Automotive wiring modules and flexible substrates

Abstract

A vehicle-mounted wiring module (20) is mounted on a plurality of storage elements (11) having electrode terminals (12A, 12B), wherein the vehicle-mounted wiring module (20) comprises: a busbar (40) connected to the electrode terminals (12A, 12B); and a flexible substrate (21) electrically connected to the busbar (40), wherein the flexible substrate (21) has a folded structure (23) folded at a folded portion (26, 27), and the folded structure (23) has a convex portion (23) provided in a convex shape from an outer edge (E1, E2) of the flexible substrate (21) in an unfolded state. The flexible substrate (21) is provided with a plurality of protrusions (24A, 24B) and slits (25A, 25B) for the protrusions (24A, 24B) to pass through. The expanded state is a state before the bending portions (26, 27) are bent. The bending portions (26, 27) are arranged between the protrusions (24A, 24B) and the slits (25A, 25B) of the flexible substrate (21) in the expanded state. The protrusions (24A, 24B) are inserted into the slits (25A, 25B) to suppress the flexible substrate (21) from recovering from the state of being bent at the bending portions (26, 27) to the expanded state.

Description

Technical Field

[0001] The present disclosure relates to a vehicle-mounted wiring module and a flexible substrate. Background Art

[0002] As a busbar module assembled to a battery assembly mounted on an electric vehicle or hybrid vehicle, a structure described in Japanese Patent Publication No. 2020-14369 (hereinafter referred to as Patent Document 1) has been known in the past. The busbar module described in Patent Document 1 includes: a busbar connected to the electrodes of a plurality of single cells; and a flexible substrate having a wiring pattern connected to the busbar. The flexible substrate includes: a main line; a first branch line portion extending from the main line; and a second branch line portion extending from the first branch line portion and having a connection portion connected to the busbar. A first folding portion and a second folding portion are provided on the second branch line portion, and the second branch line portion is bent into an S shape as a whole. Thus, the second branch line portion is configured to be stretchable and retractable, and can absorb manufacturing tolerances, assembly errors, etc. of the busbar and the single cells.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2020-14369 Summary of the Invention

[0006] Summary of the Invention

[0007] Problems to be solved by the invention

[0008] However, when the folded flexible substrate is manufactured and transported to an assembly plant, it may be deformed and lose its original shape. Moreover, depending on the manufacturing process, it is conceivable that positioning of the flexible substrate may be difficult, making it difficult to smoothly assemble other components with the flexible substrate.

[0009] Solutions to Problems

[0010] A vehicle-mounted wiring module disclosed herein is mounted on a plurality of energy storage elements having electrode terminals. The vehicle-mounted wiring module includes: a busbar connected to the electrode terminals; and a flexible substrate electrically connected to the busbar. The flexible substrate has a folded structure formed by bending at a bent portion. In an unfolded state, the folded structure includes a protrusion extending from an outer edge of the flexible substrate and a slit through which the protrusion is inserted. The unfolded state is a state before the bent portion is bent. In the unfolded state, the bent portion is arranged between the protrusion and the slit of the flexible substrate. By inserting the protrusion through the slit, the flexible substrate is prevented from deforming back from the state bent at the bent portion to the unfolded state.

[0011] Effects of the Invention

[0012] According to the present disclosure, it is possible to provide a vehicle-mounted wiring module including a flexible substrate that is less likely to deform in a bent state. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 Schematic diagram showing a vehicle equipped with the power storage module according to the embodiment.

[0014] Figure 2 This is a top view of the power storage module.

[0015] Figure 3 This is an enlarged top view of the main parts of the power storage module.

[0016] Figure 4 This is an enlarged perspective view of the main parts of the power storage module.

[0017] Figure 5 This is a perspective view of the first folded structure of the flexible substrate.

[0018] Figure 6 It is a plan view showing the unfolded state of the first folded structure of the flexible substrate.

[0019] Figure 7 This is a perspective view showing a process of forming the first folded-back structure of the flexible substrate.

[0020] Figure 8 This is a top view of the first folded-back structure of the flexible substrate.

[0021] Figure 9 This is a perspective view of the second folded structure of the flexible substrate.

[0022] Figure 10 It is a plan view showing the second folded structure of the flexible substrate in an unfolded state.

[0023] Figure 11 This is a perspective view showing a step of forming the second folded-back structure of the flexible substrate.

[0024] Figure 12 This is a top view of the second folded structure of the flexible substrate. DETAILED DESCRIPTION

[0025] [Description of Embodiments of the Present Disclosure]

[0026] First, embodiments of the present disclosure will be described by way of examples.

