Wire harness and bus bar module

Abstract

The invention provides a wire harness capable of suppressing shaking of a flat wiring material relative to a housing. A wire harness (1) is provided with a flat wiring material (3) and a housing (2) having a wiring line (23) that houses the flat wiring material, the wiring line having a bottom wall (23a) that faces the flat wiring material and a pair of side walls (23b) that are disposed on both sides in the width direction with respect to the bottom wall, and the flat wiring material is housed in the wiring line by pressing both ends in the width direction against the pair of side walls, respectively. The cross-sectional shape of the flat wiring material in a cross-section orthogonal to the extension direction of the wiring line is a shape curved in the depth direction (D3) of the wiring line.

Description

Technical Field

[0001] This invention relates to wire harnesses and busbar modules. Background Technology

[0002] Previously, busbar modules with flat wiring materials existed. Patent Document 1 discloses a busbar module having a main body and a current sensor part. The main body includes a housing, a busbar, and flexible thin-plate-shaped wires.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2023-009471 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] It is desirable to suppress the wobbling of the flat wiring material relative to the housing when the flat wiring material is housed within the housing.

[0008] The purpose of this invention is to provide a wiring harness and busbar module that can suppress the swaying of flat wiring material relative to the housing.

[0009] Methods for solving problems

[0010] The wire harness of the present invention is characterized by comprising: a flat wiring material; and a housing having wiring lines that house the flat wiring material, the wiring lines having: a bottom wall opposite to the flat wiring material; and a pair of side walls disposed on both sides of the bottom wall in the width direction, the flat wiring material being housed in the wiring lines by pressing its two ends in the width direction against the pair of side walls respectively, and the cross-sectional shape of the flat wiring material in a section orthogonal to the extension direction of the wiring lines being a shape curved toward the depth direction of the wiring lines.

[0011] Invention Effects

[0012] In the wiring harness of this invention, the wiring of the housing has a bottom wall opposite to the flat wiring material and a pair of side walls disposed on both sides in the width direction relative to the bottom wall. The two ends of the flat wiring material in the width direction are pressed against the pair of side walls and housed within the wiring. The cross-sectional shape of the flat wiring material in a section orthogonal to the extension direction of the wiring is a shape bent toward the depth direction of the wiring. According to the wiring harness of this invention, the flat wiring material is held by the pair of side walls, thereby suppressing the swaying of the flat wiring material relative to the housing. Attached Figure Description

[0013] Figure 1 This is a diagram illustrating the wiring harness and busbar module of an embodiment.

[0014] Figure 2 This is a diagram showing the wiring harness and busbar module assembled into the battery module.

[0015] Figure 3 This is a top view of the flat wiring material in the embodiment.

[0016] Figure 4 This is a top view of the housing in the embodiment.

[0017] Figure 5 This is a perspective view of the wiring harness in an embodiment.

[0018] Figure 6 This is a cross-sectional view of the wiring harness in an embodiment.

[0019] Figure 7 This is a side view of the wiring harness and busbar module of the embodiment.

[0020] Figure 8 This is a side view of the wiring harness involved in the embodiment.

[0021] Figure 9 This is a top view of the flat wiring material in the embodiment.

[0022] Figure 10 This is a diagram illustrating other wiring harness and busbar modules of the embodiment.

[0023] Figure 11 This is a cross-sectional view of other wiring harnesses and busbar modules in the embodiment.

[0024] Explanation of reference numerals in the attached figures

[0025] 1: Wiring harness

[0026] 2: Shell

[0027] 3: Flat wiring material; 4: Board components

[0028] 6: Chip fuse; 9: Testing line

[0029] 10: Busbar

[0030] 20: Main body of the shell; 21: Cover; 22: Hinge part

[0031] 23: Wiring; 23a: Bottom wall; 23b: Side wall

[0032] 24: Retaining part; 25: Support wall; 26: First cover; 27: Second cover

[0033] 28: Locking part

[0034] 30: Main line; 30c: Central section; 30e: End section

[0035] 31: Branch; 32, 33: Solder pads

[0036] 100: Battery pack; 110: Battery module; 120: Battery cell

[0037] 130: Monitoring device

[0038] 200: Busbar Module

[0039] D1: Extension direction; D2: Width direction; D3: Depth direction

[0040] L: Length direction; W: Width direction

[0041] Wd1: Width of the trunk line; Wd2: Width of the cabling line. Detailed Implementation

[0042] Hereinafter, a detailed description of the wiring harness and busbar module according to embodiments of the present invention will be provided with reference to the accompanying drawings. Furthermore, the present invention is not limited to this embodiment. Additionally, the constituent elements in the following embodiments include elements readily conceived by those skilled in the art or substantially the same elements.

