To reduce the number of components, size and weight while preventing breakage of the casing, a high-voltage device provided adjacent to a vehicle component constituting a vehicle includes: a casing housing a high-voltage portion; and a plurality of bolts fastening the casing to an attachment portion to which the casing is attached. The high-voltage device has a first end face at which the casing is in contact with the attachment portion and a second end face opposite to the first end face, and the plurality of bolts are composed of long bolts extending from the second end face to the first end face. The long bolts are each attached to the casing at a position between the vehicle component and the high-voltage portion.

TECHNICAL FIELD

The present disclosure relates to a high-voltage device.

BACKGROUND

Patent Document 1 (JP2012-152091A) provides a motor unit mounted to a vehicle such as an electric vehicle or a hybrid vehicle using a motor as a driving source.

The motor unit includes a vehicle driving motor and a high-voltage device attached to the vehicle driving motor.

The high-voltage device includes a high-voltage control for controlling the vehicle driving motor, a control casing housing the high-voltage control, and a closing plate for closing the control casing.

Such a motor unit is disposed, for example, under a floor panel of a vehicle. There is thus concern that the motor unit collides with a vehicle component such as a crossmember upon vehicle collision, resulting in breakage of the control casing and the closing plate.

Thus, it is considerable to protect the motor unit by providing a protector made of a metal plate outside the motor unit, as disclosed in Patent Document 2 (JP2014-76685A).

SUMMARY

Unfortunately, when the protector is provided as in the prior art, the motor unit increases the number of components, size, and weight.

The present invention was made in view of the above circumstances. An object of at least one embodiment of the present invention is to provide a high-voltage device that advantageously reduces the number of components, size and weight while preventing breakage of the casing.

To solve the above problem, a high-voltage device according to at least one embodiment of the present invention, provided adjacent to a vehicle component constituting a vehicle, comprises: a casing housing a high-voltage portion, and a plurality of bolts fastening the casing to an attachment portion to which the casing is attached, the high-voltage device having a first end face at which the casing is in contact with the attachment portion and a second end face opposite to the first end face, the plurality of bolts being long bolts extending from the second end face to the first end face, the long bolts each being attached to the casing at a position between the vehicle component and the high-voltage portion.

With this configuration, a portion of the casing located more inwardly than the long bolts is protected by the long bolts. Thus, it is advantageous in preventing breakage caused from outside to inside of the casing during vehicle collision.

Consequently, it is advantageous in reducing the number of components, size and weight of the vehicle structure.

In some embodiments, the long bolts are disposed, with a spatial interval, at a side of the casing which faces the vehicle component, and the long bolts respectively extend in an identical direction.

With this configuration, when one long bolt is pressed by the vehicle component upon vehicle collision and the casing is thereby rotated, the inwardly located portion of the casing is protected by the other long bolts. Thus, it is more advantageous in preventing breakage caused from outside to inside of the casing during vehicle collision.

In some embodiments, the high-voltage device is provided under a floor panel of the vehicle, the vehicle component comprises the floor panel and a frame member bonded to a lower face of the floor panel and extending along the floor panel, and the long bolts extend in a longitudinal direction of the frame member.

With this configuration, the inwardly located portion of the casing is protected by the long bolts from the floor panel or the frame member during vehicle collision. Thus, it is more advantageous in preventing breakage caused from outside to inside of the casing during vehicle collision.

In some embodiments, the long bolts are disposed at an upper end on a side of the casing which faces the frame member; at a position facing a lower end of the frame member on the side of the casing which faces the frame member; and at an end portion opposite to the frame member on a side of the casing which faces the floor panel.

This configuration is more advantageous in enhancing the effect of preventing breakage caused from outside to inside of the casing during vehicle collision.

In some embodiments, insert boss portions for receiving the bolts are provided, at portions of the casing into which the long bolts are inserted, so as to project toward the vehicle component.

With this configuration, the long bolts are strongly supported by the casing via the insert boss portions. Thus, it is more advantageous in preventing breakage caused from outside to inside of the casing, by the long bolts, during vehicle collision.

In some embodiments, the high-voltage portion is a high-voltage control, attached to a vehicle driving motor, for controlling the vehicle driving motor.

This configuration is advantageous in protecting the high-voltage control for controlling the vehicle driving motor by the long bolts during vehicle collision.

In some embodiments, the casing comprises a first casing to which the high-voltage control is attached and a second casing which covers the high-voltage control, and the long bolts penetrate the first casing and the second casing so that the long bolts fasten the first casing to the second casing and fasten the second casing to the vehicle driving motor.

This configuration is more advantageous in protecting the high-voltage control for controlling the vehicle driving motor by the long bolts during vehicle collision.

DETAILED DESCRIPTION

In the drawings, the reference FR indicates front in a front-back direction of a vehicle, whereas the reference UP indicates upper side of a vehicle.

