JP2004345454A - Structure of mounting high-voltage equipment component to vehicle - Google Patents

Structure of mounting high-voltage equipment component to vehicle Download PDF

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Publication number
JP2004345454A
JP2004345454A JP2003143415A JP2003143415A JP2004345454A JP 2004345454 A JP2004345454 A JP 2004345454A JP 2003143415 A JP2003143415 A JP 2003143415A JP 2003143415 A JP2003143415 A JP 2003143415A JP 2004345454 A JP2004345454 A JP 2004345454A
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Prior art keywords
equipment component
mounting
component
vehicle
pressure equipment
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JP2003143415A
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JP4060234B2 (en
Inventor
Ritsuo Masui
律男 桝井
Hiroshi Otsuka
浩 大塚
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Priority to JP2003143415A priority Critical patent/JP4060234B2/en
Priority to US10/850,337 priority patent/US7051825B2/en
Priority to EP04012092A priority patent/EP1479567B1/en
Priority to CNB2004100424522A priority patent/CN1281428C/en
Priority to DE602004030182T priority patent/DE602004030182D1/en
Publication of JP2004345454A publication Critical patent/JP2004345454A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0007—Measures or means for preventing or attenuating collisions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L1/00—Supplying electric power to auxiliary equipment of vehicles
    • B60L1/003—Supplying electric power to auxiliary equipment of vehicles to auxiliary motors, e.g. for pumps, compressors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/66—Arrangements of batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/18—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules
    • B60L58/21—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules having the same nominal voltage
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/24—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries
    • B60L58/26—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries by cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/40—Drive Train control parameters
    • B60L2240/54—Drive Train control parameters related to batteries
    • B60L2240/545—Temperature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Hybrid Electric Vehicles (AREA)
  • Body Structure For Vehicles (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a structure of mounting a high-voltage equipment to a vehicle component capable of enhancing the attaching/detaching workability of the high-voltage equipment component to/from a vehicle body side, forming a flow passage to pass cooling air to the high-voltage equipment component at low cost, and protecting the high-voltage equipment component even when a vehicle body floor is deformed by some force from a lower side. <P>SOLUTION: A high-voltage equipment component 41 is disposed in a hanging condition in a downwardly recessed accommodation part 20 formed in a vehicle body floor 10, and a heat insulating material 40 to form a flow passage 110 to pass cooling air to the high-voltage equipment component 41 is interposed between the high-voltage equipment component 41 and a bottom part 20E of the recessed accommodation part 20. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、高圧機器コンポーネントの車載構造に関する。
【０００２】
【従来の技術】
内燃機関エンジンの出力と電動モータの出力とを使用して走行を行うハイブリッド車両や電動モータの出力のみで走行を行う電気自動車等においては、大型の高圧機器コンポーネントが車両に搭載されることになるが、このような高圧機器コンポーネントの車載構造に関する技術として、車体フロアの下側に下方から高圧機器コンポーネントを取り付ける構造が開示されている（例えば、特許文献１および特許文献２参照）。
【０００３】
【特許文献１】
特開平７−１５６８２６号公報
【特許文献２】
特開平１１−１７８１１５号公報
【０００４】
【発明が解決しようとする課題】
しかしながら、上記のように、車体フロアの下側に下方から高圧機器コンポーネントを取り付ける構造であると、取付・取外作業を車体フロアに対し下側から行わなければならず、当然のことながら、取付・取外作業の作業性が悪いという問題があった。また、高圧機器コンポーネントは外側のカバー部材に載置されることになることから、高圧機器コンポーネントへ冷却風を通すための流路を形成する構造が複雑でコストが増大してしまうという問題もあった。また、高圧機器コンポーネントは外側のカバー部材に載置されることになるため、カバー部材が何らかの力を受けて変形するとその変形がそのまま高圧機器コンポーネントに影響を及ぼす可能性があった。
【０００５】
したがって、本発明は、高圧機器コンポーネントの車体側への取付・取外作業の作業性を向上させることができるとともに、高圧機器コンポーネントへ冷却風を通すための流路を低コストで形成することができ、さらに車体フロアが下方から何らかの力を受けて変形しても高圧機器コンポーネントを保護することができる高圧機器コンポーネントの車載構造の提供を目的とする。
【０００６】
【課題を解決するための手段】
上記目的を達成するために、請求項１に係る発明は、高圧機器コンポーネント（例えば実施の形態における高圧機器コンポーネント４１）を車体フロア（例えば実施の形態における車体フロア１０）に形成された下方に凹む収納凹部（例えば実施の形態における収納凹部２０）に吊り下げ状態で配設するとともに、前記高圧機器コンポーネントと前記収納凹部の底部との間に前記高圧機器コンポーネントに冷却風を流す流路を形成する断熱部材（例えば実施の形態におけるマット部材４０）を介装してなることを特徴としている。
【０００７】
このように、高圧機器コンポーネントが車体フロアに形成された下方に凹む収納凹部に吊り下げ状態で配設されるため、取付・取外作業を車体フロアに対し上側から行うことができる。また、高圧機器コンポーネントが吊り下げられることにより形成される高圧機器コンポーネントと収納凹部の底部との間の隙間に断熱部材を配置し、この断熱部材によって高圧機器コンポーネントに冷却風を流す流路を形成するため、比較的簡単に流路を形成することができる。さらに、高圧機器コンポーネントが吊り下げられることにより形成される高圧機器コンポーネントと収納凹部の底部との間の隙間に断熱部材を配置しているため、車体フロアが下方から何らかの力を受けて変形しても断熱部材が変形することでこの変形を吸収する。
【０００８】
請求項２に係る発明は、請求項１に係る発明において、前記断熱部材は、弾性材料からなっており、前記収納凹部に配設された前記高圧機器コンポーネントで押圧されて圧縮変形することを特徴としている。
【０００９】
このように、断熱部材が、収納凹部に配設された高圧機器コンポーネントで押圧されて圧縮変形するため、断熱部材によって形成される流路における断熱部材と高圧機器コンポーネントとの間の隙間をシールできこの隙間からの冷却風の漏れを防止できる。また、断熱部材の変形によって高圧機器コンポーネントの取付誤差を吸収することができる。
【００１０】
請求項３に係る発明は、請求項２に係る発明において、前記断熱部材は、前記高圧機器コンポーネントの各高圧機器（例えば実施の形態におけるバッテリボックス４３，ＤＣ−ＤＣコンバータ４７，ジャンクションボックス４８，コントローラ４９）同士を連結させる連結部材（例えば実施の形態における固定ブラケット５７）で押圧されて圧縮変形することを特徴としている。
【００１１】
このように、断熱部材が高圧機器コンポーネントの各高圧機器同士を連結させる連結部材で押圧されて圧縮変形する構造であるため、冷却風の流路の形成時に断熱部材の圧縮変形するシール部分については連結部材の形状を考慮すれば良くなる。
【００１２】
【発明の実施の形態】
本発明の一実施形態の高圧機器コンポーネントの車載構造を図面を参照して以下に説明する。なお、以下の説明における前後左右は車両の前進時における前後左右である。
【００１３】
本実施形態は、図示は略すが内燃機関エンジンの駆動力と走行用電動モータの駆動力とを適宜制御しながら車両の走行を行うハイブリッド方式の車両に適用されている。
【００１４】
