Fuse unit and conductive module

Abstract

Provided is a fuse unit and a conductive module capable of improving the joining strength of a resin member and a terminal fitting. A fuse unit (20) includes a chip fuse (30) having a first electrode (31), a second electrode (32), and a fusible portion that fuses due to an overcurrent, a first terminal fitting (40) connected to the first electrode (31), a second terminal fitting (50) connected to the second electrode (32), and a resin member (70) that holds the first terminal fitting (40) and the second terminal fitting (50) and maintains the interval of the first terminal fitting (40) and the second terminal fitting (50), the first terminal fitting (40) is formed with a plurality of first recesses (41b), the second terminal fitting (50) is formed with a plurality of second recesses (51b), the resin member (70) is formed with a plurality of first protrusions (71a) and a plurality of second protrusions (71b), the plurality of first recesses (41b) and the plurality of first protrusions (71a) are respectively fitted, and the plurality of second recesses (51b) and the plurality of second protrusions (71b) are respectively fitted.

Description

Technical Field

[0001] This invention relates to fuse units and conductive modules. Background Technology

[0002] In a battery module composed of multiple battery cells, a conductive module electrically connects the battery cells using multiple connecting conductors. Furthermore, the conductive module uses wiring components such as wires to electrically connect each connecting conductor to a battery monitoring unit that monitors the battery status of the battery cells. For example, Patent Document 1 discloses such a conductive module. In such a conductive module, each connecting conductor has a combination of a pair of connecting conductors and conductor portions of wiring components. Sometimes, a circuit protection component such as a fuse is provided between the connecting conductor and the conductor portion of the wiring component in each combination. For example, Patent Document 2 discloses a fuse unit (composed of a chip fuse, a pair of terminal fittings, and a resin component) suitable for this conductive module.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2020-119651

[0006] Patent Document 2: Japanese Patent No. 7561318 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, existing fuse units connect a blade fuse to a pair of terminal fittings formed with an insert-molded resin component, but there is still room for improvement in the bonding strength between the resin component and the terminal fittings. For example, if the bonding strength between the resin component and the terminal fittings is low, there is a risk of unstable connection between the terminal fittings and the blade fuse. Therefore, it is desirable to develop a technology that can improve the bonding strength between the resin component and the terminal fittings.

[0009] Therefore, the object of the present invention is to provide a fuse unit and conductive module that can improve the bonding strength between resin components and terminal fittings.

[0010] Methods for solving problems

[0011] That is, the fuse unit of the present invention includes: a blade fuse having a first electrode, a second electrode, and a fusible portion that melts due to overcurrent; a first terminal fitting having a plate shape, connected to a connected object and connected to the first electrode; a second terminal fitting having a plate shape and connected to the second electrode; and a resin component holding the first terminal fitting and the second terminal fitting and maintaining the spacing between the first terminal fitting and the second terminal fitting, wherein the first terminal fitting and the second terminal fitting have one of a plurality of recesses or a plurality of protrusions, and the resin component has another of a plurality of said recesses or a plurality of said protrusions, wherein the plurality of recesses and the plurality of said protrusions respectively engage.

[0012] Invention Effects

[0013] The fuse unit and conductive module according to the present invention can improve the bonding strength between the resin component and the terminal fitting. Attached Figure Description

[0014] Figure 1 This is a perspective view showing the fuse unit and conductive module of an embodiment.

[0015] Figure 2 This is a schematic diagram showing the battery module and busbar.

[0016] Figure 3 This is a perspective view of a fuse unit illustrating an embodiment.

[0017] Figure 4 This is an exploded perspective view of a fuse unit illustrating an embodiment.

[0018] Figure 5 This is an exploded perspective view of a fuse unit illustrating an embodiment.

[0019] Figure 6 This is an explanatory diagram of a modified example of the fuse unit in the embodiment.

[0020] Figure 7 This is an explanatory diagram of a modified example of the fuse unit in the embodiment.

[0021] Figure 8 This is an explanatory diagram of a modified example of the fuse unit in the embodiment.

[0022] Explanation of reference numerals in the attached figures

[0023] 1. Conductive module

[0024] 10 Connecting conductors (connecting objects)

[0025] 20 Fuse Units

[0026] 30-blade fuse

[0027] 31 First Electrode

[0028] 32 Second electrode

[0029] 40 First terminal accessories

[0030] 41b first recess

[0031] 50 Second terminal accessories

[0032] 51b second recess

[0033] 60 Wiring components

[0034] 61 Conductor section

[0035] 70 Resin Components

[0036] 70a Containment Room

[0037] 70A First Containment Component

[0038] 70B Second Containment Component

[0039] 71a first convex part

[0040] 71b second convex part

[0041] 76. Covered resin section

[0042] BC battery cell

[0043] BM battery module

[0044] X Connection Direction

[0045] Y-width direction Detailed Implementation

[0046] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the present invention is not limited to these embodiments. Furthermore, the constituent elements in the following embodiments include components that can be easily substituted or are substantially the same by those skilled in the art.

[0047] [Example]

[0048] This embodiment relates to a fuse unit and a conductive module. In the following description, the first direction among the intersecting first, second, and third directions is referred to as the "connection direction X," the second direction as the "width direction Y," and the third direction as the "height direction Z." Here, the connection direction X, width direction Y, and height direction Z are orthogonal to each other. It should be noted that orthogonality here includes approximately orthogonality. The connection direction X corresponds to the direction in which the fuse unit is connected to the object being connected. In addition, unless otherwise stated, all directions used in the following description refer to the directions in which the components are assembled together.

