Electrical connection unit

Abstract

An electrical connection unit according to one embodiment of the present invention comprises: a first connection target having a terminal; and a wiring member. The wiring member has a mounting hole penetrating therethrough in a first direction. The wiring member has an extension section, a heat dissipation section, and a connection section having the mounting hole. The wiring member is fixed to the terminal by a fastening member inserted into the mounting hole. The extension section extends from the connection section and is electrically connected to a second connection target. The heat dissipation section extends from the connection section in a direction different from that of the extension section. The heat dissipation section is formed by bending a metal plate forming the wiring member 2 or more times.

Description

Electrical connection unit

[0001] Embodiments of the present invention relate to an electrical connection unit. This application claims priority from Japanese Patent Application No. 2024-205956 filed in Japan on November 27, 2024, the content of which is incorporated herein by reference.

[0002] An electrical connection unit having an electronic component and a wiring material electrically connected to the electronic component is known.

[0003] Japanese Unexamined Patent Application Publication No. 2024-037492

[0004] By the way, improvement in thermal characteristics is expected for the electrical connection unit.

[0005] One embodiment provides an electrical connection unit capable of improving thermal characteristics.

[0006] The electrical connection unit of one embodiment includes a first connection target having a terminal and a wiring material. The wiring material has a mounting hole penetrating in a first direction. The wiring material has a connection portion having the mounting hole, an extension portion, and a heat dissipation portion. The wiring material is fixed to the terminal by a fastening member inserted into the mounting hole. The extension portion extends from the connection portion and is electrically connected to a second connection target. The heat dissipation portion extends from the connection portion in a direction different from that of the extension portion. The heat dissipation portion is formed by bending a metal plate forming the first wiring material two or more times.

[0007] According to one embodiment, improvement in thermal characteristics can be achieved.

[0008] Cross-sectional view showing the electrical connection unit of the embodiment. Perspective view showing a part of the electrical connection unit of the embodiment. Perspective view showing a part of the electrical connection unit of the embodiment disassembled. Development view of the bus bar in the electrical connection unit of the embodiment. Development view of the bus bar of the first modification of the embodiment. As another example of the structure shown in FIG. 1, cross-sectional view along a horizontal plane including the axis of the fastening member. Cross-sectional view showing the electrical connection unit of the third modification of the embodiment. Cross-sectional view showing the electrical connection unit of the fourth modification of the embodiment. Development view of the bus bar of the fourth modification of the embodiment. Development view of the bus bar of the fifth modification of the embodiment.

[0009] The embodiments will be described below with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numerals. Duplication of these components may be omitted. 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 directly connected, not just cases where two elements to be connected are connected with another element in between. “Facing” or “overlapping” means that the virtual projections of two objects overlap when viewed from a particular direction. That is, “Facing” or “overlapping” may include cases where two objects face each other with another member or gap between them, not just cases where two objects face 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, for example, the direction from the electronic component 10 (described later) toward the first connection portion 31 of the busbar 30 (see Figure 1). 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 and the -Y direction are directions that intersect (for example, are orthogonal to) the X direction. The +Y direction is, for example, the direction from the first terminal 13A of the electronic component 10 (described later) toward the second terminal 13B (see Figure 3). 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 first wall 5a to the second wall 5b of the housing 5 (see Figure 1). The -Z direction is the opposite direction to the +Z direction. Hereafter, when the +Z direction and the -Z direction 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 one of the "second direction" and the "third direction". The Z direction is the other of the "second direction" and the "third direction".

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

[0013] (Embodiment) <1. Configuration of the Electrical Connection Unit> Figure 1 is a cross-sectional view showing an electrical connection unit 1 of the first embodiment. 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 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. The electrical connection unit 1 has, for example, a housing 5 and a main body MU.

[0014] The housing 5 is a component that forms the outer casing of the electrical connection unit 1. The housing 5 is made of, for example, synthetic resin and has insulating properties. The housing 5 houses the main body MU. The housing 5 includes a first wall portion 5a (first portion) that covers at least a part of the main body MU from the -Z direction side, and a second wall portion 5b (second portion) that covers at least a part of the main body MU from the +Z direction side. Note that the housing 5 may be omitted.

[0015] Furthermore, the electrical connection unit 1 may have an insulating base member 6 that includes a first wall portion 5a and is open on the +Z direction side, instead of a box-shaped housing 5. The first wall portion 5a of the base member 6 may be a wall portion along the horizontal direction, or it may be a structure in which multiple ribs, each standing upright in the vertical direction, are combined. In the following description, "housing 5" may be read as "base member 6". Both the housing 5 and the base member 6 are examples of "supports" that support the electronic components 10 or busbars 30, which will be described later.