図１において符号１は、２ボックスタイプの車両を示している。この車両１は車体フロア１０上において前方から後方に向けて３列に渡って１列目シート１１、２列目シート１２および３列目シート１３が配置されたシート配置構造となっている。
【００１５】
１列目シート１１が配置された車体フロア１０の第１フロア１５は、この第１フロア１５よりも高い位置の第２フロア１６に接続され、この第２フロア１６に２列目シート１２および３列目シート１３が配置されている。
【００１６】
各列のシート１１，１２，１３は、基本的に、各々着席した乗員の臀部を支持するシートクッション１１ｃ，１２ｃ，１３ｃと、着席した乗員の背部を支承する起倒可能なシートバック１１ｂ，１２ｂ，１３ｂとを備えたものであり、各列シート１１，１２，１３のシートバック１１ｂ，１２ｂ，１３ｂには各々ヘッドレスト１１ｒ，１２ｒ，１３ｒが取り付けられている。
【００１７】
１列目シート１１が載置される第１フロア１５の第２フロア１６側には、１列目シート１１で前部が覆われるように下方に凹む収納凹部２０が形成されている。また、第２フロア１６の下側には収納凹部２０の後側に隣接するようにして燃料タンク２１が配置されている。また、図２に示すように、車体フロア１０の下側には収納凹部２０の側方に内燃機関エンジンの排気管２２が通っており、排気管２２のプリチャンバ２２Ａが収納凹部２０の右側方に位置し、排気管２２のサイレンサ２２Ｂが収納凹部２０の後側に位置している。
【００１８】
車体フロア１０についてさらに説明すると、フロアパネル２３の車幅方向両端には前後方向に沿って延在する左右のサイドシル（車体骨格部）２４が設けられており、これらサイドシル２４の間位置におけるフロアパネル２３の下面側には前後方向に沿って延在する左右のサイドフレーム（車体骨格部）２５が設けられている。ここで、図示は略すが、左右のサイドシル２４は前後方向に直交する断面が閉断面形状をなしており、左右のサイドフレーム２５もフロアパネル２３とで前後方向に直交する断面が閉断面形状をなしている。
【００１９】
また、左右のサイドフレーム２５に交差しつつ左右のサイドシル２４同士を結ぶように車幅方向に沿って延在するクロスメンバ（車体骨格部，補強メンバ）２６がフロアパネル２３の下面側であって第１フロア１５と第２フロア１６との境界位置に設けられており、このクロスメンバ２６の後ろ側にも、左右のサイドフレーム２５に交差しつつ左右のサイドシル２４同士を結ぶように車幅方向に沿って延在するクロスメンバ（車体骨格部）２７がフロアパネル２３の下面側に設けられている。
【００２０】
加えて、この後側のクロスメンバ２７の前側に近接して左右のサイドフレーム２５同士を結ぶように車幅方向に沿って延在するクロスメンバ（車体骨格部，補強メンバ）２８がフロアパネル２３の下面側に設けられている。ここで、図示は略すが、これらクロスメンバ２６〜２８はフロアパネル２３とで車幅方向に直交する断面が閉断面形状をなしている。
【００２１】
前側のクロスメンバ２６の後側に近接して左右のサイドシル２４から車幅方向に沿って内側にそれぞれ所定長さ延在するクロスメンバ分割部（車体骨格部）２９Ａ，２９Ｂがフロアパネル２３の上面側に設けられている。
【００２２】
そして、左右のサイドフレーム２５の間であって前後のクロスメンバ２６，２８の間であり左右のクロスメンバ分割部２９Ａ，２９Ｂの間のフロアパネル２３に、下方に凹む上記した収納凹部２０が形成されている。この収納凹部２０は、車幅方向に対して略直交する左側壁部２０Ａおよび右側壁部２０Ｂと前後方向に対して略直交する前壁部２０Ｃおよび後壁部２０Ｄと水平方向に略沿う図４に示す底部２０Ｅとを有する平面視が略四角形状をなしている。
【００２３】
本実施形態においては、上記した車体フロア１０の収納凹部２０に、凹形状のマット部材（断熱部材）４０を嵌合させた後、図示せぬ走行用電動モータを駆動するための高圧機器コンポーネント４１を車体フロア１０に吊り下げた状態で配設する。この高圧機器コンポーネント４１について、図２〜図６を参照して説明する。
【００２４】
高圧機器コンポーネント４１は、図３に示すように、図示せぬ走行用電動モータとの間で電力をやりとりする蓄電可能なバッテリボックス（高圧機器）４３を後部右側に有しており、このバッテリボックス４３の前側つまり高圧機器コンポーネント４１における前部右側に走行用電動モータの駆動を制御するためのインバータを含むパワードライブユニット（高圧機器）４４を有していて、さらにこのパワードライブユニット４４の下側に図４にも示すパワードライブユニット４４の冷却用のヒートシンク４５を有している。
【００２５】
また、高圧機器コンポーネント４１は、図３に示すように、パワードライブユニット４４の左側つまり高圧機器コンポーネント４１における前部左側に、走行用電動モータ用の高圧を低圧に変換するＤＣ−ＤＣコンバータ（高圧機器）４７を有しており、このＤＣ−ＤＣコンバータ４７上の右側にパワードライブユニット４４を制御するためのジャンクションボックス（高圧機器）４８を、左側にパワードライブユニット４４を制御するためのコントローラ（高圧機器）４９を有していて、さらにＤＣ−ＤＣコンバータ４７の下側に図５にも示すＤＣ−ＤＣコンバータ４７の冷却用のヒートシンク５０を有している。
【００２６】
加えて、高圧機器コンポーネント４１は、図３に示すように、ＤＣ−ＤＣコンバータ４７の後側つまり高圧機器コンポーネント４１における中間部左側に図示せぬエアコンディショナを制御するためのエアコンインバータ５２を有しており、このエアコンインバータ５２の下側に図６にも示すエアコンインバータ５２の冷却用のヒートシンク５３を有していて、エアコンインバータ５２の後側つまり高圧機器コンポーネント４１における後部左側に冷却風発生用のファンユニット５５を有している。
【００２７】
ここで、高圧機器コンポーネント４１は、図３に示すように、上記したパワードライブユニット４４、パワードライブユニット４４用のヒートシンク４５、ＤＣ−ＤＣコンバータ４７、ジャンクションボックス４８、コントローラ４９、ＤＣ−ＤＣコンバータ４７用のヒートシンク５０（図３においては図示略）、エアコンインバータ５２およびエアコンインバータ５２用のヒートシンク５３（図３においては図示略）を一体的に接合させる固定ブラケット（連結部材）５７を有しており、また、固定ブラケット５７、バッテリボックス４３およびファンユニット５５を一体的に接合させる環状のサブアッシーフレーム５８を有している。さらに、高圧機器コンポーネント４１は、サブアッシーフレーム５８に固定されるクロスメンバ分割体５９を有しており、バッテリボックス４３と固定ブラケット５７とを連結させる図４に示す内部カバー６０を有している。
【００２８】
高圧機器コンポーネント４１の各部についてさらに説明する。
【００２９】
サブアッシーフレーム５８は、図２に示すように、前後方向に沿う左側辺部５８Ａおよび右側辺部５８Ｂと、これら左側辺部５８Ａおよび右側辺部５８Ｂの前端部同士を連結させる前側辺部５８Ｃと、左側辺部５８Ａおよび右側辺部５８Ｂの後端部同士を連結させる後側辺部５８Ｄとを有する平面視略四角形の環状をなすもので、このサブアッシーフレーム５８には、前側辺部５８Ｃに前方に延出する複数の取付ブラケット６１Ａが溶接またはボルト止め等で上面側に固定されており、後側辺部５８Ｄに後方に延出する複数の取付ブラケット６１Ｂが溶接またはボルト止め等で上面側に固定されている。
【００３０】
ここで、サブアッシーフレーム５８は、前側の取付ブラケット６１Ａがフロアパネル２３の前側の取付座部６５Ａおよび前側のクロスメンバ２６にボルト６１ａで取り付けられ、かつ後側の取付ブラケット６１Ｂがフロアパネル２３の後側の取付座部６５Ｂおよび後側のクロスメンバ２８にボルト６１ａで取り付けられることによって車体フロア１０に固定されることになる。このように車体フロア１０に取り付けられた状態でサブアッシーフレーム５８は収納凹部２０の内側に沿う形状をなすことになる。つまり、左側辺部５８Ａが左側壁部２０Ａに、右側辺部５８Ｂが右側壁部２０Ｂに、前側辺部５８Ｃが前側壁部２０Ｃに、後側辺部５８Ｄが後側壁部２０Ｄにそれぞれ沿うことになる。
【００３１】
クロスメンバ分割体５９は、二カ所の取付凹部６４を有しており、これら取付凹部６４にサブアッシーフレーム５８の左側辺部５８Ａおよび右側辺部５８Ｂをそれぞれ嵌合させた状態で溶接またはボルト止め等されることにより、サブアッシーフレーム５８を横切るように固定されている。ここで、このクロスメンバ分割体５９は、上記のようにサブアッシーフレーム５８が車体フロア１０に取り付けられた状態において、収納凹部２０を車幅方向に横断するように延設されており、しかも、収納凹部２０の両側に離間して配置された左右のクロスメンバ分割部２９Ａ，２９Ｂに車幅方向両端の取付フランジ部５９Ａ，５９Ｂがボルト５９ａで連結されることになる。
【００３２】
クロスメンバ分割体５９は、このように左右のクロスメンバ分割部２９Ａ，２９Ｂ同士を連結させることでこれらとともに左右のサイドシル２４同士を連結させるように車幅方向に延在するクロスメンバ（車体骨格部，補強メンバ）６６を構成する。
【００３３】
以上により、サブアッシーフレーム５８は、収納凹部２０を車幅方向に横断するクロスメンバ６６の下部に直接結合されることになる。なお、クロスメンバ分割体５９は、車幅方向に直交する断面が閉断面形状をなしている。また、クロスメンバ分割体５９には前後方向に突出する取付フランジ部５９Ｃ，５９Ｄが形成されている。
【００３４】
バッテリボックス４３は、図３および図４に示すように、複数の開口部７０を有する蓋体７１と、この蓋体７１がボルト７１ａで固定されることによってこの蓋体７１で片側が閉塞されるとともに蓋体７１に対し反対側の開口部７２を開放させる角筒状のボックス本体７３と、ボックス本体７３内に互いに間隔をあけて平行に配置される複数の筒状セル７４とを有しており、蓋体７１には前方に延出する左右の取付フランジ部７３Ａおよび後方に延出する左右の取付フランジ部７３Ｂが形成されている。そして、蓋体７１を上側にした状態で後側の取付フランジ部７３Ｂがサブアッシーフレーム５８の後側辺部５８Ｄの上面にボルト７３ａで取り付けられ、前側の取付フランジ部７３Ａがクロスメンバ分割体５９の後側の取付フランジ部５９Ｄの上面にボルト７３ａで取り付けられる。
【００３５】
固定ブラケット５７は、アルミニウム等の鋳造品あるいはダイカスト品であり、図１０に示すように、それぞれが四角枠状をなすとともに車幅方向に並設された第１取付部７７および第２取付部７８と、第２取付部７８の後側に設けられた第２取付部７８に対し反対側が開放されたコ字状の第３取付部７９とを有している。
【００３６】
つまり、第１取付部７７は、互いに平行をなす厚肉の辺部７７Ａ，７７Ｂと、これら辺部７７Ａ，７７Ｂのそれぞれの両端の上部側同士を連結させる薄肉の辺部７７Ｃ，７７Ｄと有しており、第２取付部７８は、互いに平行をなす厚肉の辺部７８Ａ，７８Ｂと、これら辺部７８Ａ，７８Ｂのそれぞれの両端の上部側同士を連結させる薄肉の辺部７８Ｃ，７８Ｄと有している。ここで、第１取付部７７と第２取付部７８とは、辺部７７Ａ，７７Ｂ，７８Ａ，７８Ｂが平行をなし、しかも辺部７７Ａと辺部７８Ｂとが一体化されている。
【００３７】
第３取付部７９は、互いに平行をなす厚肉の辺部７９Ａ，７９Ｂと、これらの一端側の上部同士を連結させる薄肉の辺部７９Ｃとを有しており、その辺部７９Ｃを第２取付部７８の辺部７８Ｄに一体化させるようにして設けられている。ここで、第３取付部７９は、辺部７９Ｂを辺部７８Ｄに対してはその中間位置から延出させている。また、辺部７８Ｄ，７９Ｃにおける辺部７８Ｂと辺部７９Ｂとの間の介在部７８Ｅも厚肉のこれらを円滑に連続させるように湾曲する形状で厚肉とされている。
【００３８】
第２取付部７８および第１取付部７７のそれぞれの相反側つまり辺部７８Ａおよび辺部７７Ｂのそれぞれ外側に、立ち上がるように取付ブラケット８０Ａ，８０Ｂがボルト８０ａで固定されており、第１取付部７７および第２取付部７８の間から外側に立ち上がるように取付ブラケット８０Ｃがボルト８０ａで固定されている。
【００３９】
この固定ブラケット５７は、図１４に上下反転状態を示すように、取付ブラケット８０Ａがサブアッシーフレーム５８の左側辺部５８Ａの下面側に、取付ブラケット８０Ｂがサブアッシーフレーム５８の右側辺部５８Ｂの下面側に、取付ブラケット８０Ｃがサブアッシーフレーム５８の前側辺部５８Ｃの下面側に、それぞれボルト８０ａによって固定されることでサブアッシーフレーム５８から吊り下げられる状態となる。