[0027] (1) The vehicle-mounted wiring module disclosed herein is mounted on a plurality of storage elements having electrode terminals, wherein the vehicle-mounted wiring module comprises: a busbar connected to the electrode terminals; and a flexible substrate electrically connected to the busbar, wherein the flexible substrate has a folded structure formed by bending at a bent portion, wherein the folded structure has a protrusion provided in a convex shape from the outer edge of the flexible substrate and a slit through which the protrusion is inserted in an unfolded state, wherein the unfolded state is a state before the bent portion is bent, and the bent portion is arranged between the protrusion and the slit of the flexible substrate in the unfolded state, and by inserting the protrusion into the slit, the flexible substrate is prevented from deforming back from the state bent at the bent portion to the unfolded state.

[0028] According to such a configuration, the flexible substrate bent at the bent portion can be prevented from deforming back to the expanded state, thereby facilitating assembly of the vehicle-mounted wiring module.

[0029] (2) It is preferable that a pair of the protrusions and a pair of the slits are provided in one of the folded structures.

[0030] According to such a configuration, it is possible to more effectively suppress the flexible substrate bent at the bent portion from deforming back to the expanded state.

[0031] (3) Preferably, the flexible substrate has an elongated shape extending along a first direction, and the folding structure comprises: a pair of long strip portions extending in parallel along the first direction in the unfolded state; a connecting portion connecting the pair of long strip portions; and a pair of bent portions, wherein the convex portion is provided on either side of the pair of long strip portions and the slit is provided on the other side of the pair of long strip portions, and the folds of the pair of bent portions of the folding structure are arranged perpendicular to each other.

[0032] This structure allows the length of the flexible substrate in the first direction when bent at the bent portion to be greater than the length of the flexible substrate in the first direction when unfolded. Therefore, for example, even when multiple storage elements are stacked in the first direction, the vehicle wiring module can be easily manufactured.

[0033] (4) Preferably, the pair of elongated portions are arranged on the same straight line extending in the first direction by being arranged at the same position in a short-side direction of the flexible substrate perpendicular to the first direction.

[0034] With this configuration, the pair of elongated portions are aligned on the same straight line extending in the first direction, allowing the flexible substrate to be formed into an elongated shape. Consequently, the length of the vehicle wiring module in the short side direction of the flexible substrate can be reduced.

[0035] (5) Preferably, the flexible substrate has an elongated shape extending in a first direction, the slit is formed to be long in the first direction, and the length of the slit in the first direction is set to be greater than the length of the protrusion in the first direction.

[0036] With this configuration, the projection is slidable in the first direction while inserted through the slit, thereby absorbing manufacturing tolerances of the storage element, busbar, etc., and assembly tolerances of the vehicle wiring module and the plurality of storage elements in the first direction.

[0037] (6) In addition, the flexible substrate of the present disclosure is installed in a vehicle-mounted wiring module in a state in which it is bent at a bending portion, wherein the flexible substrate has a protrusion provided in a convex shape from the outer edge of the flexible substrate and a slit for inserting the protrusion in the unfolded state, the unfolded state is the state before the bending portion is bent, the bending portion is arranged between the protrusion and the slit in the unfolded state, and by inserting the protrusion into the slit, the situation of recovering deformation from the state of being bent at the bending portion to the unfolded state is suppressed.

[0038] According to such a configuration, the flexible substrate bent at the bent portion can be prevented from deforming back to the expanded state, so that the flexible substrate is less likely to deform during transportation, for example.

[0039] [Details of the embodiments of the present disclosure]

[0040] The following describes embodiments of the present disclosure. The present 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 of the claims and equivalents.

[0041] <Implementation Method>

[0042] Regarding the embodiments of the present disclosure, refer to Figures 1 to 12 For example Figure 1 As shown, the power storage module 10 of this embodiment is suitable for use in a power storage pack 2 mounted on a vehicle 1. The power storage pack 2 is mounted on a vehicle 1, such as an electric vehicle or a hybrid vehicle, and is used as a driving source for the vehicle 1. In the following description, among the various components, only some are denoted by reference numerals, and reference numerals for other components may be omitted.

[0043] like Figure 1As shown, a power storage pack 2 is arranged near the center of the vehicle 1. A PCU 3 (Power Control Unit) is arranged at the front of the vehicle 1. The power storage pack 2 and the PCU 3 are connected by a wiring harness 4. The power storage pack 2 and the wiring harness 4 are connected by a connector not shown. The power storage pack 2 has a power storage module 10, which includes a plurality of power storage elements 11. The power storage module 10 (and the vehicle wiring module 20) can be mounted in any direction, but except for the following, Figure 1 In addition, the description is made assuming that the direction indicated by the arrow line Z is upward, the direction indicated by the arrow line X is forward, and the direction indicated by the arrow line Y is left.

[0044] like Figure 2 As shown, the power storage module 10 includes: a plurality of power storage elements 11 (36 in this embodiment) arranged in the left-right direction; and a vehicle-mounted wiring module 20 mounted on the upper surface of the plurality of power storage elements 11 .