[0043] [Example]

[0044] Reference Figures 1 to 11 The following describes an embodiment. This embodiment relates to a wiring harness and busbar module. Figure 1 This is a diagram illustrating the wiring harness and busbar module of an embodiment. Figure 2 This diagram shows the wiring harness and busbar module assembled into the battery module. Figure 3 This is a top view of the flat wiring material in the embodiment. Figure 4 This is a top view of the housing in the embodiment. Figure 5 This is a perspective view of the wiring harness in the embodiment. Figure 6 This is a cross-sectional view of the wiring harness in the embodiment. Figure 7 This is a side view of the wiring harness and busbar module in the embodiment. Figure 8 This is a side view of the wiring harness in the embodiment. Figure 9 This is a top view of the flat wiring material in the embodiment. Figure 10 This is a diagram illustrating other wiring harness and busbar modules of the embodiment. Figure 11 This is a cross-sectional view of other wiring harnesses and busbar modules in the embodiment. Figure 6 Show Figure 1 The VI-VI section. In Figure 11 The middle shows Figure 10 The XI-XI section.

[0045] like Figure 1As shown, the wiring harness 1 in this embodiment has a housing 2 and a flat wiring material 3. The housing 2 of the example is configured to accommodate and hold multiple busbars 10. The wiring harness 1 can be combined with the busbars 10 to form a busbar module 200.

[0046] like Figure 2 As shown, the wiring harness 1 and the busbar module 200 can be applied to the battery module 110 of the battery pack 100. The battery module 110 has multiple battery cells 120 arranged in the arrangement direction AR. The battery pack 100 is used as a power source in vehicles such as electric vehicles and hybrid electric vehicles.

[0047] Busbar 10 is a conductor formed from a conductive metal plate and is fixed to the electrodes of battery cell 120. For example, busbar 10 connects two adjacent battery cells 120 in series. Flat wiring material 3 connects multiple busbars 10 to the monitoring device 130 of the battery pack 100. Flat wiring material 3 can also connect thermistors disposed in battery cells 120 to the monitoring device 130. The monitoring device 130 is a device for monitoring the voltage, temperature, and other states of the battery cells 120.

[0048] Flat cabling material 3 is connected to monitoring device 130, for example, via a connector. Figure 1 As shown, the flat wiring material 3 has multiple detection lines 9. The flat wiring material 3 is, for example, a flexible printed circuit board. The flexible printed circuit board has a base film, a capping layer, and a conductive layer. The base film and the capping layer are flexible, insulating resin layers. The conductive layer is protected by being sandwiched between the base film and the capping layer. The conductive layer is, for example, a conductive metal foil and has multiple circuit patterns including the detection lines 9. The detection lines 9 are connected to the circuitry of the monitoring device 130.

[0049] The detection line 9 is connected to the busbar 10 via a chip fuse 6 mounted on the flat wiring material 3. The chip fuse 6 is a protective component for the protection circuit. In the wiring harness 1 of this embodiment, the board component 4 is located between the chip fuse 6 and the busbar 10. The board component 4 is connected to the busbar 10 by soldering or the like, and electrically connects the chip fuse 6 to the busbar 10. In this embodiment, the board component 4 is disposed on the flat wiring material 3 as a voltage detection terminal for detecting the voltage of the battery cell 120.

