connection module

Abstract

A connection module (10) is housed inside a battery pack (1) provided with an upper case (1U) and a lower case (1L), and includes: a plurality of busbars (20) that electrically connect devices (4) disposed on the upper case (1U) side inside the battery pack (1) to connectors (5) disposed on the lower case (1L) side inside the battery pack (1); a plurality of holders (30) that have busbar holding portions (35A, 35B) that hold the plurality of busbars (20); and a cradle (50) that can hold the plurality of holders (30). In a state in which the plurality of holders (30) that hold the plurality of busbars (20) are held in the cradle (50), the plurality of busbars (20) are disposed side by side in a left-right direction that is orthogonal to an up-down direction. A direction that is orthogonal to the up-down direction and that intersects the left-right direction is set as a front-rear direction. The plurality of busbars (20) include: upper connection portions (21) that extend in the front-rear direction and that are connected to the devices (4); lower connection portions (22) that extend in the front-rear direction and that are connected to the connectors (5); and link portions (23) that extend in the up-down direction and that connect the upper connection portions (21) to the lower connection portions (22). A gap (CL1) is provided in the front-rear direction between the busbars (20) and the holders (30). Gaps (CL2) and (CL3) are provided in the up-down direction and the left-right direction between the holders (30) and the cradle (50).

Description

Technical Field

[0001] This disclosure relates to connection modules. Background Technology

[0002] Conventionally, the casings of automotive battery packs and the like have structures consisting of an upper casing and a lower casing. The manufacturing process for such battery packs includes electrically connecting devices housed inside the casing and sealing the gap between the lower casing and the upper casing. In casing design, it is sometimes required that devices located on the upper casing side inside the casing be connected to an external output connector. In such cases, as described in Japanese Patent Application Publication No. 2019-186043 (Patent Document 1 below), it is feasible to provide an external output connector on the upper casing side.

[0003] Prior art literature

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-186043 Summary of the Invention

[0006] Summary of the invention

[0007] The problem that the invention aims to solve

[0008] However, in the aforementioned structure, even after completing the process of connecting all the devices inside the housing (equivalent to the outer casing in this application), the manufacturing process of the battery pack, etc., cannot be completed even after the process of sealing the gap between the upper and lower housings is finished. This is because after sealing the gap between the upper and lower housings, it is necessary to separately connect the external output connector. Therefore, the manufacturing process of the battery pack, etc., may become complicated.

[0009] This disclosure is an invention made based on the above-described situation, and its object is to provide a connection module that allows for electrical connection between a device disposed on the upper housing side and a connector disposed on the lower housing side inside the housing, and is easy to assemble.

[0010] Solution for solving the problem

[0011] The connection module disclosed herein is housed within an outer casing having an upper casing and a lower casing. The connection module includes: a plurality of busbars for electrically connecting a device disposed on the upper casing side inside the outer casing to a connector disposed on the lower casing side inside the outer casing; a plurality of brackets having busbar holding portions for holding the plurality of busbars; and a bracket capable of locking the plurality of brackets. With the plurality of brackets holding the plurality of busbars locked in the bracket, the plurality of busbars are arranged side-by-side along a first direction orthogonal to the vertical direction, and a second direction is defined as a direction orthogonal to the vertical direction and intersecting the first direction. The plurality of busbars include: an upper connecting portion extending along the second direction and connected to the device; a lower connecting portion extending along the second direction and connected to the connector; and a connecting portion extending along the vertical direction to connect the upper connecting portion and the lower connecting portion. A gap is provided between the busbars and the brackets along the second direction, and a gap is provided between the brackets and the brackets along both the vertical direction and the first direction.

[0012] Invention Effects

[0013] According to this disclosure, a connection module can be provided that allows for electrical connection between a device disposed on the upper housing side and a connector disposed on the lower housing side within the housing, and is easy to assemble. Attached Figure Description

[0014] Figure 1 This is a perspective view showing an example of applying the connection module of Embodiment 1 to a battery pack.

[0015] Figure 2 This is a side view of the connection module applicable to battery packs.

[0016] Figure 3 Is Figure 2 The diagram shows the periphery of the right end support in the AA section.

[0017] Figure 4 This is a top view of the connecting module before the cover is fixed in place.

[0018] Figure 5 This is a 3D view of the connecting module before the cover is fixed in place.

[0019] Figure 6 yes Figure 4 BB cross-sectional view.

[0020] Figure 7 Is Figure 4 The diagram shows the periphery of the support in the CC section.

[0021] Figure 8 This is a 3D view of the top of the support frame.

[0022] Figure 9 This is a 3D view of the bottom of the bracket.

[0023] Figure 10 This is a top view of the two connected supports.

[0024] Figure 11 yes Figure 10 DD sectional view.

[0025] Figure 12 This is a 3D diagram of the mother row.

[0026] Figure 13 It is a 3D diagram of the bracket.

[0027] Figure 14 It is a 3D diagram of the cover.

[0028] Figure 15 This is a top view showing the locking of the bracket and the locking part of the support in Embodiment 2.

[0029] Figure 16 yes Figure 15 EE sectional view.

[0030] Figure 17 yes Figure 15 FF sectional view.

[0031] Figure 18 This is a top view of the bracket in embodiment 3.

[0032] Figure 19 This is a top view of the connecting module before the cover is fixed in place.

[0033] Figure 20 yes Figure 19 GG cross-sectional view.

[0034] Figure 21 Is Figure 19 The diagram shows the assembly of the bracket and support in the GG cross section. Detailed Implementation

[0035] [Description of embodiments of this disclosure]

[0036] First, let's illustrate the implementation forms of this disclosure.