[0045] like Figure 2 As shown, the plurality of storage elements 11 are divided into two parts, 18 in each, and are arranged at intervals in the left-right direction. The 18 storage elements 11 are stacked in the left-right direction and clamped from the left and right ends by the end plates 13. The end plates 13 have a fixing portion 14 on the side opposite to the storage element 11. Although not shown in the figure, the plurality of storage elements 11 are fixed in the storage group 2 by the fixing portion 14. Figure 3 As shown, the energy storage device 11 has a flat rectangular parallelepiped shape in which an energy storage element (not shown) is housed, and has positive and negative electrode terminals 12A and 12B on the upper surface.

[0046] [Automotive wiring module]

[0047] like Figure 2 As shown in FIG. 2 , the vehicle wiring module 20 includes a flexible substrate 21, a busbar 40 connected to the flexible substrate 21, and a protector 50 for holding the flexible substrate 21 and the busbar 40. Figure 3 As shown, the vehicle wiring module 20 is attached to the electrode terminals 12A and 12B on the front side of the plurality of energy storage elements 11. It should be noted that the vehicle wiring module attached to the electrode terminals 12A and 12B on the rear side of the plurality of energy storage elements 11 has the same structure as the vehicle wiring module 20, and therefore, illustration and description thereof are omitted.

[0048] [Flexible substrate]

[0049] The flexible substrate 21 is a sheet-like substrate with flexibility, such as Figure 2As shown, the flexible substrate 21 has an elongated shape extending in the left-right direction. Although not shown, the flexible substrate 21 includes: a base film made of an insulating synthetic resin; and conductive paths wired to the base film. The base film and conductive paths are further covered by an insulating layer made of an insulating cover film or coating. Materials such as polyimide (PI) and polyethylene terephthalate (PET) can be used as the base film or insulating layer. The conductive paths are made of a metal such as copper or a copper alloy and are electrically conductive.

[0050] like Figure 3 As shown, the flexible substrate 21 has a busbar connection portion 22 that protrudes toward the busbar 40. A solder pad (not shown) is formed on the lower surface of the busbar connection portion 22, located at the end of a conductive path. The solder pad is electrically connected to the busbar 40 by soldering or other means. The conductive path is connected to a connector (not shown) provided at the end of the flexible substrate 21, which is then connected to the PCU 3.

[0051] [Fold-back structure, first fold-back structure, second fold-back structure]

[0052] like Figure 3 As shown, the flexible substrate 21 is provided with a plurality of bent local structures, forming a folded structure 23. The plurality of folded structures 23 include a first folded structure 23A (an example of a folded structure, see Figure 5 ) and the second folded structure 23B (an example of a folded structure, see Figure 9 ), the first folded structure 23A has two different shapes. The first folded structure 23A is arranged behind the flexible portion 53 of the protector 50 described later. The second folded structure 23B is arranged at the left end of the 18 storage elements 11 arranged on the right side. Figure 2 As shown, the flexible substrate 21 includes four first folded structures 23A and one second folded structure 23B.

[0053] [Convex portion of the first folded structure]

[0054] Figure 6 FIG. 2 shows the expanded state before the flexible substrate 21 is folded to form the first folded structure 23A. Figure 6 As shown, the first folded structure 23A includes a pair of protrusions 24A and 24B, a pair of slits 25A and 25B, and a pair of bent portions 26 and 27 disposed between the protrusions 24A and 24B and the slits 25A and 25B. The protrusion 24A is disposed in a convex shape from the outer edge E1 of the flexible substrate 21 toward the front, while the protrusion 24B is disposed in a convex shape from the outer edge E2 of the flexible substrate 21 toward the rear. The pair of protrusions 24A and 24B are disposed at the same position in the left-right direction. The protrusion 24A is disposed on the front side of the flexible substrate 21, while the protrusion 24B is disposed on the rear side of the flexible substrate 21.

[0055] [Slit of the first folded structure]

[0056] like Figure 6 As shown, a pair of slits 25A and 25B are formed vertically through the flexible substrate 21, forming a shape that is elongated in the horizontal direction. Slits 25A and 25B are positioned at the same horizontal position. Slit 25A is positioned on the front side of the flexible substrate 21, while slit 25B is positioned on the rear side of the flexible substrate 21. The front edge of slit 25A serves as a receiving portion 28A, while the rear edge of slit 25B serves as a receiving portion 28B.

[0057] [Bending portion of the first folding structure]

[0058] like Figure 6 As shown, the bent portion 26 is provided on the side of the convex portions 24A and 24B, and the bent portion 27 is provided on the side of the slits 25A and 25B. The folds of the bent portions 26 and 27 extend in the front-to-back direction. Figure 7 As shown, flexible substrate 21 is convexly folded at bend 26 and concavely folded at bend 27. Convex folding refers to bending flexible substrate 21 so that the fold is on the outside of the bent flexible substrate 21, while concave folding refers to bending flexible substrate 21 so that the fold is on the inside of the bent flexible substrate 21. Flexible substrate 21 is bent at bends 26 and 27 so that the portion having convex portions 24A and 24B is positioned on the upper side.

