Abstract:
An arrangement structure of an electric junction box is provided, by which damage of the electric junction box in the event of a collision of a vehicle can be reduced and a plurality of electric wires can be easily connected to the electric junction box with good workability. The arrangement structure includes: a high voltage battery; a battery pack for receiving the battery, the battery pack being mounted on a vehicle; and an electric junction box arranged in the battery pack, the electric junction box being connected to the battery, wherein on the assumption that a collision takes place on the battery pack-mounting side of the vehicle, the electric junction box is arranged on the side of a wall of the battery pack, the wall being situated on the side opposite to the collision side of the vehicle.

Description:
BACKGROUND OF THE INVENTION 
   (1) Field of the Invention 
   The present invention relates to an arrangement structure of an electric junction box, in which the electric junction box is arranged in a battery pack mounted on an electric vehicle and electric wires are arranged from the electric junction box to an inverter and so on. 
   (2) Description of the Related Art 
     FIG. 4  shows an example of a conventional arrangement structure of an electric junction box (see Japanese Patent Application Laid-Open No. H9-277840; pages 4-5 and FIG. 1). 
   In this conventional arrangement structure, an electric junction box  72 , inverter  73  for driving a motor, motor controller  74  and DC/DC converter  75  are arranged in an electric box  71 , and the electric junction box  72 , inverter  73  for driving a motor and DC/DC converter  75  are connected to each other by an electric harness  76  and connector  77 . 
   A direct current power is supplied from a battery to the electric junction box  72  through an electric connector  78 , then on the basis of a command from the motor controller  74  a direct current power from the battery is converted to an alternating current power by the inverter  73  so as to drive the motor and then, a direct current power from the electric junction box  72  is reduced by the DC/DC converter  75  and supplied to an electric instrument with an output harness  79 . 
   The electric box  71  is placed on the front of a vehicle while the battery is placed on the rear of the vehicle. In  FIG. 4 , reference numerals  80  and  81  denote insulating casing,  82  a power transistor, and  83  a passage for cooling water. 
     FIG. 5  shows another example of a conventional arrangement structure of an electric junction box. 
   In this conventional arrangement structure, an electric junction box  85  is placed in a battery pack  84  made of metal mounted on the rear of an electric vehicle (including a hybrid vehicle), then each electric wire  86  is guided out from the electric junction box  85  penetrating through outer walls  84   a - 84   c  of the battery pack  84 . 
   The electric junction box  85  is placed in a space  87  situated on one side in the battery pack  84  and the battery  88  is placed adjacent to the electric junction box  85  in the battery pack  84 . The longitudinal direction of the battery pack  84  is parallel to the width direction of the vehicle. The battery pack  84  stably fixes the battery  88  and the electric junction box  85 , that is, the battery  88  and the electric junction box  85  are fixed to a vehicle body by means of the battery pack  84 . 
   An electric wire  89  continuing to an anode (i.e. plus electrode) of the battery  88  and an electric wire  90  continuing to a cathode (i.e. minus electrode) of the battery  88  are connected to the electric junction box  85 , then a relay  91  of an anode and a relay  92  of a cathode for high voltage mounted on the electric junction box  85  are connected to the electric wires  89  and  90 , so that the respective electric wires  86  of the anode and cathode advance toward the inverter from the electric junction box  85 , the electric wire  86  for driving the relay and the electric wire  86  for an AC 100V conversion are guided out in three directions. 
   However, in the conventional arrangement structure ( FIG. 5 ) of the electric junction box  85 , in the event that the vehicle is brought into a collision (above all, into a rear-end collision), the electric junction box  85  is affected with a great damage in the battery pack  84  so that the relays  91  and  92  of high voltage, parts such as fuses and high voltage circuit mounted on the electric junction box  85  might be brought into a trouble such as a short circuit. 
   Moreover, since a plurality of the electric wires  86  are guided out into a plurality of directions from the electric junction box  85 , the outer walls  84   a - 84   c  of the battery pack  84  must be provided with notched holes for guiding out the electric wire therethrough, causing deterioration in the collision strength of the battery pack  84 . Furthermore, since the respective electric wires  86  must be connected through a connector and terminal mount in a multi-directions of the electric junction box  85 , resulting in that the connection work needs a lot of time. Since the electric wires  86  must be protected with a vinyl tube or the like per several electric wires, resulting in that the mounting of the protection tubes needs a lot of time. Since the electric wires  86  must be separately arranged per several electric wires, resulting in that the arrangement work needs a lot of time. 
