WO2025121205A1 - Device module - Google Patents

Abstract

This device module is provided with a relay (100) that comprises: a relay body (140) including a fixed terminal (160) and a movable terminal (170); and a drive unit (120). The fixed terminal is electrically connected to a current path. The movable terminal contacts and separates from the fixed terminal. The drive unit displaces the movable terminal to switch between conduction and disconnection between the movable terminal and the fixed terminal. The relay includes a heat transfer member (180) and a housing (190). The heat transfer member forms a part of the current path and transfers heat. The housing has a first wall (191) on which the fixed terminal is provided, and second walls (193, 197) different from the first wall. A first extension part (181), which is a part of the heat transfer member, is connected to the fixed terminal. A second extension part (182), which is the remainder of the heat transfer member, extends along the second walls and is fixed to the second walls.

Description

Equipment Module CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on patent application No. 2023-205446 filed in Japan on December 5, 2023, and the contents of the original application are incorporated by reference in their entirety.

The disclosures herein relate to equipment modules.

The electrical unit of Patent Document 1 has a relay, a cooling member, a first bus bar, a second bus bar, and a housing. The relay is housed in the housing. The relay is electrically connected to the first bus bar and the second bus bar. The cooling member includes a recess that partially receives the first bus bar and the second bus bar.

US Patent Application Publication No. 2020/0136326

The cooling member in Patent Document 1 extends beyond the sides of the housing. The housing has a flange that extends away from the main body. A mounting member extends from the flange toward the cooling member. The cooling member is fixed to the flange via the mounting member. In Patent Document 1, heat from the relay is transferred to the cooling member via the flange and the mounting member, so the heat cannot be efficiently dissipated to the cooling member.

The objective of this disclosure is to provide an equipment module that can efficiently dissipate heat from the relay body to a heat transfer member.

According to one aspect of the present disclosure, an instrument module includes:
An equipment module including a relay having a relay body including a fixed terminal electrically connected to a current path and a movable terminal that contacts and separates from the fixed terminal, and a drive unit that displaces the movable terminal to switch between energization and interruption with respect to the fixed terminal,
The relay further:
A heat transfer member that forms a part of a current path and transfers heat;
The housing includes a fixed terminal, a movable terminal, and a drive unit.
The housing has a first wall on which the fixed terminal is provided;
a second wall different from the first wall;
A first extension portion that is a part of the heat transfer member is connected to the fixed terminal,
A second extension portion of the heat transfer member extends along and is secured to the second wall.

This allows the heat from the relay body to be efficiently dissipated to the heat transfer member.

The reference numbers in parentheses in the appended claims merely indicate the corresponding relationship to the configurations described in the embodiments below, and do not limit the technical scope in any way.

FIG. 2 is a circuit diagram showing the electrical configuration of a high voltage J/B. FIG. 2 is a plan view of the high voltage J/B. 3 is a cross-sectional view taken along line III-III shown in FIG. 2. FIG. 5 is a cross-sectional view taken along line VV shown in FIG. 4. FIG. 11 is a schematic diagram of a relay according to a second embodiment. 7 is a cross-sectional view taken along line VII-VII in FIG. 6. FIG. 11 is a schematic diagram showing a cross section of an equipment module according to a second embodiment. FIG. 11 is a schematic diagram of a relay according to a third embodiment. FIG. 13 is a schematic diagram showing an example of a cross section of a high voltage J/B in the third embodiment. FIG. 13 is a schematic diagram showing an example of a cross section of a high voltage J/B in the fourth embodiment. FIG. 13 is a schematic diagram of a relay according to a fifth embodiment. FIG. 13 is a schematic diagram of a relay according to a sixth embodiment.

Below, several embodiments for implementing the present disclosure will be described with reference to the drawings. In each embodiment, parts corresponding to matters described in the preceding embodiment may be given the same reference symbols, and duplicated descriptions may be omitted. In cases where only a portion of the configuration is described in each embodiment, the other embodiment described previously may be applied to the other parts of the configuration.

In addition to combinations of parts that are explicitly stated as possible in each embodiment, it is also possible to partially combine embodiments together, embodiments and variations, and variations together, even if not explicitly stated, provided that no particular problems arise with the combination.

First Embodiment
A high-voltage junction box (hereinafter, high-voltage J/B) 10 according to the first embodiment shown in Fig. 1 is used in an electric vehicle such as a BEV (Battery Electric Vehicle). The high-voltage J/B 10 is mounted on the electric vehicle together with a battery device 2, an inverter 3, a charging inlet 4, etc. The high-voltage J/B 10 is electrically connected to the battery device 2, the inverter 3, the charging inlet 4, etc. The high-voltage J/B 10 may be referred to as an equipment module. The battery device 2 may be referred to as a power supply device.

The battery device 2 is a power storage device that stores power for propelling the electric vehicle. The battery device 2 includes a chargeable and dischargeable secondary battery such as a lithium-ion battery or a nickel-metal hydride battery. The inverter 3 is electrically connected to a motor generator for propulsion. The inverter 3 controls the rotation speed and torque of the motor generator. A charging cable from a charging stand provided outside the vehicle is connected to the charging inlet 4. DC power for rapid charging the battery ES is applied to the charging inlet 4. The charging inlet 4 supplies the DC power input from the charging stand to the high-voltage J/B 10.

The high voltage J/B 10 includes a power control circuit 70, a fixing base 80 to which the power control circuit 70 is fixed, and a heat dissipation sheet 90. The power control circuit 70 includes multiple current paths. The power control circuit 70 switches between the multiple current paths. The power control circuit 70 includes pairs of battery connection lines 15P, 15N, inverter connection lines 16P, 16N, and charging lines 17P, 17N as current paths. In addition, the power control circuit 70 includes two system main relays 1P, 1N, and two DC charging relays 2P, 2N. Elements with a "P" attached to the symbol are components on the positive side. Elements with a "N" attached to the symbol are components on the negative side (ground side).