[0059] like Figure 5 and Figure 8 As shown, the protrusion 24A is arranged at the left and right center parts of the slit 25A and is inserted into the slit 25A from above. The front end of the protrusion 24A inserted into the slit 25A is arranged below the receiving portion 28A. Similarly, the protrusion 24B is inserted into the slit 25B and is arranged below the receiving portion 28B. The reaction force to restore the bent state to the expanded state acts on the bent portions 26 and 27, but the protrusions 24A and 24B are inserted into the slits 25A and 25B and are caught by the receiving portions 28A and 28B, thereby suppressing the flexible substrate 21 from the state bent at the bent portions 26 and 27 (see Figure 5 and Figure 8 ) to the expanded state (refer to Figure 6 ) to recover the deformation.

[0060] like Figure 8 As shown, the length LS1 of the slits 25A and 25B in the left-right direction is set to be greater than the length LC1 of the protrusions 24A and 24B in the left-right direction. As a result, the protrusions 24A and 24B can slide in the left-right direction while inserted into the slits 25A and 25B, and the first folded structure 23A becomes a structure that can be extended and retracted in the left-right direction.

[0061] [Long strip]

[0062] Figure 10 FIG shows the expanded state before the flexible substrate 21 is bent to form the second folded structure 23B. Figure 10 As shown, the second folding structure 23B includes a pair of elongated portions 29 and 30 extending parallel to each other in the horizontal direction in the expanded state; a connecting portion 31 connecting the pair of elongated portions 29 and 30; and a pair of bent portions 32 and 33. The elongated portion 29 is provided with a pair of protrusions 34A and 34B. The elongated portion 30 is provided with a pair of slits 35A and 35B.

[0063] [Convex portion of the second folded structure]

[0064] like Figure 10 As shown, the convex portion 34A is provided in a convex shape from the outer edge E3 of the flexible substrate 21 toward the rear, and the convex portion 34B is provided in a convex shape from the outer edge E4 of the flexible substrate 21 toward the front. The pair of convex portions 34A and 34B are arranged at the same position in the left-right direction. The convex portion 34A is arranged on the rear side of the elongated portion 29, and the convex portion 34B is arranged on the front side of the elongated portion 29. It should be noted that in the second folded structure 23B, the front and rear of the elongated portion 29 are reversed, so as shown in FIG. Figure 9 and Figure 12 As shown, the convex portion 34A is arranged on the front side of the flexible substrate 21 , and the convex portion 34B is arranged on the rear side of the flexible substrate 21 .

[0065] [Slit of the Second Folding Structure]

[0066] like Figure 10 As shown, a pair of slits 35A and 35B are formed vertically through the flexible substrate 21 (elongated portion 30), forming a shape that is elongated in the horizontal direction. Slits 35A and 35B are positioned at the same horizontal position. Slit 35A is positioned on the front side of elongated portion 30, while slit 35B is positioned on the rear side of elongated portion 30. The front edge of slit 35A serves as a receiving portion 36A, while the rear edge of slit 35B serves as a receiving portion 36B.

[0067] [Bending portion of the first folding structure]

[0068] like Figure 10 As shown, a pair of bent portions 32 and 33 are disposed between the protrusions 34A and 34B and the slits 35A and 35B. The bent portion 32 is provided on the elongated portion 29, and the bent portion 33 is provided on the connecting portion 31. The fold of the bent portion 32 extends in the front-to-back direction. The fold of the bent portion 33 extends in the left-to-right direction. In other words, the folds of the pair of bent portions 32 and 33 are disposed perpendicular to each other.

[0069] like Figure 11As shown, the flexible substrate 21 is convexly bent at the bending portion 32 and concavely bent at the bending portion 33. The flexible substrate 21 is bent at the bending portions 32 and 33 in such a manner that the long portion 29 is arranged on the upper side. Figure 9 and Figure 12 As shown, in the flexible substrate 21 bent at the bent portions 32 and 33, the pair of long strip portions 29 and 30 are arranged at the same position in the short side direction (i.e., the front-to-back direction) of the flexible substrate 21 perpendicular to the left-right direction, and are thus arranged on the same straight line extending in the left-right direction.

[0070] like Figure 9 and Figure 12 As shown, the protrusion 34A is arranged at the left and right center parts of the slit 35A and is inserted into the slit 35A from above. The front end of the protrusion 34A inserted into the slit 35A is arranged below the receiving part 36A. Similarly, the protrusion 34B is inserted into the slit 35B and is arranged below the receiving part 36B. The reaction force to restore the bent state to the expanded state acts on the bent parts 32 and 33, but the protrusions 34A and 34B are inserted into the slits 35A and 35B and are caught by the receiving parts 36A and 36B, thereby suppressing the flexible substrate 21 from the state of being bent at the bent parts 32 and 33 (refer to FIG. Figure 9 and Figure 12 ) to the expanded state (refer to Figure 10 ) to recover the deformation.

