Harness routing structure

A harness routing structure comprises: a battery case that defines an internal space which houses a battery and an electric appliance on a hybrid motor vehicle, and that is formed of a first member; a reinforcement that is provided in the battery case, and that is formed of a second member having a greater strength than the first member and that reinforces the battery case; and a harness routed at a position along the reinforcement.

This is a 371 national phase application of PCT/IB2006/003234 filed 16 Nov. 2006, claiming priority to Japanese Patent Application No. 2005-336030 filed 21 Nov. 2005, the contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a routing structure of a harness. More concretely, the invention relates to a routing structure of a harness that extends from a battery mounted in a vehicle.

BACKGROUND OF THE INVENTION

In relation to a harness routing structure, for example, Japanese Patent Application Publication No. JP-A-2003-346759 discloses a battery system for the purpose of improving safety. The battery system disclosed in this document has a buffer portion, and is equipped with a battery cover that covers a module assembly. The buffer portion is formed through the foaming molding of plastic. An electrically conductive member, such as a main battery cable or the like, that is connected to a module assembly is disposed so as to face the buffer portion.

Besides, Japanese Patent Application Publication No. JP-A-2005-153827 discloses a vehicular electricity storage device for the purpose of reducing the number of component parts and the number of man-hours for production and uniforming the height of a base plate. Besides, Japanese Patent Application Publication No. JP-A-2002-219949 discloses a vehicular electric power source device for the purpose reducing the number of component parts and lowering the production cost.

In the aforementioned battery system disclosed in Japanese Patent Application Publication No. JP-A-2003-346759, the buffer portion absorbs force exerted from the outside and thereby prevents the force from being directly transferred to an electrically conductive member such as the main battery cable or the like. However, in this case, since it is necessary to provide the buffer portion at a position where exertion of force from the outside is expected, the number of component parts of the battery system may increase, or the construction may become complicated.

DISCLOSURE OF THE INVENTION

Accordingly, it is an object of the invention to provide a harness routing structure that prevents excessive force on the harness while having a simple construction.

A harness routing structure in a first aspect of the invention comprises: a case body that defines an internal space which houses a high-voltage electric component part in a vehicle, and that is formed of a first member; a reinforcing member that is provided on the case body, and that is formed of a second member having a greater strength than the first member, and that reinforces the case body; and a harness routed at a position along the reinforcing member.

According to the harness routing structure constructed as described above, in the situation where the vehicle is struck from behind or the like, the impact on the harness can be reduced by the reinforcing member that is provided for reinforcing the case body. Therefore, excessive force on the harness can be prevented by a simple construction.

The reinforcing member may be disposed at a side of the harness opposite from the high-voltage electric component part housed in the internal space, in a sectional view taken on a plane orthogonal to an extending direction of the harness. According to the harness routing structure constructed as described above, the impact exerted on the harness from the side of the harness opposite from the high-voltage electric component part can be reduced by the reinforcing member.

The reinforcing member may be angularly bent so that a recess portion is formed at a side of the harness opposite from the high-voltage electric component part housed in the internal space, and faces the harness, in a sectional view taken on a plane orthogonal to an extending direction of the harness. Also, the reinforcing member may be curved so that a recess portion is formed at a side of the harness opposite from the high-voltage electric component part housed in the internal space, and faces the harness, in a sectional view taken on a plane orthogonal to an extending direction of the harness. According to the harness routing structure constructed as described above, the reinforcing member is provided so as to cover the harness at a side thereof opposite from the high-voltage electric component part. Therefore, the impact on the harness can be reliably reduced by the reinforcing member.

The harness may be routed in the internal space. According to the harness routing structure constructed as described above, the harness is routed at a position that is surrounded by the case body. Therefore, in addition to the reinforcing member, the case body also reduces the impact that is exerted on the harness.

Besides, the harness may be routed outside the internal space. The reinforcing member may be formed of a metal (e.g., a steel). According to the harness routing structure constructed as described above, the reinforcing member can prevent leakage of electromagnetic waves emitted from the harness.

Besides, the high-voltage electric component part may be a battery unit that includes at least a battery. According to the harness routing structure constructed as described above, the harness routed around the battery unit can be protected.

Besides, the battery unit may further include an appliance that is juxtaposed with the battery in a vehicular transverse direction. The reinforcing member may be provided on a vehicular rearward side of the case body so as to be astride the battery and the appliance. According to the harness routing structure constructed as described above, the possibility of the harness breaking in the situation where the vehicle receives impact from behind can be reduced, in comparison with a configuration in which the harness is routed on a vehicular forward side.

