WO2022264868A1 - 電気接続箱 - Google Patents
電気接続箱 Download PDFInfo
- Publication number
- WO2022264868A1 WO2022264868A1 PCT/JP2022/022878 JP2022022878W WO2022264868A1 WO 2022264868 A1 WO2022264868 A1 WO 2022264868A1 JP 2022022878 W JP2022022878 W JP 2022022878W WO 2022264868 A1 WO2022264868 A1 WO 2022264868A1
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- WO
- WIPO (PCT)
- Prior art keywords
- branch circuit
- circuit structure
- connection
- housing
- connectors
- Prior art date
Links
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- 230000002093 peripheral effect Effects 0.000 claims description 13
- 230000000630 rising effect Effects 0.000 claims description 4
- 238000003780 insertion Methods 0.000 description 26
- 230000037431 insertion Effects 0.000 description 26
- 238000007789 sealing Methods 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 230000001681 protective effect Effects 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000000057 synthetic resin Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000004308 accommodation Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
Images
Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/16—Distribution boxes; Connection or junction boxes structurally associated with support for line-connecting terminals within the box
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/023—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for transmission of signals between vehicle parts or subsystems
- B60R16/0238—Electrical distribution centers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/03—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for supply of electrical power to vehicle subsystems or for
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/081—Bases, casings or covers
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/02—Details
- H05K5/03—Covers
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/02—Arrangements of circuit components or wiring on supporting structure
- H05K7/06—Arrangements of circuit components or wiring on supporting structure on insulating boards, e.g. wiring harnesses
-
- 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
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- the present disclosure relates to electrical connection boxes.
- Patent Document 1 shows an electrical connection box that is mounted on a vehicle such as an electric vehicle or a hybrid vehicle and used to distribute electric power from a battery to various vehicle-mounted devices.
- the electric connection box includes a housing made of a metal member such as aluminum, and a branch circuit structure, etc., which is housed inside the housing and includes power lines such as bus bars and electric parts such as relays and fuses. and A plurality of connectors connected to the branch circuit constructs are provided on each of the plurality of side walls of the housing, and external connectors provided at the ends of electric wires extending from various devices are assembled to the plurality of connectors. be done. This realizes distribution of power from the battery to various devices via the electric connection box.
- an electric junction box that can realize a connection between a connector provided in a housing and a connection portion of a branch circuit structure accommodated in the housing in a space-saving manner by reducing man-hours and the number of parts. do.
- the electrical connection box of the present disclosure includes a branch circuit structure for distributing power supplied from a battery to various devices, a housing that houses the branch circuit structure, and an opening that penetrates the side wall of the housing. a lid fixed to the side wall to cover the opening; and a plurality of external connection terminals mounted in a plurality of through holes penetrating the lid in a plate thickness direction and protruding from the outer surface of the lid.
- the connector and the branch circuit structure are fixed to the inner surface of the cover, and a plurality of connection portions provided on the branch circuit structure are connected to the corresponding connection terminals of the external connection connectors.
- An electric connection box, wherein an external connection connector module is configured to include the plurality of external connection connectors, the lid and the branch circuit structure.
- connection between the connector provided in the housing and the connection portion of the branch circuit structure accommodated in the housing can be realized in a space-saving manner by reducing the man-hours and the number of parts. can be done.
- FIG. 1 is a perspective view of an electric connection box according to Embodiment 1.
- FIG. 2 is an enlarged exploded plan view of FIG. 1.
- FIG. 3 is an enlarged perspective view of the electrical connection box of FIG. 1 as viewed from the front left side, with the battery high-voltage connector removed forward.
- FIG. 4 is an exploded perspective view of FIG. 1 (however, the cover is removed and the battery high voltage connector is not removed).
- 5 is an exploded perspective enlarged view of the connector module for external connection shown in FIG. 4.
- FIG. 6 is a further exploded perspective view of the connector module for external connection shown in FIG. 5.
- FIG. 7 is an exploded perspective view of the branch circuit arrangement shown in FIG. 5;
- FIG. 8 is an enlarged exploded perspective view of the board-side connector module shown in FIG. 4.
- FIG. 1 is a perspective view of an electric connection box according to Embodiment 1.
- FIG. 2 is an enlarged exploded plan view of FIG. 1.
- FIG. 3 is an enlarged perspective
- the electrical junction box of the present disclosure is (1) A branch circuit structure for distributing electric power supplied from a battery to various devices, a housing for accommodating the branch circuit structure, an opening penetrating a side wall of the housing, and the opening a lid body fixed to the side wall by closing a portion, a plurality of external connection connectors mounted in a plurality of through holes penetrating the lid body in a plate thickness direction and protruding from the outer surface of the lid body, and the lid
- the branch circuit structure is fixed to the inner surface of the body, and a plurality of connection portions provided in the branch circuit structure are connected to the corresponding connection terminals of the external connection connectors, and the plurality of external
- the electrical connection box includes a connector for connection, the cover, and the branch circuit structure to constitute a connector module for external connection.
- a plurality of through-holes are provided in the cover that closes the opening provided through the side wall of the housing, and a plurality of external connectors are provided for these through-holes. is mounted so as to protrude from the outer surface of the lid.
- the branch circuit structure accommodated in the housing is fixed to the inner surface of the lid, and a plurality of connection portions provided on the branch circuit structure are connected to corresponding connection terminals of an external connector. In this way, the branch circuit structure having a plurality of external connectors and connection portions to which the external connectors are connected is fixed to the cover separated from the side wall of the housing.
- the external connection connector module is configured by assembling both the branch circuit structure and the external connection connector to the lid body separated from the housing to form a module. Therefore, the external connection connector module can be configured in advance by connecting the connection portion of the branch circuit structure and the external connection connector outside the housing. Furthermore, the assembly of the plurality of external connection connectors and the branch circuit structure to the housing can be completed by a single operation of assembling the external connection connector module into the opening of the housing. Therefore, unlike the conventional structure, there is no need to secure a working space inside the housing for connecting a plurality of external connection connectors and a plurality of connection parts individually with electric wires. It is also possible to save the space of the electric connection box and improve workability.
- the branch circuit structure includes an internal circuit including a bus bar and electric parts, and a case that houses the internal circuit, and the case includes a base portion and an upright portion rising from the base portion. and the upright plate portion is fixed in contact with the inner surface of the lid.
- the connecting portion is arranged on the base portion, and the external connector connected to the connecting portion is held by the lid.
- a branch circuit wiring for branching electric power from the battery can be routed in the base portion, and the lid body is used to stably hold the external connector connected to the connection portion arranged in the base portion. be able to. As a result, it is possible to improve the space efficiency and connection stability of the connector module for external connection.
