Electrical connection unit

Abstract

This electrical connection unit comprises: a plurality of first modules that are each provided with an electronic component and a first rigid member on which the electronic component is mounted; and a second rigid member on which the plurality of first modules are mounted. The second rigid member extends in a first direction and a second direction that intersects the first direction, and, when viewed from a third direction that intersects the first direction and the second direction, has a gap region that is offset from the first rigid members. The first rigid member of each of the plurality of first modules is adjacent to the gap region on one side in the first direction and on one side in the second direction.

Description

Electrical connection unit

[0001] Embodiments of the present invention relate to an electrical connection unit. This application claims priority to Japanese Patent Application No. 2024-179776, 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 a housing.

[0003] Japanese Unexamined Patent Application Publication No. 2018-113184

[0004] By the way, an electrical connection unit may be formed by combining a metal member and a synthetic resin member. Since the linear expansion coefficients of the metal and the synthetic resin are different, improvement in resistance to thermal expansion / thermal contraction of the electrical connection unit is expected.

[0005] One embodiment provides an electrical connection unit with high resistance to thermal expansion / thermal contraction.

[0006] An electrical connection unit according to one embodiment includes a plurality of first modules each including an electronic component and a first rigid member on which the electronic component is mounted, and a second rigid member on which the plurality of first modules are mounted. The second rigid member extends in a first direction and a second direction intersecting the first direction, and has a gap region deviated from the first rigid member when viewed from a third direction intersecting the first direction and the second direction. Each of the first rigid members of the plurality of first modules is adjacent to the gap region on one side in the first direction and one side in the second direction, respectively.

[0007] According to one embodiment, it has high resistance to thermal expansion / thermal contraction.

[0008] A perspective view showing the electrical connection unit of the embodiment. A plan view showing the electrical connection unit of the embodiment. A perspective view showing the relay module of the embodiment. A perspective view showing the fuse module of the embodiment. A perspective view showing the terminal module of the embodiment. A plan view showing the positional relationship of the first module of the embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the embodiment. A perspective view showing the base plate of the first modified example.

[0009] The embodiments will be described below with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numerals. Duplication of these components may be omitted. Note that the components 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 X direction is an example of the "first direction". The Y direction is an example of the "second direction". The Z direction is an example of the "third direction".

[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] (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 motor of the vehicle, 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, and a plurality of busbars 5. 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 12), 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 a metal product made of, for example, metal, 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, for example, 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] Furthermore, the base plate 2 has a gap region 20 on its first surface 2a. The gap region 20 refers to the area that is separated from the first rigid member 32 of the first module 3, which will be described later, when viewed from the Z direction. In this embodiment, the gap region 20 is defined as the area that is separated not only from the first rigid member 32 but also from the terminal block 42 of the terminal module 4 when viewed from the Z direction. In other words, the first rigid member 32 and the terminal block 42 are not mounted in the gap region 20 when viewed from the Z direction (the first rigid member 32 and the terminal block 42 do not exist).

[0018] <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.

[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 be provided with, for example, a pair of component terminals 39.

[0021] 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.

[0022] 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 formed from synthetic resin.

[0023] 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.

[0024] 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.

[0025] The pair of first flanges 33 extend from the -Z direction end of the housing portion 34 to both ends in one direction horizontally. 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. In this embodiment, the outer shape of the first rigid member 32 when viewed from the Z direction is the shape formed by combining the pair of first flanges 33 and the bottom 36. The combined shape of the pair of first flanges 33 and the bottom 36 (first bonding surface 32b) is a rectangular shape with rounded corners when viewed from the Z direction. That is, the first rigid member according to this embodiment is formed in a rectangular shape that extends in the X and Y directions when viewed from the Z direction.

[0026] Multiple first reinforcing ribs 37 support the peripheral wall 35 from its 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.

[0027] The multiple first modules 3 may include, for example, relay modules 3R. In this case, as shown in Figure 3, the relay module 3R includes a relay 31R as an electronic component 31.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] In the fuse module 3F, at least one pair of notches 35n of 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. Each fixed terminal 38 is fastened to a corresponding component terminal 39.