   SUMMARY OF THE INVENTION 
   It is therefore an objective of the present invention to solve the above problem and to provide an arrangement structure of an electric junction box, by which the damage of the electric junction box in the event of the collision of the vehicle can be reduced, the deterioration in the collision strength of the battery pack due to a plurality of the notched holes for guiding out the electric wires therethrough can be prevented from occurring, a plurality of the electric wires can be easily connected to the electric junction box with good workability, and a plurality of the electric wires can be easily arranged and protected outside the battery pack. 
   In order to attain the above objective, the present invention is to provide an arrangement structure of an electric junction box including: 
   a high voltage battery; 
   a battery pack for receiving the battery, the battery pack being mounted on a vehicle; and 
   an electric junction box arranged in the battery pack, the electric junction box being connected to the battery, 
   wherein on the assumption that a collision takes place on the battery pack-mounting side of the vehicle, the electric junction box is arranged on the side of a wall of the battery pack, the wall being situated on the side opposite to the collision side of the vehicle. 
   With the construction described above, in the event that a vehicle has a collision (a collision at the front or the back of the vehicle), since the electric junction box is arranged on the side of a wall of the battery pack, the wall being situated on a side opposite to a collision side of the vehicle, therefore a shock of the collision is absorbed in a space within the battery pack, thereby preventing the electric junction box from being affected by the direct shock. Accordingly, high voltage parts and circuits contained in the electric junction box can be prevented from being damaged, thereby preventing a trouble such as a short circuit from occurring and improving safety of the vehicle. The vehicle is an electric vehicle including a hybrid car. The high voltage parts include relays or fuses for connecting or cutting circuits of a battery and inverter. 
   Preferably, a plurality of electric wire connecting parts are concentratedly arranged on a wall of the electric junction box, and electric wires connected to the respective electric wire connecting parts are guided out from a wall of the battery pack, the wall of the battery pack being situated on the side opposite to the collision side of the vehicle. 
   With the construction described above, when the vehicle has a collision, the electric wire connection parts of the electric junction box can be prevented from being directly damaged and the electric wires guided out from the respective electric wire connection parts can also be prevented from being directly damaged. Accordingly, safety of a part for guiding out the electric wires of the electric junction box can be secured. Since the electric wires are not guided out into the respective different directions, the deterioration in the strength of the battery pack due to the notched holes for guiding out the electric wires therethrough can be prevented from occurring. The electric wire connection parts are, for example, connectors or terminal mounts. In the terminal mount, a terminal of the electric wire is connected by screwing to an end of a busbar or the like. The respective electric wires are concentratedly connected to the electric junction box on a wall of the battery pack. The connected electric wires are put together and guided out along a wall of the battery pack. Only one protection tube or uniting band is necessary to put the electric wires together as a wiring harness. 
   Further, with the construction described above, when the vehicle has a collision, since the electric wire connection parts of the electric junction box can be prevented from being directly damaged, a trouble such as a short circuit at the electric wire connecting parts can be prevented from occurring, thereby further improving safety of the vehicle. Moreover, since a plurality of the electric wires can be connected to the electric junction box at one place of the battery pack, therefore the connection workability can be improved. Since a plurality of the electric wires can be put together so as to be arranged, therefore the arranging workability can be improved. Since only one electric wire protection tube is needed, therefore the mounting workability of the protection tube can be improved, thereby reducing the cost of the parts. 
   In order to attain the above objective, the present invention is to provide an arrangement structure of an electric junction box including: 
   a high voltage battery; 
   a battery pack for receiving the battery, the battery pack being mounted on a vehicle; and 
   an electric junction box arranged in the battery pack, the electric junction box being connected to the battery, 
   wherein the electric junction box is arranged on the side of a wall of the battery pack, a plurality of electric wire connecting parts are concentratedly arranged on a wall of the electric junction box, and electric wires connected to the respective electric wire connecting parts are guided out from the wall of the battery pack. 
   With the construction described above, a plurality of the electric wires is concentratedly connected to the electric junction box on a wall of the battery pack. The connected electric wires are put together and guided out along a wall of the battery pack. Only one protection tube or uniting band is necessary to put the electric wires together as a wiring harness. Since the electric wires are not guided out into the respective different directions, the deterioration in the strength of the battery pack due to the notched holes for guiding out the electric wires therethrough can be prevented from occurring. If the wall of the battery pack is set to be a wall situated on a side opposite to a collision side of the vehicle, upon a collision of the vehicle the damage of the electric junction box and the electric wire connecting parts can be reduced. 