[0049] like Figure 1 and Figure 2 As shown, conductive module 1 is assembled into battery module BM, which has multiple battery cells BC arranged in a row, and electrically connects the multiple battery cells BC in battery module BM. Furthermore, conductive module 1 connects battery module BM to battery monitoring unit (not shown), enabling battery monitoring unit to monitor the battery state of battery cells BC. Conductive module 1 and battery module BM together constitute a battery pack. The battery pack is used, for example, in vehicles driven by a rotary motor (BEV: Battery Electric Vehicle, HEV: Hybrid Electric Vehicle, etc.) to supply power to the rotary motor.

[0050] Each battery cell BC comprises a cell body BCa and positive and negative electrode terminals BCb. In a battery module BM, multiple battery cells BC are arranged in a row along an arrangement direction. The battery module BM comprises an electrode terminal group BCc formed by arranging one electrode terminal BCb of the multiple battery cells BC along the arrangement direction, and another electrode terminal group BCc formed by arranging the other electrode terminals BCb of the multiple battery cells BC along the arrangement direction.

[0051] In the battery cell BC shown here, the cell body BCa is formed into a cuboid shape with six outer wall surfaces. Furthermore, in multiple battery cells BC, adjacent cell bodies BCa in the arrangement direction are arranged with one outer wall surface facing each other. For example, in the battery cell BC, the positive and negative electrode terminals BCb are respectively provided on one of the six outer wall surfaces of the cell body BCa, or separately provided on two of the six outer wall surfaces of the cell body BCa. In this example, each battery cell BC has positive and negative electrode terminals BCb provided on one of the six outer wall surfaces of the cell body BCa. Therefore, in the battery module BM, two electrode terminal groups BCc are provided on a single plane.

[0052] The electrode terminal BCb shown here is formed in a flat plate shape and is directly electrically connected to the connecting conductor 10 (described later) by means of laser welding or the like. However, the electrode terminal BCb can also be formed in a post shape with an external thread. In this case, the connecting conductor 10 is threadedly fixed to the electrode terminal BCb by screwing an internal threaded component onto the external thread of the electrode terminal BCb.

[0053] The conductive module 1 has a connecting conductor 10, which is directly electrically connected to the electrode terminal BCb of the battery cell BC constituting the battery module BM.

[0054] The connecting conductor 10 is made of a conductive material such as metal. This connecting conductor 10 is a plate-shaped conductive component made of metal, referred to as a busbar, and is manufactured, for example, by stamping a metal plate. The connecting conductor 10 shown here is formed into a rectangular plate shape.

[0055] In the conductive module 1, the connecting conductor 10 includes: a connecting conductor that is directly electrically connected to the adjacent electrode terminals BCb of a pair of battery cells BC in the battery module BM, a connecting conductor that is directly electrically connected to the electrode terminal BCb of the battery module BM that serves as the overall negative electrode, and a connecting conductor that is directly electrically connected to the electrode terminal BCb of the battery module BM that serves as the overall positive electrode.

[0056] The conductive module 1 includes a connecting conductor 10 and a fuse unit 20. The fuse unit 20 is connected between the connecting conductor 10 and the battery monitoring unit. The fuse unit 20 electrically connects the connecting conductor 10 and the battery monitoring unit and cuts off the power supply when an overcurrent flows between them. Each connecting conductor 10 is provided with this fuse unit 20.

[0057] like Figures 3-5 As shown, the fuse unit 20 includes a blade fuse 30, a first terminal accessory 40, a second terminal accessory 50, and a resin component 70. The blade fuse 30 is a circuit protection component that melts its fusible part when an overcurrent flows between the connecting conductor 10 and the battery monitoring unit. The blade fuse 30 is constructed by arranging a fusible part between a first electrode 31 and a second electrode 32. The first electrode 31 and the second electrode 32 are respectively arranged on a straight line at one end and the other end of the blade fuse 30.

[0058] The chip fuse 30 can be configured as a surface-mount type chip component with a fusible portion, or it can be configured as a patterned fuse with a wiring pattern having a fusible portion on a printed circuit board (e.g., a flexible printed circuit board). The chip fuse 30 shown here is configured as a cuboid chip component. A first electrode 31 is provided on five outer wall surfaces at one end of the chip fuse 30. In addition, a second electrode 32 is provided on five outer wall surfaces at the other end of the chip fuse 30.

[0059] The fuse unit 20 has a first terminal fitting 40 and a second terminal fitting 50, which are directly electrically connected to the chip fuse 30. The first terminal fitting 40 and the second terminal fitting 50 are made of conductive materials such as metal. For example, the first terminal fitting 40 and the second terminal fitting 50 are plate-shaped, for example, formed by stamping from a metal plate.

[0060] The first terminal fitting 40 has a first electrical connection portion 41, which is directly electrically connected to the first electrode 31 of the chip fuse 30. One of the four circumferentially arranged outer wall surfaces of the first electrode 31 is placed on the first electrical connection portion 41, and the first electrode 31 is directly electrically connected to the first electrical connection portion 41 by laser welding, brazing, or the like. Therefore, the first electrical connection portion 41 is formed as a flat plate shape with a plane on which the outer wall surface of the first electrode 31 is placed. The first electrical connection portion 41 shown here is formed as a convex flat plate shape, and the outer wall surface of the first electrode 31 is placed on this convex narrow portion. In this first electrical connection portion 41, the narrow portion becomes a contact portion 41a that contacts the first electrode 31, and the contact portion 41a is directly electrically connected to the first electrode 31.

