WO2026018334A1 - Electrical component - Google Patents

Abstract

This electrical component is provided with a case for accommodating an electronic device therein and comprises a protector disposed in a manner overlapping the outer surface of the case. The case includes a flat general case part and a high-rigidity case part having a rigidity higher than that of the general case part. The protector includes: a flat general protector part disposed along the outer surface; a low-rigidity protector part having a rigidity lower than that of the general protector part; and a high-rigidity protector part having a rigidity higher than that of the general protector part. The low-rigidity protector part has a fastening portion for fastening the protector to a fastening point of the case. Due to the fastening at the fastening point, the protector is attached to the case such that a portion of the high-rigidity protector part faces the high-rigidity case part.

Description

Electrical Components

The present invention relates to electrical components.

JP2013-193634A discloses an electric vehicle. The electric vehicle is equipped with a metal case that houses a power conversion device. The case is fixed to the vehicle's fixed structure by front and rear brackets.

Such cases are often constructed with an aluminum housing, to which a protector with greater rigidity than the aluminum housing is sometimes attached. Because the protector is more rigid than the aluminum housing, if a large load is applied to the protector, there is a risk that the fastening parts that fasten the protector may break. In such cases, the protector may not provide adequate protection.

The present invention was made in consideration of these problems, and aims to provide an electrical component that can prevent damage to fastening parts even when a large load is applied.

According to one aspect of the present invention, the electrical component is a component equipped with a case that houses an electronic device and includes a protector that is placed over the outer surface of the case. The case has a flat general case portion and a high-rigidity case portion that is more rigid than the general case portion. The protector has a flat general protector portion that is placed along the outer surface, a low-rigidity protector portion that is less rigid than the general protector portion, and a high-rigidity protector portion that is more rigid than the general protector portion. The low-rigidity protector portion has fastening portions that fasten the protector to fastening points on the case, and the protector is attached to the case by fastening the fastening portions so that a portion of the high-rigidity protector portion faces the high-rigidity case portion.

FIG. 1 is a perspective view showing a drive unit equipped with electrical components according to this embodiment. FIG. 2 is a perspective view showing a side portion of the electrical component. FIG. 3 is a perspective view showing a part of the case of the electrical component. FIG. 4 is an exploded perspective view showing a protector attached to an electrical component. FIG. 5 is a perspective view showing the protector as viewed from the back side. FIG. 6 is a diagram showing the portion of the drive unit where the protector is provided, as viewed from the front of the vehicle. FIG. 7 is a diagram showing the portion of the drive unit where the protector is provided, as viewed from the side of the vehicle. FIG. 8 is a cross-sectional view taken along line VIII-VIII in FIG.

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a perspective view showing a drive unit 12 equipped with an electrical component 10 according to this embodiment. FIG. 2 is a perspective view showing a side of the electrical component 10. FIG. 3 is a perspective view showing a portion of the case 30 of the electrical component 10. The vehicle front FR, vehicle rear RR, vehicle left L, and vehicle right R shown in the figures indicate the directions when the device is installed in the vehicle.

As shown in FIG. 1, a drive unit 12 equipped with electrical components 10 according to this embodiment is mounted on, for example, an electric vehicle. When the drive unit 12 is mounted on the vehicle, side members that constitute the vehicle body are disposed on either side. Specifically, a left side member 14 (see FIG. 6) is disposed on the left side L of the vehicle from the drive unit 12.

The drive unit 12 uses a motor as a power source to drive drive wheels (not shown). The drive unit 12 comprises a motor housing 20 that houses the motor, and a gear housing 22 that is provided at the end of the motor housing 20 and houses a reduction gear that is connected to the motor's rotating shaft. The electrical component 10 described above is provided above the motor housing 20.

(Electrical components)
As shown in Figures 1 and 2, the electrical component 10 includes electronic devices (not shown), such as a high-voltage circuit and an inverter that supply power to a motor, a case 30 that houses the electronic devices, and a protector 36 that is placed on top of an outer surface 32 of the case 30.