   Further, with the construction described above, since a plurality of the electric wires can be connected to the electric junction box at one place of the battery pack, therefore the connection workability can be improved. Since a plurality of the electric wires can be put together so as to be arranged, therefore the arranging workability can be improved. Since only one electric wire protection tube is needed, therefore the mounting workability of the protection tube can be improved, thereby reducing the cost of the parts. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a plan view illustrating an preferred embodiment of an arrangement structure of an electric junction box according to the present invention; 
       FIG. 2  is a plan view illustrating in detail a primary part of an preferred embodiment of an arrangement structure of an electric junction box according to the present invention; 
       FIG. 3  is a perspective view illustrating an embodiment of an electric junction box in the present invention; 
       FIG. 4  is a longitudinal cross sectional view illustrating an example of a conventional arrangement structure of an electric junction box; and 
       FIG. 5  is a plan view illustrating another example of a conventional arrangement structure of an electric junction box. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   In the following, the preferred embodiments of the present invention will be explained with reference to the attached drawings. 
     FIG. 1  is a plan view illustrating an preferred embodiment of an arrangement structure of an electric junction box according to the present invention. In  FIG. 1 , the upward direction of this drawing is the forward direction of the vehicle, while the downward direction of this drawing is the backward direction of the vehicle. 
   In the structure shown in  FIG. 1 , in which an electric junction box  1  is arranged in a casing-shaped battery pack  35  made of metal (e.g. iron) to be mounted on an electric vehicle (including a hybrid vehicle), the electric junction box  1  is arranged at a position far from an outer wall  35   a  of the battery pack  35  in a collision direction A of the vehicle. 
   A collision at the back of the vehicle (i.e. a collision which occurs on the rear side of the vehicle) is assumed in  FIG. 1  and therefore, in this case, the wall situated on the collision side of the vehicle is the outer wall  35   a  of the battery pack  35 . That is, when the laterally-long battery pack  35  is mounted in a laterally-long form on the rear of the vehicle (that is, the longitudinal direction of the battery pack  35  being the width direction of the vehicle), the electric junction box  1  is arranged on the side of a wall  35   b , thereby reducing the damage of the electric junction box  1  upon the collision at the back of the vehicle. 
   On the other hand, when the battery pack  35  is mounted on the front (i.e. on the side of a hood) of the vehicle, that is, when a collision at the front of the vehicle (i.e. a collision which occurs on the front side of the vehicle) is assumed, the battery pack  35  is arranged on the side of the outer wall  35   a . In this case, the wall situated on the collision side of the vehicle is the wall  35   b  of the battery pack  35 . 
   In the battery pack  35 , a plurality of cells for constituting a battery  45  are connected in series and arranged, and the electric junction box  1  is arranged adjacent to the battery  45  in a side space  34  of the battery pack  35  in such a direction that the electric junction box  1  is hardly affected by a shock upon a collision. 
   In the space  34  in the battery pack  35 , for example, a DC/DC converter  31  is arranged in a long and narrow form in the back-and-forth direction of the battery pack  35 , adjacently to the electric junction box  1  at an edge opposite to the battery  45 . A battery-cooling fan  32  is arranged between the DC/DC converter  31  and the battery  45  in the rear of the electric junction box  1 . The DC/DC converter  31  in a long and narrow form together with the battery  45  absorb the shock upon a collision. The hollow fan  32  is easily crushed upon the collision, thereby absorbing the shock so as to protect the electric junction box  1 . 
   The electric junction box  1  is connected to an electric wire  57  that continues to an anode (i.e. plus electrode) of the battery  45  and an electric wire  58  that continues to an cathode (i.e. minus electrode) of the battery  45 . A plurality of electric wires  51 - 56  are concentratedly guided out from a front wall  14  of the electric junction box at the front wall  35   b  of the battery pack  35 . 
   The electric wires  51 - 56  are guided out to the outside penetrating through the front wall  35   b  of the battery pack  35  and arranged in the width direction of the vehicle along the front wall  35   b . The electric wires  51 - 56  are bundled to form a wiring harness  59  with a protection tube  60  such as a vinyl tube and corrugated tube or by winding with a tape. 
