Electrical connection unit

Abstract

An electrical connection unit according to the present invention comprises a plurality of mounted components and a support body. The support body comprises: a rigid member that has a mounting surface on which the plurality of mounted components are mounted; and a plurality of protrusions that protrude from the mounting surface. The plurality of protrusions contact the plurality of mounted components along the mounting surface.

Description

Electrical connection unit

[0001] An embodiment of the present invention relates to an electrical connection unit. This application claims priority from Japanese Patent Application No. 2024-179733 filed in Japan on October 15, 2024, and incorporates its content herein by reference.

[0002] In an electrical connection unit, it is known that mounting components such as relays, fuses, and bus bars are mounted on a support.

[0003] Japanese Unexamined Patent Application Publication No. 2023-173002

[0004] However, in the case as a support disclosed in Patent Document 1, it is necessary to prepare a case having a unique shape corresponding to a plurality of mounting components to be mounted for each specification. Therefore, the case disclosed in Patent Document 1 may be inferior in versatility for different specifications.

[0005] One embodiment provides an electrical connection unit with high versatility.

[0006] An electrical connection unit according to one embodiment includes a support including a plurality of mounting components, a rigid member having a mounting surface on which the plurality of mounting components are mounted, and a plurality of protrusions protruding from the mounting surface, and the plurality of protrusions are in contact with the plurality of mounting components in a direction along the mounting surface.

[0007] According to one embodiment, the versatility is high.

[0008] Perspective view showing the electrical connection unit of the first embodiment. Perspective view showing the electrical connection unit with the cover of the first embodiment seen through. Perspective view showing the electrical connection unit with the cover of the first embodiment seen through. Perspective view showing the relay module of the first embodiment. Perspective view showing showing the fuse module of the first embodiment. Perspective view showing the support of the first embodiment. Perspective view showing the electrical connection unit of the second embodiment. Perspective view showing the electrical connection unit with the cover of the second embodiment seen through. Perspective view showing the support of the second embodiment.

[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 module 3, which will be described later (see Figure 2). 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 Z direction is an example of the "first direction." The X direction is an example of the "second direction." Note that the "second direction" is not limited to the X direction, but may be the Y 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 to 3, the electrical connection unit 1 comprises a support 8, a plurality of modules 3, a plurality of busbars 5, and a cover 6. The support 8 comprises a base plate 2 and a projection 4. Each of the plurality of modules 3 and the plurality of busbars 5 is an example of a mounted component. The base plate 2 is an example of a rigid member. Each busbar 5 is an example of a cable routing member. In the electrical connection unit 1, the plurality of modules 3 and the plurality of busbars 5 are covered by the support 8 from the -Z direction and covered by the cover 6 from the +Z direction. That is, in the electrical connection unit 1, the plurality of modules 3 and the plurality of busbars 5 are housed in a housing which is a combination structure of the cover 6 and the support 8. Figures 2 and 3 show the electrical connection unit 1 with the cover 6 visible through it.

[0015] <2. Module Configuration> The multiple modules 3 will now be described. The multiple 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 modules 3 are arranged along the first surface 2a of the base plate 2. Each module 3 is placed on the base plate 2 with its bottom surface 3b facing the first surface 2a. Each module 3 is provided on the first surface 2a side of the base plate 2. Each module 3 may, for example, be placed on the first surface 2a.

[0016] Among the multiple modules 3, each of some modules 3 may have a gap between it and other adjacent modules 3 in the X direction, for example. Among the multiple modules 3, each of some modules 3 may have a gap between it and other adjacent modules 3 in the Y direction, for example.

[0017] As shown in Figures 4 and 5, each module 3 comprises an electronic component 31 and a partial rigid member 32. One electronic component 31 is mounted on each partial rigid member 32. That is, each of the multiple electronic components 31 provided in the electrical connection unit 1 is mounted on the support 8 with each component individually mounted on a corresponding partial rigid member 32. Each module 3 may, for example, comprise only one electronic component 31 and one partial rigid member 32 corresponding to (this one electronic component 31) from the multiple electronic components 31 and multiple partial rigid members 32 included in the electrical connection unit 1.

