Abstract:
A relay box is provided with: a main housing; and a mounting section, which is provided in the main housing, and has selectively mounted thereon a relay block having a plug-in relay mounted thereon and removable therefrom, and a relay module which houses, in a module case, a circuit configuring body having a switching element mounted thereon.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a national stage application of PCT Application No. PCT/JP2010/057862, filed on May 10, 2010, which claims priority to Japanese Patent Application No. 2009-163928, filed on Jul. 10, 2009, which are hereby incorporated by reference herein in their entireties. 
     
    
     TECHNICAL FIELD  
       [0002]    Exemplary embodiments relate to an electric connection box and a relay module. 
       BACKGROUND  
       [0003]    In the related art, a relay box disposed in an engine room or the like of a motor vehicle for distributing electric power from a vehicle-mounted power source to various types of electrical equipment is known (for example, see JP-A-2004-72907). In the relay box, a relay module including a housing accommodating a circuit component having a power circuit with switching devices or control circuits incorporated therein and a relay block including a synthetic resin casing accommodating plural plug-in relays may be mounted. 
       SUMMARY  
       [0004]    Incidentally, the number of relays mounted in the relay box can be different depending on grades even though the types of motor vehicle may be the same. This is because, for example, in the case of low grade vehicles in which a low price is desirable, a reduction in number of relays to be mounted thereon may be desirable, or the relay module, which is highly functional but rather expensive, may be omitted. 
         [0005]    However, the relay box having a configuration of the related art has a problem in that the number of plug-in relays and semiconductor switching devices for one relay box are uniformly determined, and a flexible response to the difference in specifications cannot be achieved. 
         [0006]    In view of the related art, it is one object of this disclosure to provide an electric connection box that allows for flexible response to the specifications of the motor vehicle on which the electric connection box is to be mounted. 
         [0007]    An electric connection box according to an exemplary embodiment can include a base; and a mounting portion to be provided on the base, in which a relay block having a plug-in relay mounted thereon or a relay module having a cover accommodating a circuit board with a switching device mounted thereon can be selectively mounted. 
         [0008]    According to exemplary embodiments, the relay block and the relay module can be adapted to be mountable on the same mounting portion, and compatibility therebetween can be ensured. Accordingly, the relay block and the relay module can be used selectively depending on the necessity using the same base, so that the flexible design according to the demanded functions or cost can be achieved. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of a relay box according to an embodiment. 
           [0010]      FIG. 2  is a top view of the relay box according to the embodiment. 
           [0011]      FIG. 3  is a partially enlarged top view of the relay box according to the embodiment. 
           [0012]      FIG. 4  is a cross-sectional view taken along the line A-A in  FIG. 3 . 
           [0013]      FIG. 5  is a cross-sectional view taken along the line B-B in  FIG. 3 . 
           [0014]      FIG. 6  is a perspective view of a relay block according to the embodiment. 
           [0015]      FIG. 7  is a top view of the relay block according to the embodiment. 
           [0016]      FIG. 8  is a front view of the relay block according to the embodiment. 
           [0017]      FIG. 9  is a back view of the relay block according to the embodiment. 
           [0018]      FIG. 10  is a perspective view of a relay module according to the embodiment. 
           [0019]      FIG. 11  is a top view of the relay module according to the embodiment. 
           [0020]      FIG. 12  is a right side view of the relay module according to the embodiment. 
           [0021]      FIG. 13  is a perspective view showing a state in which a lower case is mounted on a circuit component according to the embodiment. 
           [0022]      FIG. 14  is a top view showing a state in which the lower case is mounted on the circuit component according to the embodiment. 
           [0023]      FIG. 15  is a cross-sectional view taken along the line C-C in  FIG. 14 . 
           [0024]      FIG. 16  is a top view showing a state in which the relay block is mounted on the relay box according to the embodiment. 
           [0025]      FIG. 17  is a cross-sectional view taken along the line D-D in  FIG. 16 . 
           [0026]      FIG. 18  is a top view showing a state in which the relay module is mounted on the relay box according to the embodiment. 
           [0027]      FIG. 19  is a cross-sectional view taken along the line E-E in  FIG. 18 . 
