, for example, synthetic resin and has insulating properties. The case 21 houses the main body 22. Note that the case 21 and the main body 22 may be formed integrally.

[0023] (Main body) The main body 22 is a part that performs the main function of the first electronic component 20. For example, if the first electronic component 20 is a relay, the main body 22 includes a switching part (e.g., a contact part) that switches between a conductive state and a non-conductive state. For example, if the first electronic component 20 is a fuse, the main body 22 includes a fusing part that melts when an overcurrent flows. For example, if the first electronic component 20 is a capacitor, the main body 22 includes a part that stores electric charge.

[0024] (Terminal Portion) The terminal portion 23 is an electrical connection portion exposed to the outside of the case 21. The terminal portion 23 is electrically connected to the main body portion 22 inside the case 21. In this embodiment, the first electronic component 20 includes a first terminal portion 23A and a second terminal portion 23B as the multiple terminal portions 23 (see FIG. 3). One of the first terminal portion 23A and the second terminal portion 23B is a positive terminal portion. The other of the first terminal portion 23A and the second terminal portion 23B is a negative terminal portion. The terminal portions 23 are arranged at a position away from the support surface 11a of the base member 11.

[0025] In this embodiment, the first terminal portion 23A and the second terminal portion 23B are provided at the end portion of the first electronic component 20 on the +X direction side. The first terminal portion 23A and the second terminal portion 23B are arranged side by side in the Y direction (see FIG. 3 ). Hereinafter, when there is no need to distinguish between the first terminal portion 23A and the second terminal portion 23B, they will simply be referred to as "terminal portion 23." The terminal portion 23 has a mounting hole 23h to which a first fastening member 81 (e.g., a screw) described below is attached. The mounting hole 23h opens in the X direction. For example, the mounting hole 23h has a threaded groove on its inner circumferential surface. The terminal portion 23 may also be referred to as a "fastening portion."

[0026] (Mounting Portion) The mounting portion 24 is a portion for fixing the first electronic component 20. For example, the mounting portion 24 is a portion for fixing the first electronic component 20 to the base member 11. In this embodiment, the first electronic component 20 includes a first mounting portion 24A and a second mounting portion 24B as the multiple mounting portions 24 (see FIG. 4). The first mounting portion 24A and the second mounting portion 24B are arranged separately on both sides of the case 21 in the Y direction. For example, the first mounting portion 24A protrudes from the case 21 in the −Y direction. The second mounting portion 24B protrudes from the case 21 in the +Y direction.

[0027] Hereinafter, when there is no need to distinguish between the first mounting portion 24A and the second mounting portion 24B, they will be simply referred to as the "mounting portion 24." The mounting portion 24 has a mounting hole 24h to which a fastening member 29 (e.g., a screw) is attached. The mounting hole 24h opens in the Z direction. The mounting hole 24h is an insertion hole through which the fastening member 29 is passed. In this embodiment, the base member 11 has a mounting hole 11h at a position corresponding to the mounting hole 24h. The mounting hole 11h opens in the Z direction. For example, the mounting hole 11h has a threaded groove on its inner circumferential surface. In this embodiment, the fastening member 29 passed through the mounting hole 24h of the mounting portion 24 engages with the mounting hole 11h, thereby fixing the first electronic component 20 to the base member 11. Note that the mounting hole 11h may be a mounting hole provided directly in the base member 11, or may be a mounting hole provided in an engaging member (e.g., a nut) embedded in the base member 11 by, for example, insert molding or other means.

[0028] <A1.2.2 Second Electronic Component> The second electronic component 30 has, for example, a case 31, a main body 32, a plurality of terminals 33, and a plurality of mounting portions 34. The details of the second electronic component 30 are similar to those of, for example, the first electronic component 20. Therefore, in the description of the second electronic component 30, the terms "first electronic component 20," "case 21," "main body 22," "terminals 23," "mounting holes 23h," "mounting portions 24," "mounting holes 24h," "fastening members 29," and "+X direction" in the above description of the first electronic component 20 can be read as "second electronic component 30," "case 31," "main body 32," "terminals 33," "mounting holes 33h," "mounting portions 34," "mounting holes 34h," "fastening members 39," and "-X direction," respectively.

[0029] <A1.3 Bus Bar> The bus bar 40 is a connection member included in the electrical connection unit 1. The bus bar 40 is, for example, a connection member that electrically connects multiple electronic components. Alternatively, the bus bar 40 may be a connection member that connects a single electronic component to the outside of the electrical connection unit 1.

[0030] At least a portion of the busbar 40 is plate-shaped. In this embodiment, the busbar 40 is plate-shaped throughout the entire busbar 40. The busbar 40 is arranged along the base member 11. The busbar 40 has a planar plate surface 40s. The plate surface 40s of the busbar 40 is parallel to the plane 11s of the base member 11 over the entire length of the busbar 40. The busbar 40 is fixed to the base member 11, for example. The busbar 40 has a plate thickness T3. The plate thickness T3 is the thickness of the busbar 40 in the Z direction. The busbar 40 is an example of a "first busbar."

[0031] Here, an example of the bus bar 40 will be described in detail, focusing on a bus bar 40 that electrically connects the first electronic component 20 and the second electronic component 30. The bus bar 40 has, for example, a first connection portion 41, a second connection portion 42, and an extension portion 43. In this embodiment, the first connection portion 41, the second connection portion 42, and the extension portion 43 are each plate-shaped and extend along the X and Y directions.

[0032] (First Connection Portion) The first connection portion 41 is a portion that is electrically connected to the first electronic component 20. The first connection portion 41 is provided at one end of the bus bar 40. The first connection portion 41 has a mounting hole 41h through which a second fastening member 82 (e.g., a screw) is passed. The mounting hole 41h is open in the Z direction. In this embodiment, the first connection portion 41 is disposed away from the terminal portion 23 of the first electronic component 20. For example, the first connection portion 41 is disposed along the base member 11.

[0033] (Second Connection Portion) The second connection portion 42 is a portion that is electrically connected to the second electronic component 30. The second connection portion 42 is provided at the other end of the bus bar 40. The second connection portion 42 has a mounting hole 42h through which a fastening member 92 (e.g., a screw) is passed. The mounting hole 42h is open in the Z direction. In this embodiment, the second connection portion 42 is disposed away from the terminal portion 33 of the second electronic component 30. For example, the second connection portion 42 is disposed along the base member 11.

