Connector structure and electric vehicle

A connector structure installed in the electric vehicle includes a plurality of connectors, an inter-connector conductive member configured to electrically connect the plurality of connectors, and a connector casing configured to house the inter-connector conductive member. A cover is attached to the unused connector of the plurality of connectors.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2016-228051 filed on Nov. 24, 2016, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a connector structure that is installed in a vehicle, for example, and supplies power to accessories, and an electric vehicle in which the connector structure is installed.

Description of the Related Art

A task of a connector fitting structure disclosed in Japanese Patent No. 3843074 is to easily fit and detach a plurality of connectors and easily replace fuses in the connectors.

To achieve the above task, the connector fitting structure adopts a structure including a slide structure that is movably arranged in a connector fitting direction in one connector group and includes a temporary locking unit for the other connector group, and a bolt that is screwed to the slide structure and enables movement of the slide structure in the connector fitting direction with respect to the one connector group.

Inside a hook portion of the one connector group, a drive plate on a side of a bolt distal end is located. An inner cover member including the hook portion is detachably fixed to a side of the one connector group, and the fuses are attached to the connector group inside the inner cover member. The slide structure includes a temporary locking frame that includes the temporary locking unit, and an outer cover member that includes a bolt and is rotatably coupled to the temporary locking frame.

A task of a fuse built-in connector disclosed in Japanese Laid-Open Patent Publication No. 2012-155943 is to provide the fuse built-in connector that saves labor of unmounting a service cover only by unmounting a connector, and can reduce parts such as the service cover and an interlock circuit for the service cover.

To achieve the above task, a housing of the fuse built-in connector includes an opening portion on a male connector connected with a female connector. The opening portion includes a fuse, an inverter connection terminal, and an interlock terminal that detects unmounting of a male connector and interrupts power distribution.

The housing includes a positive battery cable and a negative battery cable that are connected with the battery, and a positive A/C cable and a negative A/C cable that are branched from the battery cables and are connected with an electric air conditioner.

SUMMARY OF THE INVENTION

Due to a difference in car models such as a HEV (Hybrid Electric Vehicle), a PHEV (Plug-in Hybrid Electric Vehicle) and a BEV (Battery Electric Vehicle), and a difference in a specification such as two-wheel drive and four-wheel drive of the same car model, the number of power supply target components (accessories or auxiliaries) differs.

According to Japanese Patent No. 3843074 and Japanese Laid-Open Patent Publication No. 2012-155943, there is a concern that when the number of components of a vehicle increases, it is necessary to newly redesign a connector group (a cover, a shield shell, busbars and mounting points), which leads to an increase in design man-hours, an increase in inventory control man-hours and an increase in manufacturing man-hours. There is also a problem that a size of the entire connector fitting structure is large.

The present invention has been made to solve the above-mentioned problem. An object of the present invention is to provide a connector structure and an electric vehicle that, even when a difference in a car model or a specification increases the number of components, can make it unnecessary to newly change a connector shape (the entire structure, busbars, fuses, etc.) or can make a shape change less, in order to reduce design man-hours and manufacturing cost.

The present invention has the following features.

[1] A connector structure according to a first aspect of the present invention is a connector structure that is installed in an electric vehicle, that includes: a plurality of connectors; an inter-connector conductive member configured to electrically connect the plurality of connectors; and a casing configured to house the inter-connector conductive member, and in which a cover is attached to an unused connector of the plurality of connectors.

Even when various car models or specifications increase the number of components, by providing multiple connectors in advance, it is possible to make it unnecessary to newly change a connector shape (an entire structure, busbars, fuses, etc.), or decrease the change of shape, reduce design man-hours and reduce manufacturing cost.

A car model having a small number of components includes an unused connector. However, by attaching a cover to the unused connector, it is possible to provide a waterproof/dust-proof effect.

[2] According to the first aspect of the present invention, the inter-connector conductive member may include a first conductive member electrically connected with a first electrode conductive portion of a first connector of the connectors, a second conductive member electrically connected with a second electrode conductive portion of a second connector of the connectors, a first connection terminal provided to the first conductive member, and a second connection terminal provided to the second conductive member, and a fuse may be inserted in and electrically connected with the first connection terminal and the second connection terminal.

It is easy to mount the fuse by a fuse-insertion method of electrically connecting the fuse between the first connection terminal and the second connection terminal. It is possible to realize a compact structure compared to electrical connection that uses bolts or the like, and miniaturize the entire connector structure.

[3] According to the first aspect of the present invention, the casing may include at least a first casing configured to support at least the connectors, and a second casing configured to support at least the fuse, the first casing and the second casing may be separable.

The first casing that supports the connectors, and the second casing that supports the fuse are separable. Consequently, it is easy to electrically connect the first conductive member and the second conductive member during manufacturing.

[4] According to the first aspect of the present invention, an electrode conductive portion of at least one of the connectors may include a cylindrical portion and an extended portion, the cylindrical portion having a cylindrical shape extending in a mounting direction, and including a cutout extending in the mounting direction, the extended portion extending outwardly from a portion of the cutout in the cylindrical portion, and the extended portion and the inter-connector conductive member may be electrically connected.

The electrode conductive portion of the connector is formed in the cylindrical shape, and the cutout extending in the mounting direction is formed. Consequently, when the electrode conductive portion of the other connector is mounted on the electrode conductive portion of the cylindrical portion, the electrode conductive portion of the cylindrical shape elastically deforms to expand in a radial direction. Consequently, it is possible to easily mount the electrode conductive portion of the other connector in the electrode conductive portion of the cylindrical portion. The same applies to a case where the electrode conductive portion in the cylindrical shape is mounted on the electrode conductive portion of the other connector, too.

The extended portion extending from a portion of the cutout of the electrode conductive portion is formed. Consequently, it is possible to easily connect the extended portion and the inter-connector conductive member.