- (5) further comprising: a circuit board accommodated in the housing; and a board-side connector module in which a plurality of board-side connectors mounted on the circuit board are integrated, wherein the branch circuit structure is connected to the case. It is preferable to have a plurality of relay connectors protruding collectively from the base portion of and connected to the plurality of board-side connectors, respectively, to be electrically connected to the internal circuit. Even when the circuit board connected to the branch circuit structure is accommodated in the housing, a board-side connector module in which a plurality of board-side connectors are integrated is mounted on the circuit board.
- a plurality of board-side connectors are connected to the internal circuit of the branch circuit structure via a plurality of relay connectors collectively projecting from the base portion.
- the electric connection box 10 of Embodiment 1 of the present disclosure will be described with reference to FIGS. 1 to 8.
- FIG. The electrical junction box 10 is mounted on a vehicle (not shown) such as an electric vehicle or a hybrid vehicle, and distributes power supplied from a battery (not shown) to various devices via a branch circuit structure 12.
- the electric connection box 10 also has a housing 14 that houses the branch circuit structure 12 .
- the electric connection box 10 can be arranged in any direction, the vertical direction, the horizontal direction, and the front-rear direction will be described below based on the vertical direction, the horizontal direction, and the front-rear direction shown in the drawing. Further, with respect to a plurality of identical members, only some members are given reference numerals, and the reference numerals are omitted for other members.
- the housing 14 is made of metal, and the housing 14 is made of die-cast aluminum, for example.
- the housing 14 includes a housing body 16 having a rectangular bottomed box shape that opens upward, and a cover portion 18 that covers the upper opening of the housing body 16. I have.
- the housing body 16 has a bottom wall 20 and side walls 22 projecting upward from the peripheral edge of the bottom wall 20 .
- cylindrical holding plate support portions 24 protrude from six locations on the bottom wall 20 .
- the projection dimension of the holding plate support portion 24 is approximately half the projection dimension of the side wall 22 .
- the holding plate support portion 24 has a tapered structure in which the diameter is gradually reduced toward the projecting tip portion.
- a bolt fastening hole 26 having a circular cross section is formed in the protruding tip portion of the holding plate support portion 24 so as to open upward.
- the holding plate supporting portion 24 is provided with a flat reinforcement plate portion 28 that protrudes outward from the outer peripheral surface and is connected to the side wall 22 or the bottom wall 20 .
- cylindrical branch circuit component support portions 30 protrude from four locations on the bottom wall 20 of the housing 14 .
- the projecting dimension of the branch circuit structure supporting portion 30 is set to 1/10 or less of the projecting dimension of the side wall 22 .
- a bolt fastening hole 26 having a circular cross section is formed at the projecting tip of the branch circuit component supporting portion 30 so as to open upward.
- a side wall 22 on the front side of the housing 14 is integrally formed with a battery fixing portion 32 that protrudes upward and to the left and right.
- the battery fixing portion 32 is provided with bolt insertion holes 34 for fixing the housing 14 to a battery housing (not shown) at seven locations spaced apart from each other in the circumferential direction.
- a rectangular housing recess 36 for housing a connecting portion provided in the housing of the battery (not shown) is formed in a central region of the battery fixing portion 32 toward the front. It is formed with an opening.
- a protrusion 38 protruding forward with an elliptical cross-section is provided in the central portion of the accommodation recess 36 .
- the battery high-voltage connector 44 has a fixing portion 46 in the form of a rectangular flat plate.
- the fixing portion 46 is provided with bolt insertion holes 34 at two diagonal locations.
- a pair of terminal holding protrusions 48, 48 projecting forward and rearward and spaced apart in the left-right direction are provided in the central portion of the fixing portion 46.
- a bus bar 50 bent into an L-shape is disposed in each terminal holding protrusion 48 .
- the battery connecting portion 50a of the bus bar 50 is exposed at the front end of each terminal holding projection 48, and the branch circuit component connecting portion 50b of the bus bar 50 is exposed at the rear end of each terminal holding projection 48. (See Figure 2).
- a bolt insertion hole 52 is provided through the branch circuit component connection portion 50b in the plate thickness direction.
- ⁇ Opening 54> As shown in FIG. 4, the side wall 22 of the housing body 16 on the rear side is notched over substantially the entire surface so that the side wall 22 of the housing body 16 opens toward the rear and the inside of the housing body 16 .
- An opening 54 is provided therethrough.
- Bolt fastening holes 26 are formed through the side wall 22 of the housing body 16 at ten locations on the periphery of the opening 54 .
- a recessed groove-shaped sealing member accommodating portion 56 Inside the bolt fastening hole 26 at the peripheral edge of the opening 54, a recessed groove-shaped sealing member accommodating portion 56 that opens rearward is formed.
- An annular rubber seal member 58 is accommodated in the seal member accommodating portion 56 .
- the housing body 16 is provided with an annular flange-shaped portion 60 extending outward in the left-right direction and the front-rear direction from the upper opening.
- the flange-like portion 60 is provided with bolt fastening holes 26 at 14 locations spaced apart in the circumferential direction.
- ⁇ Lid 62> An opening 54 penetrating through the side wall 22 on the rear side of the housing body 16 is closed by a lid 62 .
- the lid 62 has a rectangular flat plate shape.
- a bolt insertion hole 34 is formed through the cover 62 at a position corresponding to the bolt fastening hole 26 on the peripheral edge of the opening 54 .
- the cover 62 is provided with a plurality of (eight in this embodiment) through holes 64 penetrating the cover 62 in the plate thickness direction.
- External connectors 66a, 66b, 66c, 66d, 66e, 66f, 66g and 66h are attached to the through holes 64, respectively.
- each of the external connectors 66a to 66h projects outward in the thickness direction from an outer surface 68 and an inner surface 70 of the lid 62 while being bolted to and held by the lid 62. ing.
- the lid body 62 can be used to stably hold the external connectors 66a to 66h connected to the connection portions 72a to 72h arranged on the base portion 118.
- FIG. Therefore, it is possible to improve the space efficiency and connection stability of the external connection connector module 156, which will be described later.
- External connectors 66a to 66h protruding from the outer surface 68 of the lid 62 are connected to connectors connected to various devices (not shown). 2, 5 and 6, external connectors 66a to 66h protruding from the inner surface 70 of the lid 62 are connected to connection portions 72a to 72h provided on the branch circuit structure 12. It has become so.
- substantially cylindrical branch circuit component fixing portions 74 project from the inner surface 70 of the lid 62 at three locations spaced apart in the left-right direction.
- a bolt fastening hole 26 having a circular cross-section opening forward is formed at the projecting tip of the branch circuit structure fixing portion 74 .
