Electrical connection unit

Abstract

An electrical connection unit according to one embodiment comprises a first rigid member, a second rigid member, and a plurality of heat conduction members. At least one first electronic component is mounted on the first rigid member. The second rigid member has a heat dissipation surface in a first direction. The plurality of heat conduction members thermally connect the first rigid member and the second rigid member. One of the first rigid member and the second rigid member is arranged in the first direction with respect to the other.

Description

Electrical connection unit

[0001] Embodiments of the present disclosure relate to an electrical connection unit. This application claims priority to Japanese Patent Application No. 2024-179669, filed in Japan on October 15, 2024, the content of which is incorporated herein by reference.

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

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

[0004] By the way, the circuit scale of an electrical connection unit is increasing due to function integration and the like, and it is becoming larger in area. On the other hand, it is becoming difficult to cope with such an increase in area.

[0005] One embodiment provides an electrical connection unit in which an increase in area is suppressed.

[0006] An electrical connection unit according to one embodiment includes a first rigid member, a second rigid member, and a plurality of heat conduction members. At least one or more first electronic components are mounted on the first rigid member. The second rigid member has a heat dissipation surface in a first direction. The plurality of heat conduction members thermally connect the first rigid member and the second rigid member. One of the first rigid member and the second rigid member is arranged in the first direction with respect to the other.

[0007] According to one embodiment, an increase in area is suppressed.

[0008] Perspective view showing the electrical connection unit of the embodiment. Perspective view showing the electrical connection unit with the cover of the embodiment seen through. View taken in the direction of arrow III in FIG. 2. View taken in the direction of arrow VI in FIG. 2. Perspective view showing the relay module of the embodiment. Perspective view showing the fuse module of the embodiment. Perspective view showing the terminal module of the embodiment.

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

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

[0011] In this disclosure, the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction are defined as follows: The X direction is one direction in the plane along the base plate 2, which will be described later. The +X direction is one of the X directions. The -X direction is the direction opposite to the +X direction. Hereinafter, when the +X direction and the -X direction are not distinguished, they will simply be referred to as the "X direction". The Y direction is a direction that intersects (for example, is perpendicular 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 perpendicular to) the X direction and the Y direction. The +Z direction is the direction from the first assembly 6, which will be described later, toward the second assembly 7, 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] (Embodiment) <1. Configuration of the Electrical Connection Unit> The electrical connection unit 1 is an in-vehicle device installed in a vehicle such as an EV (Electric Vehicle), HEV (Hybrid Electric Vehicle), or PHEV (Plug-in Hybrid Electric Vehicle). The electrical connection unit 1 is connected to a plurality of external devices located outside. The electrical connection unit 1 mediates the connection between the plurality of external devices. For example, the external devices may include a battery pack, a load, a charger, etc. The battery pack is installed in the vehicle. The load is a device including an inverter for driving the motor of the vehicle, which is driven using the power stored in the battery pack. The charger is a device for supplying power to charge the battery pack. The electrical connection unit 1 may be called, for example, an "electrical connection box" or a "junction box". However, the electrical connection unit 1 is not limited to a box-shaped device.

[0014] As shown in Figures 1 to 4, the electrical connection unit 1 comprises a first assembly 6, a second assembly 7, a plurality of columns 8, a plurality of relay bus bars 9, and a cover 10. The second assembly 7 is stacked on top of the first assembly 6. The plurality of columns 8 connect the first assembly 6 and the second assembly 7. Each column 8 is an example of a heat conductive member. The plurality of relay bus bars 9 connect the first assembly 6 and the second assembly 7. Each relay bus bar 9 is an example of a relay cable member.

