Electrical connection unit

Abstract

An electrical connection unit according to one embodiment comprises a plurality of electronic components, a second rigid member that spreads in a first direction and a second direction that intersects the first direction and has the plurality of electronic components mounted thereon, wiring members that are electrically connected to the plurality of electronic components, and a rib module that is formed from an insulating member and is mounted on the second rigid member. The rib module is inserted between adjacent wiring members in at least one of the first direction and the second direction and extends so as to protrude from the second rigid member in a third direction that intersects the first direction and the second direction.

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. 2024-179818, 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 Patent Application Laid-Open No. 2018-113184

[0004] By the way, further miniaturization of the electrical connection unit is required.

[0005] One embodiment provides an electrical connection unit capable of achieving miniaturization.

[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 and extends in a first direction and a second direction intersecting the first direction, a wiring member electrically connected to the plurality of electronic components, and a rib module mounted on the second rigid member and formed of an insulating member. The rib module extends so as to protrude from the second rigid member in a third direction intersecting the first direction and the second direction, and is arranged to be inserted between two adjacent wiring members in at least one of the first direction and the second direction.

[0007] According to one embodiment, miniaturization of the electrical connection unit can be achieved.

[0008] A perspective view showing an electrical connection unit of an embodiment. A plan view showing an electrical connection unit of an embodiment. A perspective view showing a relay module of an embodiment. A perspective view showing a fuse module of an embodiment. A perspective view showing a terminal module of an embodiment. A perspective view showing a rib module of an embodiment. A cross-sectional view showing a rib module of an embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of an embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of an embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of an embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of an embodiment. A perspective view illustrating the manufacturing method of the electrical connection unit of an embodiment. A perspective view showing a base plate of a first modified example.

[0009] The embodiments will be described below with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numerals. Duplication of these components may be omitted. Note that the components described below do not limit the scope of the embodiments.

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

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

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

[0013] (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 rib module 70. The base plate 2 is an example of a second rigid member. Each busbar 5 is an example of a cable routing member. Each terminal module 4 is an example of a second module. The electrical connection unit 1 may further include a cover 6 (Figure 13), 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 rib module 70 are covered by the base plate 2 from the -Z direction and by the cover 6 from the +Z direction. That is, in the electrical connection unit 1, the plurality of first modules 3, the plurality of terminal modules 4, and the plurality of busbars 5 are housed in a housing which is a combination structure of the cover 6 and the base plate 2. 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 rib module 70. The base plate 2 has a plate shape that extends in a planar manner in the X and Y directions. The base plate 2 is, for example, a metal product and has thermal conductivity. The base plate 2 is a plate-shaped member that is aligned horizontally. The base plate 2 may be made of a metal such as copper or aluminum.

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

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

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

[0019] Each first module 3 comprises an electronic component 31 and a first rigid member 32. One electronic component 31 is mounted on each first rigid member 32. That is, each of the multiple electronic components 31 provided in the electrical connection unit 1 is individually mounted on the corresponding first rigid member 32. 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.

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

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

[0028] In the relay module 3R, at least one of the multiple notches 35n in the peripheral wall 35 is cut out such that a pair of component terminals 39 are exposed from between the peripheral wall 35 toward the outside of the first rigid member 32. That is, in the relay module 3R, at least one of the multiple notches 35n in the peripheral wall 35 may be cut out such that a busbar 5 connected to the component terminals 39 can pass through the notch 35n between the inside and outside of the first rigid member 32.

[0029] In each relay module 3R, for example, a pair of component terminals 39 of the electronic component 31 may face outward from the electrical connection unit 1 via the cover 6. In each relay module 3R, for example, the electronic component 31 may be arranged such that one or both of the pair of component terminals 39 of the electronic component 31 face and are exposed to the inner surface of the cover 6 in the horizontal direction.

[0030] The multiple first modules 3 may include, for example, a fuse module 3F. In this case, as shown in Figure 4, the fuse module 3F includes a fuse 31F as an electronic component 31.

[0031] In the fuse module 3F, at least one pair of notches 35n of the peripheral wall 35 is cut out so that a pair of component terminals 39 can protrude beyond the peripheral wall 35. The fuse module 3F may also include, for example, a pair of fixed terminals 38 that are fastened to the pair of component terminals 39. Each fixed terminal 38 is fastened to a corresponding component terminal 39.

