Electrical connection unit

Abstract

An electrical connection unit according to one embodiment of the present invention comprises an electronic component, a wiring member, and a liquid-coolant cooling member. The wiring member has a connection part that is electrically connected to the electronic component. The cooling member cools the connection part.

Description

Electrical connection unit

[0001] An embodiment of the present invention relates to an electrical connection unit. This application claims priority to Japanese Patent Application No. 2024-179719, filed in Japan on October 15, 2024, the content of which is incorporated herein by reference.

[0002] In an electrical connection unit, it is known that electronic components such as relays and resistors are mounted on the mounting surface of the housing.

[0003] Japanese Patent Application Laid-Open No. 2018-113184

[0004] By the way, improvement in heat dissipation is expected for the electrical connection unit.

[0005] One embodiment provides an electrical connection unit capable of improving heat dissipation.

[0006] An electrical connection unit according to one embodiment includes an electronic component, a wiring member, and a liquid-cooled cooling member. The wiring member has a connection portion electrically connected to the electronic component. The cooling member cools the connection portion.

[0007] According to one embodiment, it is easy to improve heat dissipation.

[0008] Perspective view showing the electrical connection unit of the first embodiment. Plan view showing the electrical connection unit of the first embodiment. Perspective view showing the relay module of the first embodiment. Perspective view showing the fuse module of the first embodiment. Perspective view showing the terminal module of the first embodiment. Partial enlarged view showing a part of the electrical connection unit of the first embodiment. Perspective view showing the electrical connection unit of the first modification. Partial enlarged view showing a part of the electrical connection unit of the first modification. Partial enlarged view showing a part of the electrical connection unit of the second modification. Perspective view showing the electrical connection unit with a cover attached to the assembly of the first embodiment.

[0009] Hereinafter, embodiments will be described with reference to the drawings. In the following description, components having the same or similar functions are denoted by the same reference numerals. And redundant descriptions of those components may be omitted. Note that the configurations described below do not limit the scope of the embodiments.

[0010] In this disclosure, terms are defined as follows: “Connection” may include electrical connections, not just mechanical ones. That is, “Connection” may include cases where two elements to be connected are connected with another element in between, not just directly connected. “Accommodate” may include cases where only a part of a part is accommodated (with the remaining part protruding), not just the entire part. “Cover” may include cases where only a part of an object is covered, not just the entire object. “Facing” means that the virtual projections of two objects overlap when viewed from a particular direction. That is, “Facing” may include cases where two objects face each other with another member present between them, not just directly facing each other. “Parallel,” “orthogonal,” or “same” may include cases where they are “approximately parallel,” “approximately orthogonal,” or “approximately the same,” respectively.

[0011] In this disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows: The X direction is one direction in the plane along the base plate 2, which will be described later. The +X direction is one of the X directions. 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 a direction that intersects (for example, is orthogonal to) the X direction in the plane along the base plate 2, which will be described later. The +Y direction is one of the Y directions. 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 and the -Z direction are directions that intersect (for example, are orthogonal to) the X direction and the Y direction. The +Z direction is the direction from the base plate 2, which will be described later, toward each of the first modules 3, which will be described later (see Figure 1). The -Z direction is the opposite direction to the +Z direction. In the following, when the +Z and -Z directions are not distinguished, they will simply be referred to as the "Z direction." The Y direction is an example of the "first direction." The Z direction is an example of the "second direction." The X direction is an example of the "third direction." Note that the "first direction" is not limited to the Y direction, but may be the X direction or other directions.

[0012] In the following, when the X and Y directions are not distinguished, they may be referred to as the "horizontal direction." In the following, the Z direction may be referred to as the "vertical direction." Also, in the following, the +Z direction may be referred to as "up," and the -Z direction may be referred to as "down." However, these expressions are for the convenience of explanation and do not limit the direction of gravity of the electrical connection unit 1 (the installation orientation of the electrical connection unit 1).

[0013] (First Embodiment) <1. Configuration of the Electrical Connection Unit> The electrical connection unit 1 is an in-vehicle device installed in a vehicle such as an EV (Electric Vehicle), HEV (Hybrid Electric Vehicle), or PHEV (Plug-in Hybrid Electric Vehicle). The electrical connection unit 1 is connected to a plurality of external devices located outside. The electrical connection unit 1 mediates the connection between the plurality of external devices. For example, the external devices may include a battery pack, a load, a charger, etc. The battery pack is installed in the vehicle. The load is a device including an inverter for driving the vehicle's motor, which is driven using the power stored in the battery pack. The charger is a device for supplying power to charge the battery pack. The electrical connection unit 1 may be called, for example, an "electrical connection box" or a "junction box". However, the electrical connection unit 1 is not limited to a box-shaped device.

[0014] As shown in Figures 1 and 2, the electrical connection unit 1 comprises a base plate 2, a plurality of first modules 3, a plurality of terminal modules 4, a plurality of busbars 5, a heat transfer member 8, and a cooling member 9. The base plate 2 is an example of a second rigid member. Each busbar 5 is an example of a wiring member. Each terminal module 4 is an example of a second module. The electrical connection unit 1 may further include a cover 6 (Figure 10), which will be described later. In the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, and the plurality of busbars 5 are covered by the base plate 2 from the -Z direction and by the cover 6 from the +Z direction. That is, in the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, and the plurality of busbars 5 are housed in a housing which is a combination structure of the cover 6 and the base plate 2. Note that Figure 1 shows the electrical connection unit 1 with the cover 6 visible through it.

[0015] <2. Configuration of the Second Rigid Member> The base plate 2 will now be described. The base plate 2 is a holding member that integrally holds a plurality of first modules 3 and a plurality of terminal modules 4. The base plate 2 has a plate shape that extends in a planar manner in the X and Y directions. The base plate 2 is, for example, a metal product and has thermal conductivity. The base plate 2 is a plate-shaped member that is aligned horizontally. The base plate 2 may be made of a metal such as copper or aluminum.