In this case, as described above, the electrode conductive portion of the connector is formed in a cylindrical shape, and the cutout extending in the mounting direction is formed. Consequently, after the extended portion and the inter-connector conductive member are connected, and when the electrode conductive portion of the other connector is mounted on the electrode conductive portion of the cylindrical portion, the electrode conductive portion of the cylindrical shape elastically deforms to expand in the radial direction from the extended portion connected with the inter-connector conductive member as a base point. It is possible to easily mount the electrode conductive portion of the other connector in the electrode conductive portion having the cylindrical shape.

[5] According to the first aspect of the present invention, an end portion of the cylindrical portion may include an expanded portion expanding in a direction perpendicular to the mounting direction, and being configured to allow an end portion of an electrode conductive portion of another connector to be inserted therein.

By inserting the end portion of the electrode conductive portion of the other connector to the expanded portion of the cylindrical portion, it is possible to connect the one connector and the other connector without using bolt connection or the like, thereby reducing the number of parts and simplifying a connection operation.

[6] The first aspect of the present invention may include at least the two connector structures according to above [5], and in the expanded portion of the cylindrical portion in one sub-connector structure, an end portion opposite to the expanded portion of the cylindrical portion in another sub-connector structure may be inserted for electrical connection.

It is effective to use a method of arranging a large number of connectors in advance to prepare for an increase in the number of accessories mounted on an electric vehicle. Alternatively, by inserting the end portion opposite to the expanded portion having the cylindrical shape of the other connector structure, in the expanded portion in the cylindrical portion of the one connector structure for electrical connection, it is possible to easily increase the number of connectors.

[7] According to the first aspect of the present invention, one of an electrode conductive portion of the connector and an electrode conductive portion of another connector may include a first busbar in a plate shape extending in a mounting direction, a hole formed in the first busbar, another of the electrode conductive portion of the connector and the electrode conductive portion of the other connector may include a second busbar extending in the mounting direction, a first inclined portion raised in one direction from a plate surface of the second busbar, and a second inclined portion extending from a top portion of the first inclined portion toward the plate surface of the second busbar, and the plate surface of the second busbar and the second inclined portion may sandwich and hold the first busbar.

By pressing the one connector and the other connector against each other and further moving them in a direction to move away from each other, the one connector and the other connector can be connected firmly. When the other connector is detached from the one connector, by pressing the one connector and the other connector against each other and further moving them in the direction to move away from each other similar to the above, the other connector can be easily detached from the one connector.

[8] According to the first aspect of the present invention, one of the connector and the casing may include a first busbar of a plate shape extending in a mounting direction, a hole formed in the first busbar, another of the connector and the casing may include a second busbar extending in the mounting direction, a first inclined portion raised in one direction from a plate surface of the second busbar, and a second inclined portion extending from a top portion of the first inclined portion toward the plate surface of the second busbar, and the plate surface of the second busbar and the second inclined portion may sandwich the first busbar.

By pressing the casing and the connector against each other and further moving them in the direction to move away from each other, the connector can be connected with the casing firmly. When the connector is detached from the casing, by pressing the casing and the connector against each other and further moving them in the direction to move away from each other similar to the above, the connector can be easily detached from the casing. It is possible to connect and fix the connector and the casing without using a fastening member such as a bolt, thereby reducing the number of parts and simplifying a connection operation.

[9] According to the first aspect of the present invention, the first inclined portion and the second inclined portion may be formed integrally with the second busbar. By punching the second busbar, it is possible to easily form the first inclined portion and the second inclined portion in the second busbar, and contribute to cost reduction.

[10] According to the first aspect of the present invention, a housing configured to protect an outer periphery may be attached to one or more connectors of the plurality of connectors except the unused connector, and, instead of the housing, the cover may be attached in advance to the unused connector of the plurality of connectors. Consequently, the unused connector does not need the housing, so that it is possible to reduce the number of parts.

[11] An electric vehicle according to a second aspect of the present invention includes the connector structure according to the first aspect of the present invention. Consequently, it is possible to easily increase or decrease the number of connectors installed in the connector structure according to the number of accessories mounted on the electric vehicle, and easily cope with car models having a large number of accessories.

[12] According to the second aspect of the present invention, the connector structure may be mounted on a casing of a power converting device or a battery. By directly mounting the connector structure on the power converting device or the battery, it is possible to reduce the number of parts. It is possible to use a common connector shape between different car models, and use a common mounting point for a high voltage casing, too. As a result, it is possible to reduce man-hours of a high voltage casing design.

[13] According to the second aspect of the present invention, the connector structure may be arranged on a rear surface of the power converting device in a vehicle longitudinal direction. The connector structure is connected with a plurality of high voltage connectors. Even when frontal collision occurs, by arranging the connector structure on the rear surface of the power converting device, it is possible to effectively prevent fracture of the connector structure and exposure of a high voltage portion due to detachment of the fitted connector, while reducing reinforcing members or the like.

According to the connector structure and the electric vehicle according to the present invention, even when various car models and specifications increase the number of components, it is not necessary to newly change a connector shape (the entire structure, the busbars, the fuses, etc.), and it is possible to reduce the design man-hours, and reduce manufacturing cost.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of a connector structure and an electric vehicle according to the present invention will be described with reference toFIGS. 1 to 11C.

FIG. 1is a cross-sectional view (a cross-sectional view on a I-I line inFIG. 2) showing a connector structure (referred to as a first connector structure10A below) according to a first embodiment.FIG. 2is a view showing a rear side of the first connector structure10A from which a connector casing12described below is detached in particular.FIG. 3is an exploded perspective view of the first connector structure10A.

This first connector structure10A is a connector structure that is installed in an electric vehicle100such as a hybrid vehicle, a plug-in hybrid vehicle, an electric automobile, or a fuel-cell vehicle, and supplies power to high voltage accessories (components). The accessories include, for example, a water heater, an A/C electric compressor, a charger provided to a PHEV, a quick charger, and a non-contact charging rectifier.