[0037] (1) The connection module of this disclosure is housed inside a housing having an upper housing and a lower housing, wherein the connection module comprises: a plurality of busbars for electrically connecting a device disposed on the upper housing side inside the housing to a connector disposed on the lower housing side inside the housing; a plurality of brackets having busbar holding portions for holding the plurality of busbars; a bracket capable of locking the plurality of brackets, wherein, in a state where the plurality of brackets holding the plurality of busbars are locked in the bracket, the plurality of busbars are arranged side by side along a first direction orthogonal to the vertical direction, and a second direction is defined as a direction orthogonal to the vertical direction and intersecting the first direction, the plurality of busbars comprising: an upper connecting portion extending along the second direction and connected to the device; a lower connecting portion extending along the second direction and connected to the connector; and a connecting portion extending along the vertical direction to connect the upper connecting portion and the lower connecting portion, wherein a gap is provided between the busbars and the brackets along the second direction, and a gap is provided between the brackets and the brackets along the vertical direction and the first direction. In this specification, orthogonality includes the case of orthogonality, and even in the case of non-orthogonality, it includes the case of intersection angles of about 85° to 95° that can be considered substantially orthogonal.

[0038] With this structure, multiple busbars electrically connect devices mounted on the upper housing side inside the casing to connectors mounted on the lower housing side inside the casing. Therefore, after completing the electrical connections of all devices mounted inside the casing, the manufacturing process of the battery pack, etc., can be completed by covering the lower housing with the upper housing and sealing their gaps. Furthermore, gaps are provided between the busbars and the brackets in the front-to-back direction, and between the brackets and the supports in the vertical and horizontal directions, thus absorbing positional deviations and dimensional inconsistencies of the components and mounted devices in each direction.

[0039] (2) Preferably, the plurality of brackets each have a locking part and a locking bearing part, and adjacent brackets among the plurality of brackets are locked to each other with a gap along the first direction by locking the locking part of one bracket to the locking bearing part of the other bracket.

[0040] With this structure, the bracket has a locking part and a locking bearing part, thus enabling the connection of adjacent brackets and facilitating the assembly of the brackets. Furthermore, it eliminates the need to separately form brackets without locking parts. Multiple brackets are interlocked with a gap in the left-right direction, thereby absorbing positional deviations and dimensional inconsistencies of the components and mounted equipment in the left-right direction.

[0041] (3) Preferably, the plurality of brackets have intermediate brackets and end brackets. When the plurality of brackets are locked to the bracket, the brackets are arranged on both sides of the intermediate bracket along the first direction, and the brackets are arranged only on one side of the end bracket along the first direction. The intermediate bracket has both a locking part and a locking receiving part. One side of the end bracket has at least the locking part of the locking part and the locking receiving part, and the other side of the end bracket has only the locking part and the locking receiving part. The adjacent brackets in the plurality of brackets are locked to each other with a gap along the first direction by locking the locking part of one bracket to the locking receiving part of the other bracket.

[0042] This structure allows adjacent supports to be connected, facilitating their assembly. Furthermore, since it includes supports without locking ends, the lateral dimensions of the bracket can be reduced. Multiple supports are interlocked with gaps in the lateral direction, thus absorbing positional deviations and dimensional inconsistencies of components and mounting equipment in the lateral direction.

[0043] (4) Preferably, in the bracket, a bracket side guide is provided near the locking portion, and a bracket side guide receiving portion is provided near the locking receiving portion. The bracket side guide protrudes outward along the first direction, and the bracket side guide receiving portion receives the bracket side guide.

[0044] With this structure, the assemblies of the supports become easy to assemble.

[0045] (5) Preferably, the bracket is provided with a track extending along the first direction, and the support is provided with a track-side guide that engages with the track.

[0046] This structure makes it easy to assemble the bracket into the support.

[0047] (6) Preferably, the track and the track-side guide are provided in multiple spaces along the second direction.

[0048] This structure improves the locking force of the bracket on the support. Furthermore, it suppresses the wobbling of the support assembled with the bracket.

[0049] (7) Preferably, the plurality of brackets are provided with downwardly protruding engaging portions, and the bracket is provided with engaging receiving portions for engaging the engaging portions from below.

[0050] With this structure, the bracket can be assembled onto the holder from above, thus improving the ease of assembling the bracket onto the holder.

[0051] (8) The connection module preferably has a cover that covers the busbar and the bracket from above and is fixed to the bracket.

[0052] This structure can prevent the busbar and support from falling off the bracket.

[0053] [Details of the embodiments of this disclosure]

[0054] The embodiments of this disclosure are described below. This disclosure is not limited to these examples, but is disclosed by the claims and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0055] <Implementation Method 1>

[0056] Regarding Embodiment 1 of this disclosure, refer to Figures 1 to 14 The following explanation will be provided. In the following explanation, the direction represented by arrow Z will be defined as upward, the direction represented by arrow X as forward, and the direction represented by arrow Y as left. Here, left and right are examples of the first direction, and forward and backward are examples of the second direction. It should be noted that for multiple identical components, only a portion of the components will be labeled, and sometimes the labels of the other components will be omitted.

[0057] [Connection Module]

[0058] like Figure 5 As shown, the connection module 10 of Embodiment 1 includes a plurality of busbars 20, a plurality of supports 30 for holding the plurality of busbars 20, and a bracket 50 that engages with the plurality of supports 30. Figure 2 As shown, the connection module 10 is housed inside the battery pack 1 (an example of the housing). As will be described later, the connection module 10 is mounted on the terminal block 3 inside the battery pack 1, electrically connecting the device-side connection portion 4A of the device 4 (not shown) to the connector-side connection portion 7B of the connector 5.