(case)
The case 30 is an aluminum casting made of aluminum. The case 30 has a substantially flat top surface 40, a front side surface 42 extending from the edge of the top surface 40 on the front (FR) side of the vehicle toward the motor housing section 20, and a rear side surface 44 extending from the edge of the top surface 40 on the rear (RR) side of the vehicle toward the motor housing section 20. The case 30 also has a right side surface 46 extending from the edge of the top surface 40 on the right (R) side of the vehicle toward the motor housing section 20, and a left side surface 48 extending from the edge of the top surface 40 on the left (L) side of the vehicle toward the motor housing section 20. The top surface 40, the front side surface 42, the rear side surface 44, the right side surface 46, and the left side surface 48 form a cover-like member capable of housing an electronic device.

As shown in Figure 3, the left side surface 48 of the case 30 has a flat general case portion 50 and a high-rigidity case portion 52 that is more rigid than the general case portion 50.

The high-rigidity case portion 52 is composed of a rib 56 that protrudes outward from the outer surface 32 of the left side surface 48, or a flange 58 that protrudes outward from the end of the general case portion 50. The electrical component 10 of this embodiment has both a rib 56 and a flange 58.

(flange)
The flanges 58 are formed by portions that extend outward from the ends of the side surfaces 42, 44, 46, and 48 (see FIG. 1) of the case 30 that face the motor housing portion 20. The flanges 58 are formed on the side surfaces 42, 44, and 46, including the left side surface 48, and are formed to surround the case 30.

As shown in Figure 2, the flange 58 of the case 30 abuts against a housing flange 62 formed on the casing 60 of the motor housing 20, and is fixed to the housing flange 62 with bolts 64 (see Figures 2, 7, and 8).

As shown in Figure 3, the amount by which the flange 58 protrudes from the general case portion 50 varies depending on where it is formed. For example, the portion of the flange 58 formed on the left side surface 48 protrudes more than the portion near the corner between the left side surface 48 and the front side surface 42.

(rib)
The rib 56 is composed of a thick portion formed on the left side surface 48. The rib 56 is composed of a horizontal rib 56A extending in the front-to-rear direction of the vehicle and a vertical rib 56B extending in the up-down direction. The horizontal rib 56A and the vertical rib 56B intersect with each other. As a result, the left side surface 48 is provided with a grid-shaped portion 70 (see FIGS. 3 and 8 ) formed in a grid pattern by the horizontal ribs 56A and the vertical ribs 56B. The grid-shaped portion 70 is also located on the front (FR) side of the left side surface 48.

The lower end of the vertical rib 56B reaches the flange 58 and extends outward along the flange 58. Therefore, the amount by which the vertical rib 56B protrudes from the general case portion 50 varies depending on where it is formed. For example, the lower end of the vertical rib 56B, which is formed to reach the flange 58, protrudes more than the horizontal rib 56A.

The lower end of the vertical rib 56B extending outward along the flange 58 does not reach the edge of the flange 58. As a result, in the direction in which the protector 36 is placed on the case 30, the maximum amount of protrusion of the flange 58 from the general case portion 50 is greater than the maximum amount of protrusion of the rib 56 from the general case portion 50.

(protector)
As shown in FIG. 2 , the protector 36 has a flat protector general portion 80 arranged along the outer surface 32 on the left side surface 48 of the case 30, a protector low-rigidity portion 82 that has lower rigidity than the protector general portion 80, and a protector high-rigidity portion 84 that has higher rigidity than the protector general portion 80.

The protector low-rigidity portion 82 has a fastening portion 98 that fastens the protector 36 to a fastening point 96 on the case 30. By fastening the fastening portion 98, the protector 36 is attached to the case 30 so that a portion of the protector high-rigidity portion 84 faces the case high-rigidity portion 52 (see Figure 8).

The protector low-rigidity section 82 has an arm-like shape extending from the protector general section 80. The protector high-rigidity section 84 has a shape that bulges out from the protector general section 80 toward the outer surface 32.

The configuration of the protector 36 will be explained using Figures 4 to 8.

Figure 4 is an exploded perspective view showing the protector 36 attached to the electrical component 10. Figure 5 is a perspective view showing the protector 36 as viewed from the back side. Figure 6 is a view showing the portion of the drive unit 12 in which the protector 36 is provided as viewed from the front (FR) of the vehicle. Figure 7 is a view showing the portion of the drive unit 12 in which the protector 36 is provided as viewed from the side of the vehicle. Figure 8 is a cross-sectional view taken along line VIII-VIII in Figure 6.

