Electrical connection unit

Abstract

This electrical connection unit comprises: a plurality of electronic components; a second rigid member on which the plurality of electronic components are mounted; a routing member which is electrically connected to the plurality of electronic components; and a support member which is mounted to the second rigid member at a position away from the plurality of electronic components, and which supports the routing member.

Description

Electrical connection unit

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[0001] Embodiments of the present invention relate to an electrical connection unit. This application claims priority to Japanese Patent Application No. 2024-179665, 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 Unexamined Patent Application Publication No. 2018-113184

[0004] By the way, in an electrical connection unit, a plurality of electronic components may be connected by wiring members. In such an electrical connection unit, the stability of the wiring members when vibration is applied from the outside is required.

[0005] One embodiment provides an electrical connection unit with improved resistance to vibration.

[0006] An electrical connection unit according to one embodiment includes a plurality of electronic components, a second rigid member on which the plurality of electronic components are mounted, a wiring member electrically connected to the plurality of electronic components, and a support member mounted on the second rigid member at a position away from the plurality of electronic components and supporting the wiring member.

[0007] According to one embodiment, the resistance to vibration is improved.

[0008] A perspective view showing the electrical connection unit of the first embodiment. A plan view showing the electrical connection unit of the first embodiment. A perspective view showing the relay module of the first embodiment. A perspective view showing the fuse module of the first embodiment. A perspective view showing the terminal module of the first embodiment. A perspective view showing the support member of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of the first embodiment. A perspective view illustrating the support member of the second embodiment. A perspective view showing the support member of the third embodiment. A perspective view showing the support member of a modified example of the third embodiment. A perspective view showing the base plate of a modified example of the first 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 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] (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, and a plurality of support members 60. 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, the plurality of busbars 5, and the plurality of support members 60 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, the plurality of busbars 5, and the plurality of support members 60 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, a plurality of terminal modules 4, and a plurality of support members 60. 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] <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. In other words, each electronic component 31 is provided on the associated first rigid member 32 (first module 3). 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 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 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.

[0026] 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.

[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 horizontal direction. 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 flush and continuous plane, 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 multiple busbars 5 may be forming busbars, for example, that are curved in a horizontal plane and curved so that the direction in which the plate surface faces 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] The portion of the busbar 5 that is formed in a flat plate shape is designated as the extended portion 51. That is, some of the busbars 5 have an extended portion 51. The extended portion 51 extends along the expanding surface of the base plate 2. Furthermore, the extended portion 51 does not include the region of the busbar 5 where the direction of extension changes. For example, the extended portion 51 is a flat plate that extends in the X and Y directions, the X and Z directions, and the Y and Z directions. In the first embodiment, the extended portion 51 is the surface whose largest main plane extends in the vertical direction. That is, the main plane of the extended portion 51 is arranged to face the X and Y directions so as to be perpendicular to the Z direction. Note that some of the multiple busbars 5 may not have an extended portion 51.

[0044] Regarding the bus bar 5 of the present embodiment, those supported by the support member 60 at the extension part 51 are defined as the first bus bar 5a, the second bus bar 5b, and the third bus bar 5c. The first bus bar 5a has a first extension part 51a. The first extension part 51a extends in the Y direction and the Z direction. The first bus bar 5a is supported by the support member 60 at the first extension part 51a.

[0045] The second bus bar 5b has a second extension part 51b. The second extension part 51b extends in the X direction and the Z direction. The second bus bar 5b is supported by the support member 60 at the second extension part 51b. The third bus bar 5c has a third extension part 51c. The third extension part 51c extends in the X direction and the Z direction. The third bus bar 5c is supported by the support member 60 at the third extension part 51c.

[0046] Among the plurality of bus bars 5, some of the bus bars 5 may, for example, branch into a plurality of paths midway and head in different directions. Among the plurality of bus bars 5, some of the bus bars 5 may be, for example, an assembly in which a plurality of forming bus bars are connected so as to branch into a plurality. In that case, the plurality of forming bus bars to be combined may be connected in advance before being combined with the first module 3 or the terminal module 4.

[0047] Among the plurality of bus bars 5, some of the bus bars 5 may be flat plates having a rectangular plate surface facing 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 the vertical direction.

[0048] 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.