[0050] like Figure 3 As shown, the flat wiring material 3 has a trunk line 30 and multiple branches 31. The trunk line 30 has a length direction L and a width direction W. In the top view, the shape of the trunk line 30 is, for example, rectangular. Multiple detection lines 9 extend along the length direction L on the trunk line 30. The trunk line 30 has a width Wd1. The branches 31 branch off from the edge of the trunk line 30 in the width direction W. In this embodiment, the branches 31 extend from the trunk line 30 in the width direction W. At least one detection line 9 is disposed at each branch 31.

[0051] The conductive layer of the flat wiring material 3 has pads 32 and 33 disposed at the branch 31. A chip fuse 6 is connected to a pair of pads 32 via solder or the like. The chip fuse 6, mounted on the flat wiring material 3, is positioned between the detection line 9 and the pads 33. The board component 4 is connected to the pair of pads 33 via solder or the like. That is, the board component 4 is connected to the detection line 9 via the chip fuse 6.

[0052] like Figure 4 As shown, the housing 2 has a housing body 20, a cover 21, and a hinge portion 22. The housing 2 is molded, for example, from an insulating synthetic resin. In this embodiment, the housing body 20, the cover 21, and the hinge portion 22 are integrally molded. The cover 21 is connected to the housing body 20 via the flexible hinge portion 22.

[0053] The housing body 20 has wiring 23, multiple retaining portions 24, and multiple supporting walls 25. The wiring 23 is a passage for receiving the trunk 30 of the flat wiring material 3. The extending direction D1 of the wiring 23 is the length direction of the housing 2. The retaining portions 24 retain and receive the busbar 10. The retaining portions 24 have a rectangular frame shape and have locking protrusions that lock the busbar 10 in place. The multiple retaining portions 24 are arranged along the wiring 23 and are arranged in the extending direction D1.

[0054] The support wall 25 supports the branch portion 31 of the flat wiring material 3. The support wall 25 branches from the wiring line 23 in the width direction D2, which is orthogonal to the extension direction D1. The support wall 25 protrudes from the wiring line 23 toward the side opposite to the cover 21 and is disposed along the retaining portion 24.

[0055] The wiring 23 has a bottom wall 23a and a pair of side walls 23b. The bottom wall 23a is a wall portion opposite to the trunk 30 of the flat wiring material 3. The bottom wall 23a extends along the extension direction D1. The wiring 23 is rectangular in shape when viewed from above. The bottom wall 23a extends from one end of the housing body 20 to the other end. The pair of side walls 23b are disposed on both sides of the bottom wall 23a in the width direction D2. The pair of side walls 23b are opposite to each other in the width direction D2. The wiring 23 has a width Wd2. The width Wd2 is the distance between one side wall 23b and the other side wall 23b. The width Wd2 of the wiring 23 is narrower than the width Wd1 of the trunk 30.

[0056] The cover 21 has a first cover 26 covering the fabric lines 23 and a plurality of second covers 27. The first cover 26 is rectangular in shape when viewed from above. The first cover 26 is connected to the sidewall 23b of the fabric lines 23 via a hinge portion 22. The second covers 27 cover the support wall 25 of the housing body 20. The second covers 27 extend from the first cover 26 in the width direction D2. The plurality of second covers 27 are arranged in the extension direction D1.

[0057] In the wiring harness 1 of this embodiment, as described below, the flat wiring material 3 is pressed into the wiring line 23. This suppresses the wobbling of the flat wiring material 3 relative to the housing 2.

[0058] like Figure 5 and Figure 6 As shown, the sidewall 23b is erected from the end of the bottom wall 23a in the width direction D2. The trunk line 30 of the flat wiring material 3 is housed in the wiring line 23 in a curved shape. The bottom wall 23a of the wiring line 23 is opposite to the trunk line 30 in the depth direction D3. The trunk line 30 is housed in the wiring line 23 by pressing its two ends 30e in the width direction against a pair of sidewalls 23b respectively. That is, the trunk line 30 is housed in the wiring line 23 by pressing one end 30e against one sidewall 23b and the other end 30e against the other sidewall 23b. Therefore, the trunk line 30 is held by a pair of sidewalls 23b from both sides in the width direction D2.