As shown in Figure 4, the protector 36 has a plate-shaped inner member 90 and an outer member 92 that are arranged one on top of the other.

As shown in Figures 4 and 5, the inner member 90, which is placed on the case 30 side, has an inward bulge 100 that bulges toward the case 30, and the outer member 92, which is placed on the outside of the inner member 90, has an outward bulge 102 that bulges away from the case 30. The inward bulge 100 of the inner member 90 and the outward bulge 102 of the outer member 92 form the protector high-rigidity portion 84 (see Figure 7).

(Inner member)
More specifically, the inner member 90 is made of an iron plate and has a substantially pentagonal shape.

The edges of the inner member 90 include an upper edge 110, a front upper edge 112 that extends downward from the end of the upper edge 110 on the front side of the vehicle (FR) toward the front side of the vehicle (FR), and a front lower edge 114 that extends downward from the lower end of the front upper edge 112 toward the rear side of the vehicle (RR). The edges of the inner member 90 include a rear lower edge 116 that extends upward from the lower end of the front lower edge 114 toward the rear side of the vehicle (RR), and a rear upper edge 118 that connects the upper end of the rear lower edge 116 and the end of the upper edge 110 on the rear side of the vehicle (RR).

The upper edge 110 of the inner member 90 is positioned along the top surface 40 of the case 30 (see Figure 2). Extension pieces 121 that extend toward the case 30, which is the right R side of the vehicle, are formed at the corners of the front upper edge 112 and the front lower edge 114. The extension pieces 121 cover the corners of the case 30 when the protector 36 is attached to the case 30.

A forearm 120 extends from the front upper edge 112 of the inner member 90 toward the case 30. The forearm 120 is formed in an elongated shape with its length greater than its width. The forearm 120 constitutes the protector low-rigidity portion 82, which extends in an arm-like shape from the protector general portion 80.

As shown in Figures 2 and 4, the tip of the forearm 120 is bent along the left side surface 48 of the case 30, and the tip of the forearm 120 constitutes the aforementioned fastening portion 98 (see Figure 2). A through-hole 124 is formed in the fastening portion 98 of the forearm 120, through which the bolt 64 is inserted. The fastening portion 98 of the forearm 120 is fixed to the case 30 by threading the bolt 64 inserted into the through-hole 124 into a screw hole (not shown) provided in the fastening point 96 of the case 30 (see Figure 2).

A rear arm 130 extends from the rear upper edge 118 of the inner member 90 toward the case 30. The rear arm 130 is formed in an elongated shape with its length greater than its width. The rear arm 130 constitutes the protector low-rigidity portion 82 that extends in an arm-like shape from the protector general portion 80.

The tip of the rear arm 130 is bent along the left side surface 48 of the case 30 (see Figure 2), and forms the fastening portion 98 described above. The fastening portion 98 of the rear arm 130 is long in the width direction of the rear arm 130. A pair of insertion holes 132 through which bolts 64 are inserted are formed in the fastening portion 98 of the rear arm 130. The fastening portion 98 of the rear arm 130 is fixed to the case 30 by inserting the bolt 64 through both insertion holes 132 into a screw hole (not shown) provided at the fastening point 96 of the case 30 (see Figure 2).

The inner member 90 has step portions 140 formed at the corners of the front lower edge 114 and the rear lower edge 116, which protrude towards the vehicle's right R side, which is the case 30 side. The step portions 140 have circular holes 142 through which positioning bolts 64 are inserted. The step portions 140 are fixed to the motor housing portion 20 by threading the bolts 64 inserted into the circular holes 142 into positioning screw holes (not shown) provided in the motor housing portion 20.

As a result, the step portion 140 of the inner member 90 is positioned in the motor housing portion 20 with the flange 38 and housing portion flange 62 straddling each other. Therefore, even if the protector low-rigidity portion 82 is deformed, the protector 36 is prevented from significantly shifting in position relative to the case 30.

A rectangular first bulge 150 is formed at the top of the inner member 90. The first bulge 150 reaches the upper edge 110. The first bulge 150 is a recess that is recessed from the outside to the inside and opens upward.

A rectangular second bulge 152 is formed on the rearward (RR) side of the inner member 90. The second bulge 152 reaches the rear upper edge 118. The second bulge 152 is a recess that is recessed from the outside to the inside and opens toward the rearward (RR) side of the vehicle.