[0049] <6. Configuration of Support Members> The multiple support members 60 will now be described. Each of the multiple support members 60 is a member that supports the bus bar 5. Each support member 60 is mounted on the base plate 2 at a position away from the electronic components 31. In addition, each support member 60 is arranged so as not to overlap with the first module 3 and the terminal module 4 when viewed from the +Z direction. In this embodiment, each of the multiple support members 60 will be called the first support member 60a, the second support member 60b, and the third support member 60c. The first support member 60a supports the first bus bar 5a. The second support member 60b supports the second bus bar 5b. The third support member 60c supports the third bus bar 5c.

[0050] As shown in Figure 6, each support member 60 has a support body portion 61 and a clamping portion 65. The support member 60 is a single molded product in which the entire support body portion 61 and the clamping portion 65 are integrated. Furthermore, the support member 60 is a synthetic resin product formed from synthetic resin.

[0051] The support body portion 61 is the part positioned between the base plate 2 and the bus bar 5 (extension portion 51). The support body portion 61 has a support body 62, a pair of third flanges 63, and a plurality of third reinforcing ribs 64. The entire support body portion 61, including the support body 62, the pair of third flanges 63, and the plurality of third reinforcing ribs 64, is an integrated unit.

[0052] The support body portion 61 is fixed to the base plate 2. The support body portion 61 may be, for example, bonded to the base plate 2. The support body portion 61 may have, for example, a third bonding surface 61b. The third bonding surface 61b is a plane facing the -Z direction. The third bonding surface 61b corresponds to the flush bottom surface of the support body portion 61 extending from the support body 62 to the pair of third flanges 63. The third bonding surface 61b may be bonded to the first surface 2a by means of adhesive, thermocompression, laser welding, etc.

[0053] The support body 62 occupies most of the support body portion 61. The support body 62 is formed, for example, in the shape of a rectangular parallelepiped. The support body 62 is connected to the clamping portion 65 at its end on the +Z direction side. The support body 62 can contact and support the busbar 5 at its end on the +Z direction side, where it is not connected to the clamping portion 65.

[0054] The pair of third flanges 63 extend from the -Z end of the support body 62 to both ends in one direction horizontally. The surface of the support body 62 facing the -Z direction and the surface of the pair of third flanges 63 facing the -Z direction may, for example, be a flush and continuous plane, thereby forming a third bonding surface 61b as a whole.

[0055] Multiple third reinforcing ribs 64 support the support body 62 from its outer circumference. Each third reinforcing rib 64 may be a triangular rib that fits into the corner (concave angle) between the outer circumference 62a and each third flange 63 of the support body 62.

[0056] The clamping portion 65 is formed to be able to clamp the extending portion 51. The clamping portion 65 extends from the support body portion 61 (support body 62). Furthermore, the clamping portion 65 is formed to extend away from the base plate 2. That is, the clamping portion 65 extends from the support body portion 61 in the +Z direction. The clamping portion 65 has a clamping portion body 66 and a locking portion 67.

[0057] The clamping portion body 66 occupies most of the clamping portion 65. The clamping portion body 66 extends in the +Z direction from the +Z direction end of the support body 62. In this embodiment, the clamping portion body 66 has a first portion 66a and a second portion 66b.

[0058] The first portion 66a and the second portion 66b are formed, for example, in a flat plate shape. The first portion 66a and the second portion 66b are arranged side by side with a gap between them in a direction that intersects the plane on which the extended portion 51 expands. The first portion 66a is formed on one side in the direction that intersects the plane on which the extended portion 51 expands. The second portion 66b is formed on the other side in the direction that intersects the plane on which the extended portion 51 expands.

[0059] Specifically, the first support member 60a has a first portion 66a and a second portion 66b arranged side by side with a gap between them in the X direction. The second support member 60b and the third support member 60c have a first portion 66a and a second portion 66b arranged side by side with a gap between them in the Y direction.

[0060] The first portion 66a and the second portion 66b are arranged so as to be able to sandwich the busbar 5 (extension portion 51) in a direction that intersects the plane on which the extension portion 51 expands. Furthermore, the first portion 66a and the second portion 66b are able to bend so as to move away from each other in directions facing each other. That is, when sandwiching the busbar 5, the first portion 66a and the second portion 66b are able to elastically deform so as to move away from each other in directions facing each other.

[0061] The locking portion 67 is formed to protrude from the clamping portion body 66. Furthermore, the locking portion 67 is formed so that the first portion 66a and the second portion 66b protrude in directions facing each other. In the Z direction, the locking portion 67 is formed to clamp the bus bar 5 with the support body portion 61. That is, the locking portion 67 is formed to be positioned above the bus bar 5. The locking portion 67 has an inclined surface 68 that moves away from the first portion 66a or the second portion 66b to which the locking portion 67 is connected as it moves toward the -Z direction.