[0059] [Battery pack, upper casing, lower casing]

[0060] like Figure 2 As shown, the battery pack 1 includes an upper housing 1U that opens upwards and a lower housing 1L that opens downwards. A known sealing member (not shown) is sandwiched between the opening edge of the upper housing 1U and the opening edge of the lower housing 1L. The lower housing 1L covers the upper housing 1U in a way that closes the opening, and the gap between them is liquid-tightly sealed by the sealing member, thereby enabling the battery pack 1 to be waterproof.

[0061] like Figure 1As shown, a rectangular battery cell B is placed inside the lower housing 1L. The battery cell B is covered from above, in front, and behind by a convex battery bracket 2 protruding upwards and fixed to the lower housing 1L. A rectangular terminal plate 3 (viewed from above) is mounted and fixed to the battery bracket 2. The width of the terminal plate 3 in the left-right direction is smaller than the width of the battery bracket 2 in the left-right direction. The terminal plate 3 includes a rear terminal plate 3R mounted on the upper surface of the battery bracket 2 and extending rearwards, and a front terminal plate 3F mounted on the front surface of the battery bracket 2 and extending downwards and forwards from the front end of the rear terminal plate 3R. Figure 2 As shown, the rear terminal plate 3R protrudes upward beyond the upper edge of the lower housing 1L when it is installed in the lower housing 1L. Therefore, when the lower housing 1L and the upper housing 1U are assembled, the rear terminal plate 3R is disposed inside the battery pack 1 on the side of the upper housing 1U.

[0062] With the lower housing 1L and the upper housing 1U assembled, a device 4 (not shown) is disposed on the upper housing 1U side inside the battery pack 1, such as... Figure 1 As shown, the device-side connection portion 4A extends forward from the device 4. The device-side connection portion 4A is located behind the rear terminal plate 3R and is held by an upwardly protruding locking piece 3B. In front of the locking piece 3B of the rear terminal plate 3R, a bolt fixing portion 3A for receiving bolt BT1 is formed, protruding upward. A bolt fastening hole (not shown) formed at the front end of the device-side connection portion 4A is provided on the bolt fixing portion 3A. A connecting module 10 is mounted in front of the bolt fixing portion 3A in the rear terminal plate 3R, connecting the busbar 20 of the connecting module 10 to the device-side connection portion 4A. At the right and left ends of the location where the connecting module 10 is mounted in the rear terminal plate 3R, as shown... Figure 3 As shown, a nut receiving portion 3C is provided to accommodate the nut N that is fastened to the bolt BT3 described later. Although not shown, a protrusion receiving portion is provided in front of the nut receiving portion 3C on the right side and behind the nut receiving portion 3C on the left side to support the protrusion 59 of the bracket 50 described later. The connecting module 10 is fixed to the terminal plate 3 by engaging the protrusion 59 with the protrusion receiving portion.

[0063] like Figure 1 and Figure 2 As shown, an external output connector 5 is disposed on the front side of the lower housing 1L. Figure 1 As shown, connector 5 is formed such that it extends through the front side of the lower housing 1L in the front-rear direction. Connector 5 includes a protective cover 6 opening forward, terminal fittings 7, and a terminal receiving portion 8 extending rearward from the protective cover 6 and housing the terminal fittings 7 side-by-side. The rear end of the terminal receiving portion 8 is fixed by a front terminal plate 3F. Figure 2As shown, the terminal accessory 7 has a forward-protruding tab 7A inside the protective cover portion 6. The rear end of the terminal accessory 7 is provided as a connector-side connecting portion 7B, and a bolt fastening hole (not shown) is formed in the connector-side connecting portion 7B. Figure 1 As shown, the terminal receiving portion 8 opens upwards and rearwards, receiving the busbar 20 of the connecting module 10 from above, and can be connected to the connector-side connecting portion 7B. A bolt fixing portion (not shown) protrudes upwards and is provided at the rear end of the terminal receiving portion 8 to receive the bolt BT2. A bolt fastening hole (not shown) is provided on the bolt fixing portion.

[0064] [Busbar, upper connecting part, lower connecting part, connecting part]

[0065] Busbar 20 is made of conductive metals such as copper, such as Figure 12 As shown, the busbar 20 is a slender plate bent into a crankshaft shape. It includes an upper connecting portion 21, a lower connecting portion 22, and a connecting portion 23 that connects the upper connecting portion 21 and the lower connecting portion 22. The connecting portion 23 extends vertically, with its forward / backward direction corresponding to the plate thickness direction. The upper connecting portion 21 extends continuously rearward from the upper end of the connecting portion 23, with its vertical direction corresponding to the plate thickness direction. The lower connecting portion 22 extends continuously forward from the lower end of the connecting portion 23, with its vertical direction corresponding to the plate thickness direction. Bolt fastening holes 21A and 22A are formed on the rear side of the upper connecting portion 21 and the front side of the lower connecting portion 22, respectively. A pair of recesses 24 are provided at the left and right ends of the upper connecting portion 21. The recesses 24 are located on the front side of the upper connecting portion 21. The dimensions of the busbar 20 in the plate thickness and width directions vary depending on the width of the component connected to the other side, the required strength, etc. Multiple (eight in this embodiment) busbars 20 can be of the same shape, or they can be of different shapes. The busbars 20 in this embodiment use three different sizes.

[0066] [Support, middle support, right support, left support]

[0067] Multiple supports 30 are composed of a middle support 30M, a right-end support 30R (an example of an end support), and a left-end support 30L (an example of an end support). For example... Figure 5 As shown, in the connection module 10, multiple brackets 30 are connected to each other in a left-right direction, as detailed below. The right bracket 30R is located on the right end, and the left bracket 30L is located on the left end. The middle bracket 30M is located between the right bracket 30R and the left bracket 30L. Hereinafter, the term "bracket 30" will be used without distinguishing between the middle bracket 30M, the right bracket 30R, and the left bracket 30L.