- the cover portion 18 that covers the upper opening of the housing body 16 has a rectangular box shape with a shallow bottom that opens downward.
- the cover portion 18 is provided with an annular flange portion 75 extending outward in the left-right direction and the front-rear direction from the lower opening.
- the flange-like portion 75 is provided with bolt insertion holes 34 at 14 locations corresponding to the bolt fastening holes 26 of the housing body 16 .
- the branch circuit structure 12 includes a lower case 76a located below and an upper case 76b located above when mounted on a vehicle. It is configured.
- the case 76 is formed by injection molding an insulating synthetic resin into a predetermined shape.
- the synthetic resin forming the case 76 may contain filler such as glass fiber.
- the case 76 has, for example, a substantially T-shape in plan view as shown in FIG.
- Inside the case 76 for example, as shown in FIG. 7, a bus bar 78a extending in the front-rear direction is arranged.
- the bus bar 78a is connected to the battery through the battery high voltage connector 44 and is applied with a high voltage.
- a bus bar 78b connected to, for example, a 12V power supply and a bus bar 78c connected to an AC power supply are arranged on the rear right side of the bus bar 78a.
- the upper case 76b has a similar shape that is slightly larger than the lower case 76a in plan view.
- the upper case 76b also has a substantially T-shape similar to that of the lower case 76a.
- a pair of busbar insertion holes 84, 84 are formed in the front end portion of the upper case 76b so as to be spaced apart from each other in the left-right direction.
- the front end portion of the busbar 78a is bent into a crank shape so as to be exposed to the outside through the busbar insertion hole 84.
- FIG. As shown in FIG. As shown in FIG.
- leg portions 88 projecting outward in the form of rectangular flat plates are provided on both left and right sides of the front end portion of the upper case 76b.
- leg portions 88 projecting outward in the form of rectangular flat plates are provided on the front sides of both the left and right ends of the upper case 76b at portions extending in the left-right direction.
- a bolt insertion hole 90 having a circular cross section is provided through the central portion of each leg portion 88 .
- relay connector housings 94a, 94b, 94b, 94b, 94b, 94b, 94b, 94b, 94b, 94b, 94b, 94b and 94b are provided on the front right side of the ceiling wall portion 92 extending in the left-right direction at the rear end portion of the upper case 76b at positions corresponding to board-side connectors 140a to 140d, which will be described later.
- 94c and 94d are provided.
- Each of the four relay connector housings 94a to 94d has a rectangular tubular shape that protrudes upward from the ceiling wall portion 92 and opens vertically.
- a pair of busbar insertion holes 96, 96 are provided through the rear of the relay connector housing 94a.
- a rear end portion of a bus bar 78b provided in the lower case 76a is bent like a crank so as to be exposed to the outside through a bus bar insertion hole 96 (see FIG. 7).
- a connection portion 72a is formed by the rear end portion of the bus bar 78b exposed to the outside.
- a bus bar 78b provided in the lower case 76a has a distal end bent upward into an L shape and provided in the relay connector housing 94a.
- a relay connector 98a is configured by arranging tip portions of a pair of bus bars 78b, 78b in the relay connector housing 94a.
- the front end portion of the relay bus bar 110 bent into a crank shape is connected to the rear end portion of the bus bar 78b, and the rear end portion of the relay bus bar 110 is connected to the connection terminal 112 in the external connector 66a ( See Figure 5).
- 12V power is supplied from the external connector 66a.
- a pair of busbar insertion holes 100, 100 are also provided through the front-rear direction central portion of the ceiling wall portion 92 extending in the left-right direction at the rear end portion of the upper case 76b.
- a rear end portion of a busbar 78a disposed in the lower case 76a is bent in a crank shape so as to be exposed to the outside through a busbar insertion hole 100.
- the rear end portion of the bus bar 78a exposed to the outside constitutes a connection portion 72e.
- a pair of L-shaped bus bars 102, 102 are assembled to the rear side of the bus bar 78a disposed on the lower case 76a. More specifically, one end of the busbar 102 is bolted to the rear side of the busbar 78a, and the other end of the busbar 102 is bent upward into an L-shape and accommodated in the relay connector housing 94d. ing.
- a relay connector 98d is configured by housing the other ends of the pair of bus bars 102, 102 in the relay connector housing 94d.
- a cylindrical intermediate connector housing 104a is provided on the rear side of the intermediate connector housing 94b.
- the intermediate connector housing 104a has a tubular shape protruding upward from the top wall portion 92.
- a rod-shaped terminal 80a connected to one end of the wire harness 80 is accommodated in the relay connector housing 94b to form a relay connector 98b.
- a rod-shaped terminal 80a connected to the other end of the wire harness 80 is accommodated in the intermediate connector housing 104a to form an intermediate connector 106a.
- the intermediate connector 106a constitutes a connecting portion 72b.
- a pair of cylindrical intermediate connector housings 104b, 104b are provided on the rear side of the intermediate connector housing 94c.
- the intermediate connector housing 104b has a cylindrical shape protruding upward from the top wall portion 92. As shown in FIG. One ends of four bus bars 78c are bent upward into an L-shape to form a relay connector 98c in the relay connector housing 94c. A pair of intermediate connectors 106b, 106b are formed in the intermediate connector housing 104b by bending the other ends of the two bus bars 78c upward into an L-shape. The pair of intermediate connectors 106b, 106b constitute connecting portions 72c, 72d, respectively.
- Three cylindrical intermediate connector housings 104c are provided at the left end of the ceiling wall portion 92 extending in the left-right direction at the rear end of the upper case 76b.
- the intermediate connector housing 104c has a cylindrical shape protruding upward from the top wall portion 92. As shown in FIG.
- one end of a bus bar 78d connected to the bus bar 78a via a fuse 82 is bent upward into an L-shape.
- one end of a ground bus bar 108 connected to the ground potential is bent upward into an L-shape.
- each intermediate connector 106c is configured. Connection portions 72f, 72g, and 72h are configured by these three intermediate connectors 106c, respectively.
- the case 76 includes an upper case 76b and a lower case 76a.
- the case 76 accommodates an internal circuit including bus bars 78a to 78d and a fuse 82, which is an electric component.
- the case 76 has a base portion 118 to which the upper case 76 b and the lower case 76 a are assembled, and a standing plate portion 120 rising from the base portion 118 .
- four relay connectors 98a to 98d collectively protrude from a part of the base portion 118 of the case 76 of the branch circuit structure 12 (on the right side of the front end in this embodiment).