[0015] <2. Configuration of the First Assembly> For example, the first assembly 6 is a unit that constitutes the first floor of the two-story hierarchical structure of the electrical connection unit 1. The first assembly 6 comprises a base plate 2, a plurality of component modules 3, a plurality of terminal modules 4, and a plurality of bus bars 5. The base plate 2 of the first assembly 6 is an example of a first rigid member. Each component module 3 of the first assembly 6 is an example of a first module. Each bus bar 5 of the first assembly 6 is an example of a first wiring member. Each terminal module 4 of the first assembly 6 is an example of a third module.

[0016] <3. Configuration of the Second Assembly> For example, the second assembly 7 is a unit that constitutes the second floor of the two-story hierarchical structure of the electrical connection unit 1. Similar to the first assembly 6, the second assembly 7 comprises a base plate 2, a plurality of component modules 3, a plurality of terminal modules 4, and a plurality of bus bars 5. The base plate 2 of the second assembly 7 is an example of a second rigid member. Each component module 3 of the second assembly 7 is an example of a second module. Each bus bar 5 of the second assembly 7 is an example of a second wiring member. Each terminal module 4 of the second assembly 7 is an example of a fourth module.

[0017] <4. Configuration of the First and Second Rigid Members> The base plate 2 in the first assembly 6 and the second assembly 7 will be described below. The base plate 2 is a holding member that integrally holds a plurality of component modules 3 and a plurality of terminal modules 4. The base plate 2 has a plate shape that extends in a planar manner in the X and Y directions. The base plate 2 is, for example, a metal product and has thermal conductivity. The base plate 2 is a plate-shaped member that is aligned horizontally. The base plate 2 may be made of a metal such as copper or aluminum. In addition, as shown in the modified example 11 described later, the base plate 2 in one of the first assembly 6 and the second assembly 7 may be a synthetic resin product. In this case, the base plate 2 in the other is made of aluminum.

[0018] In a first direction (for example, the Z direction), the base plate 2 has a first surface 2a and a second surface 2b as a pair of front and back plate surfaces. 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 / or the second surface 2b function as heat dissipation surfaces. In the base plate 2 (first rigid member) of the first assembly 6, the second surface 2b may be in contact with a cooling member. For example, when a battery pack is composed of multiple battery modules, the second surface 2b is in contact with the cooling surface of at least one of the battery modules.

[0019] <5. Configuration of the First and Second Modules> The multiple component modules 3 in the first assembly 6 and the second assembly 7 will be described below. The multiple component 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 component modules 3 are arranged along the first surface 2a of the base plate 2. Each component module 3 is placed on the base plate 2 with its bottom surface 3b facing the first surface 2a. Each component module 3 is provided on the first surface 2a side of the base plate 2. Each component module 3 may, for example, be placed on the first surface 2a.

[0020] Among the multiple component modules 3, each of some component modules 3 may have a gap between it and other adjacent component modules 3 in the X direction, for example. Among the multiple component modules 3, each of some component modules 3 may have a gap between it and other adjacent component modules 3 in the Y direction, for example.

[0021] As shown in Figures 5 and 6, each component 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 individually mounted on the corresponding partial rigid member 32. Each component 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 among the multiple electronic components 31 and multiple partial rigid members 32 included in the electrical connection unit 1.

[0022] Among the multiple component modules 3, each of some component modules 3 may further comprise a pair of auxiliary busbars 30. Each auxiliary busbar 30 is an example of an auxiliary cable routing member. Such a component module 3 may comprise, for example, only one electronic component 31, a pair of auxiliary busbars 30 corresponding to this one electronic component 31, and one partial rigid member 32 corresponding to this one electronic component 31, from among the multiple electronic components 31, multiple partial rigid members 32, and multiple auxiliary busbars 30 included in the electrical connection unit 1.

[0023] <5.1 Configuration of Electronic Components> 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 in the first assembly 6 is an example of a first electronic component. Each electronic component 31 in the second assembly 7 is an example of a second electronic component.

[0024] 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. The 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. The electronic components 31 may be provided with, for example, a pair of component terminals 39.