[0016] The base plate 2 has a front and back surface, which is a pair of plate surfaces: a first surface 2a and a second surface 2b. The first surface 2a is a horizontal plane facing the +Z direction. The second surface 2b is a horizontal plane facing the -Z direction. The first surface 2a and the second surface 2b may be, for example, smooth planes.

[0017] <3. Configuration of the First Module> The multiple first modules 3 will now be described. The multiple first modules 3 are multiple units, each divided into functional units, so that each one is responsible for one of the smallest units of circuit function in the electrical connection unit 1 (interruption, switching, resistance, charging, sensing, conversion, etc.). The multiple first modules 3 are arranged along the first surface 2a of the base plate 2. Each first module 3 is placed on the base plate 2 with its bottom surface 3b facing the first surface 2a. Each first module 3 is provided on the first surface 2a side of the base plate 2. Each first module 3 may, for example, be placed on the first surface 2a.

[0018] Among the multiple first modules 3, each of some first modules 3 may have a gap between it and other adjacent first modules 3 in the X direction, for example. Among the multiple first modules 3, each of some first modules 3 may have a gap between it and other adjacent first modules 3 in the Y direction, for example.

[0019] Each first module 3 comprises an electronic component 31 and a first rigid member 32. One electronic component 31 is mounted on each first rigid member 32. That is, each of the multiple electronic components 31 provided in the electrical connection unit 1 is individually mounted on the corresponding first rigid member 32. Each first module 3 may, for example, comprise only one electronic component 31 and one first rigid member 32 corresponding to (this one electronic component 31) from among the multiple electronic components 31 and multiple first rigid members 32 included in the electrical connection unit 1.

[0020] Each electronic component 31 is an electronic component mounted in accordance with the function required of the electrical connection unit 1. As shown in Figures 1 and 2, each electronic component 31 may be fixed to the corresponding first rigid member 32 by fastening to the corresponding first rigid member 32, for example. The electronic components 31 include fuses, relays (e.g., mechanical relays or semiconductor relays), resistors (pre-charge resistors, etc.), capacitors, various sensors (e.g., current sensors or voltage sensors), ferrite cores, etc. As shown in Figures 3 and 4, each electronic component 31 may have, for example, a pair of component terminals 39. In addition, each electronic component 31 may have three or more component terminals 39.

[0021] Here, as examples of electronic components 31, we will describe a first type electronic component 31M and a second type electronic component 31N. In addition to describing the electronic components 31, we will also describe a first type component terminal 39M and a second type component terminal 39N as examples of component terminals 39.

[0022] For example, in electronic component 31M, multiple component terminals 39M are arranged side by side at one end of the electronic component 31. An example of electronic component 31M is the relay 31R shown in Figure 3. The second type of electronic component 31N is an electronic component in which two component terminals 39N are arranged separately at both horizontal ends of the electronic component 31N. An example of electronic component 31N is the fuse 31F shown in Figure 4.

[0023] The component terminal 39M electrically connects the routing member (busbar 5) by fastening it to the electronic component 31 (electronic component 31M, relay 31R) in the horizontal direction. The component terminal 39M is an example of a fastening member. The component terminal 39N electrically connects the routing member (busbar 5) by fastening it to the electronic component 31 (electronic component 31N, fuse 31F) in the vertical direction. For fastening the component terminal 39N, an engaging member 388 that can engage with the fixed terminal 38 described later is used. The engaging member 388 is an example of a fastening member.

[0024] The component terminal 39M is, for example, a bolt having a head 39a and a shaft 39b. The circumferential surface of the shaft 39b has screw grooves. The head 39a has a larger diameter than the shaft 39b. The component terminal 39M is fastened with the shaft 39b passing through the insertion hole 51h of the busbar 5.

[0025] At component terminal 39N, the fixing terminal 38 is fastened with the busbar 5 inserted through the insertion hole 51h. After the fixing terminal 38 is inserted through the insertion hole 51h, the busbar 5 is fastened by engaging an engaging member 388 (for example, a nut, see Figure 4) with the tip of the fixing terminal 38 through which it is inserted. The circumferential surface of the fixing terminal 38 has screw threads. The engaging member 388 has a through hole. The engaging member 388 has screw threads on the inner circumferential surface of the through hole.

[0026] The electronic component 31M has an insulating rib 31a. The insulating rib 31a is a rib that protrudes in one direction. The insulating rib 31a electrically insulates between the component terminals 39M that are arranged side by side at one end. For example, in this disclosure, the insulating rib 31a protrudes horizontally and extends in the Z direction. As shown in Figure 3, the insulating rib 31a extends, for example, along the entire length of the electronic component 31M in the Z direction. The insulating rib 31a is positioned between one and the other of a pair of component terminals 39M. The insulating rib 31a electrically insulates between one and the other of a pair of component terminals 39M.

[0027] In the electronic component 31M, the tip surface of the insulating rib 31a is located on the same plane as the contact surface between the wiring member 5 and the heat transfer member 8 (see Figure 6). Because the tip surface is on the same plane as the contact surface, the insulating heat transfer member 8 and the insulating rib 31a can easily electrically insulate one of the pair of component terminals 39M from the other. In addition, the heat dissipation path from the electronic component 31M to the heat transfer member 8 can be easily optimized. In this embodiment, the heat dissipation path of the electronic component 31M is thermally connected in the following order: the electronic component 31M, the heat dissipation structure 51HDS of a specific busbar 5, the heat transfer member 8, and the cooling member 9.

[0028] As shown in Figure 3, the first rigid member 32 is fixed to the base plate 2. The first rigid member 32 may be bonded to the base plate 2, for example. The first rigid member 32 may have, for example, a first bonding surface 32b. The first bonding surface 32b is a plane facing the -Z direction. The first bonding surface 32b corresponds to the bottom surface 3b of the first module 3. The first bonding surface 32b may be bonded to the first surface 2a, for example, by adhesive, thermocompression bonding, laser welding, etc., so that the first rigid member 32 is bonded to the base plate 2.