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

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

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

[0035] The terminal block 42 comprises a main body 43, a pair of second flanges 44, and a plurality of second reinforcing ribs 45. The terminal block 42 is a single-piece molded product in which the main body 43, the pair of second flanges 44, and the plurality of second reinforcing ribs 45 are integrated. The terminal block 42 is made of 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 and is conductive. Each busbar 5 may be made of a metal such as copper or aluminum.

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

[0042] Some of the busbars 5 may be forming busbars, for example, that are curved in a horizontal plane and whose orientation changes continuously from vertical to horizontal (or from horizontal to vertical). In this case, the forming busbars 5 may be pre-formed into the shape to be routed before being combined with the first module 3 or terminal module 4.

[0043] 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 this 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 oriented in 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] The bus bar 5 of this embodiment has one of two adjacent bus bars 5 as the first wiring member 52 and the other as the second wiring member 53. The first wiring member 52 and the second wiring member 53 face each other in the horizontal direction. In the horizontal direction, a rib module 70 to be described later is arranged between the first wiring member 52 and the second wiring member 53.

[0045] In the horizontal direction, the first wiring member 52 is arranged in the +X direction and the -Y direction with respect to the rib module 70. The first wiring member 52 has a first extension portion 52a, a second extension portion 52b, and a first bending portion 52c. The first extension portion 52a and the second extension portion 52b are extension portions 51 of the first wiring member 52.

[0046] The largest main plane of the first extension portion 52a extends in the Y direction and the Z direction. In the first extension portion 52a, two bus bars are connected in the X direction, but the whole whose main plane extends in the Y direction and the Z direction is the first extension portion 52a.

[0047] The largest main plane of the second extension portion 52b extends in the X direction and the Z direction. The second extension portion 52b extends so as to be orthogonal to the first extension portion 52a.

[0048] The first bending portion 52c is a region in the first wiring member 52 where the extending direction changes. When viewed from the +Z direction, the first bending portion 52c is curved so as to bend vertically. The first bending portion 52c is connected to the first extension portion 52a and the second extension portion 52b. In other words, the end of the first extension portion 52a and the end of the second extension portion 52b are connected by the first bending portion 52c.

[0049] In the horizontal direction, the second wiring member 53 is arranged at a distance from the first wiring member 52. The second wiring member 53 has a third extension portion 53a, a fourth extension portion 53b, and a second bending portion 53c. The third extension portion 53a and the fourth extension portion 53b are extension portions 51 of the second wiring member 53.

[0050] The largest main plane of the third extension portion 53a extends in the Y direction and the Z direction. The first extension portion 52a and the third extension portion 53a are adjacent to each other with a gap in the X direction.

[0051] The fourth extension 53b has its largest main plane extending in the X and Z directions. The fourth extension 53b extends perpendicularly to the third extension 53a. The second extension 52b and the fourth extension 53b are adjacent to each other with a gap in the Y direction. The fourth extension 53b is also connected at its -X end to an inflection section 54, which is bent so that the direction of the plate surface changes continuously from vertical to horizontal. The inflection section 54 is also positioned opposite the rib module 70.

[0052] The second bend 53c is a region of the second cable member 53 where the direction of extension changes. The second bend 53c is curved so as to bend perpendicularly when viewed from the +Z direction. The second bend 53c is connected to the third extension 53a and the fourth extension 53b. In other words, the end of the third extension 53a and the end of the fourth extension 53b are connected at the second bend 53c. The second bend 53c is connected to the end of the fourth extension 53b that is not connected to the inflection 54.

[0053] Some of the multiple busbars 5 may branch off into multiple paths, for example, along a different route. Some of the multiple busbars 5 may be assemblies in which multiple forming busbars are connected in such a way that they branch off into multiple paths. In this case, the multiple forming busbars to be combined may be connected in advance before being combined with the first module 3 or terminal module 4.

[0054] Some of the multiple busbars 5 may be flat plates having a rectangular surface oriented vertically. Some of the multiple busbars 5 may be flat plates having an L-shaped surface oriented vertically.