[0025] <5.2 Configuration of Partially Rigid Members> The partially rigid member 32 is fixed to the corresponding base plate 2. The partially rigid member 32 may be bonded to the corresponding base plate 2, for example. The partially 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 component module 3. The first bonding surface 32b may be bonded to the corresponding first surface 2a, for example, by adhesive, thermocompression bonding, laser welding, etc., so that the partially rigid member 32 is bonded to the corresponding base plate 2.

[0026] Each partial rigid member 32 comprises a pair of first flanges 33 and a housing portion 34. Each partial rigid member 32 in the first assembly 6 is an example of a third rigid member. Each partial rigid member 32 in the second assembly 7 is an example of a fourth rigid member.

[0027] The partial rigid member 32 is a single-piece molded product in which the entire structure, including a pair of first flanges 33 and a housing portion 34, is integrated. The partial rigid member 32 is made of synthetic resin.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] The multiple component modules 3 may include, for example, a relay module 3R. In this case, as shown in Figure 5, the relay module 3R includes a relay 31R as an electronic component 31.

[0032] 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 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, each of at least one pair of the multiple notches 35n in the peripheral wall 35 may be cut out such that one end of the corresponding auxiliary busbar 30 (the second end 30b, described later) can protrude beyond the peripheral wall 35.

[0033] 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 10. That is, 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 10 in the horizontal direction.

[0034] The multiple component modules 3 may include, for example, a fuse module 3F. In this case, as shown in Figure 6, the fuse module 3F includes a fuse 31F as an electronic component 31.

[0035] In the fuse module 3F, at least one pair of notches 35n in the peripheral wall 35 is cut out so that the corresponding component terminal 39 can protrude beyond the peripheral wall 35. The fuse module 3F may also include a pair of fixed terminals 38 that are fastened to the pair of component terminals 39. The corresponding component terminal 39 is fastened to each fixed terminal 38.

[0036] <5.3 Configuration of Auxiliary Busbars> Each auxiliary busbar 30 is an auxiliary wiring member (electrical connection member) for electrically connecting the component terminals 39 and the busbar 5. Each auxiliary busbar 30 extends between the component terminals 39 and the busbar 5. Each auxiliary busbar 30 is a metal product and is conductive. Each auxiliary busbar 30 may be made of a metal such as copper or aluminum.

[0037] Each auxiliary busbar 30 has a first end 30a and a second end 30b. The first end 30a of each auxiliary busbar 30 is electrically connected to the corresponding component terminal 39 by being fastened to the corresponding component terminal 39. The second end 30b of each auxiliary busbar 30 protrudes horizontally from the outer circumference of the partial rigid member 32. The second end 30b is electrically connected to the busbar 5 to which the component module 3 is to be connected. The second end 30b faces the connection portion of the busbar 5 to which it is to be connected from the -Z direction. The second end 30b may be fastened to the connection portion of the busbar 5 to which it is to be connected, for example. The second end 30b may be electrically connected to the busbar 5 by fastening members such as bolts, or by fastening to the busbar 5 by a mating structure.

[0038] Each auxiliary busbar 30 has a shape corresponding to the component module 3 between its first end 30a and second end 30b. As shown in Figure 5, in the relay module 3R, each auxiliary busbar 30 may be, for example, a curved plate extending from the first end 30a to the second end 30b. As shown in Figure 6, in the fuse module 3F, each auxiliary busbar 30 may be, for example, a flat plate extending straight horizontally from the first end 30a to the second end 30b. With this configuration, the auxiliary busbars 30 are responsible for a part of the wiring path that electrically connects the multiple component modules 3. Therefore, the shape of the busbars 5 can be simplified.

[0039] <6. Configuration of the Third and Fourth Modules> The multiple terminal modules 4 in the first assembly 6 and the second assembly 7 will be described below. The multiple terminal modules 4 are multiple units that are divided so that each of them is 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 7, each terminal module 4 is equipped with a connection terminal 41 and a terminal block 42.

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

[0041] 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 component modules 3 via a bus bar 5, other terminal modules 4, etc.