[0032] <4. Configuration of the Second Module> The multiple terminal modules 4 will now be described. The multiple terminal modules 4 are multiple units that are divided so that each one is responsible for one of the smallest units of connection terminal function in the electrical connection unit 1. The multiple terminal modules 4 may include, for example, a terminal module 4 for connection to external equipment. As shown in Figure 5, each terminal module 4 is equipped with a connection terminal 41 and a terminal block 42.

[0033] Each terminal module 4 may, for example, comprise only one connection terminal 41 and one terminal block 42 corresponding to this one connection terminal 41, out of the multiple connection terminals 41 and multiple terminal blocks 42 included in the electrical connection unit 1.

[0034] The connection terminal 41 extends from the end face 42a on the +Z side of the terminal block 42, protruding in the +Z direction. The connection terminal 41 is electrically connected to at least one of the multiple first modules 3 via a bus bar 5, other terminal modules 4, etc.

[0035] The terminal block 42 comprises a main body 43, a pair of second flanges 44, and a plurality of second reinforcing ribs 45. The terminal block 42 is a single-piece molded product in which the main body 43, the pair of second flanges 44, and the plurality of second reinforcing ribs 45 are integrated. The terminal block 42 is a synthetic resin product formed from synthetic resin.

[0036] The terminal block 42 is fixed to the base plate 2. The terminal block 42 may be bonded to the base plate 2, for example. The terminal block 42 may have, for example, a second bonding surface 42b. The second bonding surface 42b is a plane facing the -Z direction. The second bonding surface 42b corresponds to the flush bottom surface of the terminal block 42 extending from the main body 43 to the pair of second flanges 44. The second bonding surface 42b may be bonded to the first surface 2a, for example, by adhesive, thermocompression, laser welding, etc., so that the connection terminals 41 are bonded to the base plate 2.

[0037] The main body portion 43 occupies most of the terminal block 42. The end face of the main body portion 43 on the +Z direction side may correspond to, for example, the end face 42a. The main body portion 43 supports the connection terminal 41.

[0038] The pair of second flanges 44 extend from the -Z direction end of the main body portion 43 to both ends in one direction horizontally. The surface of the main body portion 43 facing the -Z direction and the surface of the pair of second flanges 44 facing the -Z direction may, for example, be a continuous plane that is flush with the surface, thereby forming a second bonding surface 42b as a whole.

[0039] Multiple second reinforcing ribs 45 support the main body portion 43 from the outer circumference. Each second reinforcing rib 45 may be a triangular rib that fits into the corner (concave angle) between the outer circumference 43a and each second flange 44 of the main body portion 43.

[0040] <5. Configuration of the Routing Members> The multiple busbars 5 will now be described. Each busbar 5 is a routing member (electrical connection member) for electrically connecting the first module 3 to the first module 3, the first module 3 to the terminal module 4, or the terminal module 4 to the terminal module 4. Each busbar 5 extends between the first module 3 to the first module 3, between the first module 3 to the terminal module 4, or between the terminal module 4 to the terminal module 4. Each busbar 5 is a metal product formed of metal and is conductive. Each busbar 5 may be made of a metal such as copper or aluminum.

[0041] At least a portion of each busbar 5 is plate-shaped. As shown in Figures 1 and 2, some of the busbars 5 may be, for example, curved plates throughout.

[0042] 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.

[0043] 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.

[0044] Among the plurality of bus bars 5, some of the bus bars 5 may be flat plates having a rectangular plate surface facing in the vertical direction. Among the plurality of bus bars 5, some of the bus bars 5 may be flat plates having an L-shaped plate surface facing in the vertical direction.

[0045] Among the ends of each bus bar 5, the end connected to the first module 3 may be fastened to, for example, the component terminal 39. Among the ends of each bus bar 5, the end connected to the terminal module 4 may be fastened to, for example, the connection terminal 41.