[0018] Each electronic component 31 is an electronic component mounted in accordance with the function required of the electrical connection unit 1. Each electronic component 31 may be fixed to the corresponding partial rigid member 32 by fastening to the corresponding partial rigid member 32, for example. Each electronic component 31 may be mounted on the base plate 2 while housed in the corresponding partial rigid member 32, for example. Examples of electronic components 31 include fuses, relays (e.g., mechanical relays or semiconductor relays), resistors (e.g., pre-charge resistors), capacitors, various sensors (e.g., current sensors or voltage sensors), ferrite cores, etc. Each electronic component 31 may have, for example, a pair of component terminals 39.

[0019] The partial rigid member 32 is placed on the first surface 2a of the base plate 2 via a heat conductive member or the like. The partial rigid member 32 may have, for example, a heat dissipation surface 32b. The heat dissipation surface 32b is a plane facing the -Z direction. The heat dissipation surface 32b corresponds to the bottom surface 3b of the module 3. With this configuration, each module 3 is fixed in the Z direction to the base plate 2 and the cover 6 by, for example, the bottom surface 3b being pressed against the base plate 2 from the -Z direction side, and at least one of the electronic component 31 and the partial rigid member 32 being pressed against the cover 6 from the +Z direction side.

[0020] The partial rigid member 32 comprises a pair of first flanges 33 and a housing portion 34. The partial rigid member 32 is an integrally molded product in which the pair of first flanges 33 and the housing portion 34 are integrated. The partial rigid member 32 is a synthetic resin product.

[0021] 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.

[0022] 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.

[0023] The pair of first flanges 33 protrude 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 be flush with each other, for example, to form a heat dissipation surface 32b as a whole.

[0024] The multiple modules 3 may include, for example, a relay module 3R. In this case, as shown in Figure 4, the relay module 3R includes a relay 31R as an electronic component 31.

[0025] 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 partial rigid member 32. In the relay module 3R, at least another pair of the multiple notches 35n in the peripheral wall 35 is cut out such that a pair of busbars 5 connected to the component terminals 39 can pass through the other pair of notches 35n across the inside and outside of the partial rigid member 32.

[0026] 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.

[0027] The multiple modules 3 may include, for example, a fuse module 3F. In this case, as shown in Figure 5, the fuse module 3F includes a fuse 31F as an electronic component 31.

[0028] 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.

[0029] <3. Configuration of Rigid Members> The base plate 2 will now be described. The base plate 2 is a holding member that integrally holds multiple modules 3 and multiple busbars 5. As shown in Figure 6, 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. When the base plate 2 is in contact with an energized mounted component such as a busbar 5, the base plate 2 may have an insulating member or insulating film on the contact surface. Conversely, when the base plate 2 is in contact with an energized mounted component such as a busbar 5, the energized mounted component may have an insulating member or insulating film on the contact bottom surface.

[0030] The base plate 2 has a first surface 2a and a second surface 2b as a pair of front and back surfaces. The first surface 2a is an example of a mounting surface. 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.

[0031] <4. Configuration of the Protrusions> The multiple protrusions 4 will now be described. The multiple protrusions 4 are fixing structures for fixing the combined multiple modules 3 and multiple busbars 5 in the horizontal direction. The multiple protrusions 4 are arranged in the horizontal direction. The multiple protrusions 4 may be arranged horizontally at equal intervals, for example. The multiple protrusions 4 may be arranged horizontally in multiple rows and multiple columns (for example, 3 rows and 5 columns) at equal intervals in the X direction and the Y direction, for example. The multiple protrusions 4 may have the same height from the first surface 2a, for example.

[0032] Each projection 4 protrudes from the first surface 2a. The multiple projections 4 and the base plate 2 may be integrally molded so that each projection 4 protrudes continuously from the first surface 2a, for example. Each projection 4 has a columnar shape. Each projection 4 may have a rectangular prism shape with the Z direction as its axis, for example.

[0033] As described above, multiple modules 3 and multiple busbars 5 are combined. As shown in Figures 2 and 3, for example, multiple modules 3 and multiple busbars 5 are combined to form a single assembly 9 by fastening or other means. On the other hand, the assembly 9 is mounted on a support 8 so as to fit into multiple protrusions 4.