[0071] like Figure 12 As shown, the length LS2 of the slits 35A and 35B in the left-right direction is set to be greater than the length LC2 of the protrusions 34A and 34B in the left-right direction. As a result, the protrusions 34A and 34B can slide in the left-right direction while inserted into the slits 35A and 35B, and the second folded structure 23B becomes a structure that can be extended and retracted in the left-right direction.

[0072] In the second folded structure 23B, Figure 10 In the unfolded state shown in FIG, a pair of elongated portions 29 and 30 extend rightward from the connecting portion 31. That is, the connecting portion 31 is arranged at the left end portion of the flexible substrate 21. Figure 12 In the state shown in FIG. 2 , in which the bent portions 32 and 33 are bent, the strip portion 29 extends to the left, and the strip portion 30 extends to the right. That is, at the left end portion of the flexible substrate 21, the strip portion 29 extends to the left of the connecting portion 31. Therefore, by forming the second folded structure 23B, the flexible substrate 21 in the bent state (see FIG. 2 ) can be Figure 12 ) is set larger than the flexible substrate 21 in the unfolded state (refer to Figure 10 ) is long in the left-right direction. Therefore, the flexible substrate 21 having the second folded structure 23B is easily applicable to the vehicle wiring module 20 formed long in the stacking direction of the storage element 11. In this embodiment, as Figure 2 As shown, the second folded structure 23B is located near the left-right center of the vehicle wiring module 20 , and the flexible substrate 21 folded in the second folded structure 23B is approximately twice as long as that in the unfolded state.

[0073] [Busbar]

[0074] like Figure 3 As shown, the busbar 40 is a member used to connect three storage elements 11 in a row. It is made of a conductive metal plate. Examples of metals used to form the busbar 40 include copper, copper alloys, aluminum, aluminum alloys, and stainless steel (SUS). The busbar 40 is generally rectangular and has six electrode insertion holes 41 through which the electrode terminals 12A and 12B can be inserted. The busbar 40 is electrically connected to the electrode terminals 12A and 12B by welding. The busbar 40 is electrically connected to the busbar connection portion 22 of the flexible substrate 21 by soldering or other means.

[0075] like Figure 3 As shown, the protector 50 is made of an insulating synthetic resin and has a plate-like shape. The protector 50 consists of two components: a first protector 50A, which is positioned on the right side of the vehicle wiring module 20, and a second protector 50B, which is positioned on the left side of the vehicle wiring module 20. The first protector 50A and the second protector 50B have the same structure. Therefore, the following detailed description will focus on the common structure of the first protector 50A and the second protector 50B.

[0076] like Figure 4 As shown, the first protector 50A includes a busbar arrangement portion 51, located at the front end and housing the busbars 40, and a wiring board portion 52, located adjacent to the rear of the busbar arrangement portion 51 and housing the flexible substrate 21. The busbar arrangement portion 51 is a bottomless frame, formed to separate the busbars 40 arranged in the horizontal direction. The busbar arrangement portion 51 includes latching claws (not shown) and other features to retain the busbars 40. Flexible portions 53, which are capable of flexing and deforming in the horizontal direction, are provided between the busbar arrangement portions 51. The provision of the flexible portions 53 allows for lateral manufacturing tolerances of the storage elements 11, busbars 40, and the assembly tolerances of the busbars 40 and the multiple storage elements 11 to be accommodated. A cutout 54 is provided in the rear wall of the busbar arrangement portion 51 to accommodate the busbar connection portions 22 of the flexible substrate 21.

[0077] like Figure 4As shown, the wiring board portion 52 is formed into a plate shape extending in the horizontal direction. The wiring board portion 52 is located adjacent to the rear of the busbar arrangement portion 51 and is not located behind the flexible portion 53. The flexible substrate 21 is placed on the wiring board portion 52. The flexible substrate 21 has a portion secured to the wiring board portion 52 using an adhesive or adhesive tape, and is configured to be extendable in the horizontal direction between the first folded structure 23A and the second folded structure 23B. The first folded structure 23A is arranged between the wiring board portion 52 in front of the flexible portion 53, allowing the flexible substrate 21 to follow changes in the horizontal dimension caused by the flexure of the flexible portion 53.

[0078] like Figure 3 and Figure 4 As shown, a bridge portion 55 is provided at the right end of the second protector 50B. The bridge portion 55 extends above the left end plate 13, where the 18 energy storage elements 11 on the left side are mounted. A groove-shaped guide recess 56 is formed to the right of the bridge portion 55. A guide plate portion 57 extending leftward is provided on the wiring board portion 52 at the left end of the first protector 50A. The guide plate portion 57 and the guide recess 56 engage with each other and are able to slide in the left-right direction. This allows for accommodating assembly tolerances of the first and second protectors 50A, 50B, and the multiple energy storage elements 11 in the left-right direction. The second folded structure 23B is arranged near the guide plate portion 57, allowing the flexible substrate 21 to follow changes in the left-right dimensions associated with the engagement of the first and second protectors 50A, 50B.