- the upright plate portion 120 has a rectangular flat plate shape, is connected to the rear end side of the side wall 122 of the upper case 76b, and protrudes upward beyond the top wall portion 92. is set. Notch portions 124 a , 124 b , 124 c , 124 d , 124 e , 124 f , 124 g , and 124 h having substantially rectangular cross-sections are provided at eight locations on the upright plate portion 120 .
- Connectors 66a and 66e for external connection which are connected to connection portions 72a and 72e arranged on base portion 118 via relay bus bars 110 and 114, are assembled and supported in notches 124a and 124e, respectively.
- the notches 124b to 124d and 124f to 124h are connected to the connection portions 72b to 72d and 72f to 72h arranged on the base portion 118, respectively.
- 66f-66h are assembled and supported.
- Bolt insertion holes 126 are provided at three locations on the upper portion of the upright plate portion 120 .
- the upright plate portion 120 After aligning the bolt insertion holes 126 of the upright plate portion 120 with the bolt fastening holes 26 of the branch circuit structure fixing portion 74 in the lid 62 , the upright plate portion 120 is brought into contact with the inner surface 70 of the lid 62 by tightening the bolts. It is designed to be fixed by By providing the upright portion 120 on the upper case 76b, it is possible to secure a large area that contacts the lid 62. As shown in FIG. Therefore, the fixing strength between the cover 62 and the case 76 of the branch circuit structure 12 can be improved. In addition, the upright plate portion 120 can be used to stably hold the external connectors 66a to 66h connected to the connection portions 72a to 72h arranged on the base portion 118. FIG. Therefore, it is possible to improve the space efficiency and connection stability of the external connection connector module 156, which will be described later.
- circuit board 130 is accommodated in the housing 14, and a board-side connector module 128, which will be described later, is mounted on the circuit board 130.
- the circuit board 130 is held by a metal holding plate 132 having a rectangular flat plate shape.
- the circuit board 130 has a substantially rectangular flat plate shape made of a known insulating material such as glass epoxy resin, and a power supply pattern is formed on the circuit board 130 by printed wiring (not shown).
- circuit board 130 mounts an on-board charger.
- the metal holding plate 132 is preferably made of a metal having good thermal conductivity, and may be made of relatively lightweight aluminum, an aluminum alloy, or the like.
- connection portions 134 Two pairs of connection sites 134 , 134 are provided on the circuit board 130 .
- Each connection portion 134 has an insulating terminal fixing portion 134a projecting from the circuit board 130 and a terminal 134b.
- the terminal 134b is bent in an L shape, and one end is connected to the printed wiring of the circuit board 130 by soldering or the like.
- the other end of the terminal 134b is placed on the projecting end face of the terminal fixing portion 134a.
- One side (right side) of the pair of connection portions 134 , 134 is supplied with power of, for example, 12 V from the circuit board 130 .
- the other (left) set of the pair of connection parts 134 , 134 is connected to, for example, a battery to supply high voltage power to the circuit board 130 .
- the holding plate 132 is made of die-cast aluminum, for example.
- a circuit board 130 is held on the right side of the holding plate 132 .
- a transformer 136 is held on the left side of the holding plate 132 .
- the transformer 136 is connected to the circuit board 130 by a connection structure (not shown).
- a transformer 136 is used to transform the high voltage of the battery to the desired voltage.
- a board-side connector accommodating portion 138 in the form of a rectangular frame is provided at the rear end portion on the right side of the holding plate 132 so as to protrude rearward.
- the board-side connector accommodating portion 138 accommodates four integrated board-side connectors 140 a, 140 b, 140 c, and 140 d that constitute the board-side connector module 128 .
- the peripheral wall on the rear side of the board-side connector accommodating portion 138 protrudes upward with a larger projection dimension than the peripheral walls of other portions.
- the peripheral wall on the rear side constitutes a protective wall portion 142 that surrounds the outer peripheral wall portions of the four board-side connectors 140 a to 140 d that constitute the board-side connector module 128 .
- the protective wall portion 142 can suppress or prevent deformation when the board-side connectors 140a to 140d and the relay connectors 98a to 98d are fitted. As a result, it is possible to contribute to securing a stable connection state and durability between the board-side connectors 140a to 140d and the relay connectors 98a to 98d.
- fixed legs 144 project outward from both ends of the board-side connector accommodating portion 138 in the left-right direction. Further, leg portions 146 are provided at six locations on the outer peripheral edge portion of the holding plate 132 .
- ⁇ Board-side connector module 128> The four board-side connectors 140 a to 140 d are integrated to form a board-side connector module 128 . Leg portions 148 project outward from both ends of the board-side connector module 128 in the left-right direction. Board-side connector module 128 is fixed to holding plate 132 by bolting legs 148 to fixing legs 144 of holding plate 132 .
- the four board-side connectors 140 a to 140 d constituting the board-side connector module 128 are mounted on the circuit board 130 mounted on the holding plate 132 . More specifically, the board-side connectors 140a and 140d are bolted and connected to a terminal 134b on the connecting portion 134 via a pair of relay terminals 150 and 150 bent into a crank shape.
- the board-side connector 140b is connected to a printed wiring connected to a low-voltage power supply line in the circuit board 130 via a relay connector 152. As shown in FIG. Further, the board-side connector 140c is connected to a printed wiring connected to an AC power supply line in the circuit board 130 via an electric wire 154 with a terminal.
- the case 76 of the branch circuit structure 12 is fixed to the inner surface 70 of the lid 62 .
- External connectors 66 a to 66 h protruding from the inner surface 70 of the lid 62 are connected to connection portions 72 a to 72 h provided in the internal circuit of the branch circuit structure 12 .
- the connection terminal 112 of the external connection connector 66a is connected to the connection portion 72a using the relay bus bar 110 .
- the external connection connector module 156 including the external connection connectors 66a to 66h, the cover 62 and the branch circuit structure 12 is configured.
- the branch circuit structure 12 of the connector module 156 for external connection is inserted inside from the opening 54 of the housing main body 16 .
- the bolt insertion holes 34 provided in the lid 62 of the connector module 156 for external connection are aligned with the bolt fastening holes 26 provided in the periphery of the opening 54 , and the lid 62 is attached to the housing body 16 . bolt it against.
- the leg portion 88 provided on the branch circuit construct 12 is aligned with the branch circuit construct supporting portion 30 projecting from the bottom wall 20 of the housing body 16 and bolted.
- the battery high voltage connector 44 and a pair of relay bus bars 86 are prepared.
- the relay bus bar 86 is connected to the branch circuit component connection portion 50 b of the bus bar 50 accommodated and arranged in the battery high voltage connector 44 .
- the battery high voltage connector 44 configured in this manner is fixed to the battery high voltage connector support portion 42 provided in the housing body 16 .