[0046] <6. Positional relationship of the first module> The positional relationship of the plurality of first modules 3 will be described. FIG. 6 shows the positional relationship between the plurality of first modules 3 and the gap region 20. For convenience, the first first module 3 is designated as the first module 3A. Another first module 3 (the second first module 3) that is in contact with and adjacent to the first module 3A in the Y direction is designated as the first module 3B.

[0047] Also, regarding the gap region 20, for convenience, it is subdivided as gap regions 21, 22, 23, 24, 25 as follows. The gap region 21 is adjacent to the first module 3A in the X direction. Specifically, the gap region 21 is adjacent to the +X direction side among the pair of sides extending in the Y direction of the first module 3A. The gap region 22 is adjacent to the -X direction side of the first module 3A. That is, the gap region 22 is adjacent to the first module 3A at a position opposite to the gap region 21 in the X direction. Therefore, the first module 3A is sandwiched between the gap regions 20 that are separated from each other in the X direction. The gap region 23 is adjacent to the first module 3A in the Y direction. Specifically, the gap region 23 is adjacent to the +Y direction side among the pair of sides extending in the X direction of the first module 3A. The first module 3A is adjacent to the gap region 20 only on one side in the Y direction.

[0048] The gap region 24 is adjacent to the first module 3B in the X direction. Specifically, the gap region 24 is adjacent to the side in the -X direction among the pair of sides extending in the Y direction of the first module 3B. The first module 3B is adjacent to the gap region 20 only on one side in the X direction. The gap region 25 is adjacent to the first module 3B in the Y direction. The gap region 25 is adjacent to the side in the -Y direction among the pair of sides extending in the X direction of the first module 3B. The first module 3B is adjacent to the gap region 20 only on one side in the Y direction.

[0049] The first module 3A and the first module 3B are in contact with each other in the Y direction. Specifically, the respective first rigid members 32 of the first modules 3A and 3B are in contact. The first module 3A and the first module 3B are adjacent to the gap region 20 at the other position (the position where they are not in contact with each other) while being in contact with each other in the Y direction. Also, the first module 3B is in contact with a third first module 3 that is not the first module 3A in the +X direction. The first module 3B is not adjacent to any other first module 3 other than the first module 3A.

[0050] As described above, the first module 3A and the first module 3B are adjacent to the gap region 20 on at least one side in the X direction and the Y direction, respectively. In the first module 3A and the first module 3B, one side on one side in the X direction is defined as the first side, and one side on one side in the Y direction is defined as the second side. The first module 3A and the first module 3B of the present embodiment are adjacent to the gap region 20 over the entire first side and the second side. Also, not only the first module 3A and the first module 3B, but all the first modules 3 are adjacent to the gap region 20 over the entire first side and the second side on at least one side. In other words, all the first rigid members 32 are adjacent to the gap region 20 over the entire first side and the second side on at least one side. [[ID=,8]]

[0051] <7. Manufacturing method of the electrical connection unit> The manufacturing method of the electrical connection unit 1 will be described. The manufacturer manufactures the electrical connection unit 1 by performing the following first step to sixth step.

[0052] (First step) As shown in Figure 7, in the first step, the manufacturer prepares the base plate 2.

[0053] (Second Step) As shown in Figure 8, in the second step, the manufacturer attaches the multiple first rigid members 32 and the multiple terminal modules 4 to the base plate 2. The manufacturer may also bond the multiple first rigid members 32 and the multiple terminal modules 4 to the base plate 2. Alternatively, the manufacturer may attach the multiple first rigid members 32 such that at least one entire side in each of the X and Y directions is adjacent to the gap region 20.

[0054] (Third Step) As shown in Figure 9, in the third step, the manufacturer mounts some of the multiple electronic components 31 to be mounted on the first rigid member 32 onto the corresponding first rigid member 32. The manufacturer may fasten and fix the electronic components 31 to each first rigid member 32. As shown in Figure 9, in the third step, the manufacturer may mount, for example, a relay module 3R from the multiple electronic components 31 onto the corresponding first rigid member 32.