[0079] [Effects of the embodiment]

[0080] According to the embodiment, the following actions and effects are achieved.

[0081] The vehicle wiring module 20 of the embodiment is mounted on a plurality of energy storage elements 11 having electrode terminals 12A and 12B. The vehicle wiring module 20 includes a busbar 40 connected to the electrode terminals 12A and 12B, and a flexible substrate 21 electrically connected to the busbar 40. The flexible substrate 21 has a first folded structure 23A folded at bends 26 and 27, and a second folded structure 23B folded at bends 32 and 33. The first folded structure 23A includes, in the expanded state, protrusions 24A, 24B provided protruding from the outer edges E1, E2 of the flexible substrate 21, and slits 25A, 25B through which the protrusions 24A, 24B are inserted. The expanded state is the state before the bent portions 26, 27 are bent. In the expanded state, the bent portions 26, 27 are arranged between the protrusions 24A, 24B and the slits 25A, 25B of the flexible substrate 21, and the protrusions 24A, 24B are inserted into the slits 25A, 25B. This prevents the flexible substrate 21 from deforming back to the expanded state from the state bent at the bent portions 26, 27. The second folded structure 23B includes, in the expanded state, protrusions 34A, 34B extending from the outer edges E3, E4 of the flexible substrate 21, and slits 35A, 35B through which the protrusions 34A, 34B are inserted. The expanded state is the state before the bent portions 32, 33 are bent. In the expanded state, the bent portions 32, 33 are disposed between the protrusions 34A, 34B and the slits 35A, 35B of the flexible substrate 21, and the protrusions 34A, 34B are inserted through the slits 35A, 35B. This prevents the flexible substrate 21 from deforming back from the state of being bent at the bent portions 32, 33 to the expanded state.

[0082] According to the above configuration, the flexible substrate 21 bent at the bent portions 26 , 27 and the bent portions 32 , 33 can be prevented from deforming back to the expanded state, thereby facilitating assembly of the vehicle wiring module 20 .

[0083] In the embodiment, a pair of protrusions 24A, 24B and a pair of slits 25A, 25B are provided in one first folded structure 23A, and a pair of protrusions 34A, 34B and a pair of slits 35A, 35B are provided in one second folded structure 23B.

[0084] According to the above-described configuration, it is possible to more effectively suppress the flexible substrate 21 bent at the bent portions 26 , 27 and the bent portions 32 , 33 from deforming back to the expanded state.

[0085] In the embodiment, the flexible substrate 21 has an elongated shape extending in the left-right direction. The second folded structure 23B includes a pair of elongated portions 29 and 30 extending parallel to each other in the left-right direction in the unfolded state, a connecting portion 31 connecting the pair of elongated portions 29 and 30, and a pair of bent portions 32 and 33. Protrusions 34A and 34B are provided on the elongated portion 29, and slits 35A and 35B are provided on the elongated portion 30. The folds of the pair of bent portions 32 and 33 of the second folded structure 23B are arranged perpendicular to each other.

[0086] With the above-described structure, the length of the flexible substrate 21 in the left-right direction when bent at the bent portions 32 and 33 can be made longer than the length of the flexible substrate 21 in the left-right direction when in the unfolded state. Therefore, even when, for example, a plurality of energy storage elements 11 are stacked in the left-right direction, the in-vehicle wiring module 20 can be manufactured more easily.

[0087] In the embodiment, the pair of elongated portions 29 and 30 are arranged at the same position in the short-side direction perpendicular to the left-right direction of the flexible substrate 21 , and are thus arranged on the same straight line extending in the left-right direction.

[0088] With the above configuration, the pair of elongated portions 29 and 30 are aligned on the same straight line extending in the left-right direction, thereby forming the flexible substrate 21 into an elongated shape. Consequently, the length of the vehicle wiring module 20 in the short side direction of the flexible substrate 21 can be reduced.

[0089] In the embodiment, the flexible substrate 21 has an elongated shape extending in the left-right direction, and the slits 25A, 25B, 35A, and 35B are formed to be longer in the left-right direction. The length LS1 of the slits 25A and 25B in the left-right direction is set to be greater than the length LC1 of the protrusions 24A and 24B in the left-right direction, and the length LS2 of the slits 35A and 35B in the left-right direction is set to be greater than the length LC2 of the protrusions 34A and 34B in the left-right direction.

[0090] According to the above-mentioned structure, the protrusions 24A and 24B can slide in the left-right direction when inserted into the slits 25A and 25B, and the protrusions 34A and 34B can slide in the left-right direction when inserted into the slits 35A and 35B, thereby absorbing the manufacturing tolerances of the storage element 11, busbar 40, etc. in the left-right direction and the assembly tolerances of the vehicle-mounted wiring module 20 and multiple storage elements 11.