[0034] (Extension Portion) The extension portion 43 is provided between the first connection portion 41 and the second connection portion 42. The extension portion 43 extends, for example, in the X direction along the base member 11 and connects the first connection portion 41 and the second connection portion 42. In the present embodiment, the extension portion 43 has an attachment hole 43h through which a fastening member 51 is passed. The bus bar 40 is placed on the flat surface 11s of the base member 11 with the shaft portion of the fastening member 51 passing through the attachment hole 43h. Then, with the shaft portion of the fastening member 51 passing through the attachment hole 43h, an engaging member 52 (e.g., a nut) is attached to the shaft portion of the fastening member 51 from the +Z direction side, thereby fixing the bus bar 40 to the base member 11.

[0035] <A1.4 Metal Components> The multiple metal components 60, 70 are heat storage members (heat absorption members) that increase the heat capacity of the current paths of the electrical connection unit 1. The multiple metal components 60, 70 store (absorb) at least a portion of the heat generated by the electronic components 20, 30, for example. Alternatively or in addition to this, the multiple metal components 60, 70 may store (absorb) at least a portion of the heat generated by the bus bar 40 when current is applied. Each of the metal components 60, 70 may be referred to as a "heat storage component" or a "heat absorption component."

[0036] For ease of explanation, the metal component 60 may be referred to as the "first metal component 60" below. The metal component 70 may be referred to as the "second metal component 70" below. Note that instead of having a plurality of metal components 60, 70, the electrical connection unit 1 may have only one metal component (for example, only one of the metal components 60, 70).

[0037] <A1.4.1 First Metal Component> The first metal component 60 is disposed between the first electronic component 20 and the bus bar 40. Note that in this disclosure, "the metal component is disposed between the electronic component and the bus bar" is not limited to the case where a portion of the metal component is located between the electronic component and the bus bar when viewed in the X direction or Y direction. "The metal component is disposed between the electronic component and the bus bar" may also apply to the case where a portion of the metal component is located between the electronic component and the bus bar when viewed in a direction tilted with respect to the X direction or Y direction. The first metal component 60 electrically connects the terminal portion 23 of the first electronic component 20 and the first connection portion 41 of the bus bar 40. The first metal component 60 has, for example, a first portion 61 and a second portion 62.

[0038] (First portion) The first portion 61 is a portion connected to the terminal portion 23 of the first electronic component 20. The first portion 61 is a relatively thick plate portion along the Y direction and the Z direction. The first portion 61 extends in the Z direction along the end of the first electronic component 20 on the +X direction side. The first portion 61 is in an upright position relative to the support surface 11a (e.g., the plane 11s) of the base member 11.

[0039] The first portion 61 is adjacent to the first electronic component 20 in the X direction. For example, the first portion 61 is adjacent to at least a part of the main body 22 of the first electronic component 20 in the X direction. The first portion 61 faces the terminal portion 23 of the first electronic component 20 from the +X direction side. The first portion 61 is connected to the terminal portion 23 of the first electronic component 20 from the X direction.

[0040] In this embodiment, the first portion 61 has a first mounting hole 61h through which a first fastening member 81 (e.g., a screw) is passed. The first mounting hole 61h is open in the X direction. The first portion 61 also has a recess 65 on the +X direction side of the first mounting hole 61h. The recess 65 is a receiving portion that receives the head of the first fastening member 81 inserted into the first mounting hole 61h. The first fastening member 81 passed through the first mounting hole 61h engages with the mounting hole 23h of the terminal portion 23 of the first electronic component 20, thereby physically and electrically connecting the first portion 61 to the terminal portion 23 of the first electronic component 20.

[0041] (Second Part) The second part 62 is a part that is connected to the first connection part 41 of the bus bar 40. The second part 62 protrudes in the +X direction from the end of the first part 61 on the -Z direction side. The second part 62 is a plate part that extends along the X direction and the Y direction. The second part 62 extends in the X direction along the first connection part 41 of the bus bar 40. In this embodiment, the first part 61 and the second part 62 form an L-shaped, single piece first metal component 60.

[0042] The second portion 62 is adjacent to the first connection portion 41 of the bus bar 40 in the Z direction. The first portion 61 faces the first connection portion 41 of the bus bar 40 from the +Z direction side. The second portion 62 is connected to the first connection portion 41 of the bus bar 40 from the Z direction.

[0043] In the present embodiment, the second portion 62 has a second mounting hole 62h through which a second fastening member 82 (e.g., a screw) is passed. The second mounting hole 62h is open in the Z direction. The second fastening member 82 passed through the second mounting hole 62h engages with the mounting hole 41h of the first connecting portion 41 of the bus bar 40, thereby physically and electrically connecting the second portion 62 to the first connecting portion 41 of the bus bar 40.

[0044] (Shape of First Metal Component) In the present embodiment, the thickness of at least a portion of the first metal component 60 is greater than the thickness T3 of the bus bar 40. For example, the thickness T1 in the X direction of at least a portion of the first metal component 60 is greater than the thickness T3 of the bus bar 40. In the present embodiment, the thickness T1 in the X direction of the first portion 61 of the first metal component 60 is greater than the thickness T3 of the bus bar 40. In the present embodiment, the first portion 61 has a thickness T1 in the X direction that is greater than the thickness T3 of the bus bar 40 across the entire width of the first portion 61 in the Z direction. From another perspective, the thickness T2 in the Z direction of the second portion 62 of the first metal component 60 may be greater than the thickness T3 of the bus bar 40.

[0045] In this embodiment, the thickness T1 in the X direction of the first portion 61 of the first metal component 60 is greater than the thickness T2 in the Z direction of the second portion 62 of the first metal component 60. In this embodiment, the first portion 61 has a thickness T1 across the entire width of the first portion 61 in the Z direction that is greater than the thickness T2 of the second portion 62.

[0046] In this embodiment, the longitudinal direction of the first electronic component 20 is the X direction. The width WA2 of the first metal component 60 in the X direction is smaller than, for example, the width WA1 of the first electronic component 20 in the X direction. Note that when the longitudinal direction of the first electronic component 20 is the Y direction, the width of the first metal component 60 in the Y direction is smaller than, for example, the width of the first electronic component 20 in the Y direction.

[0047] (Example of arrangement of first metal components) Fig. 2 is a perspective view showing a portion of the electrical connection unit 1. Fig. 3 is a perspective view showing a portion of the electrical connection unit 1 in an exploded state. In this embodiment, the electrical connection unit 1 has metal components 60A and 60B as the plurality of first metal components 60. Metal components 60A and 60B have, for example, the same shape.