[0016] The main unit MU is the part of the electrical connection unit 1 that performs the main function (for example, switching the electrical connection state or overcurrent protection). The main unit MU may also be referred to as a "circuit configuration". The main unit MU includes, for example, one or more electronic components 10 and a plurality of busbars 30 (see Figure 2).

[0017] <2. Electronic Components> First, let's explain the electronic components 10. The electronic components 10 are electronic components that are mounted on the main unit MU according to the required functions. The electronic components 10 are, for example, connectors, fuses, relays (e.g., mechanical relays or semiconductor relays), capacitors, branching components, various sensors (e.g., current sensors or voltage sensors), electronic control units, or electronic component units that combine two or more of these into a single unit. However, the types of electronic components 10 are not limited to the above examples. The electronic components 10 are, for example, heat-generating components that generate heat when energized.

[0018] Figure 2 is a perspective view showing a part of the electrical connection unit 1. Figure 3 is a perspective view showing a disassembled part of the electrical connection unit 1. The electronic component 10 has, for example, a case 11, a component body 12, a plurality of terminals 13, and a plurality of mounting parts 14 (only one is shown in Figure 3).

[0019] The case 11 is an outer casing that forms most of the external shape of the electronic component 10. The case 11 is made of, for example, synthetic resin and has insulating properties. The case 11 houses the component body 12. The case 11 and the component body 12 may be formed as a single unit.

[0020] In this embodiment, the case 11 has insulating ribs 11a that protrude horizontally (for example, in the +X direction) and extend in the Z direction. The insulating ribs 11a are, for example, plate-shaped and aligned along the X and Z directions. The insulating ribs 11a extend, for example, along the entire length of the case 11 in the Z direction. The insulating ribs 11a are positioned between a plurality of terminals 13 (terminals 13A and 13B, described later). The insulating ribs 11a electrically insulate terminals 13A and 13B.

[0021] The main body portion 12 of the component is responsible for the main function of the electronic component 10. For example, if the electronic component 10 is a relay, the main body portion 12 includes a switching portion (e.g., a contact portion) that switches between a conductive state and a non-conductive state. For example, if the electronic component 10 is a fuse, the main body portion 12 includes a fuse that melts when an overcurrent flows. For example, if the electronic component 10 is a capacitor, the main body portion 12 includes a portion that stores electric charge.

[0022] Terminal 13 is an electrical connection part exposed to the outside of the case 11. Terminal 13 is electrically connected to the component body 12 inside the case 11. In this embodiment, the electronic component 10 includes terminals 13A and terminal 13B as a plurality of terminals 13. One of terminals 13A and terminal 13B is the positive terminal. The other of terminals 13A and terminal 13B is the negative terminal. One of terminals 13A and terminal 13B is an example of a "first terminal". The other of terminals 13A and terminal 13B is an example of a "second terminal".

[0023] In this embodiment, terminals 13A and 13B are provided at one end of the electronic component 10 in the horizontal direction (e.g., the X direction). Terminals 13A and 13B are arranged side by side in the horizontal direction (e.g., the Y direction). Each of terminals 13A and 13B faces the horizontal direction (e.g., the X direction).

[0024] Each terminal 13 has a mounting hole 13h into which a fastening member 41 (for example, a screw or bolt), described later, is inserted. The mounting hole 13h opens in the horizontal direction (for example, the +X direction). The inner circumferential surface of the mounting hole 13h of the electronic component 10 has a screw groove. The mounting hole 13h is a bottomed hole provided in the electronic component 10. In this disclosure, the term "mounting hole" is not limited to a hole with a screw groove, but may also be a hole without a screw groove. Furthermore, in this disclosure, if the terminal 13 is plate-shaped, the "mounting hole" may be a through hole that penetrates the terminal 13 in the thickness direction of the terminal 13.

[0025] The fastening member 41 in this disclosure has a shaft portion 41b on which a male screw is provided, and a head portion 41a that is larger than the shaft portion 41b.