The present embodiment describes a case where a high-voltage device is attached to a vehicle driving motor for driving rear wheels of a vehicle, and a motor unit is composed of the high-voltage device and the vehicle driving motor.

First, the explanation will be given about the structure of vehicle rear at which the motor unit is disposed.

As shown inFIG. 3, the vehicle rear is provided with a pair of rear side members (vehicle frame member)10extending in the vehicle front-back direction at both sides in the vehicle width direction, a rear floor crossmember (vehicle frame member)12extending in the vehicle width direction and connecting the pair of rear side members10, a rear floor panel14disposed above the rear side members10and the rear floor crossmember12, and rear wheels (not shown).

The motor unit20is disposed behind the rear floor crossmember12and under the rear floor panel14.

As shown inFIG. 1andFIG. 2, the motor unit20includes a vehicle driving motor22and a high-voltage device21. The high-voltage device21includes a high-voltage control24, a control casing26, and a closing plate28.

The vehicle driving motor22is configured to drive the rear wheels and includes a motor casing23made of aluminum alloy, as well as a stator and a rotor (not shown) provided inside the motor casing23.

The high-voltage control24, which is configured to control the vehicle driving motor22, includes, as shown inFIG. 3, a substrate2404on which a semiconductor device2402for controlling electric power is mounted, a condenser2406for controlling electric power, and a current sensor2408, and serves as a high voltage portion which controls high-voltage electric power to be supplied to the vehicle driving motor22.

The control casing26is configured to house the high-voltage control24and made of aluminum alloy.

The closing plate28is configured to close the control casing26and made of aluminum alloy.

In the present embodiment, the control casing26and the closing plate28constitute the casing in scope of the claims.

The high-voltage control24is fixed to the closing plate28.

At the motor casing23side, the control casing26has a three-phase bus bar connecting the high-voltage control24to a winding of the stator provided inside the motor casing23, a hole into which a cable is inserted from a sensor provided inside the motor casing23for measuring the rotational speed or the temperature of the rotor, a rotor bearing, etc.

The high-voltage control24is fixed to the motor casing23by fixing the control casing26to the motor casing23and then fastening the closing plate28to the control casing26.

The closing plate28, the control casing26, and the motor casing23are arranged in the vehicle width direction and fastened with a plurality of bolts (long bolts)34,38which are located at outer peripheral portions of the closing plate28, the control casing26, and the motor casing23, i.e., at outer peripheral portions of the motor unit20.

In the present embodiment, the plurality of bolts34,38fasten the closing plate28to the control casing26and fix the closing plate28and the control casing26to the motor casing23.

In the present embodiment, the motor casing23corresponds to the attachment portion, to which the casing is attached, in scope of the claims.

Additionally, the bolts34,38are each attached to the closing plate28and the control casing26at a position between the high-voltage portion and the vehicle component which includes the rear floor crossmember (vehicle frame member)12and the rear floor panel (floor panel)14.

The bolts34,38are made of a stronger material than at least the control casing26and the closing plate28, for example a steel material.

As shown inFIG. 1, the closing plate28is provided with a plurality of mount attachment portions30. With mounts (not shown) attached to the mount attachment portions30, the motor unit20is connected to the vehicle frame member such as the rear side member10via a rear suspension crossmember (not shown).

In this context, the plurality of bolts34,38may be used to attach the mounts. That is, the mount attachment portions30may be insert boss portions36,40into which the plurality of bolts34,38are inserted. This eliminates additional bolts for attaching the mounts, thus reducing the number of components and man-hours.

Additionally, as shown inFIG. 2, a reduction mechanism32for transmitting motor power with reduced rotational speed to the rear wheels is connected to an end portion of the motor casing23opposite to the closing plate28.

One of the bolts fastening the closing plate28to the control casing26and fixing the closing plate28and the control casing26to the motor casing23, a first bolt34, is disposed at the closest position to the rear floor crossmember12on a side of the closing plate28and the control casing26which faces the rear floor crossmember12. In other words, the first bolt34is disposed at an upper end of the side of the closing plate28and the control casing26which faces the rear floor crossmember12.

That is, as shown inFIG. 4, one of the bolts, namely, the first bolt34is located at a position where the motor unit20firstly collides with the rear floor crossmember12of the vehicle component upon vehicle collision.

A shaft portion35of the first bolt34extends in the vehicle width direction parallel to a direction in which the rear floor crossmember12extends. Moreover, the shaft portion35penetrates the control casing26and the closing plate28and extends over the entire length of the control casing26and the closing plate28in the vehicle width direction.

In other words, the control casing26is in contact with the motor casing23at a first end face, and the first bolt34extends from a second end face opposite to the first end face, to the first end face.