The battery connection lines 15P, 15N, the inverter connection lines 16P, 16N, and the charging lines 17P, 17N are formed of copper plate members such as bus bars. The battery connection lines 15P, 15N, the inverter connection lines 16P, 16N, and the charging lines 17P, 17N are capable of passing large currents. These form multiple current paths in the power control circuit 70. The battery connection lines 15P, 15N are current paths electrically connected to the battery device 2. The inverter connection lines 16P, 16N are current paths electrically connected to the inverter 3. The charging lines 17P, 17N are current paths electrically connected to the charging inlet 4. Power is supplied to the charging lines 17P, 17N to charge the battery device 2. The battery connection lines 15P, 15N, the inverter connection lines 16P, 16N, and the charging lines 17P, 17N may be collectively referred to as wiring 15, 16, 17. Wiring 15, 16, and 17 are formed from copper plate members such as bus bars.

System main relay 1P is located between battery connection line 15P and inverter connection line 16P. System main relay 1N is located between battery connection line 15N and inverter connection line 16N. System main relays 1P, 1N switch the state of the current path between the battery device 2 and inverter 3 between a conducting state (ON) and a non-conducting state (OFF).

The DC charging relay 2P is located between the system main relay 1P and the charging line 17P. The DC charging relay 2P is connected in series to the system main relay 1P. The DC charging relay 2N is located between the system main relay 1N and the charging line 17N. The DC charging relay 2N is connected in series to the system main relay 1N. The DC charging relays 2P, 2N switch the state of the current path between the battery device 2 and the charging inlet 4 between a conducting state (ON) and a non-conducting state (OFF).

The operation of the system main relays 1P, 1N and the DC charging relays 2P, 2N is individually controlled by a control device installed in the vehicle. The control device is an on-board ECU (Electronic Control Unit). The control device has an arithmetic processing circuit including a processor, RAM (Random Access Memory), and storage. The control device outputs control signals that control on/off switching to each of the system main relays 1P, 1N and the DC charging relays 2P, 2N.

The power control circuit 70 includes two relays 100 and wiring 15, 16, and 17. One relay 100 is an integrated configuration of a positive side system main relay 1P and a DC charging relay 2P. The other relay 100 is an integrated configuration of a negative side system main relay 1N and a DC charging relay 2N. The relay 100 switches the multiple wiring 15, 16, and 17 in accordance with control signals obtained from the control device. A large DC current of tens to hundreds of amperes flows through these wiring 15, 16, and 17.

<Configuration of high voltage J/B>
Next, the configuration of the high voltage J/B 10 will be described with reference to Figures 2 and 3. Note that each drawing shows the components of the high voltage J/B 10 in a schematic manner. In the following, the three mutually orthogonal directions are referred to as the X direction, the Y direction, and the Z direction. In the drawings, the indication of "directions" is omitted, and the directions are simply indicated as X, Y, and Z. The high voltage J/B 10 is provided in the body of the vehicle. As an example, the high voltage J/B 10 is disposed under the floor of the passenger compartment.

The high voltage J/B 10 has a relay 100, wiring 15, 16, 17, a fixing base 80, and a heat dissipation sheet 90. The fixing base 80 has a roughly rectangular parallelepiped shape. The fixing base 80 has a mounting surface 81 on which the relay 100 and wiring 15, 16, 17 are mounted, and a mounting surface on the reverse side. A heat dissipation sheet 90 is provided on the mounting surface 81. The relay 100 is mounted on the mounting surface 81 via the heat dissipation sheet 90. The heat dissipation sheet 90 is a member for reducing the thermal resistance between the relay 100 and the fixing base 80. A heat dissipation gel or the like can be used for the heat dissipation sheet 90. The heat dissipation sheet 90 is also sometimes referred to as a thermal interface material.

The direction in which the relay 100 and the fixed base 80 are aligned corresponds to the Z direction. The relay 100 is fixed to the fixed base 80 in the Z direction. The mounting surface 81 and the placement surface are arranged apart in the Z direction. The placement surface is the surface that faces the floor of the vehicle compartment. The high voltage J/B 10 is fixed to the vehicle by fixing the placement surface to the floor of the vehicle compartment. The fixed base 80 is made primarily of insulating resin.

<Relay configuration>
FIG. 4 is a schematic diagram of the relay 100. FIG. 5 is a cross-sectional view of the relay 100. The relay 100 is composed of an electromagnetic actuator 120, a relay body 140, a housing 190, and the like. The electromagnetic actuator 120 and the relay body 140 are housed in the housing 190. The electromagnetic actuator 120 may be referred to as a drive unit. The reciprocating direction of the electromagnetic actuator 120 in the relay 100 corresponds to the axial direction of a rod 129 described later. The Y direction is defined along the reciprocating direction of the electromagnetic actuator 120. The Y direction corresponds to the direction in which a first storage chamber 190A and a second storage chamber 190B described later are aligned. The direction perpendicular to the axis along the Y direction may be referred to as the perpendicular direction. The axial direction of the rod 129 can be rephrased as the extension direction of the rod 129.

The electromagnetic actuator 120 is aligned with the relay body 140 in the axial direction. For convenience, the side of the relay body 140 relative to the electromagnetic actuator 120 is referred to as the upper direction, and the side of the electromagnetic actuator 120 relative to the relay body 140 is referred to as the lower direction. The electromagnetic actuator 120 is mechanically connected to the relay body 140. The electromagnetic actuator 120 supplies the driving force for switching operation to the relay body 140.

The electromagnetic actuator 120 has two actuator parts 120A and 120B that function as linear actuators. The first actuator part 120A and the second actuator part 120B can operate independently of each other. The electromagnetic actuator 120 is composed of a fixed core 121, a movable core 126, a rod 129, an excitation coil 130, a coil housing 132, a return spring 133, a damper sheet 135, and a storage cylinder 136. Of these components, the movable core 126, the rod 129, the excitation coil 130, the coil housing 132, the return spring 133, the damper sheet 135, and the storage cylinder 136 are provided in each of the actuator parts 120A and 120B.

The fixed core 121 is made of a magnetic material such as iron. The fixed core 121 has a base portion 122 and two cylinder portions 123. The base portion 122 is formed in the shape of a plate with a thin thickness in the axial direction. The fixed core 121 is arranged in a position facing the relay body 140 with the main surface of the base portion 122 aligned with the XZ plane. The base portion 122 has a through hole formed therein that communicates with the spring accommodating hole 123A described below.