A triangular third bulge 154 is formed on the front (FR) side of the vehicle of the inner member 90. The third bulge 154 is a recess that is recessed from the outside to the inside and opens in a direction away from the case 30.

The first bulge portion 150, the third bulge portion 154, and the second bulge portion 152 constitute the inward bulge portion 100 that bulges toward the case 30.

(Outer member)
The outer member 92 is formed of an iron plate material and has a trapezoidal shape. The outer member 92 has a smaller area than the inner member 90.

The edge of the outer member 92 has an upper base 160 and front legs 162 that extend downward from the end of the upper base 160 on the front side of the vehicle (FR) toward the front side of the vehicle (FR). The edge of the outer member 92 has a lower base 164 that extends from the lower end of the front legs 162 toward the rear side of the vehicle (RR), and rear legs 166 that connect the end of the lower base 164 on the rear side of the vehicle (RR) with the end of the upper base 160 on the rear side of the vehicle (RR). The upper base 160 of the outer member 92 is positioned along the top surface 40 of the case 30 (see Figure 2).

The outer member 92 has the aforementioned outward bulge 102 formed in the center. The outward bulge 102 is trapezoidal in shape and is positioned so that its upper base faces upward. The outward bulge 102 is recessed from the inside to the outside, and bulges out in a direction away from the case 30.

As shown in Figures 4 to 6, when the outer member 92 is placed on top of the inner member 90, the outer periphery of the outwardly bulging portion 102 is fixed to the inner member 90 by, for example, spot welding. This integrates the outer member 92 and the inner member 90, forming the protector 36.

As shown in Figures 7 and 8, the inner bulge 100 and outer bulge 102 that make up the protector 36 are arranged so that they at least partially overlap in the direction in which the inner member 90 and outer member 92 overlap.

Specifically, the upper part of the outward bulge portion 102 of the outer member 92 overlaps with part of the first bulge portion 150 of the inner member 90. The lower part of the outward bulge portion 102 of the outer member 92 on the vehicle front (FR) side overlaps with part of the third bulge portion 154 of the inner member 90. The lower part of the outward bulge portion 102 of the outer member 92 on the vehicle rear (RR) side overlaps with part of the second bulge portion 152 of the inner member 90.

As a result, the internal spaces of the outward bulging portion 102 and the first bulging portion 150, the internal spaces of the outward bulging portion 102 and the third bulging portion 154, and the internal spaces of the outward bulging portion 102 and the second bulging portion 152 are open to the outside. Therefore, even if paint used to paint the protector 36, for example, seeps into each internal space, the paint is expelled to the outside.

At least one pair of fastening portions 98 provided on the protector 36 and fastening points 96 on the case 30 to which the fastening portions 98 are fastened is provided, and a rib 56 is arranged between the fastening points 96 in each pair. In this embodiment, one pair of fastening portions 98 on the protector 36 and fastening points 96 on the case 30 to which the fastening portions 98 are fastened is provided.

In other words, one of the pair of fastening points 96 provided on the case 30 is located further forward (FR) than the lattice-shaped portion 70 formed on the case 30. Furthermore, the other of the pair of fastening points 96 provided on the case 30 is located at a location further rearward (RR) than the lattice-shaped portion 70 formed on the case 30. As a result, the rib 56 that constitutes the lattice-shaped portion 70 is located between the one fastening point 96 and the other fastening point 96.

When the protector 36 is attached to the case 30, a portion of the outward bulge 102 that constitutes the protector high rigidity portion 84 faces the rib 56 (see Figure 8) of the lattice-shaped portion 70 that constitutes the case high rigidity portion 52. Furthermore, a portion of the first bulge 150, second bulge 152, and third bulge 154 that constitute the protector high rigidity portion 84 faces the rib 56 (see Figure 8) of the lattice-shaped portion 70 that constitutes the case high rigidity portion 52. Furthermore, a portion of the third bulge 154 and second bulge 152 that constitute the protector high rigidity portion 84 faces the end face of the flange 58 that constitutes the case high rigidity portion 52.