Besides, the harness may be connected to the high-voltage electric component part. According to the harness routing structure constructed as described above, the harness connected to the high-voltage electric component part can be protected.

As described above, according to the aspects and forms of carrying out the invention, a harness routing structure that prevents exertion of excessive force on the harness while adopting a simple construction can be provided.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiments of this invention will be described with reference to the drawings. In the drawings that are referred to below, the same or comparable members are denoted by the same reference characters.

FIG. 1is a perspective view showing a vehicle to which a harness routing structure in accordance with a first embodiment is applied. The drawing shows a hybrid motor vehicle that has an internal combustion engine, such as a gasoline engine, a diesel engine, etc., and a chargeable and dischargeable secondary cell (battery), as motive power sources.

As shown inFIG. 1, the hybrid motor vehicle is provided with a vehicle cabin52for accommodating vehicle occupants, and a luggage compartment51for storing luggage. The vehicle cabin52and the luggage compartment51are separated by a partition panel (not shown). The hybrid motor vehicle has a front bumper54that is disposed at a forefront end of the vehicle, and a rear bumper55that is disposed at a rearmost end of the vehicle. The front bumper54and the rear bumper55are provided as body portions that are disposed along outer peripheries of the vehicle when seen from above.

A battery pack20is disposed in the luggage compartment51. The battery pack20is provided at a position that is further from the front bumper54than from the rear bumper55.

The battery pack20has a battery case21for housing a battery (not shown). The battery case21has a generally rectangular parallelepiped shape that has a longer side and a shorter side. The battery case21is placed so that the shorter side thereof substantially coincides with the longitudinal direction of the vehicle and the longer side thereof substantially coincides with the transverse direction of the vehicle.

The battery case21is formed of a metal. For example, it is formed of a zinc-plated steel sheet. The battery case21in this embodiment is formed of a steel sheet that has a thickness of 0.7 mm.

FIG. 2is a perspective view showing the battery pack20shown inFIG. 1. The battery case21has an internal space18. A battery27is housed in the internal space18. The battery27supplies electric power to an electric motor when the vehicle is starting off, accelerating, climbing a hill, or the like, and stores electric power provided by the regenerative power generation during deceleration of the vehicle. The battery27is not particularly limited as long as it is a chargeable and dischargeable secondary battery. For example, it may be nickel metal hydride battery, or a lithium ion battery.

An electric appliance28that is electrically connected to the battery27is also housed in the internal space18. The battery27and the electric appliance28are juxtaposed substantially horizontally. Furthermore, the battery27and the electric appliance28are juxtaposed in the transverse direction of the vehicle. The battery27has a greater weight than the electric appliance28.

The electric appliance28comprises a plurality of appliances, including a DC-DC converter, a battery computer, a relay that controls a high-voltage circuit of the battery27, various sensors that detect states of the battery27, a service plug for disconnecting the high-voltage circuit at the time of check/maintenance of the battery pack20, etc. The DC-DC converter drops the high voltage output from the battery27to a voltage for use for accessories of the vehicle, such as lamps, audio components, etc., and various ECUs (electronic control units) mounted in the vehicle, and thus charges an auxiliary battery (not shown).

The battery case21has a lower case24and an upper case25. The lower case24is a component part that receives the weight of the battery27and the electric appliance28. The upper case25is a component part disposed on an upper side of the lower case24and attached to the lower case24so as to cover the battery27and the electric appliance28. That is, the battery case21has the lower case24and the upper case25as first and second case body portions that are combined to cover the battery27and the electric appliance28.

The battery case21has a side face21athat faces the rear of the vehicle. The battery case21is provided with plates46and47as case body-fixing members that are fixed to the vehicle main body. The plates46and47are provided on a vehicular rearward side of the battery case21that is rearward in the vehicle. The plates46,47are provided at opposite ends of the battery case21that are apart from each other in the vehicular transverse direction.

In this embodiment, the plates46,47are fixed to a cross member that is a vehicle body frame provided in the luggage compartment51. The member or the like to which the plates46,47are fixed is not particularly limited as long as it is a structural part having rigidity, on the vehicle main body side. For example, the plates46,47may be fixed to side members, or may also be directly fixed to a floor surface of the luggage compartment51. Furthermore, a vehicular forward side of the battery case21that is forward in the vehicle is also fixed to the vehicle main body, at a plurality of fixture positions that are spaced from each other in the vehicular transverse direction.