[0062] In this embodiment, multiple locking portions 67 are formed. A first locking portion 67a is formed by connecting to the first portion 66a, and a second locking portion 67b and a third locking portion 67c are formed by connecting to the second portion 66b. The first locking portion 67a, the second locking portion 67b, and the third locking portion 67c are located at the same position in the Z direction. The second locking portion 67b and the third locking portion 67c are spaced apart from each other in the direction in which the first portion 66a and the second portion 66b face each other and in the direction intersecting the Z direction. The first locking portion 67a is located between the second locking portion 67b and the third locking portion 67c in the direction in which the first portion 66a and the second portion 66b face each other and in the direction intersecting the Z direction. Furthermore, the first locking portion 67a, the second locking portion 67b, and the third locking portion 67c are all positioned to overlap with the busbar 5 when viewed from the +Z direction.

[0063] <7. Method for Manufacturing the Electrical Connection Unit> The method for manufacturing the electrical connection unit 1 will be described below. The manufacturer manufactures the electrical connection unit 1 by carrying out the following steps 1 to 6.

[0064] (First step) As shown in Figure 7, in the first step, the manufacturer prepares the base plate 2.

[0065] (Second step) As shown in Figure 8, in the second step, the manufacturer attaches the multiple first rigid members 32, the multiple terminal modules 4, and the multiple support members 60 to the base plate 2. The manufacturer may also bond the multiple first rigid members 32, the multiple terminal modules 4, and the multiple support members 60 to the base plate 2.

[0066] (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.

[0067] (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. Also, 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. Also, in the fourth step, the manufacturer attaches some of the busbars 5 to the support members 60 installed at the corresponding positions by sandwiching them between them. At this time, the busbars 5 may be attached to the support members 60 along the inclined surface 68.

[0068] (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.

[0069] (Sixth step) As shown in Figure 12, in the sixth step, the manufacturer attaches the cover 6 to the assembly on which the multiple first modules 3, multiple terminal modules 4, multiple busbars 5, and multiple support members 60 are attached to the base plate 2.

[0070] <8. Advantages> In the electrical connection unit 1 of this embodiment, a plurality of electronic components 31 are mounted on the base plate 2 via a first rigid member 32. Busbars 5 connect the electronic components 31. The busbars 5 are supported by support members 60 mounted on the base plate 2 at a position away from the electronic components 31. With this configuration, the position of the busbars 5 can be stabilized. Therefore, when vibration is applied to such an electrical connection unit 1 from the outside, the position of the busbars 5 is less likely to change, and the overall resistance to vibration of the electrical connection unit 1 can be improved. Furthermore, because the support members 60 are mounted at a position away from the electronic components 31, the above-mentioned effects can be achieved by utilizing any position in the dead space on the first surface 2a of the base plate 2.

[0071] The busbar 5 in this embodiment has an extended portion 51 that is formed in a flat plate shape. The support member 60 supports the extended portion 51. With this configuration, the support member 60 can support the busbar 5 by the flat extended portion 51, rather than by any curved portion of the busbar 5. Therefore, the support member 60 can support the busbar 5 in a more stable state. Consequently, the vibration resistance of the electrical connection unit 1 can be further improved.

[0072] The support member 60 in this embodiment has a support body portion 61 and a clamping portion 65 that extends from the support body portion 61 in the +Z direction and clamps the extension portion 51. With this configuration, the bus bar 5 is restricted from moving in the -Z direction by the support body portion 61. In addition, the bus bar 5 is restricted from moving in a direction intersecting the plane on which the extension portion 51 expands by the clamping portion 65. Therefore, the overall resistance to vibration of the electrical connection unit 1 can be further improved.

[0073] The clamping portion 65 of this embodiment has a first portion 66a and a second portion 66b, and a locking portion 67 formed so as to protrude in directions where the first portion 66a and the second portion 66b face each other. Furthermore, the locking portion 67 is positioned to overlap with the busbar 5 when viewed from the +Z direction. With this configuration, the busbar 5 is restricted from moving in the +Z direction. Therefore, the overall resistance to vibration of the electrical connection unit 1 can be further improved.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] (Second Embodiment) <9. Configuration of the Second Embodiment> Next, the second embodiment will be described. Compared to the electrical connection unit 1 of the first embodiment, the electrical connection unit 100 of the second embodiment is equipped with a different support member 70 than that of the first embodiment. The configuration of the electrical connection unit 100 of the second embodiment, other than that described below, is the same as that of the electrical connection unit 1 of the first embodiment.