[0026] (Mounting portion) The mounting portion 14 is a portion for fixing the electronic component 10. The mounting portion 14 is superimposed in the Z direction on a fixing portion 5f (e.g., a boss, see Figure 2) provided on the first wall portion 5a or the second wall portion 5b of the housing 5. The mounting portion 14 has a mounting hole 14h into which a fastening member 19 (e.g., a screw or bolt) is inserted. The mounting hole 14h is open in the Z direction. The mounting hole 14h is an insertion hole through which the fastening member 19 passes. The mounting portion 14 is fixed to the fixing portion 5f of the housing 5 by the fastening member 19. With this configuration, the electronic component 10 is fixed to the housing 5. Alternatively, the electronic component 10 may be fixed to the base member 6 described above.

[0027] <3. Busbar> Next, we will return to Figure 1 and describe the busbar 30. The busbar 30 is a wiring material that electrically connects multiple connection targets. The busbar 30 is made of metal (for example, copper, copper alloy, aluminum, or aluminum alloy) and is conductive. The busbar 30 electrically connects a first connection target (first component) and a second connection target (second component). For example, the busbar 30 electrically connects an electronic component 10 to another busbar 9 in the electrical connection unit 1. The electronic component 10 is an example of a "first connection target" or "first component". The busbar 9 is an example of a "second connection target" or "second component". The busbar 30 is an example of a "wiring material". In this disclosure, "wiring material" is not limited to the busbar 30.

[0028] Furthermore, the first and second connection targets are not limited to the examples above. The first connection target is any one of the following: an electronic component, a connecting component, another busbar in the electrical connection unit 1, or a busbar for external connection. The second connection target is any one of the following: an electronic component, a connecting component, another busbar in the electrical connection unit 1, or a busbar for external connection. For example, busbar 30 may electrically connect an electronic component 10 (first connection target) to another electronic component 10 (second connection target). Busbar 30 may electrically connect a connecting component (first connection target) to another connecting component (second connection target). In this disclosure, "connecting component" means a component that is placed between the busbar and the connection target (e.g., an electronic component or another busbar) and connects the busbar and the connection target.

[0029] In the following, as an example of a busbar 30, a busbar 30 that electrically connects an electronic component 10 (first connection target) and another busbar 9 (second connection target) in the electrical connection unit 1 will be described. However, in the following description, the terms "electronic component 10" and "busbar 9" may be appropriately replaced with other components based on the above-mentioned purpose.

[0030] As shown in Figure 1, the busbar 30 has, for example, a first connecting portion 31, a second connecting portion 32, an extended portion 33, an extended portion 34, and a bent portion 35. In this embodiment, the entire busbar 30, including the first connecting portion 31, the second connecting portion 32, the extended portion 33, the extended portion 34, and the bent portion 35, is formed from a single sheet of material (for example, formed by bending a single sheet of material).

[0031] (First connection portion) The first connection portion 31 is the portion that is connected to the first connection target (for example, the electronic component 10). The first connection portion 31 is located in the middle of the bus bar 30 or at the first end of the bus bar 30. In this embodiment, the first connection portion 31 is arranged in an upright position in the Z direction. The first connection portion 31 is a plate portion that is aligned with the Y and Z directions. The first connection portion 31 is adjacent to the electronic component 10 in the X direction. When viewed from the X direction, the first connection portion 31 includes a portion that overlaps with the terminal 13 of the electronic component 10. In another view, when viewed from the X direction, the first connection portion 31 includes a portion that overlaps with the fastening member 41 inserted into the terminal 13 or the washer 42 through which the fastening member 41 passes.

[0032] The first connecting portion 31 has a mounting hole 31h into which a fastening member 41 is inserted. The mounting hole 31h does not have, for example, a screw thread. The mounting hole 31h is, for example, a through hole that penetrates the first connecting portion 31 in the X direction. The mounting hole 31h of the first connecting portion 31 faces the mounting hole 13h of the electronic component 10 in the X direction. The fastening member 41 is inserted into the mounting hole 31h of the first connecting portion 31 along the X direction. The fastening member 41 passed through the mounting hole 31h of the first connecting portion 31 engages with the mounting hole 13h of the electronic component 10. With this configuration, the first connecting portion 31 of the busbar 30 and the terminal 13 of the electronic component 10 are physically and electrically connected.