[0059] In a cross-section orthogonal to the extension direction D1 of the wiring line 23, the cross-sectional shape of the trunk line 30 is a shape that curves toward the depth direction D3 of the wiring line 23. Figure 5 and Figure 6 In the flat wiring material 3 shown, the trunk 30 has a shape that bends toward the bottom wall 23a. That is, relative to the two ends 30e, the central portion 30c in the width direction bends toward the bottom wall 23a.

[0060] The width-direction end 30e of the trunk line 30 is supported by the sidewall 23b, thereby suppressing the swaying of the flat wiring material 3. The sidewall 23b, for example, can suppress the swaying of the flat wiring material 3 in the width direction D2. Additionally, the sidewall 23b can suppress the swaying of the flat wiring material 3 in the depth direction D3. The trunk line 30 can also be housed in the wiring line 23 with its width-direction central portion 30c in contact with the bottom wall 23a. In this case, the bottom wall 23a supports the central portion 30c, suppressing the swaying of the flat wiring material 3 in the depth direction D3.

[0061] Flat wiring material 3 is housed in housing 2, for example, with busbars 10 connected to it. In this case, chip fuses 6 and board components 4 are mounted on each branch 31, and board components 4 are engaged with busbars 10. Multiple busbars 10 are respectively housed in corresponding holding portions 24, and the trunk lines 30 of the flat wiring material 3 are pressed into the wiring lines 23. The assembly of the flat wiring material 3 and the busbars 10 relative to housing 2 is performed, for example, by an operator. The operator presses the trunk lines 30 of the flat wiring material 3 into the wiring lines 23 while bending them. When the trunk lines 30 are pressed into the wiring lines 23, the two ends 30e of the trunk lines 30 are pressed against the sidewalls 23b and supported by the sidewalls 23b.

[0062] The flat wiring material 3 can be connected to the busbar 10 after being housed in the housing 2. In this case, the chip fuse 6 and the board component 4 are pre-installed in each branch 31. The board component 4 engages, for example, with the busbar 10 held by the housing 2. The assembly of the busbar 10 relative to the housing 2 and the assembly of the flat wiring material 3 relative to the housing 2 are performed, for example, by an operator.

[0063] After the flat wiring material 3 is contained in the wiring 23, the cover 21 is closed. Figure 7 The cover 21 indicates the closed state. The first cover 26 of the cover 21 is positioned in the depth direction D3 opposite the bottom wall 23a and the trunk line 30 of the flat wiring material 3. The first cover 26 covers the wiring line 23, forming a receiving space 29. The receiving space 29 is a space for receiving the trunk line 30 of the flat wiring material 3, and is surrounded by the first cover 26, the bottom wall 23a, and a pair of side walls 23b. The first cover 26 restricts the movement of the trunk line 30 so that the trunk line 30 does not detach from the wiring line 23. By positioning the trunk line 30 inside the wiring line 23, the first cover 26 is able to maintain the curved shape of the trunk line 30.

[0064] The busbar module 200 is assembled to the battery module 110 with the cover 21 of the housing 2 closed. For example... Figure 5 As shown, the housing 2 has engaging portions 20a and 20b that engage with the battery module 110. The engaging portions 20a and 20b protrude from the housing body 20 along the depth direction D3. The engaging portions 20a and 20b engage, for example, with the end plate of the battery module 110, fixing the housing body 20 relative to the battery module 110.

[0065] like Figure 7 As shown, the battery module 110 has a side surface 110a in the vertical direction. The side surface 110a is the surface along the vertical direction of the vehicle when the battery pack 100 is mounted in the vehicle. The busbar module 200 is assembled to the battery module 110 with its bottom wall 23a facing the side surface 110a in the vertical direction. In this case, the width direction D2 of the wiring 23 is vertical, and a pair of side walls 23b are facing each other in the vertical direction.

[0066] The trunk line 30 of the flat wiring material 3 is supported from both sides in the vertical direction by the sidewall 23b. Therefore, the swaying caused by vibration of the flat wiring material 3 relative to the vertical direction is suppressed. Furthermore, the sidewall 23b holds the trunk line 30, thus suppressing the swaying caused by vibration of the flat wiring material 3 relative to the horizontal direction. For example, it suppresses the swaying caused by vibration of the flat wiring material 3 relative to the depth direction D3.

