Battery module

Abstract

Disclosed is a battery module capable of connecting battery cells to each other and detecting the voltage of each battery cell while reducing the number of components and the number of man-hours. The battery module (10) includes battery cells (12a, 12b, 12c), a base end terminal (28), a terminal end terminal (30), a first and a second intermediate terminals (32, 34), the base end terminal (28) is connected in conduction with a first battery cell (12a) and a power input side conductor (58), the terminal end terminal (30) is connected in conduction with a third battery cell (12c) and a ground line (62), the first intermediate terminal (32) is connected in conduction with the first battery cell (12a), a second battery cell (12b), and a circuit substrate (72) to constitute a first voltage detection line (118), the second intermediate terminal (34) is connected in conduction with the second battery cell (12b), the third battery cell (12c), and the circuit substrate (72) to constitute a second voltage detection line (119), and a current path (16) connecting the first battery cell (12a) to the third battery cell (12c) in series is constituted by the base end terminal (28), the first intermediate terminal (32), the second intermediate terminal (34), and the terminal end terminal (30).

Description

Technical Field

[0001] This disclosure relates to battery modules. Background Technology

[0002] Patent documents 1 and 2 disclose battery modules that are constructed by arranging multiple rechargeable battery cells in one direction and connecting the electrode terminals of adjacent battery cells with metal connecting members. In both documents, wiring for voltage detection is connected to the connecting members between the electrode terminals by soldering, brazing, or the like, thereby enabling monitoring of the voltage status of the battery module. Existing technical documents Patent documents

[0003] Patent Document 1: Japanese Patent Application Publication No. 2004-47167 Patent Document 2: Japanese Patent Application Publication No. 2022-083610 Summary of the Invention The problem that the invention aims to solve

[0004] However, both patent documents 1 and 2 require a connecting component to connect the electrode terminals of the battery cells and a separate wiring component for voltage detection. This increases the number of components and necessitates welding and other work to connect the connecting component and the wiring component, thus increasing the workload.

[0005] Therefore, a battery module is disclosed that can connect individual battery cells to each other and detect the voltage of each individual battery cell while reducing the number of components and operating time. Solution for solving the problem

[0006] The battery module disclosed herein includes: at least three battery cells arranged in series; a pair of electrode tabs disposed in each of the battery cells; and a plurality of connection terminals connected to the electrode tabs to form a current path connecting the at least three battery cells. The pair of electrode tabs protrudes from each of the battery cells on both sides in an intersecting direction that intersects the arrangement direction of the plurality of battery cells. The at least three battery cells include a first battery cell, a second battery cell, and a third battery cell arranged sequentially from the base end side to the end side in the arrangement direction. The connection terminals include a base end terminal, an end terminal, and a plurality of intermediate terminals. The base end terminal and the end terminal each include: a protrusion extending from the base end side to the end side in the arrangement direction; a base end side connection portion extending in a flange-like manner from the base end side of the protrusion to the outer periphery of the protrusion; and an end side connection portion disposed on the end side of the protrusion. Each intermediate terminal includes: the protrusion; the base end side connection portion; and the end side connection portion.The intermediate connecting portion is disposed between the base-side connecting portion and the end-side connecting portion and extends outward in a flange shape towards the outer periphery of the protrusion. The base-side terminal is configured such that the base-side connecting portion is conductively connected to the electrode tab on one side of the first battery cell in the crossing direction, the end-side connecting portion is conductively connected to the power input conductor, and the protrusion penetrates the electrode tab on one side of the other battery cell in an insulated state. The end terminal is configured such that the base-side connecting portion is conductively connected to the electrode tab on the other side of the crossing direction of the third battery cell, and the end-side connecting portion is conductively connected to the ground wire. The plurality of intermediate terminals include a first intermediate terminal and a second intermediate terminal. The first intermediate terminal is configured such that the base-side connecting portion is conductively connected to the electrode tab on the other side of the crossing direction of the first battery cell, and the protrusion penetrates the second intermediate terminal in an insulated state. The first voltage detection line is formed by connecting the electrode tab on one side of the cross direction of the second battery cell to the electrode tab on the other side of the cross direction of the third battery cell, and the end-side connection is connected to the circuit board. The second intermediate terminal is configured such that the base-side connection is connected to the electrode tab on one side of the cross direction of the second battery cell, and the protrusion extends through the electrode tab on one side of the cross direction of the third battery cell in an insulated state, while the intermediate connection is connected to the electrode tab on one side of the cross direction of the third battery cell, and the end-side connection is connected to the circuit board. This forms a second voltage detection line. The current path connecting the first battery cell to the third battery cell in series is formed by the base-side terminal, the first intermediate terminal, the second intermediate terminal, and the end terminal. Invention Effects

[0007] According to this disclosure, a battery module can be provided that enables the connection of individual battery cells and the voltage detection of each individual battery cell while reducing the number of components and operating hours. Attached Figure Description