[0033] (Second connection portion) The second connection portion 32 is the portion that is connected to a second connection target (for example, another bus bar 9). The second connection portion 32 is located in the middle of the bus bar 30 or at the second end of the bus bar 30. In this embodiment, the second connection portion 32 is parallel to the first wall portion 5a of the housing 5. The second connection portion 32 is a plate portion that is aligned with the X and Y directions. The second connection portion 32 overlaps with the end of the bus bar 9 in the Z direction. When viewed from the Z direction, the second connection portion 32 includes a portion that overlaps with the fastening member 45 or the washer 46 through which the fastening member 45 passes, which will be described later. In this embodiment, the bus bar 9 has a mounting hole 9h through which the fastening member 45 is inserted. The mounting hole 9h does not have screw threads, for example.

[0034] The second connecting portion 32 has a mounting hole 32h into which a fastening member 45 is inserted. The mounting hole 32h does not have, for example, a screw thread. The mounting hole 32h is, for example, a through hole that penetrates the second connecting portion 32 in the Z direction. The mounting hole 32h of the second connecting portion 32 faces the mounting hole 9h of the busbar 9 in the Z direction. The fastening member 45 is inserted along the Z direction into the mounting hole 32h of the second connecting portion 32 and the mounting hole 9h of the busbar 9. An engaging member 47 (for example, a nut) is engaged with the tip of the fastening member 45 that has passed through the mounting hole 32h of the second connecting portion 32 and the mounting hole 9h of the busbar 9. With this configuration, the second connecting portion 32 of the busbar 30 and another busbar 9 are physically and electrically connected.

[0035] Alternatively, instead of the above example, either the mounting hole 32h of the second connecting portion 32 or the mounting hole 9h of the busbar 9 may have a screw groove so that the fastening member 45 can engage with it. In this case, the engaging member 47 may be omitted.

[0036] (Extended section) The extended section 33 is provided between the first connecting section 31 and the second connecting section 32. The extended section 33 extends from the first connecting section 31 toward the second connecting section 32. The extended section 33 extends across the first connecting section 31 and the second connecting section 32. The extended section 33 connects the first connecting section 31 and the second connecting section 32.

[0037] The extension portion 33 of the busbar 30 shown in Figure 1 includes a first extension portion 33a, a second extension portion 33b, and a third extension portion 33c. The extension portion 33 in this embodiment further includes a fourth extension portion 33d.

[0038] The first extension portion 33a extends from the first connection portion 31 along a plane intersecting in the Z direction. The second extension portion 33b extends continuously from the first extension portion 33a and extends in the direction toward the second connection portion 32 in the X direction or in the Y direction.

[0039] In this embodiment, the first extension portion 33a extends, for example, from the first connecting portion 31 in the -Z direction. The second extension portion 33b extends, for example, from the first extension portion 33a along the horizontal direction in the -X direction. The third extension portion 33c extends, for example, from the second extension portion 33b in the +Z direction. The fourth extension portion 33d extends, for example, from the third extension portion 33c along the horizontal direction in the -X direction. Note that the shape of the extension portion 33 is not limited to the above example. For example, the extension portion 33 may have only the first extension portion 33a and extend in a straight line, or it may be bent in a more complex manner.

[0040] (Extension) The extension 34 extends in a predetermined direction. The extension 34 of the busbar 30 shown in Figure 1 includes a first extension 34a, a second extension 34b, a third extension 34c, and a fourth extension 34d. The extension 34 in this disclosure is an example of a "heat dissipation section". The extension 34, which is a "heat dissipation section", extends from the first connection section 31 in a direction different from the extension section 33. The extension 34, which is a "heat dissipation section", is formed by bending a metal plate that forms the cable material two or more times.

[0041] The first extension 34a is plate-shaped and extends from the first connection 31 in a second or third direction. In this case, the first extension 34a extends from the first connection 31 in a direction different from the direction in which the first extension 33a extends. For example, in the first busbar 30A described later, the first extension 34a may extend from the first connection 31 in the +Z direction (-Z direction), and the first extension 33a may extend from the first connection 31 in the -Z direction (+Z direction). The second extension 34b is plate-shaped and extends in a first direction (for example, the X direction) or a fourth direction. The fourth direction is the opposite direction to the direction in which the first extension 34a extends. The third extension 34c is plate-shaped and extends in a predetermined direction. The third extension 34c may extend in the same direction as the first extension 34a or in a fourth direction, for example. Alternatively, if the second extension 34b extends in a fourth direction, the third extension 34c may extend in a direction intersecting the direction in which the second extension 34b extends.

[0042] In this embodiment, the first extension portion 34a extends, for example, in the +Z direction from the first connection portion 31. The second extension portion 34b extends, for example, in the +X direction along the horizontal direction. The third extension portion 34c extends, for example, in the -Z direction. In this embodiment, the second extension portion 34b extends in a direction away from the terminal 13. However, depending on the length of the first extension portion 34a, the second extension portion 34b may extend in the -X direction along the horizontal direction.