[0061] Furthermore, the first terminal fitting 40 has a conductor connection portion 42, which is directly or indirectly electrically connected to the connecting conductor 10. The conductor connection portion 42 is formed in a flat plate shape and is placed on the connecting conductor 10 with its planes overlapping each other. Moreover, the conductor connection portion 42 is directly electrically connected to the connecting conductor 10 by laser welding, ultrasonic bonding, or the like. The conductor connection portion 42 shown here is formed in a rectangular flat plate shape. The connecting conductor 10 is the object to which the first terminal fitting 40 is connected.

[0062] The first terminal fitting 40 shown here is formed as a flat plate with the first electrical connection portion 41 adjacent to the conductor connection portion 42.

[0063] The second terminal fitting 50 has a second electrical connection portion 51, which is directly electrically connected to the second electrode 32 of the chip fuse 30. One of the four outer wall surfaces of the second electrode 32 arranged circumferentially rests on the second electrical connection portion 51, and the second electrode 32 is directly electrically connected to the second electrical connection portion 51 by laser welding, brazing, or the like. Therefore, the second electrical connection portion 51 is formed as a flat plate shape with a plane on which the outer wall surface of the second electrode 32 rests. The second electrical connection portion 51 shown here is formed as a convex flat plate shape, and the outer wall surface of the second electrode 32 rests on this convex narrow portion. In this second electrical connection portion 51, the narrow portion becomes a contact portion 51a that contacts the second electrode 32, and the contact portion 51a is directly electrically connected to the second electrode 32.

[0064] Furthermore, the second terminal accessory 50 is indirectly electrically connected to the battery monitoring unit. The fuse unit 20 includes a wiring component 60, which is disposed between the second terminal accessory 50 and the battery monitoring unit, thereby indirectly connecting the second terminal accessory 50 to the battery monitoring unit. The second terminal accessory 50 has a wiring connection portion 52, which is directly electrically connected to the wiring component 60.

[0065] The wiring component 60 includes a conductor portion 61, one end of which is directly electrically connected to the second terminal fitting 50, and the other end is directly or indirectly electrically connected to the battery monitoring unit. Furthermore, the wiring component 60 includes an electrically insulating sheath 62, which covers the portion of the wiring component 60 at least one end closer to the battery monitoring unit than the conductor portion 61. The wiring component 60 shown here is a linear conductor having a conductor portion 61 formed in a linear shape. Specifically, the wiring component 60 is an electrical wire whose core wire of the conductor portion 61 is covered by an electrically insulating sheath 62, and the wiring connection portion 52 is directly electrically connected to one end of the conductor portion 61 at that end.

[0066] For example, in the wiring component 60, the insulation sheath 62 is peeled off at this end, exposing one end of the conductor portion 61. In this case, the wiring connection portion 52 can be structured as a fastening crimp, which is fastened to one end of the conductor portion 61 (i.e., the core wire at the end of the wire). Alternatively, for example, the wiring component 60 can also be structured with the insulation sheath 62 covering one end of the conductor portion 61 at this end. In this case, the wiring connection portion 52 can be structured as a pair of crimping blades, which form cuts in the insulation sheath 62 at the end of the wiring component 60, clamping one end of the conductor portion 61 (the core wire at the end of the wire). The wiring connection portion 52 shown here is formed as a fastening crimp.

[0067] In the second terminal accessory 50 shown here, the second electrical connection portion 51 is adjacent to the wiring connection portion 52. The wiring connection portion 52 leads the wiring component 60 out in the adjacent direction and along the direction of the second electrical connection portion 51.

[0068] It should be noted that the wiring component 60 may also be a flat wiring material such as a flexible printed circuit board, and its conductor portion 61 is formed into a wiring pattern. In this case, the wiring component 60 has a conductor portion 61 corresponding to each of the second terminal fittings 50 of the plurality of fuse units 20, and one end of the conductor portion 61 is provided at the end of the branch portion that branches from the main body to each second terminal fitting 50. One end of the conductor portion 61 is directly electrically connected to the wiring connection portion 52, for example, by laser welding, brazing, or the like.

[0069] In this fuse unit 20, the first electrical connection portion 41 of the first terminal fitting 40 and the second electrical connection portion 51 of the second terminal fitting 50 are arranged on the same plane at a predetermined interval. This predetermined interval is the interval between the first electrode 31 and the second electrode 32 of the chip fuse 30 (i.e., the electrode spacing). Therefore, the first terminal fitting 40 and the second terminal fitting 50 are arranged such that the interval between the first electrical connection portion 41 and the second electrical connection portion 51 matches the electrode spacing between the first electrode 31 and the second electrode 32. The chip fuse 30 is provided across the first electrical connection portion 41 and the second electrical connection portion 51. Here, the first terminal fitting 40 and the second terminal fitting 50 are arranged such that the interval between the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51 matches the electrode spacing between the first electrode 31 and the second electrode 32. Therefore, the chip fuse 30 is provided across the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51.