FIG. 3is a sectional view of the battery pack20taken along line III-III inFIG. 2. As shown inFIG. 2andFIG. 3, the battery case21is provided with a reinforcement31. The reinforcement31is provided on the side face21aof the battery case21. The reinforcement31is interposed between the upper case25and the lower case24. Specifically, the reinforcement31is welded to the lower case24, and the upper case25is fastened to the reinforcement31by bolts. The reinforcement31, together with the battery case21, forms the internal space18. The reinforcement31is provided on a portion of the battery case21which faces the rear bumper55inFIG. 1, that is, the vehicular rearward side of the battery case21.

The reinforcement31extends in the vehicular transverse direction. The reinforcement31extends from an end of the battery21to another end thereof in the vehicular transverse direction. The reinforcement31extends continuously between the plate46and the plate47. The reinforcement31extends astride the battery27and the electric appliance28that are housed in the internal space18. The reinforcement31extends in a predetermined direction, around the internal space18.

The reinforcement31reinforces the battery case21. The reinforcement31functions as a rib that reinforces the battery case21between a plurality of positions at which the battery case21is supported, that is, between the plate46and the plate47in this embodiment. The reinforcement31is formed of a member that has a greater strength than a member that forms the battery case21. In this embodiment, the reinforcement31is formed of a steel sheet that has a thickness of 2 mm. Incidentally, the difference in strength between the member forming the battery case21and the member forming reinforcement31is not limited to the difference based on the different sheet thicknesses of the steel sheets. For example, the strength difference therebetween may be based on the material of the steel sheets, or may be based on both the material and the sheet thickness of the steel sheets. If the strength difference between the battery case21and the reinforcement31is based on the material, it is permissible, for example, that only the reinforcement31is formed of a high-tensile steel.

In the internal space18, a harness41extending between the battery27and the electric appliance28is routed. The harness41is a voltage detection purpose cable for detecting the voltage of the battery27. The harness41is connected to the battery computer that constitutes the electric appliance28.

The harness41is not limited to a voltage detection purpose cable, but may also be, for example, an output cable of the battery27. In that construction, current having a voltage of, for example, 200V or higher, flows through the harness41. Besides, the harness41is not limited to the wiring that extends between the battery27and the electric appliance28. For example, the harness41may be a wiring that is connected to one of the battery27and the electric appliance28. Or, the harness41may be a wiring that is not connected to either the battery27or the electric appliance28.

The harness41extends out of a side of the battery27opposite from the side thereof adjacent to the electric appliance28, and reaches the electric appliance28through a vehicular rearward side portion of the internal space18. A section of the harness41extending in the vehicular rearward side portion of the internal space18is routed at a position along the reinforcement31. The section of the harness41extending throughout the vehicular rearward side portion of the internal space18is routed on the position along the reinforcement31. The harness41extends substantially in parallel with the extending direction of the reinforcement31. The harness41may be routed so as to contact the reinforcement31.

The reinforcement31has a sectional shape that is angularly bent so that a recess portion is formed at a side of the harness41which is opposite from the battery27housed in the internal space18, and faces the harness41, in a sectional view taken on a plane orthogonal to the extending direction of the harness41. The reinforcement31has a sectional shape that is angularly bent so as to be recessed in the direction toward the inside of the internal space18where the battery27is disposed, and so as to be protruded toward the outside of the internal space18. The reinforcement31has a sectional shape that covers the harness41from three sides and that has an opening at the side where the battery27is disposed. The reinforcement31may have a sectional shape that surrounds the entire periphery of the harness41.

The reinforcement31is disposed at a side of the harness41which is opposite from the battery27and the electric appliance28that are housed in the internal space18, in a sectional view taken on a plane orthogonal to the extending direction of the harness41. The reinforcement31is positioned between the harness41and the rear bumper55shown inFIG. 1. The reinforcement31is provided so that, in a plane orthogonal to the extending direction of the harness41, the distance between the reinforcement31and the rear bumper55as a body member that is disposed on an outer periphery of the vehicle when seen from above and is the nearest to the battery case21is smaller than the distance between the harness41and the rear bumper55.

FIG. 4is a plan view showing the battery pack20shown inFIG. 1.FIG. 5is a sectional view of the battery pack20taken on line V-V inFIG. 4. As shown inFIGS. 4 and 5, the reinforcement31is provided with an auxiliary rib33. The auxiliary rib33, together with the reinforcement31, reinforces the battery case21.

The auxiliary rib33is provided at a boundary position between the battery27and the electric appliance28. The auxiliary rib33extends in the vehicular transverse direction. The reinforcement31and the auxiliary rib33have a sectional shape that surrounds the entire periphery of the harness41in a sectional view taken on a plane orthogonal to the extending direction of the harness41. The reinforcement31and the auxiliary rib33have a closed annular sectional shape. The auxiliary rib33is fixed to the reinforcement31, for example, by welding.