           [0028]      FIG. 20  is a cross-sectional view showing a state in which a lower case is mounted on a circuit component of the related art. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    An exemplary embodiment will be described with reference to  FIG. 1  to  FIG. 20 . The relay box in the embodiment (corresponding to an electric connection box)  1  can be disposed in an engine room of a motor vehicle or the like and can be configured to allow a relay module  30  and a relay block  20  to be mounted therein. In the description below, as regards the fore-and-aft direction, the front direction means obliquely right front in  FIG. 1 , as regards the up-and-down direction (vertical direction), the upper direction means the upside in  FIG. 1 , and the right-and-left direction (lateral direction) means the direction extending orthogonally to the fore-and-aft direction and the up-and-down direction (the obliquely right rear-obliquely left front in  FIG. 1 ). 
         [0030]    A relay box  1  includes a main housing formed of a synthetic resin (corresponding to a base)  10  and a mounting portion  11  provided in the main housing  10  so as to allow both of a relay block  20  and a relay module  30 , described later, to be mounted therein. The mounting portion  11  can be a void portion opening upward and downward and having a laterally elongated parallelepiped shape, and can be adapted to accommodate two pieces of the relay blocks  20  or one piece of the relay module  30  therein. Block latching portions  12  which are engageable with block-side locking arms  25  and are provided on the relay block  20 , and module locking claws  14  which are engageable with module-side locking arms  42  provided on the relay module  30 , can be provided in the interior of the mounting portion  11 , respectively. 
         [0031]    Two of the block latching portions  12  can be provided on a front wall portion  16 F of an inner wall portion of the mounting portion  11 , and four of the block latching portions  12  can be provided on a rear wall portion  16 B of the same. The front wall portion  16 F and the rear wall portion  16 B can be provided with depressions  17  which are capable of receiving swelled portions  23  provided on the relay block  20 , and one each of the block latching portions  12  can be provided in a protruding condition at substantially the center of each of the depression  17  in the left-and-right direction. The respective block latching portions  12  can be formed into a block shape projecting inward. The upper side surfaces can be locking surfaces  12 A which engage the block-side locking arms  25  of the relay block  20 , and a pair of linear rib portions  13  extending upward can be provided in a protruding condition from both side edges thereof. In contrast, the lower side surfaces can be tapered guiding surfaces  12 B inclining outward as they go downward. 
         [0032]    One each of the module locking claws  14  can be provided on both of left and right wall portions  16 R,  16 L of the inner wall portion of the mounting portion  11 . The module locking claws  14  can be provided by shaving off the left and right both wall portions  16 R,  16 L of the mounting portion  11  at substantially center portions of in the fore-and-aft direction except for the upper end portions, and can be formed into a hook shape projecting inward respectively. Then, lower side surfaces can be locking surfaces  14 A which engage module-side locking arms  42  of the relay module  30 , and upper end surfaces can be tapered guiding surfaces  14 B inclining outward as they extend upward. 
         [0033]    Provided on the left and right both wall portions  16 R,  16 L at positions away to a certain distance from the module locking claws  14  in the fore-and-aft direction can be a pair of guide grooves  15  which can receive the guide rails  44  of the relay module  30 . The guide grooves  15  can be opened upward, and also inward of the mounting portion  11 , and can be formed into an elongated groove shape extending in the vertical direction. 
         [0034]    The relay block  20  includes a block housing  21  formed of a synthetic resin into a block shape as a whole. The width of the block housing  21  in a fore-and-aft direction can be substantially the same as the width of the mounting portion  11  of the relay box  1  in the fore-and-aft direction, and the width in the left-and-right direction can be approximately half the width of the mounting portion  11  in the left-and-right direction. Therefore, two of the relay blocks  20  can be accommodated in the mounting portion  11 . 
         [0035]    Formed in the block housing  21  can be relay mounting portions  22  for mounting plug-in relays. The plug-in relays (not shown) can be mounted to the relay mounting portions  22  from below and, in a state in which the plug-in relays can be mounted, cable lines of the plug-in relays can be drawn out from the lower side. 