[0029] The first rigid member 32 comprises a pair of first flanges 33, a housing portion 34, and a plurality of first reinforcing ribs 37. The first rigid member 32 is an integrally molded product in which the pair of first flanges 33, the housing portion 34, and the plurality of first reinforcing ribs 37 are all integrated. The first rigid member 32 is a synthetic resin product.

[0030] The housing section 34 comprises a peripheral wall 35 and a bottom 36. The peripheral wall 35 protrudes upright from the bottom 36 in the +Z direction. The peripheral wall 35 may have a plurality of notches 35n cut out in the -Z direction from the +Z side edge 35t in a portion of the periphery of the electronic component 31.

[0031] The housing section 34 has a housing space 34s that houses at least a portion of the electronic components 31. The housing space 34s is a space defined by the contour of the inner surface of the peripheral wall 35 and the surface of the bottom 36 facing the +Z direction. The housing space 34s may, for example, have a roughly rectangular parallelepiped contour.

[0032] The pair of first flanges 33 extend from the -Z direction end of the housing portion 34 to both ends in one horizontal direction. The surface of the bottom 36 facing the -Z direction and the surfaces of the pair of first flanges 33 facing the -Z direction may, for example, be flush with each other, thereby forming the first bonding surface 32b as a whole.

[0033] Multiple first reinforcing ribs 37 support the peripheral wall 35 from the outer circumference. Each first reinforcing rib 37 may be a triangular rib fitted into the corner (concave angle) between the peripheral wall 35 and each first flange 33.

[0034] The multiple first modules 3 may include, for example, a relay module 3R. In this case, as shown in Figure 3, the relay module 3R includes a relay 31R as an electronic component 31. As described above, the relay 31R is an example of an electronic component 31M.

[0035] In the relay module 3R, at least one of the multiple notches 35n in the peripheral wall 35 is cut out such that a pair of component terminals 39 are exposed from between the peripheral wall 35 toward the outside of the first rigid member 32. That is, in the relay module 3R, at least one of the multiple notches 35n in the peripheral wall 35 may be cut out such that a busbar 5 connected to the component terminals 39 can pass through the notch 35n between the inside and outside of the first rigid member 32.

[0036] In each relay module 3R, for example, a pair of component terminals 39 of the electronic component 31 may face outward from the electrical connection unit 1 via the cover 6. In each relay module 3R, for example, the electronic component 31 may be arranged such that one or both of the pair of component terminals 39 of the electronic component 31 face and are exposed to the inner surface of the cover 6 in the horizontal direction.

[0037] The multiple first modules 3 may include, for example, a fuse module 3F. In this case, as shown in Figure 4, the fuse module 3F includes a fuse 31F as an electronic component 31. As described above, the fuse 31F is an example of an electronic component 31N.

[0038] In the fuse module 3F, at least one pair of the multiple notches 35n in the peripheral wall 35 is cut out so that a pair of component terminals 39 can protrude beyond the peripheral wall 35. The fuse module 3F may also include, for example, a pair of fixed terminals 38 that are fastened to the pair of component terminals 39. A corresponding component terminal 39 is fastened to each fixed terminal 38. As described above, an engaging member 388 that can engage with the fixed terminal 38 is used to fasten the component terminals 39N.

[0039] <4. Configuration of the Second Module>A plurality of terminal modules 4 will be described. The plurality of terminal modules 4 are a plurality of units that are divided so that each bears one of the minimum units of the connection terminal function in the electrical connection unit 1. The plurality of terminal modules 4 may include, for example, a terminal module 4 for connection to an external device. As shown in FIG. 5, each terminal module 4 includes a connection terminal 41 and a terminal block 42.

[0040] Each terminal module 4 may include, for example, only one connection terminal 41 and one terminal block 42 corresponding to this one connection terminal 41 among the plurality of connection terminals 41 and the plurality of terminal blocks 42 included in the electrical connection unit 1.

[0041] The connection terminal 41 protrudes and extends in the +Z direction from the end face 42a on the +Z direction side of the terminal block 42. The connection terminal 41 is electrically connected to at least one of the plurality of first modules 3 via a bus bar 5, other terminal modules 4, etc.

[0042] The terminal block 42 includes a main body portion 43, a pair of second flanges 44, and a plurality of second reinforcing ribs 45. The terminal block 42 is an integrally molded product in which the entire body including the main body portion 43, the pair of second flanges 44, and the plurality of second reinforcing ribs 45 is integrated. The terminal block 42 is a synthetic resin product.

[0043] The terminal block 42 is fixed to the base plate 2. The terminal block 42 may be fixed to the base plate 2, for example, by adhesion. The terminal block 42 may have, for example, a second adhesive surface 42b. The second adhesive surface 42b is a plane facing in the -Z direction. The second adhesive surface 42b corresponds to the bottom surface of the entire surface of the terminal block 42 extending from the main body portion 43 to the pair of second flanges 44. The second adhesive surface 42b may be adhered to the first surface 2a by, for example, an adhesive, thermocompression bonding, laser welding, etc., so that the connection terminal 41 is adhered to the base plate 2.

[0044] The main body portion 43 is a portion that occupies most of the terminal block 42. The end face on the +Z direction side of the main body portion 43 may correspond to, for example, the end face 42a. The main body portion 43 supports the connection terminal 41.

[0045] A pair of second flanges 44 project from both ends in one horizontal direction from the -Z direction end of the main body 43. The surface of the main body 43 facing the -Z direction and the surfaces of the pair of second flanges 44 facing the -Z direction may form a continuous flat surface, for example, a flat surface in surface continuity, to constitute the second bonding surface 42b as a whole.