[0091] Some of the extension portions 51 in the second embodiment have surfaces that extend in the Z direction. The electrical connection unit 100 includes a plurality of support members 70 as shown in Figure 13. The support members 70 are members that support the bus bar 5 having extension portions 51 that have surfaces that extend in the Z direction. Specifically, the support members 70 are connected from a direction intersecting the extending surfaces of the extension portions 51 and are capable of supporting the bus bar 5. The support members 70 include a heat storage member 71 and a heat transfer member 75.

[0092] The heat storage member 71 is capable of contacting the busbar 5. Furthermore, the heat storage member 71 is made of a material capable of storing heat. That is, the heat storage member 71 is capable of contacting the busbar 5 and absorbing heat from the busbar 5. The heat storage member 71 is made of a metal such as aluminum. The heat storage member 71 is thermally connected to the base plate 2 via a heat transfer member 75. The heat storage member 71 has a first member 72 and a second member 73.

[0093] The first member 72 is a flat plate-shaped member that extends along the surface on which the extended portion 51 of the busbar 5, which is intended to be in contact with the busbar 5, widens. That is, the first member 72 can make surface contact with the extended portion 51. Furthermore, both the first member 72 and the busbar 5 have screw holes formed in a direction that intersects the surface on which the extended portion 51 widens. The first member 72 and the busbar 5 are fixed together by fastening members 80 that are screwed into the screw holes while in surface contact with each other.

[0094] The end of the first member 72 in the +Z direction is formed to be located above the end of the busbar 5 in the +Z direction that is capable of contact. However, it is not limited to this, and the end of the first member 72 in the +Z direction may be formed to be located at the same position as or below the end of the busbar 5 in the +Z direction that is capable of contact. The first member 72 is connected to the second member 73 and the heat transfer member 75 at its end in the -Z direction.

[0095] The second member 73 is a flat plate-shaped member extending horizontally from the -Z end of the first member 72. The surface of the first member 72 facing the -Z direction and the surface of the second member 73 facing the -Z direction are flush and continuous planes, and are in contact with the heat transfer member 75 as a whole. The first member 72 and the second member 73 are formed as a single unit, for example.

[0096] The heat transfer member 75 is positioned to connect the heat storage member 71 and the base plate 2. The heat transfer member 75 is also formed to transfer heat from the heat storage member 71 to the base plate 2. The heat transfer member 75 is a flat, plate-shaped member extending horizontally. The heat transfer member 75 is made of a heat-transmitting material. The heat transfer member 75 is made of an insulating material.

[0097] The heat transfer member 75 is fixed to the base plate 2 by a third bonding surface 75b which faces the -Z direction. The third bonding surface 75b of the heat transfer member 75 may be bonded to the base plate 2 by means of adhesive, thermocompression, laser welding, etc. The heat transfer member 75 is connected and fixed to the heat storage member 71 by a surface facing the +Z direction. When viewed from the +Z direction, the heat transfer member 75 is formed to completely overlap with the surface formed by combining the -Z-facing surface of the first member 72 and the -Z-facing surface of the second member 73. Preferably, when viewed from the +Z direction, the heat transfer member 75 is formed to extend beyond the surface formed by combining the -Z-facing surface of the first member 72 and the -Z-facing surface of the second member 73.

[0098] <10. Advantages of the Second Embodiment> The support member 70 of the second embodiment further includes a heat storage member 71 that contacts the busbar 5 and is made of a material capable of storing heat from the busbar 5. With this configuration, the position of the busbar 5 can be stabilized while heat is removed from the busbar 5 by the heat storage member 71. Because the heat storage member 71 extends in the Z direction, the surface area from which heat can be dissipated is increased. Therefore, the heat dissipation of the busbar 5 can be promoted by the heat storage member 71. Accordingly, the support member 70 of the second embodiment can improve the vibration resistance of the electrical connection unit 100 and improve the heat dissipation of the electrical connection unit 100.

[0099] In the second embodiment, the heat storage member 71 is thermally connected to the base plate 2. With this configuration, heat from the busbar 5 can be transferred to the base plate 2 through the heat storage member 71. Therefore, the surface area that can dissipate heat can be further increased. Consequently, the heat dissipation performance of the electrical connection unit 100 can be further improved.