[0068] The support 30 is made of insulating synthetic resin, such as Figure 8As shown, it is a rectangular frame that opens upwards. A bracket 30 holds a busbar 20. Each bracket 30 is formed to correspond to the size of each busbar 20. In this embodiment, three different types of structures of different sizes are used as brackets 30 to hold the busbar 20, corresponding to the size of the busbar 20. The bracket 30 has a pair of sidewalls 31A and 31B on the left and right sides. The pair of sidewalls 31A and 31B are connected at the front end by a front wall 32 and at the rear end by a rear wall 33. The lower ends of the pair of sidewalls 31A and 31B, the front wall 32, and the rear wall 33 are connected by a bottom wall 34.

[0069] [Busbar retaining section, track-side guide]

[0070] like Figure 8 As shown, the bracket 30 has a pair of busbar holding portions 35A and 35B on a pair of sidewalls 31A and 31B. The busbar holding portions 35A and 35B are located at the center of the bracket 30 in the front-rear direction. The busbar holding portions 35A and 35B protrude towards the opposing sidewalls 31B and 31A, respectively. Cutouts 36 are formed in the sidewalls 31B and 31A in front of and behind the busbar holding portions 35A and 35B. Therefore, the sidewalls 31A and 31B with the central busbar holding portions 35A and 35B can be flexed and deformed in the left-right direction. A conical surface 37 is provided on the upper side of the busbar holding portions 35A and 35B, which slopes closer to the sidewalls 31A and 31B as it faces upwards. Figure 6 As shown, the lower ends of the busbar retaining parts 35A and 35B are provided as a lower surface 35C with a steeply upright shape. Figure 7 As shown, the upper surfaces 32A and 33A of the front wall 32 and the rear wall 33 are positioned below the lower surfaces 35C of the busbar holding portions 35A and 35B. The vertical distance between the lower surfaces 35C of the busbar holding portions 35A and 35B and the upper surfaces 32A and 33A of the front wall 32 and the rear wall 33 is set to be equal to or slightly greater than the thickness of the upper connecting portion 21. Figure 8 As shown, a pair of protrusions 38 are continuously provided from a pair of sidewalls 31A, 31B at the left and right ends of the front wall 32. The protrusions 38 are positioned above the upper surface 32A of the front wall 32. Figure 4 As shown, the thickness of the protrusion 38 in the front-rear direction is set to be smaller than the front-rear dimension of the recess 24. Figure 9 As shown, a pair of track-side guides 39 are disposed on the front and rear sides of the bottom wall 34, extending downwards. The lower ends of the pair of track-side guides 39 extend back and forth away from each other.

[0071] [Locking part, first bracket side guide, second bracket side guide]

[0072] like Figure 8As shown, a locking piece 40, a first bracket-side guide 41 (an example of a bracket-side guide), and a second bracket-side guide 42 (an example of a bracket-side guide) are provided on the side wall 31A of the intermediate bracket 30M. The locking piece 40 is disposed in the center of the intermediate bracket 30M in the front-rear direction and protrudes to the left of the side wall 31A. A locking part 40A is provided at the front end of the locking piece 40, protruding upward. The left side of the locking part 40A forms a tapered surface 40B that points upward towards the right. The right end of the locking part 40A has a sloping shape. The first bracket-side guide 41 and the second bracket-side guide 42 protrude to the left of the side wall 31A, and their protrusion dimensions are smaller than the protrusion dimensions of the locking piece 40. A pair of second bracket-side guides 42 are provided on the front and rear sides of the side wall 31A. The front-rear dimension of the second bracket-side guide 42 is larger than that in the vertical direction. A pair of first bracket-side guides 41 are disposed between the locking piece 40 and the second bracket-side guide 42 in the front-rear direction. The vertical dimension of the first bracket side guide 41 is larger than the front-to-back dimension. The right bracket 30R also has a locking piece 40, the first bracket side guide 41, and the second bracket side guide 42, just like the middle bracket 30M.

[0073] [Locking bearing part, first bracket side guide bearing part, second bracket side guide bearing part]

[0074] like Figure 8 As shown, a locking receiving portion 43 is formed at the center of the bottom wall 34 of the bracket 30 in the front-rear direction. The locking receiving portion 43 is located on the right side of the bottom wall 34. Figure 6 As shown, the locking receiving part 43 engages with the locking part 40A of the adjacent bracket 30 on the right. A left-right gap CL4 is provided in the engagement between the locking part 40A and the locking receiving part 43. Figure 8 As shown, a pair of second bracket-side guide receiving portions 44 (an example of a bracket-side guide receiving portion) are provided on the side wall 31B of the bottom wall 34, both on the front and rear sides. The second bracket-side guide receiving portions 44 are recessed downwards from the height of one of the bottom walls 34 of the locking receiving portion 43. The pair of second bracket-side guide receiving portions 44 are connected to the front wall 32 or the rear wall 33, but not to the side wall 31B, and open to the right. Thus, as... Figure 11 As shown, a pair of second bracket-side guide receiving portions 44 receive a pair of second bracket-side guides 42 of another adjacent bracket 30 on the right. The first bracket-side guide 41 can engage with a first bracket-side guide receiving portion 45 (an example of a bracket-side guide receiving portion) formed by a part of the bottom wall 34.