More specifically, the first connector structure10A includes the connector casing12whose outer shape is made of, for example, a resin, three mounted side connectors (a first mounted side connector14A to a third mounted side connector14C) that are mounted on the connector casing12, and a high voltage connection portion16that is connected with a high voltage electric wire from an unillustrated power converting device (PCU) or a battery.

The connector casing12is formed in, for example, a cuboid shape. A first insertion port18A, a second insertion port18B and a third insertion port (not illustrated) are formed on, for example, a front surface that faces toward a rear side of the electric vehicle100, and allow the first mounted side connector14A, the second mounted side connector14B, and the third mounted side connector14C to be mounted thereon. A fourth insertion port18D is formed on a rear surface that faces toward a front side of the electric vehicle100, and allows the high voltage connection portion16to be mounted thereon.

The first mounted side connector14A to the third mounted side connector14C according to the inventive example are arranged facing toward the rear side of the electric vehicle100, but may be arranged on an upper or lower surface or a side surface (a surface in a height direction or a surface in a width direction of the electric vehicle100) of the connector casing12. The number of mounted side connectors may be two or more yet is desirably three or more.

The connector casing12can be separated into two in a connector mounting direction (longitudinal direction of the electric vehicle100: directions indicated by arrow A inFIGS. 1 and 2), i.e., can be separated into a first casing12A on a front surface side and a second casing12B on a rear surface side. That is, the first casing12A and the second casing12B are detachable in the mounting direction. This attaching/detaching mechanism includes, for example, a plurality of engagement recess portions20that are formed on an end surface (an end surface facing toward the first casing12A) of the second casing12B, and an engagement protrusion22that is formed on the end surface (an end surface facing toward the second casing12B) of the first casing12A and is inserted in the engagement recess portions20.

When the first casing12A and the second casing12B are separated, a portion of the side surface of the first casing12A near the end surface is inwardly pressed, and thereby the engagement protrusion22is separated from the engagement recess portions20. Consequently, it is possible to easily separate the first casing12A from the second casing12B or separate the second casing12B from the first casing12A. On the other hand, the end surface of the first casing12A and the end surface of the second casing12B face and press each other in a direction to come close to each other, and thereby the engagement protrusion22of the first casing12A fit in the engagement recess portions20of the second casing12B. Consequently, it is possible to easily attach the first casing12A to the second casing12B or attach the second casing12B to the first casing12A.

The first mounted side connector14A includes two first support members24A in cylindrical shapes that are attached to the first insertion port18A of the connector casing12and extend in the longitudinal direction of the electric vehicle100, and a first electrode conductive member26A (a first positive electrode conductive member26Ap and a first negative electrode conductive member26An) that is inserted in each first support member24A.

As shown inFIG. 4, the first electrode conductive member26A (the first positive electrode conductive member26Ap and the first negative electrode conductive member26An) includes a cylindrical portion30that has a cylindrical shape extending in the mounting direction and includes a cutout28extending in the mounting direction, and an extended portion32(a positive electrode side extended portion32pand a negative electrode side extended portion32n) that extends outwardly from the portion of the cutout28in the cylindrical portion30. The positive electrode side extended portion32phas a rectangular shape. The negative electrode side extended portion32nhas an L shape. The cylindrical portion30includes at the end portion an expanded portion38that expands in a direction perpendicular to the mounting direction and in which an end portion of an electrode conductive portion36(indicated by a two-dot-dashed line inFIG. 1) of a mounting side connector34is inserted.

The second mounted side connector14B includes a second support member24B that is attached to the second insertion port18B of the connector casing12, extends in the longitudinal direction of the electric vehicle100, and is made of, for example, a resin, a second electrode conductive member26B (second positive electrode conductive member26Bp) that is attached to the second support member24B, a second positive electrode conductive plate54Bp (seeFIG. 3) that extends from the second positive electrode conductive member26Bp in a depth direction, and a housing40that is attached to a periphery of the second support member24B and is made of, for example, a resin. A rear end portion of the second positive electrode conductive plate54Bp extends to the second casing12B.

The third mounted side connector14C also employs the same configuration as that of the above second mounted side connector14B. The third mounted side connector14C includes a third support member24C that is attached to the third insertion port (not shown) of the connector casing12and is made of, for example, a resin, a third electrode conductive member26C (third positive electrode conductive member26Cp) that is an inter-connector conductive member attached in the longitudinal direction of the third support member24C, a third positive electrode conductive plate54Cp (seeFIG. 3) that extends from the third positive electrode conductive member26Cp in the depth direction, and a housing40that is attached to a periphery of the third support member24C and is made of, for example, a resin. A rear end portion of the third positive electrode conductive plate54Cp also extends to the second casing12B.

An opening41is formed at each distal end portion of the above first support member24A to third support member24C to allow the mounting side connector34to be inserted in the depth direction.

Meanwhile, the second casing12B includes at a rear portion a fuse housing portion44(seeFIG. 1) that houses a first fuse42A and a second fuse42B. A rear portion cover46is detachably mounted on a rear portion of the fuse housing portion44. Consequently, by detaching the rear portion cover46of the fuse housing portion44, it is possible to easily house the first fuse42A and the second fuse42B in the fuse housing portion44.

Four through-holes50(seeFIG. 3) are formed at a front portion of the fuse housing portion44(a boundary with respect to the first casing12A), and communicate with the first casing12A and allow insertion of each of a pair of lead terminals48Aa,48Ab of the first fuse42A and a pair of lead terminals48Ba,48Bb of the second fuse42B.

That is, when the first fuse42A and the second fuse42B are housed in the fuse housing portion44, the pair of lead terminals48Aa,48Ab of the first fuse42A and the pair of lead terminals48Ba,48Bb of the second fuse42B face toward the first casing12A, and the pair of lead terminals48Aa,48Ab of the first fuse42A and the pair of lead terminals48Ba,48Bb of the second fuse42B are inserted in the corresponding through-holes50. Consequently, it is possible to house the first fuse42A and the second fuse42B in the fuse housing portion44.