[0048] The metal component 60A is disposed in correspondence with the half of the first electronic component 20 on the −Y direction side. The metal component 60A is adjacent to the terminal portion 23A of the first electronic component 20 in the X direction and is connected to the terminal portion 23A of the first electronic component 20 in the X direction. On the other hand, the metal component 60B is disposed in correspondence with the half of the first electronic component 20 on the +Y direction side. The metal component 60B is adjacent to the terminal portion 23B of the first electronic component 20 in the X direction and is connected to the terminal portion 23B of the first electronic component 20 in the X direction.

[0049] In this embodiment, the case 21 has an insulating wall 21a that protrudes in the +X direction (see FIG. 2 ). The insulating wall 21a is provided in the center of the case 21 in the Y direction. The insulating wall 21a extends along the X and Y directions. For example, the insulating wall 21a extends over the entire height of the case 21 in the Z direction. The insulating wall 21a is disposed between the first terminal 23A and the second terminal 23B. The insulating wall 21a electrically insulates the first terminal 23A from the second terminal 23B. In this embodiment, the insulating wall 21a is disposed between the first portion 61 of the metal component 60A and the first portion 61 of the metal component 60B. The insulating wall 21a electrically insulates the first portion 61 of the metal component 60A from the first portion 61 of the metal component 60B.

[0050] 4 is a plan view showing the first electronic component 20 and the metal components 60A and 60B. In this embodiment, the case 21 of the first electronic component 20 has an end 21e1 in the −Y direction and an end 21e2 in the +Y direction.

[0051] A portion of the metal component 60A protrudes in the −Y direction beyond the end 21e1 of the case 21 of the first electronic component 20. When viewed in the X direction, the portion of the metal component 60A protrudes to an area that does not overlap with the first electronic component 20. This increases the heat capacity of the metal component 60A.

[0052] Similarly, a portion of the metal component 60B protrudes in the +Y direction beyond the end 21e2 of the case 21 of the first electronic component 20. When viewed in the X direction, the portion of the metal component 60B protrudes to an area that does not overlap with the first electronic component 20. This increases the heat capacity of the metal component 60B.

[0053] <A1.4.2 Second Metal Component> Next, returning to Fig. 1 , the second metal component 70 will be described. The second metal component 70 is disposed between the second electronic component 30 and the bus bar 40. The second metal component 70 electrically connects the terminal portion 33 of the second electronic component 30 and the second connection portion 42 of the bus bar 40. The second metal component 70 has, for example, a first portion 71 and a second portion 72.

[0054] The details of the second metal component 70 are similar to those of the first metal component 60, for example. Therefore, in the description of the second metal component 70, the terms "first portion 61," "first mounting hole 61h," "second portion 62," "second mounting hole 62h," "first electronic component 20," "main body 22," "terminal portion 23," "mounting hole 23h," "first fastening member 81," "second fastening member 82," "first connecting portion 41," "mounting hole 41h," and "+X direction" in the description of the first metal component 60 described above can be read as "first portion 71," "first mounting hole 71h," "second portion 72," "second mounting hole 72h," "second electronic component 30," "main body 32," "terminal portion 33," "mounting hole 33h," "first fastening member 91," "second fastening member 92," "second connecting portion 42," "mounting hole 42h," and "-X direction," respectively.

[0055] In this embodiment, the longitudinal direction of the second electronic component 30 is the X direction. The width WB2 of the second metal component 70 in the X direction is smaller than, for example, the width WB1 of the second electronic component 30 in the X direction. Note that when the longitudinal direction of the second electronic component 30 is the Y direction, the width of the second metal component 70 in the Y direction is smaller than, for example, the width of the second electronic component 30 in the Y direction.

[0056] <A2. Manufacturing Method of Electrical Connection Unit> Next, a description will be given of a manufacturing method of the electrical connection unit 1. Figures 5 to 7 are cross-sectional views for explaining the manufacturing method of the electrical connection unit 1.

[0057] 5 shows the first step. In the first step, the first metal component 60 is fixed to the terminal portion 23 of the first electronic component 20 using a fastening member 81. This forms a first assembly SA in which the first electronic component 20 and the first metal component 60 are integrated together.

[0058] The first step is performed, for example, as follows. First, the first electronic component 20 is placed on the mounting table MP with the mounting holes 23h of the terminal portions 23 of the first electronic component 20 facing vertically. Next, the first metal component 60 is placed on the first electronic component 20 with the first mounting holes 61h of the first metal component 60 facing vertically. Then, the first mounting holes 61h of the first metal component 60 are aligned with the mounting holes 23h of the terminal portions 23 of the first electronic component 20. The first step is performed with the first electronic component 20 and the first metal component 60 in a first position. The first position is a position in which the mounting holes 23h and the first mounting holes 61h are facing vertically.

[0059] Next, the fastening member 81 is inserted vertically into the first mounting hole 61h of the first metal component 60. Then, the fastening member 81 that has passed through the mounting hole 61h of the first metal component 60 engages with the mounting hole 23h of the terminal portion 23 of the first electronic component 20. This forms a first assembly SA in which the first electronic component 20 and the first metal component 60 are integrated together. The vertical direction is an example of a "first mounting direction."

[0060] Similarly, the second metal component 70 is fixed to the terminal portion 33 of the second electronic component 30 using the fastening member 91. This forms a second assembly SB in which the second electronic component 30 and the second metal component 70 are integrated together.

[0061] 6 shows the second step. In the second step, the bus bar 40 is fixed to the base member 11. This step may be performed before the first step, after the first step, or in parallel with the first step.

[0062] The second step is performed, for example, as follows. As described above, the fastening members 51 are first fixed to, for example, the base member 11. The fastening members 51 protrude in the vertical direction. Then, the bus bar 40 is placed on the base member 11 by inserting the fastening members 51 vertically into the mounting holes 43h of the bus bar 40. Next, the engaging members 52 (for example, nuts) are engaged with the upper ends of the fastening members 51 from the vertical direction. This fixes the bus bar 40 to the base member 11. In this embodiment, the bus bar 40 is fixed to the base member 11 before the electronic components 20 and 30 are fixed to the base member 11.

[0063] (Third Step) Fig. 7 shows the third step. The third step is performed after the first and second steps. In the third step, the first assembly SA is fixed to the first connection portion 41 of the bus bar 40 using the second fastening member 82. For example, the first metal component 60 included in the first assembly SA is fixed to the first connection portion 41 of the bus bar 40 using the second fastening member 82. This electrically connects the first electronic component 20 and the bus bar 40.