[0075] As described above, multiple brackets 30 are assembled in the connecting module 10 in a left-right connected state by locking parts 40A and locking bearing parts 43. At this time, brackets 30 are arranged on both sides of the central bracket 30M in the left-right direction. On the other hand, as... Figure 6 and Figure 10 As shown, no bracket 30 is configured on the left side of the left end bracket 30L, therefore, the locking piece 40 including the locking part 40A, the first bracket side guide 41, and the second bracket side guide 42 are not provided. Similarly, as Figure 3 As shown, no bracket 30 is provided on the right side of the right-end bracket 30R. Therefore, the right-end bracket 30R may have a locking receiving part 43, a first bracket-side guide receiving part 45, and a second bracket-side guide receiving part 44, or it may not have these parts. It should be noted that in Embodiment 1, the intermediate bracket 30M, which has the locking receiving part 43, the first bracket-side guide receiving part 45, and the second bracket-side guide receiving part 44, is used as the right-end bracket 30R.

[0076] [Bracket, Rail]

[0077] The bracket 50 is made of insulating synthetic resin, such as Figure 13 As shown, it includes a support platform 51 and a busbar receiving section 52. The support platform 51 is a frame shape extending horizontally. A pair of rails 53, which extend vertically through the support platform 51, extend horizontally to form a slit shape. The pair of rails 53 are arranged side-by-side with a gap between them. Figure 4 As shown, the right end of track 53 forms a wide insertion port 54. (As indicated...) Figure 13 As shown, a wall-shaped limiting part 55 extending upwards is provided at the left end of the track 53. (As indicated...) Figure 6 As shown, with multiple supports 30 assembled on the bracket 50, the limiting part 55 faces the side wall 31A of the left-end support 30L. Figure 13 As shown, a pair of tracks 53 includes a rear track 53B located at the rear and a front track 53F located at the front. A rearwardly extending portion 56B is formed at the rear edge of the hole in the rear track 53B. A rearwardly extending portion 56F is formed at the front edge of the hole in the front track 53F. The rearwardly extending portion 56B and the frontwardly extending portion 56F are collectively defined as an extension 56. Figure 7 As shown, with the bracket 30 assembled on the bracket 50, the front extension 56F and the rear extension 56B support the bracket 30 from below. Figure 4 As shown, fixing holes 57 for fixing the cover 60 (described later) are formed at the right and left ends of the support platform 51. A protruding receiving portion 59B is provided behind the fixing hole 57 on the right side and in front of the fixing hole 57 on the left side. The protruding receiving portion 59B receives the protrusion 67 of the cover 60 (described later). Figure 13As shown, the protrusion 59A is provided downwards in front of the right-side fixing hole 57 and behind the left-side fixing hole 57. The busbar receiving portion 52 extends downwards from the front end of the support platform portion 51. The busbar receiving portion 52 has a plurality of partition plates 58 arranged side-by-side in the left-right direction. Figure 5 As shown, multiple brackets 30 and multiple busbars 20 are assembled into the bracket 50. The busbars 20 are separated from each other by partition plates 58 and do not contact each other.

[0078] [cover]

[0079] Cover 60 is made of insulating synthetic resin, such as Figure 14 As shown, the device includes a plate-shaped main body 61 extending in the left-right direction and fixing portions 66 disposed on both sides of the main body 61 in the left-right direction. The fixing portions 66 are shaped to protrude downwards from the main body 61. A fixing hole 62 is formed in the center of the fixing portion 66 in the front-rear direction. A protrusion 67 is provided downwards behind the fixing hole 62 on the right side and in front of the fixing hole 62 on the left side. A protective wall 63 is provided at the front end of the main body 61 extending downwards. A groove 64 is provided in the protective wall 63. Figure 1 and Figure 3 As shown, the cover 60 covers and is fixed to the bracket 50, which is assembled with multiple supports 30 and multiple busbars 20. Figure 1 As shown, the groove 64 receives the partition plate 58. (As indicated...) Figure 3 As shown, the right end of the main body 61 is provided with a downward-extending wall-shaped anti-detachment part 65, facing the side wall 31B of the right end bracket 30R. The anti-detachment part 65 suppresses the detachment of the multiple brackets 30 to the right of the bracket 50.

[0080] [Assembly of the connection module]

[0081] Insert the track-side guide 39 of the bracket 30 into the insertion port 54 of the bracket 50. By moving the bracket 30 to the left, assemble the bracket 30 into the bracket 50 with the track-side guide 39 engaged in the track 53 (see reference). Figure 4 At this point, the left end bracket 30L is assembled first, and the right end bracket 30R is assembled last. During this assembly process, adjacent brackets 30 are connected to each other left and right. If the brackets 30 are brought closer together, the conical surface 40B of the bracket 30 first contacts the side wall 31B of the adjacent left bracket 30. By further bringing the brackets 30 closer together, the locking piece 40 flexes downwards and enters under the bottom wall 34 of the left bracket 30, locking into the locking receiving part 43 (see reference). Figure 6 During this period, the first bracket-side guide 41 and the second bracket-side guide 42 of the bracket 30 engage with the first bracket-side guide receiving portion 45 and the second bracket-side guide receiving portion 44 of the left bracket 30, respectively, to assist in the locking of the locking portion 40A and the locking receiving portion 43 (see reference). Figure 10 and Figure 11 With the bracket 30 assembled on the support bracket 50, between the bracket 30 and the support bracket 50, such as... Figure 7 As shown, a gap CL2 is set along the vertical direction, such as... Figure 6 As shown, a gap CL3 is set along the left and right directions.