         [0036]    Formed on an outer wall surface of the block housing  21  can be the swelled portions  23  swelled outward with respect to other portions, and one of them can be formed on a front wall surface and two of them can be formed on a rear wall surface. A pair of side wall portions  24  extending in the vertical direction can be projected in a protruding condition outward from both left and right side edges of each of the swelled portions  23 , and block-side locking arms  25  can be disposed inside the side wall portions  24 . The block-side locking arms  25  can be formed into a cantilevered shape extending downward from upper end portions of the swelled portions  23  as proximal end portions, and can be adapted to be resiliently deformable along the fore-and-aft direction of the block housing  21 . Provided on the block-side locking arms  25  substantially at the center positions in the vertical direction so as to project outward can be block-side locking projections  26 . Upper surfaces of the block-side locking projections  26  can be tapered guiding surfaces  26 B inclining inward as they go upward. In contrast, lower side surfaces thereof can be locking surfaces  26 A engaging the block latching portions  12  the relay box  1 . 
         [0037]    The relay module  30  includes a circuit component (corresponding to a circuit board)  31 , and a module case (corresponding to a cover)  32  which can be capable of accommodating the circuit component  31 . 
         [0038]    The circuit component  31  can include a printed board having a predetermined conducting path formed on the surface thereof, and mounted parts such as semiconductor switching devices mounted on the surface of the printed board, although not illustrated in detail. In the embodiment, six of the semiconductor switching devices can be mounted on the printed board. 
         [0039]    The module case  32  which accommodates the circuit component  31  can be formed of a synthetic resin, and includes a lower case  32 S configured to be assembled to the circuit component  31  from below and an upper case  32 U configured to accommodate the circuit component  31  in the interior thereof and then be assembled from above. 
         [0040]    The lower case  32 S can be formed into a box-shape being slightly wider than the circuit component  31  as a whole. The lower case  32 S serves also as a connector for connection to external connecters (not shown), can be opened downward, and can be provided with plural tubular hood portions  33  arranged side by side in the left-and-right direction so as to allow the external connectors to be fitted thereto. Ends of the respective terminals  34  bent into an L-shape can be projected into the interior of the respective hood portions  33  through a ceiling wall  35 . The other ends of the terminals  34  can be inserted into through holes opened in the circuit component  31 , and can be fixed by soldering. 
         [0041]    The lower case  32 S can be provided at both side edges thereof with screw clamp portions (corresponding to fixing portion described in claims  36  at the right of the hood portion  33  on the right side and at the left of the hood portion  33  on the left side. The screw clamp portions  36  can be formed to be slightly higher than the hood portions  33 , and can be provided with screw holes (corresponding to the fixing portion in claims  37  at positions slightly higher than the ceiling wall  35  of the hood portions  33 . In contrast, the circuit component  31  can be formed with hole portions  38  for allowing passage of screws S at positions aligned with the screw holes. The lower case  32 S can be fixed to the circuit component  31  by inserting the screws S into the hole portions  38  and the screw holes  37  from the rear surface side of the circuit component  31  and tightening the same. 
         [0042]    A front wall surface and a rear wall surface of an outer wall surface of the lower case  32 S can be provided with lower-case-side locking projections  39  configured to engage locking strips  40  of the upper case  32 U so as to project outward. 
         [0043]    The upper case  32 U has a flat box-shape opening downward, and can be configured to cover an entire circumference (front, rear, left, and right) of the circuit component  31  and an upper side entirely. The lower end portion (opening end portion) of the upper case  32 U can be provided with the upper-case-side locking strips  40  which can be capable of engaging the lower-case-side locking projections  39  provided on the lower case  32 S. By the engagement between the upper-case-side locking strips  40  and the lower-case-side locking projections  39 , the upper case  32 U and the lower case  32 S can be maintained in the assembled state. For reference&#39;s sake, in a state in which the upper case  32 U and the lower case  32 S can be assembled, the lower end portion of the lower case  32 S projects downward from the upper case  32 U. 
         [0044]    An outer wall surface on the right side and an outer wall surface on the left side of the upper case  32 U can be provided with groove portions  41  respectively at center positions in the fore-and-aft direction thereof so as to extend downward from upper ends to positions to some extent. Module-side locking arms  42  can be provided in the groove portions  41  respectively. The respective module-side locking arms  42  can be formed into a cantilevered shape extending respectively upward from outer edge portions of lower ends of the groove portions  41 , and can be configured to be resiliently deformable along the left-and-right direction of the upper case  32 U. On the module-side locking arms  42  substantially at the center positions thereof in the vertical direction, module-side locking projection  43  can be provided so as to project outward. Lower side surfaces of the module-side locking projections  43  can be tapered guiding surfaces  43 B inclining inward as they go downward. In contrast, the upper side surfaces thereof can be locking surfaces  43 A engaging the module locking claws  14  of the relay box  1 . 