[0043] In this embodiment, the third extension portion 34c faces the first connection portion 31 from the side opposite to the first connection target with a gap between the third extension portion 34c and the first connection portion 31. At this time, the third extension portion 34c may have a through hole through which the fastening member 41 can be inserted. Specifically, the third extension portion 34c faces the mounting hole 31h and has an insertion portion 30r through which the head portion 41a can be inserted. Note that it includes not only through holes but also U-shaped cutouts provided at the ends of the third extension portion 34c. The third extension portion 34c in the present disclosure is an example of a "plate portion".

[0044] (Bending portion) The bending portion 35 switches the direction in which the extension portion 34 extends. The bending portion 35 has a bending line BL described later. Note that the bending portion 35 may be bent or curved. The bending portion 35 of the bus bar 30 shown in FIG. 1 includes a first bending portion 35a, a second bending portion 35b, and a third bending portion 35c. The first bending portion 35a connects between the first extension portion 34a and the second extension portion 34b. The second bending portion 35b connects between the second extension portion 34b and the third extension portion 34c. The third bending portion 35c connects between the third extension portion 34c and the fourth extension portion 34d.

[0045] In the electrical connection unit 1 of this disclosure, the first bent portion 35a and the second bent portion 35b are located on one side (for example, the +Z direction side) of the mounting hole 31h in the direction in which the first extension portion 34a extends. The length L51 between the first bent portion 35a and the mounting hole 31h in the Z direction may be greater than the length between the top surface of the case 11 (the surface facing the +Z direction) and the mounting hole 31h in the Z direction (see Figure 1). Similarly, the length L52 between the second bent portion 35b and the mounting hole 31h in the Z direction may be greater than the length between the top surface of the case 11 (the surface facing the +Z direction) and the mounting hole 31h in the Z direction (see Figure 1). Furthermore, the length L53 between the first extension portion 34a and the second bent portion 35b in the X direction may be, for example, more than twice the length of the head in the X direction when the fastening member 41 is a bolt (or screw) having a head and a shaft (see Figure 1).

[0046] Next, the arrangement of the multiple busbars 30 will be described. As shown in Figure 3, the electrical connection unit 1 has multiple busbars 30, including a first busbar 30A and a second busbar 30B. In the following, when the first busbar 30A and the second busbar 30B are not distinguished, they will simply be referred to as "busbar 30".

[0047] The first connection portion 31 of the first busbar 30A is adjacent to the first terminal 13A of the electronic component 10 in the X direction. The first connection portion 31 of the first busbar 30A is fixed to the first terminal 13A of the electronic component 10 by a fastening member 41 (fastening member 41A) inserted into the mounting hole 31h of the first connection portion 31 of the first busbar 30A. The first busbar 30A is an example of the "first cable routing member". The mounting hole 31h of the first connection portion 31 of the first busbar 30A is an example of the "first mounting hole". The fastening member 41A is an example of the "first fastening member".

[0048] The second bus bar 30B is adjacent to the first bus bar 30A in the Y direction. The first connection part 31 of the second bus bar 30B is adjacent to the second terminal 13B of the electronic component 10 in the X direction. The first connection part 31 of the second bus bar 30B is fixed to the second terminal 13B of the electronic component 10 by a fastening member 41 (fastening member 41B) inserted into the mounting hole 31h of the first connection part 31 of the second bus bar 30B. The second bus bar 30B is an example of a "second wiring material". The mounting hole 31h of the first connection part 31 of the second bus bar 30B is an example of a "third mounting hole". The fastening member 41B is an example of a "second fastening member".

[0049] Next, an exploded view of a plurality of bus bars 30 will be described. FIG. 4 shows an exploded view 30A' of the first bus bar 30A. For example, a sheet metal material (hereinafter also referred to as a "blank material") that has been blanked according to the exploded view 30A' has scribing lines L (first scribing line L1, second scribing line L2, third scribing line L3). As shown in FIG. 4, the first scribing line L1 is located between the first extension part 34a and the second extension part 34b' extending therefrom. The second scribing line L2 is located between the second extension part 34b' and the third extension part 34c' extending therefrom. The third scribing line L3 is located between the third extension part 34c' and the fourth extension part 34d' extending therefrom.