Each cylinder portion 123 is formed in a cylindrical shape. Two cylinder portions 123 are integrally connected to the main surface of the base portion 122 on the electromagnetic actuator 120 side. The two cylinder portions 123 are arranged in the X direction with a gap between them. The cylinder portion 123 is provided with a spring accommodating hole 123A and a first opposing surface 124. The spring accommodating hole 123A is a hole in which the return spring 133 is accommodated. The spring accommodating hole 123A is formed by the inner wall surface of the cylinder portion 123. The spring accommodating hole 123A is connected to a through hole formed in the base portion 122. The diameter of the through hole is smaller than the diameter of the spring accommodating hole 123A. The first opposing surface 124 is formed by the lower end surface of the cylinder portion 123 facing downward.

The movable core 126 is cylindrically formed from a magnetic material such as iron. The outer diameter of the movable core 126 is substantially the same as or slightly smaller than the outer diameter of the cylinder portion 123. The movable core 126 is disposed below the cylinder portion 123 so as to be coaxial with the cylinder portion 123. The movable core 126 is provided with a rod retaining hole 127 and a second opposing surface 128. The rod retaining hole 127 is a hole for retaining a rod 129. The rod retaining hole 127 is formed by the inner peripheral wall surface of the movable core 126. The second opposing surface 128 is formed by the upper end surface of the movable core 126 facing upward. A gap is interposed between the second opposing surface 128 and the first opposing surface 124. The fixed core 121 and the movable core 126 face each other via a gap.

The rod 129 is formed into a long, thin cylinder shape from a non-magnetic metal material or the like. The rod 129 is inserted into a through hole of the fixed core 121, including the spring accommodating hole 123A. The lower portion of the rod 129 is fitted into the rod holding hole 127. The rod 129 moves back and forth along the axial direction together with the movable core 126. The upper portion of the rod 129 passes through the spring accommodating hole 123A and protrudes upward from the base portion 122. The upper portion of the rod 129 is housed in the relay body 140.

The excitation coil 130 is formed by winding a thin wire material such as copper around the coil bobbin 131. The coil bobbin 131 is formed into a cylindrical or rectangular tube shape from a resin material. The excitation coil 130 is arranged so as to surround the outer periphery of the cylinder portion 123 and the movable core 126. Electricity is applied to the excitation coil 130 in accordance with a control signal output from the control device. When electricity is applied to the excitation coil 130, it becomes excited, generating a magnetic flux along the axial direction on the inner periphery side.

The coil housing 132 is made of a magnetic material such as stainless steel having ferromagnetic properties and is shaped like a bottomed container. The coil housing 132 is disposed below the base portion 122. The upper edge of the coil housing 132 is in contact with the outer edge of the base portion 122. The excitation coil 130 is housed inside the coil housing 132.

The return spring 133 is made of a metal wire wound in a spiral shape. The return spring 133 is arranged on the outer periphery of the rod 129. The return spring 133 is accommodated in the spring accommodation hole 123A in a state where it is compressed in the axial direction between the cylinder portion 123 and the movable core 126. The return spring 133 biases the movable core 126 in the axial direction away from the cylinder portion 123 by its restoring force.

The damper sheet 135 is formed into a thin disk shape using a rubber material, a resin material, or the like. The damper sheet 135 is disposed below the movable core 126. The damper sheet 135 comes into contact with the lower end surface of the movable core 126 facing downward, and restricts the movement of the movable core 126 in a direction away from the cylinder portion 123.

The accommodating cylinder 136 is made of a metal material and has a cylindrical shape with a bottom. The accommodating cylinder 136 accommodates the movable core 126 and the damper sheet 135. The upper edge of the peripheral wall of the accommodating cylinder 136 is fitted onto the outer peripheral wall surface of the cylinder portion 123. The inner peripheral wall surface of the accommodating cylinder 136 supports the outer peripheral wall surface of the movable core 126 so that it can slide freely. The movable core 126 can reciprocate along the axial direction within the accommodating cylinder 136.

A magnetic circuit is formed in the electromagnetic actuator 120. The magnetic circuit allows the magnetic flux generated by the excitation coil 130 to pass through efficiently. The magnetic circuit is formed by the fixed core 121, the movable core 126, the coil housing 132, and the containing cylinder 136 so as to circulate around the excitation coil 130. When the excitation coil 130 is energized and magnetic flux is generated in the magnetic circuit, the movable core 126 is attracted to the fixed core 121 by magnetic force. It moves upward so as to reduce the gap between the fixed core 121 and the movable core 126. When the excitation coil 130 is de-energized and the magnetic flux generated in the magnetic circuit disappears, the movable core 126 moves downward by the biasing force of the return spring 133. By providing two magnetically independent magnetic circuits and excitation coils 130 in the electromagnetic actuator 120, the first actuator unit 120A and the second actuator unit 120B can move back and forth individually.

The relay main body 140 has two relay units 140A, 140B that switch between allowing and blocking the passage of current between the fixed terminal 160 and the movable terminal 170. For convenience, the relay unit mechanically connected to the first actuator unit 120A is referred to as the first relay unit 140A. The relay unit mechanically connected to the second actuator unit 120B is referred to as the second relay unit 140B. The first relay unit 140A and the second relay unit 140B can switch between allowing and blocking the passage of current independently of each other. Specifically, even if the first relay unit 140A allows the passage of current, the second relay unit 140B can block the passage of current. Similarly, even if the first relay unit 140A blocks the passage of current, the second relay unit 140B can allow the passage of current.

The relay body 140 is composed of a pressure spring 145, a pressure plate 146, a spring holder 147, a movable terminal 148, a sealed case 150, a fixed terminal 160, and a movable terminal 170. Of these components, the pressure spring 145, the pressure plate 146, the spring holder 147, the movable terminal 148, the fixed terminal 160, and the movable terminal 170 are provided one each for each of the relay parts 140A and 140B. The pressure spring 145, the pressure plate 146, the spring holder 147, the movable terminal 170, and the movable terminal 148 are attached to the upper part of the rod 129 protruding from the electromagnetic actuator 120.

The pressure spring 145 is made of a metal wire wound in a spiral shape. The pressure spring 145 is arranged on the outer periphery of the rod 129. The pressure spring 145 is arranged between the pressure plate 146 and the spring holder 147. The pressure spring 145 is compressed between the pressure plate 146 and the spring holder 147 when the rod 129 is displaced upward. The restoring force of the pressure spring 145 becomes a biasing force that presses the movable terminal 170 against the fixed terminal 160.