         [0045]    Also, elongated guide rails  44  extending in the vertical direction can be provided so as to project outward at positions slightly apart from the module-side locking arms  42  in both lateral directions. 
         [0046]    The widths of the module case  32  in the fore-and-aft direction and in the left-and-right direction can be substantially the same as the widths of the mounting portion  11  of the relay box  1  in the fore-and-aft direction and in the left-and-right direction, and one piece of the relay module  30  can be accommodated in the interior of each of the mounting portions  11 . 
         [0047]    Subsequently, assembly of the relay block  20  and the relay module  30  to the relay box  1  will be described. 
         [0048]    First of all, a case of assembling the relay block  20  will be described. When assembling the relay block  20  to the mounting portion  11  of the relay box  1 , plug-in relays are attached to the relay block  20  in advance, and then the relay block  20  is inserted into the mounting portion  11 . At this time, since the cable lines being drawn out from the plug-in relay extend downward of the relay block  20 , the relay block  20  is inserted from the opening on the lower side of the mounting portion  11 . 
         [0049]    Since two of the relay blocks  20  can be mounted in the interior of each of the mounting portions  11 , one of the relay blocks  20  can be inserted to either the left side or the right side of the mounting portions  11 . 
         [0050]    When the relay block  20  is pushed inward of the mounting portion  11 , three of the block latching portions  12  positioned on the side where the relay block  20  is inserted from among six of the block latching portions  12  provided on the inner wall portion of the mounting portion  11  engage three of the block-side locking arms  25  provided on the front and rear walls of the relay block  20 . More specifically, the block latching portions  12  climb over the guiding surfaces of the block-side locking projections  26  provided on the block-side locking arms  25  and the block-side locking arms  25  are resiliently deformed inward. Then, when the relay block  20  is further pushed inward, the block latching portions  12  climb over the block-side locking projections  26  and the block-side locking arms  25  are resiliently restored. In this state, the block-side locking projections  26  can be just fitted between a pair of the rib portions  13  formed on upper portions of the block latching portions  12 , and the locking surfaces of the block latching portions  12  and the locking surfaces of the block-side locking projections  26  engage with each other. Accordingly, the relay block  20  can be fixed in a retained state. 
         [0051]    When one of the relay blocks  20  is mounted, the other relay block  20  can be mounted in the mounting portion  11  in the same manner. 
         [0052]    Subsequently, a case where the relay module  30  is assembled will be described. The external connector connected to the distal end of a wire harness is inserted from the opening on the lower side of the mounting portion  11 , and is pulled upward through the interior of the mounting portion  11 . Subsequently, the external connector is fitted to the hood portion  33  of the relay module  30  at a position above the mounting portion  11 . Then, the wire harness is brought into a state of being guided from the lower side of the relay module  30  and passed through the mounting portion  11 . In this state, the relay module  30  can be inserted from the upper opening of the mounting portion  11  in a state in which the guide rails  44  provided on the left and right outer wall portions of the relay module  30  are aligned with the guide grooves  15  provided on the left and right inner wall portions of the mounting portion  11 . 
         [0053]    When the relay module  30  is inserted into the mounting portion  11 , a pair of the module locking claws  14  provided on the inner wall portions of the mounting portion  11  engage the module-side locking arms  42  provided on the left and right outer wall portion of the relay module  30 . More specifically, the module locking claws  14  climb over the guiding surfaces of the module-side locking projections  43  provided on the module-side locking arms  42  and the module-side locking arms  42  can be resiliently deformed inward. Then, when the relay module  30  can be further pushed inward, the module locking claws  14  climb over the module-side locking projections  43  and the module-side locking arms  42  can be resiliently restored. In this state, the locking surfaces of the module locking claws  14  and the locking surfaces of the module-side locking projections  43  engage with each other. Accordingly, the relay module  30  can be fixed in the retained state. 
