Method for manufacturing a flexible busbar

Abstract

This invention provides a method for manufacturing a flexible busbar that can maintain stable quality and improve production efficiency even for complex shapes. Multiple conductive material foils 1 are stacked (see Figure 1(a)). The two sides (upper fixing portion 2, lower fixing portion 3) of the stacked conductive material foils 1 are fixed, and upper fixing portion 2, lower fixing portion 3, and non-fixed portion 4 are formed on the multiple conductive material foils 1 (see Figure 1(c)). Then, a flexible busbar (5) of a predetermined shape is cut from the multiple conductive material foils 1 with upper fixing portion 2, lower fixing portion 3, and non-fixed portion 4 (see Figures 1(c) and (d)).

Description

Technical Field

[0001] This invention relates to a method for manufacturing a flexible busbar. Background Technology

[0002] Generally, flexible busbars are known to be used when connecting electrically conductive components (e.g., batteries mounted in electric or hybrid vehicles). For example, the flexible busbar described in Patent Document 1 is known as such. The flexible busbar described in Patent Document 1 is manufactured by stacking and fixing conductive material foils made of copper or other metals that are pre-cut into a predetermined shape and have flexibility.

[0003] Existing technical documents Patent documents [Patent Document 1] International Publication No. 2012 / 118046 Summary of the Invention Technical issues Here, regarding the aforementioned traditional manufacturing method for flexible busbars, refer to... Figure 5 To provide a more detailed explanation.

[0004] In manufacturing such Figure 5 When using the flexible busbar 100 shown in (c), firstly, prepare a sheet as shown in the diagram. Figure 5 (a) shows a conductive material foil 101 in a long rectangular shape (straight line shape) made of a thin, flexible metal such as copper. Then, from the prepared conductive material foil 101, wire or the like is used to cut out... Figure 5 (a) shows a complex shape (non-linear shape) as indicated by the dashed line S100. This allows for the creation of shapes such as... Figure 5 (b) shows a flexible busbar sheet 102 with a complex shape (non-linear shape).

[0005] Therefore, as Figure 5 As shown in (b), multiple flexible busbar sheets 102 manufactured in this manner are stacked such that the upper end face 102a and the lower end face 102b of the flexible busbar sheet 102 are flush with each other. Then, in this state, by fixing as... Figure 5 (b) shows the upper end face 102a side of the flexible busbar sheet 102, as Figure 5 (c) shows the upper fixing part 103 formed, which is fixed as shown in the figure. Figure 5 (b) shows the lower end face 102b side of the flexible busbar sheet 102, as... Figure 5 (c) shows the formation of the lower fixing part 104. Thus, as shown... Figure 5As shown in (c), a flexible busbar 100 is manufactured with a non-fixed portion 105 formed between the upper fixed portion 103 and the lower fixed portion 104. Furthermore, the non-fixed portion 105 is flexible.

[0006] However, in the manufacturing method described above, such as Figure 5 As shown in (b), since multiple flexible busbar sheets 102 are stacked so that the upper end face 102a and the lower end face 102b are flush with each other, there is a possibility of deviation during stacking. Therefore, there is a problem as follows: Figure 5 (c) illustrates the problem of unstable quality and potentially reduced production efficiency of the flexible busbar 100. This is especially true in the manufacture of... Figure 5 The aforementioned problems are particularly pronounced when the flexible busbar sheet 102 has a complex shape (non-linear shape) as shown in (b).

[0007] Therefore, in view of the above-mentioned problems, the present invention aims to provide a method for manufacturing flexible busbars that can maintain stable quality and improve production efficiency even for complex shapes.

[0008] Technical means The objectives of the present invention described above are achieved by the following means. Furthermore, reference numerals for the embodiments described later are enclosed in parentheses, but the present invention is not limited thereto.

[0009] The method for manufacturing the flexible busbar according to claim 1 is characterized by comprising: a process of stacking multiple conductive materials (conductive material foil 1) (see reference). Figure 1 (a)); the process of forming fixed portions (upper fixed portion 2, lower fixed portion 3) and non-fixed portions (4) on both sides of the multiple conductive materials (conductive material foil 1) after fixing the stacked layers (refer to the process of forming fixed portions (upper fixed portion 2, lower fixed portion 3) and non-fixed portions (4) on the multiple conductive materials (conductive material foil 1) ... after fixing the stacked layers (refer to the process of forming fixed portions (upper fixed portion 2, lower fixed portion 3) and non-fixed portions (4) on the multiple conductive materials (conductive material foil 1) (refer to the process of forming fixed portions Figure 1 (c)); and the process of cutting a flexible busbar (5) of a predetermined shape from the plurality of conductive materials (conductive material foil 1) having the fixed portion (upper fixed portion 2, lower fixed portion 3) and the non-fixed portion (4) (see reference) Figure 1 (c) and (d)).