The pressure plate 146 is formed into a plate shape from a metal material or the like. The pressure plate 146 is disposed between the pressure spring 145 and the movable terminal 170. The pressure plate 146 is freely displaceable in the vertical direction relative to the rod 129. The pressure plate 146 transmits the upward driving force of the electromagnetic actuator 120 and the upward biasing force of the pressure spring 145 to the movable terminal 170.

The spring holder 147 is made of a metal material or the like and is formed into a flat, bottomed cylinder. The spring holder 147 is fitted onto the rod 129 and is held by the rod 129. The spring holder 147 moves back and forth along the axial direction together with the rod 129. The spring holder 147 houses the lower end of the pressure spring 145. When the rod 129 is displaced upward, the spring holder 147 compresses the pressure spring 145 in the axial direction.

The movable piece stopper 148 is formed into a cylindrical shape with a flange from a metal material or a hard resin material. The flange portion of the movable piece stopper 148 is located above the movable terminal 170. The movable piece stopper 148 moves back and forth along the axial direction together with the rod 129. When the rod 129 is displaced downward (returning direction), the movable piece stopper 148 comes into contact with the movable terminal 170 and pushes the movable terminal 170 downward.

The sealed case 150 is made of a ceramic material. The sealed case 150 has a bottomed container shape. The sealed case 150 is positioned above the electromagnetic actuator 120 with its opening facing downward. The sealed case 150 has an upper wall 151, a side wall 152, a shielding wall 158, and a rod stopper 157.

The upper wall 151 is formed in a plate shape having a thickness in the axial direction. Three terminal accommodating holes 154, 155, 156 are formed in the upper wall 151. The terminal accommodating holes 154, 155, 156 are through holes that penetrate the upper wall 151 in the plate thickness direction. The terminal accommodating holes 154, 155, 156 are formed at intervals from each other in the X direction. The terminal accommodating holes 154, 156 are circular openings. The terminal accommodating hole 155 is an oval opening.

The shielding wall 158 is formed in a thick plate shape. The shielding wall 158 is integrated with the side wall 152. The shielding wall 158 is positioned between the two movable terminals 170 in an orientation along the YZ plane. The upper end surface of the shielding wall 158 is in contact with the bottom wall surface of the shared fixed terminal 163 described below, or faces the bottom wall surface with a very small gap therebetween. The lower end surface of the shielding wall 158 faces the upper edges of the two accommodating cylinders 136 in the Y direction. The shielding wall 158 shields the space between the first movable terminal 171 and the second movable terminal 172.

The rod stopper 157 is formed into a plate shape from a metal material or a hard resin material. The rod stopper 157 is held in a housing 190 or the like. The rod stopper 157 is located above the upper end 129A of the rod 129 and faces the upper end 129A in the axial direction. The rod stopper 157 restricts the upward movement of the rod 129 by contacting the upper end 129A. The housing 190 is a case body that houses the electromagnetic actuator 120 and the relay main body 140. The housing 190 is formed into a box shape overall from a resin material or the like.

The housing 190 has an upper wall 191, a lower wall 192, a side wall 193, and a fixed wall 197. The upper wall 191 may be referred to as a first wall. The side wall 193 and the fixed wall 197 may be referred to as a second wall. The lower wall 192 may be referred to as a third wall. The upper wall 191 and the lower wall 192 are arranged spaced apart in the Y direction. The upper wall 191 and the lower wall 192 are connected via the side wall 193. The side wall 193 is a continuous wall that is continuous with the upper wall 191 and the lower wall 192. The upper wall 191 has holes 194, 195, and 196 through which the fixed terminal 160 passes. The terminal accommodating hole 154 and the hole 194 are connected. The first fixed terminal 161 passes through this connecting hole. A portion of the first fixed terminal 161 is exposed from the hole 194. The terminal accommodating hole 155 and the hole 195 are in communication. The common fixed terminal 163 is passed through this communication hole. A part of the common fixed terminal 163 is exposed from the hole 155. The terminal accommodating hole 156 and the hole 196 are in communication. The second fixed terminal 162 is passed through this communication hole. A part of the second fixed terminal 162 is exposed from the hole 196.

The bottom wall 192 is provided at the bottom end of the housing 190. The bottom wall 192 is provided with a fixed wall 197 that protrudes from the bottom wall 192. The fixed wall 197 is a portion for fixing a bus bar that forms part of the inverter connection lines 16P, 16N. The bus bar that forms part of the inverter connection lines 16P, 16N electrically connects the shared fixed terminal 163 and the inverter 3. This bus bar may be referred to as an external connection bus bar 180. The external connection bus bar 180 electrically connects the shared fixed terminal 163 and the inverter 3. The relay 100 has an external connection bus bar 180 in addition to the electromagnetic actuator 120, the relay body 140, and the housing 190. The specific configuration of the external connection bus bar 180 will be described later.

The external connection bus bar 180 is fixed to the fixed wall 197 via fastening members 198 such as bolts. The external connection bus bar 180 has a hole 184 formed therein for passing the shaft of the fastening member 198 therethrough. The fixed wall 197 has a hole 199 formed therein for passing the shaft of the fastening member 198 therethrough. The external connection bus bar 180 is fixed to the fixed wall 197 by passing the shaft through the two holes 184, 199. Note that the fixing form between the external connection bus bar 180 and the housing 190 is not limited to this. Other fixing forms will be described later.

The fixed terminal 160 is made of a metal material with excellent conductivity, such as copper. The fixed terminal 160 is electrically connected to one of the wirings 15, 16, and 17. The fixed terminal 160 is provided with a connection hole 165 and a fixed contact 167. The connection hole 165 is formed in a cylindrical hole shape. The connection hole 165 is used to fix conductive members, such as bus bars that form the wirings 15, 16, and 17, to the fixed terminal 160. The fixed contact 167 is formed on the bottom wall surface of the fixed terminal 160 facing downward. The fixed contact 167 faces the movable terminal 170 in the axial direction. The fixed contact 167 comes into contact with the movable terminal 170 displaced upward.