The battery case21has a portion12in which the battery27is mounted, and a portion13adjacent to the portion12in which the electric appliance28is mounted. In this embodiment, the battery27has a greater weight than the electric appliance28. Therefore, the strength of the portion13of the battery case21is smaller than the strength of the portion12of the battery case21. Therefore, since the strength of the battery case21greatly changes at the boundary position between the portion12and the portion13, the battery case21is likely to break at the boundary position if external force is exerted on the battery case21.

In this embodiment, however, since the auxiliary rib33is provided at the boundary position between the portion12and the portion13, the rigidity of the battery case21can be effectively improved.

FIG. 6is a plan view the battery pack20showing a modification of the position where the auxiliary rib33as shown inFIG. 4is provided. As shown inFIG. 6, in this modification, the auxiliary rib33is provided at a position adjacent to the portion13of the battery case21. According to this constitution, the portion13of the battery case21that is inferior in strength is reinforced, so that the rigidity of the battery case21can be effectively improved.

FIG. 7is a plan view of the battery pack20representing a broken state of the battery case. As shown inFIG. 7, a situation is assumed in which a hybrid motor vehicle is struck from behind, and a thereby caused impact is exerted on the battery case21as shown by an arrow101.

In this situation, there is a possibility of the battery case21breaking so that the portion12and the portion13separate greatly apart from each other at a vehicular forward side, with a fulcrum of the breakage being at a boundary position between the portion12and the portion13at which the strength of the battery case21greatly changes and which is a vehicular rearward side that receives the impact. However, in this embodiment, since the harness41is routed at a position along the reinforcement31that is provided on the vehicular rearward side of the battery case21, the risk of breakage of the harness41can be reduced in comparison with the situation where the harness41is routed on the vehicular forward side.

FIG. 8is a sectional view showing a modification of the battery pack20shown inFIG. 3. As shown inFIG. 8, in this modification, the reinforcement31has a sectional shape that is curved so that a recess portion is formed at a side of the harness41which is opposite from the battery27housed in the internal space18, and faces the harness41, in a sectional view taken on a plane orthogonal to the extending direction of the harness41. The reinforcement31has a sectional shape that is curved so as to be recessed in the direction toward the inside of the internal space18where the battery27is disposed, and so as to be protruded toward the outside of the internal space18. That is, the reinforcement31may have an angularly bent sectional shape as shown inFIG. 3, or may also have a curved sectional shape as shown inFIG. 8.

The harness routing structure in the first embodiment of the invention has the battery case21, the reinforcement31and the harness41. The battery case21is a case body that defines the internal space18that houses the battery27and the electric appliance28as high-voltage electric component parts in a hybrid motor vehicle as a vehicle. The reinforcement31is a reinforcing member which is provided on the battery case21, and which is formed of a member that has a greater strength than the battery case21, and which reinforces the battery case21. The harness41is routed at a position along the reinforcement31.

According to the harness routing structure in the first embodiment constructed as described above, the reinforcement31reinforcing the battery case21reduces, to a low level, the impact that is exerted on the harness41in the situation where the hybrid motor vehicle is struck from behind, or the like. Hence, it is possible to protect the harness41while retaining a simple structure of the battery pack20.

Incidentally, the high-voltage electric component parts housed in the case body may also be an inverter, a converter, a fuel cell, etc. Besides, the high-voltage electric component parts are not limited to a battery cell that creates electricity through chemical changes or the like. For example, the high-voltage electric component parts may include an electricity storage device, such as a capacitor or the like, that stores electricity supplied from the outside.

The capacitor is an electric double-layer capacitor whose operation principle is an electric double layer that occurs in an interface between active carbon and an electrolytic solution. If the active carbon employed as a solid and the electrolytic solution (dilute sulfuric acid aqueous solution) as a liquid are placed in contact with each other, plus and minus electrodes are distributed with very short distance therebetween in the interface therebetween. If a pair of electrodes are dipped in an ionic solution and voltage is applied therebetween to such an extent that electrolysis does not occur, ions are adsorbed to the surfaces of the electrodes, so that plus and minus electricities are stored (charge). If electricity is released to the outside, the positive and negative ions are detached from the electrodes, so that a neutral state is resumed (discharge).