[0042] The terminal block 42 comprises a main body 43 and a pair of second flanges 44. The terminal block 42 is a single-piece molded product in which the main body 43 and the pair of second flanges 44 are integrated. The terminal block 42 is made of synthetic resin.

[0043] The terminal block 42 is fixed to the corresponding 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.

[0044] 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.

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

[0046] <7. Configuration of the first cable member and the second cable member> A plurality of bus bars 5 in each of the first assembly 6 and the second assembly 7 will be described. As shown in FIGS. 2 to 4, each bus bar 5 is a cable member (electrical connection member) for electrically connecting between component modules 3 or between a component module 3 and a terminal module 4. Each bus bar 5 extends between component modules 3 or between a component module 3 and a terminal module 4. Each bus bar 5 is a metal product and has conductivity. Each bus bar 5 may be made of a metal such as copper or aluminum, for example.

[0047] Some of the plurality of bus bars 5 may be flat plates having a rectangular plate surface facing the vertical direction. Some of the plurality of bus bars 5 may be flat plates having an L-shaped plate surface facing the vertical direction. Some of the bus bars 5 may be crank-shaped plates that extend in one horizontal direction with the plate surface facing the vertical direction, bend vertically from the extended end, and further extend in one horizontal direction from the bent end.

[0048] Of the ends of each bus bar 5, the end connected to the component module 3 is connected to the auxiliary bus bar 30 by joining, fitting, fastening, etc. Of the ends of each bus bar 5, the end connected to the terminal module 4 is fastened to the connection terminal 41.

[0049] <8. Column Configuration> Multiple columns 8 connect the first assembly 6 and the second assembly 7 in the Z direction. This connection causes one of the base plates 2 (first rigid member) of the first assembly 6 and the base plate 2 (second rigid member) of the second assembly 7 to be aligned in a first direction (for example, the Z direction) relative to the other. For example, in this disclosure, the second rigid member is aligned in the +Z direction relative to the first rigid member. Due to this alignment, the second assembly 7 in this disclosure is stacked on the first assembly 6.

[0050] Furthermore, the multiple columns 8 thermally connect the first rigid member and the second rigid member. This connection thermally connects the first rigid member and the second rigid member. For example, in this disclosure, each column 8 achieves this connection by making contact with each of the first rigid member and the second rigid member.

[0051] Multiple columns 8 may be used to fix the second assembly 7 to the first assembly 6 such that the base plate 2 of the first assembly 6 and the base plate 2 of the second assembly 7 are parallel to each other along a horizontal plane, for example. Multiple columns 8 may have the same length to each other in the Z direction, for example. Multiple columns 8 are arranged along the peripheral edge 2e of the base plate 2. Multiple columns 8 include three or more columns. In this embodiment, five columns 8 are provided at the five corners of the base plate 2. Multiple columns 8 may be integrally molded with the base plate 2 of the first assembly 6, for example.

[0052] Each column 8 extends from a corner of the base plate 2 of the first assembly 6 to a corner of the base plate 2 of the second assembly 7. Each column 8 is fixed to the base plate 2 of the first assembly 6. Each column 8 rises from the base plate 2 of the first assembly 6 so as to extend in the +Z direction. The +Z end of each column 8 is fastened to the base plate 2 of the first assembly 6 by bolts or the like inserted from the +Z direction. Each column 8 has a columnar or block-shaped contour. For example, each column 8 in this disclosure has a cylindrical contour with the Z direction as its axial direction. Each column 8 has sufficient strength to support the second assembly 7 while fixed to the first assembly 6 so as to maintain the two-story structure of the first assembly 6 and the second assembly 7. Each column 8 is a metal product, a graphite solid material, or a ceramic having a predetermined thermal conductivity.

[0053] <9. Configuration of the relay busbars> Each relay busbar 9 connects the first assembly 6 and the second assembly 7, electrically connecting the first assembly 6 and the second assembly 7. Each relay busbar 9 extends in the Z direction across the first assembly 6 and the second assembly 7.