[0082] Next, the busbar 20 is assembled to the bracket 30. The upper connecting part 21 is pressed from above the bracket 30, contacting the conical surface 37 of the busbar holding parts 35A and 35B. While causing the busbar holding parts 35A and 35B to flex outward, the upper connecting part 21 slides on the conical surface 37 and passes over the busbar holding parts 35A and 35B (see reference). Figure 6 With the busbar 20 held in place by the support 30, the busbar 20 is located below the lower surface 35C of the busbar holding portions 35A and 35B. At this time, as... Figure 4 As shown, the busbar 20 is positioned relative to the bracket 30 by fitting the protrusion 38 of the bracket 30 into the recess 24 of the upper connecting part 21. A gap CL1 is provided between the bracket 30 and the busbar 20 in the front-to-back direction.

[0083] like Figure 3 As shown, the cover 60 is finally placed over the bracket 50 from above, so that the protrusion 67 and the protrusion receiving part 59B are locked together, thereby completing the assembly of the connecting module 10.

[0084] [Installation of the connection module to the battery pack]

[0085] As described above, the connection module 10 is assembled as follows: Figure 1 and Figure 2 As shown, a terminal plate 3 is placed inside the battery pack 1. The connecting module 10 is fixed to the terminal plate 3 by engaging the protrusion 59 of the bracket 50 with the protrusion receiving part (not shown) of the terminal plate 3. Bolts BT3 are inserted into the fixing holes 62 and 57, and the nut N is tightened to the bolts BT3, thereby fixing the cover 60 to the bracket 50. Bolts BT1 are inserted into the bolt fastening holes 21A of the upper connecting part 21 and the bolt fastening holes (not shown) of the device-side connecting part 4A, and bolts BT3 are tightened to the bolt fixing part 3A, thereby electrically connecting the connecting module 10 to the device 4. Bolts BT2 are inserted into the bolt fastening holes 22A of the lower connecting part 22 and the bolt fastening holes (not shown) of the connector-side connecting part 7B, and bolts BT2 are tightened to the bolt fixing part of the terminal receiving part 8, thereby electrically connecting the connecting module 10 to the connector 5. Therefore, the device 4 is electrically connected to the connector 5.

[0086] [Effects of Implementation Method 1]

[0087] According to implementation method 1, it performs the following functions and effects.

[0088] The connection module 10 according to Embodiment 1 is housed inside a battery pack 1 having an upper housing 1U and a lower housing 1L, and includes: a plurality of busbars 20 for electrically connecting a device 4 disposed on the upper housing 1U side inside the battery pack 1 to a connector 5 disposed on the lower housing 1L side inside the battery pack 1; a plurality of brackets 30 having busbar holding portions 35A and 35B for holding the plurality of busbars 20; and a bracket 50 capable of locking the plurality of brackets 30, wherein the plurality of busbars 20 are connected along the upper and lower housings 1L. The busbars are arranged side by side in the left and right directions, and the direction that is orthogonal to the up and down direction and intersects with the left and right directions is the front and back direction. The multiple busbars 20 have: an upper connecting part 21 that extends in the front and back direction and is connected to the device 4; a lower connecting part 22 that extends in the front and back direction and is connected to the connector 5; and a connecting part 23 that extends in the up and down direction to connect the upper connecting part 21 and the lower connecting part 22. A gap CL1 is provided between the busbars 20 and the bracket 30 in the front and back direction, and gaps CL2 and CL3 are provided between the bracket 30 and the support 50 in the up and down direction and the left and right direction, respectively.

[0089] According to the above structure, since multiple busbars 20 electrically connect the devices 4 disposed on the upper housing 1U side inside the battery pack 1 to the connectors 5 disposed on the lower housing 1L side inside the battery pack 1, after the electrical connection of all the devices mounted inside the battery pack 1 is completed, the manufacturing process of the battery pack 1 can be completed by covering the lower housing 1L with the upper housing 1U and sealing their gaps. Moreover, a gap CL1 is provided between the busbars 20 and the bracket 30 in the front-to-back direction, and gaps CL2 and CL3 are provided between the bracket 30 and the support 50 in the vertical and horizontal directions, respectively. Therefore, positional deviations and dimensional inconsistencies of the components and mounted devices can be absorbed in each direction.

[0090] In Embodiment 1, the plurality of brackets 30 include a middle bracket 30M, a right-end bracket 30R, and a left-end bracket 30L. With the plurality of brackets 30 locked to the bracket 50, brackets 30 are arranged on both sides of the middle bracket 30M along the left-right direction. A bracket 30 is arranged only on the left side of the right-end bracket 30R along the left-right direction. A bracket 30 is arranged only on the right side of the left-end bracket 30L along the left-right direction. The middle bracket 30M has both a locking portion 40A and a locking receiving portion 43. The right-end bracket 30R has both a locking portion 40A and a locking receiving portion 43. The left-end bracket 30L has only the locking receiving portion 43 of the locking portion 40A and the locking receiving portion 43. Adjacent brackets 30 are locked to each other with a gap CL4 in the left-right direction by locking the locking portion 40A of one bracket 30 to the locking receiving portion 43 of the other bracket 30.

[0091] According to the above structure, adjacent brackets 30 can be connected, making the assembly of brackets 30 easier. Furthermore, since the structure includes a left-end bracket 30L without a locking part 40A, the lateral dimensions of the bracket 50 can be reduced. The multiple brackets 30 are locked together with a gap CL4 in the lateral direction, thus absorbing positional deviations and dimensional inconsistencies of the components and mounted equipment in the lateral direction.

[0092] In Embodiment 1, in the bracket 30, a first bracket-side guide 41 and a second bracket-side guide 42 are provided near the locking portion 40A, and a first bracket-side guide receiving portion 45 and a second bracket-side guide receiving portion 44 are provided near the locking receiving portion 43. The first bracket-side guide 41 and the second bracket-side guide 42 protrude outward in the left-right direction, and the first bracket-side guide receiving portion 45 and the second bracket-side guide receiving portion 44 receive the first bracket-side guide 41 and the second bracket-side guide 42.