【００４０】
パワードライブユニット４４は、図４および図５に示すように、ヒートシンク４５に取り付けられており、このヒートシンク４５は、パワードライブユニット４４を載置させる載置板部８２とこの載置板部８２のパワードライブユニット４４に対し反対側に突出する複数の平行なフィン８３とを有している。そして、パワードライブユニット４４は、ヒートシンク４５を下側にしヒートシンク４５のフィン８３を固定ブラケット５７の第１取付部７７の内側に挿入させて載置板部８２において第１取付部７７の上面に固定される。ここで、ヒートシンク４５の各フィン８３は車幅方向に対し直交した状態で車幅方向に並列配置される。
【００４１】
ＤＣ−ＤＣコンバータ４７は、図５および図６に示すように、ヒートシンク５０に取り付けられており、このヒートシンク５０は、ＤＣ−ＤＣコンバータ４７を載置させる載置板部８５とこの載置板部８５のＤＣ−ＤＣコンバータ４７に対し反対側に突出する複数の平行なフィン８６とを有している。なお、ＤＣ−ＤＣコンバータ４７のヒートシンク５０に対し反対側にジャンクションボックス４８およびコントローラ４９が取り付けられている。そして、ＤＣ−ＤＣコンバータ４７は、ヒートシンク５０を下側にしヒートシンク５０のフィン８６を固定ブラケット５７の第２取付部７８の内側に挿入させて載置板部８５において第２取付部７８の上面に固定される。ここで、ヒートシンク５０の各フィン８６は車幅方向に対し直交した状態で車幅方向に並列配置される。
【００４２】
エアコンインバータ５２は、図６に示すように、ヒートシンク５３に取り付けられており、このヒートシンク５３は、エアコンインバータ５２を載置させる載置板部８８とこの載置板部８８のエアコンインバータ５２に対し反対側に突出する複数の平行なフィン８９とを有している。そして、エアコンインバータ５２は、ヒートシンク５３を下側にしヒートシンク５３のフィン８９を固定ブラケット５７の第３取付部７９の内側に挿入させて載置板部８８において第３取付部７９の上面に固定される。ここで、ヒートシンク５３の各フィン８９は車幅方向に直交した状態で車幅方向に並列配置される。
【００４３】
ファンユニット５５は、図６に示すように、ファン５５Ａの回転軸の軸上の上部に吸気口９１を有しており、ファン５５Ａの半径上に排気口９２を有していて、排気口９２には排気ダクト９３が取り付けられている。このファンユニット５５は、吸気口９１を上側にした状態で後部が図３に示す取付ブラケット９４を介してサブアッシーフレーム５８の後側辺部５８Ｄの下面に取り付けられ、前部が取付ブラケット９５を介してクロスメンバ分割体５９の後側の取付フランジ部５９Ｄの下面に取り付けられる。
【００４４】
次に、上記した構成の高圧機器コンポーネント４１の一体化の手順について説明する。
【００４５】
まず、図８に示すように予めサブアッシーフレーム５８の上面に、取付ブラケット６１Ａ，６１Ｂが溶接等で取り付けられかつクロスメンバ分割体５９が溶接等で取り付けられた状態の第１組体９８を、図９に示すように取付ブラケット６１Ａ，６１Ｂおよびクロスメンバ分割体５９が下側になるように裏返す。そして、ファンユニット５５の後部を取付ブラケット９４を介してサブアッシーフレーム５８にボルトで取り付け、ファンユニット５５の前部を取付ブラケット９５を介してクロスメンバ分割体５９のフランジ部５９Ｄにボルトで取り付ける。このような状態の第２組体９９をサブ組立工程において形成しておく。
【００４６】
一方で、図１０に示すように固定ブラケット５７および取付ブラケット８０Ａ，８０Ｂ，８０Ｃが予めサブ組立工程においてボルト８０ａで取り付けられた第３組体１００の第２取付部７８に、ヒートシンク５０、ＤＣ−ＤＣコンバータ４７、ジャンクションボックス４８およびコントローラ４９が予めサブ組立工程においてされた第４組体１０１をボルトにより組み付けて、図１１に示す状態とする。
【００４７】
次に、図１２に示すように、第３組体１００の第１取付部７７に、ヒートシンク４５およびパワードライブユニット４４が予めサブ組立工程においてされた第５組体１０２をボルトにより組み付けるとともに、第３組体１００の第３取付部７９に、ヒートシンク５３およびエアコンインバータ５２が予めサブ組立工程においてされた第６組体１０３をボルトにより組み付けて図１３に示す第７組体１０４の状態とする。このような状態の第７組体１０４をサブ組立工程において形成しておく。
【００４８】
そして、図１４に示すように第７組体１０４を裏返しその取付ブラケット８０Ａ，８０Ｂ，８０Ｃにおいて第２組体９９のサブアッシーフレーム５８にボルト８０ａで取り付けて第８組体１０５を形成する。
【００４９】
次に、第８組体１０５を上下反転して元に戻し、図１５に示すバッテリボックス４３の取付フランジ部７３Ａ，７３Ｂをサブアッシーフレーム５８およびクロスメンバ分割体５９に、図７に示すようにボルト７３ａによって取り付ける。ここで、バッテリボックス４３には図４に示す内部カバー６０が取り付けられており、この内部カバー６０が固定ブラケット５７とバッテリボックス４３との隙間を閉塞させる。このようにして、図７に示すように、バッテリボックス４３，パワードライブユニット４４、これ用のヒートシンク４５、ＤＣ−ＤＣコンバータ４７、これ用のヒートシンク５０、ジャンクションボックス４８、コントローラ４９、エアコンインバータ５２、これ用のヒートシンク５３およびファンユニット５５が、枠状のサブアッシーフレーム５８の内側に一体的に保持された高圧機器コンポーネント４１が形成される。
【００５０】
そして、このような高圧機器コンポーネント４１を、図１６に示すように、そのサブアッシーフレーム５８を上側にし、しかも各機器が上記した配置となるように、つまりバッテリボックス４３が後部右側に、パワードライブユニット４４が前部右側に、ＤＣ−ＤＣコンバータ４７が前部左側に、ファンユニット５５が後部左側に位置するようにし、さらに固定ブラケット５７を前部で左右方向に延在するようにして、マット部材４０が予め配置された車体フロア１０の収納凹部２０に上側から挿入する。
【００５１】
続いて、図２および図１７に示すように、サブアッシーフレーム５８の前側の取付ブラケット６１Ａをフロアパネル２３の前側の取付座部６５Ａおよび前側のクロスメンバ２６にボルト６１ａで取り付け、サブアッシーフレーム５８の後側の取付ブラケット６１Ｂをフロアパネル２３の後側の取付座部６５Ｂおよび後側のクロスメンバ２８にボルト６１ａで取り付けることによって高圧機器コンポーネント４１が車体フロア１０に固定される。
【００５２】
また、高圧機器コンポーネント４１は、そのクロスメンバ分割体５９が、収納凹部２０を車幅方向に横断するように延設された状態で、収納凹部２０の両側に離間して配置された左右のクロスメンバ分割部２９Ａ，２９Ｂに車幅方向両端の取付フランジ部５９Ａ，５９Ｂにおいてボルト５９ａで固定される。
【００５３】
この状態で、高圧機器コンポーネント４１は、図４〜図６に示すように、収納凹部２０の底部２０Ｅに対し上下方向に間隔をあけることになり、その結果、車体フロア１０に支持されるサブアッシーフレーム５８を介して吊り下げ状態で収納凹部２０内に収納されることになる。また、この状態で、図２に示すように、サブアッシーフレーム５８は、車体フロア１０の下面に設けられたクロスメンバ２６，２８に取付部ブラケット６１Ａ，６１Ｂを介して間接的に結合されており、車体フロア１０の上面に設けられたクロスメンバ６６に直接的に結合されている。なお、サブアッシーフレーム５８は、クロスメンバ６６等の補強メンバに対しブラケットを介した間接的結合および直接的結合の少なくともいずれか一方の結合状態で結合されるのが好ましい。
【００５４】
上記のように収納凹部２０に吊り下げ状態で配設された高圧機器コンポーネント４１と収納凹部２０の底部２０Ｅとの間に介装されるマット部材４０は、図４〜図６に示すように、高圧機器コンポーネント４１に冷却風を流す冷却風流路（通路）１１０を形成している。
【００５５】
マット部材４０は、熱の進入を防止するためのもので、発泡ウレタン等の弾性断熱部材からなっており、図２に示すように、収納凹部２０の左側壁部２０Ａに沿って配置される左側壁部４０Ａと、収納凹部２０の右側壁部２０Ｂに沿って配置される右側壁部４０Ｂと、収納凹部２０の前側壁部２０Ｃに沿って配置される前側壁部４０Ｃと、収納凹部２０の後側壁部２０Ｄに沿って配置される後側壁部４０Ｄと、図４〜図６に示すように、収納凹部２０の底部２０Ｅに沿って配置される底部４０Ｅとを有している。
【００５６】
底部４０Ｅには、図１８〜図２０に示すように、左端、右端および車幅方向における中間部に略前後方向に沿う内側壁部１１１Ａ〜１１１Ｃがそれぞれ立設されており、また、前端および後端にも略車幅方向に沿う内側壁部１１１Ｄ，１１１Ｅが立設されている。その結果、底部４０Ｅには下方に凹む流路形成凹部１１２Ａ，１１２Ｂが車幅方向における両側つまり内側壁部１１１Ａ，１１１Ｃ間および内側壁部１１１Ｃ，１１１Ｂ間にそれぞれ形成されている。なお、前端の内側壁部１１１Ｄと内側壁部１１１Ｃとは離間しており、その結果、これらの間に流路形成凹部１１２Ａ，１１２Ｂ同士を車幅方向に連通させるように下方に凹む図２０に示す流路形成溝１１３が形成されている。
【００５７】
そして、上記のように収納凹部２０に吊り下げられた状態で、高圧機器コンポーネント４１は、図４に示すように流路形成凹部１１２Ｂ内にパワードライブユニット４４のヒートシンク４５を配置することになり、図６に示すように流路形成凹部１１２Ａ内にＤＣ−ＤＣコンバータ４７のヒートシンク５０およびエアコンインバータ５２のヒートシンク５３を配置することになる。
【００５８】
また、この吊下状態で、高圧機器コンポーネント４１は、図２０および図４に示すように、上記した固定ブラケット５７の前端側の辺部７７Ｃ，７８Ｃがこれらの連続する下面を全面的に前端の内側壁部１１１Ｄの上面に当接させながらこの内側壁部１１１Ｄを圧縮変形させることになり、その結果、辺部７７Ｃ，７８Ｃと内側壁部１１１Ｄとが密着する。
【００５９】
同吊下状態で、図２０および図５に示すように、固定ブラケット５７の辺部７８Ａおよび辺部７９Ａがその下面を全面的に内側壁部１１１Ａの上面に当接させながらこの内側壁部１１１Ａを圧縮変形させることになり、その結果、辺部７８Ａ，７９Ａと内側壁部１１１Ａとが密着する。
【００６０】
同吊下状態で、図１９および図５に示すように、固定ブラケット５７の辺部７７Ｂがその下面を全面的に内側壁部１１１Ｂの上面に当接させながらこの内側壁部１１１Ｂを圧縮変形させることになり、その結果、辺部７７Ｂと内側壁部１１１Ｂとが密着する。
【００６１】
同吊下状態で、図１９および図５に示すように、固定ブラケット５７の辺部７７Ａ，７８Ｂ、介在部７８Ｅおよび辺部７９Ｂがこれらの連続する下面を全面的に内側壁部１１１Ｃの上面に当接させながらこの内側壁部１１１Ｃを圧縮変形させることになり、その結果、辺部７７Ａ，７８Ｂ、介在部７８Ｅおよび辺部７９Ｂと内側壁部１１１Ｃとが密着する。
【００６２】
以上により、マット部材４０は、収納凹部２０に配設された高圧機器コンポーネント４１で押圧されて圧縮変形することになり、より具体的には、パワードライブユニット４４、ＤＣ−ＤＣコンバータ４７およびエアコンインバータ５２同士を連結させる固定ブラケット５７で押圧されて圧縮変形する。
【００６３】
加えて、上記吊下状態でバッテリボックス４３は、その図５に示す左側面部４３Ａが図１６に示す内側壁部１１１Ｃの内側面に密着して隙間をシールし、その図５に示す右側面部４３Ｂが図１６に示す内側壁部１１１Ｂの内側面に密着して隙間をシールし、その図４に示す後面部４３Ｄが内側壁部１１１Ｅの内側面に密着して隙間をシールするとともに、前面部４３Ｃに取り付けられた内部カバー６０がバッテリボックス４３と固定ブラケット５７の第１取付部７７との隙間を閉塞させる。その結果、バッテリボックス４３、内部カバー６０、固定ブラケット５７の第１取付部７７およびパワードライブユニット４４のヒートシンク４５で流路形成凹部１１２Ｂの上側全体が閉塞される。
【００６４】
また、図２０に示すように、固定ブラケット５７の第１取付部７７および第２取付部７８の辺部７７Ａ，７８Ｂで流路形成溝１１３の上側が閉塞される。
さらに、図６に示すように固定ブラケット５７の第２取付部７８、第３取付部７９、ＤＣ−ＤＣコンバータ４７のヒートシンク５０およびエアコンインバータ５２のヒートシンク５３で流路形成凹部１１２Ａの前部上側が閉塞される。
【００６５】