[0070] Furthermore, the first terminal accessory 40 shown here is arranged such that the adjacent direction of the first electrical connection portion 41 and the conductor connection portion 42 is aligned with the opposing arrangement direction of each contact portion 41a, 51a. Similarly, the second terminal accessory 50 shown here is arranged such that the adjacent direction of the second electrical connection portion 51 and the wiring connection portion 52 is aligned with the opposing arrangement direction of each contact portion 41a, 51a.

[0071] The fuse unit 20 has a resin component 70 that holds the first terminal fitting 40 and the second terminal fitting 50 and maintains the distance between them. The resin component 70 is made of electrically insulating resin and, for example, houses the first electrical connection portion 41, the second electrical connection portion 51, and the blade fuse 30. That is, the resin component 70 is provided with a receiving chamber 70a that houses the first electrical connection portion 41, the second electrical connection portion 51, and the blade fuse 30.

[0072] The resin component 70 has multiple housing components that are assembled and fixed together to form a housing chamber 70a inside. These multiple housing components are formed of an electrically insulating material such as synthetic resin. The multiple housing components are formed as separate components from the first electrical connection portion 41, the second electrical connection portion 51, and the chip fuse 30, and surround and house the first electrical connection portion 41, the second electrical connection portion 51, and the chip fuse 30 within the housing chamber 70a.

[0073] Specifically, the resin component 70 shown here includes a first receiving component 70A and a second receiving component 70B as multiple receiving components. The first receiving component 70A and the second receiving component 70B clamp the first electrical connection 41, the second electrical connection 51 and the chip fuse 30 between each other and house them in the receiving chamber 70a.

[0074] The first receiving member 70A is provided with a mounting surface 71, on which the first electrical connection portion 41 and the second electrical connection portion 51 are mounted. A chip fuse 30 is mounted on the first electrical connection portion 41 and the second electrical connection portion 51 mounted on the mounting surface 71. For example, the first receiving member 70A is formed as a base member that mounts the first electrical connection portion 41 and the second electrical connection portion 51 on the mounting surface 71. The first receiving member 70A shown here is formed in a rectangular flat plate shape.

[0075] When the second receiving member 70B is in the assembled position corresponding to the first receiving member 70A which is the base member, it is formed as a cover member that covers the first electrical connection part 41, the second electrical connection part 51 and the chip fuse 30.

[0076] The second receiving component 70B has a cover 72, which, in the assembled position, places the first electrical connection 41, the second electrical connection 51, and the chip fuse 30 in the middle and is positioned opposite the mounting surface 71 of the first receiving component 70A. The cover 72 shown here is formed in a rectangular flat plate shape and is arranged parallel to the mounting surface 71 of the first receiving component 70A in the assembled position.

[0077] Furthermore, the second receiving member 70B has a pair of first sidewall portions 73, which are vertically disposed from the cover portion 72 and are spaced apart from each other in the opposing configuration direction of the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51. The first sidewall portions 73 shown here are formed in the shape of rectangular flat plates, and in the assembled position, their end edges abut against the mounting surface 71 of the first receiving member 70A. However, a first cut 73a is formed on the edge of the end of one of the first sidewall portions 73, which allows the conductor connection portion 42 of the first electrical connection portion 41 to extend out of the receiving chamber 70a. In addition, a second cut 73b is formed on the edge of the end of the other first sidewall portion 73, which allows the wiring connection portion 52 of the second electrical connection portion 51 to extend out of the receiving chamber 70a.

[0078] Furthermore, the second receiving member 70B has a pair of second sidewall portions 74, which are vertically disposed from the cover portion 72 and are spaced apart from each other in a direction orthogonal to the opposing arrangement direction of the cover portion 72 and the first receiving member 70A, as well as the opposing arrangement direction of each contact portion 41a, 51a. The second sidewall portions 74 shown here are formed in the shape of rectangular flat plates, and in the assembled position, the edge of the end abuts against the mounting surface 71 of the first receiving member 70A.

[0079] The second receiving component 70B has an internal space surrounded by the cover 72, a pair of first sidewalls 73, and a pair of second sidewalls 74. In the resin component 70, when the first receiving component 70A and the second receiving component 70B are in the assembled position, the opening of the internal space of the second receiving component 70B is closed by the first receiving component 70A, and the internal space becomes the receiving chamber 70a.

[0080] For example, in the resin component 70, at the assembled position, the edges of the ends of a pair of first sidewall portions 73 and the edges of the ends of a pair of second sidewall portions 74 are fixed to the mounting surface 71 of the first receiving component 70A by means of heat fusion or the like.

[0081] Furthermore, for example, the first receiving component 70A and the second receiving component 70B are preferably formed in such a way that the receiving chamber 70a becomes a sealed space when assembled, and are fixed in such a shape that there are no gaps between them when assembled. As a result, the fuse unit 20 can prevent liquids, dust, etc. from entering the receiving chamber 70a, thereby preventing the quality degradation and reduced durability associated with such liquid intrusion.

[0082] Here, a first positioning structure 75A is provided between the mounting surface 71 of the first receiving member 70A and the first electrical connection portion 41, which is responsible for positioning the first electrical connection portion 41 relative to the mounting surface 71. Furthermore, a second positioning structure 75B is provided between the mounting surface 71 of the first receiving member 70A and the second electrical connection portion 51, which is responsible for positioning the second electrical connection portion 51 relative to the mounting surface 71. The first positioning structure 75A and the second positioning structure 75B position the first electrical connection portion 41 and the second electrical connection portion 51 such that the interval between the contact portions 41a of the first electrical connection portion 41 and the contact portions 51a of the second electrical connection portion 51 matches the electrode spacing between the first electrode 31 and the second electrode 32.