[0055] Of the ends of each busbar 5, the end connected to the first module 3 may be fastened to, for example, a component terminal 39. Of the ends of each busbar 5, the end connected to the terminal module 4 may be fastened to, for example, a connection terminal 41.

[0056] <6. Rib Module Configuration> The rib module 70 will now be described. The rib module 70 is a member that is positioned to be inserted between two adjacent busbars 5 in at least one of the X and Y directions. The rib module 70 may be positioned, for example, between two busbars 5 that are closest to each other in the horizontal direction. Specifically, the rib module 70 may be positioned, for example, between two busbars 5 that are spaced at an interval of less than or equal to the insulation distance in the horizontal direction.

[0057] In this embodiment, the rib module 70 is positioned to be inserted between the extended portions 51 (first extended portion 52a, second extended portion 52b, third extended portion 53a, and fourth extended portion 53b) of the first cable member 52 and the second cable member 53.

[0058] In this embodiment, the first cable member 52 is positioned horizontally in the +X and -Y directions relative to the rib module 70. Specifically, the first extension portion 52a is positioned spaced apart from the rib module 70 in the +X direction. The first extension portion 52a faces the rib module 70 so as to face it in the X direction. Furthermore, the second extension portion 52b is positioned spaced apart from the rib module 70 in the -Y direction. The second extension portion 52b faces the rib module 70 so as to face it in the Y direction.

[0059] Furthermore, the second cable member 53 is positioned horizontally in the -X and +Y directions relative to the rib module 70. Specifically, the third extension portion 53a is positioned spaced apart from the rib module 70 in the -X direction. The third extension portion 53a faces the rib module 70 so as to face it in the X direction. In addition, the fourth extension portion 53b is positioned spaced apart from the rib module 70 in the +Y direction. The fourth extension portion 53b faces the rib module 70 so as to face it in the Y direction.

[0060] Here, the direction in which the first cable member 52, the rib module 70, and the second cable member 53 are aligned is defined as the opposing direction. That is, in this embodiment, the opposing direction is the X direction or the Y direction, which is the direction in which the first cable member 52 and the second cable member 53 are aligned.

[0061] The rib module 70 is mounted on the base plate 2. The rib module extends from the base plate 2 so as to protrude in the +Z direction. When viewed from the +Z direction, the rib module 70 is positioned away from the electronic components 31 and the busbar 5. The rib module 70 is made of an insulating material. The rib module 70 is a synthetic resin product, for example, made of synthetic resin. As shown in Figure 6, the rib module 70 has a base portion 71, a rib body 80, and a protruding portion 90.

[0062] The base portion 71 is a plate-shaped part that extends horizontally. The base portion 71 is fixed to the base plate 2 in an immovable manner. The base portion 71 may be, for example, bonded to the base plate 2. The base portion 71 may have, for example, a third bonding surface 71b. The third bonding surface 71b is a plane facing the -Z direction. The third bonding surface 71b may be bonded to the first surface 2a by, for example, adhesive, thermocompression, laser welding, etc. Also, the base portion 71 may be positioned so as not to come into contact with, for example, the first module 3 or the terminal module 4. The base portion 71 is connected to the rib body 80 on a surface facing the +Z direction.

[0063] The rib body 80 is the portion that extends from the base portion 71 in the +Z direction. The rib body 80 is formed, for example, in the shape of a rectangular parallelepiped. The rib body 80 is connected to the base portion 71 at its end in the -Z direction. The end of the rib body 80 in the +Z direction is formed so that it does not come into contact with the cover 6 when the cover 6 is combined with the base plate 2. Furthermore, the end of the rib body 80 in the +Z direction is formed to be further away from the base plate 2 than the adjacent busbars 5 (first cable member 52 and second cable member 53).

[0064] Figure 7 shows a cross-section of the rib module 70 (rib body 80) in the horizontal direction when viewed from the +Z direction. As shown in Figures 6 and 7, the rib body 80 has a first wall portion 81, a second wall portion 82, a connecting portion 83, and an upper surface 84. Note that Figure 7 shows the upper surface 84 as seen through.