[0054] One end of each intermediate busbar 9 is connected to the busbar 5 or auxiliary busbar 30 of the first assembly 6 from the +Z direction. One end of each intermediate busbar 9 may, for example, extend in the -Z direction, then bend horizontally, and be fastened to the busbar 5 or auxiliary busbar 30 of the first assembly 6 by a bolt or the like inserted from the +Z direction.

[0055] The other end of each intermediate busbar 9 is connected to the busbar 5 or auxiliary busbar 30 of the second assembly 7 from the +Z direction side. The other end of each intermediate busbar 9 may, for example, extend in the +Z direction, then bend horizontally, and be fastened at the bent end to the busbar 5 or auxiliary busbar 30 of the second assembly 7 by a bolt or the like inserted from the +Z direction.

[0056] Each relay bus bar 9 is positioned to wrap around the peripheral end 2e of the base plate 2 of the first assembly 6. Each relay bus bar 9 passes through the base plate 2 of the first assembly 6 in the Z direction such that it passes outside the area occupied by the base plate 2 of the first assembly 6 when viewed from the Z direction. In this case, the base plate 2 of the first assembly 6 may be cut out in the portion through which the relay bus bar 9 passes, for example, in a horizontal direction away from the relay bus bar 9.

[0057] <10. Cover Configuration> The configuration of the cover 10 will now be described. As shown in Figure 1, in the electrical connection unit 1, the cover 10 covers the first assembly 6, the second assembly 7, the multiple columns 8, and the multiple relay bus bars 9 from the +Z direction. However, of the first assembly 6, for example, the lower surface of the base plate 2 of the first assembly 6 may not be covered by the cover 10 and may be exposed. That is, in the electrical connection unit 1, the first assembly 6 excluding the base plate 2, the second assembly 7, the multiple columns 8, and the multiple relay bus bars 9 may be housed in a housing that is a combination structure of the cover 10 and the base plate 2 of the first assembly 6. The cover 10 has multiple openings 10p so that the multiple terminal modules 4 provided in the first assembly 6 and the second assembly 7 can be routed to the outside of the electrical connection unit 1.

[0058] <11. Advantages> According to this embodiment, the electrical connection unit 1 comprises a first rigid member (base plate 2 provided by the first assembly 6), a second rigid member (base plate 2 provided by the second assembly 7), and a plurality of heat conductive members. A first electronic component (electronic component 31) is mounted on the first rigid member. The second rigid member has a heat dissipation surface (first surface 2a and / or second surface 2b) in a first direction (for example, the Z direction). The heat conductive members (for example, a plurality of columns 8) thermally connect the first rigid member and the second rigid member. One of the first rigid member and the second rigid member is aligned with respect to the other in the first direction. With this configuration, the arrangement of at least one or more electronic components 31 can be determined to be in a predetermined layer in the hierarchical structure, and the arrangement area can be reduced. Therefore, the need for large area is suppressed.

[0059] Furthermore, according to this embodiment, the base plate 2 of the first assembly 6 and the base plate 2 of the first assembly 6 are metal products. With this configuration, a metal-containing skeleton can be formed in the electrical connection unit 1. Therefore, the strength of the hierarchical structure can be ensured.

[0060] In addition, in this embodiment, the heat conductive member transmits the heat generated by the electronic component 31 located on the first rigid member to the second rigid member. The second rigid member, having received heat via the heat conductive member, releases the heat to the outside from its heat dissipation surface (first surface 2a and / or second surface 2b). This configuration allows the heat generated by the electronic component 31 located on a predetermined layer to be transmitted to the outside. Therefore, in a layered structure, it is possible to suppress the accumulation of heat on a predetermined layer.