(Action and effect)
As described above, the electrical component 10 of this embodiment is a component including a case 30 that houses an electronic device, and includes a protector 36 that is disposed over the outer surface 32 of the case 30. The case 30 has a flat general case portion 50 and a high-rigidity case portion 52 that is more rigid than the general case portion 50. The protector 36 has a flat general protector portion 80 that is disposed along the outer surface 32, a low-rigidity protector portion 82 that is less rigid than the general case portion 80, and a high-rigidity protector portion 84 that is more rigid than the general protector portion 80. The low-rigidity protector portion 82 has fastening portions 98 that fasten the protector 36 to fastening points 96 of the case 30. By fastening the fastening portions 98, the protector 36 is attached to the case 30 so that a portion of the high-rigidity protector portion 84 faces the high-rigidity case portion 52.

In this configuration, the protector 36 is placed over the outer surface 32 of the case 30, and the fastening portion 98 provided on the protector low-rigidity portion 82 is fastened to the fastening point 96 of the case 30.

For example, when the left side member 14 on the side of the drive unit 12 bends and abuts against the protector 36, and a large load is applied to the protector 36, the protector low rigidity section 82 of the protector 36 can deform. This reduces damage to the fastened portion of the protector 36 compared to when the protector general section 80 or the protector high rigidity section 84 is fastened to the fastening point 96 of the case 30.

Furthermore, because the protector 36 is attached to the case 30 so that a portion of the protector high rigidity portion 84 faces the case high rigidity portion 52, the load applied to the protector 36 can be borne by the protector high rigidity portion 84 and the case high rigidity portion 52. This allows the protector 36 to enhance its protective function for the electrical component 10 compared to when the protector general portion 80 faces the case general portion 50 of the case 30.

Furthermore, as described above, damage to the fastening portion of the protector 36 is suppressed, allowing the protector 36 to perform its protective function more appropriately than if the fastening portion were to break and the protector 36 were to become misaligned.

In this embodiment, the electrical component 10 houses electronic devices such as high-voltage circuits and inverters within the case 30, and the protector 36 receives the applied load, thereby protecting the electronic devices that handle high voltages.

In this embodiment, the left side member 14 is provided on the side of the electrical component 10, but this embodiment is not limited to this configuration. The configuration of the electrical component 10 in this embodiment may also be applied when a radiator or fan motor is provided nearby. In this case, the electrical component 10 can prevent damage to the fastening portion even if a large load is applied to the protector 36 from the radiator or fan motor.

Furthermore, in this embodiment, the protector low rigidity section 82 has an arm-like shape extending from the protector general section 80, and the protector high rigidity section 84 has a shape that bulges out from the protector general section 80 toward the outer surface 32.

In this configuration, the protector low-rigidity section 82 has an arm-like extension, which achieves low rigidity. Furthermore, by forming a convex shape on the protector general section 80, it is possible to form a high-rigidity section.

In addition, in this embodiment, the case high rigidity portion 52 is a rib 56 protruding outward from the outer surface 32, or a flange 58 protruding outward from the end of the case general portion 50.

In such a configuration, the case 30 is generally made of an aluminum casting.

As a result, it is relatively easy to form convex shapes such as ribs 56 or flanges 58 on the case 30. This makes it relatively easy to form the high-rigidity case portion 52 on the electrical component 10.

In addition, in this embodiment, the protector 36 has a plate-shaped inner member 90 and an outer member 92 that are arranged one on top of the other. The inner member 90, which is arranged on the case 30 side, has an inward bulge portion 100 that bulges toward the case 30, and the outer member 92, which is arranged on the outside of the inner member 90, has an outward bulge portion 102 that bulges away from the case 30. The inward bulge portion 100 and the outward bulge portion 102 are the protector high-rigidity portion 84.

In this configuration, the electrical component 10 can withstand the load applied to the protector 36 with the inward bulging portion 100 that bulges toward the case 30 and the outward bulging portion 102 that bulges away from the case 30. This allows the electrical component 10 to further enhance the protective function provided by the protector 36.

Furthermore, in this embodiment, the inward bulging portion 100 and the outward bulging portion 102 are arranged so that they at least partially overlap in the direction in which the inner member 90 and the outer member 92 overlap.

In this configuration, the electrical component 10 can support the load applied to the protector 36 with the inward bulge 100 and outward bulge 102, which are positioned so that they overlap. This allows the rigidity of the protector 36 to be further increased compared to when the electrical component 10 is positioned so that the inward bulge 100 and outward bulge 102 do not overlap.