The fixed terminals 160 include a first fixed terminal 161, a second fixed terminal 162, and a shared fixed terminal 163. These three fixed terminals 160 are electrically connected to different wirings 15, 16, and 17. The three fixed terminals 160 are accommodated in terminal accommodating holes 154, 155, and 156, respectively, and are arranged at intervals from each other along the X direction. The first fixed terminal 161 and the second fixed terminal 162 are located on both sides of the shared fixed terminal 163 in the X direction. The X direction is the arrangement direction in which the three fixed terminals 160 are arranged.

The first fixed terminal 161 is generally formed in a cylindrical shape. The first fixed terminal 161 is the fixed terminal 160 included in the first relay unit 140A. The first fixed terminal 161 is accommodated in the terminal accommodating hole 154. The first fixed terminal 161 is held by the upper wall 151 by being fitted into the terminal accommodating hole 154. A bus bar or the like that forms part of the battery connection lines 15P, 15N is fixed to the first fixed terminal 161.

The second fixed terminal 162 is a fixed terminal 160 having the same shape as the first fixed terminal 161. The second fixed terminal 162 is a fixed terminal 160 included in the second relay unit 140B. The second fixed terminal 162 is accommodated in the terminal accommodating hole 156. The second fixed terminal 162 is held by the upper wall 151 by being fitted into the terminal accommodating hole 156. A bus bar forming part of the charging lines 17P, 17N is fixed to the second fixed terminal 162.

The shared fixed terminal 163 is formed into an elliptical cylinder shape overall. The shared fixed terminal 163 is a fixed terminal 160 that is larger than the first fixed terminal 161 and the second fixed terminal 162. The shared fixed terminal 163 is a fixed terminal 160 shared by the first relay unit 140A and the second relay unit 140B. The shared fixed terminal 163 is accommodated in the terminal accommodating hole 155. The shared fixed terminal 163 is held by the upper wall 151 by being fitted into the terminal accommodating hole 155. An external connection bus bar 180 is fixed to the shared fixed terminal 163. The external connection bus bar 180 may be referred to as a heat transfer member.

Two fixed contacts 167 are formed on the bottom wall surface of the shared fixed terminal 163. By having two fixed contacts 167, the conductive area of the shared fixed terminal 163 is larger than the conductive area of each of the first fixed terminal 161 and the second fixed terminal 162. The conductive area is the area of the portion that contacts the conductive object, and specifically, is the sum of the areas of the two fixed contacts 167 provided on the shared fixed terminal 163.

The movable terminal 170 is formed in a plate shape having a thickness in the axial direction and is made of a metal material with excellent conductivity such as copper. The movable terminal 170 is provided with a rod insertion hole 174. The rod insertion hole 174 is a through hole that penetrates the movable terminal 170 in the plate thickness direction. The rod 129 is inserted into the rod insertion hole 174. The movable terminal 170 is attached to the rod 129 with its main surface aligned with the XZ plane. The movable terminal 170 is allowed to move up and down between the pressure plate 146 and the movable terminal stopper 148.

The movable terminal 170 includes a first movable terminal 171 and a second movable terminal 172. The first movable terminal 171 is the movable terminal 170 included in the first relay unit 140A. The first movable terminal 171 is connected to the rod 129 of the first actuator unit 120A. The first movable terminal 171 is driven by the first actuator unit 120A. The first movable terminal 171 comes into contact with and separates from the first fixed terminal 161 and the shared fixed terminal 163 of the three fixed terminals 160. The first movable terminal 171 is pressed approximately evenly against both the first fixed terminal 161 and the shared fixed terminal 163 by the biasing force of the pressure spring 145.

The second movable terminal 172 is a movable terminal 170 included in the second relay unit 140B. The second movable terminal 172 is connected to the rod 129 of the second actuator unit 120B. The second movable terminal 172 is driven by the second actuator unit 120B. The second movable terminal 172 comes into contact with and separates from the second fixed terminal 162 and the shared fixed terminal 163 of the three fixed terminals 160. The second movable terminal 172 is pressed approximately evenly against both the second fixed terminal 162 and the shared fixed terminal 163 by the biasing force of the pressure spring 145.

The first movable terminal 171 and the second movable terminal 172 are individually displaced by the driving of the first actuator unit 120A and the second actuator unit 120B. This makes it possible to independently switch between allowing and blocking the passage of current between the first fixed terminal 161 and the shared fixed terminal 163, and allowing and blocking the passage of current between the second fixed terminal 162 and the shared fixed terminal 163.

<Housing and external connection busbar>
As described above, the housing 190 has the upper wall 191, the lower wall 192, the side walls 193, and the fixed wall 197. As shown in Fig. 3, the housing 190 is fixed to the fixed base 80 so that the side walls 193 face the mounting surface 81. One of the side walls 193 that faces the mounting surface 81 may be referred to as the facing wall 193A. The fixed wall 197 is provided on the lower wall 192 so as to be flush with the facing wall 193A. The surface of the fixed wall 197 that faces the fixed base 80 is flush with the surface of the facing wall 193A that faces the fixed base 80.

The external connection busbar 180 is formed of a copper plate member. The external connection busbar 180 is substantially L-shaped when viewed in the YZ plane. The external connection busbar 180 has a first extension 181 and a second extension 182. The first extension 181 and the second extension 182 are integrally connected by the same member. The length of the external connection busbar 180 in the X direction is shorter than the length between the first fixed terminal 161 and the second fixed terminal 162. The first extension 181 extends along the upper wall 191 so as to be connected to the shared fixed terminal 163. As an example, the first extension 181 is connected to the shared fixed terminal 163 by welding. Note that the connection between the first extension 181 and the shared fixed terminal 163 is not limited to welding.

The first extension 181 extends in the Z direction along the upper wall 191. The second extension 182 is connected to the end of the first extension 181. The second extension 182 extends in the Y direction along the opposing wall 193A and the fixed wall 197. The thickness direction of the second extension 182 corresponds to the Z direction. The length of the second extension 182 is longer than the combined length of the opposing wall 193A and the fixed wall 197. In addition to the above-mentioned hole 184, the second extension 182 has a hole 185 to which a bus bar forming the remainder of the inverter connection lines 16P, 16N is connected. This bus bar is fastened to the external connection bus bar 180 via a fastening member or the like, electrically connecting the shared fixed terminal 163 and the inverter 3.