[0061] Furthermore, according to this embodiment, the heat conductive member is a metal product. This configuration provides a robust framework for maintaining the hierarchical structure in the electrical connection unit 1. Therefore, the strength of the hierarchical structure in the electrical connection unit 1 can be ensured.

[0062] In addition, in this embodiment, since the heat conductive member is a metal product, the heat generated by the electronic component 31 placed on the first rigid member is easily transmitted by the second rigid member. Therefore, the electrical connection unit 1 of this embodiment is better able to transmit the heat generated by the electronic component 31 at a predetermined level to the outside.

[0063] Furthermore, according to this embodiment, the electrical connection unit 1 further comprises a plurality of first modules (a plurality of component modules 3), each of which is equipped with the first electronic component. The plurality of first modules are mounted on the first rigid member. This configuration allows the arrangement of the plurality of electronic components 31 to be in a hierarchical structure, thereby reducing the area required for arrangement. Consequently, the need for large area is suppressed.

[0064] Furthermore, according to this embodiment, the electrical connection unit 1 further comprises a plurality of second modules (a plurality of component modules 3), each of which is equipped with a second electronic component (electronic component 31). The plurality of second modules are mounted on the second rigid member. With this configuration, the plurality of electronic components 31 are arranged on each layer, so the arrangement area can be reduced. Therefore, the need for large area is suppressed.

[0065] Furthermore, according to this embodiment, the electrical connection unit 1 further includes a relay wiring member (for example, a relay busbar 9) that connects the first assembly 6 and the second assembly 7. The first assembly 6 comprises a plurality of first modules and a first rigid member. The second assembly 7 comprises a plurality of second modules and the second rigid member. This configuration facilitates wiring across different layers. Therefore, the degree of freedom in arranging the electronic components 31 is increased.

[0066] Furthermore, according to this embodiment, the relay busbar 9 is positioned to wrap around the peripheral end 2e of the base plate 2 of the first assembly 6. This structure allows for wiring that makes effective use of the space on the outer circumference of the base plate 2 of the first assembly 6, compared to wiring that penetrates the inside of the first rigid member. Therefore, the degree of freedom in arranging the electronic components 31 is increased. In addition, it becomes possible to neatly lay out the wiring in the electrical connection unit 1.

[0067] Furthermore, according to this embodiment, the second assembly 7 is stacked on the first assembly 6. This configuration allows for a hierarchical arrangement of multiple electronic components 31, thereby reducing the required area. Consequently, the need for large-area components is suppressed.

[0068] Furthermore, according to the electrical connection unit 1 of this embodiment, each electronic component 31 is mounted on the base plate 2 via a partially rigid member 32. With this configuration, the arrangement of multiple electronic components 31 on the base plate 2 can be freely set. With such an electrical connection unit 1, each component module 3, which is an element module at the electronic component level, can be arranged on the base plate 2 in a free layout according to the functions required of the product, for example. In addition, with such an electrical connection unit 1, the electronic components 31 can be flexibly arranged on the base plate 2 in response to changes, modifications, etc. in the layout. Therefore, the development period can be shortened.

[0069] 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.

[0070] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each component module 3 to be freely arranged according to the functions required of the product. Therefore, as described above, the development period can be shortened.

[0071] 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.

[0072] In contrast to such comparative examples, the electrical connection unit 1 of this embodiment allows each component 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.

[0073] 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 component modules 3 to be reused among multiple electrical connection units 1 with different arrangements of component modules 3, or within an electrical connection unit 1. Therefore, the quality and reliability of the electrical connection unit 1 can be improved.

[0074] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to use standard unit modules as multiple component modules 3. Therefore, lead time and cost can be reduced.

[0075] Furthermore, with the electrical connection unit 1 of this embodiment, existing modules can be utilized as each component module 3. Therefore, the time and cost required for design and manufacturing can be reduced.

[0076] Furthermore, according to the electrical connection unit 1 of this embodiment, if improvements are needed for specific component modules 3 among the multiple component modules 3, efficient modifications can be made focusing on those specific component modules 3. Therefore, it can contribute to improving the efficiency of maintenance work.