[0050] When a pushing type such as a die is pressed against the blank material by a bender, the blank material bends or curves, and a bending line is formed on the contact surface between the blank material and the pushing type. For example, when the blank material is pressed along the first scribing line L1, the surface that abuts against the die facing the pushing type is bisected. If one of the bisected surfaces is the abutting surface in the first extension part 34a, the other surface becomes the abutting surface in the second extension part 34b. At that time, a first bending part 35a having a bending line following the first scribing line L1 is formed. Similarly, when the blank material is pressed along the second scribing line L2, the third extension part 34c and the second bending part 35b are formed. Similarly, when the blank material is pressed along the third scribing line L3, the fourth extension part 34d and the third bending part 35c are formed. In this way, the extension parts 34 and the bending parts 35 of the first bus bar 30A are formed from the blank material following the exploded view 30A'.

[0051] Furthermore, the blank material may have a ninth marking line L9. The ninth marking line L9 is located between the first extended portion 33a and the second extended portion 33b' extending therefrom. When the blank material is pressed along the ninth marking line L9, a second extended portion 33b is formed that extends in a direction intersecting the first extended portion 33a.

[0052] Furthermore, the second busbar 30B has a shape that is a left-right inversion of the first busbar 30A. That is, in the unfolded view of the second busbar 30B, the unfolded view 30A' of the first busbar 30A is inverted left to right.

[0053] The unfolded view 30A' of the first busbar 30A in this disclosure may be inverted vertically. In other words, the first busbar 30A, rotated 180 degrees around the axis of the mounting hole 31h, may be fixed to the first terminal 13A. The same applies to the unfolded view of the second busbar 30B and the fixing of the second busbar 30B. In this case, in the first busbar 30A, the first extension portion 34a extends in the -Z direction starting from the first connection portion 31, and the first extension portion 33a extends in the +Z direction starting from the first connection portion 31.

[0054] <4. Advantages> As a comparative example, consider a structure in which the extension portion 34 and the bent portion 35 do not exist. In such a structure, if sufficient heat capacity is not secured within the electrical connection unit, a large temperature rise may occur in a part of the electrical connection unit, and / or thermal interference with the first connection target or the second connection target may increase. For example, when a large transient current flows, a large temperature rise may occur in a part of the electrical connection unit, and / or thermal interference with the first connection target or the second connection target may increase. For this reason, it may become difficult to improve the thermal characteristics of the electrical connection unit.

[0055] On the other hand, the electrical connection unit 1 of this embodiment comprises a first connection target (e.g., an electronic component 10) having a terminal 13, and a first wiring member (e.g., a first busbar 30A). The first wiring member has a first mounting hole (e.g., a mounting hole 31h) penetrating in a first direction (e.g., the X direction). The first wiring member has a connection portion (first connection portion 31) having the mounting hole 31h, an extension portion 33, and a heat dissipation portion (e.g., an extension portion 34). The first wiring member is fixed to the terminal by a fastening member 41 inserted into the mounting hole. The extension portion 33 extends from the connection portion and is electrically connected to a second connection target. The heat dissipation portion extends from the connection portion in a direction different from the extension portion 33. The heat dissipation portion is formed by bending a metal plate forming the first wiring member two or more times.

[0056] With this configuration, the heat dissipation section enhances the heat storage capacity near the connection point of the first wiring member. Compared to the configuration of the comparative example above, this configuration suppresses a large temperature rise in a part of the electrical connection unit and / or suppresses increased thermal interference with the first or second connection target. For example, with this configuration, when a large transient current flows, it is possible to suppress a large temperature rise in a part of the electrical connection unit and / or suppress increased thermal interference with the first or second connection target. This configuration improves the thermal characteristics of the electrical connection unit.

[0057] Furthermore, in this embodiment, the heat dissipation section includes a plate portion (for example, a third extension 34c) that faces the connection section from the opposite side of the first connection target, with a gap between it and the connection section. With this configuration, the heat dissipation section is more easily brought into contact with air. This improves the heat dissipation performance of the electrical connection unit.

[0058] Furthermore, in this embodiment, the fastening member has a shaft portion 41b with a male screw and a head portion 41a that is larger than the shaft portion 41b. The plate portion faces the mounting hole and has an insertion portion 30r through which the head portion can be inserted. With this configuration, the plate portion is less likely to interfere with the fastening member 41A. This makes it possible to improve the heat dissipation area of ​​the heat dissipation section.