As shown inFIG. 2, the first positive electrode conductive member26Ap of the above first mounted side connector14A includes a first positive electrode conductive plate52Ap that is formed integrally with the positive electrode side extended portion32p. The first positive electrode conductive plate52Ap includes a positive electrode side elongated portion54pthat is provided for the positive electrode side extended portion32p. This positive electrode side elongated portion54pincludes one end portion that faces toward the first fuse42A, and the other end portion that faces toward the second fuse42B. As shown inFIG. 3, the positive electrode side elongated portion54pincludes a first positive electrode side bent portion56pain an L shape formed integrally with the one end portion. The positive electrode side elongated portion54pincludes a second positive electrode side bent portion56pbin an L shape formed integrally with the other end portion. The first positive electrode side bent portion56paincludes a first positive electrode side raised portion58pathat is raised upward from the one end portion of the positive electrode side elongated portion54p, and a first positive electrode side connection portion60pathat extends backward from the first positive electrode side raised portion58pa. Similarly, the second positive electrode side bent portion56pbincludes a second positive electrode side raised portion58pbthat is raised upward from the other end portion of the positive electrode side elongated portion54p, and a second positive electrode side connection portion60pbthat extends backward from the second positive electrode side raised portion58pb.

As shown inFIG. 2, the first negative electrode conductive member26An of the first mounted side connector14A includes a first negative electrode conductive plate52An formed integrally with the negative electrode side extended portion32nin the L shape. The first negative electrode conductive plate52An includes an L-shaped conductive portion62that is raised upward, and a negative electrode side elongated portion54nthat is formed integrally with the L-shaped conductive portion62. The negative electrode side elongated portion54nincludes a first negative electrode side bent portion56nain an L shape formed integrally with one end portion. The negative electrode side elongated portion54nincludes a second negative electrode side bent portion56nbin an L shape formed integrally with the other end portion. The first negative electrode side bent portion56naincludes a first negative electrode side raised portion58nathat is raised upward from the one end portion of the negative electrode side elongated portion54n, and a first negative electrode side connection portion60nathat extends backward from the first negative electrode side raised portion58na. Similarly, the second negative electrode side bent portion56nbincludes a second negative electrode side raised portion58nbthat is raised upward from the other end portion of the negative electrode side elongated portion54n, and a second negative electrode side connection portion60nbthat extends backward from the second negative electrode side raised portion58nb. An end portion of the first negative electrode side connection portion60nais inserted in the third mounted side connector14C. An end portion of the second negative electrode side connection portion60nbis inserted in the second mounted side connector14B.

Bonding terminals64ato64dmade of, for example, metal are mounted on a surface of the second casing12B on a side of the first casing12A to meet each through-hole50. When, for example, the lead terminal48Aa of the first fuse42A and the third positive electrode conductive plate54Cp of the third mounted side connector14C are inserted in the bonding terminal64afrom both of directions, the bonding terminal64aelectrically connects these terminals. The same applies to the other bonding terminals64bto64d.

As shown inFIG. 1, this first connector structure10A is mounted on a casing70of a power converting unit (PCU) or a battery installed in the electric vehicle100. A high voltage electric wire (not shown) from the power converting device (PCU) or the battery is connected with the high voltage connection portion16. When the first connector structure10A is mounted on the power converting device, the first connector structure10A is preferably arranged on a rear surface of the power converting device in the vehicle longitudinal direction.

In particular, in the present embodiment, a cover72(seeFIGS. 1 and 2) is mounted and closes the opening41of the mounted side connector that is not connected with the mounting side connector of a component among the plurality of mounted side connectors, i.e., the unused mounted side connector.FIGS. 1 and 2show examples where the cover72for closing the opening41is mounted on a distal end portion of the second mounted side connector14B.FIG. 2shows the cover72as a two-dot-dashed line. The cover72is not limited to a cover that covers the opening41as in the inventive example, and may adopt, for example, a structure that inserts a grommet in the mounted side connector to close.

As shown inFIG. 5, the housing40may not be arranged in advance for the unused connector (e.g., second mounted side connector14B), and the cover72may be configured to directly close the second insertion port18B. Consequently, the unused connector does not need the housing40, so that it is possible to reduce the number of parts.

Next, an example of a procedure of assembling this first connector structure10A will be described below. The following assembling procedure is only an example, and this first connector structure10A may be assembled by other procedures.

First, for example, the second positive electrode conductive member26Bp is mounted on the second mounted side connector14B, and the third positive electrode conductive member26Cp is mounted on the third mounted side connector14C. Subsequently, the second mounted side connector14B is attached to the second insertion port18B of the first casing12A, and the third mounted side connector14C is attached to the third insertion port (not shown).

Next, the first positive electrode conductive member26Ap and the first negative electrode conductive member26An are inserted in the first support member24A of the first mounted side connector14A. Subsequently, the positive electrode side elongated portion54pof the first positive electrode conductive plate52Ap is electrically connected with the positive electrode side extended portion32pof the first positive electrode conductive member26Ap by welding or the like. The negative electrode side elongated portion54nof the first negative electrode conductive plate52An is electrically connected with the negative electrode side extended portion32nof the first negative electrode conductive member26An by welding or the like. The connector casing12can be separated into the first casing12A and the second casing12B, so that this operation can be easily performed.

Next, the four bonding terminals64ato64dare attached to the second casing12B on a side facing the first casing12A. Subsequently, by attaching the second casing12B to the first casing12A, the third positive electrode conductive plate54Cp of the third mounted side connector14C is inserted in the bonding terminal64a. Further, the second positive electrode conductive plate54Bp of the second mounted side connector14B is inserted in the bonding terminal64b. Furthermore, the first positive electrode side connection portion60paof the first positive electrode conductive plate52Ap of the first mounted side connector14A is inserted in the bonding terminal64c. Still further, the second positive electrode side connection portion60pbof the first mounted side connector14A is inserted in the bonding terminal64d.