[0055] (Fourth Step) As shown in Figure 10, in the fourth step, the manufacturer places a plurality of busbars 5 on a plurality of first modules 3 and a plurality of terminal modules 4. For example, in the fourth step, the manufacturer may mount some of the remaining electronic components 31 to be mounted on the corresponding first rigid member 32. For example, as shown in Figure 10, in the fourth step, the manufacturer may mount a fuse module 3F on the corresponding first rigid member 32 from among the plurality of electronic components 31. Furthermore, in the fourth step, the manufacturer may mount a portion 31T of the remaining electronic components 31 to be mounted on the corresponding first rigid member 32.

[0056] (Fifth Step) In the fifth step, the manufacturer fastens multiple busbars 5 to multiple first modules 3 and multiple terminal modules 4. For example, as shown in Figure 11, in the fifth step, the manufacturer may mount the remaining parts of the electronic components 31 to be mounted onto the corresponding first rigid member 32.

[0057] (Sixth step) As shown in Figure 12, in the sixth step, the manufacturer attaches a cover 6 to the assembly on which the multiple first modules 3, multiple terminal modules 4, and multiple busbars 5 are attached to the base plate 2.

[0058] <8. Advantages> According to the electrical connection unit 1 of this embodiment, the first rigid member 32 is adjacent to the gap region 20 on one side in the X direction (first side) and one side in the Y direction (second side). With this configuration, even if the thermal expansion coefficients of the first rigid member 32 and the base plate 2 are different, the first rigid member 32 can easily expand / contract freely relative to the base plate 2. Therefore, the resistance of the electrical connection unit 1 to thermal expansion / contraction can be increased.

[0059] Furthermore, in this embodiment, the electrical connection unit 1 is adjacent to the gap region 20 along the entire length of both the first and second sides. This configuration allows the first rigid member 32 to expand and contract more freely with respect to the base plate 2. Therefore, the electrical connection unit 1 can be made more resistant to thermal expansion and contraction.

[0060] Furthermore, in the electrical connection unit 1 of this embodiment, all first rigid members 32 are adjacent to the gap region 20 on the first and second sides, respectively. With this configuration, all first rigid members 32 of the first module 3 can expand and contract freely with respect to the base plate 2. Therefore, the electrical connection unit 1 can be made more resistant to thermal expansion and contraction.

[0061] Furthermore, the first rigid member 32 in this embodiment is a synthetic resin product formed from synthetic resin. The base plate 2 (second rigid member) is a metal product formed from metal. Therefore, there is a tendency for the difference in thermal expansion coefficients between the first rigid member 32 and the base plate 2 to be significantly different. Even with such a combination of the first rigid member 32 and the base plate 2, the resistance of the electrical connection unit 1 to thermal expansion / contraction can be increased because all of the first rigid members 32 are adjacent to the gap region 20 on their first and second sides, respectively.

[0062] Furthermore, according to the electrical connection unit 1 of this embodiment, each electronic component 31 is mounted on the base plate 2 via the first rigid member 32. With this configuration, the arrangement of multiple electronic components 31 on the base plate 2 can be freely set. With such an electrical connection unit 1, each first module 3, which is an element module in the form of an electronic component, can be arranged on the base plate 2 in a free layout according to the functions required of the product. In addition, with such an 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each first module 3 to be constructed from standard components. Therefore, it has high versatility for use in other products and is easy to adapt to other products.

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] Furthermore, according to the electrical connection unit 1 of this embodiment, the first rigid member 32 is a synthetic resin product formed from synthetic resin, which makes the electrical connection unit 1 lighter. On the other hand, because the base plate 2 is a metal part, deformation of the base plate 2 caused by the weight of the multiple first modules 3 is suppressed.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] Furthermore, in the electrical connection unit 1 of this embodiment, the busbar 5 is fastened to the component terminal 39. This configuration reduces the number of wiring members that electrically connect the multiple first modules 3.

[0078] (Various Modifications) Next, several modifications will be described. Note that in each modification, the configuration other than that described below is the same as that of the embodiment described above.