このようにして、図４に示すようにバッテリボックス４３の上部開口部７０、バッテリボックス４３の内部流路１１５、バッテリボックス４３の下部開口部７２、バッテリボックス４３の下方であって底部４０Ｅと内側壁部１１１Ｂ，１１１Ｃ，１１１Ｅとで囲まれた内部流路１１６、バッテリボックス４３とヒートシンク４５との間であって内部カバー６０と固定ブラケット５７の辺部７７Ｄと内側壁部１１１Ｂ，１１１Ｃとで囲まれた内部流路１１７、ヒートシンク４５と底部４０Ｅと壁部１１１Ｂ，１１１Ｃとで囲まれた主にフィン８３間を通る内部通路１１８、ヒートシンク４５と壁部１１１Ｄとの間であって固定ブラケット５７の辺部７７Ｃと底部４０Ｅと壁部１１１Ｂ，１１１Ｃ，１１１Ｄとで囲まれた内部流路１１９、図２０に示す固定ブラケット５７と流路形成溝１１３とで囲まれた内部流路１２０、図６に示すようにヒートシンク５０と壁部１１１Ｄとの間であって固定ブラケット５７の辺部７８Ｃと底部４０Ｅと壁部１１１Ａ，１１１Ｃ，１１１Ｄとで囲まれた内部流路１２１、ヒートシンク５０と底部４０Ｅと壁部１１１Ａ，１１１Ｃとで囲まれた主にフィン８６間を通る内部通路１２２、ヒートシンク５０とヒートシンク５３との間であって固定ブラケット５７の辺部７８Ｄ，７９Ｃと底部４０Ｅと壁部１１１Ａ，１１１Ｃとで囲まれた内部流路１２３、ヒートシンク５３と底部４０Ｅと壁部１１１Ａ，１１１Ｃとで囲まれた主にフィン８９間を通る内部通路１２４が、この順番で直列に連通して冷却風流路１１０を構成することになる。そして、流路上バッテリボックス４３に対し反対側となるヒートシンク５３のフィン８９よりも外側が一旦マット部材４０と高圧機器コンポーネント４１との隙間の内部流路１２４に開放されてファンユニット５５の吸気口９１に連通する。
【００６６】
ここで、図２１および図２２に示すように、収納凹部２０のクロスメンバ分割体５９よりも前側の開口部分はクロスメンバ分割体５９の前側のフランジ部５９Ｃと収納凹部２０の外側のフロアパネル２３とで支持される前部リッド１３０で閉塞されることになり、収納凹部２０のクロスメンバ分割体５９よりも後側の開口部分はクロスメンバ分割体５９の後側のフランジ部５９Ｄと収納凹部２０の外側のフロアパネル２３とで支持される後部リッド１３１で閉塞されることになる。
【００６７】
なお、後部リッド１３１には、後部リッド１３１よりも外側まで延出する外部吸気ダクト１３２と外部排気ダクト１３３とが、それぞれ接合部分を空気漏れがないようにシールした状態で取り付けられており、これら外部吸気ダクト１３２および外部排気ダクト１３３はいずれも車室内に延出先端側が開口させられている。そして、外部吸気ダクト１３２が、図４に示すようにバッテリボックス４３の複数の開口部７０の全体を囲むようにバッテリボックス４３の蓋体７１に接合させられ、また、外部排気ダクト１３３が、図６に示すようにファンユニット５５の排気ダクト９３に連通させられている。なお、蓋体７１と外部吸気ダクト１３２との接合部分も空気漏れがないようにシールされており、外部排気ダクト１３３と排気ダクト９３との接合部分も空気漏れがないようにシールされている。さらには、前部リッド１３０および後部リッド１３１のそれぞれの車体フロア１０との接合部分も空気漏れがないようにシールされている。
【００６８】
その結果、ファンユニット５５がファン５５Ａの回転により吸気口９１から排気口９２に向けて空気の流れを生じさせると、車室内から、外部吸気ダクト１３２、バッテリボックス４３の内部流路１１５、バッテリボックス４３の下方の内部流路１１６、バッテリボックス４３とヒートシンク４５との間の内部流路１１７、ヒートシンク４５のフィン８３間を通る内部通路１１８、ヒートシンク４５と壁部１１１Ｄとの間の内部流路１１９、流路形成溝１１３の内部流路１２０、ヒートシンク５０と壁部１１１Ｄとの間の内部流路１２１、ヒートシンク５０のフィン８６間を通る内部通路１２２、ヒートシンク５０とヒートシンク５３との間の内部流路１２３、ヒートシンク５３のフィン８９間を通る内部通路１２４、内部通路１２４とファンユニット５５とを連通させる内部流路１２５、ファンユニット５５、外部排気ダクト１３３、および車室内の順に流れる冷却風が生じる。そして、この冷却風がバッテリボックス４３内を通過するときに各筒状セル７４を冷却し、ヒートシンク４５を通過するときにパワードライブユニット４４を冷却し、ヒートシンク５０を通過するときにＤＣ−ＤＣコンバータ４７を冷却し、ヒートシンク５３を通過するときにエアコンインバータ５２を冷却することになる。なお、内部通路１２５とファンユニット５５とを結ぶダクトは設けられていない。
【００６９】
以上に述べた本実施形態によれば、高圧機器コンポーネント４１が車体フロア１０に形成された下方に凹む収納凹部２０に吊り下げ状態で配設されるため、取付・取外作業を車体フロア１０に対し上側から行うことができる。しかも、高圧機器コンポーネント４１を一度に車体側に搭載することができる。したがって、取付・取外作業の作業性を向上させることができる。加えて、収納凹部２０には荷重がかからないため収納凹部２０の軽量化が図れる。
【００７０】
また、高圧機器コンポーネント４１が吊り下げられることにより形成される高圧機器コンポーネント４１と収納凹部２０の底部２０Ｅとの間の隙間に弾性断熱部材からなるマット部材４０を配置し、このマット部材４０によって高圧機器コンポーネント４１に冷却風を流す冷却風流路１１０を形成するため、比較的簡単に冷却風流路１１０を形成することができる。したがって、高圧機器コンポーネント４１へ冷却風を通すための冷却風流路１１０を低コストで形成することができる。しかも、高圧機器コンポーネント４１として一カ所にまとめて搭載するため、一つのファンユニット５５で効果的に冷却を行うことができる。
【００７１】
さらに、高圧機器コンポーネント４１が吊り下げられることにより形成される高圧機器コンポーネント４１と収納凹部２０の底部２０Ｅとの間の隙間に弾性断熱部材からなるマット部材４０を配置しているため、車体フロア１０が下方から何らかの力を受けて変形してもマット部材４０が弾性変形することでこの変形を吸収する。したがって、高圧機器コンポーネント４１をマット部材４０のクッション作用で保護することができる。
【００７２】
加えて、マット部材４０が、収納凹部２０に配設された高圧機器コンポーネント４１の搭載圧で押圧されて圧縮変形するため、マット部材４０によって形成される冷却風流路１１０におけるマット部材４０と高圧機器コンポーネント４１との間の隙間をシールできこの隙間からの冷却風の漏れを防止できる。したがって、冷却効率を向上させることができる。
【００７３】
また、マット部材４０の変形によって高圧機器コンポーネント４１の取付誤差を吸収することができる。したがって、取付誤差が許容されるため高圧機器コンポーネント４１の取付作業が容易となる上、製造上の歩留まりが向上する。
【００７４】
さらに、マット部材４０が高圧機器コンポーネント４１の各高圧機器同士を連結させる固定ブラケット５７で押圧されて圧縮変形する構造であるため、冷却風流路１１０の形成時にマット部材４０の圧縮変形するシール部分については固定ブラケット５７の形状を考慮すれば良くなる。したがって、マット部材４０を容易に設計することができる。
【００７５】
加えて、バッテリボックス４３の温度は比較的低く、ＤＣ−ＤＣコンバータ４７およびエアコンインバータ５２の温度は比較的高いため、上記のようにバッテリボックス４３をＤＣ−ＤＣコンバータ４７およびエアコンインバータ５２よりも先に冷却するとこれらすべてを効率的に冷却できる。
【００７６】
内燃機関エンジンの駆動力での走行中において、ラジエータファンの排風およびエアコン駆動時のコンデンサファンの排風は高温であり、これらの排風がエンジンルームからフロア下に排出されるが、断熱材料からなるマット部材４０がこの排風の熱が高圧機器コンポーネント４１に伝わるのを防止できる。
【００７７】
【発明の効果】
以上詳述したように、請求項１に係る発明によれば、高圧機器コンポーネントが車体フロアに形成された下方に凹む収納凹部に吊り下げ状態で配設されるため、取付・取外作業を車体フロアに対し上側から行うことができる。したがって、取付・取外作業の作業性を向上させることができる。また、高圧機器コンポーネントが吊り下げられることにより形成される高圧機器コンポーネントと収納凹部の底部との間の隙間に断熱部材を配置し、この断熱部材によって高圧機器コンポーネントに冷却風を流す流路を形成するため、比較的簡単に流路を形成することができる。したがって、高圧機器コンポーネントへ冷却風を通すための流路を低コストで形成することができる。さらに、高圧機器コンポーネントが吊り下げられることにより形成される高圧機器コンポーネントと収納凹部の底部との間の隙間に断熱部材を配置しているため、車体フロアが下方から何らかの力を受けて変形しても断熱部材が変形することでこの変形を吸収する。したがって、高圧機器コンポーネントを断熱部材のクッション作用で保護することができる。
【００７８】
請求項２に係る発明によれば、断熱部材が、収納凹部に配設された高圧機器コンポーネントで押圧されて圧縮変形するため、断熱部材によって形成される流路における断熱部材と高圧機器コンポーネントとの間の隙間をシールできこの隙間からの冷却風の漏れを防止できる。したがって、冷却効率を向上させることができる。また、断熱部材の変形によって高圧機器コンポーネントの取付誤差を吸収することができる。したがって、取付誤差が許容されるため高圧機器コンポーネントの取付作業が容易となる上、製造上の歩留まりが向上する。
【００７９】
請求項３に係る発明によれば、断熱部材が高圧機器コンポーネントの各高圧機器同士を連結させる連結部材で押圧されて圧縮変形する構造であるため、冷却風の流路の形成時に断熱部材の圧縮変形するシール部分については連結部材の形状を考慮すれば良くなる。したがって、断熱部材を容易に設計することができる。
【図面の簡単な説明】
【図１】本発明の一実施形態の高圧機器コンポーネントの車載構造が適用された車両を概略的に示す側面図である。
【図２】本発明の一実施形態の高圧機器コンポーネントの車載構造を示す平面図である。
【図３】高圧機器コンポーネントを示す平面図である。
【図４】本発明の一実施形態の高圧機器コンポーネントの車載構造を示す右側部分の側断面図である。
【図５】本発明の一実施形態の高圧機器コンポーネントの車載構造を示す正断面図である。
【図６】本発明の一実施形態の高圧機器コンポーネントの車載構造を示す左側部分の側断面図である。
【図７】高圧機器コンポーネントを示す斜視図である。
【図８】高圧機器コンポーネントの組み立て手順を示す斜視図である。
【図９】高圧機器コンポーネントの組み立て手順を示す図８の後の状態を示す斜視図である。
【図１０】高圧機器コンポーネントの組み立て手順を示す斜視図である。
【図１１】高圧機器コンポーネントの組み立て手順を示す図１０の後の状態を示す斜視図である。
【図１２】高圧機器コンポーネントの組み立て手順を示す図１１の後の状態を示す斜視図である。
【図１３】高圧機器コンポーネントの組み立て手順を示す図１２の後の状態を示す斜視図である。
【図１４】高圧機器コンポーネントの組み立て手順を示す図９および図１３の後の状態を示す斜視図である。
【図１５】バッテリボックスを示す斜視図である。
【図１６】高圧機器コンポーネントを車載する手順を示す図１４の後の状態を示す斜視図である。
【図１７】高圧機器コンポーネントを車載する手順を示す図１５の後の状態を示す斜視図である。
【図１８】マット部材を示す前側から見た斜視図である。
【図１９】マット部材および固定ブラケット等を示す前側から見た斜視図である。
【図２０】マット部材および固定ブラケット等を示す後側から見た斜視図である。
【図２１】高圧機器コンポーネントを車載する手順を示す図１７の後の状態を示す斜視図である。
【図２２】高圧機器コンポーネントを車載する手順を示す図２１の後の状態を示す斜視図である。
【符号の説明】
１０ 車体フロア
２０ 収納凹部
２０Ｅ 底部
４０ マット部材（断熱部材）
４１ 高圧機器コンポーネント
４３ バッテリボックス（高圧機器）
４７ ＤＣ−ＤＣコンバータ（高圧機器）
４８ ジャンクションボックス（高圧機器）
４９ コントローラ（高圧機器）
５７ 固定ブラケット（連結部材）
１１０ 冷却風流路（流路）[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an in-vehicle structure for high-voltage equipment components.