[0010] The method for manufacturing the flexible busbar according to claim 2 is characterized by comprising: a process of stacking multiple conductive materials (conductive material foil 1A) (see reference). Figure 4 (a)); the process of forming fixed portions (upper fixed portion 2, lower fixed portion 3) and non-fixed portions (4) on both sides of the multiple conductive materials (conductive material foil 1A) after fixing the stacked layers (refer to the process of forming fixed portions (upper fixed portion 2, lower fixed portion 3) and non-fixed portions (4) on the multiple conductive materials (conductive material foil 1A) ... after fixing the stacked layers (refer to the process of forming fixed portions (upper fixed portion 2, lower fixed portion 3) and non-fixed portions (4) on the multiple conductive materials (conductive material foil 1A) (refer to the Figure 4(c)); and the process of cutting out a plurality of flexible busbars (5) of predetermined shapes from the plurality of conductive materials (conductive material foil 1A) having the fixed portions (upper fixed portion 2, lower fixed portion 3) and the non-fixed portions (4) (see reference). Figure 4 (c) and (d)).

[0011] The method for manufacturing a flexible busbar according to claim 3 is characterized in that, in the method for manufacturing a flexible busbar according to claim 1 or 2, the non-fixed portion (4) of the cut flexible busbar (5) of the predetermined shape is formed into a rectangular shape, and the lengths of the diagonals (4a, 4b) are the same (see reference). Figure 2 (a-2)).

[0012] The method for manufacturing a flexible busbar according to claim 4 is characterized in that, in the method for manufacturing a flexible busbar according to claim 1 or 2, protrusions (upper protrusion 2b, lower protrusion 3b) or recesses are formed on the cut flexible busbar (5) of the predetermined shape.

[0013] The method for manufacturing a flexible busbar according to claim 5 is characterized in that, in the method for manufacturing a flexible busbar according to claim 1 or 2, the fixing part (upper fixing part 2, lower fixing part 3) is formed by thermal fusion.

[0014] Technical effect Next, the effects of the present invention will be explained with reference to the reference numerals in the accompanying drawings. Furthermore, reference numerals for embodiments described later are enclosed in parentheses, but the present invention is not limited thereto.

[0015] According to the invention described in claims 1 and 2, since the flexible busbar (5) of a predetermined shape is cut from multiple conductive materials (conductive material foils 1 and 1A) having fixed portions (upper fixed portion 2 and lower fixed portion 3) and non-fixed portions (4), it is not necessary to flush the complex-shaped (non-linear) parts as in conventional manufacturing methods. Therefore, it is possible to eliminate the possibility of deviation during stacking.

[0016] Therefore, according to the present invention, even complex shapes can achieve stable quality and improved production efficiency.

[0017] Furthermore, according to claim 2, since multiple pieces can be cut out in batches, manufacturing time can be reduced.

[0018] According to the invention of claim 3, since the non-fixed portion (4) of the flexible busbar (5) of the predetermined shape is formed into a rectangular shape and the lengths of the diagonals (4a, 4b) are the same (see reference). Figure 2(a-2) Therefore, when using the flexible busbar (5) for bending, no distance difference will be generated when bending, regardless of which direction the bending is performed. Therefore, the non-fixed part (4) will not wrinkle due to bending.

[0019] According to claim 4, the invention can easily handle the formation of protrusions (upper protrusion 2b, lower protrusion 3b) or recesses, while ensuring quality stability and improving production efficiency.

[0020] According to the invention of claim 5, there is no possibility that the solder used for welding, etc., will melt when the flexible busbar (5) is heated. Furthermore, there is no possibility that the required resistance value of the flexible busbar (5) cannot be obtained due to the influence of components used for welding, etc. Attached Figure Description

[0021] Figure 1 Figures (a) to (d) are explanatory diagrams illustrating a method for manufacturing a flexible busbar according to an embodiment of the present invention.