The housing 190 also has a first storage chamber 190A and a second storage chamber 190B. The first storage chamber 190A is a chamber that stores the relay body 140. The second storage chamber 190B is a chamber that stores the electromagnetic actuator 120. The first storage chamber 190A and the second storage chamber 190B are aligned in the Y direction. The inside of the first storage chamber 190A is connected to the inside of the second storage chamber 190B. The first storage chamber 190A is partitioned by the upper part of the side wall 193. The second storage chamber 190B is partitioned by the lower part of the side wall 193. A large direct current of tens to hundreds of amperes flows into the relay body 140 from the wiring 15, 16, and 17. This causes the relay body 140 to generate heat and reach a high temperature. As a result, the first storage chamber 190A that stores the relay body 140 reaches a high temperature. The temperature of the first storage chamber 190A is higher than the temperature of the second storage chamber 190B.

<Relay and terminal block>
As shown in FIG. 3, the relay 100 is disposed on the mounting surface 81 of the fixed base 80 via a heat dissipation sheet 90. The relay 100 is fixed to the fixed base 80 via a fastening member (not shown) or the like. The relay 100 does not have to be fixed to the fixed base 80. The relay 100 may be disposed on the mounting surface 81 via a heat dissipation sheet 90. The relay 100 may be disposed on the mounting surface 81 without the heat dissipation sheet 90. As described above, a large amount of heat is generated in the relay main body 140. In this embodiment, in order to efficiently dissipate heat from the relay main body 140 to the fixed base 80, a heat dissipation sheet 90 with low thermal resistance is provided on the mounting surface 81. The heat generated in the relay 100 is dissipated to the fixed base 80 via the heat dissipation sheet 90.

Furthermore, a flow path 82 through which a refrigerant can flow is formed inside the fixed base 80. A liquid or a gas such as a gas is used as the refrigerant. As an example, the flow path 82 is arranged so as to overlap the relay 100 in the Z direction. The flow path 82 is arranged so as to overlap the housing 190 in the Z direction. The flow path 82 is arranged so as to overlap the second extension portion 182 in the Z direction. The second extension portion 182 is provided between the housing 190 and the flow path 82. By overlapping the housing 190 and the second extension portion 182 with the flow path 82, heat from the relay main body 140 is efficiently dissipated to the fixed base 80 via the second extension portion 182.

In this way, the fixing base 80 serves to fix the relay 100 and also to cool the relay 100. Note that the flow path 82 does not have to be provided inside the fixing base 80. The high voltage J/B 10 may have a cooler in addition to the components described so far. In that case, the cooler may be mounted on the mounting surface 81. The relay 100 may be placed on the cooler via a heat dissipation sheet 90.

<Action and effect>
The high voltage J/B 10 includes a relay 100 and wirings 15, 16, and 17. The relay 100 includes an electromagnetic actuator 120, a relay body 140, an external connection bus bar 180, and a housing 190. The external connection bus bar 180 is connected to a fixed terminal 160 of the electromagnetic actuator 120. The housing 190 includes an upper wall 191, a lower wall 192, a side wall 193, and a fixed wall 197. A first extension portion 181 of the external connection bus bar 180 extends along the upper wall 191 so as to be connected to the fixed terminal 160. A second extension portion 182 of the external connection bus bar 180 extends along an opposing wall 193A and the fixed wall 197. The external connection bus bar 180 is connected to the fixed terminal 160 and fixed to the fixed wall 197. This allows the second extension portion 182 to be in close contact with the fixed wall 197. The heat of the relay body 140 can be efficiently dissipated to the second extension portion 182 via the housing 190 .

The external connection busbar 180 is fixed to the fixed terminal 160 by welding. The external connection busbar 180 is fixed to the fixed wall 197 via fastening members 198. This makes it difficult for a difference in relative movement to occur between the fixed points of the external connection busbar 180 and the fixed terminal 160 and the fixed points of the external connection busbar 180 and the fixed wall 197 during vibration. As a result, stress concentration on the external connection busbar 180 and the fixed terminal 160 during vibration is suppressed. Poor connection between the external connection busbar 180 and the fixed terminal 160 is suppressed.

A flow path 82 is formed inside the fixed base 80, through which a refrigerant can flow. The opposing wall 193A and the flow path 82 overlap in the Z direction. A second extension 182 is provided between the opposing wall 193A and the flow path 82. This makes the distance between the second extension 182 and the flow path 82 short. Therefore, heat can be dissipated more efficiently from the second extension 182 to the flow path 82, compared to when the distance between the second extension 182 and the flow path 82 is long.

Moreover, a fixing point between the second extension 182 and the fixed wall 197 is provided between the fixed wall 197 and the flow path 82. The adhesion between the second extension 182 and the fixed wall 197 is increased at the fixing point. Therefore, heat is easily transferred from the fixed wall 197 to the second extension 182 at the fixing point. Compared to a configuration in which a fixing point between the second extension 182 and the fixed wall 197 is not provided between the fixed wall 197 and the flow path 82, heat from the relay main body 140 can be dissipated to the flow path 82 more efficiently. Also, since the flow path 82 is formed inside the fixed base 80, space can be saved compared to providing a new cooler. This leads to miniaturization and cost reduction.

Second Embodiment
FIG. 6 is a schematic diagram of a relay 100 of the second embodiment. FIG. 7 is a cross-sectional view taken along line VII-VII in FIG. 6. FIG. 8 is a schematic diagram showing a cross section of a high voltage J/B 10 of the second embodiment. Below, configurations different from the first embodiment will be mainly described. Configurations not described are similar to those of the first embodiment, and therefore will not be described. In the second embodiment, the housing 190 does not have a fixed wall 197. In the second embodiment, an accommodation hole 293 for accommodating the second extension 182 is formed in the facing wall 193A. The second extension 182 is accommodated in the accommodation hole 293. The second extension 182 is fitted into the accommodation hole 293. The facing wall 193A and the second extension 182 have opposing surfaces facing the fixed base 80. The opposing surfaces of the facing wall 193A and the second extension 182 are flush with each other in the XY plane. In the second embodiment, the second extension portion 182 is fixed to the outside of the first storage chamber 190A and the outside of the second storage chamber 190B.