[0079] (First Modification) In the above-described embodiment, the first surface 2a and the second surface 2b of the base plate 2 are smooth planes relative to each other. However, the first surface of the base plate 2 may be configured in any way as long as each first module 3 can be placed on it. As a modification, the electrical connection unit 1 may include a base plate 102 instead of the base plate 2. In the base plate 102, for example, as shown in Figure 13, the surface roughness of the first surface 102a is rougher than that of the second surface 102b by applying a minute uneven surface treatment to the first surface 102a. The second surface 102b is a smooth plane similar to the second surface 2b of the base plate 2. Due to the large surface roughness of the first surface 102a, the base plate 102 can exert a fixing anchor effect on the first module 3 and terminal module 4 on which it is placed. In this case, each first module 3 may be bonded to the first surface 102a of the base plate 102, for example, as in the above-described embodiments. As a result of this effect, the first module 3 and the terminal module 4 are less likely to detach from the base plate 102. Therefore, the electrical connection unit 1 can be made more robust. As another modification, a minute uneven surface treatment may be applied only to the area of ​​the first surface 102a of the base plate 102 on which the first module 3 and the terminal module 4 are placed.

[0080] (Second Modification) In the above-described embodiment, 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.

[0081] (Third Modification) In the above embodiment, the electrical connection unit 1 includes a busbar 5 as a wiring member. However, the electrical connection unit 1 may include 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 include wiring as a wiring member instead of the busbar 5.

[0082] (Fourth Modification) In the above-described embodiment, 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.

[0083] (Fifth Modification) In the above-described embodiment, 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.

[0084] (Sixth Modification) In the above embodiment, all first rigid members 32 are adjacent to the gap region 20 over the entirety of at least one first side and second side. However, not all first rigid members 32 are adjacent to the gap region 20 over the entirety of at least one first side and second side. That is, some of the first rigid members 32 are adjacent to the gap region 20 over the entirety of at least one first side and second side.

[0085] Embodiments and several modifications have been described above. However, the embodiments and modifications are not limited to the examples described above. For example, embodiments and modifications may be implemented in combination with each other.

[0086] According to one embodiment, it has high resistance to thermal expansion / contraction.

[0087] 1 Electrical connection unit 2 Base plate (second rigid member) 2a First surface 2b Second surface 20, 21, 22, 23, 24, 25 Gap area 3, 3A, 3B First module 3b Bottom surface 3F Fuse module 3R Relay module 4 Terminal module (second module) 5 Bus bar (routing member) 6 Cover 31 Electronic component 31F Fuse 31R Relay 31T Part 32 First rigid member 32b First adhesive surface 33 First flange 34 Housing section 34s Housing space 35 Peripheral wall 35n Notch 35t Edge 36 Bottom 37 First reinforcing rib 38 Fixing terminal 39 Component terminal 41 Connection terminal 42 Terminal block 42a End surface 42b Second adhesive surface 43 Main body 43a Outer circumference 44 Second flange 45 Second reinforcing rib 102 Base plate (second rigid member) 102a First surface 102b Second surface

Claims

1. An electrical connection unit comprising: a plurality of first modules, each having an electronic component and a first rigid member on which the electronic component is mounted; and a second rigid member on which the plurality of first modules are mounted, wherein the second rigid member extends in a first direction and in a second direction intersecting the first direction, and has a gap region that is separated from the first rigid member when viewed from a third direction intersecting the first and second directions, and each of the plurality of first modules' first rigid members is adjacent to the gap region on one side in the first direction and on one side in the second direction.

2. The electrical connection unit according to claim 1, wherein the first rigid member is formed in a rectangular shape that extends in the first and second directions when viewed from the third direction, and is adjacent to the gap region along the entire first side on one side in the first direction and the entire second side on one side in the second direction.

3. The electrical connection unit according to claim 1 or 2, wherein all of the first rigid members of the plurality of first modules are adjacent to the gap region on one side in the first direction and on one side in the second direction.

4. The electrical connection unit according to claim 1 or 2, wherein the first rigid member is made of synthetic resin and the second rigid member is made of metal.

5. The electrical connection unit according to claim 1 or 2, wherein the first rigid member is bonded to the second rigid member.

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