[0093] Based on the above structure, the assembly of the supports 30 to each other becomes easy.

[0094] In embodiment 1, a track 53 extending in the left-right direction is provided on the bracket 50, and a track-side guide 39 that fits into the track 53 is provided on the support 30.

[0095] Based on the above structure, assembling the bracket 30 to the support 50 becomes easy.

[0096] In embodiment 1, a pair of track 53 and track-side guides 39 are provided at intervals along the front-rear direction.

[0097] According to the above structure, the locking force of the bracket 50 on the support 30 can be improved. Moreover, the shaking of the support 30 assembled to the bracket 50 can be suppressed.

[0098] In Embodiment 1, a cover 60 is provided that covers the busbar 20 and the support 30 from above and is fixed to the bracket 50.

[0099] Based on the above structure, it is possible to prevent the busbar 20 and the support 30 from falling off the bracket 50.

[0100] <Implementation Method 2>

[0101] Regarding embodiment 2 of this disclosure, refer to Figures 15-17 The following explanation will be provided. In the following explanation, components and effects identical to those in Embodiment 1 will be omitted. It should be noted that, regarding multiple identical components, sometimes only a subset of the components will be labeled, omitting the labels for the other components.

[0102] The connection module 110 of embodiment 2 includes a plurality of busbars 20, a plurality of supports 30 for holding the plurality of busbars 20, and a bracket 150 that is engaged with the plurality of supports 30.

[0103] like Figure 15 and Figure 16 As shown, a limiting part 155 extending upwards and forming a wall shape is provided at the left end of the bracket 150. A locking receiving part 143, identical to that of the bracket 30, is provided to the left and below the limiting part 155. The locking receiving part 143 engages with the locking part 40A of the bracket 30. Figure 17 As shown, the bracket 150 is provided with a first bracket-side guide receiving part 145 and a second bracket-side guide receiving part 144, which are the same as those of the bracket 30. The first bracket-side guide receiving part 145 and the second bracket-side guide receiving part 144 are respectively engaged with the first bracket-side guide 41 and the second bracket-side guide 42 of the bracket 30.

[0104] [Effects of Implementation Method 2]

[0105] According to implementation method 2, the following functions and effects are achieved.

[0106] like Figure 16 As shown, the plurality of brackets 30 each have a locking part 40A and a locking receiving part 43. Adjacent brackets 30 among the plurality of brackets 30 are locked to each other with a gap CL4 in the left-right direction by locking the locking part 40A of one bracket 30 to the locking receiving part 43 of the other bracket 30.

[0107] According to the above structure, the bracket 30 has a locking part 40A and a locking bearing part 43, so adjacent brackets 30 can be connected, and the assembly of the brackets 30 is easy. Moreover, it is not necessary to form a bracket 30 without the locking part 40A as in the left bracket 30L of Embodiment 1. The multiple brackets 30 are locked together with a gap CL4 in the left-right direction, so the positional deviation and dimensional unevenness of each component and the mounted equipment can be absorbed in the left-right direction.

[0108] <Implementation Method 3>

[0109] Regarding embodiment 3 of this disclosure, refer to Figures 18-21 The following explanation will be provided. In the following explanation, components and effects identical to those in Embodiment 1 will be omitted. It should be noted that, regarding multiple identical components, sometimes only a subset of the components will be labeled, omitting the labels for the other components.

[0110] The connection module 210 of embodiment 3 includes a plurality of busbars 20, a plurality of supports 30 for holding the plurality of busbars 20, and a bracket 250 that is engaged with the plurality of supports 30.

[0111] [Effects of Implementation Method 3]

[0112] like Figure 18 As shown, the insertion ports 254 of the bracket 250 are formed in multiple extensions 256. For example... Figure 20 As shown, the insertion port 254 is positioned to the right of the correct locking position of each bracket 30. The track-side guide 39 (an example of an engaging portion) engages from below with the engaging receiving portion 256A located to the left of the insertion port 254 in the extension portion 256, thereby holding each bracket 30 in an anti-detachment state to prevent it from falling upwards. Therefore, instead of inserting the track-side guide 39 of the bracket 30 from the insertion port 54 at the right end of the bracket 50 as in Embodiment 1, the brackets 30 are assembled onto the bracket 50 one by one (see Figure 1). Figure 4 ), but as Figure 21 As shown, after inserting the track-side guides 39 of the pre-connected brackets 30 into the respective insertion ports 254 from above, the brackets 30 can be assembled with the bracket 250 by moving the connected brackets 30 to the left.

[0113] Additionally, in embodiment 1, the insertion port 54 is located at the right end of the bracket 50 (see reference). Figure 4 However, it is possible to do so. Figure 19 As shown, the insertion port 254 is provided in the extension portion 256 in the connection module 210, so the bracket 250 can be formed smaller than the bracket 50 in the left-right direction.

[0114] <Other Implementation Methods>

[0115] (1) In Embodiments 1 to 3, it was described that the connection modules 10, 110, and 210 are applicable to the battery pack 1, but it is not limited to this. The connection modules can also be applied to the housing other than the battery pack.

[0116] (2) In embodiments 1 to 3, the busbar receiving part 52 that houses the connecting part 23 of the busbar 20 is provided in the brackets 50, 150, and 250. However, it is not limited to this. It can also be provided in the structure that a busbar receiving part of one bracket is provided in each bracket.