[0034] The multiple protrusions 4 are in contact with the assembly 9 in the horizontal direction. In each of the multiple protrusions 4, the X-direction-facing surface of the protrusion 4 is in contact with the corresponding X-direction-facing surface of the assembly 9. In each of the multiple protrusions 4, the Y-direction-facing surface of the protrusion 4 is in contact with the corresponding Y-direction-facing surface of the assembly 9. Each of the multiple protrusions 4, each of the multiple protrusions 4, may be in contact with, for example, the corresponding busbar 5. Each of the multiple protrusions 4, each of the multiple protrusions 4, may be in contact with, for example, the corresponding module 3. Note that the protrusions 4 that are in contact with energized mounted components such as the busbar 5 may have an insulating material or insulating film on the contact surface. Conversely, energized mounted components such as the busbar 5 may have an insulating material or insulating film on the contact surface of the portion that is in contact with the protrusion 4.

[0035] When the assembly 9 fits into the multiple protrusions 4, specifically, the assembly 9 is in contact with the multiple protrusions 4 as follows: The +X-facing surface of at least one of the multiple modules 3 and multiple busbars 5 is in contact with the -X-facing surface of the corresponding protrusion 4. Also, the -X-facing surface of at least one of the multiple modules 3 and multiple busbars 5 is in contact with the +X-facing surface of the corresponding protrusion 4. Also, the +Y-facing surface of at least one of the multiple modules 3 and multiple busbars 5 is in contact with the -Y-facing surface of the corresponding protrusion 4. Also, the -Y-facing surface of at least one of the multiple modules 3 and multiple busbars 5 is in contact with the +Y-facing surface of the corresponding protrusion 4.

[0036] <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 modules 3 to modules 3. Each busbar 5 extends between modules 3 to modules 3. Each busbar 5 is a metal product and is conductive. Each busbar 5 may be made of a metal such as copper or aluminum. The ends of each busbar 5 may be fastened to component terminals 39, for example.

[0037] Some of the busbars 5 may be, for example, L-shaped flat plates aligned horizontally, where the entire surface of the plate remains oriented vertically while being curved in the horizontal plane.

[0038] Some of the busbars 5 may be formed busbars that are curved in the horizontal plane and whose orientation changes from the Z direction to the Y direction, or from the X direction to the Y direction (or from the horizontal direction to the vertical direction). In this case, each busbar 5 may be pre-formed into the shape to be routed before being assembled into the module 3.

[0039] <6. Advantages> According to the electrical connection unit 1 of this embodiment, the multiple protrusions 4 contact the multiple mounted components (any of the multiple modules 3 and multiple busbars 5) in a direction along the horizontal. With this configuration, the multiple protrusions 4 fix the multiple mounted components. This fixing method allows a single support 8 to be used universally for multiple mounted components, regardless of the shape, size, position, etc. of the multiple mounted components. In addition, this fixing method can accommodate a free layout of the multiple mounted components. Therefore, it is highly versatile.

[0040] In Comparative Example 1, with a fixing method using additional parts such as bolts, depending on the shape, size, and arrangement of the multiple mounted parts, it may not be possible to fix the additional parts to the support. Therefore, a fixing method like that in Comparative Example may lack versatility for different specifications. In contrast to Comparative Example 1, the present embodiment, as described above, is a fixing method that does not depend on the shape, size, and arrangement of the multiple mounted parts, and therefore offers high versatility.

[0041] Furthermore, compared to Comparative Example 1, according to this embodiment, as described above, multiple mounted components can be fixed without using additional parts such as bolts, thus accommodating a flexible layout. In particular, in the electrical connection unit 1 of this embodiment, each electronic component 31 is mounted on the support 8 via a partially rigid member 32. With this configuration, the arrangement of multiple electronic components 31 on the support 8 can be freely set. On the other hand, by applying multiple protrusions 4 to such an electrical connection unit 1, the multiple protrusions 4 can flexibly accommodate modules 3 that are freely arranged on the base plate 2. Therefore, the multiple protrusions 4 can flexibly accommodate the free arrangement of modules 3.

[0042] Furthermore, in the electrical connection unit 1 of this embodiment, the multiple protrusions 4 are arranged at equal intervals in the horizontal direction. With this arrangement of the multiple protrusions 4, regardless of the shape, size, or arrangement of the multiple mounted components, any of the multiple protrusions 4 will act on the multiple mounted components. Therefore, for example, one support 8 can be used in a general-purpose manner, thus providing high versatility.

[0043] In the electrical connection unit 1 of this embodiment, the multiple protrusions 4 contact the multiple modules 3 in the horizontal direction. With this configuration, the multiple protrusions 4 fix the multiple modules 3. This fixing method allows a single support 8 to be used universally for multiple modules 3, regardless of their shape, size, position, etc. Therefore, it offers high versatility.