[0046] A plurality of second reinforcing ribs 45 support the main body 43 from the outer periphery. Each second reinforcing rib 45 may be a triangular rib that fits into the corner (concave corner) between the outer periphery 43a of the main body 43 and each second flange 44.

[0047] <5. Configuration of wiring members> A plurality of busbars 5 will be described. Each busbar 5 is a wiring member (electrical connection member) for electrically connecting between the first module 3 and the first module 3, between the first module 3 and the terminal module 4, or between the terminal module 4 and the terminal module 4. Each busbar 5 extends between the first module 3 and the first module 3, between the first module 3 and the terminal module 4, or between the terminal module 4 and the terminal module 4. Each busbar 5 is a metal product and has conductivity. Each busbar 5 may be made of a metal such as copper or aluminum, for example.

[0048] (Configuration of busbar) First, as examples of the busbar 5, a first-type busbar 5A, a second-type busbar 5B, a third-type busbar 5C, a fourth-type busbar 5D, and a fifth-type busbar 5E can be cited.

[0049] The first-type busbar 5A has, for example, a first connection portion 51, a second connection portion 52, and an extension portion 54. The second-type busbar 5B has a plurality of second connection portions 52 and an extension portion 54. The third-type busbar 5C has a first connection portion 51, a third connection portion 53, and an extension portion 54. The fourth-type busbar 5D has a second connection portion 52, a third connection portion 53, and an extension portion 54. The fifth-type busbar 5E has a plurality of first connection portions 51 and an extension portion 54.

[0050] In this embodiment, each of the first connecting portion 51, the second connecting portion 52, the third connecting portion 53, and the extended portion 54 has a partially flattened rectangular cross-sectional shape. In this embodiment, each of the second connecting portion 52, the third connecting portion 53, and the extended portion 54 is plate-shaped. Furthermore, in the modified examples described later (second and third modified examples), each of the first connecting portion 51, the second connecting portion 52, and the extended portion 54 is plate-shaped.

[0051] (First connection part) The first connection part 51 is the part that is electrically connected to the electronic component 31. The first connection part 51 is provided at one end of the busbar 5. The first connection part 51 has a first surface 51a and a second surface 51b. The first surface 51a is the surface facing the component terminal 39. The first surface 51a is the surface facing away from the component terminal 39. In the first direction, the first connection part 51 has an insertion hole 51h used for fastening by a fastening member. For example, in this embodiment, the first connection part 51 has an insertion hole 51h (see Figure 1) through which the component terminal 39 of the electronic component 31M (or / and the fixed terminal 38 of the electronic component 31N) passes.

[0052] Furthermore, among the busbars having the first connection portion 51, a specific busbar 5 has a heat dissipation structure 51HDS on the first surface 51a of the first connection portion 51. The heat dissipation structure 51HDS will be described later. In the first direction (for example, the Y direction), the maximum thickness of the first connection portion 51 is greater than the thickness of the extension portion 54 in the first direction. That is, the thickness of the first connection portion 51 in the heat dissipation structure 51HDS is greater than the thickness of the extension portion 54 in the first direction.

[0053] (Second connection part) The second connection part 52 is the part that is connected to an external device via the terminal module 4. The second connection part 52 is provided on the part of the busbar 5 excluding one end. The second connection part 52 has an insertion hole through which the connection terminal 41 passes.

[0054] (Third connection part) The third connection part 53 is a part that is joined to a predetermined busbar by mechanical joining, metallurgical joining, or chemical joining. The third connection part 53 is provided on the part of the busbar 5 excluding one end. The third connection part 53 may have notches, openings, or other configurations for joining purposes.

[0055] (Extended portion) The extended portion 54 extends from the first connection portion 51 or the second connection portion 52. For example, in this disclosure, the extended portion 54 in busbar 5A is provided between the first connection portion 51 and the second connection portion 52. In busbar 5B, the extended portion 54 is provided between a plurality of second connection portions 52. In busbar 5C, the extended portion 54 is provided between the first connection portion 51 and the third connection portion 53. In busbar 5D, the extended portion 54 is provided between the second connection portion 52 and the third connection portion 53. In busbar 5E, the extended portion 54 is provided between a plurality of first connection portions 51.

[0056] At least a portion of each busbar 5 (busbars 5A, 5B, 5C, 5D, 5E) is plate-shaped. As shown in Figures 1 and 2, some of the busbars 5 may be, for example, curved plates throughout.

[0057] Some of the busbars 5 may be forming busbars, for example, that are curved in a horizontal plane and whose orientation changes continuously from vertical to horizontal (or from horizontal to vertical). In this case, the forming busbars 5 may be pre-formed into the shape to be routed before being combined with the first module 3 or terminal module 4.

[0058] For example, some of the busbars 5 in busbar 5A are bent in the horizontal plane at the extended portion 54, and are bent so that the direction in which the plate surface faces changes continuously from vertical to horizontal (or from horizontal to vertical). For example, the extended portion 54 in busbar 5D is bent in the horizontal plane, and is bent so that the direction in which the plate surface faces changes continuously from vertical to horizontal (or from horizontal to vertical). For example, some of the busbars 5 in busbar 5E are bent in the horizontal plane at the extended portion 54, and are bent so that the direction in which the plate surface faces changes continuously from vertical to horizontal (or from horizontal to vertical).

[0059] Some of the multiple busbars 5 may branch off into multiple paths, for example, along a different route. Some of the multiple busbars 5 may be assemblies in which multiple forming busbars are connected in such a way that they branch off into multiple paths. In this case, the multiple forming busbars to be combined may be connected in advance before being combined with the first module 3 or terminal module 4.

[0060] For example, bus bar 5E in this disclosure branches to bus bar 5C via a third connection part 53. For example, bus bar 5E in this disclosure branches to bus bar 5D via a third connection part 53.

[0061] Some of the multiple busbars 5 may be flat plates having a rectangular surface oriented vertically. Some of the multiple busbars 5 may be flat plates having an L-shaped surface oriented vertically.