[0064] The third step is performed, for example, as follows: First, the posture of the first assembly SA is rotated 90 degrees from that in the first step. That is, the posture is changed from a first posture (see FIG. 5 ) in which the mounting holes 23 h and the first mounting holes 61 h are oriented vertically to a second posture (see FIG. 7 ) in which the mounting holes 23 h and the first mounting holes 61 h are oriented horizontally and the second mounting holes 62 h of the first metal component 60 are oriented vertically.

[0065] Then, in the second posture, the second portion 62 of the first metal component 60 is placed on the first connection portion 41 of the bus bar 40. Then, the second mounting hole 62h of the first metal component 60 and the mounting hole 41h of the first connection portion 41 of the bus bar 40 are aligned.

[0066] Next, the second fastening member 82 is inserted vertically into the second mounting hole 62h of the first metal component 60. Then, the second fastening member 82 that has passed through the second mounting hole 62h of the first metal component 60 engages with the mounting hole 41h of the first connection portion 41 of the bus bar 40. This fixes the first metal component 60 to the first connection portion 41 of the bus bar 40. That is, the first assembly SA is fixed to the first connection portion 41 of the bus bar 40. This electrically connects the first electronic component 20 and the first connection portion 41 of the bus bar 40. In this embodiment, the direction in which the bus bar 40 is fixed to the base member 11 and the direction in which the first assembly SA is fixed to the bus bar 40 coincide with each other.

[0067] Furthermore, in the third step, the mounting portion 24 of the first electronic component 20 may be fixed to the base member 11 using fastening members 29. This operation is performed, for example, as follows. First, the mounting holes 24h of the mounting portions 24 of the first electronic component 20 are aligned with the mounting holes 11h of the base member 11. Next, the fastening members 29 are inserted vertically into the mounting holes 24h of the first electronic component 20. Then, the fastening members 29 that have passed through the mounting holes 24h of the first electronic component 20 engage with the mounting holes 11h of the base member 11. This fixes the first electronic component 20 to the base member 11. Note that the operation of fixing the first electronic component 20 to the base member 11 using the fastening members 29 may be performed before or after the operation of fixing the first metal component 60 to the bus bar 40 using the second fastening members 82. In this embodiment, the direction in which the bus bar 40 is fixed to the base member 11, the direction in which the first assembly SA is fixed to the bus bar 40, and the direction in which the first electronic component 20 is fixed to the base member 11 are the same.

[0068] Similarly, the posture of the second assembly SB is rotated 90 degrees from that in the first step, i.e., from a first posture (see FIG. 5 ) in which the mounting holes 33 h and the first mounting holes 71 h are oriented vertically to a second posture (see FIG. 7 ) in which the mounting holes 33 h and the first mounting holes 71 h are oriented horizontally and the second mounting holes 72 h of the second metal component 70 are oriented vertically.

[0069] Then, in the second posture, the second portion 72 of the second metal component 70 is placed on the second connection portion 42 of the bus bar 40. Then, the second mounting hole 72 h of the second metal component 70 and the mounting hole 42 h of the second connection portion 42 of the bus bar 40 are aligned.

[0070] Next, the second fastening member 92 is inserted vertically into the second mounting hole 72h of the second metal component 70. Then, the second fastening member 92 that has passed through the second mounting hole 72h of the second metal component 70 engages with the mounting hole 42h of the second connection portion 42 of the bus bar 40. This fixes the second metal component 70 to the second connection portion 42 of the bus bar 40. That is, the second assembly SB is fixed to the second connection portion 42 of the bus bar 40. This electrically connects the second electronic component 30 and the second connection portion 42 of the bus bar 40. In this embodiment, the direction in which the bus bar 40 is fixed to the base member 11 and the direction in which the second assembly SB is fixed to the bus bar 40 coincide with each other.

[0071] Furthermore, in the third step, the mounting portion 34 of the second electronic component 30 may be fixed to the base member 11 using fastening members 39. This operation is performed, for example, as follows. First, the mounting holes 34h of the mounting portions 34 of the second electronic component 30 are aligned with the mounting holes 11h of the base member 11. Next, the fastening members 39 are inserted vertically into the mounting holes 34h of the second electronic component 30. Then, the fastening members 39 that have passed through the mounting holes 34h of the second electronic component 30 engage with the mounting holes 11h of the base member 11. This fixes the second electronic component 30 to the base member 11. Note that the operation of fixing the second electronic component 30 to the base member 11 using the fastening members 39 may be performed before or after the operation of fixing the second metal component 70 to the bus bar 40 using the second fastening members 92. In this embodiment, the direction in which the bus bar 40 is fixed to the base member 11, the direction in which the second assembly body SB is fixed to the bus bar 40, and the direction in which the second electronic component 30 is fixed to the base member 11 are the same.

[0072] <A3. Function> Next, the function of the electrical connection unit 1 will be described. FIG. 8 is a cross-sectional view for explaining the function of the electrical connection unit 1. When current is applied to the first electronic component 20, the main body 22 of the first electronic component 20 generates heat, and the terminal portion 23 connected to the main body 22 becomes hot. A portion of the heat from the terminal portion 23 (indicated by arrow HE in FIG. 8 ) transfers to the metal component 60. A portion of the heat transferred to the metal component 60 is dissipated from the metal component 60 into the housing 10. Another portion of the heat transferred to the metal component 60 transfers from the metal component 60 to the bus bar 40. A portion of the heat transferred to the bus bar 40 is dissipated from the bus bar 40 into the housing 10.

[0073] Here, when a short-term large current flows through the first electronic component 20 and heats up the main body 22 of the first electronic component 20, the terminal 23 connected to the main body 22 also retains heat. In this embodiment, a metal component 60, which has a larger heat capacity per unit length than the bus bar 40, is present next to the terminal 23. Therefore, some of the heat generated by the terminal 23 is stored (absorbed) by the metal component 60. This makes it possible to prevent excessive heat from being transferred to the bus bar 40 or other electronic components 30, even when a short-term large current flows through the first electronic component 20. Note that the same effects are true for the metal component 70.

[0074] <A4. Advantages> <A4.1 Advantages as a heat storage component (heat absorption component)> In this embodiment, the electrical connection unit 1 has a bus bar 40 and a first metal component 60. At least a portion of the bus bar 40 is plate-shaped. The first metal component 60 is disposed between the bus bar 40 and the first electronic component 20. The first metal component 60 electrically connects the bus bar 40 and the first electronic component 20. The thickness of at least a portion of the first metal component 60 is greater than the plate thickness T3 of the bus bar 40.