[0077] Furthermore, with the electrical connection unit 1 of this embodiment, it is possible to create a layout in which, for example, multiple component 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.

[0078] 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 component modules 3 is suppressed.

[0079] 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.

[0080] 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.

[0081] Furthermore, in the electrical connection unit 1 of this embodiment, the partial rigid members 32 are bonded to the base plate 2. This configuration allows for the free arrangement of each partial rigid member 32 relative to the base plate 2. Therefore, the manufacturer can freely set the arrangement layout of multiple component modules 3.

[0082] Furthermore, according to the electrical connection unit 1 of this embodiment, multiple component 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.

[0083] (Various Modifications) Next, several modifications will be described. Note that in each modification, the configuration other than that described below is the same as that of the embodiment described above.

[0084] (First Modification) In the above embodiment, the electrical connection unit 1 has a two-story structure by comprising a first assembly 6 and a second assembly 7. However, the electrical connection unit 1 may be configured in any way as long as a hierarchical structure is formed. As a modification, the electrical connection unit 1 may have a three-story structure, a four-story structure, etc., in addition to a third assembly, a fourth assembly, etc.

[0085] (Second Modification) In the above embodiment, the first assembly 6 includes a base plate 2 as the first rigid member. However, the first rigid member can be configured in any way as long as it can mount multiple component modules 3 and support the second assembly 7. As a modification, the first rigid member may be a block, a box, or the like instead of the base plate 2.

[0086] (Third Modification) In the above-described embodiment, the second assembly 7 includes a base plate 2 as a second rigid member. However, the second rigid member can be configured in any way as long as it can accommodate multiple component modules 3. As a modification, the second rigid member may be a block, a box, or the like instead of the base plate 2.

[0087] (Fourth Modification) In the above embodiment, the electrical connection unit 1 is equipped with a relay busbar 9 as a relay wiring member. However, the electrical connection unit 1 may be equipped with any relay wiring member as long as it connects the first assembly 6 and the second assembly 7. As a modification, the electrical connection unit 1 may be equipped with relay wiring as a relay wiring member instead of the relay busbar 9.

[0088] (Fifth Modification) In the above embodiment, the electrical connection unit 1 includes a busbar 5 as a wiring member. However, the electrical connection unit 1 may include any wiring member as long as it can be wired to multiple component modules 3. As a modification, the electrical connection unit 1 may include wiring as a wiring member instead of the busbar 5.

[0089] (Sixth Modification) In the above-described embodiment, each of several component modules 3 is provided with an auxiliary busbar 30 as an auxiliary wiring member. However, each component module 3 may be provided with any auxiliary wiring member as long as it can be wired to the component terminals 39 and the busbar 5. As a modification, each component module 3 may be provided with auxiliary wiring as an auxiliary wiring member instead of the auxiliary busbar 30.

[0090] (Seventh Modification) In the above-described embodiment, the multiple partial rigid members 32 are bonded to the base plate 2. However, the multiple partial 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 partial rigid members 32 may be fastened to the base plate 2.

[0091] (Eighth Modification) In the above embodiment, the multiple terminal modules 4 are bonded to the base plate 2. However, the multiple terminal modules 4 can be fixed in any way as long as they can be arranged on the base plate 2 in a free layout. As a modification, the multiple terminal modules 4 may be fastened to the base plate 2.

[0092] (9th Modification) In the above-described embodiment, each component module 3 comprises an electronic component 31 and a partially rigid member 32. However, each component module 3 may be configured in any way as long as multiple electronic components 31 are mounted on the base plate 2. As a modification, each component 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 plate 2 without going through the partially rigid member 32.