[0002]
[Prior art]
In a hybrid vehicle that runs using the output of an internal combustion engine and the output of an electric motor, or an electric vehicle that runs using only the output of an electric motor, a large high-voltage component is mounted on the vehicle. However, as a technology related to the on-board structure of such a high-voltage device component, a structure is disclosed in which a high-voltage device component is mounted below a vehicle body floor from below (for example, see Patent Documents 1 and 2).
[0003]
[Patent Document 1]
JP-A-7-156826
[Patent Document 2]
JP-A-11-178115
[0004]
[Problems to be solved by the invention]
However, as described above, in the structure in which the high-voltage equipment component is attached to the lower side of the vehicle body floor from below, the mounting and dismounting work must be performed from the lower side with respect to the vehicle body floor. -There was a problem that the workability of the removal work was poor. Further, since the high-pressure equipment component is mounted on the outer cover member, there is also a problem that a structure for forming a flow path for passing cooling air to the high-pressure equipment component is complicated and costs are increased. Was. In addition, since the high-voltage component is placed on the outer cover member, if the cover member is deformed by receiving some force, the deformation may directly affect the high-voltage component.
[0005]
Therefore, the present invention can improve the workability of the work of attaching and detaching the high-pressure equipment component to the vehicle body side, and can form the flow path for passing the cooling air to the high-pressure equipment component at low cost. It is another object of the present invention to provide a vehicle-mounted structure of a high-voltage equipment component capable of protecting a high-pressure equipment component even if the vehicle body floor is deformed by receiving some force from below.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, according to the first aspect of the present invention, a high-pressure equipment component (for example, the high-pressure equipment component 41 in the embodiment) is recessed below a vehicle body floor (for example, the body floor 10 in the embodiment). It is arranged in a storage recess (for example, the storage recess 20 in the embodiment) in a suspended state, and forms a flow path through which the cooling air flows through the high-pressure equipment component between the high-pressure equipment component and the bottom of the storage recess. It is characterized by being provided with a heat insulating member (for example, the mat member 40 in the embodiment).
[0007]
As described above, since the high-pressure equipment component is suspended from the storage recess formed on the vehicle body floor, the mounting / removal operation can be performed from above the vehicle body floor. In addition, a heat insulating member is disposed in a gap between the high-pressure equipment component formed by hanging the high-pressure equipment component and the bottom of the storage recess, and the heat-insulating member forms a flow path for flowing cooling air through the high-pressure equipment component. Therefore, the flow path can be formed relatively easily. Further, since the heat insulating member is disposed in a gap between the high-pressure equipment component formed by hanging the high-pressure equipment component and the bottom of the storage recess, the vehicle body floor is deformed by receiving some force from below. Also, the deformation of the heat insulating member absorbs this deformation.
[0008]
According to a second aspect of the present invention, in the first aspect of the invention, the heat insulating member is made of an elastic material, and is compressed and deformed by being pressed by the high-pressure equipment component disposed in the storage recess. And
[0009]
As described above, since the heat insulating member is pressed and deformed by the high-pressure equipment component disposed in the storage recess, a gap between the heat insulating member and the high-pressure equipment component in the flow path formed by the heat insulating member can be sealed. Leakage of cooling air from this gap can be prevented. In addition, the deformation of the heat insulating member can absorb a mounting error of the high-voltage component.
[0010]
According to a third aspect of the present invention, in the invention according to the second aspect, the heat-insulating member includes a high-voltage device (for example, a battery box 43, a DC-DC converter 47, a junction box 48, and a controller in the embodiment). 49) It is characterized in that it is compressed and deformed by being pressed by a connecting member (for example, the fixing bracket 57 in the embodiment) for connecting each other.
[0011]
As described above, since the heat insulating member has a structure in which the heat insulating member is pressed by the connecting member that connects the high-pressure devices of the high-pressure device components and is compressed and deformed, the sealing portion of the heat insulating member that is compressed and deformed when the cooling air flow path is formed. It suffices to consider the shape of the connecting member.
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
An on-board structure of a high-voltage component according to an embodiment of the present invention will be described below with reference to the drawings. The front, rear, left and right in the following description are the front, rear, left and right when the vehicle is moving forward.
[0013]
Although not shown, the present embodiment is applied to a hybrid vehicle in which the vehicle travels while appropriately controlling the driving force of the internal combustion engine and the driving force of the traveling electric motor.
[0014]
In FIG. 1, reference numeral 1 indicates a two-box type vehicle. The vehicle 1 has a seat arrangement structure in which a first-row seat 11, a second-row seat 12, and a third-row seat 13 are arranged in three rows from the front to the rear on a vehicle body floor 10.
[0015]
The first floor 15 of the vehicle body floor 10 on which the first-row seats 11 are arranged is connected to a second floor 16 at a position higher than the first floor 15, and the second-row seats 12 and 3 are connected to the second floor 16. The row sheet 13 is arranged.
[0016]
The seats 11, 12, and 13 in each row are basically seat cushions 11c, 12c, and 13c for supporting the buttocks of the seated occupant, and tiltable seatbacks 11b and 12b for supporting the back of the seated occupant. , 13b, and headrests 11r, 12r, 13r are attached to the seatbacks 11b, 12b, 13b of the row seats 11, 12, 13 respectively.
[0017]
On the second floor 16 side of the first floor 15 on which the first row of sheets 11 is placed, a storage recess 20 that is recessed downward so as to cover the front portion with the first row of sheets 11 is formed. Further, a fuel tank 21 is arranged below the second floor 16 so as to be adjacent to the rear side of the storage recess 20. As shown in FIG. 2, an exhaust pipe 22 of the internal combustion engine passes through the storage recess 20 below the vehicle body floor 10, and a pre-chamber 22 </ b> A of the exhaust pipe 22 is located on the right side of the storage recess 20. The silencer 22 </ b> B of the exhaust pipe 22 is located behind the storage recess 20.
[0018]
The vehicle body floor 10 will be further described. Left and right side sills (vehicle body frame) 24 extending in the front-rear direction are provided at both ends in the vehicle width direction of the floor panel 23, and the floor panel is located between the side sills 24. Left and right side frames (vehicle body frame portions) 25 extending in the front-rear direction are provided on the lower surface side of 23. Here, though not shown, the left and right side sills 24 have a closed cross-sectional shape perpendicular to the front-rear direction, and the left and right side frames 25 also have a closed cross-sectional shape perpendicular to the front-rear direction with the floor panel 23. No.
[0019]
Further, a cross member (vehicle body frame portion, reinforcing member) 26 extending along the vehicle width direction so as to connect the left and right side sills 24 while intersecting the left and right side frames 25 is a lower surface side of the floor panel 23. It is provided at a boundary position between the first floor 15 and the second floor 16, and is also provided on the rear side of the cross member 26 so as to cross the left and right side frames 25 and connect the left and right side sills 24 to each other. A cross member (vehicle body frame) 27 extending along is provided on the lower surface side of the floor panel 23.
[0020]
In addition, a cross member (body frame, reinforcing member) 28 extending along the vehicle width direction so as to connect the left and right side frames 25 near the front side of the rear cross member 27 is provided on the floor panel 23. Is provided on the lower surface side. Here, though not shown, the cross members 26 to 28 have a closed cross-sectional shape perpendicular to the vehicle width direction with the floor panel 23.
[0021]
The cross member dividing portions (vehicle body frame portions) 29A and 29B extending a predetermined length inward in the vehicle width direction from the left and right side sills 24 near the rear side of the front cross member 26 are formed on the upper surface of the floor panel 23. It is provided on the side.
[0022]
The above-described storage recess 20 that is recessed downward is formed in the floor panel 23 between the left and right side frames 25 and between the front and rear cross members 26 and 28 and between the left and right cross member divisions 29A and 29B. Have been. This storage recess 20 is substantially horizontally aligned with a front wall portion 20C and a rear wall portion 20D substantially perpendicular to the front-rear direction with the left side wall portion 20A and the right side wall portion 20B substantially perpendicular to the vehicle width direction. The bottom view 20E shown in FIG.
[0023]
In this embodiment, after fitting a concave mat member (heat insulation member) 40 into the storage recess 20 of the vehicle body floor 10 described above, a high-voltage equipment component 41 for driving an electric motor for traveling (not shown). Is suspended from the vehicle body floor 10. The high-voltage component 41 will be described with reference to FIGS.
[0024]
As shown in FIG. 3, the high-voltage device component 41 has a battery box (high-voltage device) 43 that can store power and exchanges electric power with a traveling electric motor (not shown) on the rear right side. A power drive unit (high-voltage device) 44 including an inverter for controlling the drive of the electric motor for traveling is provided on the front side of 43, that is, on the front right side of the high-voltage device component 41, and further below the power drive unit 44 4 has a heat sink 45 for cooling the power drive unit 44.
[0025]
As shown in FIG. 3, the high-voltage device component 41 includes a DC-DC converter (high-voltage device) that converts a high voltage for the traveling electric motor into a low voltage on the left side of the power drive unit 44, that is, on the front left side of the high-voltage device component 41. ) 47, a junction box (high-voltage device) 48 for controlling the power drive unit 44 on the right side of the DC-DC converter 47, and a controller (high-voltage device) for controlling the power drive unit 44 on the left side. 49, and a heat sink 50 for cooling the DC-DC converter 47 shown in FIG. 5 below the DC-DC converter 47.