[0083] The first positioning structure 75A comprises a first protrusion 71a and a first recess 41b. The first protrusion 71a is formed on the first receiving member 70A of the resin member 70. That is, the first protrusion 71a protrudes from the mounting surface 71 of the first receiving member 70A. The first recess 41b is formed on the first electrical connection portion 41 of the first terminal fitting 40, and its size is configured to fit with the first protrusion 71a. In the first positioning structure 75A shown here, the first protrusion 71a is formed in a cylindrical shape, and the first recess 41b is formed in a circular through hole. However, in the first positioning structure 75A, in order to suppress the rotation of the first terminal fitting 40 about the axis of the first protrusion 71a, for example, the first protrusion 71a may also be formed in a prism shape, and the first recess 41b may also be formed in a rectangular through hole.

[0084] Multiple first protrusions 71a and multiple first recesses 41b are formed. The multiple first protrusions 71a and multiple first recesses 41b are respectively configured to engage. For example, two first protrusions 71a are formed side-by-side along the width direction Y, and two first recesses 41b are formed side-by-side along the width direction Y. The formation interval between the first protrusions 71a and the formation interval between the first recesses 41b are set to the same distance. The resin component 70 and the first terminal fitting 40 are joined by the engagement of the multiple first protrusions 71a and the multiple first recesses 41b. It should be noted that the number of first protrusions 71a and first recesses 41b may also be three or more.

[0085] The resin component 70 and the first terminal fitting 40 are securely joined by a plurality of first protrusions 71a and a plurality of first recesses 41b respectively. For example, the joint strength can be improved compared to the case where the resin component 70 and the first terminal fitting 40 are joined by a first protrusion 71a and a first recess 41b respectively.

[0086] Furthermore, the resin component 70 and the first terminal fitting 40 are respectively engaged with each other by a plurality of first protrusions 71a and a plurality of first recesses 41b, which can suppress the relative rotation of the resin component 70 and the first terminal fitting 40 around the engagement position of the first protrusions 71a and the first recesses 41b, thereby stabilizing the engagement state of the resin component 70 and the first terminal fitting 40.

[0087] Furthermore, in the resin component 70 and the first terminal fitting 40, a plurality of first protrusions 71a are formed side by side along the width direction Y, and a plurality of first recesses 41b are formed side by side along the width direction Y. This allows for a compact structure of the resin component 70 and the first terminal fitting 40, achieving miniaturization of the fuse unit 20. For example, if the plurality of first protrusions 71a and the plurality of first recesses 41b are formed side by side along the connection direction X, the resin component 70 and the first terminal fitting 40 would be longer in the connection direction X. In contrast, in the fuse unit 20 of this embodiment, the plurality of first protrusions 71a and the plurality of first recesses 41b are formed side by side along the width direction Y, thereby enabling a compact structure of the resin component 70 and the first terminal fitting 40, achieving miniaturization.

[0088] The second positioning structure 75B comprises a second protrusion 71b and a second recess 51b. The second protrusion 71b is formed on the first receiving member 70A of the resin member 70. That is, the second protrusion 71b protrudes from the mounting surface 71 of the first receiving member 70A. The second recess 51b is formed on the second electrical connection portion 51 of the second terminal accessory 50, and its size is configured to fit with the second protrusion 71b. In the second positioning structure 75B shown here, the second protrusion 71b is formed in a cylindrical shape, and the second recess 51b is formed in a circular through hole. However, in the second positioning structure 75B, in order to suppress the rotation of the second terminal accessory 50 about the axis of the second protrusion 71b, for example, the second protrusion 71b may also be formed in a prism shape, and the second recess 51b may also be formed in a rectangular through hole.

[0089] The first receiving member 70A is a plate extending along the connection direction X, and its forming range includes a region from a first forming position of the first terminal accessory 40 where a first recess 41b is formed to a second forming position of the second terminal accessory 50 where a second recess 51b is formed. The first receiving member 70A retains the first terminal accessory 40 and the second terminal accessory 50 and maintains the spacing between the first terminal accessory 40 and the second terminal accessory 50 by fitting a first protrusion 71a into the first recess 41b and fitting a second protrusion 71b into the second recess 51b.

[0090] Multiple second protrusions 71b and multiple second recesses 51b are formed. The multiple second protrusions 71b and multiple second recesses 51b are respectively configured to engage. For example, two second protrusions 71b and two second recesses 51b are formed side-by-side along the width direction Y. The formation interval between the second protrusions 71b and the second recesses 51b is set to the same distance. The resin component 70 and the second terminal fitting 50 are joined by the separate engagement of the multiple second protrusions 71b and the multiple second recesses 51b. It should be noted that the number of second protrusions 71b and second recesses 51b can also be three or more.

[0091] The resin component 70 and the second terminal fitting 50 are securely joined by a plurality of second protrusions 71b and a plurality of second recesses 51b respectively fitting into each other. For example, compared with the case where the resin component 70 and the second terminal fitting 50 are joined by a second protrusion 71b fitting into a second recess 51b, the joint strength can be improved.

[0092] Furthermore, the resin component 70 and the second terminal fitting 50 are respectively fitted with a plurality of second protrusions 71b and a plurality of second recesses 51b, thereby suppressing the relative rotation of the resin component 70 and the second terminal fitting 50 around the fitting position of the second protrusions 71b and the second recesses 51b, thereby stabilizing the engagement state of the resin component 70 and the second terminal fitting 50.