[0062] Of the ends of each busbar 5, the end connected to the first module 3 may be fastened to, for example, a component terminal 39. Of the ends of each busbar 5, the end connected to the terminal module 4 may be fastened to, for example, a connection terminal 41.

[0063] (Bus bar heat dissipation structure) The heat dissipation structure of the bus bar 5 will now be described. As described above, the heat dissipation structure 51HDS is present in a specific bus bar 5 among the bus bars having the first connection portion 51. For example, in this embodiment, each of the bus bars 5A and 5C that are electrically connected to the electronic components 31 (electronic components 31R, 31M) has a heat dissipation structure 51HDS on the first surface 51a of the first connection portion 51.

[0064] The first surface 51a of the first connection portion 51 has a heat dissipation structure 51HDS that includes at least one of a recess and / or a projection. The recess and / or projection is located around the insertion hole 51h. For example, the heat dissipation structure 51HDS in this embodiment includes two projections. In this busbar, one projection is located on the -X side with respect to the insertion hole 51h. In this busbar, the other projection is located on the +X side with respect to the insertion hole 51h. The amount of protrusion of each projection is preferably such that, when viewed from one direction, the head 39a of the component terminal 39 of the electronic component 31M (or / or the engaging member 388 that engages with the fixed terminal 38 of the electronic component 31N) is covered. It is preferable that the amount of protrusion of each projection is about the same, but even if there is a difference in the amount of protrusion between each projection, the heat transfer member 8 can compensate for the difference in the amount of protrusion.

[0065] Furthermore, the heat dissipation structure 51HDS may include a recess. For example, the heat dissipation structure 51HDS is a counterbore capable of accommodating the head 39a (or / and the engaging member 388) of the component terminal 39. In addition, the heat dissipation structure 51HDS may have a notch that is cut out vertically or horizontally in a portion of the periphery of the electronic component 31. This notch allows the heat dissipation structure 51HDS to include a recess. The width of the notch is greater than the diameter of the head 39a (or / and the width across flats of the engaging member 388) of the component terminal 39.

[0066] In this embodiment, the first connection part 51 having a heat dissipation structure 51HDS is used for electrical connection with the relay 31R. In this embodiment, the components constituting the heat dissipation path are arranged in the order of the first connection part 51, the heat transfer member 8, and the cooling member 9. The shaft portion 39b of the component terminal 39M is passed through the insertion hole 51h.

[0067] <6. Heat Transfer Member> (Heat Transfer Member) The heat transfer member 8 is a member for transferring heat generated by the electronic components 31 (electronic components 31M, electronic components 31N) when energized, and / or heat generated by the busbar 5 itself (Joule heat) when energized, to the cooling member 9. The heat transfer member 8 is, for example, an elastic heat transfer sheet (for example, a thermally conductive silicone sheet). The heat transfer member 8 is formed of a material with a higher thermal conductivity than, for example, the base plate 2. However, the heat transfer member 8 is not limited to the above example, and may be a heat transfer member formed of a thermally conductive gel or other material. The heat transfer member 8 in this disclosure is insulating.

[0068] The heat transfer member 8 has a first surface 8a and a second surface 8b. The first surface 8a faces the cooling surface 9CS of the cooling member 9. The second surface 8b faces at least the first connection portion 51 of the busbar 5. On the second surface 8b, the component terminals 39 may be in contact with the heat transfer member 8. The first surface 8a is an example of a second surface on the heat transfer member 8. The second surface 8b is an example of a third surface on the heat transfer member 8.

[0069] The heat transfer member 8 is positioned between the busbar 5 or heat dissipation member 99 and the cooling member 9. The heat dissipation member 99 will be explained in the modified examples described later.

[0070] Examples of the heat transfer member 8 include a first-type heat transfer member 8A and a second-type heat transfer member 8B. The heat transfer member 8B will be described later in a modified example. The first-type heat transfer member 8A has a size that spans the heat dissipation structure 51HDS of busbars 5A and 5C, which are electrically connected to the electronic component 31 (electronic components 31R, 31M). For example, when viewed from the Y direction, the heat transfer member 8A is positioned to overlap with the heat dissipation structure 51HDS of busbar 5A and busbar 5C (see Figures 1 and 6).

[0071] In this embodiment, the heat transfer member 8A is positioned between the busbar 5 and the cooling member 9. The heat transfer member 8A is in contact with the heat dissipation structure 51HDS and the cooling surface 9CS of the cooling member 9, respectively. The heat transfer member 8A transfers heat from the electronic components 31 (electronic components 31M, electronic components 31N) to the busbar 5, and / or heat generated by the busbar 5, from the heat dissipation structure 51HDS of the busbar 5 to the main body 90 of the cooling member 9.

[0072] <7. Cooling Member> The cooling member 9 is a cooling member that employs a liquid cooling method. The cooling member 9 cools the heat received from the heat transfer member 8 by water cooling. The cooling member 9 has a cooling surface 9CS. The cooling surface 9CS is at least a part of the surface of the cooling member 9. On the cooling surface 9CS, the heat transferred from the electronic components 31 (electronic components 31M, electronic components 31N) to the busbar 42, and / or the heat generated by the busbar 42, is transferred by the heat transfer member 8. In this embodiment, the cooling surface 9CS includes a second direction and a third direction. That is, the cooling surface 9CS intersects with respect to the first direction (for example, the Z direction).

[0073] The cooling member 9 comprises a main body 90 and a flow path 91. The flow path 91 includes a first flow path 91a and a second flow path 91b. The first flow path 91a is located on the -X direction side with respect to the main body 90. The second flow path 91b is located on the +X direction side with respect to the main body 90. The main body 90 has a metal surface at least on the cooling surface 9CS. For example, the main body 90 may be made of a metal such as copper or aluminum. Cooling water is introduced into the main body 90, flowing from the first flow path 91a to the second flow path 91b. When the main body 90 receives heat through the cooling surface 9CS, the main body 90 is cooled by the cooling water introduced into the main body 90.

