Flexible busbar
By forming additional fixing parts at predetermined positions on the flexible busbar, the problems of wrinkling and quality instability during bending are solved, resulting in improved appearance and stable product quality, and supporting complex bending processes.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SUNCALL CORP
- Filing Date
- 2025-09-02
- Publication Date
- 2026-07-31
AI Technical Summary
During the bending process of flexible busbars, wrinkling and dimensional discrepancies are prone to occur, affecting the product's appearance and quality stability.
An additional fixing part (for bending) is formed at a predetermined position on the flexible busbar, and is formed separately from the original fixing part by heat fusion, so as to avoid the non-fixed part from participating in the bending process.
It effectively prevents wrinkling, improves product appearance and quality stability, allows for complex bending processes, and avoids the instability caused by cutting processes.
Smart Images
Figure CN122498062A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a flexible busbar. Background Technology
[0002] Generally, flexible busbars are 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.
[0003] Existing technical documents Patent documents [Patent Document 1] Japanese Patent Application Publication No. 2008-41330 Summary of the Invention Technical issues When bending the flexible busbars described above, the following problems arise. Regarding this, please refer to... Figure 4 and Figure 5 Please provide a detailed explanation.
[0004] like Figure 4 As shown in (a), the conventional flexible busbar 100 has a flexible busbar body 101 with a wide rectangular shape. Figure 4 As shown in (b), the flexible busbar body 101 is formed by stacking conductive material foils 102 made of thin, flexible metals such as copper. Furthermore, the flexible busbar body 101 thus formed can carry large currents.
[0005] Therefore, as Figure 4 As shown in (a), the left side 101a of the flexible busbar body 101 thus constructed is fixed to form a left fixing part 101a1, and the right side 101b is fixed to form a right fixing part 101b1. Thus, as... Figure 4 As shown in (a), a non-fixed portion 101c is formed between the left fixed portion 101a1 and the right fixed portion 101b1. Therefore, in this manner, a non-fixed portion 101c is formed... Figure 4 (a) shows the flexible busbar 100. In addition, the non-fixed part 101c is flexible.
[0006] Therefore, when the flexible busbar 100 formed in this way is along Figure 4 When the bend line S100 shown in (a) is bent at a 90-degree angle, it becomes as follows: Figure 4 The state shown in (b). That is, as Figure 4 As shown in (b), since the non-fixed portion 101c participates in the 90-degree bending process, the conductive material foil 102 located on the outermost peripheral surface 101ca side of the non-fixed portion 101c and the conductive material foil 102 located on the innermost peripheral surface 101cb side of the non-fixed portion 101c are separated by a distance along... Figure 4(a) A 90-degree bend in the bent line S100 will create a distance difference, resulting in an internal / external difference. Therefore, if... Figure 4 As shown in (a) and (b), if a left fixed portion 101a1 and a right fixed portion 101b1 are formed, then due to the difference between the inner and outer surfaces, the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c will, as shown in (a) and (b), be as shown in (b). Figure 4 (b) shows the expansion that causes wrinkling. The flexible busbar 100 that exhibits this phenomenon has a poor appearance and may not be able to be properly connected to electrically conductive components (e.g., batteries mounted in electric or hybrid vehicles) due to size mismatch or other reasons.
[0007] Therefore, in order to solve the problems mentioned above, we can consider the following: Figure 5 The method shown.
[0008] That is, such as Figure 5 As shown in (a), a left fixing part 101a1 is formed by fixing only the left side surface 101a of the flexible busbar body 101. Then, in this state, along Figure 5 (a) The bent line S101 shown is bent at a 90-degree angle to become as follows: Figure 5 The state shown in (b). That is, as Figure 5 As shown in (b), since the non-fixed portion 101c participates in the 90-degree bending process, the conductive material foil 102 located on the outermost peripheral surface 101ca side of the non-fixed portion 101c and the conductive material foil 102 located on the innermost peripheral surface 101cb side of the non-fixed portion 101c are separated by a distance along... Figure 5 (a) A 90-degree bend in the bent line S101 will result in a distance difference. However, if... Figure 5 As shown in (b), since the right fixed portion 101b1 is not formed, the length of the conductive material foil 102 on the outermost peripheral surface 101ca side of the non-fixed portion 101c becomes longer, resulting in a state where the length of the conductive material foil 102 gradually decreases towards the innermost peripheral surface 101cb side of the non-fixed portion 101c. This prevents the formation of... Figure 4 The wrinkling phenomenon shown in (b) is as shown.
[0009] Then, as Figure 5 As shown in (c), a right fixing part 101b1 is formed on the right side surface 101b of the fixed flexible busbar body 101. At this time, in order to Figure 5 (c) The end face of the right fixing part 101b1 (the right side face 101b of the flexible busbar body 101) shown is flush with the right fixing part 101b1, and the right fixing part 101b1 is cut along the cutting line S102. Therefore, it will not produce the effect shown in the image. Figure 4 The wrinkling phenomenon shown in (b) can be observed along... Figure 5(a) shows the bending line S101, which bends the flexible busbar 100 at a 90-degree angle.