   The electric junction box  1  includes a high voltage relay  19  of the anode that continues to the electric wire  57  of the anode and a high voltage relay  20  of the cathode that continues to the electric wire  58  of the cathode of the battery-side. The relay  19  of the anode is connected to an electric wire  53  of the anode of the inverter-side while the relay  20  of the cathode is connected to an electric wire  54  of the cathode of the inverter-side. The relays  19  and  20  are used for connecting or cutting a circuit that connects the battery  45  to the inverter (not shown in the figure). 
   In  FIG. 1 , the reference numeral  51  denotes an electric wire of the anode for AC100V and so on at the inverter-side,  52  an electric wire for driving a relay (i.e. for magnetization),  55  an electric wire of the cathode for AC100V and so on, and  56  an electric wire for detection circuit of a service plug (explained later on). The wires  51  and  55  are plug-connected to accessories and so on. An electric wire that connects the electric junction box  1  to the DC/DC converter  31  is arranged inside the battery pack  35 . A battery pack unit  36  includes at least the battery  45 , electric junction box  1  and battery pack  35 . 
     FIG. 2  is a plan view illustrating in detail an arrangement structure, in which the electric junction box  1  is arranged in the battery pack  35 . 
   In  FIG. 2 , the reference numeral  19  denotes a relay of the anode,  20  a relay of the cathode,  22  a connector of the anode for connecting the wire  57  (see  FIG. 1 ) of the anode on the battery-side,  25  a connector of the cathode for connecting the wire  58  of the cathode on the battery-side,  4  a terminal mount that continues to a circuit of the relay  19  of the anode,  5  a terminal mount that continues to a circuit of the relay  20  of the cathode,  7  a terminal mount for connecting the DC/DC converter,  6  a terminal mount for ground,  44  a small current fuse,  37  a connector that continues to the small current fuse  44 ,  39  a connector of cathode of a circuit for AC100V conversion,  40  a connector of the anode for a service plug detection circuit,  45   a  each cell for constructing the battery  45 , and  31  a DC/DC converter. 
   The terminal mounts  4 ,  5  and  6  are connected to the respective shielded electric wires  53 ,  54  through plate-shaped terminals  9 . The electric wires  53 ,  54  are horizontally arranged along the front wall  35   b  of the battery pack  35  as a group. The electric junction box  1  is bolt-fixed on a bottom wall  35   c  of the battery pack  35  with a bracket  43 . 
   The terminal mounts (electric wire connecting parts)  4  and  5  of the anode and cathode, the terminal mount (electric wire connecting part)  6  for ground, and the connectors (electric wire connecting parts)  37 - 40  are arranged in a lateral line in its plan view. The front wall  35   b  of the battery pack  35  projects forward a little as a projecting wall  35   b ′, in which the respective terminal mounts  4 - 6  are situated. 
     FIG. 3  is a perspective view of the electric junction box  1  viewed from the front. The respective connectors  37 - 40  project a little from a front wall surface  14  of the electric junction box  1 . Connector-receiving chambers of the respective connectors  37 - 40  are opened forwardly. A male terminal is arranged in the connector-receiving chamber. A connector housing and the terminal constitute each connector  37 - 40 . If a female terminal is received in the connector housing, the connector does not have the connector-receiving chamber. 
   In  FIG. 3 , the reference numeral  37  denotes a connector of the anode for AC100V conversion circuit,  38  a connector for a relay driving circuit,  39  denotes a connector of the cathode for AC100V conversion circuit,  40  a connector for a service plug detection circuit,  41  and  42  connectors for connecting circuits on the side of the vehicle. 
   The terminal mounts  4 - 6  are raised up vertically from the front wall surface  14  of the electric junction box  1  and have respective terminal plates  17 ,  18  and  26  at the top ends. The terminal mounts  4 - 6  are constructed by placing the terminal plates  17 ,  18  and  26  of busbars on insulating seats, nuts (not shown in the figure) are provided in the seats, and the plate terminals of the electric wires  53 ,  54  are screw-connected to the terminal plates having respective holes. The busbars are arranged in the electric junction box  1 . 
   In  FIG. 3 , the reference numeral  4  denotes a terminal mount of the anode for connecting a inverter circuit,  5  a terminal mount of the cathode for connecting a inverter circuit,  6  a terminal mount for connecting a ground circuit, and  7  a terminal mount for connecting a DC/DC converter circuit. Only the terminal mount  7  has a structure, in which a bolt projects. The other terminal mounts  4 - 6  have respective nuts inside. 