[0022] Figure 2 (a-1) shows a front view of a flexible busbar manufactured by the manufacturing method of the same embodiment, (a-2) is a front view after removing the non-fixed part of the flexible busbar shown in (a-1), (b-1) shows a front view of a flexible busbar manufactured by a conventional manufacturing method, and (b-2) is a front view after removing the non-fixed part of the flexible busbar shown in (b-1).

[0023] Figure 3 This is a front view showing a flexible busbar with protrusions in a flexible busbar manufactured by the manufacturing method involved in the same embodiment.

[0024] Figure 4 This is an explanatory diagram illustrating a method for manufacturing multiple flexible busbars using the manufacturing method described in the same embodiment.

[0025] Figure 5 Figures (a) to (c) are explanatory diagrams illustrating the traditional manufacturing method of flexible busbars. Detailed Implementation

[0026] Hereinafter, a method for manufacturing a flexible busbar according to an embodiment of the present invention will be specifically described with reference to the accompanying drawings. Furthermore, in the following description, the directions up, down, left, and right refer to the views from the front of the illustration.

[0027] <Explanation of the manufacturing method for flexible busbars> The manufacturing method for flexible busbars described in this embodiment can ensure stable quality and improve production efficiency even for complex shapes. Specifically, it is manufactured as follows.

[0028] First, prepare as follows Figure 1(a) shows a component in which multiple sheets of conductive material foil 1, made of thin, flexible metals such as copper, are stacked in a longitudinal rectangular shape (linear shape). At this time, as... Figure 1 As shown in (b), imagine cutting out a piece from a stack of multiple conductive material foils 1, such as... Figure 1 (b) The complex shape (non-linear shape) shown by the dashed line S1. In the cutting conception, it is envisioned that the right side 1a of multiple layers of conductive material foil 1 is... Figure 1 (b) The right long side S1a of the complex shape (non-linear shape) shown by the dashed line S1 is parallel to the left side 1b of the multiple layers of conductive material foil 1. Figure 1 (b) The left long side S1b of the complex shape (non-linear shape) shown by the dashed line S1 is parallel. Furthermore, at this stage, it is only conceived and has not yet been cut.

[0029] Next, fix it by heat fusion. Figure 1 (b) shows the upper end face 1c side of the stacked multiple conductive material foils 1, as shown in the figure. Figure 1 (c) shows the upper fixing part 2, which is fixed by heat fusion. Figure 1 (b) shows the lower end face 1d side of the stacked multiple conductive material foils 1, as shown in the figure. Figure 1 (c) shows the formation of the lower fixing part 3. Thus, as shown... Figure 1 As shown in (c), a non-fixed portion 4 is formed between the upper fixed portion 2 and the lower fixed portion 3. Furthermore, the non-fixed portion 4 is flexible.

[0030] Next, in the stated state, along the envisioned cut Figure 1 The dashed line S1 shown in (c) is cut using wire, stamping, or laser cutting. This produces a product like... Figure 1 (d) shows the flexible busbar 5.

[0031] Therefore, as described above, if multiple layers of conductive material foil 1 are fixed at both ends ( Figure 1 (c) After cutting the upper fixing part 2 and the lower fixing part 3, it is not necessary to flush the complex-shaped (non-linear) parts as in conventional manufacturing methods. Therefore, it is possible to avoid the possibility of deviation during stacking as in conventional manufacturing methods.

[0032] Therefore, according to this embodiment, it is possible to... Figure 1 (d) shows that the quality of the flexible busbar 5 is stable, which can improve production efficiency.

[0033] Therefore, according to this embodiment, even complex shapes can achieve stable quality and improved production efficiency.

[0034] Furthermore, in this embodiment, in manufacturing such as Figure 2When the flexible busbar 5 shown in (a-1) is cut, the non-fixed part 4 is cut into the shape shown in (a-1). Figure 2 The rectangular shape shown in (a-2) is cut as follows: the right side 1a of multiple layers of conductive material foil 1 is cut with... Figure 1 (b) The right long side S1a of the complex shape (non-linear shape) shown by the dashed line S1 is parallel to the left side 1b of the multiple layers of conductive material foil 1. Figure 1 (b) The left long side S1b of the complex shape (non-linear shape) shown by the dashed line S1 is parallel. Therefore, the non-fixed part 4 can be cut into the shape shown by the dashed line S1. Figure 2 The rectangular shape shown in (a-2). Figure 2 As shown in (a-2), the diagonals 4a and 4b of the non-fixed portion 4 are of the same length. If this is done, then when using the flexible busbar 5 for bending, as... Figure 2 As shown in (a-2), since diagonals 4a and 4b have the same length, there will be no difference in the bending distance regardless of the direction of the bend. Therefore, the non-fixed part 4 will not wrinkle due to bending.