[0065] The first wall portion 81 is the portion of the rib module 70 (rib body 80) that is facing the first cable member 52 in the opposing direction. The first wall portion 81 has a first Y wall portion 81a extending in the Y direction and a first X wall portion 81b extending in the X direction. The first Y wall portion 81a extends along the first extension portion 52a and the third extension portion 53a. The first X wall portion 81b extends along the second extension portion 52b and the fourth extension portion 53b. The -Y end of the first Y wall portion 81a is connected to the +X end of the first X wall portion 81b.

[0066] The second wall portion 82 is the portion of the rib module 70 (rib body 80) that is facing the second cable member 53 in the opposing direction. The second wall portion 82 has a second Y wall portion 82a extending in the Y direction and a second X wall portion 82b extending in the X direction. The second Y wall portion 82a extends along the first Y wall portion 81a, the first extension portion 52a, and the third extension portion 53a. The second X wall portion 82b extends along the first X wall portion 81b, the second extension portion 52b, and the fourth extension portion 53b. The -Y end of the second Y wall portion 82a is connected to the +X end of the second X wall portion 82b.

[0067] The connecting portion 83 connects the first wall portion 81 and the second wall portion 82 in opposing directions. The connecting portion 83 extends from the base portion 71 in the +Z direction. Multiple connecting portions 83 may be formed, spaced apart from each other. In this embodiment, a space is formed enclosed by the first wall portion 81, the second wall portion 82, and the multiple connecting portions 83. In other words, a space extending in opposing directions is formed between the first wall portion 81 and the second wall portion 82.

[0068] The upper surface 84 is connected to the first wall portion 81, the second wall portion 82, and the +Z direction ends of the connecting portion 83. The upper surface 84 connects the first wall portion 81 and the second wall portion 82 in opposing directions. The upper surface 84 is a plate-shaped portion that extends horizontally. The space formed by the first wall portion 81, the second wall portion 82, and the multiple connecting portions 83 is covered by the upper surface 84 from the +Z direction. The +Z direction end of the upper surface 84, i.e., the +Z direction end of the rib module 70, may be formed so as not to come into contact with the cover 6 when the cover 6 is combined with the base plate 2.

[0069] The protruding portion 90 is a part that extends from the second wall portion 82 (second Y wall portion 82a) in the Y direction. The protruding portion 90 is a part that is not connected to the base portion 71 at its -Z end. The protruding portion 90 is connected to the +Y end of the second Y wall portion 82a. The protruding portion 90 spreads out parallel to the second Y wall portion 82a. The -Z end of the protruding portion 90 may be formed to contact, for example, the +Z end of the first rigid member 32. <7. Method for manufacturing the electrical connection unit> A 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.

[0070] (First step) As shown in Figure 8, the first step is for the manufacturer to prepare the base plate 2.

[0071] (Second step) As shown in Figure 9, in the second step, the manufacturer attaches the multiple first rigid members 32, the multiple terminal modules 4, and the rib module 70 to the base plate 2. The manufacturer may also bond the multiple first rigid members 32, the multiple terminal modules 4, and the rib module 70 to the base plate 2.

[0072] (Third Step) As shown in Figure 10, 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 10, 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.

[0073] (Fourth step) As shown in Figure 11, 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 11, in the fourth step, the manufacturer may mount a fuse module 3F from the plurality of electronic components 31 on the corresponding first rigid member 32. Furthermore, in the fourth step, the manufacturer may mount a portion 31T of the remaining electronic components 31 to be mounted on the corresponding first rigid member 32.

[0074] (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 12, 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.

[0075] (Sixth step) As shown in Figure 13, in the sixth step, the manufacturer attaches a cover 6 to the assembly on which the multiple first modules 3, multiple terminal modules 4, and multiple busbars 5 are attached to the base plate 2.

[0076] <8. Advantages> The electrical connection unit 1 of this embodiment has a rib module 70 that extends from the base plate 2 so as to protrude in the +Z direction. The rib module 70 is arranged to be inserted between two adjacent busbars 5 in at least one of the X and Y directions. With such an electrical connection unit 1, even if the potentials applied to each of the two adjacent busbars 5 are different, the insulation distance can be increased by the rib module 70. Therefore, it is possible to bring the distance between two adjacent busbars 5 closer. Consequently, the electrical connection unit 1 can be made smaller.