Next, the first fuse42A and the second fuse42B are attached to the fuse housing portion44at a rear portion of the second casing12B. In this case, the lead terminal48Aa of the first fuse42A is inserted in the bonding terminal64avia the through-hole50, and is electrically connected with the third positive electrode conductive plate54Cp of the third mounted side connector14C. The lead terminal48Ab of the first fuse42A is inserted in the bonding terminal64cvia the through-hole50, and is electrically connected with the first positive electrode conductive plate52Ap of the first mounted side connector14A.

Similarly, the lead terminal48Ba of the second fuse42B is inserted in the bonding terminal64bvia the through-hole50, and is electrically connected with the second positive electrode conductive plate54Bp of the second mounted side connector14B. The lead terminal48Bb of the second fuse42B is inserted in the bonding terminal64dvia the through-hole50, and is electrically connected with the first positive electrode conductive plate52Ap of the first mounted side connector14A.

Then, the rear portion cover46is mounted on the rear portion of the second casing12B, so that the first connector structure10A is completed.

Next, a connector structure (referred to as a second connector structure10B below) according to a second embodiment will be described with reference toFIG. 6.

As shown inFIG. 6, the second connector structure10B includes the two first connector structures (sub-connector structures)10A. More specifically, in the expanded portion38of the cylindrical portion30of the first connector structure10A, an end portion opposite to the expanded portion38of the cylindrical portion30of another first connector structure10A is inserted for electrical connection.

In this case, one first connector structure10A can include three mounted side connectors. However, this second connector structure10B can include two more mounted side connectors. That is, the second connector structure10B can include the five mounted side connectors.

Consequently, by sequentially connecting the end portion opposite to the expanded portion38of the cylindrical portion30of another first connector structure10A to the expanded portion38of each first connector structure10A, it is possible to increase the number of mounted side connectors by two at a time.

FIG. 6shows an example where the number of the first connector structures10A is two-dimensionally increased. However, the number of the first connector structures10A may be three-dimensionally increased.

Comparison between the electric vehicle100according to the inventive example and an electric vehicle200according to a comparative example, and comparison between power distribution branch structures will be described with reference toFIGS. 7 and 8.

As shown inFIG. 7, in the power distribution branch structure of the electric vehicle200according to the comparative example, a first connector CN1and a second connector CN2are connected between a first unit U1and a second unit U2installed in a first region80A such as an interior of a vehicle compartment or a region below a floor. For example, two accessories (a first accessory CP1and a second accessory CP2) are installed in the first unit U1. For example, a high voltage battery device82is installed in the second unit U2. The first accessory CP1and the second accessory CP2are PDUs (power drive units). The high voltage battery device82includes a battery (BATT), a main junction block (MAIN J/B) and a sub junction block (SUB J/B).

For example, there are 12 connectors CN3to CN14connected between the second unit U2and a third unit U3installed in a second region80B such as an engine room of the electric vehicle200. For example, five accessories (a third accessory CP3to a seventh accessory CP7) are installed in the third unit U3.

The third accessory CP3is a DC quick charging/power feeding board. The fourth accessory CP4is an AC charger. The fifth accessory CP5is a PCU (Power Control Unit (Power Converting Device)). The sixth accessory CP6is a water heater. The seventh accessory CP7is an electric compressor.

The high voltage battery device82and the third accessory CP3are connected via the third connector CN3and the eighth connector CN8. The high voltage battery device82and the fourth accessory CP4are connected via the fourth connector CN4and the ninth connector CN9. The high voltage battery device82and the fifth accessory CP5are connected via the fifth connector CN5and the tenth connector CN10. The high voltage battery device82and the sixth accessory CP6are connected via the sixth connector CN6, the eleventh connector CN11and the thirteenth connector CN13. The high voltage battery device82and the seventh accessory CP7are connected via the seventh connector CN7, the twelfth connector CN12and the fourteenth connector CN14.

The power distribution branch structure of the electric vehicle200according to the comparative example distributes power from the high voltage battery device82of the electric vehicle200to the first accessory CP1through the seventh accessory CP7via the 14 connectors CN1to CN14. Therefore, high voltage power distribution is complicated. Moreover, the second unit U2needs to supply power from the high voltage battery device82to three or more connectors (the second connector CN2, the third connector CN3, the fourth connector CN4, etc.). Therefore, the sub junction block (SUB J/B) is necessary in addition to the main junction block (MAIN J/B), and therefore the high voltage battery device82becomes large.

There are multiple routes of power distribution from the high voltage battery device82. Therefore, the third accessory CP3(DC quick charging/power feeding junction block) for quick charging/power feeding is necessary. Therefore, the power distribution branch structure becomes complicated and larger.

Also in future, it is possible that an AC indoor 100 V power feeder (eighth accessory CP8), an AC non-contact charging rectifier (ninth accessory CP9), etc. will be further added in the engine room80B. In this case, twice connectors as the number of accessories to be increased need to be connected. Therefore, it is concerned that a wiring layout also becomes more complicated, and that an installation space will reach a limit.

In addition to an AC charger (fourth accessory CP4), as necessary, it is assumed that an AC bidirectional charger (tenth accessory CP10) may be installed, and that one of the fourth accessory CP4and the tenth accessory CP10may be selected. However, the wiring layout is originally complicated. Therefore, even in a case of an identical car body, only one of the fourth accessory CP4and the tenth accessory CP10is selected and installed according to a specification, and it is concerned that development efficiency is also lowered.

By contrast with this, as shown inFIG. 8, in the power distribution branch structure of the electric vehicle100according to the inventive example, the high voltage battery device82in the first region80A and the fifth accessory CP5(PCU) in the second region80B are connected via a first multi connector MCN1and a second multi connector MCN2of the first connector structure10A.