[0035] That is, as described above, the traditional flexible busbar 100, such as Figure 2 As shown in (b-1). Figure 2 As shown in (b-1), the non-fixed portion 105 of the flexible busbar 100 is as follows: Figure 2 The parallelogram shown in (b-2). And, as... Figure 2 As shown in (b-2), the parallelogram is a parallelogram with different lengths for diagonals 105a and 105b. Therefore, when using the flexible busbar 100 for bending, as... Figure 2 As shown in (b-2), since the lengths of diagonals 105a and 105b are different, the bending method will also differ depending on the bending direction. Therefore, distance differences are easily generated during bending, and the non-fixed part 105 may wrinkle due to bending. If such wrinkling occurs, the appearance is poor, and when connecting electrically conductive components (e.g., batteries mounted in electric vehicles or hybrid vehicles), problems may arise due to incompatibility in size, making proper connection impossible.

[0036] However, if, as in this embodiment, the diagonals 4a and 4b of the non-fixed part 4 have the same length, the aforementioned problem will not occur.

[0037] Furthermore, if a non-fixed portion 4 with the same length as diagonal 4a and diagonal 4b is formed as described above, then... Figure 2 The length L1 of the non-fixed part 4 in the vertical direction shown in (a-1) is greater than that of the non-fixed part 4 in the vertical direction. Figure 2The non-fixed portion 105 shown in (b-1) has a longer vertical length L2. As a result, the flexibility (range of motion) of the flexible busbar 5 can be greater than that of the conventional flexible busbar 100.

[0038] Furthermore, since the number of layers of conductive material foil 1 remaining after cutting the flexible busbar 5 from the multiple layers of conductive material foil 1 is less than that of the traditional method, material loss can be reduced.

[0039] Incidentally, such as Figure 3 As shown, the flexible busbar 5 manufactured in the above manner has an upper bolt hole 2a through the upper fixing part 2 and a lower bolt hole 3a through the lower fixing part 3 during use. That is, bolts (not shown) are inserted into the upper bolt hole 2a and the lower bolt hole 3a, and then... Figure 3 The flexible busbar 5 shown connects to electrically conductive components (e.g., batteries mounted in electric or hybrid vehicles). If an attempt is made to secure it by passing bolts (not shown) through the upper bolt hole 2a and lower bolt hole 3a, a load will be applied to... Figure 3 As shown, the upper fixing part 2 and the lower fixing part 3 may be squeezed and deformed, potentially preventing connection to electrically conductive components. Therefore, to avoid this situation, and to allow the upper fixing part 2 and the lower fixing part 3 to be hung on the aforementioned components, as follows... Figure 3 As shown, sometimes an upper protrusion 2b is provided on the upper end surface of the upper fixing part 2, and a lower protrusion 3b is provided on the lower end surface of the lower fixing part 3. In addition, not limited to the upper protrusion 2b and the lower protrusion 3b, a recess formed by a concave cut may also be provided.

[0040] Therefore, when setting such an upper protrusion 2b and a lower protrusion 3b, or a recess not shown, in conventional manufacturing methods, when from... Figure 5 When the conductive material foil 101 shown in (a) is cut using wire or the like, it is necessary to provide an upper protrusion 2b and a lower protrusion 3b, or a recess (not shown), for cutting. Therefore, when multiple cut components are stacked, deviations may occur when attempting to align the upper protrusion 2b and the lower protrusion 3b, or the recess (not shown), with each other.

[0041] However, in this embodiment, since multiple layers of conductive material foil 1 can be fixed at both ends ( Figure 1 After the upper fixing part 2 and the lower fixing part 3 shown in (c), the cutting is performed by setting the upper protrusion 2b and the lower protrusion 3b, or the recess (not shown), so there is no possibility of the above-mentioned deviation.

[0042] Therefore, even in settings such as Figure 3In the case of the upper protrusion 2b and lower protrusion 3b shown, or the recess not shown, it can be easily handled, while ensuring quality stability and improving production efficiency.