[0093] (Tenth Modification) In the above-described embodiment, the first assembly 6 was a unit that constituted the first floor of the two-story hierarchical structure of the electrical connection unit 1. The second assembly 7 was a unit that constituted the second floor of the two-story hierarchical structure of the electrical connection unit 1. In contrast, in this modification, the first assembly 6 may be a unit that constitutes the second floor. In that case, the second assembly 7 is a unit that constitutes the first floor. In this modification, the direction in which the heat conduction member transmits heat is different from that of the above-described embodiment. In this modification, the first surface 2a of the base plate 2 (second rigid member) in the second assembly 7 may be in contact with the cooling member.

[0094] (11th Modification) In the above-described embodiment, the base plate 2 (first rigid member) of the first assembly 6 and the base plate 2 (second rigid member) of the first assembly 6 are metal products. In contrast, in this modification, the base plate 2 in one of the first assembly 6 and the second assembly 7 may be a synthetic resin product. In this case, the base plate 2 in the other is made of aluminum. In the above-described embodiment, the base plate 2 in the second assembly 7 may be a synthetic resin product. According to this modification, when one of the first rigid member and the second rigid member is aligned with respect to the other in the first direction (for example, the +Z direction), one of them is a synthetic resin product. As a result, heat generated by the electronic component 31 placed on one (the synthetic resin product) is easily transferred to the other via the heat conductive member.

[0095] Furthermore, according to Modification 11, by having one of the base plates 2 be made of synthetic resin, the weight of the base plates 2 aligned in the +Z direction when viewed from the other is reduced. By having one of the base plates 2 be made of synthetic resin, deformation of the other base plate 2 caused by the weight of multiple component modules 3 is suppressed. In the case of Modification 10, the base plate 2 in the first assembly 6 may also be made of synthetic resin.

[0096] 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.

[0097] According to one embodiment of this disclosure, the need for large-area expansion is suppressed.

[0098] 1 Electrical connection unit 2 Base plate (first rigid member, second rigid member) 2a First surface 2b Second surface 2e Peripheral end 3 Component module (first module, second module) 3b Bottom surface 3F Fuse module 3R Relay module 4 Terminal module (third module, fourth module) 5 Bus bar (first wiring member, second wiring member) 6 First assembly 7 Second assembly 8 Column 9 Intermediate bus bar (intermediate wiring member) 10 Cover 10p Opening 30 Auxiliary bus bar (auxiliary wiring member) 30a First end 30b Second end 31 Electronic component (first electronic component, second electronic component) 31F Fuse 31R Relay 32 Partial rigid member (third rigid member, fourth rigid member) 32b First bonding 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 41 Connection terminal 42 Terminal block 42a End face 42b Second bonding surface 43 Main body 44 Second flange

Claims

1. An electrical connection unit comprising: a first rigid member on which at least one first electronic component is mounted; a second rigid member having a heat dissipation surface in a first direction; and a plurality of heat conductive members thermally connecting the first rigid member and the second rigid member, wherein one of the first rigid member and the second rigid member is aligned with respect to the other in the first direction.

2. The electrical connection unit according to claim 1, wherein the first rigid member and the second rigid member are metal products.

3. The electrical connection unit according to claim 1, wherein the first rigid member is a synthetic resin product and the second rigid member is a metal product.

4. The electrical connection unit according to any one of claims 1 to 3, wherein the heat conductive member is a metal product.

5. The electrical connection unit according to claim 4, further comprising a plurality of first modules, each having the first electronic component, wherein the plurality of first modules are mounted on the first rigid member.

6. The electrical connection unit according to claim 5, further comprising a plurality of second modules, each having a second electronic component, wherein the plurality of second modules are mounted on the second rigid member.

7. The electrical connection unit according to claim 6, further comprising a relay wiring member connecting a first assembly comprising the plurality of first modules and the first rigid member, and a second assembly comprising the plurality of second modules and the second rigid member.

8. The electrical connection unit according to claim 7, wherein the relay cable member is arranged to wrap around the peripheral end of the first rigid member.

9. The electrical connection unit according to claim 7, wherein the second assembly is laminated on the first assembly.

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