- the relay bus bar 86 is connected to the bus bar 78 a provided in the branch circuit structure 12 .
- the board-side connector module 128 is prepared.
- the board-side connector module 128 is configured by mounting a circuit board 130 and a transformer 136 on which an on-board charger is mounted on a holding plate 132 .
- a board-side connector module 128 composed of integrated board-side connectors 140a to 140d is accommodated and fixed in a board-side connector accommodating portion 138 provided on the rear right side of the holding plate 132. As shown in FIG. Each board-side connector 140a to 140d is connected to the printed wiring of the circuit board 130 via a relay terminal 150, a relay connector 152, and an electric wire 154 with terminals. Then, the holding plate 132 holding the circuit board 130 on which the board-side connector module 128 is mounted and the transformer 136 are assembled to the branch circuit structure 12 housed in the housing body 16 from above.
- the leg portion 146 of the holding plate 132 is placed on the holding plate support portion 24 projecting from the bottom wall 20 of the housing body 16 and fixed by bolting.
- the holding plate 132 is attached to the housing 14 so as to be heat-transferable by bolting the holding plate 132 to the holding plate support portion 24 provided on the metal housing body 16 .
- a heat dissipation path for transferring heat generated in the circuit board 130 to the housing 14 via the holding plate 132 made of metal, which has a higher thermal conductivity than synthetic resin or the like, can be constructed. Therefore, it is particularly useful when an electronic device such as a DC/DC converter or an on-board charger, which is likely to generate heat, is mounted on the circuit board 130 .
- the electric power supplied to the circuit board 130 via the board-side connector 140d is converted by the board-side connector module 128 and transferred from the other board-side connectors 140a-140c to the relay connectors 98a-98c of the branch circuit structure 12. is output to
- the relay connectors 98a to 98c are connected to connectors connected to various devices (not shown) from the external connectors 66a to 66h via connection portions 72a to 72h and relay terminals (for example, relay bus bars 110 and 114).
- the electric connection box 10 shown in is completed.
- the electrical connection box 10 is used with the battery fixing portion 32 of the housing 14 fixed to a battery housing (not shown).
- the electrical connection box 10 of the present disclosure having such a structure, eight through holes 64 are provided in the lid 62 that closes the opening 54 of the housing 14 .
- External connectors 66 a to 66 h are attached to the through holes 64 , and the external connectors 66 a to 66 h protrude from the outer surface 68 of the lid 62 .
- the branch circuit structure 12 fixed to the inner surface 70 of the lid 62 is provided with eight connection portions 72a to 72h, which are connected to the corresponding connection terminals of the external connectors 66a to 66h. It has become.
- both the branch circuit structure 12 and the external connection connectors 66a to 66h are fixed to the same lid body 62, when connecting the branch circuit structure 12 and the external connection connectors 66a to 66h, dimensional tolerance can be reduced.
- electric wires are not required. As a result, it is possible to reduce the work man-hours and the number of parts.
- the branch circuit structure 12 and the external connection connectors 66a to 66h are assembled to the lid 62 to form the external connection connector module 156.
- FIG. the external connection connector module 156 can be configured in advance by assembling the branch circuit structure 12 and the external connection connectors 66a to 66h to the lid 62 before being assembled in the housing 14.
- FIG. when assembling the branch circuit structure 12, the external connection connectors 66a to 66h, and the cover 62 to the housing 14, the work of assembling the external connection connector module 156 into the opening 54 of the housing 14 is sufficient. can be done.
- the branch circuit structure 12, the external connection connectors 66a to 66h, and the cover 62 are individually assembled to the housing 14, and the branch circuit structure 12 and the external connection connectors 66a to 66a are assembled separately.
- 66h are not required to be individually connected with electric wires. Therefore, it is not necessary to secure a working space, and it is possible to save the space of the electrical connection box 10 and improve workability.
- the circuit board 130 connected to the branch circuit structure 12 may be accommodated within the same housing 14 . Even in such a case, the board-side connector module 128 integrated with the board-side connectors 140a to 140d is mounted on the circuit board 130, and a part of the base portion 118 is mounted on the branch circuit structure 12.
- Relay connectors 98a to 98d are provided, which are collectively protruded from and connected to the board-side connectors 140a to 140d, respectively. By collectively connecting the relay connectors 98a to 98d to the board-side connectors 140a to 140d, the circuit board 130 and the branch circuit structure 12 can be connected.
- the number of parts and man-hours for connection work can be reduced as compared with the conventional structure in which electric wires are required for connection between the circuit board and the branch circuit structure. Furthermore, since it is not necessary to secure a work space between the circuit board 130 and the branch circuit structure 12, the space of the electric junction box 10 can be saved.
- the number of board-side connectors 140a to 140d and the number of relay connectors 98a to 98d are four, respectively. is. Any number and shape of connectors can be used for the external connection connectors 66a to 66h.
- the branch circuit structure 12 has the base portion 118 and the upright plate portion 120, but the shape of the branch circuit structure 12 is not limited to this. Any shape can be adopted as long as it can be fixed to the cover provided with the connector and the connection portion can be connected to the connection terminal of the external connector.
- the seal member 58 is sandwiched between the contact surfaces of the opening 54 and the cover 62, but it may be omitted depending on the required waterproof performance.