[0026]
In addition, as shown in FIG. 3, the high-voltage component 41 has an air conditioner inverter 52 for controlling an air conditioner (not shown) on the rear side of the DC-DC converter 47, that is, on the left side of the middle part of the high-voltage component 41. A heat sink 53 for cooling the air conditioner inverter 52 shown in FIG. 6 is provided below the air conditioner inverter 52, and cooling air is generated on the rear side of the air conditioner inverter 52, that is, on the rear left side of the high-voltage component 41. Fan unit 55.
[0027]
Here, as shown in FIG. 3, the high-voltage equipment component 41 includes the power drive unit 44, the heat sink 45 for the power drive unit 44, the DC-DC converter 47, the junction box 48, the controller 49, and the DC-DC converter 47. A heat sink 50 (not shown in FIG. 3), a fixing bracket (connecting member) 57 for integrally joining the air conditioner inverter 52 and a heat sink 53 (not shown in FIG. 3) for the air conditioner inverter 52 are provided. , A fixing bracket 57, an annular sub-assembly frame 58 for integrally joining the battery box 43 and the fan unit 55. Further, the high-voltage equipment component 41 has a cross member divided body 59 fixed to the sub-assembly frame 58, and has an internal cover 60 shown in FIG. 4 for connecting the battery box 43 and the fixing bracket 57. .
[0028]
Each part of the high-voltage equipment component 41 will be further described.
[0029]
As shown in FIG. 2, the sub-assembly frame 58 includes a left side portion 58A and a right side portion 58B along the front-rear direction, and a front side portion 58C connecting the front ends of the left side portion 58A and the right side portion 58B. The sub-assembly frame 58 includes a left side portion 58A and a right side portion 58B, and a rear side portion 58D for connecting the rear ends of the right side portion 58B. A plurality of mounting brackets 61A extending forward are fixed to the upper surface by welding or bolting, and a plurality of mounting brackets 61B extending rearward to the rear side 58D are welded or bolted to the upper surface. Fixed to.
[0030]
Here, in the sub-assembly frame 58, the front mounting bracket 61A is mounted on the front mounting seat 65A and the front cross member 26 of the floor panel 23 with bolts 61a, and the rear mounting bracket 61B is mounted on the floor panel 23. It is fixed to the vehicle body floor 10 by being attached to the rear mounting seat 65B and the rear cross member 28 with bolts 61a. Thus, the sub-assembly frame 58 has a shape along the inside of the storage recess 20 in a state where the sub-assembly frame 58 is mounted on the vehicle body floor 10. In other words, the left side portion 58A is along the left side wall portion 20A, the right side portion 58B is along the right side wall portion 20B, the front side portion 58C is along the front side wall portion 20C, and the rear side portion 58D is along the rear side wall portion 20D. Become.
[0031]
The cross member divided body 59 has two mounting recesses 64, and is welded or bolted with the left side 58A and the right side 58B of the sub-assembly frame 58 fitted into these mounting recesses 64, respectively. By being equalized, it is fixed so as to cross the sub-assembly frame 58. Here, the cross member divided body 59 extends so as to cross the storage recess 20 in the vehicle width direction when the sub-assembly frame 58 is attached to the vehicle body floor 10 as described above. The mounting flange portions 59A, 59B at both ends in the vehicle width direction are connected to the left and right cross member divided portions 29A, 29B spaced apart on both sides of the storage recess 20 by bolts 59a.
[0032]
The cross member split body 59 is formed by connecting the left and right cross member split portions 29A and 29B to each other, thereby connecting the left and right side sills 24 together with the cross member (the body frame portion) extending in the vehicle width direction. , Reinforcement member) 66.
[0033]
Thus, the sub-assembly frame 58 is directly connected to the lower portion of the cross member 66 that crosses the storage recess 20 in the vehicle width direction. The cross section of the cross member divided body 59 has a closed cross-sectional shape orthogonal to the vehicle width direction. In addition, the cross member divided body 59 is formed with mounting flange portions 59C and 59D protruding in the front-rear direction.
[0034]
As shown in FIGS. 3 and 4, the battery box 43 has a lid 71 having a plurality of openings 70, and one side of the lid 71 is closed by fixing the lid 71 with bolts 71 a. A box-shaped box body 73 that opens an opening 72 on the opposite side to the lid 71, and a plurality of cylindrical cells 74 that are arranged in the box body 73 in parallel at intervals. The lid 71 has left and right mounting flange portions 73A extending forward and left and right mounting flange portions 73B extending rearward. Then, the rear mounting flange portion 73B is mounted on the upper surface of the rear side portion 58D of the sub-assembly frame 58 with the cover 71 upward with the bolt 73a, and the front mounting flange portion 73A is connected to the cross member divided body 59. Is mounted on the upper surface of the rear mounting flange portion 59D with a bolt 73a.
[0035]
The fixing bracket 57 is a cast product or a die-cast product of aluminum or the like. As shown in FIG. 10, each of the first and second mounting portions 77 and 78 has a rectangular frame shape and is juxtaposed in the vehicle width direction. And a U-shaped third mounting portion 79 provided on the rear side of the second mounting portion 78 and having an open side opposite to the second mounting portion 78.
[0036]
That is, the first mounting portion 77 has thick sides 77A and 77B that are parallel to each other, and thin sides 77C and 77D that connect the upper ends of both ends of each of the sides 77A and 77B. The second mounting portion 78 has thick sides 78A, 78B that are parallel to each other, and thin sides 78C, 78D that connect the upper ends of both ends of the sides 78A, 78B. are doing. Here, sides 77A, 77B, 78A, 78B of the first mounting portion 77 and the second mounting portion 78 are parallel to each other, and the side 77A and the side 78B are integrated.
[0037]
The third mounting portion 79 has thick sides 79A and 79B that are parallel to each other, and a thin side 79C that connects the upper portions at one end thereof, and the side 79C is connected to the second side. It is provided so as to be integrated with the side part 78D of the mounting part 78. Here, the third mounting portion 79 extends the side portion 79B from the intermediate position with respect to the side portion 78D. In addition, the intervening portion 78E between the side portion 78B and the side portion 79B in the side portions 78D and 79C is also thick in a curved shape so as to smoothly connect them.
[0038]
Mounting brackets 80A and 80B are fixed with bolts 80a so as to stand on opposite sides of the second mounting portion 78 and the first mounting portion 77, that is, outside the sides 78A and 77B, respectively. A mounting bracket 80C is fixed by bolts 80a so as to rise outward from between the portion 77 and the second mounting portion 78.
[0039]
As shown in FIG. 14, the fixing bracket 57 has a mounting bracket 80A on a lower surface side of a left side portion 58A of the sub-assembly frame 58 and a mounting bracket 80B on a lower surface of a right side portion 58B of the sub-assembly frame 58. The mounting bracket 80C is fixed to the lower surface side of the front side 58C of the sub-assembly frame 58 by the bolts 80a, so that the mounting bracket 80C is suspended from the sub-assembly frame 58.
[0040]
As shown in FIGS. 4 and 5, the power drive unit 44 is mounted on a heat sink 45. The heat sink 45 includes a mounting plate 82 on which the power drive unit 44 is mounted and a power drive unit of the mounting plate 82. 44 and a plurality of parallel fins 83 projecting to the opposite side. Then, the power drive unit 44 is fixed to the upper surface of the first mounting portion 77 on the mounting plate portion 82 by inserting the fins 83 of the heat sink 45 inside the first mounting portion 77 of the fixing bracket 57 with the heat sink 45 facing downward. You. Here, the fins 83 of the heat sink 45 are arranged side by side in the vehicle width direction so as to be orthogonal to the vehicle width direction.
[0041]
As shown in FIGS. 5 and 6, the DC-DC converter 47 is attached to a heat sink 50. The heat sink 50 includes a mounting plate portion 85 on which the DC-DC converter 47 is mounted and a mounting plate portion 85. 85, a plurality of parallel fins 86 protruding on the opposite side to the DC-DC converter 47. Note that a junction box 48 and a controller 49 are attached to a side of the DC-DC converter 47 opposite to the heat sink 50. Then, the DC-DC converter 47 inserts the fin 86 of the heat sink 50 inside the second mounting portion 78 of the fixing bracket 57 with the heat sink 50 on the lower side, and places the heat sink 50 on the upper surface of the second mounting portion 78 on the mounting plate portion 85. Fixed. Here, the fins 86 of the heat sink 50 are arranged side by side in the vehicle width direction so as to be orthogonal to the vehicle width direction.
[0042]
As shown in FIG. 6, the air conditioner inverter 52 is attached to a heat sink 53, and the heat sink 53 is mounted on a mounting plate 88 on which the air conditioner inverter 52 is mounted and an air conditioning inverter 52 of the mounting plate 88. And a plurality of parallel fins 89 protruding on the opposite side. Then, the air conditioner inverter 52 is fixed to the upper surface of the third mounting portion 79 on the mounting plate portion 88 by inserting the fins 89 of the heat sink 53 inside the third mounting portion 79 of the fixing bracket 57 with the heat sink 53 facing downward. You. Here, the fins 89 of the heat sink 53 are arranged side by side in the vehicle width direction so as to be orthogonal to the vehicle width direction.
[0043]
As shown in FIG. 6, the fan unit 55 has an intake port 91 on the upper part of the rotation axis of the fan 55A, and has an exhaust port 92 on the radius of the fan 55A. Is provided with an exhaust duct 93. The fan unit 55 has a rear portion attached to a lower surface of a rear side portion 58D of the sub-assembly frame 58 via a mounting bracket 94 shown in FIG. It is attached to the lower surface of the attachment flange portion 59D on the rear side of the cross member split body 59 through the intermediary portion.
[0044]
Next, a procedure for integrating the high-voltage equipment component 41 having the above configuration will be described.
[0045]
First, as shown in FIG. 8, the first assembly 98 in which the mounting brackets 61A and 61B are attached to the upper surface of the sub-assembly frame 58 in advance by welding or the like, and the cross member split body 59 is attached by welding or the like, As shown in FIG. 9, the mounting brackets 61A and 61B and the cross member split body 59 are turned over so that they face down. Then, the rear portion of the fan unit 55 is attached to the sub-assembly frame 58 via a mounting bracket 94 with bolts, and the front portion of the fan unit 55 is attached to the flange portion 59D of the cross member divided body 59 with a bolt via the attachment bracket 95. The second assembled body 99 in such a state is formed in a sub-assembly step.
[0046]
On the other hand, as shown in FIG. 10, the heat sink 50 and the DC-connector are attached to the second mounting portion 78 of the third assembly 100 in which the fixing bracket 57 and the mounting brackets 80A, 80B, 80C have been mounted in advance in the sub-assembly process with the bolts 80a. The DC converter 47, the junction box 48, and the controller 49 assemble the fourth assembly 101, which has been preliminarily subjected to the sub-assembly process, with bolts, and the state shown in FIG.
[0047]
Next, as shown in FIG. 12, the heat sink 45 and the power drive unit 44 are assembled to the first mounting portion 77 of the third assembly 100 in the sub-assembly process using the fifth assembly 102 with bolts. The heat sink 53 and the air conditioner inverter 52 are assembled to the third mounting portion 79 of the assembly 100 in the sub-assembly process in advance by the sixth assembly 103 with bolts, and the state of the seventh assembly 104 shown in FIG. 13 is obtained. The seventh assembled body 104 in such a state is formed in a sub-assembly step.