[0093] Furthermore, in the resin component 70 and the second terminal fitting 50, a plurality of second protrusions 71b are formed side by side along the width direction Y, and a plurality of second recesses 51b are formed side by side along the width direction Y. This allows for a compact structure of the resin component 70 and the second terminal fitting 50, achieving miniaturization of the fuse unit 20. For example, if the plurality of second protrusions 71b and the plurality of second recesses 51b are formed side by side along the connection direction X, the resin component 70 and the second terminal fitting 50 will be longer in the connection direction X. In contrast, in the fuse unit 20 of this embodiment, a plurality of second protrusions 71b and a plurality of second recesses 51b are formed side by side along the width direction Y, thereby enabling a compact structure of the resin component 70 and the second terminal fitting 50, achieving miniaturization.

[0094] For example, in this fuse unit 20, a first electrical connection portion 41 and a second electrical connection portion 51 are disposed on the mounting surface 71 of the first receiving member 70A. The first electrical connection portion 41 and the second electrical connection portion 51 are positioned by a first positioning structure 75A and a second positioning structure 75B, such that the spacing between their respective contact portions 41a and 51a matches the spacing between the first electrode 31 and the second electrode 32. Therefore, in the fuse unit 20, by disposing of the chip fuse 30 at the respective contact portions 41a and 51a of the first electrical connection portion 41 and the second electrical connection portion 51, the first electrode 31 of the chip fuse 30 can be placed on the contact portion 41a of the first electrical connection portion 41, and the second electrode 32 of the chip fuse 30 can be placed on the contact portion 51a of the second electrical connection portion 51. In this fuse unit 20, the first electrode 31 is directly electrically connected to the contact portion 41a of the first electrical connection portion 41 by laser welding, brazing or the like, and the second electrode 32 is directly electrically connected to the contact portion 51a of the second electrical connection portion 51 by laser welding, brazing or the like.

[0095] Here, in this fuse unit 20, the first receiving member 70A serves as a base member, and there is no wall covering the first electrical connection portion 41, the second electrical connection portion 51, and the area surrounding the chip fuse 30 provided on the mounting surface 71. Therefore, in this fuse unit 20, a laser irradiator and a soldering iron can be brought close to the contact portion 41a between the first electrode 31 and the first electrical connection portion 41, and the contact portion 51a between the second electrode 32 and the second electrical connection portion 51, from multiple directions. Lasers can be irradiated between the first electrode 31 and the contact portion 41a and between the second electrode 32 and the contact portion 51a from all directions, and soldering can be performed between these portions from all directions using a soldering iron. Therefore, this fuse unit 20 increases the manufacturing freedom when directly electrically connecting the first electrical connection portion 41, the second electrical connection portion 51, and the chip fuse 30.

[0096] Next, in the fuse unit 20, the second receiving member 70B covers the first electrical connection portion 41, the second electrical connection portion 51, and the chip fuse 30, and the first receiving member 70A and the second receiving member 70B are fixed in the assembled position by heat sealing or the like. It should be noted that it is assumed here that the wiring member 60 has been pre-connected to the wiring connection portion 52 of the second terminal accessory 50.

[0097] In this fuse unit 20, the first electrical connection 41, the second electrical connection 51, and the blade fuse 30 in the housing 70a are exposed. Therefore, as Figure 6 As shown, the fuse unit 20 may also have an electrically insulating covering resin portion 76 in the housing chamber 70a, which covers the blade fuse 30, the first electrical connection portion 41, and the second electrical connection portion 51. By covering the blade fuse 30, the first electrical connection portion 41, and the second electrical connection portion 51, the covering resin portion 76 suppresses the energization between the first electrical connection portion 41 and the second electrical connection portion 51. For example, even if condensation occurs in the housing chamber 70a, the covering resin portion 76 can suppress short circuits in the housing chamber 70a caused by the condensation. Furthermore, the covering resin portion 76, by being fixed to the mounting surface 71 of the first housing member 70A, can also function as a fixing member for fixing the first electrical connection portion 41, the second electrical connection portion 51, and the blade fuse 30 to the first housing member 70A in the housing chamber 70a.

[0098] For example, the covering resin portion 76 is a cured product of a liquid resin material (so-called potting material) supplied by dripping or other means, which encapsulates the chip fuse 30, the first electrical connection portion 41, and the second electrical connection portion 51. In this case, firstly, liquid potting material is supplied to the chip fuse 30, the first electrical connection portion 41, and the second electrical connection portion 51, which are mounted on the mounting surface 71 of the first receiving member 70A. Then, depending on the characteristics of the potting material, it is cured by irradiating the potting material with ultraviolet light, heating the potting material, or other methods to form the covering resin portion 76. Since the covering resin portion 76 undergoes such a manufacturing process, it is desirable to use a liquid potting material with a viscosity sufficient to stand on the mounting surface 71 before curing, so that the liquid potting material does not flow out from the mounting surface 71 of the first receiving member 70A, which is a base component, before curing.