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- Casings For Electric Apparatus (AREA)
Abstract
Description
最初に、本開示の実施態様を列記して説明する。
本開示の電気接続箱は、
(1)バッテリから給電される電力を、各種機器に分配するための分岐回路構成体と、前記分岐回路構成体を収容する筐体と、前記筐体の側壁を貫通する開口部と、前記開口部を塞いで前記側壁に固定される蓋体と、前記蓋体を板厚方向に貫通する複数の貫通穴に装着されて前記蓋体の外面から突出する複数の外部接続用コネクタと、前記蓋体の内面に前記分岐回路構成体が固定されて、前記分岐回路構成体に設けられた複数の接続部位が、対応する各前記外部接続用コネクタの接続端子に接続されており、前記複数の外部接続用コネクタと前記蓋体と前記分岐回路構成体を含んで外部接続用コネクタモジュールが構成されている、電気接続箱である。
本開示の電気接続箱の具体例を、以下に図面を参照しつつ説明する。なお、本開示は、これらの例示に限定されるものではなく、特許請求の範囲によって示され、特許請求の範囲と均等の意味および範囲内でのすべての変更が含まれることが意図される。
以下、本開示の実施形態1の電気接続箱10について、図1から図8を参照しつつ説明する。電気接続箱10は、例えば電気自動車やハイブリッド自動車等の車両(図示せず)に搭載され、バッテリ(図示せず)から給電される電力を、分岐回路構成体12を介して各種機器に分配する。また、電気接続箱10は、分岐回路構成体12を収容する筐体14を有している。なお、電気接続箱10は、任意の向きで配置することができるが、以下では、上下方向,左右方向,前後方向を、図中に示す上下方向,左右方向および前後方向を基準として説明する。また、複数の同一部材については、一部の部材にのみ符号を付し、他の部材については符号を省略する場合がある。
筐体14は、金属製であり、筐体14は、例えばアルミダイキャスト製である。図1~図2に示すように、筐体14は、上方に向かって開口する矩形の有底箱形状を有する筐体本体16と、筐体本体16の上方開口部を覆蓋するカバー部18を備えている。筐体本体16は、底壁20と、底壁20の周縁部から上方に向かって突出する側壁22を有している。図2および図4に示すように、底壁20の6箇所には、円筒形状の保持プレート支持部24が突設されている。保持プレート支持部24の突出寸法は、側壁22の突出寸法のおよそ半分とされている。保持プレート支持部24は、突出先端部に向かって徐々に小径とされた先細構造となっている。保持プレート支持部24の突出先端部には、円形断面のボルト締結穴26が上方に開口して形成されている。保持プレート支持部24は、外周面から外方に向かって突出して、側壁22あるいは底壁20に連結された平板状の補強プレート部28が設けられている。加えて、筐体14の底壁20の4箇所には、円筒形状の分岐回路構成体支持部30が突設されている。分岐回路構成体支持部30の突出寸法は、側壁22の突出寸法の1/10以下とされている。分岐回路構成体支持部30の突出先端部には、円形断面のボルト締結穴26が上方に開口して形成されている。
図3に示すように、バッテリ高圧コネクタ44は、矩形平板状の固定部46を有している。固定部46には、対角の2箇所にボルト挿通孔34が貫設されている。固定部46の中央部には、前方および後方に向かって突出し左右方向に離隔配置された一対の角筒状の端子保持突部48,48が設けられている。各端子保持突部48内にはそれぞれL字状に屈曲形成されたバスバー50が配設されている。各端子保持突部48の前端部にはそれぞれバスバー50のバッテリ接続部50aが露出されており、各端子保持突部48の後端部にはそれぞれバスバー50の分岐回路構成体接続部50bが露出されている(図2参照)。分岐回路構成体接続部50bには、ボルト挿通孔52が板厚方向に貫設されている。
図4に示すように、筐体本体16の後方側の側壁22には、略全面に亘って切欠かれることにより後方および筐体本体16の内部に向かって開口して筐体本体16の側壁22を貫通する開口部54が設けられている。開口部54の周縁部の10箇所には、ボルト締結穴26が筐体本体16の側壁22を貫通して形成されている。開口部54の周縁部におけるボルト締結穴26の内側には、後方に向かって開口する凹溝状のシール部材収容部56が形成されている。シール部材収容部56内には、環状のゴム製のシール部材58が収容されている。すなわち、シール部材58は、筐体本体16の開口部54の外周縁部と後述する蓋体62との当接面間に挟持されるようになっている。この結果、シール部材58によって蓋体62で塞がれる筐体本体16の開口部54の防水性が向上されている。筐体本体16には、上方開口部から左右方向および前後方向外方に向かって延出する環状のフランジ状部60が設けられている。フランジ状部60には、周方向に離隔した14箇所にボルト締結穴26が設けられている。
筐体本体16の後方側の側壁22に貫設された開口部54は、蓋体62によって塞がれている。蓋体62は、矩形平板形状を有している。蓋体62において、開口部54の周縁部のボルト締結穴26に対応する位置には、ボルト挿通孔34が貫設されている。蓋体62のボルト挿通孔34を開口部54の周縁部のボルト締結穴26に位置合わせ後、図1に示すようにボルト締結することにより蓋体62が筐体14の後方側の側壁22に固定されるようになっている。図6に示すように、蓋体62には、蓋体62を板厚方向に貫通する複数(本実施形態では8個)の貫通穴64が設けられている。各貫通穴64に対して、外部接続用コネクタ66a,66b,66c,66d,66e,66f,66g,66hがそれぞれ装着されている。例えば図5に示すように、各外部接続用コネクタ66a~66hは、蓋体62にボルト締結されて保持された状態で蓋体62の外面68および内面70から厚さ方向外方に向かって突出している。これにより、蓋体62を利用して、ベース部118に配置される接続部位72a~72hに接続される外部接続用コネクタ66a~66hを安定して保持できる。それゆえ、後述する外部接続用コネクタモジュール156のスペース効率や接続安定性の向上を図ることができる。蓋体62の外面68から突出した外部接続用コネクタ66a~66hは、図示しない各種機器に接続されたコネクタと接続されるようになっている。また、図2,図5および図6に示すように、蓋体62の内面70から突出した外部接続用コネクタ66a~66hは、分岐回路構成体12に設けられた接続部位72a~72hと接続されるようになっている。さらに、図5に示すように、蓋体62の内面70には、左右方向に離隔する3箇所に略筒状の分岐回路構成体固定部74が突設されている。分岐回路構成体固定部74の突出先端部には、前方に向かって開口する円形断面形状のボルト締結穴26が形成されている。
図1および図2に示すように、筐体本体16の上方開口部を覆蓋するカバー部18は、下方に向かって開口する矩形浅底の有底箱形状を有している。カバー部18には、下方開口部から左右方向および前後方向外方に向かって延出する環状のフランジ状部75が設けられている。フランジ状部75には、筐体本体16のボルト締結穴26に対応した14箇所にボルト挿通孔34が設けられている。カバー部18が筐体本体16にボルト締結されることにより、筐体本体16の側壁22の上面に配設されたシールゴム73が、筐体本体16の側壁22の上面とカバー部18のフランジ状部75との間で挟持され、シール性が確保されている。