[0077] In this embodiment, the rib module 70 is positioned away from the electronic component 31 and the busbar 5 when viewed from the Z direction. With this configuration, it is possible to achieve the above-mentioned effects while suppressing the occurrence of problems such as friction that may occur due to the rib module 70 coming into contact with the electronic component 31 and the busbar 5.

[0078] Furthermore, the rib module 70 of this embodiment has a first wall portion 81 located closer to the first cable member 52 and a second wall portion 82 located closer to the second cable member 53. A space is formed between the first cable member 52 and the second cable member 53, extending in the opposing direction. With this structure, the rib module 70 can be positioned closer to the first cable member 52 and the second cable member 53. Therefore, it becomes more difficult for debris such as metal fragments to enter between the first cable member 52 and the second cable member 53. In addition, the presence of an upper surface 84 prevents debris from entering from the +Z direction. Therefore, it is possible to suppress the reduction in the insulation distance between the first cable member 52 and the second cable member 53 due to the entry of debris. Furthermore, by having a structure in which a space is formed between the first cable member 52 and the second cable member 53, the above effects can be achieved while suppressing an increase in the amount of material constituting the rib module 70.

[0079] Furthermore, the rib module 70 in this embodiment is positioned to be inserted between the extended portions 51 (first extended portion 52a, second extended portion 52b, third extended portion 53a, and fourth extended portion 53b) of the first cable member 52 and the second cable member 53. With this configuration, the rib module 70, the first cable member 52, and the second cable member 53 all have main planes that extend in the same direction. Therefore, it becomes easier to reduce the distance between the rib module 70, the first cable member 52, and the second cable member 53. Consequently, the electrical connection unit 1 can be further miniaturized.

[0080] Furthermore, by forming the rib module 70 so that its +Z-direction end is further away from the base plate 2 than the adjacent busbar 5, the creepage distance between adjacent busbars 5 can be increased. Therefore, the distance between adjacent busbars 5 can be reduced. Consequently, the electrical connection unit 1 can be further miniaturized.

[0081] The rib module 70 of this embodiment further has a projection 90 that extends in the Y direction, extending the second wall portion 82 (second Y wall portion 82a). This makes it possible to increase the insulation distance between adjacent busbars 5 even in positions where the base portion 71 cannot be placed. In addition, the projection 90 can be positioned stably by forming the end of the projection 90 in the -Z direction to contact the end of the first rigid member 32 in the +Z direction.

[0082] 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. With this configuration, the arrangement of multiple electronic components 31 on the base plate 2 can be freely set. In addition, the rib module 70 can be appropriately placed at desired locations. With such an electrical connection unit 1, each first module 3, which is an element module in the form of an electronic component, can be arranged on the base plate 2 in a free layout according to the function required of the product. Furthermore, with such an electrical connection unit 1, for example, the electronic components 31 and rib module 70 can be flexibly arranged on the base plate 2 in response to changes or modifications in the layout. Therefore, the development period can be shortened.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] (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.

[0099] (First Modification) In the above-described embodiment, the first surface 2a and the second surface 2b of the base plate 2 are smooth planes relative to each other. However, the first surface of the base plate 2 may be configured in any way as long as each first module 3 can be placed on it. As a modification, the electrical connection unit 1 may include a base plate 102 instead of the base plate 2. In the base plate 102, for example, as shown in Figure 14, the surface roughness of the first surface 102a is rougher than that of the second surface 102b by applying a minute uneven surface treatment to the first surface 102a. The second surface 102b is a smooth plane similar to the second surface 2b of the base plate 2. Due to the large surface roughness of the first surface 102a, the base plate 102 can exert a fixing anchor effect on the first module 3, terminal module 4, and rib module 70 on which it is placed. In this case, each first module 3 may be bonded to the first surface 102a of the base plate 102, for example, as in the above-described embodiments. As a result of this effect, the first module 3, terminal module 4, and rib module 70 are less likely to detach from the base plate 102. Therefore, the electrical connection unit 1 can be made more robust. As another modification, a fine uneven surface treatment may be applied only to the area of ​​the first surface 102a of the base plate 102 on which the first module 3, terminal module 4, and rib module 70 are placed.