         [0054]    In the relay box  1  in the embodiment described above, both of the relay block  20  and the relay module  30  can be mounted on the same mounting portion  11 . More specifically, the mounting portion  11  has a configuration in which the relay blocks  20  may be mounted, and also has a configuration in which the relay modules  30  may be mounted. The mounting portion  11  allows the relay blocks  20  and the relay modules  30  to be selectively mounted. 
         [0055]    Here, when the relay blocks  20  can be mounted in the mounting portion  11 , since two of the plug-in relays can be mounted in each of the relay block  20  and two of the relay block  20  can be mounted in each of the mounting portions  11 , four of the plug-in relays can be mounted in the interior of each of the mounting portions  11 . In contrast, when the relay modules  30  can be mounted in the mounting portion  11 , six of the switching devices can be mounted in the interior of each of the mounting portions  11 . Therefore, even the vehicle types of the motor vehicle can be the same, for example, the relay box  1  having the relay block  20  mounted in the mounting portions  11  may be used for high-grade vehicles which use a relatively large number of relays, and the relay box  1  having the relay modules  30  mounted in the mounting portions  11  may be used for low-grade vehicles which use a relatively small number of relays. 
         [0056]    In this manner, selective usage of the relay modules  30  and the relay blocks  20  depending on the specifications such that the relay modules  30  having higher performance and higher relay-mounting density can be mounted on high-grade vehicles and the relay blocks  20  having lower relay-mounting density but being less expensive in comparison with the relay modules  30  can be mounted on the low-grade vehicles can be easily achieved. 
         [0057]    Also, in the embodiment, the direction of mounting the relay block  20  in the mounting portion  11  can be different from the direction of mounting the relay module  30 . 
         [0058]    In other words, when mounting the relay block  20  in the mounting portion  11 , the relay blocks  20  can be inserted upward from the lower opening of the mounting portion  11 . In contrast, the relay module  30  can be configured to be inserted downward from the upper opening of the mounting portion  11 . The reason is as follows. 
         [0059]    When assembling the relay block  20  to the mounting portion  11  of the relay box  1 , the plug-in relays are attached to the relay block  20  in advance, and then the relay block  20  is inserted into the mounting portion  11 . At this time, since the cable lines being drawn out from the plug-in relays extend downward of the relay block  20 , it can be convenient to insert the relay block  20  from the opening on the lower side of the mounting portion  11 . 
         [0060]    Also, after the relay box  1  has been mounted on the vehicle, maintenance can easily be performed. In other words, when any failure occurs in the plug-in relay, the plug-in relays may be pulled out and replaced from above the mounting portion  11  with the relay block  20  attached to the relay box  1 . In contrast, when any failure occurs in the switching device, the relay module  30  in its entirety has to be replaced. In this case, the relay module  30  may be pulled out and replaced from above the mounting portion  11 . In this manner, since the replacement work of the plug-in relay and the relay module  30  may be performed only above the mounting portion  11 , good workability of maintenance can be ensured. 
         [0061]    In this configuration, the block-side locking arms  25  to be provided on the side of the relay block  20  can be each formed into the cantilevered shape having a proximal end on the upper side and a free end on the lower side, and the block-side locking projections  26  each have a guiding surface  26 B on the upper surface and a locking surface  26 A on the lower surface. Then, the block latching portions  12  which can be provided on the side of the mounting portion  11  to be paired therewith each have the locking surface  12 A on the upper surface and the guiding surface  12 B on the lower surface. In contrast, the module-side locking arms  42  can be each formed into the cantilevered shape having a proximal end on the lower side and a free end on the upper side, and the module-side locking projections  43  each have the locking surface  43 A on the upper surface and the guiding surface  43 B on the lower surface. Then, the module locking claws  14  which can be provided on the side of the mounting portion  11  to be paired therewith each have the guiding surfaces  14 B on the upper surface and the locking surfaces  14 A on the lower surface. 
         [0062]    In this manner, it can be beneficial to differentiate the direction of extension of the locking arms or the orientations of the locking surface or the guiding surface for causing the relay blocks  20  and the relay modules  30  to be engaged with the mounting portion  11  depending on the difference in mounting direction between the relay blocks  20  and the relay modules  30 . 