[0044] According to the electrical connection unit 1 of the present embodiment, the plurality of protrusions 4 are in contact with the plurality of busbars 5 in the horizontal direction. With this configuration, the plurality of protrusions 4 fix the plurality of busbars 5. With this fixing method, one support 8 can be generally used for the plurality of busbars 5 regardless of the shape, size, position, etc. of the plurality of busbars 5. Therefore, the versatility is high.

[0045] According to the electrical connection unit 1 of the present embodiment, since the support 8 is a metal product, for example, it can withstand the vibration of a vehicle. In addition, since the support 8 is a metal product, for example, the heat of the mounted components that become hot can be absorbed by the support 8 to equalize the heat.

[0046] According to the electrical connection unit 1 of the present embodiment, the plurality of protrusions 4 have a columnar shape. With this configuration, the plurality of protrusions 4 can firmly fix the plurality of mounted components.

[0047] According to the electrical connection unit 1 of the present embodiment, each electronic component 31 is mounted on the base plate 2 via the partial rigidity member 32. With such a configuration, the arrangement of the plurality of electronic components 31 can be freely set with respect to the base plate 2. According to such an electrical connection unit 1, each module 3, which is a module elementized by electronic component unit, can be arranged on the base plate 2 in a free layout according to the functions required for the product. In addition, according to such an electrical connection unit 1, for example, the electronic component 31 can be flexibly arranged on the base plate 2 for changes, corrections, etc. of the layout. Therefore, the development period can be shortened.

[0048] As Comparative Example 2, there is an electrical connection unit in which a resin component that integrally holds a plurality of electronic components is arranged. In such an electrical connection unit of Comparative Example 2, the designer needs to design the arrangement of the plurality of electronic components on the resin component. When such a design is required, the arrangement of the plurality of electronic components on the resin component needs to be designed for each electrical connection unit with different specifications. Therefore, in such Comparative Example 2, it takes time to design the electrical connection unit.

[0049] In contrast to Comparative Example 2, the electrical connection unit 1 of this embodiment allows each module 3 to be freely arranged according to the functions required of the product. Therefore, as described above, the development period can be shortened.

[0050] Furthermore, in Comparative Example 2 described above, the electrical connection unit may have a unique design for the product to which it is applied. Therefore, Comparative Example 2 has low versatility for other products and is difficult to adapt.

[0051] In contrast to Comparative Example 2, the electrical connection unit 1 of this embodiment allows each 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.

[0052] Furthermore, in the electrical connection unit 1 of this embodiment, one of the electronic components used is mounted on a single partial rigid member 32. This configuration allows the modules 3 to be reused among multiple electrical connection units 1 with different arrangements of modules 3, or within an electrical connection unit 1. Therefore, the quality and reliability of the electrical connection unit 1 can be improved.

[0053] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to use standard unit modules as multiple modules 3. Therefore, lead time and cost can be reduced.

[0054] Furthermore, with the electrical connection unit 1 of this embodiment, existing modules can be utilized as each module 3. Therefore, the time and cost required for design and manufacturing can be reduced.

[0055] Furthermore, according to the electrical connection unit 1 of this embodiment, if improvements are needed in specific modules 3 among the multiple modules 3, efficient modifications can be made focusing on those specific modules 3. Therefore, it can contribute to improving the efficiency of maintenance work.

[0056] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to create a layout in which, for example, multiple 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.

[0057] Furthermore, according to the electrical connection unit 1 of this embodiment, the partial rigidity 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 modules 3 is suppressed.

[0058] Furthermore, in the electrical connection unit 1 of this embodiment, the electronic component 31 is protected because the partially rigid member 32 is equipped with a housing portion 34. Therefore, the electrical connection unit 1 can be made more robust.

[0059] Furthermore, according to the electrical connection unit 1 of this embodiment, multiple 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.

[0060] 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 multiple modules 3.

[0061] (Second Embodiment) Next, a second embodiment will be described. Compared to the electrical connection unit 1 of the first embodiment, the electrical connection unit 101 of the second embodiment is equipped with a support 108 instead of a support 8. The configuration of the electrical connection unit 101 of the second embodiment, other than that described below, is the same as the configuration of the electrical connection unit 1 of the first embodiment.