The first multi connector MCN1is selectively connected with the fourth accessory CP4(AC charger) or the tenth accessory CP10(AC bidirectional charger). The second multi connector MCN2is further connected with the sixth accessory CP6(water heater) and the seventh accessory CP7(electric compressor).

In this case, the high voltage connection portion16of the first connector structure10A in the first multi connector MCN1is connected with a high voltage electric wire from the high voltage battery device82. For example, the first mounted side connector14A is connected with a high voltage electric wire connected with the fifth accessory CP5. For example, the third mounted side connector14C is connected with the third connector CN3of the fourth accessory CP4. The second mounted side connector14B is not used, and therefore is attached with the cover72.

Meanwhile, the high voltage connection portion16of the first connector structure10A in the second multi connector MCN2is connected with a high voltage electric wire from the first multi connector MCN1. For example, the first mounted side connector14A is connected with the mounted side connector of the fifth accessory CP5. For example, the second mounted side connector14B is connected with the fourth connector CN4of the sixth accessory CP6. The third mounted side connector14C is connected with the fifth connector CN5of the seventh accessory CP7.

Thus, the power distribution branch structure of the electric vehicle100according to the embodiment can integrate wires connected with the high voltage battery device82. Consequently, it is possible to increase the degree of freedom of the wiring layout. The sub junction block (SUB J/B) does not need to be installed in the high voltage battery device82, so that it is possible to miniaturize the high voltage battery device82. The DC quick charging/power feeding junction block does not need to be mounted, so that it is possible to simplify and miniaturize the power distribution branch structure.

When the AC non-contact charging rectifier (ninth accessory CP9) is additionally installed in the engine room80B in future, it is possible to connect the AC non-contact charging rectifier with the second mounted side connector14B of the unused first multi connector MCN1, and it is not necessary to install a new connector. When the number of accessories to be additionally installed is larger, the first multi connector MCN1and the second multi connector MCN2may be composed by the second connector structure10B, and it is not necessary to increase a connector in response to additional installation of accessories.

That is, even when the number of accessories to be additionally installed is larger, it is possible to exhibit an effect of improving the degree of freedom of the wiring layout, and simplifying and miniaturizing the power distribution branch structure. Hence, for example, in addition to the AC charger (fourth accessory CP4), the AC bidirectional charger (tenth accessory CP10) can be installed. Consequently, it is not necessary that only one of the fourth accessory CP4and the tenth accessory CP10is installed according to a specification. As a result, it is possible to provide identical equipment to an identical car body, and enhance development efficiency.

FIG. 8shows a structure that the first multi connector MCN1and the second multi connector MCN2are mounted on casings of the high voltage battery device82and the fifth accessory CP5(PCU), etc. However, the first multi connector MCN1and the second multi connector MCN2may not be mounted on the casings. For example, the power distribution branch structure may include the first multi connector MCN1and the second multi connector MCN2between cables.

Incidentally, as schematically shown inFIGS. 9A and 9B, a mounting side connector110and a mounted side connector112are electrically connected by fastening a first busbar116A of a first electrode conductive portion114A in the mounting side connector110, and a second busbar116B of the second electrode conductive portion114B in the mounted side connector112by using, for example, a bolt118. In this case, the number of parts increases, and a space for fastening the bolt needs to be secured. The degree of design freedom is limited, and cost reduction is also limited.

As schematically shown inFIGS. 10A to 10C, a connector structure10C (referred to as a third connector structure10C) according to a third embodiment employs different configurations of electrode conductive portions of the mounting side connector110and the mounted side connector112from the example inFIGS. 9A and 9B. The mounting side connector110corresponds to the above mounting side connector34, and the mounted side connector112corresponds to the above first mounted side connector14A or the like.

That is, the mounting side connector110includes the first busbar116A that constitutes the first electrode conductive portion114A and extends in the mounting direction, and a hole120that is formed in the first busbar116A.

The mounted side connector112includes the second busbar116B that constitutes the second electrode conductive portion114B and extends in the mounting direction, a first inclined portion124A that is raised in one direction from a plate surface122of the second busbar116B, and a second inclined portion124B that extends from a top portion of the first inclined portion124A toward the plate surface122of the second busbar116B. That is, the first inclined portion124A and the second inclined portion124B are formed integrally with the second busbar116B.

When the mounting side connector110is attached to the mounted side connector112, the plate surface122of the second busbar116B and the second inclined portion124B sandwich and hold the first busbar116A.

That is, as shown inFIG. 10A, for example, the mounting side connector110is pressed against the mounted side connector112. In this case, for example, the mounting side connector110is pressed against the mounted side connector112such that the hole120of the first busbar116A and the first inclined portion124A and the second inclined portion124B of the second busbar116B face toward each other.

Subsequently, as shown inFIG. 10B, the mounting side connector110is moved downward, for example, to insert a top portion of the first inclined portion124A of the second busbar116B into the hole120of the first busbar116A.

Subsequently, when the mounting side connector110moves in a direction away from the mounted side connector112as shown inFIG. 10C, a lower surface of the first busbar116A moves along the plate surface122of the second busbar116B, so that the first busbar116A and the second busbar116B are assembled. In this case, the second inclined portion124B of the second busbar116B is bent obliquely downward. Therefore, a distal end portion of the second inclined portion124B and the plate surface122of the second busbar116B sandwich the first busbar116A. Consequently, it is possible to increase a contact area of the first busbar116A and the second busbar116B, so that the first busbar116A and the second busbar116B are electrically conducted.

Similar to the above, when the mounting side connector110is detached from the mounted side connector112, the mounting side connector110is pressed against the mounted side connector112to release a sandwiching relation between the first busbar116A and the second inclined portion124B and the plate surface122of the second busbar116B. Subsequently, by further moving the mounting side connector110and the mounted side connector112in the direction to move away from each other, it is possible to detach the mounting side connector110from the mounted side connector112. In this case, an inclined surface of the second inclined portion124B functions as a guide surface in a detaching direction of the first busbar116A. Consequently, it is possible to easily detach the mounting side connector110from the mounted side connector112.