分岐回路構成体12は、例えば図7に示すように、車両搭載時において下方に位置するロアケース76aと上方に位置するアッパケース76bを備えており、ロアケース76aとアッパケース76bを含んでケース76が構成されている。ケース76は、絶縁性の合成樹脂を所定の形状に射出成形してなる。ケース76を構成する合成樹脂は、ガラスファイバー等のフィラーを含んでいてもよい。ケース76は、例えば図2に示すように平面視で略T字形状を有している。ケース76の内部には、例えば図7に示すように、前後方向に延び出すバスバー78aが配設されている。バスバー78aは、バッテリ高圧コネクタ44を介してバッテリに接続されて高電圧が印加される。バスバー78aの後方右側には、例えば12V電源に接続されるバスバー78bやAC電源に接続されるバスバー78cが配設されている。バスバー78bとバスバー78cの間には、後述する基板側コネクタモジュール128で生成された低電圧電源を基板側コネクタ140bから中継コネクタ98bを介して外部接続用コネクタ66bに伝達するためのワイヤハーネス80が収容されている。バスバー78aの後方左側には、バスバー78aに対して電気部品であるヒューズ82を介して接続されるバスバー78dが配設されている。
アッパケース76bは、平面視でロアケース76aよりやや大きい相似形状を有している。アッパケース76bもロアケース76aと相似の略T字形状を有している。アッパケース76bにおいて前方に向かって延び出す部位の前端部には、左右方向に離隔して一対のバスバー挿通孔84,84が貫設されている。図7に示すように、バスバー78aの前端部がクランク状に屈曲されてバスバー挿通孔84から外部に露出されるようになっている。図2に示すように、このバスバー78aの前端部に対してクランク状に屈曲形成された中継バスバー86の後端部を接続し、中継バスバー86の先端部をバッテリ高圧コネクタ44の分岐回路構成体接続部50bに接続する。これにより、バッテリからバスバー78aに高電圧が供給されるようになっている。例えば図5に示すように、アッパケース76bの前端部の左右両端側には、外方に向かって矩形平板形状で突出する脚部88が設けられている。また、アッパケース76bにおいて左右方向に向かって延び出す部位にも、左右両端部の前方側において外方に向かって矩形平板形状で突出する脚部88が設けられている。各脚部88の中央部には、円形断面形状のボルト挿通孔90が貫設されている。
ケース76は、アッパケース76bとロアケース76aを含んで構成されている。ケース76は、バスバー78a~78dと電気部品であるヒューズ82を含んで構成された内部回路を収容している。ケース76は、アッパケース76bとロアケース76aが組み付けられたベース部118と、ベース部118から立ち上がる立板部120を有している。また、分岐回路構成体12のケース76のベース部118の一部領域(本実施形態では前端側の右方側)には4個の中継コネクタ98a~98dが集約して突設されており、後述する4個の基板側コネクタ140a~140dにそれぞれ接続されてケース76内の内部回路に導通するようになっている。すなわち、筐体本体16内に分岐回路構成体12と後述する回路基板130を組み付けた状態で、各基板側コネクタ140a~140dが対応する各中継コネクタ98a~98dに一括して接続されるようになっている。
図5~7に示すように、立板部120は、矩形平板形状を有しており、アッパケース76bの側壁122の後端側に連結されて天壁部92を越えて上方に向かって突設されている。立板部120には、8箇所に略矩形断面形状の切欠部124a,124b,124c,124d,124e,124f,124g,124hが貫設されている。切欠部124aおよび124eにはそれぞれ、ベース部118に配置された接続部位72a,72eに中継バスバー110,114を介して接続される外部接続用コネクタ66a,66eが組み付けられて支持されている。また、切欠部124b~124dおよび124f~124hにはそれぞれ、ベース部118に配置された接続部位72b~72dおよび72f~72hに図示しない通電部品を介して接続される外部接続用コネクタ66b~66dおよび66f~66hが組み付けられて支持されている。立板部120の上部の3箇所には、ボルト挿通孔126が貫設されている。立板部120のボルト挿通孔126を蓋体62における分岐回路構成体固定部74のボルト締結穴26に位置合わせ後、ボルト締結することにより立板部120が蓋体62の内面70に接触して固定されるようになっている。アッパケース76bに立板部120を設けることにより、蓋体62に接触する面積を広く確保することができる。それゆえ、蓋体62と分岐回路構成体12のケース76との固定強度を向上させることができる。また、立板部120を利用して、ベース部118に配置される接続部位72a~72hに接続される外部接続用コネクタ66a~66hを安定して保持できる。それゆえ、後述する外部接続用コネクタモジュール156のスペース効率や接続安定性の向上を図ることができる。
筐体14内には、回路基板130が収容されており、回路基板130には、後述する基板側コネクタモジュール128が実装されている。図8に示すように、回路基板130は、金属製の矩形平板状の保持プレート132に保持されている。回路基板130は、例えばガラスエポキシ樹脂などの公知の絶縁材料で形成された略矩形の平板形状を有しており、回路基板130上には、図示しないプリント配線により給電パターンが形成されている。本実施形態では、回路基板130は、オンボードチャージャーを実装している。また、金属製の保持プレート132は熱伝導率の良い金属で形成することが好ましく、比較的軽量のアルミニウムやアルミニウム合金等で構成してもよい。回路基板130上には、2組の一対の接続部位134,134が設けられている。各接続部位134は、回路基板130に突設された絶縁性の端子固定部134aと、端子134bを有している。端子134bは、L字状に屈曲されて、一端部が回路基板130のプリント配線に半田付け等によって接続されている。端子134bの他端部は、端子固定部134aの突出端面上に載置されている。一対の接続部位134,134の一方側(右方側)の組は、回路基板130から例えば12V電源が給電されている。一対の接続部位134,134の他方側(左方側)の組には、例えばバッテリに接続されて回路基板130に高電圧電源が給電されている。
保持プレート132は、例えばアルミダイキャスト製とされている。保持プレート132の右方側には、回路基板130が保持されている。保持プレート132の左方側には、トランス136が保持されている。後述するように、保持プレート132は筐体14に対して伝熱可能に組み付けられていることから、回路基板130やトランス136で発生した熱を保持プレート132を介して筐体14に伝熱できる。それゆえ、電気接続箱10の放熱性の向上を図ることができ、トランス136も回路基板130に安定的に接続できる。トランス136は図示しない接続構造によって回路基板130に接続されている。トランス136を用いてバッテリの高電圧が所望の電圧に変圧されている。保持プレート132の右方側の後端部には、矩形枠体状の基板側コネクタ収容部138が後方に向かって突出して設けられている。基板側コネクタ収容部138には、基板側コネクタモジュール128を構成する一体化された4つの基板側コネクタ140a,140b,140c,140dが収容されるようになっている。基板側コネクタ収容部138の後方側の周壁はその他の部分の周壁よりも上方に向かって大きな突出寸法で突出している。この後方側の周壁によって、基板側コネクタモジュール128を構成する4つの基板側コネクタ140a~140dの外周壁部を囲う保護壁部142が構成されている。これにより、基板側コネクタモジュール128の他部材との干渉を抑制できる。また、基板側コネクタ140a~140dと中継コネクタ98a~98dとの嵌合時の変形を保護壁部142により抑制または阻止することができる。この結果、基板側コネクタ140a~140dと中継コネクタ98a~98dとの安定した接続状態の確保や耐久性の確保に寄与し得る。加えて、基板側コネクタ収容部138の左右方向両端部にはそれぞれ固定脚部144が外方に向かって突設されている。また、保持プレート132の外周縁部の6箇所には、脚部146が設けられている。