[0059] Furthermore, in this embodiment, since the first bent portion 35a and the second bent portion 35b are located on one side of the first mounting hole, the thermal characteristics of the electrical connection unit can be improved without the fastening member 41 having to stack the busbars 30 multiple times to fix them. This makes it easier to avoid the "reduction in axial force of the fastening member 41" that was a concern when the busbars 30 were stacked multiple times and fixed to the terminal 13 by the fastening member 41.

[0060] In this embodiment, the second extension 34b extends away from the terminal 13 in the first direction. The third extension 34c extends in the fourth direction. With this configuration, the first extension 34a, the second extension 34b, and the third extension 34c are more easily brought into contact with the air. This improves the heat dissipation of the electrical connection unit.

[0061] In this embodiment, the connection target is an electronic component (e.g., electronic component 10) including a first terminal (e.g., terminal 13A) and a second terminal (e.g., terminal 13B). The first cable is fastened together with the first terminal. With this configuration, a portion of the heat generated from the electronic component can be dissipated or stored through the extension portion 34 and the bent portion 35. This configuration makes it possible to further improve the thermal characteristics of the electrical connection unit.

[0062] <5. Modifications> Next, some modifications of the first embodiment will be described. Note that in each modification, the configuration other than that described below is the same as that of the first embodiment.

[0063] <5.1 First Modification> Figure 5 shows an unfolded view 30A' of the first busbar 30A. When the blank material is pressed along the ninth marking line L9, a second extension portion 33b is formed that extends in a direction intersecting the first extension portion 33a. In this modification, the second extension portion 33b may be routed along the side surface of the case 11. With this configuration, the height of the electrical connection unit can be easily reduced.

[0064] <5.2 Second Modification> Figure 6 shows a second modification of the structure shown in Figure 1, in which the electrical connection unit 100 is cut along a horizontal plane containing the axis of the fastening member 41. This horizontal plane is a plane along the X and Y directions. In this modification, the first busbar 30A, which is rotated 90 degrees around the axis of the mounting hole 31h, may be fixed to the first terminal 13A. This configuration also enhances the heat storage capacity of the electrical connection unit and improves its thermal characteristics. The same applies to the fixing of the second busbar 30B.

[0065] <5.3 Third Modification> In Figure 7, the bent portion 35 includes only the first bent portion 35a and the second bent portion 35b. In this modification, the third extension portion 34c extends while avoiding the axis of the fastening member 41. Even with this configuration, the heat storage capacity of the electrical connection unit can be increased, and the thermal characteristics of the electrical connection unit can be improved.

[0066] <5.4 Fourth Modification> As shown in Figure 8, in this modification, the extension portion 34 differs from that of the first embodiment. The extension portion 34 of the busbar 30 shown in Figure 8 includes a first extension portion 34a, a second extension portion 34b, and a third extension portion 34c.

[0067] In this modified example, the first extension 34a extends, for example, from the first connection portion 31 in the +Z direction. The second extension 34b extends in the fourth direction. The third extension 34c extends in the same direction as the first extension 34a. Specifically, in the extension 34 which is the "heat dissipation portion," the second extension 34b facing the first connection portion 31 in the first direction is formed by bending from the end of the first connection portion 31 toward the first side (for example, the -Z direction side). In this modified example, the second extension 34b is an example of the "first plate portion." The third extension 34c facing the second extension 34b from the opposite side of the first connection portion 31 is formed by bending from the end of the second extension 34b toward the second side opposite to the first side (for example, the +Z direction side). In this modified example, the third extension 34c is an example of the "second plate portion." In this configuration, the length L51 between the first bent portion 35a and the mounting hole 31h in the Z direction is set to avoid the axis of the fastening member 41. That is, the second extension portion 34b and the third extension portion 34c are located on the second side (one side of the mounting hole 31h (for example, the +Z direction side)) with respect to the fastening member 41. This configuration also enhances the heat storage capacity of the electrical connection unit and improves its thermal characteristics. Figure 9 shows an unfolded view 30A' of the first busbar 30A in this modified example.

[0068] <5.5 Fifth Modification> Figure 10 shows another example of the unfolded view 30A' of the first busbar 30A shown in Figure 9. In this modification as well, the second extension portion 33b may be routed along the side surface of the case 11, similar to the second modification. With this configuration, the height of the electrical connection unit can be easily reduced.