[0091] Furthermore, the flexible substrate 21 of the embodiment is incorporated into the vehicle-mounted wiring module 20 in a state bent at the bent portions 26, 27 and the bent portions 32, 33. In the expanded state, the flexible substrate 21 includes protrusions 24A, 24B extending from the outer edges E1, E2 of the flexible substrate 21, and slits 25A, 25B through which the protrusions 24A, 24B are inserted. The expanded state is the state before the bent portions 26, 27 are bent. In the expanded state, the bent portions 26, 27 are positioned between the protrusions 24A, 24B and the slits 25A, 25B. By inserting the protrusions 24A, 24B through the slits 25A, 25B, deformation from the state bent at the bent portions 26, 27 back to the expanded state is suppressed. Furthermore, the flexible substrate 21 has, in the expanded state, protrusions 34A, 34B provided protruding from the outer edges E3, E4 of the flexible substrate 21, and slits 35A, 35B through which the protrusions 34A, 34B are inserted. The expanded state is the state before the bent portions 32, 33 are bent. In the expanded state, the bent portions 32, 33 are arranged between the protrusions 34A, 34B and the slits 35A, 35B. By inserting the protrusions 34A, 34B through the slits 35A, 35B, recovery from the bent state at the bent portions 32, 33 to the expanded state is suppressed.

[0092] According to the above configuration, the flexible substrate 21 bent at the bent portions 26 , 27 and the bent portions 32 , 33 can be prevented from returning to the expanded state. Therefore, the flexible substrate 21 is less likely to deform during transportation, for example.

[0093] <Other Implementation Methods>

[0094] (1) In the above embodiment, the first folded structure 23A and the second folded structure 23B are configured to be extendable in the left-right direction, and the second folded structure 23B extends the flexible substrate 21 in the left-right direction. However, the present invention is not limited to this embodiment. The folded structure may not be extendable or may not extend the flexible substrate. In other words, as long as the folded structure includes a protrusion, a slit through which the protrusion is inserted, and a bent portion disposed between the protrusion and the slit, and suppresses the flexible substrate from returning to its extended state after being bent at the bent portion, it may not have other structures or functions.

[0095] (2) In the above embodiment, the flexible substrate 21 includes four first folded structures 23A and one second folded structure 23B. However, the present invention is not limited thereto, and the flexible substrate may include any number of folded structures.

[0096] (3) In the above embodiment, the first folding structure 23A has a pair of protrusions 24A, 24B, a pair of slits 25A, 25B, and a pair of bends 26, 27, and the second folding structure 23B has a pair of protrusions 34A, 34B, a pair of slits 35A, 35B, and a pair of bends 32, 33, but this is not limited to this, and the number of protrusions, slits and bends in the folding structure is arbitrary.

[0097] (4) In the above embodiment, the vehicle-mounted wiring module 20 includes the protector 50 composed of two components, the first protector 50A and the second protector 50B. However, the present invention is not limited to this. The vehicle-mounted wiring module may not include a protector, or may include a protector composed of three or more components.

[0098] (5) In the above embodiment, the vehicle wiring module 20 is mounted on two storage element groups composed of 18 stacked storage elements 11. However, the present invention is not limited to this. The number of storage element groups to which the vehicle wiring module is mounted and the number of storage elements constituting the storage element groups can be arbitrary.

[0099] Description of labels

[0100] 1: Vehicle

[0101] 2: Battery pack

[0102] 3: PCU

[0103] 4: Wiring harness

[0104] 10: Power storage module

[0105] 11: Storage element

[0106] 12A, 12B: Electrode terminals

[0107] 13: End plate

[0108] 14: Fixed part

[0109] 20: Vehicle wiring module

[0110] 21: Flexible substrate

[0111] 22: Busbar connection

[0112] 23: Turn-back structure

[0113] 23A: First turn structure

[0114] 23B: Second fold structure

[0115] 24A, 24B, 34A, 34B: convex part

[0116] 25A, 25B, 35A, 35B: Slit

[0117] 26, 27, 32, 33: Bending parts

[0118] 28A, 28B, 36A, 36B: Bearing part

[0119] 29, 30: long strips

[0120] 31: Connection

[0121] 40: Busbar

[0122] 41: Electrode insertion hole

[0123] 50: Protector

[0124] 50A: First protector

[0125] 50B: Second protector

[0126] 51: Busbar configuration section

[0127] 52: Wiring board

[0128] 53: Flexible part

[0129] 54: Incision

[0130] 55: Bridge Department

[0131] 56: Guide recess

[0132] 57: Guide plate

[0133] E1, E2, E3, E4: outer edge of the flexible substrate

[0134] LC1, LC2: Length of the convex part in the left-right direction

[0135] LS1, LS2: Length of the slit in the left-right direction.