[0062] As shown in Figures 7 and 8, the electrical connection unit 101 comprises a support 108, a plurality of modules 3, a plurality of busbars 5, and a cover 6. The support 108 comprises a base plate 102 and a projection 104. The base plate 102 is an example of a rigid member. In the electrical connection unit 101, the plurality of modules 3 and the plurality of busbars 5 are covered by the support 108 from the -Z direction and by the cover 6 from the +Z direction. That is, in the electrical connection unit 101, the plurality of modules 3 and the plurality of busbars 5 are housed in a housing which is a combination structure of the cover 6 and the support 108. Figure 8 shows the electrical connection unit 101 with the cover 6 visible through it. The plurality of modules 3 are arranged along the first surface 102a of the base plate 102. Each module 3 is provided on the first surface 102a side of the base plate 102.

[0063] The base plate 102 is a holding member that integrally holds multiple modules 3 and multiple busbars 5. As shown in Figure 9, the base plate 102 has a plate shape that extends in a planar manner in the X and Y directions. The base plate 102 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.

[0064] The base plate 102 has a first surface 102a and a second surface 102b as a pair of front and back surfaces. The first surface 102a is an example of a mounting surface. The first surface 102a is a horizontal plane facing the +Z direction. The second surface 102b is a horizontal plane facing the -Z direction. The first surface 102a and the second surface 102b may be, for example, smooth planes.

[0065] The base plate 102 has a plurality of openings 102c and a plurality of remaining pieces 102d. The plurality of openings 102c are U-shaped openings formed by sheet metal processing, punched out at regular intervals in the X and Y directions. Each remaining piece 102d is a sheet metal portion left over from the U-shaped punching process. Each remaining piece 102d extends in the +X direction into the area enclosed by the U-shape.

[0066] The multiple protrusions 104 are a fixing structure for securing the combined multiple modules 3 and multiple busbars 5 in the horizontal direction. The multiple protrusions 104 are arranged horizontally. The multiple protrusions 4 may, for example, have the same height from the first surface 102a.

[0067] Each projection 4 protrudes from the first surface 102a. Each projection 104 may be, for example, a sheet metal piece that curves and rises from the base plate 102 in the +Z direction so as to protrude continuously from the first surface 102a. Each projection 104 may be, for example, a sheet metal piece that is bent at 90° with respect to the first surface 102a from the base plate 102. Each projection 104 may be a sheet metal piece formed by, for example, bending a corresponding remaining piece 102d so as to extend in the +Z direction. During the bending process, depending on the multiple mounted components to be mounted, multiple remaining pieces 102d at positions necessary to fix the multiple mounted components in the horizontal plane may be bent to form each projection 104.

[0068] Similar to the first embodiment, the multiple protrusions 104 are in contact with the multiple mounted components in the horizontal direction. In each of the multiple protrusions 104, one protrusion 4 or several protrusions 104 may have a surface of the protrusion 104 facing the X direction (the plate surface of the sheet metal piece) in contact with the corresponding surface of the mounted component facing the X direction. In each of the multiple protrusions 104, one protrusion 104 or several protrusions 104 may have a surface of the protrusion 104 facing the Y direction (the end surface of the sheet metal piece) in contact with the corresponding surface of the mounted component facing the Y direction. In each of the multiple protrusions 104, one protrusion 104 or several protrusions 4 may be in contact with the corresponding bus bar 5. In each of the multiple protrusions 104, one protrusion 4 or several protrusions 104 may be in contact with the corresponding module 3.

[0069] The electrical connection unit 101 of this embodiment has the same functions and effects as the electrical connection unit 1 of the first embodiment. In addition, according to this embodiment, multiple protrusions 104 can be formed by sheet metal processing. Therefore, the support 108 is easier to manufacture. Furthermore, according to this embodiment, multiple mounted components can be fixed by bending the remaining piece 102d after punching out without using additional parts such as bolts. Therefore, it is possible to accommodate a free layout of multiple mounted components with relatively simple sheet metal processing.

[0070] (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.

[0071] (First Modification) In the embodiments described above, each projection 4, 104 is integrally molded with the base plates 2, 102 and protrudes continuously from the first surfaces 2a, 102a. However, it may be configured in any way as long as it protrudes from the first surfaces 2a, 102a. As a modification, each projection 4 may be separate from the base plates 2, 102 and fastened to the base plates 2, 102 so as to protrude from the first surfaces 2a, 102a.