[0100] The support member 70 of the second embodiment further includes a heat transfer member 75 that connects the heat storage member 71 and the base plate 2 and is made of a material capable of transferring heat from the heat storage member 71 to the base plate 2. The base plate 2 is made of metal, the heat storage member 71 is made of metal, and the heat transfer member 75 is made of an insulating material. With this structure, by making the heat storage member 71 of metal, it is possible to maintain heat dissipation while preventing electricity passing through the busbar 5 from flowing to the base plate 2. In addition, by increasing the surface area of ​​the heat transfer member 75, it is possible to transfer heat to the base plate 2 more easily, and the heat dissipation of the electrical connection unit 100 can be further improved.

[0101] (Third Embodiment) <10. Configuration of the Third Embodiment> Next, the third embodiment will be described. In the electrical connection unit 101 of the third embodiment, the configuration of the support member 70 is partially different from that of the electrical connection unit 100 of the second embodiment. The support member of the third embodiment will be described below as 70a. In the support member 70a of the third embodiment, the arrangement of the supported extension portion 51 and the direction in which the extension portion 51 is supported are different from those of the support member 70 of the second embodiment. Note that the configuration of the electrical connection unit 101 of the third embodiment, other than that described below, is the same as that of the electrical connection unit 1 of the first embodiment and the electrical connection unit 100 of the second embodiment.

[0102] In some of the extensions 51 of the third embodiment, the largest main plane is a surface that extends horizontally. In other words, some of the extensions 51 of the third embodiment are arranged in a position rotated 90 degrees relative to the extensions 51 of the first and second embodiments. The electrical connection unit 101 includes a plurality of support members 70a as shown in Figure 14. The support members 70a are members that support the busbar 5 having an extension 51 with a main plane that extends horizontally. Specifically, the support members 70a can support the busbar 5 by being connected from the +Z direction. The support members 70a of the third embodiment include a heat storage member 71a and a heat transfer member 75. Note that the heat transfer member 75 is the same as in the second embodiment, so its description is omitted.

[0103] The heat storage member 71a of the third embodiment has a first member 72a, a second member 73, and a third member 74. The first member 72a has the same shape as the first member 72 of the second embodiment, except that it does not have screw holes. The first member 72a is connected to the third member 74 at its end in the +Z direction. The first member 72a is made contact with the side surface of the busbar 5. The second member 73 is the same as in the second embodiment, so its description is omitted.

[0104] The third member 74 is a flat plate-shaped member that extends along the main plane of the extension portion 51. It extends horizontally from the +Z side end of the first member 72a. The third member 74 is capable of contacting the main plane of the extension portion 51. That is, the third member 74 is capable of surface contact with the busbar 5. Furthermore, the third member 74 and the busbar 5 have screw holes formed in them that extend in a direction intersecting the main plane of the extension portion 51. The third member 74 and the busbar 5 are fixed in an immovable state by fastening members 80 that are screwed into the screw holes while in surface contact with each other. Also, the third member 74 extends in the same direction as the second member 73. The first member 72a, the second member 73, and the third member 74 are formed, for example, as a single unit.

[0105] <11. Advantages of the Third Embodiment> The support member 70a of the third embodiment further has a third member 74 that extends horizontally. With this structure, it is possible to support the bus bar 5 having an extended portion 51 that has a horizontally extending surface. Therefore, it is possible to hold the bus bar 5 even if its shape is difficult to hold with the support member 70 of the second embodiment, improving the vibration resistance of the electrical connection unit 101 and improving the heat dissipation of the electrical connection unit 101.

[0106] (Modification of the Third Embodiment) As a modification of the third embodiment, a support member 70b as shown in Figure 15 may be provided. In the modified support member 70b, the direction in which the third member 74 extends relative to the second member 73 is different from that of the support member 70a of the third embodiment. The support member 70b is arranged such that the second member 73 and the third member 74 extend in different directions in the horizontal direction. The second member 73 and the third member 74 are arranged such that they extend in opposite directions relative to the first member 72a, for example.

[0107] With such a support member 70b, it is possible to position it in accordance with the three-dimensional arrangement of the first module 3, terminal module 4, bus bar 5, etc. Therefore, while maintaining ease of assembly, it is possible to improve the vibration resistance of the electrical connection unit 101 and improve the heat dissipation of the electrical connection unit 101.