[0067] Figure 8An example of the curved shape of the flat wiring material 3 housed in the wiring 23 is shown. The trunk line 30 housed in the wiring 23 may have a shape that curves toward the side opposite to the bottom wall 23a. In this case, in a cross-section orthogonal to the extension direction D1, the cross-sectional shape of the trunk line 30 is a curved shape with both ends 30e located on the bottom wall 23a side relative to the central portion 30c. The trunk line 30 may also be housed in the wiring 23 with the central portion 30c in contact with the first cover 26.

[0068] The flat cabling material 3 may have a widened portion 34 in a part of the trunk 30. Figure 9 A flat wiring material 3 with a widened portion 34 is shown. The widened portion 34 is provided on both sides of the trunk line 30 in the width direction W. That is, in the portion with the widened portion 34, both ends of the trunk line 30 in the width direction W protrude toward the width direction W. The shape of the widened portion 34 when viewed from above is, for example, rectangular or trapezoidal.

[0069] In the main line 30, the width Wd1 of the portion having the widening section 34 is larger than the width Wd3 of the portion not having the widening section 34. The width Wd1 of the portion having the widening section 34 is larger than the width Wd2 of the wiring line 23. The width Wd3 of the portion not having the widening section 34 is, for example, smaller than the width Wd2 of the wiring line 23. Figure 9 In the example flat cabling material 3, extensions 34 are disposed at multiple locations on the trunk 30. For example, extensions 34 are disposed between two adjacent branches 31. Multiple extensions 34 may also be disposed at equal intervals along the length direction L.

[0070] The trunk line 30 presses the widened portions 34 at both ends of the width direction W against a pair of sidewalls 23b and is then housed in the wiring 23. By pressing multiple portions of the trunk line 30 into the wiring 23, the swaying of the flat wiring material 3 is appropriately suppressed.

[0071] exist Figure 10 and Figure 11 The image shows a housing 2 with a locking portion 28. The locking portion 28 is configured to lock the flat wiring material 3 in place, thereby suppressing the shaking of the flat wiring material 3. Figure 10 and Figure 11 The locking portion 28 is disposed on the wiring 23 of the housing 2. More specifically, the locking portion 28 is a protrusion that protrudes from a pair of sidewalls 23b.

[0072] like Figure 10 As shown, on each sidewall 23b, a plurality of locking portions 28 are arranged at intervals along the extending direction D1. The locking portions 28 are, for example, arranged between two adjacent support walls 25. The locking portion 28 arranged on one sidewall 23b and the locking portion 28 arranged on the other sidewall 23b are opposite to each other in the width direction D2.

[0073] like Figure 11 As shown, the locking portion 28 protrudes from the inner wall surface of the side wall 23b toward the width direction D2. The locking portion 28 protrudes from the end of the side wall 23b. The locking portion 28 has a locking surface 28a toward the bottom wall 23a. The trunk line 30 of the flat wiring material 3 is housed in the wiring line 23 in a bent manner toward the bottom wall 23a. The locking portion 28 locks the end 30e of the trunk line 30 in place by the locking surface 28a. The housing 2 with the locking portion 28 can stabilize the posture of the trunk line 30 by locking the end 30e of the trunk line 30. In addition, the locking portion 28 can restrict the movement of the trunk line 30 so that the trunk line 30 will not detach from the wiring line 23.

[0074] The trunk line 30 can also be inserted into the wiring 23 such that its central portion 30c in the width direction contacts the bottom wall 23a and its two ends 30e are locked by the locking portion 28. In this case, since the two ends 30e and the central portion 30c of the trunk line 30 are supported, the swaying of the flat wiring material 3 is effectively suppressed. When the flat wiring material 3 has a widening portion 34, the locking portion 28 is preferably provided at a position that can lock the widening portion 34.

[0075] Furthermore, the location where the locking portion 28 is provided is not limited to the side wall 23b. The housing 2 may also have a locking portion 28 provided on the cover 21, for example. In this case, the locking portion 28 may also be a protrusion protruding from the first cover 26 toward the bottom wall 23a.