[0069] <5.6 Sixth Modification> In the first embodiment, the extension 34 of the busbar 30 included three extensions (first extension 34a, second extension 34b, and third extension 34c). Since the bent portion 35 connects each extension, the bent portion 35 in the first embodiment had two bent portions (first bent portion 35a and second bent portion 35b). In contrast, the extension 34 of the busbar 30 in this modification may include 2n+1 (n≧1) extensions. In this case, the bent portion 35 includes 2n bent portions. The 2nth bent portion connects the 2nth extension and the 2n+1th extension.

[0070] When this modified example is combined with the fourth modified example, the 2nth (n=1, 2, ...) bent portion may be located on one side of the mounting hole 31h, just like the first bent portion 35a and the second bent portion 35b. With this configuration, each extended portion (first extended portion 34a, second extended portion 34b, third extended portion 34c, etc.) included in the extension portion 34 of the fourth modified example can be easily stacked multiple times without fastening by the fastening member 41.

[0071] <5.7 Seventh Modification> In this modification, at least a portion of the first wall portion 5a of the housing 5 (or base member 6) may be formed of a metal plate. The metal plate may be, for example, made of aluminum, an aluminum alloy, copper, or a copper alloy, but is not limited to these. The metal plate is a plate portion that extends horizontally. The metal plate is exposed to the outside of the electrical connection unit 1, for example. The metal plate is an example of a "heat dissipation member". The metal plate may also be referred to as a "metal member" or a "rigid member". The term "heat dissipation member" as used in this disclosure is not limited to a metal member provided as part of the housing 5 (or base member 6). The term "heat dissipation member" as used in this disclosure may be a metal member provided separately from the housing 5 (or base member 6).

[0072] In this modified example, at least a portion of the busbar 30 overlaps with the metal plate when viewed from the Z direction. The busbar 30 may be positioned with a gap between it and the metal plate to ensure insulation between the busbar 30 and the metal plate. Alternatively, an insulating heat transfer member may be provided between the busbar 30 and the metal plate to ensure insulation between them. The heat transfer member is, for example, an elastic heat transfer sheet (e.g., a thermally conductive silicone sheet). The heat transfer member is made of a material with a higher thermal conductivity than, for example, the second wall portion 5b of the housing 5. However, the heat transfer member is not limited to the above example and may be made of a thermally conductive gel or other material.

[0073] Several embodiments and variations have been described above. However, the embodiments and variations are not limited to the examples described above. For example, some of the embodiments or variations described above may be implemented in combination with each other.

[0074] According to one embodiment of this disclosure, it is possible to improve thermal properties.

[0075] 1...Electrical connection unit 10...Electronic component (first connection target) 13...Terminal 13A...First terminal 13B...Second terminal 13h...Mounting hole 30...Bus bar (wire routing material) 30A...First bus bar (first wire routing material) 30B...Second bus bar (second wire routing material) 30r...Insertion part 31...First connection part 31h...Mounting hole 33...Extended part 34...Extension part 34a...First extension part 34b...Second extension part 34c...Third extension part 35...Bent part 35a...First bend part 35b...Second bend part 41...Fastening member 41a...Head part 41b...Shaft part 41A...Fastening member (first fastening member) 41B...Fastening member (second fastening member) 50...Heat storage member 50h...Mounting hole

Claims

1. An electrical connection unit comprising: a first connection target having a terminal; and a cable material having a mounting hole penetrating in a first direction and fixed to the terminal by a fastening member inserted into the mounting hole, wherein the cable material has a connection portion having the mounting hole, an extension portion extending from the connection portion and electrically connected to a second connection target, and a heat dissipation portion extending from the connection portion in a direction different from the extension portion, the heat dissipation portion being formed by bending a metal plate forming the cable material two or more times.

2. The electrical connection unit according to claim 1, wherein the heat dissipation portion includes a plate portion that faces the connection portion from the opposite side of the first connection target, with a gap between it and the connection portion.

3. The fastening member has a shaft portion on which a male screw is provided and a head portion larger than the shaft portion, and the plate portion faces the mounting hole and has an insertion portion through which the head portion can be inserted, as described in claim 2.

4. The electrical connection unit according to claim 1, wherein the heat dissipation portion includes a first plate portion that is bent from the end of the connection portion toward the first side and faces the connection portion in the first direction, and a second plate portion that is bent from the end of the first plate portion toward the second side opposite to the first side and faces the first plate portion from the side opposite to the connection portion.

5. The electrical connection unit according to claim 4, wherein the first plate portion and the second plate portion are located on the second side with respect to the fastening member.

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