In more detail, as shown inFIGS. 1, 3, and 4, an insert boss portion36for receiving the first bolt34is provided so as to project toward the rear floor crossmember12at a portion where the closing plate28, the control casing26, and the motor casing23collide with the rear floor crossmember12upon vehicle collision.

As shown inFIG. 2, the insert boss portion36extends across the closing plate28, the control casing26, and the motor casing23over the entire length of the shaft portion35of the first bolt34, and extends over the entire length of the control casing26and the closing plate28in the vehicle width direction. Thus, the shaft portion35of the first bolt34is strongly supported.

Additionally, a second bolt38is located in the motor unit20at a different position from the first bolt34.

A shaft portion35of the second bolt38extends in a direction intersecting with a direction in which the motor unit20collides with the rear floor crossmember12or the rear floor panel14of the vehicle component, in other words, extends in the vehicle width direction, and extends over the entire length of the control casing26and the closing plate28in the vehicle width direction. Thus, the shaft portion35of the second bolt38is strongly supported.

In other words, the second bolt38extends from the second end face, opposite to the first end face at which the control casing26is in contact with the motor casing23, to the first end face.

In more detail, two second bolts38are provided in the present embodiment.

One of the two second bolts38, a second bolt38A, is provided at an end portion opposite to the rear floor crossmember12on a side of the motor unit20which faces the rear floor panel14, as shown inFIGS. 1, 3, and 5.

That is, an insert boss portion40A for receiving the second bolt38A is provided so as to project toward the rear floor panel14at a position where, after the motor unit20collides with the rear floor crossmember12upon vehicle collision, the motor unit20firstly collides with the rear floor panel14by further being pressed and thereby rotating a rear end portion of the motor unit20around the first bolt34upwardly.

The insert boss portion40A extends across the closing plate28, the control casing26, and the motor casing23over the entire length of the shaft portion35of the second bolt38A, in other words, extends in the vehicle width direction, and extends over the entire length of the control casing26and the closing plate28in the vehicle width direction. Thus, the shaft portion35of the second bolt38A is strongly supported.

The other of the two second bolts38, a second bolt38B, is provided at a portion lower than the first bolt34in the vehicle direction and upper than the lower end of the rear floor crossmember12in the vehicle direction, on the side of the motor unit20which faces the rear floor crossmember12, as shown inFIGS. 1, 3, and 6. In other words, the second bolt38B is disposed at a position facing the lower end of the rear floor crossmember12on the side of the control casing26and the closing plate28which faces the rear floor crossmember12.

That is, an insert boss portion40B for receiving the second bolt38B is provided so as to project toward the rear floor crossmember12at a position where, after the motor unit20collides with the rear floor crossmember12upon vehicle collision, the motor unit20collides with the rear floor crossmember12by further being pressed and thereby rotating a lower end portion of the motor unit20around the first bolt34forwardly.

The insert boss portion40B extends across the closing plate28, the control casing26, and the motor casing23over the entire length of the shaft portion35of the second bolt38B, in other words, extends in the vehicle width direction, and extends over the entire length of the control casing26and the closing plate28in the vehicle width direction. Thus, the shaft portion35of the second bolt38B is strongly supported.

As described above, the first bolt34and the second bolts38A,38B are disposed at a side of the closing plate28and the control casing26which faces the vehicle component (rear floor crossmember12and rear floor member14) with a spatial interval. The bolts34,38A,38B each extend in an identical direction.

As shown inFIG. 3andFIG. 4, when the motor unit20is pressed upon vehicle collision, the motor unit20approaches the rear floor crossmember12, and the insert boss portion36of the first bolt34collides with the rear floor crossmember12.

In this regard, the first bolt34is located at the closest position to the rear floor crossmember12on the side of the motor unit20which faces the rear floor crossmember12, and the shaft portion35of the first bolt34extends in the direction intersecting with the direction in which the motor unit collides with the rear floor crossmember12. Thus, a portion of the control casing26and a portion of the closing plate28located more inwardly in the motor unit20than the shaft portion35of the first bolt34are protected from the collision with the rear floor crossmember12by the shaft portion35of the first bolt34. It is thus advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

Additionally, since the shaft portion35of the first bolt34extends over the entire length of the control casing26and the closing plate28in the vehicle width direction, it is more advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

Additionally, since the insert boss portion36of the first bolt34projects toward the rear floor crossmember12so that the first bolt34is strongly supported by the control casing26and the closing plate28via the insert boss portion36, it is advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28by the shaft portion35of the first bolt34.

Additionally, since the insert boss portion36extends over the entire length of the control casing26and the closing plate28in the vehicle width direction, it is advantageous in more strongly supporting the shaft portion35of the first bolt34, and it is more advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

As shown inFIG. 4andFIG. 5, when the insert boss portion36of the first bolt34collides with the rear floor crossmember12upon vehicle collision, and then a rear portion of the motor casing23is biased upwardly due to a load applied to the motor casing23, the insert boss portion40A of the second bolt38A collides with the rear floor panel14.