[0075] With this configuration, the first metal component 60 has a larger heat capacity per unit length than the bus bar 40. Therefore, even if a large current flows through the first electronic component 20 for a short period of time and the first electronic component 20 generates heat, some of the heat generated by the first electronic component 20 is stored in the metal component 60. This makes it possible to suppress temperature changes inside the electrical connection unit 1. This makes it possible to improve the thermal characteristics of the electrical connection unit 1.

[0076] In this embodiment, the first metal component 60 is connected to the terminal portion 23 of the first electronic component 20 in the X direction using the first fastening member 81. With this configuration, a portion of the heat generated by the first electronic component 20 can be stored using the metal component 60 that is firmly fixed to the terminal portion 23 of the first electronic component 20 using the first fastening member 81. This allows for further improvement in the thermal characteristics of the electrical connection unit 1.

[0077] In this embodiment, the first metal component 60 is connected to the terminal portion 23 of the first electronic component 20 from the X direction. The thickness T1 of at least a portion of the first metal component 60 in the X direction is greater than the plate thickness T3 of the bus bar 40. With this configuration, a metal portion with a large heat capacity is disposed near the terminal portion 23, which is the part of the first electronic component 20 that tends to heat up, and heat is more easily transferred from the terminal portion 23 to the first metal component 60. This further improves the thermal characteristics of the electrical connection unit 1.

[0078] In this embodiment, the first metal component 60 has a first portion 61 connected to the terminal portion 23 of the first electronic component 20 from the X direction, and a second portion 62 that protrudes from the first portion 61 and is connected to the bus bar 40 from the Z direction. With this configuration, the direction in which the bus bar 40 is fixed to the base member 11 can be made to coincide with the direction in which the first metal component 60 is fixed to the bus bar 40. This improves the ease of assembly of the electrical connection unit 1.

[0079] In this embodiment, the thickness T1 in the X direction of the first portion 61 of the first metal component 60 is greater than the thickness T2 in the Z direction of the second portion 62 of the first metal component 60. This configuration ensures a greater heat capacity for the first portion 61 of the first metal component 60. This further improves the thermal characteristics of the electrical connection unit 1.

[0080] In this embodiment, the bus bar 40 has a first connection portion 41 arranged along the base member 11. The first metal component 60 has a first portion 61 that stands upright relative to the base member 11 and is connected to the terminal portion 23 of the first electronic component 20, and a second portion 62 that is connected to the first connection portion 41 of the bus bar 40. This configuration makes it easy to form the first portion 61 large, making it easier to ensure the thermal capacity of the first portion 61. Furthermore, this configuration makes it possible to employ a bus bar 40 that has the first connection portion 41 arranged along the base member 11. This allows for a simplification of the shape of the bus bar 40, thereby reducing the cost of the electrical connection unit 1.

[0081] <A4.2 Advantages as a Connection Member> In the present embodiment, the first fastening member 81 is used to fasten the first metal component 60 to the terminal portion 23 of the first electronic component 20, thereby forming a first assembly SA in which the first electronic component 20 and the first metal component 60 are integrated. Then, after forming the first assembly SA, the second fastening member 82 is used to fasten the first metal component 60 included in the first assembly SA to the bus bar 40, thereby electrically connecting the first electronic component 20 and the bus bar 40. With this configuration, the first assembly SA in which the first electronic component 20 and the first metal component 60 are integrated is formed first. This improves the ease of assembling the first electronic component 20 and the first metal component 60 to the bus bar 40. This improves the ease of assembling the electrical connection unit 1.

[0082] Furthermore, with the above configuration, it is possible to form an upright current-carrying portion inside the housing 10 using the first metal component 60, which makes it easier to employ a bus bar 40 with a simple shape (for example, a plate-shaped bus bar 40 with few bends). This improves the ease of assembling the first electronic component 20 and the first metal component 60 to the bus bar 40.

[0083] Furthermore, with the above configuration, the first metal component 60 can form an upright current-carrying portion inside the housing 10, thereby reducing the number of bent portions of the busbar 40. Here, busbars 40 that can handle large currents tend to have a large cross-sectional area to suppress self-heating of the busbar, which increases the cost of bending. Therefore, reducing the number of bent portions of the busbar 40 can reduce the cost of the electrical connection unit 1.

[0084] In this embodiment, the width of the first metal component 60 in the longitudinal direction of the first electronic component 20 is smaller than the width of the first electronic component 20 in the longitudinal direction. With this configuration, when the first assembly SA is formed by fixing the first electronic component 20 and the first metal component 60 together, the first assembly SA is relatively small, which improves the ease of assembly to the bus bar 40 that has been previously integrated with the base member 11. This further improves the ease of assembly of the electrical connection unit 1.

[0085] In this embodiment, the first assembly SA is fixed to the bus bar 40 using the second fastening members 82 after the bus bar 40 has been fixed to the insulating base member 11. With this configuration, the bus bar 40 is fixed to the base member 11 first, which improves the ease of assembling the first assembly SA to the base member 11 and the bus bar 40. This further improves the ease of assembling the electrical connection unit 1.

[0086] In the present embodiment, the first metal component 60 is fixed to the terminal portion 23 of the first electronic component 20 using the first fastening member 81 while the first metal component 60 is in a first position. The first metal component 60 included in the first assembly SA is fixed to the bus bar 40 using the second fastening member 82 while the first metal component 60 is in a second position different from the first position. With this configuration, by changing the position of the first metal component 60, the fixing using the first fastening member 81 and the fixing using the second fastening member 82 can each be performed in a more appropriate position. This further improves the ease of assembly of the electrical connection unit 1.

[0087] In this embodiment, the first metal component 60 has a first mounting hole 61h into which the first fastening member 81 is inserted and a second mounting hole 62h into which the second fastening member 82 is inserted. The first position is a position in which the first mounting hole 61h faces a first mounting direction (e.g., vertical direction). The second position is a position in which the first mounting hole 61h faces a direction different from the first mounting direction and the second mounting hole 62h faces the first mounting direction (Z direction). This configuration allows the direction in which the first fastening member 81 fastens the first electronic component 20 and the first metal component 60 to be aligned with the direction in which the second fastening member 82 fastens the first metal component 60 and the bus bar 40 to be aligned. This improves workability and further improves the ease of assembly of the electrical connection unit 1.

[0088] <A5. Modifications> Next, several modifications will be described. In each modification, the configuration other than that described below is the same as that of the first embodiment.