Claims

1. A vehicle-mounted wiring module, mounted on a plurality of storage elements having electrode terminals, wherein: The vehicle wiring module comprises: a busbar connected to the electrode terminals; and a flexible substrate, electrically connected to the busbar, The flexible substrate has a folded structure formed by being bent at a pair of bending portions. The folding structure includes a pair of protrusions provided in a protruding shape from the outer edge of the flexible substrate and a pair of slits through which the protrusions are inserted in an expanded state. The expanded state is a state before the bending portion is bent. The bent portion is arranged between the convex portion and the slit of the flexible substrate in the expanded state. By inserting the protrusion into the slit, the flexible substrate is prevented from deforming back from the state bent at the bending portion to the expanded state. One of the pair of bent portions is arranged on the side of the pair of convex portions, and the other bent portion is arranged on the side of the pair of slits. The flexible substrate is convexly folded at one of the folded portions and concavely folded at the other folded portion, and is folded at the pair of folded portions such that the portion having the pair of convex portions is positioned above the portion having the pair of slits.

2. The vehicle-mounted wiring module according to claim 1, wherein: The flexible substrate has an elongated shape extending along a first direction, The slit is formed to be long in the first direction, The length of the slit in the first direction is set to be greater than the length of the protrusion in the first direction.

3. A vehicle-mounted wiring module, mounted on a plurality of storage elements having electrode terminals, wherein: The vehicle wiring module comprises: a busbar connected to the electrode terminals; and a flexible substrate, electrically connected to the busbar, The flexible substrate has a folded structure formed by being bent at a pair of bending portions. The folding structure includes a pair of protrusions provided in a protruding shape from the outer edge of the flexible substrate and a pair of slits through which the protrusions are inserted in an expanded state. The expanded state is a state before the bending portion is bent. The bent portion is arranged between the convex portion and the slit of the flexible substrate in the expanded state. By inserting the protrusion into the slit, the flexible substrate is prevented from deforming back from the state bent at the bending portion to the expanded state. The folding structure includes a pair of elongated portions extending in parallel along a first direction in an expanded state and a connecting portion connecting the pair of elongated portions, wherein the pair of protrusions are provided on one of the pair of elongated portions, and the pair of slits are provided on the other of the pair of elongated portions. The pair of bent portions are arranged between the pair of convex portions and the pair of slits, one of the pair of bent portions is provided on the one elongated portion, and the other bent portion is provided on the connecting portion, and the folds of the pair of bent portions are arranged perpendicular to each other. The flexible substrate is convexly folded at one bending portion and concavely folded at the other bending portion, and the flexible substrate is bent at the pair of bending portions such that the one elongated portion is arranged above the other elongated portion. In the flexible substrate in which the pair of bent portions are bent, the pair of elongated portions are arranged at the same position in a second direction perpendicular to the first direction of the flexible substrate, and are aligned on the same straight line extending along the first direction.

4. The vehicle-mounted wiring module according to claim 3, wherein: The flexible substrate has an elongated shape extending along a first direction, The slit is formed to be long in the first direction, The length of the slit in the first direction is set to be greater than the length of the protrusion in the first direction.

5. A flexible substrate, which is incorporated into a vehicle-mounted wiring module in a state where it is bent at a pair of bent portions, wherein: The flexible substrate has a pair of protrusions provided in a protruding shape from the outer edge of the flexible substrate and a pair of slits through which the protrusions are inserted in an expanded state, and the expanded state is a state before the bending portion is bent. The bent portion is arranged between the convex portion and the slit in the expanded state, By inserting the convex portion through the slit, the restoration deformation from the state bent at the bending portion to the expanded state is suppressed. One of the pair of bent portions is arranged on the side of the pair of convex portions, and the other bent portion is arranged on the side of the pair of slits. The flexible substrate is convexly folded at one of the folded portions and concavely folded at the other folded portion, and is folded at the pair of folded portions such that the portion having the pair of convex portions is positioned above the portion having the pair of slits.

6. A flexible substrate, which is incorporated into a vehicle wiring module in a state where it is bent at a pair of bent portions, wherein: The flexible substrate has a pair of protrusions provided in a protruding shape from the outer edge of the flexible substrate and a pair of slits through which the protrusions are inserted in an expanded state, and the expanded state is a state before the bending portion is bent. The bent portion is arranged between the convex portion and the slit in the expanded state, By inserting the convex portion through the slit, the restoration deformation from the state bent at the bending portion to the expanded state is suppressed. The flexible substrate includes a pair of elongated portions extending in parallel along a first direction in an unfolded state and a connecting portion connecting the pair of elongated portions, wherein the pair of protrusions are provided on one of the pair of elongated portions, and the pair of slits are provided on the other elongated portion. The pair of bent portions are arranged between the pair of convex portions and the pair of slits, one of the pair of bent portions is provided on the one elongated portion, and the other bent portion is provided on the connecting portion, and the folds of the pair of bent portions are arranged perpendicular to each other. The flexible substrate is convexly folded at one bending portion and concavely folded at the other bending portion, and the flexible substrate is bent at the pair of bending portions such that the one elongated portion is arranged above the other elongated portion. In the flexible substrate in which the pair of bent portions are bent, the pair of elongated portions are arranged at the same position in a second direction perpendicular to the first direction of the flexible substrate, and are aligned on the same straight line extending along the first direction.

Images