   A pair of the terminal mounts  6  for ground is provided right and left. Both of the terminal mounts  6  are connected by the busbar  8 . The busbar  8  is screwed to the front wall  35   b  of the battery pack  35  (see  FIG. 2 ) with a bolt  33 . An electric wire for ground (ground wire of the shielded electric wires  53 ,  54  shown in  FIG. 2 ) is grounded to the vehicle body (not shown in the figure) through the busbar  8  and the battery pack  35 . 
   In  FIG. 3 , the reference numeral  19  denotes a relay of the anode,  20  a relay of the cathode,  22  a connector of the anode for connecting a battery,  25  a connector of the cathode for connecting a battery,  53  a small current fuse,  21  a service plug, and  27  a current sensor. The service plug is used for an operator to cut a circuit between the battery  45  and the relays  19 ,  20 . A service plug detecting circuit  56  (see  FIG. 1 ) is a short circuit for detecting whether or not the shielding is present. 
   The small current fuse  44  continues to an output circuit of the relay  19  of the anode. The terminal mount  7  for connecting a DC/DC converter circuit and the connectors  37 ,  39  for connecting an AC100V conversion circuit are connected to a circuit on the side of output of the respective relays  19 ,  20 . The current sensor  27  is arranged on a busbar circuit between the relay  20  of the cathode and the service plug  21 . 
   The electric junction box  1  includes an upper cover  46  made of synthetic resin as a junction box body, middle cover (not shown in the figure), and lower cover  49 . The relays  19 ,  20  and connectors  22 ,  25  are provided in the upper cover  46 . The busbar circuit (not shown in the figure) as a high voltage circuit is arranged being laminated between the upper cover  46  and the middle cover. The relays  19 ,  20  are connected to the busbar circuit through a junction terminal (not shown). The busbar circuit integrally continues to the terminal plate  17 ,  18  on the terminal mount  4 ,  5  or a terminal in the connector  37 - 40 . A large current fuse (not shown) and the current sensor  27  are provided in the middle cover. The large current fuse is situated between the circuit  57  (see  FIG. 1 ) of the anode at the battery-side and the service plug  21 . An electronic control circuit is provided in the lower cover  49 . 
   As shown in  FIG. 1 , since the electric junction box  1  described above is arranged on the side of the front end of the battery pack  35 , therefore the damage of the electric junction box  1  caused by a collision of the vehicle from the back can be minimized, thereby preventing a short circuit due to the relay  19 ,  20  as a high pressure component, a large current fuse and a busbar as a high pressure circuit from occurring. 
   As shown in  FIGS. 2 and 3 , since the connectors  37 - 40  and the terminal mounts  4 - 7  are concentratedly arranged on the front wall surface  35   b  of the electric junction box  1 , therefore as shown in  FIG. 1  a plurality of the electric wires  51 - 56  can be concentratedly arranged on the front wall surface  14  of the electric junction box  1 , thereby improving the efficiency of the connection work. Moreover, since a plurality of the electric wires  51 - 56  can be arranged as a group, therefore the arranging workability can be improved. Since a plurality of the electric wires  51 - 56  can be united with a protection tube, a band or a tape so as to be protected, therefore the protection property can be improved and furthermore, the number of the components such as the protection tube and the cost of the components can be reduced. 
   In a case when the battery pack  35  is not mounted on the rear side of the vehicle but on the front side of the vehicle, in  FIG. 1  the electric junction box  1  is arranged on the rear side of the battery pack  35  (i.e. on the lower side of this drawing), that is, the electric junction box  1  is arranged on the side of the outer wall  35   a  of the battery pack  35 , and the connectors  37 - 40  and the terminal mounts  4 - 7  are concentratedly arranged on the side of the rear wall surface of the electric junction box  1  (i.e. on the lower side of this drawing). 
   The electric junction box  1  as explained above with reference to  FIG. 3  is merely an example. That is, the arrangement structure of the electric junction box of the present invention is not limited by the electric junction box  1  as explained above. One terminal mount  6  for ground may be sufficient and in this case the outside busbar  8  may not be necessary. A terminal mount may be provided instead of the connector  22 ,  25  for supplying electric power. A connector may be provided instead of the terminal mount  4 - 6 . The service plug  21  or the fuse  44  may or may not be provided according to need. The busbar in the electric junction box may be replaced by an electric wire. That is, an electric junction box having various different forms may be used according to need.