[0089] <A5.1 First Modification> Figure 9 is a cross-sectional view showing an electrical connection unit 1 of a first modification. In the first modification, the bus bar 40 has an extension 45 and an extension 46. The extension 45 extends in the -X direction beyond the first connection portion 41. When viewed from the Z direction, the extension 45 overlaps with the first portion 61 of the first metal component 60. On the other hand, the extension 46 extends in the +X direction beyond the second connection portion 42. When viewed from the Z direction, the extension 46 overlaps with the first portion 71 of the second metal component 70. The extensions 45 and 46 are plate-shaped and extend along the X and Y directions.

[0090] With this configuration, the thermal capacity and heat dissipation area of ​​the bus bar 40 are increased by the extensions 45, 46. This makes it possible to further suppress temperature changes inside the electrical connection unit 1 and improve the heat dissipation performance of the electrical connection unit 1.

[0091] <A5.2 Second Modification> FIG. 10 is a cross-sectional view showing an electrical connection unit 1 of a second modification. In the second modification, the bus bar 40 has extensions 47 and 48. Extension 47 extends in the −X direction beyond extension 45. When viewed from the Z direction, extension 47 overlaps with the first electronic component 20. Extension 47 extends in the X direction between the first electronic component 20 and the base member 11. On the other hand, extension 48 extends in the +X direction beyond extension 46. When viewed from the Z direction, extension 48 overlaps with the second electronic component 30. Extension 48 extends in the X direction between the second electronic component 30 and the base member 11. Extensions 47 and 48 are plate-shaped and extend along the X and Y directions.

[0092] According to this configuration, the extension 47 or the extension 48 increases the heat capacity and heat dissipation area of ​​the bus bar 40. Here, for example, by providing the first metal component 60, it is not necessary to bend the bus bar 40 to fit the first electronic component 20. Therefore, a portion of the bus bar 40 can be extended, for example, between the first electronic component 20 and the base member 11. This can further suppress sudden temperature changes inside the electrical connection unit 1 and further improve the heat dissipation performance of the electrical connection unit 1.

[0093] A heat transfer member 150 may be provided between the first electronic component 20 and the extension 47. The heat transfer member 150 transfers a portion of the heat generated by the first electronic component 20 to the extension 47. The portion of the heat transferred to the extension 47 is dissipated through the base member 11. Similarly, the heat transfer member 150 may be provided between the second electronic component 30 and the extension 48. The portion of the heat transferred to the extension 48 is dissipated through the base member 11. The heat transfer member 150 transfers a portion of the heat generated by the second electronic component 30 to the extension 48. The heat transfer member 150 is, for example, a resin member with excellent thermal conductivity. This makes it possible to further improve the heat dissipation performance of the electrical connection unit 1.

[0094] <A5.3 Third Modification> Figure 11 is a cross-sectional view showing an electrical connection unit 1 of a third modification. In the third modification, the first metal component 60 has a third component 63 in addition to the first component 61 and the second component 62. The second metal component 70 has a third component 73 in addition to the first component 71 and the second component 72. The third component 73 has a similar shape to the third component 63 of the first metal component 60. Therefore, the third component 63 of the first metal component 60 will be described below.

[0095] 12 is a perspective view showing a portion of the electrical connection unit 1 of the third modified example. The third portion 63 is an upright wall (side wall) that stands on the side of the fastening members 81, 82. The first metal component 60 has, for example, a third portion 63 at each end of the first metal component 60 in the Y direction. The third portion 63 is a wall that extends along the X direction and the Y direction. The third portion 63 is connected to the first portion 61 and also to the second portion 62. The third portion 63 extends, for example, at an incline so that its inclination increases in the +X direction as it progresses in the -Z direction.

[0096] According to this configuration, the third portion 63 increases the heat capacity and heat dissipation area of ​​the first metal component 60. This makes it possible to further suppress temperature changes inside the electrical connection unit 1 and further improve the heat dissipation performance of the electrical connection unit 1. Note that instead of being provided at both ends of the first metal component 60 in the Y direction, the third portion 63 may be provided at either end of the first metal component 60 in the Y direction.

[0097] Second Embodiment Next, a second embodiment will be described. The second embodiment differs from the first embodiment in that the first fastening member 81 is attached along the Z direction. Note that the configuration other than that described below is the same as that of the first embodiment. In the second embodiment, the Z direction is an example of the "first direction." The X direction is an example of the "second direction."

[0098] 13 is a cross-sectional view showing a part of the electrical connection unit 1 of the second embodiment. The electrical connection unit 1 has, for example, an electronic component 20, a plurality of bus bars 40, and a plurality of metal components 100.

[0099] <B1.1 Electronic Component> The electronic component 20 has, for example, a main body 22 and multiple terminals 23 (first terminals 23A and second terminals 23B). The main body 22 is, for example, cylindrical with its axis along the X direction. The multiple terminals 23 are provided separately on both ends of the main body 22 in the X direction. For example, the first terminal 23A extends in the +X direction from the end of the main body 22 in the +X direction. The second terminal 23B extends in the −X direction from the end of the main body 22 in the −X direction. Each of the first terminal 23A and the second terminal 23B has a mounting hole 23h. The mounting hole 23h opens in the Z direction.

[0100] <B1.2 Bus Bars> The multiple bus bars 40 are arranged separately in the X direction of the electronic component 20. The multiple bus bars 40 include a first bus bar 40A and a second bus bar 40B. The first bus bar 40A is arranged on the +X direction side of the electronic component 20. The second bus bar 40B is arranged on the −X direction side of the electronic component 20.

[0101] <B1.3 Metal Components> The multiple metal components 100 are heat storage members (heat absorption members) that increase the heat capacity of the current paths of the electrical connection unit 1. The multiple metal components 100 store (absorb) at least a portion of the heat generated by the electronic components 20, for example. Alternatively / in addition to this, the multiple metal components 100 may store (absorb) at least a portion of the heat generated by the bus bar 40 when current is applied. The multiple metal components 100 include a first metal component 100A and a second metal component 100B.

[0102] <B1.3.1 First Metal Component> The first metal component 100A is disposed between the electronic component 20 and the first bus bar 40A. The first metal component 100A electrically connects the terminal portion 23A of the electronic component 20 and the first connection portion 41 of the first bus bar 40A. The first metal component 100A has, for example, a first portion 101, a second portion 102, and a third portion 103.