[0099] Here, when using UV-curable potting materials, it is necessary to bring the UV irradiator close to the liquid potting material. In this fuse unit 20, the first receiving member 70A serves as a base member, and there are no walls or other parts that cover the surrounding liquid potting material. Therefore, in this fuse unit 20, the UV irradiator can be brought close to the liquid potting material on the mounting surface 71 of the first receiving member 70A from multiple directions, and UV light can be irradiated onto the liquid potting material from all directions. Therefore, this fuse unit 20 can improve the manufacturing freedom when forming the covering resin portion 76.

[0100] Furthermore, for example, the resin covering 76 may be a cured material that fills the receiving chamber 70a and encapsulates the chip fuse 30, the first electrical connection portion 41, and the second electrical connection portion 51. In this case, for example, a supply hole (not shown) is provided in either the first receiving member 70A or the second receiving member 70B, which is used to supply liquid resin material into the interior (receiving chamber 70a) of the first receiving member 70A and the second receiving member 70B in the assembled position. Here, if there is no gap between the first receiving member 70A and the second receiving member 70B in the assembled position (in other words, if the airtightness of the receiving chamber 70a is high), an vent hole (not shown) is provided in either the first receiving member 70A or the second receiving member 70B, which is used to expel gas in the receiving chamber 70a to the outside when the liquid resin material is supplied. In this case, liquid resin material is supplied and filled into the interior (reception chamber 70a) of the first receiving component 70A and the second receiving component 70B in the assembled position through the supply port, and the resin material is cured to form the resin-covered portion 76. If there is a gap between the first receiving component 70A and the second receiving component 70B in the assembled position (in other words, if the airtightness of the reception chamber 70a is low), or if the supply port or vent port must be located, for example, vertically below, or if there is a concern that the liquid resin material may flow out of the reception chamber 70a, it is desirable to use a liquid resin material with a viscosity that allows the liquid resin material to remain in the reception chamber 70a before curing to form the resin-covered portion 76.

[0101] Figure 1 In the conductive module 1, there is an electrically insulating module resin portion 80, which together with the connecting conductor 10 houses the fuse unit 20. The module resin portion 80 is provided with a housing chamber (hereinafter referred to as "conductor housing chamber") 80a for housing the connecting conductor 10 and a housing chamber (hereinafter referred to as "unit housing chamber") 80b for housing the fuse unit 20.

[0102] For example, the module resin section 80 has a conductor housing chamber 80a, which corresponds to each connecting conductor 10 connected to each electrode terminal BCb of the electrode terminal group BCc. On the other hand, the module resin section 80 has a unit housing chamber 80b, which centrally houses the fuse unit 20 corresponding to each connecting conductor 10.

[0103] In the unit housing 80b, the wiring components 60 (wires) of each fuse unit 20 are routed towards the battery monitoring unit side. The other end of each wiring component 60 (wire) leading to the battery monitoring unit side is connected to a connector 65. Figure 1 Each wiring component 60 (wire) is electrically connected to the battery monitoring unit via the connector 65.

[0104] Furthermore, when the wiring component 60 is a flat wiring material, the wiring component 60 (flat wiring material) (not shown) is housed in the unit housing chamber 80b. The wiring component 60 has a conductor portion 61 that is connected to the second terminal fitting 50 of each fuse unit 20.

[0105] The module resin section 80 includes a first receiving component (hereinafter referred to as "first module receiving component") 80A and a second receiving component (hereinafter referred to as "second module receiving component," omitted from the illustration). The first module receiving component 80A and the second module receiving component are assembled and fixed to each other, forming a plurality of conductor receiving chambers 80a and unit receiving chambers 80b inside. The first module receiving component 80A and the second module receiving component are molded from an electrically insulating material such as synthetic resin.

[0106] The first module housing component 80A is provided with a space portion, which is used to form a plurality of conductor housing chambers 80a and unit housing chambers 80b at the position after assembly with the second module housing component. Furthermore, the second module housing component forms a cover component that covers the openings of each space portion.

[0107] As described above, the fuse unit 20 and conductive module 1 of this embodiment can improve the bonding strength of the first terminal accessory 40, the second terminal accessory 50 and the resin component 70 by fitting the first terminal accessory 40 and the resin component 70 together through a plurality of first recesses 41b and a plurality of first protrusions 71a, and by fitting the second terminal accessory 50 and the resin component 70 together through a plurality of second recesses 51b and a plurality of second protrusions 71b.

[0108] Furthermore, in this embodiment, the fuse unit 20 and the conductive module 1 are joined by the first terminal fitting 40 and the resin component 70 through a plurality of first recesses 41b and a plurality of first protrusions 71a, and the second terminal fitting 50 and the resin component 70 are joined by a plurality of second recesses 51b and a plurality of second protrusions 71b. This enables the suppression of relative rotation between the first terminal fitting 40 and the resin component 70 around the first protrusion 71a, and also suppresses relative rotation between the second terminal fitting 50 and the resin component 70 around the second protrusion 71b.

[0109] Furthermore, in the fuse unit 20 and conductive module 1 of this embodiment, the first recess 41b and the first protrusion 71a are formed side by side along the width direction Y, and the second recess 51b and the second protrusion 71b are formed side by side along the width direction Y. This enables the size of the first terminal accessory 40 and the second terminal accessory 50 in the connection direction X to be miniaturized, thereby realizing the miniaturization of the fuse unit 20.