[0100] (Second Modification) In the above-described embodiment, the electrical connection unit 1 includes a base plate 2 as a second rigid member. However, the second rigid member may be configured in any way as long as multiple first modules 3 can be mounted on it. As a modification, the second rigid member may be a block, a box, or the like instead of the base plate 2.

[0101] (Third Modification) In the above embodiment, the electrical connection unit 1 includes a busbar 5 as a wiring member. However, the electrical connection unit 1 may include any wiring member as long as it can be wired to a plurality of first modules 3. As a modification, the electrical connection unit 1 may include wiring as a wiring member instead of the busbar 5.

[0102] (Fourth Modification) In the above-described embodiment, the multiple first rigid members 32 are bonded to the base plate 2. However, the first rigid members 32 may be fixed in any way as long as the electronic components 31 can be arranged on the base plate 2 in a free layout. As a modification, the multiple first rigid members 32 may be fastened to the base plate 2.

[0103] (Fifth Modification) In the above-described embodiment, the multiple terminal modules 4 are bonded to the base plate 2. However, the multiple terminal modules 4 can be fixed in any way as long as they can be arranged on the base plate 2 in a free layout. As a modification, the multiple terminal modules 4 may be fastened to the base plate 2.

[0104] (Sixth Modification) In the above-described embodiment, the rib module 70 is bonded to the base plate 2. However, the rib module 70 may be fixed in any way as long as it can be arranged on the base plate 2 in a free layout. As a modification, the rib module 70 may be fastened to the base plate 2.

[0105] (Seventh Modification) In the above embodiment, the rib module 70 has a protruding portion 90. However, the rib module 70 may be in a form that does not have a protruding portion 90. That is, the rib module may be in a form that does not have a portion that protrudes horizontally from the base portion 71 when viewed from the +Z direction.

[0106] 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.

[0107] According to one embodiment of the present disclosure, the electrical connection unit can be miniaturized.

[0108] 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) 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 section 43a Outer circumference 44 Second flange 45 Second reinforcing rib 51 Extension section 52 First routing member 52a First extension section 52b Second extension section 52c First bending section 53 Second cable member 53a Third extension section 53b Fourth extension section 53c Second bending section 54 Curved section 70 Rib module 71 Base section 71b Third bonding surface 80 Rib body 81 First wall section 81a First Y wall section 81b First X wall section 82 Second wall section 82a Second Y wall section 82b Second X wall section 83 Connection section 84 Top surface 90 Protruding section 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 and which extends in a first direction and a second direction intersecting the first direction; a wiring member electrically connected to the plurality of electronic components; and a rib module mounted on the second rigid member and formed of an insulating member, wherein the rib module extends so as to protrude from the second rigid member in a third direction intersecting the first and second directions, and is arranged to be inserted between two adjacent wiring members in at least one of the first and second directions.

2. The electrical connection unit according to claim 1, wherein the rib module is positioned away from the plurality of electronic components and the wiring member when viewed from the third direction.

3. When one of two adjacent cable members is designated as a first cable member and the other as a second cable member, the direction in which the first cable member, the rib module, and the second cable member are aligned is defined as the opposing direction, and the rib module has a first wall portion that faces the first cable member on the side closer to the first cable member in the opposing direction, and a second wall portion that faces the second cable member on the side closer to the second cable member in the opposing direction, and a space is formed between the first wall portion and the second wall portion in the opposing direction, the electrical connection unit according to claim 1 or 2.

4. The electrical connection unit according to claim 1 or 2, wherein each of the two adjacent cable members is formed in a flat shape and has an extended portion that extends along the spreading surface of the second rigid member, and the rib module is positioned between the extended portions of the two cable members.

5. The electrical connection unit according to claim 1 or 2, wherein the rib module is formed such that its end in the third direction is located further away from the second rigid member than two adjacent cable members.

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

7. The electrical connection unit according to claim 6, wherein the first rigid member and the rib module are bonded to the second rigid member.

8. The electrical connection unit according to claim 6, wherein the first rigid member is made of synthetic resin, the second rigid member is made of metal, and the rib module is made of an insulating material.

9. The electrical connection unit according to claim 1 or 2, wherein the second rigid member has a first surface facing the plurality of electronic components and a second surface facing the opposite direction from the first surface, and the surface roughness of the first surface is rougher than the surface roughness of the second surface.

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