In the second embodiment, the second extension 182 is fixed to both the first storage chamber 190A and the second storage chamber 190B. The second extension 182 is in close contact with the first storage chamber 190A and the second storage chamber 190B. In the second embodiment, the heat of the relay main body 140 can be actively dissipated to the second extension 182. This allows the heat of the relay main body 140 to be dissipated efficiently. Also in the second embodiment, the second extension 182 is provided between the opposing wall 193A and the flow path 82. Furthermore, a fixing point between the second extension 182 and the opposing wall 193A is provided between the opposing wall 193A and the flow path 82. Heat is easily transferred from the opposing wall 193A to the second extension 182 at the fixing point. This allows the heat of the relay 100 to be dissipated to the flow path 82 more efficiently than in a configuration in which there is no fixed location between the opposing wall 193A and the flow path 82 and the second extension 182.

Also in the second embodiment, the external connection bus bar 180 is connected to the fixed terminal 160 and fixed to the opposing wall 193A. During vibration, a difference in relative movement between the fixed point of the external connection bus bar 180 and the fixed terminal 160 and the fixed point of the external connection bus bar 180 and the opposing wall 193A is unlikely to occur. Stress concentration on the external connection bus bar 180 and the fixed terminal 160 during vibration is suppressed.

Third Embodiment
FIG. 9 is a schematic diagram of the relay 100 of the third embodiment. FIG. 10 is a schematic diagram showing an example of a cross section of the high voltage J/B 10 in the third embodiment. In the third embodiment, the second extension 182 is fixed to the opposing wall 193A by caulking via a fastening member 382. In the third embodiment, the second extension 182 is fixed to the outside of the first storage chamber 190A. The second extension 182 is provided between the opposing wall 193A and the flow path 82. More specifically, a fixing portion between the second extension 182 and the opposing wall 193A is provided between the opposing wall 193A and the flow path 82. This allows the heat of the relay main body 140 to be dissipated to the flow path 82 more efficiently than a configuration in which a fixing portion between the second extension 182 and the opposing wall 193A is not provided between the opposing wall 193A and the flow path 82. Also in the third embodiment, the external connection bus bar 180 is connected to the fixed terminal 160 and fixed to the opposing wall 193A. Stress concentration on the external connection bus bar 180 and the fixed terminal 160 during vibration is suppressed.

Fourth Embodiment
11 is a cross-sectional view showing a part of the high voltage J/B 10 in the fourth embodiment. In the fourth embodiment, the second extension portion 182 is connected to the opposing wall 193A at two points. In the housing 190, the first storage chamber 190A is provided on the upper wall 191 side of the center CR in the Y direction. In the housing 190, the second storage chamber 190B is provided on the lower wall 192 side of the center CR in the Y direction. The second storage chamber 190B may extend toward the upper wall 191 side of the center CR of the housing 190. In the fourth embodiment, the opposing wall 193A and the second extension portion 182 are fixed at one point each on the upper wall 191 side and the lower wall 192 side of the center CR of the housing 190. As an example, the opposing wall 193A of the first storage chamber 190A and the second extension portion 182 are fixed via a fastening member 482A as the first point. As a second location, the opposing wall 193A of the second storage chamber 190B and the second extension portion 182 are fixed to each other via a fastening member 482B. This allows the heat of the relay main body 140 to be dissipated to the second extension portion 182 more efficiently than in a configuration in which the opposing wall 193A and the second extension portion 182 are fixed to each other at one location.

Furthermore, the fixing point between the first storage chamber 190A and the second extension 182 overlaps with the flow path 82 in the Z direction. The fixing point between the second storage chamber 190B and the second extension 182 overlaps with the flow path 82 in the Z direction. This allows the heat of the relay body 140 to be dissipated to the flow path 82 more efficiently than in a configuration in which the fixing point between the opposing wall 193A and the second extension 182 overlaps with the flow path 82 in the Z direction at one point. The external connection bus bar 180 is connected to the fixed terminal 160 and fixed to the opposing wall 193A at two points. Therefore, stress concentration on the external connection bus bar 180 and the fixed terminal 160 during vibration is effectively suppressed compared to a configuration in which the external connection bus bar 180 is fixed to the opposing wall 193A at one point. Note that, although the drawings show a crimped form as an example in the fourth embodiment, the method of fixing the second extension 182 to the opposing wall 193A is not limited to this.

Fifth Embodiment
12 is a schematic diagram of the relay 100 of the fifth embodiment. In the fifth embodiment, the second extension 182 is fixed to the inside of the opposing wall 193A. The second extension 182 is inserted into the housing 190. In the fifth embodiment, a fixing portion between the second extension 182 and the opposing wall 193A is provided so as to overlap with the flow path 82 in the Z direction. This also produces the above-mentioned effects. Two methods are conceivable as a manufacturing method for the relay 100 of the fifth embodiment.

One is a method of assembling two housing pieces divided in the Y direction so as to encase the electromagnetic actuator 120 and the relay body 140. When molding the housing pieces, the external connection bus bar 180 is inserted into one housing piece. The external connection bus bar 180 is not inserted into the other housing piece. The housing piece into which the external connection bus bar 180 is inserted may be referred to as the first housing piece. The housing piece into which the external connection bus bar 180 is not inserted may be referred to as the second housing piece. The electromagnetic actuator 120 and the relay body 140 are assembled into the first housing piece so that the fixed terminal 160 can be connected to the external connection bus bar 180. The first extension 181 is welded to the fixed terminal 160. Then, the second housing piece is assembled to the first housing piece from the Y direction so as to encase the electromagnetic actuator 120, the relay body 140, and the second extension 182. One of the fourth embodiments manufactures the relay 100 in this manner.

Another method is to assemble two housing pieces divided in the Z direction so as to encase the electromagnetic actuator 120 and the relay body 140. The housing piece into which the external connection bus bar 180 is inserted may be referred to as the third housing piece. The housing piece into which the external connection bus bar 180 is not inserted may be referred to as the fourth housing piece. The electromagnetic actuator 120 and the relay body 140 are assembled to the third housing piece so that the fixed terminal 160 can be connected to the external connection bus bar 180. The first extension 181 is welded to the fixed terminal 160. Then, the fourth housing piece is assembled to the third housing piece from the Z direction so as to encase the electromagnetic actuator 120, the relay body 140, and the second extension 182. Another method of the fourth embodiment is to manufacture the relay 100 in this manner.