[0074] <8. Advantages> The electrical connection unit 1 of this embodiment comprises an electronic component 31, a wiring member (for example, a busbar 5), and a cooling member 9. The wiring member has a connection portion (for example, a first connection portion 51) that is electrically connected to the electronic component 31. The cooling member 9 cools the connection portion. With this configuration, it is possible to suppress a localized temperature rise at the connection portion of the wiring member, thereby improving the thermal characteristics of the electrical connection unit. Therefore, the electrical connection unit of this disclosure is more likely to improve heat dissipation.

[0075] Furthermore, the electrical connection unit 1 of this embodiment further comprises fastening members (component terminals 39, engaging members 388). In a first direction (for example, the Y direction and the Z direction), the fastening members electrically connect the wiring member by fastening to the electronic components 31 (electronic components 31M, 31N). In the first direction, the connection portion has a first through hole (through hole 51h) used for fastening by the fastening members. In the first direction, the first surface (first surface 51a) of the connection portion has a heat dissipation structure 51HDS including at least one of a recess and a projection. The first surface 51a is the surface facing the fastening members. With this configuration, it is easy to increase the heat transfer area between the wiring member and the cooling member 9. Therefore, the electrical connection unit of this embodiment can be further improved in terms of heat dissipation.

[0076] Furthermore, in the electrical connection unit 1 of this embodiment, the cable routing member further includes an extended portion 54 extending from the connection portion. The maximum thickness of the connection portion (for example, the first connection portion 51) in the first direction is greater than the thickness of the extended portion 54 in the first direction. With this configuration, the cable routing member easily accumulates heat at the connection portion. The heat accumulated at the connection portion is dissipated by the cooling member 9. Therefore, the electrical connection unit of this embodiment is designed to easily improve heat dissipation efficiency.

[0077] Furthermore, in the electrical connection unit 1 of this embodiment, the wiring member includes a first wiring member (bus bar 5A) and a second wiring member (bus bar 5C). The heat transfer member 8 faces the connection portion of the first wiring member and the second wiring member. With this configuration, the heat transfer member 8A thermally connects the bus bar 5A and the bus bar 5C. In this case, if the temperature of the bus bar 5A becomes lower than the temperature of the bus bar 5C, some of the heat from the bus bar 5A is transferred to the cooling member 9 and the bus bar 5C via the heat transfer member 8. By equalizing the heat of the multiple bus bars 5, the heat dissipation performance of the electrical connection unit 1 can be further improved.

[0078] In this embodiment of the electrical connection unit 1, each electronic component 31 is mounted on the base plate 2 via a first rigid member 32. This configuration allows for the free arrangement of multiple electronic components 31 on the base plate 2. With this electrical connection unit 1, each first module 3, which is an element-based module of electronic components, can be arranged on the base plate 2 in a free layout according to the functions required by the product. In addition, with this electrical connection unit 1, the electronic components 31 can be flexibly arranged on the base plate 2 in response to changes or modifications to the layout, for example. Therefore, the development period can be shortened.

[0079] As a comparative example, consider an electrical connection unit in which a resin component holds multiple electronic components together. In such a comparative example, the designer needs to design the arrangement of the multiple electronic components on the resin component. When such a design is required, the arrangement of the multiple electronic components on the resin component must be designed for each electrical connection unit with different specifications. Therefore, in such a comparative example, the design of the electrical connection unit is time-consuming.

[0080] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each first module 3 to be freely arranged according to the functions required for the product. Therefore, as described above, the development period can be shortened.

[0081] Furthermore, in the comparative examples described above, the electrical connection unit may have a unique design for the product to which it is applied. Therefore, the comparative examples have low versatility for other products and are difficult to adapt.

[0082] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each first module 3 to be composed of standard parts. Therefore, it has high versatility for use in other products and is easy to adapt to other products.

[0083] Furthermore, in the electrical connection unit 1 of this embodiment, one of the electronic components used is mounted on one first rigid member 32. With this configuration, the first modules 3 can be reused among multiple electrical connection units 1 with different arrangements of the first modules 3, or within an electrical connection unit 1. Therefore, the quality and reliability of the electrical connection unit 1 can be improved.

[0084] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to use standard unit modules as multiple first modules 3. Therefore, lead time and cost can be reduced.

[0085] Furthermore, with the electrical connection unit 1 of this embodiment, existing modules can be utilized as each first module 3. Therefore, the time and cost required for design and manufacturing can be reduced.

[0086] Furthermore, according to the electrical connection unit 1 of this embodiment, if improvements are needed in a specific set of first modules 3, efficient modifications can be made focusing on those specific modules 3. Therefore, this can contribute to improving the efficiency of maintenance work.

[0087] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to create a layout in which, for example, multiple first modules 3 are arranged on a base plate 2 of a specified size. Therefore, the electrical connection unit 1 can be configured freely, flexibly, and quickly.

[0088] Furthermore, according to the electrical connection unit 1 of this embodiment, the first rigid member 32 is made of synthetic resin, which makes the electrical connection unit 1 lighter. On the other hand, because the base plate 2 is made of metal, deformation of the base plate 2 caused by the weight of the multiple first modules 3 is suppressed.

[0089] Furthermore, in the electrical connection unit 1 of this embodiment, the first rigid member 32 is equipped with a housing portion 34, thereby protecting the electronic component 31. Therefore, the electrical connection unit 1 can be made more robust.

[0090] Furthermore, according to the electrical connection unit 1 of this embodiment, the terminal module 4 is equipped with connection terminals 41, which allows for flexible adaptation to the connection specifications of the electrical connection unit 1. For example, if the connection terminals 41 for connecting to external devices are modularized as individual terminals, such as in the terminal module 4, then flexible adaptation to the specifications of external devices becomes possible.