[0010] However, this not only increases the cutting process, but also easily leads to product fluctuations and potential instability in product quality.
[0011] Therefore, in view of the above-mentioned problems, the present invention aims to provide a flexible busbar that can not only improve the appearance but also stabilize the product quality.
[0012] 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.
[0013] The flexible busbar according to claim 1 is characterized in that, in the flexible busbar (1) comprising a flexible busbar body (2) having flexibility and a first fixing part (left fixing part 2a1, right fixing part 2b1) fixing both sides of the flexible busbar body (2), when bending is performed from a predetermined position (bending line S1) of the flexible busbar body (2), a second fixing part (bending fixing part 2d) including the predetermined position (bending line S1) is formed on the flexible busbar body (2) separately from the first fixing part (left fixing part 2a1, right fixing part 2b1).
[0014] The flexible busbar according to claim 2 is characterized in that, in the flexible busbar (1) according to claim 1, when bending is performed from a plurality of predetermined positions of the flexible busbar body (2), the second fixing part (bending fixing part 2d) is formed on the flexible busbar body (2) at each of the plurality of predetermined positions separately from the first fixing part (left fixing part 2a1, right fixing part 2b1) in such a manner as to include the plurality of predetermined positions.
[0015] The flexible busbar according to claim 3 is characterized in that, in the flexible busbar (1) according to claim 1 or 2 above, the first fixing part (left fixing part 2a1, right fixing part 2b1) and the second fixing part (bending fixing part 2d) are formed by thermal fusion.
[0016] Invention Effects 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.
[0017] According to the invention of claim 1, when bending is performed from a predetermined position (bend line S1) of the flexible busbar body (2), a second fixing part (bending fixing part 2d) including the predetermined position (bend line S1) is formed on the flexible busbar body (2). Therefore, even when bending is performed from the predetermined position (bend line S1) of the flexible busbar body (2), the flexible busbar body (2) portion with flexibility (e.g., as...) remains flexible. Figure 1 The non-fixed part (2c) shown will also not be affected.
[0018] Therefore, this invention not only improves the appearance but also stabilizes product quality.
[0019] Furthermore, through this invention, since the second fixing part (bending fixing part 2d) is formed only in the portion including the predetermined position (bending line S1), the flexibility of the flexible busbar body (2) portion can be maximized (e.g., as shown in the invention). Figure 1 The softness of the non-fixed part (2c) shown.
[0020] With the invention described in claim 2, if a second fixing part (bending fixing part 2d) is formed on the flexible busbar body (2) in a manner that includes multiple predetermined positions at each of multiple predetermined positions, complex bending processes can be performed.
[0021] With the invention described in claim 3, there is no possibility that the solder used for welding, etc., will melt when the flexible busbar (1) is heated. Furthermore, there is no possibility that the required resistance value of the flexible busbar (1) cannot be obtained due to the influence of components used for welding, etc. Attached Figure Description
[0022] Figure 1 (a) is a plan view of a flexible busbar according to an embodiment of the present invention, and (b) is a side view of the flexible busbar according to the same embodiment when it is bent at 90 degrees.
[0023] Figure 2 This is a side view of the flexible busbar involved in the same embodiment being subjected to a stepped bending process.
[0024] Figure 3 This is a side view of the flexible busbar involved in the same embodiment being bent into a U-shape.
[0025] Figure 4 (a) is a plan view of a traditional flexible busbar, and (b) is a side view of the flexible busbar in (a) when it is bent at 90 degrees.
[0026] Figure 5(a) is a plan view of a traditional flexible busbar, (b) is a side view of the flexible busbar in (a) being bent at 90 degrees, and (c) is an explanatory diagram illustrating the state of cutting in progress. Detailed Implementation
[0027] Hereinafter, 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 of up, down, left, and right refer to the up, down, left, and right views as seen from the front of the illustration.
[0028] <Overview of Flexible Busbars> The flexible busbar 1 involved in this embodiment not only prevents wrinkling but also allows for bending processes that ensure stable product quality. Specifically, Figure 1 The flexible busbar 1 shown has a flexible busbar body 2.
[0029] <Description of the Flexible Busbar Body> like Figure 1 As shown in (a), the flexible busbar body 2 is formed into a horizontally elongated rectangular shape in planar view, as... Figure 1 As shown in (b), it is formed by stacking conductive material foil 3 made of thin, flexible metals such as copper. Furthermore, the flexible busbar body 2 formed in this way can carry large currents.
[0030] Therefore, as Figure 1 As shown in (a), the left side 2a of the flexible busbar body 2 thus constructed is fixed by heat fusion to form a left fixing part 2a1, and the right side 2b is fixed by heat fusion to form a right fixing part 2b1. Thus, as... Figure 1 As shown in (a), a non-fixed portion 2c is formed between the left fixed portion 2a1 and the right fixed portion 2b1, and the non-fixed portion 2c is flexible.
[0031] Therefore, the flexible busbar 1 is constructed in this way.