[0048]
Then, as shown in FIG. 14, the seventh assembly 104 is turned upside down and attached to the sub-assembly frame 58 of the second assembly 99 with the bolts 80a at the mounting brackets 80A, 80B, 80C to form the eighth assembly 105.
[0049]
Next, the eighth assembly 105 is turned upside down and returned to the original position, and the mounting flange portions 73A and 73B of the battery box 43 shown in FIG. 15 are attached to the sub-assembly frame 58 and the cross member split body 59 as shown in FIG. Attach by bolts 73a. Here, an internal cover 60 shown in FIG. 4 is attached to the battery box 43, and the internal cover 60 closes a gap between the fixing bracket 57 and the battery box 43. Thus, as shown in FIG. 7, the battery box 43, the power drive unit 44, the heat sink 45, the DC-DC converter 47, the heat sink 50, the junction box 48, the controller 49, the air conditioner inverter 52, High-pressure equipment component 41 is formed in which a heat sink 53 and a fan unit 55 are integrally held inside a frame-shaped sub-assembly frame 58.
[0050]
Then, as shown in FIG. 16, such a high-voltage equipment component 41 is placed such that the sub-assembly frame 58 is on the upper side and the respective devices are arranged as described above, that is, the battery box 43 is placed on the rear right side of the power drive unit. The mat member is arranged so that 44 is located on the front right side, DC-DC converter 47 is located on the front left side, and fan unit 55 is located on the rear left side. 40 is inserted from the upper side into the storage recess 20 of the vehicle body floor 10 arranged in advance.
[0051]
Subsequently, as shown in FIGS. 2 and 17, the front mounting bracket 61A of the sub-assembly frame 58 is mounted on the front mounting seat 65A and the front cross member 26 of the floor panel 23 with bolts 61a. The high-voltage equipment component 41 is fixed to the vehicle body floor 10 by attaching the rear mounting bracket 61B to the rear mounting seat 65B and the rear cross member 28 on the floor panel 23 with bolts 61a.
[0052]
The high-pressure equipment component 41 includes left and right cross members spaced apart on both sides of the storage recess 20 in a state in which the cross member divided body 59 extends so as to cross the storage recess 20 in the vehicle width direction. Bolts 59a are fixed to the member dividing portions 29A and 29B at mounting flange portions 59A and 59B at both ends in the vehicle width direction.
[0053]
In this state, as shown in FIGS. 4 to 6, the high-pressure equipment component 41 is vertically spaced from the bottom 20 </ b> E of the storage recess 20, and as a result, the sub-assembly supported on the vehicle body floor 10. It is stored in the storage recess 20 in a suspended state via the frame 58. In this state, as shown in FIG. 2, the sub-assembly frame 58 is indirectly connected to the cross members 26 and 28 provided on the lower surface of the vehicle body floor 10 via the mounting brackets 61A and 61B. , Is directly connected to a cross member 66 provided on the upper surface of the vehicle body floor 10. Preferably, the sub-assembly frame 58 is connected to a reinforcing member such as the cross member 66 in at least one of an indirect connection and a direct connection via a bracket.
[0054]
As shown in FIGS. 4 to 6, the mat member 40 interposed between the high-pressure equipment component 41 disposed in the storage recess 20 in a suspended state and the bottom 20 </ b> E of the storage recess 20 as described above, A cooling air flow path (passage) 110 for flowing cooling air to the high-pressure equipment component 41 is formed.
[0055]
The mat member 40 is for preventing heat from entering, and is made of an elastic heat insulating member such as urethane foam. As shown in FIG. 2, the mat member 40 is disposed on the left side along the left side wall 20A of the storage recess 20. The wall portion 40A, the right side wall portion 40B arranged along the right side wall portion 20B of the storage recessed portion 20, the front side wall portion 40C arranged along the front side wall portion 20C of the storage recessed portion 20, and the rear portion of the storage recessed portion 20 It has a rear side wall part 40D arranged along the side wall part 20D, and a bottom part 40E arranged along the bottom part 20E of the storage recess 20 as shown in FIGS.
[0056]
As shown in FIGS. 18 to 20, inner bottom walls 111 </ b> A to 111 </ b> C extending substantially in the front-rear direction are provided on the bottom end 40 </ b> E at the left end, the right end, and the middle part in the vehicle width direction. Inner side wall portions 111D and 111E extending substantially in the vehicle width direction are also provided upright at the ends. As a result, the flow path forming recesses 112A and 112B that are recessed downward are formed in the bottom 40E on both sides in the vehicle width direction, that is, between the inner wall portions 111A and 111C and between the inner wall portions 111C and 111B. The inner wall portion 111D and the inner wall portion 111C at the front end are separated from each other, and as a result, the flow path forming recesses 112A and 112B are recessed downward so as to communicate with each other in the vehicle width direction as shown in FIG. The illustrated flow channel forming groove 113 is formed.
[0057]
Then, in the state of being suspended in the storage recess 20 as described above, the high-pressure equipment component 41 arranges the heat sink 45 of the power drive unit 44 in the flow passage formation recess 112B as shown in FIG. As shown in FIG. 6, the heat sink 50 of the DC-DC converter 47 and the heat sink 53 of the air conditioner inverter 52 are arranged in the channel forming recess 112A.
[0058]
In this suspended state, as shown in FIGS. 20 and 4, the high-pressure equipment component 41 is configured such that the front sides 77C and 78C of the fixing bracket 57 have their continuous lower surfaces entirely at the front end. The inner wall portion 111D is compressed and deformed while being in contact with the upper surface of the inner wall portion 111D. As a result, the side portions 77C and 78C and the inner wall portion 111D come into close contact with each other.
[0059]
In the suspended state, as shown in FIGS. 20 and 5, the side portions 78A and 79A of the fixing bracket 57 have their lower surfaces entirely abutting against the upper surface of the inner wall portion 111A. Are compressed and deformed, and as a result, the side portions 78A and 79A and the inner wall portion 111A come into close contact with each other.
[0060]
In the suspended state, as shown in FIG. 19 and FIG. 5, the side 77B of the fixing bracket 57 compresses and deforms the inner wall 111B while the lower surface thereof is entirely in contact with the upper surface of the inner wall 111B. As a result, the side portion 77B and the inner wall portion 111B come into close contact with each other.
[0061]
In the suspended state, as shown in FIGS. 19 and 5, the side portions 77A and 78B, the intervening portion 78E and the side portion 79B of the fixing bracket 57 completely connect the continuous lower surface to the upper surface of the inner wall portion 111C. The inner wall portion 111C is compressed and deformed while being brought into contact, and as a result, the side portions 77A and 78B, the intervening portion 78E and the side portion 79B and the inner wall portion 111C come into close contact with each other.
[0062]
As described above, the mat member 40 is compressed and deformed by being pressed by the high-voltage equipment component 41 disposed in the storage recess 20. More specifically, the power drive unit 44, the DC-DC converter 47, and the air conditioner inverter 52 It is pressed by the fixing bracket 57 that connects them, and is compressed and deformed.
[0063]
In addition, in the suspended state, the battery box 43 has a left side surface portion 43A shown in FIG. 5 in close contact with the inner side surface of the inner side wall portion 111C shown in FIG. 16 to seal the gap, and a right side surface portion 43B shown in FIG. 16 is in close contact with the inner surface of the inner wall portion 111B shown in FIG. 16 to seal the gap, and the rear surface portion 43D shown in FIG. 4 is in close contact with the inner surface of the inner wall portion 111E to seal the gap. The inner cover 60 attached to the battery box 43 closes a gap between the battery box 43 and the first mounting portion 77 of the fixing bracket 57. As a result, the entire upper side of the channel forming recess 112B is closed by the battery box 43, the inner cover 60, the first mounting portion 77 of the fixing bracket 57, and the heat sink 45 of the power drive unit 44.
[0064]
In addition, as shown in FIG. 20, the upper side of the flow path forming groove 113 is closed by the side portions 77A and 78B of the first mounting portion 77 and the second mounting portion 78 of the fixing bracket 57.
Further, as shown in FIG. 6, the second mounting portion 78 and the third mounting portion 79 of the fixing bracket 57, the heat sink 50 of the DC-DC converter 47, and the heat sink 53 of the air conditioner inverter 52 cause the front upper side of the channel forming recess 112 </ b> A Closed.
[0065]
In this way, as shown in FIG. 4, the upper opening 70 of the battery box 43, the internal flow path 115 of the battery box 43, the lower opening 72 of the battery box 43, and the lower part 40E An internal flow path 116 surrounded by the walls 111B, 111C, and 111E, between the battery box 43 and the heat sink 45, and surrounded by the inner cover 60, the side 77D of the fixing bracket 57, and the inner side walls 111B and 111C. The internal passage 117, the internal passage 118 mainly passing between the fins 83 surrounded by the heat sink 45, the bottom 40E, and the walls 111B and 111C, the internal passage 118 between the heat sink 45 and the wall 111D, An internal channel 119 surrounded by a side 77C, a bottom 40E, and walls 111B, 111C, 111D, FIG. 6, the inner passage 120 surrounded by the fixing bracket 57 and the passage forming groove 113, between the heat sink 50 and the wall 111D, and the side 78C, the bottom 40E, and the wall of the fixing bracket 57 as shown in FIG. The internal flow path 121 surrounded by the portions 111A, 111C and 111D, the internal passage 122 mainly passing between the fins 86 surrounded by the heat sink 50 and the bottom 40E and the walls 111A and 111C, and the heat sink 50 and the heat sink 53 An internal flow path 123 surrounded by the sides 78D and 79C, the bottom 40E, and the walls 111A and 111C of the fixed bracket 57, and mainly surrounded by the heat sink 53, the bottom 40E, and the walls 111A and 111C. The internal passages 124 passing between the fins 89 are connected in series in this order to form the cooling air flow passage 110. Then, the outside of the fin 89 of the heat sink 53 opposite to the upper battery box 43 on the flow path is once opened to the internal flow path 124 in the gap between the mat member 40 and the high-pressure equipment component 41, and the intake port 91 of the fan unit 55 is opened. Communicate with
[0066]
Here, as shown in FIGS. 21 and 22, the opening of the storage recess 20 on the front side of the cross member split body 59 is formed by the front flange portion 59 </ b> C of the cross member split body 59 and the floor panel 23 outside the storage recess 20. The opening of the storage recess 20 on the rear side of the cross member divided body 59 is closed by the front lid 130 supported by the front lid 130 and the flange 59D on the rear side of the cross member divided body 59 and the storage recess 20. Is closed by the rear lid 131 supported by the floor panel 23 on the outside.
[0067]
An external intake duct 132 and an external exhaust duct 133 extending to the outside of the rear lid 131 to the outside are attached to the rear lid 131 in a state where the joints are sealed so as not to leak air. Each of the external intake duct 132 and the external exhaust duct 133 extends into the vehicle interior and is open at the tip end. Then, the external air intake duct 132 is joined to the cover 71 of the battery box 43 so as to surround the whole of the plurality of openings 70 of the battery box 43 as shown in FIG. As shown in FIG. 6, it is communicated with the exhaust duct 93 of the fan unit 55. The joint between the lid 71 and the external intake duct 132 is also sealed so that there is no air leakage, and the joint between the external exhaust duct 133 and the exhaust duct 93 is also sealed so that there is no air leakage. Further, the joint portions of the front lid 130 and the rear lid 131 with the vehicle body floor 10 are also sealed so that there is no air leakage.