[0072] (Second Modification) In the embodiments described above, the bottom surface 3b of each module 3 dissipates heat to the base plates 2 and 102 via a heat conductive member or the like. However, the configuration can be any way as long as the heat from each module 3 can be dissipated to the base plates 2 and 102. As a modification, the bottom surface 3b of each module 3 may be in direct contact with the base plates 2 and 102. According to this modification, the heat from the mounted components that become hot can be directly absorbed by the supports 8 and 108, thereby equalizing the heat.

[0073] (Third Modification) In the first embodiment described above, the projection 4 has a columnar shape. However, the projection 4 can have any shape as long as it can fix multiple mounted components in the horizontal direction. As a modification, the projection 4 may have a cylindrical shape, a wall shape, a pyramidal shape, a conical shape, etc.

[0074] (Fourth Modification) In each of the embodiments described above, the electrical connection units 1 and 101 are provided with base plates 2 and 102 as rigid members. However, the rigid members may be configured in any way as long as multiple modules 3 can be mounted. As a modification, the rigid members may be blocks, boxes, etc. instead of the base plates 2 and 102.

[0075] (Fifth Modification) In each of the embodiments described above, the electrical connection units 1 and 101 are provided with busbars 5 as routing members. However, the electrical connection units 1 and 101 may be provided with any routing member as long as the multiple protrusions 4 and 104 can route and integrate multiple modules 3 so that multiple mounted components can be fixed together as a single unit. As a modification, the electrical connection units 1 and 101 may be provided with wiring as routing members instead of busbars 5.

[0076] (Sixth Modification) In each of the embodiments described above, the multiple partial rigid members 32 are mounted on the base plates 2 and 102. However, if the multiple electronic components 31 are mounted on the support 8 and 108, the multiple partial rigid members 32 may be mounted on the base plates 2 and 102 in any way. As a modification, the multiple partial rigid members 32 may be fastened to the base plates 2 and 102. As another modification, the multiple partial rigid members 32 may be directly bonded to the base plates 2 and 102 by adhesive, thermocompression bonding, laser welding, etc., without the use of heat conductive members or the like.

[0077] (Seventh Modification) In each of the embodiments described above, each module 3 comprises an electronic component 31 and a partially rigid member 32. However, each module 3 may be configured in any way as long as multiple electronic components 31 are mounted on the supports 8 and 108. As a modification, each module 3 may comprise only the electronic component 31 among the electronic component 31 and the partially rigid member 32. In this case, each electronic component 31 may be mounted directly on the base plates 2 and 102 without going through the partially rigid member 32.

[0078] 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.

[0079] The embodiments of this disclosure are highly versatile.

[0080] 1 Electrical connection unit 2 Base plate (rigid member) 2a First surface (mounting surface) 2b Second surface 3 Module (mounted component) 3b Bottom surface 3F Fuse module 3R Relay module 4 Protrusion 5 Bus bar (mounted component) 6 Cover 8 Support body 9 Assembly 31 Electronic component 31F Fuse 31R Relay 32 Partial rigid member 32b Heat dissipation surface 33 First flange 34 Housing section 34s Housing space 35 Peripheral wall 35n Notch 35t Edge 36 Bottom 38 Fixing terminal 39 Component terminal 101 Electrical connection unit 102 Base plate 102a First surface (mounting surface) 102b Second surface 102c Opening 102d Remnant 104 Protrusion 108 Support body

Claims

1. An electrical connection unit comprising: a support body having a plurality of mounting components; a rigid member having a mounting surface on which the plurality of mounting components are mounted; and a plurality of protrusions projecting from the mounting surface, wherein the plurality of protrusions are in contact with the plurality of mounting components in a direction along the mounting surface.

2. The electrical connection unit according to claim 1, wherein the plurality of protrusions are arranged at equal intervals in a direction along the mounting surface.

3. The electrical connection unit according to claim 1 or 2, wherein the plurality of mounted components comprises a plurality of modules, each of which comprises an electronic component.

4. The electrical connection unit according to claim 3, wherein the plurality of mounted components further comprises wiring members connected to the plurality of modules.

5. The electrical connection unit according to claim 1 or 2, wherein the support is a metal product.

6. The electrical connection unit according to claim 1 or 2, wherein each of the plurality of protrusions has a columnar shape.

7. The electrical connection unit according to claim 1 or 2, wherein the plurality of protrusions are curved and rising from the rigid member.

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