In the present embodiment, the hole120is formed in the first busbar116A of the mounting side connector110, and the first inclined portion124A and the second inclined portion124B are formed in the second busbar116B of the mounted side connector112. However, there may be a structure including the first inclined portion124A and the second inclined portion124B formed in the first busbar116A of the mounting side connector110, and the hole120formed in the second busbar116B of the mounted side connector112.

Next, a connector structure (referred to as a fourth connector structure10D) according to a fourth embodiment will be described with reference toFIGS. 11A to 11C.

This fourth connector structure10D is applied to a case where a mounted side connector132is attached to and detached from a casing130. The casing130corresponds to the above casing mounting side connector34, and the mounted side connector132corresponds to the above first mounted side connector14A or the like.

That is, the mounted side connector132includes a third busbar116C that constitutes a third electrode conductive portion114C and extends in the mounting direction, and a hole134that is formed in the third busbar116C.

The casing130includes a fourth busbar116D that constitutes a fourth electrode conductive portion114D and extends in the mounting direction, a third inclined portion124C that is raised in one direction from a plate surface136of the fourth busbar116D, and a fourth inclined portion124D that extends from a top portion of the third inclined portion124C toward the plate surface136of the fourth busbar116D. That is, the third inclined portion124C and the fourth inclined portion124D are formed integrally with the fourth busbar116D.

When the mounted side connector132is mounted on the casing130, the plate surface136of the fourth busbar116D and the fourth inclined portion124D sandwich and hold the third busbar116C.

That is, similar to the case of the above third connector structure10C, by pressing the mounted side connector132against the casing130and moving the mounted side connector132and the casing130in a direction away from each other, it is possible to connect the mounted side connector132with the casing130firmly. When the mounted side connector132is detached from the casing130, by pressing the mounted side connector132against the casing130and moving the mounted side connector132and the casing130in the direction away from each other similar to the above, it is possible to easily detach the mounted side connector132from the casing130.

In the present embodiment, the hole134is formed in the third busbar116C of the mounted side connector132, and the third inclined portion124C and the fourth inclined portion124D are formed in the fourth busbar116D of the casing130. However, there may be a structure including the third inclined portion124C and the fourth inclined portion124D formed in the third busbar116C of the mounted side connector132, and the hole134formed in the fourth busbar116D of the casing130.

In the present embodiment, the connector structures10A,10B installed in the electric vehicle100includes: the plurality of connectors (e.g., the first mounted side connector14A to the third mounted side connector14C); the inter-connector conductive members (e.g., the first positive electrode conductive plate52Ap and the first negative electrode conductive plate52An) that electrically connect the plurality of connectors; and the casing12that houses the inter-connector conductive members, and the cover72is attached to an unused connector (e.g., the second mounted side connector14B) among the plurality of connectors.

Even when various car models or specifications increase the number of components, by providing multiple connectors in advance, it is possible to make it unnecessary to newly change a connector shape (an entire structure, busbars, fuses, etc.), or decrease the change of shape, reduce design man-hours and reduce manufacturing cost.

A car model including a small number of components includes an unused connector. However, by attaching the cover72to the unused connector, it is possible to provide a waterproof/dust-proof effect.

In the present embodiment, each inter-connector conductive member includes a first conductive member (e.g., first negative electrode conductive plate52An) that is electrically connected with a first electrode conductive portion (e.g., first negative electrode conductive member26An) of the first connector (e.g., first mounted side connector14A), a second conductive member (e.g., second positive electrode conductive plate54Bp) that is electrically connected with a second electrode conductive portion (e.g., second positive electrode conductive member26Bp) of the second connector (e.g., second mounted side connector14B), a first connection terminal (e.g., bonding terminal64b) that is provided to the first conductive member, and a second connection terminal (e.g., bonding terminal64d) that is provided to the second conductive member. A fuse (e.g., second fuse42B) is inserted in and electrically connected with the first connection terminal and the second connection terminal.

It is easy to mount the fuse by a fuse-insertion method of electrically connecting the fuse between the first connection terminal and the second connection terminal. It is possible to realize a compact structure compared to electrical connection that uses bolts or the like, and miniaturize the entire connector structure.

In the present embodiment, the connector casing12at least includes the first casing12A that supports at least the connectors, and the second casing12B that supports at least the fuses, and the first casing12A and the second casing12B are separable.

The first casing12A that supports the connectors, and the second casing12B that supports the fuses are separable. Consequently, it is easy to electrically connect the first conductive member and the second conductive member during manufacturing.

In the present embodiment, an electrode conductive portion (e.g., first electrode conductive member26A) of at least one of the connectors includes the cylindrical portion30and the extended portion32. The cylindrical portion30has the cylindrical shape extending in the mounting direction, and includes the cutout28extending in the mounting direction. The extended portion32extends outwardly from the portion of the cutout28. The extended portion32and the inter-connector conductive member are electrically connected.

The electrode conductive portion (e.g., first conduct electrode conductive member26A) of the connector (e.g., first mounted side connector14A) is formed in a cylindrical shape, and the cutout28extending in the mounting direction is formed. Consequently, when the electrode conductive portion36of another connector (e.g., mounting side connector34) is mounted on the electrode conductive portion in the cylindrical shape, the electrode conductive portion in the cylindrical shape elastically deforms to expand in the radial direction. Consequently, it is possible to easily mount the electrode conductive portion36of the other connector on the electrode conductive portion in the cylindrical shape. The same applies to a case where the electrode conductive portion in the cylindrical shape is mounted on the electrode conductive portion36of the other connector, too.

By forming the extended portion32extending from the portions of the cutout28of the electrode conductive portion, it is possible to easily connect the extended portions32and the inter-connector conductive member.