[0117] (3) In embodiments 1 to 3, the electrical connection between the busbar 20 and the device 4 and the electrical connection between the busbar 20 and the connector 5 are made by fastening with bolts. However, it is not limited to this. For example, it can also be made by welding.

[0118] Label Explanation

[0119] 1: Battery pack

[0120] 1L: Lower shell

[0121] 1U: Upper shell

[0122] 2: Battery holder

[0123] 3: Terminal board

[0124] 3A: Bolt fixing part

[0125] 3C: Nut housing

[0126] 3B: Cadence tablets

[0127] 59B: Protrusion bearing part

[0128] 3F: Front terminal block

[0129] 3R: Rear Terminal Board

[0130] 4: Equipment

[0131] 4A: Equipment-side connection part

[0132] 5: Connector

[0133] 6: Protective Cover Section

[0134] 7: Terminal accessories

[0135] 7A: Lug

[0136] 7B: Connector-side connection part

[0137] 8: Terminal housing section

[0138] 10, 110, 210: Connection modules

[0139] 20: Mother row

[0140] 21: Upper connecting part

[0141] 22: Lower connecting part

[0142] 21A, 22A: Bolt fastening holes

[0143] 23: Connecting Part

[0144] 24: concave part

[0145] 30: Bracket

[0146] 30L: Left end bracket

[0147] 30M: Intermediate support

[0148] 30R: Right-end bracket

[0149] 31A, 31B: Sidewalls

[0150] 32: Anterior wall

[0151] 32A, 33A: Upper surface

[0152] 33: Posterior wall

[0153] 34: Bottom wall

[0154] 35A, 35B: Busbar retaining section

[0155] 35C: Lower surface

[0156] 36: Incision area

[0157] 37, 40B: Conical surface

[0158] 38: convex part

[0159] 39: Track-side guide (an example of an engaging part)

[0160] 40: Locking plate

[0161] 40A: Locking section

[0162] 41: First support side guide

[0163] 42: Second bracket side guide

[0164] 43, 143: Locking bearing part

[0165] 44, 144: Second bracket side guide bearing part

[0166] 45, 145: First support side guide bearing part

[0167] 50, 150, 250: Bracket

[0168] 51: Support platform

[0169] 52: Mother Volleyball Reception Department

[0170] 53: Track

[0171] 53F: Front track

[0172] 53B: Rear track

[0173] 54, 254: Insertion port

[0174] 55, 155: Limited movement section

[0175] 56, 256: Extended Part

[0176] 56F: Front extension

[0177] 56B: Rear extension

[0178] 57, 62: Fixing holes

[0179] 58: Divider

[0180] 59A, 67: Protrusions

[0181] 60: Cover

[0182] 61: Main body

[0183] 63: Protective wall

[0184] 64: Groove

[0185] 65: Anti-hair loss section

[0186] 66: Fixing part

[0187] 256A: Clamping bearing part

[0188] B: Battery cell

[0189] BT1, BT2, BT3: Bolts

[0190] CL1, CL2, CL3, CL4: Gap

[0191] N: Nut.

Claims

1. A connection module, housed within an outer casing having an upper housing and a lower housing, wherein, The connection module includes: Multiple busbars electrically connect devices disposed on the upper housing side inside the housing to connectors disposed on the lower housing side inside the housing; Multiple supports, each having a busbar holding portion for holding the multiple busbars; and The bracket is capable of securing the multiple supports. With the plurality of brackets holding the plurality of busbars secured in the bracket, the plurality of busbars are arranged side by side along a first direction orthogonal to the vertical direction. The direction that is orthogonal to the up and down direction and intersects the first direction is defined as the second direction. The plurality of busbars include: an upper connecting portion extending along the second direction and connected to the device; a lower connecting portion extending along the second direction and connected to the connector; and a connecting portion extending in a vertical direction and connecting the upper connecting portion and the lower connecting portion. A gap is provided between the busbar and the support along the second direction. A gap is provided between the bracket and the support along the vertical direction and the first direction.

2. The connection module according to claim 1, wherein, Each of the plurality of brackets has a locking part and a locking bearing part. The adjacent brackets of the plurality of brackets are locked to each other with a gap along the first direction by locking the locking part of one bracket to the locking bearing part of the other bracket.

3. The connection module according to claim 1, wherein, The plurality of supports have intermediate supports and end supports. With the plurality of brackets secured to the bracket, the brackets are arranged on both sides of the intermediate bracket along the first direction, and the brackets are arranged only on one side of the end brackets along the first direction. The intermediate support has a locking part and a locking bearing part on both sides. One of the end brackets has at least the locking part in the locking part and the locking receiving part. The other side of the end bracket only has the locking part and the locking bearing part. The adjacent brackets of the plurality of brackets are locked to each other with a gap along the first direction by locking the locking part of one bracket to the locking bearing part of the other bracket.

4. The connection module according to claim 2 or 3, wherein, In the bracket, a bracket-side guide is provided near the locking portion, and a bracket-side guide receiving portion is provided near the locking receiving portion. The bracket-side guide protrudes outward along the first direction. The bracket-side guide receiving portion receives the bracket-side guide.

5. The connection module according to any one of claims 1 to 3, wherein, The bracket is provided with a track extending along the first direction. A track-side guide is provided on the bracket to fit into the track.

6. The connection module according to claim 5, wherein, The track and the track-side guide are arranged in multiple intervals along the second direction.

7. The connection module according to any one of claims 1 to 3, wherein, Each of the plurality of brackets is provided with a downwardly protruding engaging portion. The bracket has an engagement receiving portion for engaging the engagement portion from below.

8. The connection module according to any one of claims 1 to 3, wherein, The connection module has a cover that covers the busbar and the bracket from above and is fixed to the bracket.

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