[0091] Furthermore, in the electrical connection unit 1 of this embodiment, the first rigid member 32 is bonded to the base plate 2. With this configuration, the arrangement of each first rigid member 32 on the base plate 2 can be freely set. Therefore, the manufacturer can freely set the arrangement layout of multiple first modules 3.

[0092] Furthermore, according to the electrical connection unit 1 of this embodiment, multiple first modules 3 can be arranged on one side of the base plate 2. Therefore, the electrical connection unit 1 can be made lower in profile.

[0093] Furthermore, according to the electrical connection unit 1 of this embodiment, the busbar 5 is fastened to the component terminals 39 (component terminals 39M, 39N). This configuration reduces the number of wiring members that electrically connect the multiple first modules 3.

[0094] (Various Modifications) Next, several modifications will be described. Note that, apart from the configurations described below, each modification is the same as that of the first or second embodiment described above.

[0095] (First Modified Example) In the above embodiment, the first connection portion 51 having the heat dissipation structure 51HDS is used for electrical connection with the relay 31R. On the other hand, in this modified example, the first connection portion 51 having the heat dissipation structure 51HDS may be used for electrical connection with the fuse 31F. In that case, the components constituting the heat dissipation path are arranged in the order of component terminal 39N, first connection portion 51, heat transfer member 8, and cooling member 9. In the heat dissipation path of the electronic component 31N in this modified example, the electronic component 31N, the heat dissipation structure 51HDS of the specific busbar 5, the heat transfer member 8, and the cooling member 9 are thermally connected in that order. Also in this modified example, the engaging member 388 may be in contact with the heat transfer member 8 on the second surface 8b.

[0096] (Second Modification) In the above embodiment, each of the busbars 5A and 5C electrically connected to the electronic component 31 (electronic component 31R, 31M) has a heat dissipation structure 51HDS including two protrusions. On the other hand, in this modification, a busbar 5' is connected to the electronic component 31 (electronic component 31R, 31M). The busbar 5' is the same as the busbars 5A and 5C, except that it does not have a heat dissipation structure 51HDS on the first surface 51a of the first connection portion 51. With the electrical connection of the busbar 5', the electrical connection unit 1 further includes a heat dissipation member 99. The heat dissipation member 99 serves as a substitute for the heat dissipation structure 51HDS and plays a role in increasing the heat transfer area between the busbar 5' and the cooling member 9.

[0097] The heat dissipation member 99 has a through hole 99h (see Figure 7) through which the component terminal 39 of the electronic component 31M (or / and the fixed terminal 38 of the electronic component 31N) passes. The through hole 99h is an example of a second insertion hole. The size of the through hole 99h is larger than the diameter of the head of the component terminal 39 (or / and the width across flats of the engaging member 388). The heat dissipation member 99 has a predetermined thickness. The heat dissipation member 99 has a predetermined thickness so that the head of the component terminal 39 (or / and the engaging member 388) is accommodated in the through hole 99h. In the first direction (for example, the Y direction), the heat dissipation member 99 is positioned between the bus bar 5' and the cooling member 9.

[0098] The heat dissipation member 99 has an L-shaped cross-section in the first direction (see Figures 7 and 8). The L-shaped cross-section helps to suppress misalignment of the heat transfer member 8 relative to the heat dissipation member 99. The heat dissipation member 99 may be made of a metal such as copper or aluminum.

[0099] In this modified example, the heat dissipation path of the electronic component 31M is thermally connected in the following order: the electronic component 31M, the first connection portion 51 of the busbar 5', the heat dissipation member 99, the heat transfer member 8, and the cooling member 9. In combination with this modified example and modified example 1, the heat dissipation path of the electronic component 31N is thermally connected in the following order: the electronic component 31N, the first connection portion 51 of the busbar 5', the heat dissipation member 99, the heat transfer member 8, and the cooling member 9.

[0100] Furthermore, the heat dissipation member 99 and the busbar 5' may be integrated. When the heat dissipation member 99 is joined to the busbar 5' by mechanical joining, metallurgical joining, or chemical joining, the workability during assembly of the electrical connection unit 1 is improved.

[0101] (Third Modification) In the above embodiment, each of the busbars 5A and 5C electrically connected to the electronic component 31 (electronic components 31R, 31M) has a heat dissipation structure 90HDS including two protrusions. On the other hand, in this modification, a busbar 5' is connected to the electronic component 31 (electronic components 31R, 31M). The busbar 5' is the same as the busbars 5A and 5C, except that it does not have a heat dissipation structure 51HDS on the first surface 51a of the first connection portion 51. With the electrical connection of the busbar 5', the cooling member 9 has a heat dissipation structure 90HDS on the cooling surface 9CS that includes at least one of a recess and a protrusion. The heat dissipation structure 90HDS serves as a substitute for the heat dissipation structure 51HDS and plays a role in increasing the heat transfer area between the busbar 5' and the cooling member 9. The recess and / or protrusion are located on the axis of the fastening member. For example, the heat dissipation structure 90HDS in this modified example includes three protrusions. The amount of protrusion of each protrusion is preferably such that, when viewed from one direction, the head 39a (and / or the engaging member 388) of the component terminal 39 is covered. It is also preferable that the amount of protrusion of each protrusion is approximately the same. However, as shown in Figure 9 of this modified example, even if there is a difference in the amount of protrusion between the protrusions, the heat transfer member 8B described later can compensate for this difference in protrusion.

[0102] Furthermore, the heat dissipation structure 90HDS may include a recess. For example, the heat dissipation structure 90HDS is a counterbore capable of accommodating the head 39a (or / and the engaging member 388) of the component terminal 39. In addition, the heat dissipation structure 90HDS may have a notch that is cut out vertically or horizontally in a portion of the periphery of the electronic component 31. This notch allows the heat dissipation structure 90HDS to include a recess. The width of the notch is greater than the diameter of the head 39a (or / and the width across flats of the engaging member 388).