Furthermore, in this embodiment, the maximum amount of protrusion of the flange 58 from the general case portion 50 in the direction in which the case 30 and the protector 36 are stacked is greater than the maximum amount of protrusion of the rib 56 from the general case portion 50.

In this configuration, the maximum protrusion amount of the flange 58 is greater than the maximum protrusion amount of the rib 56, so when a load is applied, the protector 36 abuts against the flange 58, deforming it, and then abuts against the rib 56, deforming it as well.

As a result, the electrical component 10 can absorb the load applied to the protector 36 in stages through deformation of the flange 58 and the rib 56, making it possible to absorb impact energy more efficiently than when the flange 58 and rib 56 deform simultaneously.

The flange 58 of the case 30 forms a mating surface that abuts against the housing flange 62 of the motor housing 20. Therefore, in order to widen the mating surface, the flange 58 of the case 30 can be designed to protrude more from the general case portion 50. This makes it easier to design the electrical component 10 so that the maximum protrusion of the flange 58 is greater than the maximum protrusion of the rib 56.

Furthermore, in this embodiment, at least one pair of combinations of a fastening portion 98 and a fastening point 96 to which the fastening portion 98 is fastened is provided, and a rib 56 is arranged between the fastening points 96 in each combination.

In this configuration, the rib 56 is positioned between the fastening points 96 of the fastening portion 98, so even if the protector low-rigidity portion 82 where the fastening portion 98 is provided is deformed, it is possible to prevent significant misalignment between the protector 36 and the rib 56.

This allows the electrical component 10 to properly perform the protective function of the protector 36 compared to when there is a significant misalignment between the protector 36 and the rib 56.

The above describes embodiments and variations of the present invention, but the above embodiments merely illustrate some of the application examples of the present invention, and are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments.

The electrical component 10 of this embodiment has been described above using an example in which electronic devices such as a high-voltage circuit and an inverter are housed within the case 30, but the electronic devices housed within the case 30 may also be low-voltage electronic devices.

Furthermore, in the electrical component 10 of the present embodiment described above, the protector 36 is disposed overlapping the left side surface 48 of the case 30, but the protector 36 may also be disposed overlapping another surface of the case 30.

Claims (7)

An electrical component having a case for accommodating an electronic device,
a protector disposed on an outer surface of the case,
The case has a flat general case portion and a high-rigidity case portion having higher rigidity than the general case portion,
The protector has a flat protector general portion disposed along the outer surface, a protector low-rigidity portion having lower rigidity than the protector general portion, and a protector high-rigidity portion having higher rigidity than the protector general portion,
the protector low-rigidity portion has a fastening portion that fastens the protector to a fastening point of the case,
the protector is attached to the case by fastening the fastening portion such that a portion of the protector high rigidity portion faces the case high rigidity portion;
Electrical components. The electrical component according to claim 1,
the protector low-rigidity portion has an arm-like shape extending from the protector general portion,
the protector high-rigidity portion has a shape that bulges out from the protector general portion toward the outer surface;
Electrical components. The electrical component according to claim 2,
The case high rigidity portion is a rib protruding outward from the outer surface or a flange protruding outward from an end of the case general portion.
Electrical components. The electrical component according to claim 3,
The protector has a plate-shaped inner member and an outer member that are arranged in a stacked manner,
the inner member disposed on the case side has an inward bulging portion bulging toward the case side, and the outer member placed on the outside of the inner member has an outward bulging portion bulging in a direction away from the case,
the inward bulging portion and the outward bulging portion are the protector high rigidity portion;
Electrical components. The electrical component according to claim 4,
the inward bulging portion and the outward bulging portion are arranged so as to overlap at least partially in a direction in which the inner member and the outer member overlap.
Electrical components. The electrical component according to claim 5,
In a direction in which the case and the protector are stacked, a maximum value of the amount of protrusion of the flange from the case general portion is greater than a maximum value of the amount of protrusion of the rib from the case general portion.
Electrical components. The electrical component according to claim 5,
At least one pair of combinations of the fastening portion and the fastening point to which the fastening portion is fastened is provided, and the rib is disposed between the fastening points in the pair of combinations.
Electrical components.