[0103] (First Part) The first part 101 is a part that is connected to the terminal portion 23A of the electronic component 20. The first part 101 is a rectangular parallelepiped metal part. The first part 101 extends along the Z direction. The first part 101 is adjacent to at least a part of the main body portion 22 of the electronic component 20 in the X direction. The first part 101 faces the terminal portion 23A of the electronic component 20 from the +Z direction side. The terminal portion 23A of the electronic component 20 is connected to the first part 101 from the Z direction.

[0104] In this embodiment, the first portion 101 has a first mounting hole 101h into which a first fastening member 81 (e.g., a screw) is engaged. The first mounting hole 101h is open in the Z direction. The first fastening member 81 is passed through the mounting hole 23h of the terminal portion 23A of the electronic component 20 and engages with the first mounting hole 101h of the first portion 101, thereby physically and electrically connecting the first portion 61 to the terminal portion 23A of the electronic component 20.

[0105] (Second Part) The second part 102 is a part that is connected to the first connection part 41 of the first bus bar 40A. The second part 102 protrudes in the +X direction from the end of the first part 101 on the -Z direction side. The second part 102 is a plate part that extends along the X direction and the Y direction. The second part 102 extends in the X direction along the first connection part 41 of the first bus bar 40A. In this embodiment, the first part 101 and the second part 102 form an L-shaped metal part.

[0106] The second portion 102 is adjacent to the first connection portion 41 of the first bus bar 40A in the Z direction. The second portion 102 faces the first connection portion 41 of the first bus bar 40A from the +Z direction side. The second portion 102 is connected to the first connection portion 41 of the first bus bar 40A from the Z direction.

[0107] In this embodiment, the second portion 102 has a second mounting hole 102h through which a second fastening member 82 (e.g., a screw) is passed. The second mounting hole 102h is open in the Z direction. The second fastening member 82 passed through the second mounting hole 102h engages with the mounting hole 41h of the first connecting portion 41 of the first bus bar 40A, thereby physically and electrically connecting the second portion 102 to the first connecting portion 41 of the bus bar 40A.

[0108] (Third Part) Figure 14 is a perspective view showing a part of the electrical connection unit 1 of the second embodiment. The third part 103 is an upright wall (side wall) that stands on the side of the second fastening member 82. The first metal component 100A has, for example, a third part 103 at each end of the first metal component 100A in the Y direction. The third part 103 is a wall that extends along the X and Y directions. The third part 103 is connected to the first part 101 and also to the second part 102. The third part 103 extends at an angle that increases in the +X direction as it progresses in the -Z direction, for example.

[0109] (Shape of First Metal Component) Returning to FIG. 13 , the shape of the first metal component 100A will be described. In the present embodiment, the thickness of at least a portion of the first metal component 100A is greater than the thickness T3 of the first bus bar 40A. For example, the Z-direction thickness T11 of at least a portion of the first metal component 100A is greater than the thickness T3 of the first bus bar 40A. In the present embodiment, the Z-direction thickness T11 of the first portion 101 of the first metal component 100A is greater than the Z-direction thickness T12 of the second portion 102 of the first metal component 100A. From another perspective, the X-direction thickness T13 of the first portion 101 of the first metal component 100A is greater than the thickness T3 of the first bus bar 40A. From another perspective, the Z-direction thickness T12 of the second portion 102 of the first metal component 100A may be greater than the thickness T3 of the bus bar 40A.

[0110] In this embodiment, the longitudinal direction of the electronic component 20 is the X direction. The width WA2 of the first metal component 100A in the X direction is smaller than, for example, the width WA1 of the electronic component 20 in the X direction. Note that when the longitudinal direction of the first electronic component 20 is the Y direction, the width of the first metal component 100A in the Y direction is smaller than, for example, the width of the electronic component 20 in the Y direction.

[0111] <B1.3.2 Second Metal Component> Next, the second metal component 100B will be described. The second metal component 100B is disposed between the electronic component 20 and the second bus bar 40B. The second metal component 100B electrically connects the terminal portion 33B of the electronic component 30 and the first connection portion 41 of the second bus bar 40B. Like the first metal component 100A, the second metal component 100B has a first portion 101, a second portion 102, and a third portion 103.

[0112] The details of the second metal component 100B are the same as, for example, the first metal component 100A. Therefore, in the description of the second metal component 100B, the "terminal portion 23A," the "first bus bar 40A," and the "+X direction" in the above description of the first metal component 100A can be read as the "terminal portion 23B," the "second bus bar 40B," and the "-X direction," respectively.

[0113] <B2. Manufacturing Method of Electrical Connection Unit> Next, a method of manufacturing the electrical connection unit 1 of the second embodiment will be described. Figures 15 and 16 are cross-sectional views for explaining the manufacturing method of the electrical connection unit 1 of the second embodiment.

[0114] 15 shows the first step. In the first step, the terminal portion 23A of the electronic component 20 is fixed to the first metal component 100A using the fastening member 81, and the terminal portion 23B of the electronic component 20 is fixed to the second metal component 100B using the fastening member 81. This forms an assembly SC in which the electronic component 20, the first metal component 100A, and the second metal component 100B are integrated together.

[0115] The first step is performed, for example, as follows: First, the first metal component 100A is placed on the mounting table MP in an orientation in which the first mounting hole 101h of the first metal component 100A is oriented vertically. Next, the terminal portion 23A of the electronic component 20 is placed on the first portion 101 of the first metal component 100A in a first orientation in which the mounting hole 23h of the terminal portion 23A of the electronic component 20 is oriented vertically. Then, the mounting hole 23h of the electronic component 20 is aligned with the first mounting hole 101h of the first metal component 100A.

[0116] Next, the fastening member 81 is inserted vertically into the mounting hole 23h of the electronic component 20. Then, the fastening member 81 that has passed through the mounting hole 23h of the electronic component 20 engages with the first mounting hole 101h of the first metal component 100A. This fixes the first metal component 100A to the electronic component 20. Using a similar procedure, the second terminal portion 23B of the electronic component 20 is fixed to the second metal component 100B. This forms an assembly SC in which the electronic component 20, the first metal component 100A, and the second metal component 100B are integrated together.

[0117] (Second Step) In the second step, the first bus bar 40A and the second bus bar 40B are fixed to the base member 11. The second step is the same as in the first embodiment, and therefore a duplicated description will be omitted.