[0043] <Explanation of the variations> Furthermore, the shape shown in this embodiment is merely an example, and various modifications and alterations can be made within the scope of the invention as described in the claims. For example, this embodiment shows an example of manufacturing one flexible busbar 5, but according to the manufacturing method described above, multiple flexible busbars 5 can also be manufactured in batches. Regarding this, see [reference needed]. Figure 4 Please provide a detailed explanation.

[0044] Preparation Figure 4 (a) shows a component in which multiple sheets of conductive material foil 1A, made of thin, flexible metals such as copper, are stacked in a horizontally elongated rectangular shape (linear shape). At this time, as... Figure 4 As shown in (b), imagine batch cutting multiple sheets of conductive material foil 1A, as shown in Figure (b), into one sheet. Figure 4 (b) The complex shape (non-linear shape) shown by the dashed line S1. In the cutting conception, it is envisioned as: the right side 1Aa of multiple layers of conductive material foil 1A and... Figure 4 (b) The right long side S1a of the complex shape (non-linear shape) shown by the dashed line S1 is parallel to the left side 1Ab of the multiple layers of conductive material foil 1A. Figure 4 (b) The left long side S1b of the complex shape (non-linear shape) shown by the dashed line S1 is parallel. Furthermore, at this stage, it is only conceived and has not yet been cut.

[0045] Next, fix it by heat fusion. Figure 4 (b) shows the upper end face 1Ac side of the stacked multiple conductive material foils 1A, as shown in the figure. Figure 4 (c) shows the upper fixing part 2, which is fixed by heat fusion. Figure 4 (b) shows the lower end face 1Ad side of the stacked multiple conductive material foils 1A, as shown in the figure. Figure 4 (c) shows the formation of the lower fixing part 3. Thus, as shown... Figure 4 As shown in (c), a non-fixed portion 4 is formed between the upper fixed portion 2 and the lower fixed portion 3. Furthermore, the non-fixed portion 4 is flexible.

[0046] Next, in the stated state, along the envisioned cut Figure 4 (c) shows multiple dashed lines S1, which are cut using wire, stamping, or laser cutting. This produces multiple [products] as shown. Figure 4 (d) shows the flexible busbar 5.

[0047] Therefore, even with this approach, as mentioned above, even complex shapes can maintain consistent quality and improve production efficiency.

[0048] Furthermore, since multiple pieces can be cut in batches, manufacturing time can be reduced.

[0049] Furthermore, this embodiment shows an example of forming the upper fixing part 2 and the lower fixing part 3 by thermal fusion, but it is not limited to this; solder or the like can also be used for forming. However, thermal fusion is preferred. This is because if solder or the like is used for forming, the solder used for welding or the like may melt when the flexible busbar 5 is heated, and thus, due to the influence of the components used for welding or the like, the required resistance value of the flexible busbar 5 may not be obtained. Therefore, thermal fusion is preferred.

[0050] Symbol Explanation 1,1A conductive material foil (conductive material) 2. Upper fixing part (fixing part) 2b has a protrusion (protrusion) 3. Lower fixing part (fixing part) 3b Lower protrusion (protrusion) 4 Non-fixed parts 4a, 4b diagonals 5 Flexible busbars

Claims

1. A method of manufacturing a flexible busbar, characterized by, include: The process of stacking multiple conductive materials; The process of fixing both sides of the plurality of conductive materials after fixed lamination, and forming fixed and non-fixed portions on the plurality of conductive materials; and The process of cutting a flexible busbar of a predetermined shape from the plurality of conductive materials having the fixed portion and the non-fixed portion.

2. A method for manufacturing a flexible busbar, characterized in that, include: The process of stacking multiple conductive materials; The process of forming fixed and non-fixed portions on both sides of the plurality of conductive materials after fixing the stacked layers; as well as The process of cutting out multiple flexible busbars of predetermined shapes from the multiple conductive materials having the fixed portion and the non-fixed portion.

3. The method for manufacturing a flexible busbar as described in claim 1 or 2, characterized in that, The non-fixed portion of the cut flexible busbar of the predetermined shape is formed into a rectangular shape, and the lengths of the diagonals are the same.

4. The method for manufacturing a flexible busbar as described in claim 1 or 2, characterized in that, Protrusions or recesses are formed on the flexible busbar of the predetermined shape that has been cut out.

5. The method for manufacturing a flexible busbar as described in claim 1 or 2, characterized in that, The fixing part is formed by heat fusion.

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