[0032] <Instructions for bending flexible busbars> Incidentally, such as Figure 1 As shown in (a), in the non-fixed part 2c, on the central left side, a bending fixing part 2d is formed separately from the aforementioned left fixing part 2a1 and right fixing part 2b1, and is fixed by heat fusion. Figure 1 As shown in (a), the bending fixing part 2d is provided in such a way that it includes a bend line S1 when the flexible busbar body 2 is bent at 90 degrees.
[0033] Therefore, if such a bend is formed using a fixing part 2d, then along... Figure 1 (a) The bending line S1 shown in the figure bends the flexible busbar 1, i.e., the flexible busbar body 2, to form a flexible busbar 1. Figure 1 The state shown in (b). That is, through this bending process, as... Figure 1 As shown in (b), in the non-fixed part 2c, there is no distance difference, i.e., no inner / outer difference, between the conductive material foil 3 located on the outermost peripheral surface 2ca side and the conductive material foil 3 located on the innermost peripheral surface 2cb side. In other words, by using the bending fixing part 2d, as... Figure 1 As shown in (b), the flexible portion of the non-fixed part 2c does not participate in the bending process and is therefore completely unaffected by it. Therefore, no distance difference, i.e., an inner-outer difference, is generated. Consequently, the conductive material foil 3 located on the innermost circumferential surface 2cb will not experience the same issues that occur due to a distance difference, i.e., an inner-outer difference. Figure 4 The wrinkling phenomenon shown in (b) is as shown.
[0034] Furthermore, there is no need to conduct such... Figure 5 (c) shows the cutting process to make the end face (right side face 2b of the flexible busbar body 2) of the right fixed part 2b1 flush with the distance difference, i.e., the difference between inside and outside, caused by the distance difference.
[0035] Therefore, according to the embodiment described above, since there is no distance difference, i.e., an inner-outer difference, between the conductive material foil 3 located on the outermost peripheral surface 2ca side and the conductive material foil 3 located on the innermost peripheral surface 2cb side in the non-fixed part 2c, the traditional wrinkling phenomenon will not occur, nor will the problem of product fluctuation and potentially unstable product quality due to the increase in cutting processes occur.
[0036] Therefore, according to this embodiment, not only can the appearance be improved, but the product quality can also be stabilized.
[0037] Furthermore, according to this embodiment, since only located in Figure 1 (a) shows a portion of the bend line S1 forming a bending fixing part 2d, thus minimizing the influence of the flexibility of the non-fixed part 2c. Therefore, the flexibility of the non-fixed part 2c can be maximized.
[0038] Furthermore, if the bending fixing part 2d as described above is formed, then the following can also be performed: Figure 2 and Figure 3 The complex bending process shown. That is, as illustrated. Figure 2 As shown, when the flexible busbar 1, i.e., the flexible busbar body 2, is bent into a stepped shape, as long as the part undergoing the bending process ( Figure 2 The portions shown by the dashed lines X1 and X2) can be respectively formed into bending fixing parts 2d. Furthermore, as... Figure 3 As shown, when the flexible busbar 1, i.e., the flexible busbar body 2, is bent into a U-shape, as long as the part undergoing the bending process ( Figure 3The portions shown by the dashed lines X3 and X4 can be respectively formed into bending fixing portions 2d. Therefore, even with complex bending processes, since there is no distance difference (i.e., an inner / outer difference) between the conductive material foil 3 located on the outermost peripheral surface 2ca and the conductive material foil 3 located on the innermost peripheral surface 2cb in the non-fixed portion 2c, conventional wrinkling will not occur. Furthermore, since it is not necessary to perform such bending processes... Figure 5 (c) shows a cutting process that makes the end face (right side face 2b of the flexible busbar body 2) of the right fixed part 2b1 flush with the end face of the right fixed part 2b1 (the right side face 2b of the flexible busbar body 2) caused by the distance difference, i.e. the difference between inside and outside. Therefore, the problem of product fluctuation and unstable product quality caused by the increase of cutting process will not occur.
[0039] Therefore, if the part undergoing bending processing ( Figure 2 The portions indicated by the dashed lines X1 and X2, Figure 3 The parts shown by the dashed lines X3 and X4 are respectively formed into bending fixing parts 2d, which can not only improve the appearance, but also stabilize the product quality, and thus also enable complex bending processes.
[0040] Symbol Explanation 1 Flexible busbar 2 Flexible busbar body 2a1 Left fixing part (first fixing part) 2b1 Right fixing part (first fixing part) 2c Non-fixed part 2D bending fixing part (second fixing part) S1 bend line (pre-determined position)
Claims
1. A flexible busbar, comprising a flexible busbar body having flexibility and a first fixing portion fixing both sides of the flexible busbar body, characterized in that, When bending is performed from a predetermined position on the flexible busbar body, a second fixing part including the predetermined position is formed on the flexible busbar body separately from the first fixing part.
2. The flexible busbar as described in claim 1, characterized in that, When bending is performed at multiple predetermined positions of the flexible busbar body, the second fixing portion is formed on the flexible busbar body at each of the multiple predetermined positions separately from the first fixing portion, in a manner that includes the multiple predetermined positions.
3. The flexible busbar as described in claim 1 or 2, characterized in that, The first fixing part and the second fixing part are formed by heat fusion.