         [0063]    Therefore, in the mounting portion  11 , the block latching portions  12  to be engaged with the relay blocks  20  and the module locking claws  14  to be engaged with the relay modules  30  can be mounted on the different wall portions. More specifically, the block latching portions  12  to be engaged with the relay block  20  can be provided on one (the front and rear wall portions  16 F,  16 B) of two pairs of the inner wall portions opposing to each other, and the module locking claws  14  to be engaged with the relay module  30  can be provided on the other pair (the left and right wall portions  16 R,  16 L). Accordingly, mounting of the relay block  20  and the relay module  30  different in mounting direction to the same mounting portion  11  can be enabled. 
         [0064]    In order to enable the mounting of both of the relay blocks  20  and the relay modules  30  to the same mounting portion  11 , reduction in size of the relay modules  30 , which can be susceptible to size increase in comparison with the relay blocks  20 ,can be advisable. Therefore, in the relay modules  30  in the embodiment, a configuration of screw-tightening between the circuit component  31  and the lower case  32 S can be added with a twist. In other words, a screw hole  53  for screw-tightening with respect to the circuit component  51  can be provided at a position behind a hood portion  52  of a lower case  51  (see  FIG. 20 ) in the relay module of the related art, while the screw clamp portions  36  formed to be slightly higher than the hood portions  33  can be provided adjacent to the right side and the left side of the hood portions  33  in the relay module  30  in the embodiment. Then, the screw holes  37  can be provided on the screw clamp portions  36  at the positions higher than the ceiling wall  35  of the hood portions  33 . In this manner, by providing the screw clamp portions  36  and the screw holes  37  so as to be deviated from the hood portions  33 , the thickness of the relay modules  30  (the width in the fore-and-aft direction) can be reduced by an amount corresponding to the depth of the screw hole in comparison with the relay module  50  in the related art, so that reduction in size of the relay module  30  can be achieved. 
         [0065]    The present invention is not limited to the exemplary embodiments described in the description and the drawings, and embodiments given below, for example, can be also included in the technical scope of the present invention. 
         [0066]    In the embodiment described above, two of the relay blocks  20  can be mounted in each of the mounting portions  11 . However, the number of the relay blocks to be mounted in the mounting portion is not limited, and one or three or more can be also applicable. 
         [0067]    In the embodiment described above, the block latching portions  12  to be engaged with the relay block  20  and the module locking claws  14  to be engaged with the relay module  30  can be provided on the different wall portions of the mounting portion  11  with each other. However, if the mounting directions of the relay box can be the same as the mounting direction of the relay module, the engaging portions may be commonly used. 
         [0068]    In the embodiment described above, the locking arms  25 ,  42  can be provided on the relay block  20  and the relay module  30 , and the latching portion  12 , module locking claw  14  engaging therewith can be provided in the mounting portion  11 . However, a configuration in which the locking arms can be provided in the mounting portion and the latching portions can be provided on the relay block and the relay module can be also applicable. 
         [0069]    In the embodiment described above, the mounting portion  11  can be opened in the vertical direction of the relay box  1 , and the relay block  20  can be mounted from below and the relay module  30  can be mounted from above. However, for example, a configuration in which the mounting portion is opened in the left-and-right direction or in the fore-and-aft direction, and one of the relay box and the relay module is mounted from the left side or the front side, and the other one of those is mounted from the right side or the rear side is also applicable. 
         [0070]    In the embodiments described above, the printed board of the circuit component  31  includes the semi-conductor switching devices mounted thereon. However, the invention is not limited thereto, and a configuration in which a mechanical relay is mounted on the printed board is also applicable. A configuration in which both of the semi-conductor switching devices and the mechanical relays are mounted on the printed board is also applicable. 
         [0071]    In the embodiment described above, a single piece of the printed board can be accommodated in the module case  32  of the relay module  30 . However, exemplary embodiments are not limited thereto, and a configuration in which plural printed boards are accommodated in the module case  32  may also be applicable. 
         [0072]    The relay box  1  may be configured in such a manner that the upper surface of the main housing  10  can be covered with an upper cover, not shown, and the lower surface of the main housing  10  can be covered with a lower cover, not shown.