[0068]
As a result, when the fan unit 55 causes the flow of air from the intake port 91 to the exhaust port 92 by the rotation of the fan 55A, the external intake duct 132, the internal flow path 115 of the battery box 43, the battery box 43, an internal passage 117 between the battery box 43 and the heat sink 45, an internal passage 118 passing between the fins 83 of the heat sink 45, and an internal passage 119 between the heat sink 45 and the wall 111D. , An internal flow path 120 between the heat sink 50 and the wall 111D, an internal flow path 122 between the fins 86 of the heat sink 50, and an internal flow between the heat sink 50 and the heat sink 53. Path 123, an internal passage 124 passing between the fins 89 of the heat sink 53, and the internal passage 124 and the fan. Internal flow passage 125 for communicating the unit 55, the fan unit 55, cooling air flows in the forward external exhaust duct 133 and the in-room, occurs. When the cooling air passes through the inside of the battery box 43, it cools the cylindrical cells 74, cools the power drive unit 44 when passing through the heat sink 45, and cools the DC-DC converter 47 when passing through the heat sink 50. To cool the air conditioner inverter 52 when passing through the heat sink 53. Note that no duct is provided between the internal passage 125 and the fan unit 55.
[0069]
According to the present embodiment described above, the high-pressure equipment component 41 is disposed in a suspended state in the downwardly recessed storage recess 20 formed in the vehicle body floor 10, so that the mounting / removing operation is performed on the vehicle body floor 10. On the other hand, it can be performed from above. Moreover, the high-voltage component 41 can be mounted on the vehicle body at one time. Therefore, the workability of the attaching / detaching operation can be improved. In addition, since no load is applied to the storage recess 20, the weight of the storage recess 20 can be reduced.
[0070]
In addition, a mat member 40 made of an elastic heat insulating member is arranged in a gap between the high-pressure equipment component 41 formed by hanging the high-pressure equipment component 41 and the bottom 20 </ b> E of the storage recess 20. Since the cooling air flow path 110 for flowing the cooling air to the device component 41 is formed, the cooling air flow path 110 can be formed relatively easily. Therefore, the cooling air flow path 110 for passing the cooling air to the high-pressure equipment component 41 can be formed at low cost. In addition, since the high-pressure component 41 is mounted together in one place, cooling can be effectively performed by one fan unit 55.
[0071]
Further, since the mat member 40 made of an elastic heat insulating member is disposed in a gap between the high-pressure equipment component 41 formed by suspending the high-pressure equipment component 41 and the bottom 20E of the storage recess 20, the vehicle body floor 10 Even if is deformed by receiving some force from below, the mat member 40 elastically deforms and absorbs this deformation. Therefore, the high-pressure equipment component 41 can be protected by the cushion function of the mat member 40.
[0072]
In addition, since the mat member 40 is pressed and deformed by the mounting pressure of the high-pressure equipment component 41 disposed in the storage recess 20, the mat member 40 and the high-pressure equipment in the cooling air flow path 110 formed by the mat member 40 are deformed. It is possible to seal a gap between the component 41 and prevent leakage of cooling air from the gap. Therefore, the cooling efficiency can be improved.
[0073]
In addition, due to the deformation of the mat member 40, the mounting error of the high-voltage component 41 can be absorbed. Therefore, since a mounting error is allowed, the mounting operation of the high-voltage component 41 is facilitated, and the production yield is improved.
[0074]
Further, since the mat member 40 is configured to be compressed and deformed by being pressed by the fixing bracket 57 that connects the high-voltage devices of the high-voltage device component 41, the sealing portion of the mat member 40 that is compressed and deformed when the cooling air flow path 110 is formed. Can be determined by considering the shape of the fixing bracket 57. Therefore, the mat member 40 can be easily designed.
[0075]
In addition, since the temperature of the battery box 43 is relatively low, and the temperatures of the DC-DC converter 47 and the air conditioner inverter 52 are relatively high, the battery box 43 is placed before the DC-DC converter 47 and the air conditioner inverter 52 as described above. All of these can be efficiently cooled when cooled.
[0076]
During running with the driving force of the internal combustion engine, the exhaust air from the radiator fan and the exhaust air from the condenser fan when the air conditioner is driven are hot, and these exhaust air is exhausted from the engine room to below the floor. Can prevent the heat of the exhaust air from being transmitted to the high-pressure equipment component 41.
[0077]
【The invention's effect】
As described in detail above, according to the first aspect of the present invention, since the high-pressure equipment component is suspended in the downwardly recessed storage recess formed on the vehicle body floor, the mounting and dismounting work is performed on the vehicle body. This can be done from above for the floor. Therefore, the workability of the attaching / detaching operation can be improved. In addition, a heat insulating member is disposed in a gap between the high-pressure equipment component formed by hanging the high-pressure equipment component and the bottom of the storage recess, and the heat-insulating member forms a flow path for flowing cooling air through the high-pressure equipment component. Therefore, the flow path can be formed relatively easily. Therefore, a flow path for passing the cooling air to the high-pressure equipment component can be formed at low cost. Further, since the heat insulating member is disposed in a gap between the high-pressure equipment component formed by hanging the high-pressure equipment component and the bottom of the storage recess, the vehicle body floor is deformed by receiving some force from below. Also, the deformation of the heat insulating member absorbs this deformation. Therefore, the high-pressure equipment component can be protected by the cushion function of the heat insulating member.
[0078]
According to the second aspect of the present invention, since the heat insulating member is pressed and deformed by the high-pressure equipment component disposed in the storage recess, the heat-insulating member and the high-pressure equipment component in the flow path formed by the heat insulating member are separated from each other. The gap between them can be sealed, and leakage of cooling air from this gap can be prevented. Therefore, the cooling efficiency can be improved. In addition, the deformation of the heat insulating member can absorb a mounting error of the high-voltage component. Therefore, since a mounting error is allowed, the mounting operation of the high-voltage equipment component is facilitated, and the production yield is improved.
[0079]
According to the third aspect of the present invention, since the heat insulating member is configured to be compressed and deformed by being pressed by the connecting member that connects the high-pressure devices of the high-pressure device components, the heat insulating member is compressed when the cooling air flow path is formed. For the deformed seal portion, the shape of the connecting member may be considered. Therefore, the heat insulating member can be easily designed.
[Brief description of the drawings]
FIG. 1 is a side view schematically illustrating a vehicle to which a vehicle-mounted structure of a high-voltage component according to an embodiment of the present invention is applied.
FIG. 2 is a plan view showing a vehicle-mounted structure of a high-voltage component according to an embodiment of the present invention.
FIG. 3 is a plan view showing high-voltage equipment components.
FIG. 4 is a side sectional view of a right side portion showing a vehicle-mounted structure of a high-voltage device component according to an embodiment of the present invention.
FIG. 5 is a front sectional view showing a vehicle-mounted structure of a high-voltage component according to an embodiment of the present invention.
FIG. 6 is a side sectional view of a left side portion showing a vehicle-mounted structure of a high-voltage device component according to an embodiment of the present invention.
FIG. 7 is a perspective view showing a high-voltage equipment component.
FIG. 8 is a perspective view showing a procedure for assembling a high-voltage component.
FIG. 9 is a perspective view showing a state after FIG. 8 showing an assembling procedure of the high-voltage equipment component.
FIG. 10 is a perspective view showing a procedure of assembling the high-voltage component.
FIG. 11 is a perspective view showing a state after FIG. 10 showing an assembling procedure of the high-voltage equipment component.
FIG. 12 is a perspective view showing a state after FIG. 11 showing a procedure for assembling the high-voltage component.
FIG. 13 is a perspective view showing a state after FIG. 12 showing a procedure for assembling the high-voltage component.
FIG. 14 is a perspective view showing a state after FIGS. 9 and 13 showing a procedure for assembling the high-voltage component.
FIG. 15 is a perspective view showing a battery box.
FIG. 16 is a perspective view showing a state after FIG. 14 showing a procedure for mounting the high-voltage component.
FIG. 17 is a perspective view showing a state after FIG. 15 showing a procedure for mounting the high-voltage component on the vehicle.
FIG. 18 is a perspective view showing the mat member as viewed from the front side.
FIG. 19 is a perspective view showing a mat member, a fixing bracket, and the like, as viewed from the front side.
FIG. 20 is a perspective view showing a mat member, a fixing bracket, and the like as viewed from the rear side.
FIG. 21 is a perspective view showing a state after FIG. 17 showing a procedure for mounting a high-voltage component.
FIG. 22 is a perspective view showing a state after FIG. 21 showing a procedure for mounting the high-voltage equipment component on the vehicle.
[Explanation of symbols]
10 Body floor
20 storage recess
20E bottom
40 Mat member (heat insulation member)
41 High-voltage equipment components
43 Battery box (high-voltage equipment)
47 DC-DC converter (high voltage equipment)
48 Junction Box (High Pressure Equipment)
49 Controller (High-pressure equipment)
57 Fixing bracket (connecting member)
110 Cooling air flow path (flow path)

Claims (3)

高圧機器コンポーネントを車体フロアに形成された下方に凹む収納凹部に吊り下げ状態で配設するとともに、前記高圧機器コンポーネントと前記収納凹部の底部との間に前記高圧機器コンポーネントに冷却風を流す流路を形成する断熱部材を介装してなることを特徴とする高圧機器コンポーネントの車載構造。A high-pressure equipment component is suspended in a downwardly-recessed storage recess formed in the vehicle body floor, and a flow path for flowing cooling air to the high-pressure equipment component between the high-pressure equipment component and the bottom of the storage recess. A vehicle-mounted structure for a high-voltage component, comprising a heat insulating member forming a component. 前記断熱部材は、弾性材料からなっており、前記収納凹部に配設された前記高圧機器コンポーネントで押圧されて圧縮変形することを特徴とする請求項１記載の高圧機器コンポーネントの車載構造。The vehicle-mounted structure of a high-pressure equipment component according to claim 1, wherein the heat-insulating member is made of an elastic material, and is pressed and deformed by the high-pressure equipment component disposed in the storage recess. 前記断熱部材は、前記高圧機器コンポーネントの各高圧機器同士を連結させる連結部材で押圧されて圧縮変形することを特徴とする請求項２記載の高圧機器コンポーネントの車載構造。The on-vehicle structure for a high-pressure equipment component according to claim 2, wherein the heat-insulating member is pressed and deformed by a connecting member that connects the high-pressure equipments of the high-pressure equipment component.
JP2003143415A 2003-05-21 2003-05-21 In-vehicle structure of high-voltage equipment components Expired - Fee Related JP4060234B2 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
JP2003143415A JP4060234B2 (en) 2003-05-21 2003-05-21 In-vehicle structure of high-voltage equipment components
US10/850,337 US7051825B2 (en) 2003-05-21 2004-05-20 Structure for installing high-voltage equipment component to vehicle
EP04012092A EP1479567B1 (en) 2003-05-21 2004-05-21 Structure for installing highvoltage equipment component to vehicle
CNB2004100424522A CN1281428C (en) 2003-05-21 2004-05-21 Structure for installing high-voltage equipment component to vehicle
DE602004030182T DE602004030182D1 (en) 2003-05-21 2004-05-21 Structure for installing a high voltage component in motor vehicles

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JP2003143415A JP4060234B2 (en) 2003-05-21 2003-05-21 In-vehicle structure of high-voltage equipment components

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