[0110] Furthermore, the fuse unit 20 and conductive module 1 of this embodiment have a first receiving member 70A. The formation range of the first receiving member 70A includes a region from a first forming position of the first terminal accessory 40 where a first recess 41b is formed to a second forming position of the second terminal accessory 50 where a second recess 51b is formed. Therefore, by fitting the first protrusion 71a into the first recess 41b and the second protrusion 71b into the second recess 51b, the fuse unit 20 and conductive module 1 of this embodiment can retain the first terminal accessory 40 and the second terminal accessory 50 through the first receiving member 70A and maintain the spacing between the first terminal accessory 40 and the second terminal accessory 50.

[0111] Furthermore, the fuse unit 20 and conductive module 1 of this embodiment have a resin covering portion 76, which is configured to cover the sheet fuse 30 through the resin component 70 and contact the first terminal accessory 40 and the second terminal accessory 50, thereby protecting the sheet fuse 30 through the resin covering portion 76.

[0112] It should be noted that the fuse unit and conductive module of the present invention are not limited to the above embodiments, and various modifications can be made within the scope of the claims. The fuse unit 20 and conductive module 1 of this embodiment can also be constructed by appropriately combining the constituent elements of the various embodiments and modifications described above.

[0113] For example, in the fuse unit 20 and conductive module 1 of the above embodiments, all or part of the resin component 70 can be formed by resin molding. For example, as Figure 7As shown, the resin covering portion 76 covering the blade fuse 30 can also be formed by resin molding. Specifically, the resin covering portion 76 can be formed by insert molding of an assembly in which the first terminal fitting 40 and the second terminal fitting 50 are assembled and connected between the first terminal fitting 40 and the second terminal fitting 50. Alternatively, the resin covering portion 76 can be formed by insert molding of an assembly in which the blade fuse 30 is connected between the first terminal fitting 40 and the second terminal fitting 50. In this case, the portion of the resin component 70 formed by resin molding is embedded between the first recess 41b and the second recess 51b, resulting in a structure having a first protrusion 71a and a second protrusion 71b.

[0114] Furthermore, in the fuse unit 20 and conductive module 1 of the above embodiments, a first protrusion 71a and a second protrusion 71b are formed in the first receiving member 70A, a first recess 41b is formed in the first terminal fitting 40, and a second recess 51b is formed in the second terminal fitting 50. However, the first receiving member 70A may also have a first recess 41b and a second recess 51b. For example, as... Figure 8 As shown, a first recess 41b and a second recess 51b are formed on the surface of the first receiving member 70A, a first protrusion 71a protruding toward the first receiving member 70A is formed on the first terminal fitting 40, and a second protrusion 71b protruding toward the first receiving member 70A is formed on the second terminal fitting 50. Even with such a fuse unit and conductive module, by providing multiple first recesses 41b, second recesses 51b, first protrusions 71a, and second protrusions 71b, the bonding strength between the first terminal fitting 40, the second terminal fitting 50, and the resin member 70 can be improved in the same way as the fuse unit 20 and the conductive module 1, and the relative rotation between the first terminal fitting 40 and the resin member 70 can be suppressed, and the relative rotation between the second terminal fitting 50 and the resin member 70 can be suppressed.

Claims

1. A fuse unit, characterized in that, include: A chip fuse having a first electrode, a second electrode, and a fusible part that will melt due to overcurrent; The first terminal accessory is plate-shaped and is connected to the object to be connected and to the first electrode. The second terminal accessory is plate-shaped and connected to the second electrode; as well as A resin component that holds the first terminal accessory and the second terminal accessory together, and maintains the spacing between the first terminal accessory and the second terminal accessory. The first terminal accessory and the second terminal accessory are formed with one of a plurality of recesses or a plurality of protrusions. The resin component is formed with one of the plurality of recesses or the plurality of protrusions. The plurality of recesses are respectively fitted into the plurality of convex portions.

2. The fuse unit as described in claim 1, characterized in that, The recess and the protrusion are formed side by side along the width direction that intersects the connection direction of the connected object.

3. The fuse unit as described in claim 1 or 2, characterized in that, The resin component includes a first receiving component, which is formed as a plate or block disposed along the connection direction with the object to be connected. The first receiving member is formed as a region extending from a first forming position in the first terminal fitting where one of the plurality of recesses or the plurality of protrusions is formed to a second forming position in the second terminal fitting where one of the plurality of recesses or the plurality of protrusions is formed, and the first receiving member is formed with the other of the plurality of recesses or the plurality of protrusions.

4. The fuse unit as described in claim 1 or 2, characterized in that, The resin component includes a covering resin portion configured to cover the chip fuse and contact the first terminal fitting and the second terminal fitting, and is formed by curing a liquid or fluid.

5. A conductive module, characterized in that, include: A connecting conductor is electrically connected to the electrode terminals of the battery cells constituting the battery module; as well as A fuse unit that electrically connects the connecting conductor to a battery monitoring unit that monitors the battery status of the individual battery cells. The fuse unit includes: A chip fuse having a first electrode, a second electrode, and a fusible part that will melt due to overcurrent; A first terminal accessory, which is plate-shaped, is connected to the connecting conductor and the first electrode; A second terminal accessory, which is plate-shaped, is connected to the second electrode; and A resin component that holds the first terminal accessory and the second terminal accessory together, and maintains the spacing between the first terminal accessory and the second terminal accessory. The first terminal accessory and the second terminal accessory are formed with one of a plurality of recesses or a plurality of protrusions. The resin component is formed with one of the plurality of recesses or the plurality of protrusions. The plurality of recesses are respectively fitted into the plurality of convex portions.

Images