[0118] (Third Step) FIG. 16 shows the third step. The third step is performed after the first and second steps. In the third step, the assembly SC is fixed to the first bus bar 40A and the second bus bar 40B using the second fastening members 82. For example, the second fastening members 82 are attached vertically to fix the first metal component 100A of the assembly SC to the first connection portion 41 of the first bus bar 40A. This electrically connects the electronic component 20 to the first bus bar 40A. Similarly, the second fastening members 82 are attached vertically to fix the second metal component 100B of the assembly SC to the first connection portion 41 of the second bus bar 40B. This electrically connects the electronic component 20 to the second bus bar 40B.

[0119] <B3. Advantages> In this embodiment, the first metal component 100A has a first portion 101 and a second portion 102. The first portion 101 is connected to the terminal portion 23A of the electronic component 20 in the Z direction. The second portion 102 protrudes from the first portion 101 in the X direction and is adjacent to the first bus bar 40A in the Z direction and connected to the first bus bar 40A. The thickness T11 of the first portion 101 in the Z direction is greater than the plate thickness T3 of the first bus bar 40A. This configuration can prevent sudden temperature changes from occurring inside the electrical connection unit 1. This can improve the thermal characteristics of the electrical connection unit 1.

[0120] In this embodiment, the first fastening members 81 fasten the terminal portions 23A of the electronic component 20 to the first metal component 100A from the Z direction. The second fastening members 82 fasten the first metal component 100A to the first bus bar 40A from the Z direction. With this configuration, the direction in which the first fastening members 81 fasten the electronic component 20 to the first metal component 100A can be aligned with the direction in which the second fastening members 82 fasten the first metal component 100A to the first bus bar 40A. This improves workability and the ease of assembly of the electrical connection unit 1.

[0121] Third Embodiment Next, a third embodiment will be described. The third embodiment differs from the first embodiment in that the component to be connected is a bus bar 201. Note that the configuration other than that described below is the same as the configuration of the second embodiment. In the third embodiment, the Z direction is an example of the "first direction."

[0122] 17 is a perspective view showing a portion of the electrical connection unit 1 of the third embodiment. In this embodiment, the electrical connection unit 1 has a bus bar 40, a metal component 100, and a bus bar 201. The bus bar 201 is an example of a "component to be connected."

[0123] The metal part 100 is disposed between the bus bar 201 and the bus bar 40. The bus bar 201 faces the first portion 101 of the metal part 100 from the +Z direction side. The bus bar 201 has a mounting hole 201h. The mounting hole 201h opens in the Z direction. The mounting hole 201h of the bus bar 201 is disposed to correspond to the mounting hole 101h of the metal part 100. The first fastening member 81 is passed through the mounting hole 201h of the bus bar 201 from the vertical direction and engages with the mounting hole 101h of the metal part 100, thereby fixing the bus bar 201 and the metal part 100 together. The metal part 100 electrically connects the bus bar 201 and the bus bar 40.

[0124] With this configuration, a portion of the heat generated at the bus bar 201 or at the connection destination of the bus bar 201 can be stored (absorbed) by the metal component 100. This improves the thermal characteristics of the electrical connection unit 1.

[0125] Several embodiments and modifications have been described above. However, the embodiments and modifications are not limited to the above examples. For example, two or more of the above-described embodiments or modifications may be combined with each other. Furthermore, the above-described embodiments and modifications are merely exemplary. The electrical connection unit 1 is not limited to a configuration that includes all of the above-described dimensional relationships, and may be configured to have only some of the above-described dimensional relationships. Furthermore, when focusing on the function of the metal components 60 and 70 as connecting members (the function of improving assembly), the metal components 60 and 70 are not necessarily limited to members that have heat storage properties. For example, L-shaped thin metal plates (metal components) may be used instead of the metal components 60 and 70.

[0126] According to the present disclosure, the assembly of the electrical connection unit can be improved.

[0127] DESCRIPTION OF SYMBOLS 1...electrical connection unit 10...housing 11...base member 12...cover member 20...first electronic component 23, 23A, 23B...terminal portion 30...second electronic component 33, 33A, 33B...terminal portion 40...bus bar 60...first metal component 61...first portion 61h...first mounting hole 62...second portion 62h...second mounting hole 70...second metal component 71...first portion 71h...first mounting hole 72...second portion 72h...second mounting hole 81...first fastening member 82...second fastening member 91...first fastening member 92...second fastening member 100...metal component 100A...first metal component 101...first portion 102...second portion 100B...second metal component SA...first assembly SB...second assembly

Claims

1. A method for manufacturing an electrical connection unit, comprising: using a first fastening member to fasten a metal part to a part to be connected, to form an assembly in which the part to be connected and the metal part are integrated; and after forming the assembly, using a second fastening member to fasten the metal part included in the assembly to a bus bar, thereby electrically connecting the part to be connected and the bus bar.

2. The method for manufacturing an electrical connection unit according to claim 1, wherein the component to be connected is an electronic component having a terminal portion, and the metal component is fixed to the terminal portion of the electronic component using the first fastening member.

3. The method for manufacturing an electrical connection unit according to claim 2, wherein the width of the metal component in the longitudinal direction of the electronic component is smaller than the width of the electronic component in the longitudinal direction.

4. A method for manufacturing an electrical connection unit as described in any one of claims 1 to 3, wherein the fixing of the metal part to the bus bar using the second fastening member is performed in a state where the bus bar is fixed to an insulating support body.

5. A method for manufacturing an electrical connection unit as described in any one of claims 1 to 3, wherein fixing the metal component to the component to be connected using the first fastening member is performed with the component to be connected and the metal component in a first position, and fixing the metal component included in the assembly to the bus bar using the second fastening member is performed with the component to be connected and the metal component in a second position different from the first position.

6. A method for manufacturing an electrical connection unit as described in claim 5, wherein the metal part has a first mounting hole into which the first fastening member is inserted and a second mounting hole that opens in a direction different from the first mounting hole and into which the second fastening member is inserted, the first position being a position in which the first mounting hole faces a first mounting direction, and the second position being a position in which the first mounting hole faces a direction different from the first mounting direction and the second mounting hole faces the first mounting direction.

7. A method for manufacturing an electrical connection unit as described in claim 2 or claim 3, wherein the first fastening member fixes the terminal portion to the metal part from a first mounting direction, and the second fastening member fixes the metal part to the bus bar from the first mounting direction.

8. A metal part used in an electrical connection unit, comprising: a first part fixed to an electronic part using a first fastening member; and a second part fixed to a bus bar using a second fastening member after the electronic part and the metal part have been integrated using the first fastening member; the metal part electrically connects the electronic part and the bus bar; and the width of the metal part in the longitudinal direction of the electronic part is smaller than the width of the electronic part in the longitudinal direction.

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