[0076] As described above, the wiring harness 1 of this embodiment has a flat wiring material 3 and a housing 2. The housing 2 has a wiring line 23 that houses the flat wiring material 3. The wiring line 23 has a bottom wall 23a opposite to the flat wiring material 3 and a pair of side walls 23b disposed on both sides of the bottom wall 23a in the width direction D2. The flat wiring material 3 is housed in the wiring line 23 by pressing its two ends 30e in the width direction against the pair of side walls 23b. The cross-sectional shape of the flat wiring material 3 in a section orthogonal to the extension direction D1 of the wiring line 23 is a shape that bends toward the depth direction D3 of the wiring line 23. By pressing the two ends 30e of the bent flat wiring material 3 against the side walls 23b, the swaying of the flat wiring material 3 in the wiring line 23 is suppressed.

[0077] The flat wiring material 3 of this embodiment includes a trunk line 30 and branch portions 31 branching from the trunk line 30. In this case, the flat wiring material 3, for example, presses the two ends 30e of the trunk line 30 in the width direction against a pair of sidewalls 23b and is housed in the wiring line 23. The trunk line 30 is supported from both sides by the sidewalls 23b, thereby suppressing the swaying of the flat wiring material 3.

[0078] The housing 2 may also have a locking portion 28 that locks the two ends 30e of the flat wiring material 3 housed in the width direction of the wiring line 23. In this case, the cross-sectional shape of the flat wiring material 3 in a section orthogonal to the extension direction D1 of the wiring line 23 is a shape that bends toward the bottom wall 23a. The two ends 30e are locked by the locking portion 28, thereby suppressing the shaking of the flat wiring material 3.

[0079] The locking portion 28 is, for example, a protrusion that protrudes from a pair of sidewalls 23b. In this case, the locking portion 28 locks the two ends 30e of the flat wiring material 3 pressed into the wiring 23, thereby stabilizing the posture of the flat wiring material 3.

[0080] The busbar module 200 of this embodiment includes a wiring harness 1 and a busbar 10 held by a housing 2 and connected to a flat wiring material 3. The busbar module 200 is assembled to the battery module 110 with its bottom wall 23a facing the vertical side 110a of the battery module 110. When the bottom wall 23a of the wiring 23 faces the vertical side 110a, the flat wiring material 3 is prone to wobbling if it is not held. In the busbar module 200 of this embodiment, the wobbling of the flat wiring material 3 is suppressed by holding the flat wiring material 3 with a pair of side walls 23b.

[0081] Furthermore, the flat wiring material 3 is not limited to flexible printed circuit boards. The flat wiring material 3 can be a flexible flat cable (FFC) or other plate-shaped wiring material that can be elastically deformed.

[0082] The contents disclosed in the above embodiments can be appropriately combined to perform the tasks.

Claims

1. A wire harness, characterized in that, have: Flat cabling materials; and Housing, the housing having wiring that accommodates the flat wiring material, The wiring diagram has: a bottom wall, which is opposite to the flat wiring material; And a pair of sidewalls, the pair of sidewalls being disposed on opposite sides of the bottom wall in the width direction. The flat wiring material is housed within the wiring by pressing its two ends in the width direction against a pair of sidewalls. The cross-sectional shape of the flat wiring material in a section orthogonal to the extension direction of the wiring is a shape that bends toward the depth direction of the wiring.

2. The wire harness according to claim 1, characterized in that, The flat wiring material has a trunk and branches branching off from the trunk. The flat wiring material is housed within the wiring by pressing the two ends of the trunk line in the width direction against a pair of sidewalls.

3. The wire harness according to claim 1, characterized in that, The housing has a locking portion that locks in place both ends of the flat wiring material housed in the wiring diagram in the width direction. The cross-sectional shape of the flat wiring material in a section orthogonal to the extension direction of the wiring is a shape that bends toward the bottom wall.

4. The wire harness according to claim 3, characterized in that, The locking portion is a protrusion that extends from the pair of sidewalls.

5. A busbar module, characterized in that, have: The wire harness as claimed in claim 1; and Busbar, which is held by the housing and connected to the flat wiring material, The busbar module is assembled to the battery module with its bottom wall facing the side of the battery module in the vertical direction.

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