In this case, as described above, the electrode conductive portion of the connector is formed in a cylindrical shape, and the cutout28extending in the mounting direction is formed. Consequently, after the extended portion32and the inter-connector conductive member are connected, and when the electrode conductive portion36of the other connector is mounted on the electrode conductive portion in the cylindrical shape, the electrode conductive portion in the cylindrical shape elastically deforms to expand in the radial direction from the extended portion32connected with the inter-connector conductive member as a base point. Consequently, it is possible to easily mount the electrode conductive portion36of the other connector on the electrode conductive portion in the cylindrical shape.

In the present embodiment, the end portion of the cylindrical shape includes the expanded portion38that expands in the direction perpendicular to the mounting direction and is configured to allow the end portion of the electrode conductive portion36of the mounting side connector34to be inserted therein.

By inserting the end portion of the electrode conductive portion36of the mounting side connector34in the expanded portion38in the cylindrical shape, it is possible to connect the first mounted side connector and the mounting side connector without using bolt connection or the like, thereby reducing the number of parts and simplifying a connection operation.

In the present embodiment, in the expanded portion38in the cylindrical shape of the one connector structure10A, the end portion opposite to the expanded portion38of the cylindrical shape in the other connector structure10A is inserted for electrical connection.

It may be effective to use a method of arranging a large number of connectors in advance to prepare for an increase in the number of accessories mounted on the electric vehicle100. Additionally, by inserting the end portion opposite to the expanded portion38having the cylindrical shape of the other connector structure10A, in the expanded portion38having the cylindrical shape of the one connector structure10A for electrical connection, it is possible to easily increase the number of connectors.

In the present embodiment, one of the first electrode conductive portion114A of the mounting side connector110and the second electrode conductive portion114B of the mounted side connector112includes the first busbar116A in the plate shape that extends in the mounting direction, and the hole120that is formed in the first busbar116A. The other of the electrode conductive portion114A of the mounting side connector110and the second electrode conductive portion114B of the mounted side connector112includes the second busbar116B that extends in the mounting direction, the first inclined portion124A that is raised in one direction from the plate surface122of the second busbar116B, and the second inclined portion124B that extends from the top portion of the first inclined portion124A toward the plate surface122of the second busbar116B, and the plate surface122and the second inclined portion124B of the second busbar116B sandwich and hold the first busbar116A.

By pressing the mounting side connector110and the mounted side connector112against each other and further moving them in the direction to move away from each other, the mounting side connector110and the mounted side connector112can be connected firmly. When the mounting side connector110is detached from the mounted side connector112, by pressing the mounting side connector110and the mounted side connector112against each other and further moving them in the direction to move away from each other similar to the above, the mounting side connector110can be detached from the mounted side connector112.

In the present embodiment, one of the mounted side connector132and the casing130includes the third busbar116C of the plate shape that extends in the mounting direction, and the hole134that is formed in the third busbar116C. The other of the mounted side connector132and the casing130includes the fourth busbar116D that extends in the mounting direction, the third inclined portion124C that is raised in the one direction from the plate surface136of the fourth busbar116D, and the fourth inclined portion124D that extends from the top portion of the third inclined portion124C toward the plate surface136of the fourth busbar116D, and the plate surface136of the fourth busbar116D and the fourth inclined portion124D sandwich the third busbar116C.

By pressing the casing130and the mounted side connector132against each other and further moving them in the direction to move away from each other, the mounted side connector132can be connected with the casing130firmly. When the mounted side connector132is detached from the casing130, by pressing the casing130and the mounted side connector132against each other and further moving them in the direction to move away from each other similar to the above, the mounted side connector132can be easily detached from the casing130.

It is possible to connect and fix the mounted side connector132and the casing130without using a fastening member such as a bolt, thereby reducing the number of parts and simplifying a connection operation.

In the present embodiment, the first inclined portion124A and the second inclined portion124B are formed integrally with the second busbar116B. The third inclined portion124C and the fourth inclined portion124D are formed integrally with the fourth busbar116D.

Consequently, by performing punching machining on the second busbar116B (fourth busbar116D), it is possible to easily form the first inclined portion124A (third inclined portion124C) and the second inclined portion124B (fourth inclined portion124D) in the second busbar116B (fourth busbar116D), thereby contributing to cost reduction.

In the present embodiment, the housing40that protects an outer periphery may be attached to one or more of the connectors among the plurality of connectors except the unused connector. Instead of the housing40, the cover72may be attached in advance to the unused connector among the plurality of connectors. For example, the housing40may not be arranged in advance, and the cover72may be configured to directly close the insertion port of the housing40. Consequently, the unused connector does not need the housing40, so that it is possible to reduce the number of parts.

The electric vehicle100according to the present embodiment includes one or more of the above first connector structure10A to fourth connector structure10D.

Consequently, it is possible to easily increase or decrease the number of connectors installed in the connector structure according to the number of accessories mounted on the electric vehicle100, and easily cope with car models having a large number of accessories.

According to the present embodiment, the first connector structure10A to the fourth connector structure10D are mounted on a casing of a power converting device or a battery. Consequently, by directly mounting the connector structure on the power converting device or the battery, it is possible to reduce the number of parts. It is possible to use a common connector shape between different car models, and use a common mounting point for high voltage casings. As a result, it is possible to reduce man-hours of high voltage casing design.

According to the present embodiment, the first connector structure10A to the fourth connector structure10D may be arranged on a rear surface of the power converting device in a vehicle longitudinal direction. The connector structure is connected with a plurality of high voltage connectors. Even when frontal collision occurs, by arranging the connector structure on the rear surface of the power converting device, it is possible to effectively prevent fracture of the connector structure and exposure of a high voltage portion due to detachment of the fitted connector, while reducing reinforcing members or the like.

The present invention is not limited to the above embodiments, and can be changed freely without departing from the gist of the present invention.