4つの基板側コネクタ140a~140dは一体化されて基板側コネクタモジュール128を構成している。基板側コネクタモジュール128の左右方向両端部にはそれぞれ脚部148が外方に向かって突設されている。基板側コネクタモジュール128は、脚部148を保持プレート132の固定脚部144に対してボルト締結することにより保持プレート132に固定されている。そして、基板側コネクタモジュール128を構成する4つの基板側コネクタ140a~140dは、保持プレート132に装着された回路基板130に実装されている。より詳細には、基板側コネクタ140a,140dはそれぞれ、クランク状に屈曲形成された一対の中継端子150,150を介して接続部位134上の端子134bにボルト締結され接続されている。また、基板側コネクタ140bは、中継用コネクタ152を介して回路基板130内の低圧電源ラインにつながるプリント配線に接続されている。さらに、基板側コネクタ140cは、端子付電線154を介して回路基板130内のAC電源ラインにつながるプリント配線に接続されている。
本開示の実施形態1の電気接続箱10の組立方法の概略について説明する。はじめに、筐体14を構成する筐体本体16とカバー部18を準備する。続いて、分岐回路構成体12と蓋体62と外部接続用コネクタ66a~66hを準備する。蓋体62の貫通穴64に外部接続用コネクタ66a~66hを装着後、外部接続用コネクタ66a~66hを蓋体62に対してボルト締結する。そして、蓋体62の内面70に設けられた分岐回路構成体固定部74のボルト締結穴26に対して、分岐回路構成体12の立板部120に設けられたボルト挿通孔126を位置合わせ後ボルト締結する。これにより、蓋体62の内面70に分岐回路構成体12のケース76が固定されるようになっている。そして、蓋体62の内面70から突出した外部接続用コネクタ66a~66hを、分岐回路構成体12の内部回路に設けられた接続部位72a~72hに対して接続する。例えば、外部接続用コネクタ66aの接続端子112を中継バスバー110を用いて接続部位72aに対して接続する。この結果、外部接続用コネクタ66a~66hと蓋体62と分岐回路構成体12を含んで外部接続用コネクタモジュール156が構成されるようになっている。
本明細書に記載された技術は上記記述および図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本明細書に記載された技術の技術的範囲に含まれる。
12 分岐回路構成体
14 筐体
16 筐体本体
18 カバー部
20 底壁
22 側壁
24 保持プレート支持部
26 ボルト締結穴
28 補強プレート部
30 分岐回路構成体支持部
32 バッテリ固定部
34 ボルト挿通孔
36 収容凹所
38 突部
40 バッテリ高圧コネクタ挿通孔
41 シールゴム
42 バッテリ高圧コネクタ支持部
44 バッテリ高圧コネクタ
46 固定部
48 端子保持突部
50 バスバー
50a バッテリ接続部
50b 分岐回路構成体接続部
52 ボルト挿通孔
54 開口部
56 シール部材収容部
58 シール部材
60 フランジ状部
62 蓋体
64 貫通穴
66a~66h 外部接続用コネクタ
68 外面
70 内面
72a~72h 接続部位
73 シールゴム
74 分岐回路構成体固定部
75 フランジ状部
76 ケース
76a ロアケース
76b アッパケース
78a~78d バスバー
80 ワイヤハーネス
80a 端子
82 ヒューズ(電気部品)
84 バスバー挿通孔
86 中継バスバー
88 脚部
90 ボルト挿通孔
92 天壁部
94a~94d 中継コネクタハウジング
96 バスバー挿通孔
98a~98d 中継コネクタ
100 バスバー挿通孔
102 バスバー
104a~104c 中間コネクタハウジング
106a~106c 中間コネクタ
108 グランドバスバー
110 中継バスバー(中継端子)
112 接続端子
114 中継バスバー(中継端子)
116 接続端子
118 ベース部
120 立板部
122 側壁
124a~124h 切欠部
126 ボルト挿通孔
128 基板側コネクタモジュール
130 回路基板
132 保持プレート
134 接続部位
134a 端子固定部
134b 端子
136 トランス
138 基板側コネクタ収容部
140a~140d 基板側コネクタ
142 保護壁部
144 固定脚部
146 脚部
148 脚部
150 中継端子
152 中継用コネクタ
154 端子付電線
156 外部接続用コネクタモジュール
Claims (5)
- バッテリから給電される電力を、各種機器に分配するための分岐回路構成体と、
前記分岐回路構成体を収容する筐体と、
前記筐体の側壁を貫通する開口部と、
前記開口部を塞いで前記側壁に固定される蓋体と、
前記蓋体を板厚方向に貫通する複数の貫通穴に装着されて前記蓋体の外面から突出する複数の外部接続用コネクタと、
前記蓋体の内面に前記分岐回路構成体が固定されて、前記分岐回路構成体に設けられた複数の接続部位が、対応する各前記外部接続用コネクタの接続端子に接続されており、
前記複数の外部接続用コネクタと前記蓋体と前記分岐回路構成体を含んで外部接続用コネクタモジュールが構成されている、
電気接続箱。 - 前記筐体の前記開口部の外周縁部と前記蓋体との当接面間に挟持されるシール部材を有する、請求項1に記載の電気接続箱。
- 前記分岐回路構成体が、バスバーと電気部品を含んで構成された内部回路と、該内部回路を収容するケースとを含み、
前記ケースが、ベース部と該ベース部から立ち上がる立板部を有し、前記立板部が前記蓋体の前記内面に接触して固定されている、請求項1または請求項2に記載の電気接続箱。 - 前記接続部位が前記ベース部に配置され、前記接続部位に接続される前記外部接続用コネクタが前記蓋体に保持されている、請求項3に記載の電気接続箱。
- 前記筐体に収容される回路基板と、
前記回路基板に実装された複数の基板側コネクタが一体化された基板側コネクタモジュールと、をさらに備え、
前記分岐回路構成体が、前記ケースの前記ベース部に集約して突設し、複数の前記基板側コネクタにそれぞれ接続されて前記内部回路に導通する複数の中継コネクタを有している、請求項3または請求項4に記載の電気接続箱。
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JP2005348495A (ja) * | 2004-06-02 | 2005-12-15 | Auto Network Gijutsu Kenkyusho:Kk | 電源分配ボックス |
JP2006187125A (ja) * | 2004-12-27 | 2006-07-13 | Auto Network Gijutsu Kenkyusho:Kk | 電気接続箱 |
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JP2005295724A (ja) * | 2004-04-01 | 2005-10-20 | Sumitomo Wiring Syst Ltd | 電気接続箱 |
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