Sixth Embodiment
13 is a schematic diagram of the relay 100 of the sixth embodiment. In the sixth embodiment, the second extension 182 is fixed to the inside of the opposing wall 193A. The second extension 182 is inserted into the housing 190. In the sixth embodiment, the second extension 182 is fixed to the opposing wall 193A at a location that overlaps with the flow path 82 in the Z direction. This also provides the above-mentioned effects. The following method can be considered as a method for manufacturing the relay 100 of the sixth embodiment.

This is a method of assembling two housing pieces divided to encase the electromagnetic actuator 120 and the relay body 140. In the sixth embodiment, unlike the fifth embodiment, the external connection bus bar 180 is originally separated into a first extension 181 and a second extension 182. The housing piece into which the first extension 181 is inserted may be referred to as the fifth housing piece. The housing piece into which the second extension 182 is inserted may be referred to as the sixth housing piece. The electromagnetic actuator 120 and the relay body 140 are assembled to the fifth housing piece so that the fixed terminal 160 can be connected to the external connection bus bar 180. The first extension 181 is welded to the fixed terminal 160. Then, the sixth housing piece is assembled to the fifth housing piece so as to encase the electromagnetic actuator 120, the relay body 140, and the second extension 182.

In the sixth embodiment, after the sixth housing piece is assembled to the fifth housing piece, the first extension 181 and the second extension 182 are joined by welding or the like. In the drawings, the welded portion between the first extension 181 and the second extension 182 is hatched. By welding the first extension 181 and the second extension 182 together later, it is possible to prevent stress from concentrating at the connection portion between the external connection bus bar 180 and the fixed terminal 160.

Although the present disclosure has been described with reference to an embodiment, it is understood that the present disclosure is not limited to that embodiment or structure. The present disclosure also encompasses various modifications and variations within the scope of equivalents. In addition, while various combinations and forms are shown in the present disclosure, other combinations and forms including only one element, more, or less are also within the scope and spirit of the present disclosure.

(Disclosure of technical ideas)
This specification discloses multiple technical ideas described in the following multiple dependent claims. Some of the claims may be described in a multiple dependent form, where the subsequent claim alternatively refers to the preceding claim. Some of the claims may be described in a multiple dependent form, where the subsequent claim alternatively refers to the preceding claim. The multiple dependent form claims define multiple technical ideas.
(Technical thought 1)
An equipment module (10) including a relay (100) having a relay body (140) including a fixed terminal (160) electrically connected to a current path (15, 16, 17) and a movable terminal (170) that contacts and separates from the fixed terminal, and a drive unit (120) that displaces the movable terminal to switch between energization and interruption of the fixed terminal,
The relay further comprises:
A heat transfer member (180) that forms a part of the current path and transfers heat;
A housing (190) that houses the fixed terminal, the movable terminal, and the driving unit,
The housing has a first wall (191) on which the fixed terminal is provided;
a second wall (193, 197) different from the first wall;
A first extension portion (181) that is a part of the heat transfer member is connected to the fixed terminal,
The remainder of the heat transfer member, a second extension (182), extends along the second wall and is secured to the second wall, an equipment module.
(Technical thought 2)
the second wall is a side wall continuous with the first wall,
A first storage chamber (190A) for storing the relay body is formed by a part of the second wall,
A second storage chamber (190B) for storing the drive unit is formed by the remainder of the second wall,
The equipment module according to technical idea 1, wherein the second extension portion is fixed to the first storage chamber.
(Technical thought 3)
The equipment module according to Technical Idea 2, wherein the second extension portion is fixed to the outside or inside of the first storage chamber.
(Technical thought 4)
A flow path (82) through which a coolant for cooling the relay flows,
The second wall has an opposing wall (193A) facing the flow path in the thickness direction (Z) of the second extension portion,
The device module according to Technical Idea 2 or 3, wherein the second extension portion is provided between the opposing wall and the flow path in the thickness direction.
(Technical Thought 5)
The equipment module according to Technical Concept 4, wherein a fixed portion between the second extension portion and the opposing wall overlaps with the flow path in the thickness direction.
(Technical Thought 6)
The housing further includes a third wall (192) disposed opposite the first wall through the second wall,
An equipment module described in technical idea 4 or 5, in which the second extension portion is further fixed to the opposing wall between the center of the housing and the third wall in relation to the alignment direction (Y) in which the first storage chamber and the second storage chamber are aligned.

Claims (6)

An equipment module (10) including a relay (100) having a relay body (140) including a fixed terminal (160) electrically connected to a current path (15, 16, 17) and a movable terminal (170) that contacts and separates from the fixed terminal, and a drive unit (120) that displaces the movable terminal to switch between energization and interruption of the fixed terminal,
The relay further comprises:
A heat transfer member (180) that forms a part of the current path and transfers heat;
A housing (190) that houses the fixed terminal, the movable terminal, and the driving unit,
The housing has a first wall (191) on which the fixed terminal is provided;
a second wall (193, 197) different from the first wall;
A first extension portion (181) that is a part of the heat transfer member is connected to the fixed terminal,
The remainder of the heat transfer member, a second extension (182), extends along the second wall and is secured to the second wall, an equipment module. the second wall is a side wall continuous with the first wall,
A first storage chamber (190A) for storing the relay body is formed by a part of the second wall,
A second storage chamber (190B) for storing the drive unit is formed by the remainder of the second wall,
2. The equipment module of claim 1, wherein the second extension is secured to the first compartment. The equipment module of claim 2, wherein the second extension is fixed to the outside or inside of the first storage chamber. A flow path (82) through which a coolant for cooling the relay flows,
The second wall has an opposing wall (193A) facing the flow path in the thickness direction (Z) of the second extension portion,
The equipment module according to claim 2 or 3, wherein the second extension portion is provided between the opposing wall and the flow path in the thickness direction. The equipment module according to claim 4, wherein the fixing point between the second extension and the opposing wall overlaps with the flow path in the thickness direction. The housing further includes a third wall (192) disposed opposite the first wall through the second wall,
The equipment module according to claim 5 , wherein the second extension portion is further fixed to the opposing wall between the center of the housing and the third wall in relation to an alignment direction (Y) in which the first storage chamber and the second storage chamber are aligned.

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