In this regard, the second bolt38A is located at an outer peripheral portion of the motor unit20, and the shaft portion35of the second bolt38A extends in the direction intersecting with the direction in which the motor unit collides with the rear floor panel14. Thus, a portion of the control casing26and a portion of the closing plate28located more inwardly in the motor unit20than the shaft portion35of the second bolt38A are protected from the collision with the rear floor panel14by the shaft portion35of the second bolt38A. It is thus advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

Additionally, since the shaft portion35of the second bolt38A extends over the entire length of the control casing26and the closing plate28in the vehicle width direction, it is more advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

Additionally, since the insert boss portion40A of the second bolt38A projects toward the rear floor panel14so that the second bolt38A is strongly supported by the control casing26and the closing plate28via the insert boss portion40A, it is advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28by the shaft portion35of the second bolt38A.

Additionally, since the insert boss portion40A extends over the entire length of the control casing26and the closing plate28in the vehicle width direction, it is advantageous in more strongly supporting the shaft portion35of the second bolt38A, and it is more advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

As shown inFIG. 4andFIG. 6, when the insert boss portion36of the first bolt34collides with the rear floor crossmember12upon vehicle collision, and then a front portion of the motor casing23is biased upwardly due to a load applied to the motor casing23, the insert boss portion40B of the second bolt38B collides with the rear floor crossmember12.

In this regard, the second bolt38B is located at an outer peripheral portion of the motor unit20, and the shaft portion35of the second bolt38B extends in the direction intersecting with the direction in which the motor unit collides with the rear floor crossmember12. Thus, a portion of the control casing26and a portion of the closing plate28located more inwardly in the motor unit20than the shaft portion35of the second bolt38B are protected by the shaft portion35of the second bolt38B. It is thus advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28. Additionally, since the shaft portion35of the second bolt38B extends over the entire length of the control casing26and the closing plate28in the vehicle width direction, it is more advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

Additionally, since the insert boss portion40B of the second bolt38B projects toward the rear floor crossmember12so that the second bolt38B is strongly supported by the control casing26and the closing plate28via the insert boss portion40B, it is advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28by the shaft portion35of the second bolt38B.

Additionally, since the insert boss portion40B extends over the entire length of the control casing26and the closing plate28in the vehicle width direction, it is advantageous in more strongly supporting the shaft portion35of the second bolt38B, and it is more advantageous in preventing breakage caused from outside to inside of the control casing26and the closing plate28.

Additionally, the use of the first bolt34and the second bolts38A,38B for sandwiching the control casing26between the closing plate28and the motor casing23enables the control casing26and the closing plate28to be protected during vehicle collision, thus advantageously reducing the number of components, size and weight of motor unit20, compared with the case where a protector is provided at the motor unit20.

Furthermore, since fastening of the closing plate28to the control casing26and attachment of the control casing26to the motor casing23are simultaneously performed by the first bolt34and the second bolts38, it is possible to reduce the number of fastening bolts and thereby reduce man-hours.

In this context, fastening of the closing plate28to the control casing26and attachment of the control casing26to the motor casing23may be performed only by the bolts, such as the first bolt34and the second bolts38, penetrating the control casing26and the closing plate28; or may partially use bolts for fastening only the closing plate28and the control casing26or bolts only for attaching the control casing26to the motor casing23.

It is only needed that the bolts penetrating the control casing26and the closing plate28are provided at least at portions where the motor unit20will collide with the vehicle component such as the rear floor crossmember12and the rear floor panel14.

The insert boss portions36,40A,40B may be provided at multiple sites with a spatial interval in a longitudinal direction of the shaft portions35of the first bolt34and the second bolts38A.38B. Advantageously, the insert boss portions36,40A,40B extend over the entire length of the control casing26and the closing plate28in the vehicle width direction as in the present embodiment, in that the shaft portions35of the first bolt34and the second bolts38A,38B are strongly supported. In the present embodiment, the explanation was made in conjunction with the case where the vehicle structure mounted to a vehicle is the motor unit20, but the vehicle structure may be any structure that includes the control casing26(first casing) for housing a high-voltage portion, the closing plate28(second casing) for closing the control casing26(first casing), and a plurality of bolts disposed at outer peripheral portions of the casings so as to fasten them. The present invention can be applied to various known vehicle structures having a high-voltage portion, such as an inverter, a converter, and a battery charger.

Moreover, in the embodiment, the explanation was made in conjunction with the case where the vehicle component with which the vehicle structure collides is the rear floor crossmember12and the rear floor panel14, but the vehicle component is not limited to such members and may be a rigid member or component attached to the vehicle frame member of the rear side member10or the rear floor crossmember12, of course.