[0108] (Other Modifications) Next, several other modifications will be described. Note that in each modification, the configuration other than that described below is the same as that of any of the first, second, and third embodiments described above.

[0109] (First Modification) In the embodiments described above, 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 units 1, 100, and 101 may be equipped with a base plate 102 instead of the base plate 2. In the base plate 102, for example, as shown in Figure 16, the first surface 102a is subjected to a surface treatment with minute bumps and irregularities, so that the surface roughness of the first surface 102a is rougher than the surface roughness of the second surface 102b. 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, terminal module 4, and support member 60 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, as in the embodiments described above. This effect makes it difficult for the first module 3, terminal module 4, and support member 60 to detach from the base plate 102. Therefore, the electrical connection units 1, 100, and 101 can be made more robust. As another modification, only the area of ​​the first surface 102a of the base plate 102 on which the first module 3, terminal module 4, and support member 60 are placed may be subjected to a microscopic uneven surface treatment.

[0110] (Second Modification) In each of the embodiments described above, the electrical connection units 1, 100, and 101 are provided with 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.

[0111] (Third Modification) In each of the embodiments described above, the electrical connection units 1, 100, and 101 are provided with busbars 5 as routing members. However, the electrical connection units 1, 100, and 101 may be provided with any routing member as long as they can be routed to a plurality of first modules 3. As a modification, the electrical connection units 1, 100, and 101 may be provided with wiring as routing members instead of busbars 5.

[0112] (Fourth 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.

[0113] (Fifth 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.

[0114] (Sixth Modification) In each of the embodiments described above, the multiple support members 60 are bonded to the base plate 2. However, the multiple support members 60 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 support members 60 may be fastened to the base plate 2.

[0115] (Seventh Modification) In the first embodiment described above, the support member 60 has three locking portions 67. However, the support member 60 may have one or two locking portions 67, or four or more locking portions 67. Furthermore, the support member 60 may be in a form that does not have locking portions 67.

[0116] 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.

[0117] According to one embodiment of the present disclosure, resistance to vibration is improved.

[0118] 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 Bus bar (routing member) 5a First bus bar 5b Second bus bar 5c Third bus bar 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 End 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 51 Extended portion 51a First extended portion 51b Second extended portion 51c Third extended portion 60 Support member 60a First support member 60b Second support member 60c Third support member 61 Support body portion 61b Third adhesive surface 62 Support body 62a Outer circumference 63 Third flange 64 Third reinforcing rib 65 Clamping portion 66 Clamping portion body 66a First portion 66b Second portion 67 Locking portion 68 Inclined surface 100 Electrical connection unit 70 Support member 71 Heat storage member 72 First member 73 Second member 75 Heat transfer member 75b Third adhesive surface 80 Fastening member 101 Electrical connection unit 70a Support member 71a Heat storage member 72a First member 74 Third member 70b Support member 102 Base plate (second rigid member) 102a First surface 102b Second surface

Claims

1. An electrical connection unit comprising: a plurality of electronic components; a second rigid member on which the plurality of electronic components are mounted; a wiring member electrically connected to the plurality of electronic components; and a support member mounted on the second rigid member at a position away from the plurality of electronic components and supporting the wiring member.

2. The electrical connection unit according to claim 1, wherein each of the plurality of electronic components is provided in a related first module, and the first module is mounted on the second rigid member, each having a first rigid member on which the electronic component is mounted.

3. The electrical connection unit according to claim 1 or 2, wherein the cable routing member is formed in a flat plate shape and has an extended portion that extends along the spreading surface of the second rigid member, and the support member supports the extended portion.

4. The electrical connection unit according to claim 3, wherein the support member comprises a support body portion disposed between the second rigid member and the extension portion, and a clamping portion extending from the support body portion so as to be away from the second rigid member and clamping the extension portion.

5. The electrical connection unit according to claim 1 or 2, wherein the support member further comprises a heat storage member that contacts the cable routing member and is made of a material capable of storing heat from the cable routing member.

6. The electrical connection unit according to claim 5, wherein the heat storage member is thermally connected to the second rigid member.

7. The electrical connection unit according to claim 6, wherein the support member further comprises a heat transfer member formed of a material capable of transferring heat from the heat storage member to the second rigid member, connecting the heat storage member and the second rigid member.

8. The electrical connection unit according to claim 7, wherein the second rigid member is made of metal, the heat storage member is made of metal, and the heat transfer member is made of an insulating material.

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