Furthermore, although the embodiment is applied to a hybrid motor vehicle that has an internal combustion engine and a secondary battery as motive power sources, the invention is not limited thereto. For example, the invention is applicable to a fuel cell hybrid vehicle (FCHV: Fuel Cell Hybrid Vehicle) that has a fuel cell and a secondary battery cell as motive power sources, or an electric motor vehicle (EV: Electric Vehicle). In the hybrid motor vehicle of this embodiment, the internal combustion engine is driven at a fuel economy optimal operation point, whereas in the fuel cell hybrid motor vehicle, the fuel cell is driven at an electric power generation optimal operation point. Besides, with regard to the use of the secondary battery, there is no fundamental difference between the two types of hybrid motor vehicle.

FIGS. 9A to 9Care sectional views of the battery pack20showing a harness routing structure in a second embodiment of the invention.FIGS. 9A to 9Ccorrespond toFIG. 3in the first embodiment. Compared with the harness routing structure in the first embodiment, the harness routing structure in the second embodiment has basically the same structure. Hereinafter, the same structure portions will not be described again.

As shown inFIGS. 9A to 9C, a reinforcement31is provided outside an internal space18in this embodiment. The harness41is routed at a position along the reinforcement31. In the first embodiment, the harness41is routed in the internal space18. In contrast, in this embodiment, the harness41is routed outside the internal space18.

As shown inFIGS. 9A and 9B, theFIG. 9Ahas a sectional shape that surrounds the harness41from three sides in a sectional view taken on a plane orthogonal to the extending direction of the harness41. Particularly inFIG. 9A, the entire periphery of the harness41is surrounded by the reinforcement31and a side face21aof a battery case21. InFIG. 9C, a reinforcement31having an L-sectional shape is provided on the battery case21.

In any of the examples shown inFIGS. 9A to 9C, too, the reinforcement31is disposed at a side of the harness41which is opposite from the battery27and an electric appliance28housed in the internal space18, in a sectional view taken on a plane orthogonal to the extending direction of the harness41. The reinforcement31is provided so that, in a plane orthogonal to the extending direction of the harness41, the distance between the reinforcement31and the rear bumper55shown inFIG. 1is smaller than the distance between the harness41and the rear bumper55.

FIG. 10is a perspective view of the battery pack20showing a first modification of the harness routing structure in the second embodiment. As shown inFIG. 10, the battery case21further has a bottom face21ethat faces vertically downward. In this modification, the reinforcement31is fixed to the bottom face21e. The reinforcement31is provided at a plurality of positions that are distanced from each other in the traveling direction of the vehicle. The reinforcement31extends in the vehicular transverse direction. The reinforcement31and the bottom face21eof the battery case21surround the entire periphery of the harness41.

FIG. 11is a plan view of the battery pack20showing a second modification of the harness routing structure in the second embodiment. As shown inFIG. 11, the battery case21further has a side face21dwhich faces forward of the vehicle, and side faces21band21cthat face in the vehicular transverse directions. In this modification, the reinforcement31is fixed to the side face21d. The reinforcement31is provided between the battery case21and a partition panel57that divides the luggage compartment51and the vehicle cabin52. The reinforcement31is provided on a portion of the battery case21which faces the partition panel57, that is, a vehicular forward side of the battery case21.

The harness41is routed at a position along the reinforcement31, in a path that passes along the vehicular forward side of the battery case21. The harness41is, for example, a high-voltage cable that extends out from the electric appliance28to an electronic controlled power steering (EPS).

According to the harness routing structure in the second embodiment constructed as described above, substantially the same effect as described above in connection with the first embodiment can be attained. In addition, in this embodiment, since the harness41is routed at a position along the reinforcement31that is formed of metal, leakage of electromagnetic waves emitted from the harness41can be reduced to a low level.

Incidentally, the harness routing structures described in conjunction with the first embodiment and the second embodiment may be appropriately combined to construct a different harness routing structure. For example, in a construction as shown inFIG. 11, the reinforcement31may be formed inside the battery case21, and the harness41may be routed in the internal space18. The position of the reinforcement31is not limited to the above-described positioned, but the reinforcement31may be provided, for example, on the side face21bor the side face21cinFIG. 11. Besides, the reinforcement31may be provided on a plurality of side faces of the battery case21. In that construction, the harness41may be routed at a position along the reinforcement31over the plurality of side faces of the battery case21.

Besides, although in the first embodiment and the second embodiment the battery pack20is disposed in the luggage compartment51, this is not restrictive. The battery pack20may also be disposed, for example, under a front seat or a rear seat, or under a center console disposed between the driver seat and the navigator seat at the front, or the like. Besides, in a three-row seat vehicle, the battery pack may be disposed under the second seat or the third seat.

While the invention has been described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the preferred embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the preferred embodiments are shown in various combinations and configurations, which are exemplary, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.