[0103] In this modified example, the electrical connection unit 1 includes a second type of heat transfer member 8B. The heat transfer member 8B is positioned between the bus bar 5' and the cooling member 9, and between the fastening member and the cooling member 9. In this modified example, one heat transfer member 8B is provided for one first connection portion 51 of the particular bus bar 5'. The heat transfer member 8B is positioned so as to overlap with the heat dissipation structure 90HDS of the cooling member 9 when viewed from a first direction (for example, the Y direction).

[0104] In this modified example, the heat dissipation path of the electronic component 31M is thermally connected in the following order: the electronic component 31M, the first connection portion 51 and / or extension portion 54 of the busbar 5', the heat transfer member 8, and the cooling member 9. In combination with this modified example and modified example 1, the heat dissipation path of the electronic component 31N is thermally connected in the following order: the electronic component 31N, the first connection portion 51 and / or extension portion 54 of the busbar 5', the heat transfer member 8, and the cooling member 9.

[0105] Furthermore, in this modified example, the heat dissipation structure 90HDS also plays a role in positioning the cooling member 9.

[0106] (Fourth Modification) In each of the embodiments described above, the electrical connection unit 1 includes a base plate 2 as a second rigid member. However, the second rigid member may be configured in any way as long as multiple first modules 3 can be mounted on it. As a modification, the second rigid member may be a block, a box, or the like instead of the base plate 2.

[0107] (Fifth Modification) In each of the embodiments described above, the electrical connection unit 1 is provided with a busbar 5 as a wiring member. However, the electrical connection unit 1 may be provided with any wiring member as long as it can be wired to a plurality of first modules 3. As a modification, the electrical connection unit 1 may be provided with wiring as a wiring member instead of the busbar 5.

[0108] (Sixth Modification) In each of the embodiments described above, the multiple first rigid members 32 are bonded to the base plate 2. However, the first rigid members 32 may be fixed in any way as long as the electronic components 31 can be arranged on the base plate 2 in a free layout. As a modification, the multiple first rigid members 32 may be fastened to the base plate 2.

[0109] (Seventh Modification) In each of the embodiments described above, the multiple terminal modules 4 are bonded to the base plate 2. However, the multiple terminal modules 4 can be fixed in any way as long as they can be arranged on the base plate 2 in a free layout. As a modification, the multiple terminal modules 4 may be fastened to the base plate 2.

[0110] Several embodiments and modifications have been described above. However, the embodiments and modifications are not limited to the examples described above. For example, multiple embodiments may be implemented in combination with each other.

[0111] According to one embodiment of this disclosure, it is easier to improve heat dissipation.

[0112] 1 Electrical connection unit 2 Base plate (second rigid member) 2a First surface 2b Second surface 3 First module 3b Bottom surface 3F Fuse module 3R Relay module 4 Terminal module (second module) 5, 5A, 5B, 5C, 5D, 5E Bus bar (wiring member) 51 First connection part 51h Through hole 51a First surface 51HDS Heat dissipation structure 51b Second surface 52 Second connection part 53 Third connection part 54 Extension part 6 Cover 8, 8A, 8B Heat transfer member 8a First surface 8b Second surface 9 Cooling member 90 Main body part 9CS Cooling surface 90HDS Heat dissipation structure 91, 91a, 91b Flow path 99 Heat dissipation member 99h Through hole 31, 31M, 31N Electronic component 31F Fuse 31R Relay 31T Part 32 First rigid member 32b First bonding surface 33 First flange 34 Housing section 34s Housing space 35 Peripheral wall 35n Notch 35t End edge 36 Bottom 37 First reinforcing rib 38 Fixing terminal 388 Engaging member 39 Component terminal 39a Head 39b Shaft section 41 Connection terminal 42 Terminal block 42a End face 42b Second bonding surface 43 Main body section 43a Outer circumference 44 Second flange 45 Second reinforcing rib

Claims

1. An electrical connection unit comprising: an electronic component; a wiring member having a connection portion electrically connected to the electronic component; and a liquid-cooled cooling member for cooling the connection portion.

2. The electrical connection unit according to claim 1, further comprising a fastening member for electrically connecting the wiring member by fastening with the electronic component in a first direction, wherein the connection portion has a first insertion hole used for fastening by the fastening member in the first direction, wherein the first surface of the connection portion has a heat dissipation structure including at least one of a recess and a projection, and the first surface is the surface facing the fastening member.

3. The electrical connection unit according to claim 2, wherein the cable member further includes an extended portion extending from the connection portion, and the maximum thickness of the connection portion in the first direction is greater than the thickness of the extended portion in the first direction.

4. The electrical connection unit according to claim 1, further comprising: a fastening member for electrically connecting the cable member by fastening with the electronic component in a first direction; and a heat dissipation member having a second through hole used for fastening by the fastening member, wherein the fastening member has a screw groove, the heat dissipation member accommodates the fastening member, the connection portion has a first through hole used for fastening by the fastening member in the first direction, and the heat dissipation member is positioned between the cable member and the cooling member in the first direction.

5. The electrical connection unit according to claim 1, further comprising a fastening member for electrically connecting the cable member by fastening with the electronic component in a first direction, the connection portion having a first insertion hole used for fastening by the fastening member in the first direction, and the surface of the cooling member having a heat dissipation structure including at least one of a recess and a protrusion in the first direction.

6. An electrical connection unit according to any one of claims 1 to 5, further comprising an insulating heat transfer member, wherein the cooling member has a cooling surface facing the wiring member, and the heat transfer member has a second surface facing the cooling surface and a third surface facing the wiring member.

7. The electrical connection unit according to claim 6, wherein the wiring member includes a first wiring member and a second wiring member, and the heat transfer member faces the connection portion of the first wiring member and the second wiring member.

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