[0008] Figure 1 This is a perspective view of the battery module according to Embodiment 1. Figure 2 yes Figure 1 The battery module shown is shown in top view. Figure 3 It is Figure 2 The enlarged longitudinal section view shown in section III-III is shown in the image. Figure 4 It is Figure 2 The enlarged longitudinal section view shown in section IV-IV is shown in the image. Figure 5 yes Figure 1 The image shows an exploded perspective view of the battery module. Figure 6 It is Figure 5 The battery cell shown is further disassembled to reveal an exploded perspective view. Figure 7 It indicates composition Figure 1 The diagram shows the base terminals of the battery module. The left side is a perspective view, and the right side is a longitudinal sectional view. Figure 8 It indicates composition Figure 1 The diagram shows the first intermediate terminal of the battery module. The left side is a perspective view, and the right side is a longitudinal sectional view. Figure 9 It indicates composition Figure 1 The diagram shows the second intermediate terminal of the battery module. The left side is a perspective view, and the right side is a longitudinal sectional view. Figure 10 It indicates composition Figure 1 The diagram shows the end terminals of the battery module. The left side is a perspective view, and the right side is a longitudinal sectional view. Figure 11 It indicates composition Figure 5 The diagram shows a perspective view of the power supply unit's substrate assembly, with the top view being a top-down perspective view and the bottom view being a bottom-up perspective view. Figure 12 It is used to explain the composition Figure 1 The diagram illustrates a specific example of the manufacturing process of the power unit section of the battery module shown. Figure 13 It is used to explain the composition Figure 1 The diagram illustrates a specific example of the manufacturing process of the power unit section of the battery module, showing the subsequent... Figure 12 The diagram shows the process steps. Figure 14 It is used to explain the composition Figure 1 The diagram illustrates a specific example of the manufacturing process of the power unit section of the battery module, showing the subsequent... Figure 13 The diagram shows the process steps. Figure 15 It is used to explain the composition Figure 1 The diagram illustrates a specific example of the manufacturing process of the battery cell section of the battery module shown. Figure 16 It is used to explain the composition Figure 1 The illustrated diagram shows a specific example of the manufacturing process of the battery cell section of the battery module, illustrating the following steps. Figure 15 The diagram shows the process steps. Figure 17 It is used to explain the composition Figure 1The illustrated diagram shows a specific example of the manufacturing process of the battery cell section of the battery module, illustrating the following steps. Figure 16 The diagram shows the process steps. Figure 18 It is used for explanation Figure 1 The diagram shown is an example of a specific manufacturing process for a battery module, illustrating the following steps. Figure 17 The diagram shows the process steps. Figure 19 It is used for explanation Figure 1 The diagram shown is an example of a specific manufacturing process for a battery module, illustrating the following steps. Figure 18 The diagram shows the process steps. Detailed Implementation

[0009] (Description of embodiments of this disclosure) The embodiments of this disclosure are first described in detail. (1) The battery module of this disclosure has: at least three battery cells arranged in series; a pair of electrode tabs disposed in each of the battery cells; and a plurality of connection terminals connected to the electrode tabs to form a current path connecting the at least three battery cells, wherein the pair of electrode tabs protrudes from each of the battery cells on both sides in an intersecting direction that intersects the arrangement direction of the plurality of battery cells, the at least three battery cells include a first battery cell, a second battery cell, and a third battery cell arranged sequentially from the base end side to the end side in the arrangement direction, the connection terminals include a base end terminal, an end terminal, and a plurality of intermediate terminals, the base end terminal and the end terminal each include: a protrusion extending from the base end side to the end side in the arrangement direction; a base end side connection portion extending in a flange shape from the base end side of the protrusion portion to the outer periphery of the protrusion portion; and an end side connection portion disposed on the end side of the protrusion portion, each of the intermediate terminals includes: the protrusion portion; the base end side connection portion; and the end side connection portion;The intermediate connecting portion is disposed between the base-side connecting portion and the end-side connecting portion and extends outward in a flange shape towards the outer periphery of the protrusion. The base-side terminal is configured such that the base-side connecting portion is conductively connected to the electrode tab on one side of the first battery cell in the crossing direction, the end-side connecting portion is conductively connected to the power input conductor, and the protrusion penetrates the electrode tab on one side of the other battery cell in an insulated state. The end terminal is configured such that the base-side connecting portion is conductively connected to the electrode tab on the other side of the crossing direction of the third battery cell, and the end-side connecting portion is conductively connected to the ground wire. The plurality of intermediate terminals include a first intermediate terminal and a second intermediate terminal. The first intermediate terminal is configured such that the base-side connecting portion is conductively connected to the electrode tab on the other side of the crossing direction of the first battery cell, and the protrusion penetrates the second intermediate terminal in an insulated state. The first voltage detection line is formed by connecting the electrode tab on one side of the cross direction of the second battery cell to the electrode tab on the other side of the cross direction of the third battery cell, and the end-side connection is connected to the circuit board. The second intermediate terminal is configured such that the base-side connection is connected to the electrode tab on one side of the cross direction of the second battery cell, and the protrusion extends through the electrode tab on one side of the cross direction of the third battery cell in an insulated state, while the intermediate connection is connected to the electrode tab on one side of the cross direction of the third battery cell, and the end-side connection is connected to the circuit board. This forms a second voltage detection line. The current path connecting the first battery cell to the third battery cell in series is formed by the base-side terminal, the first intermediate terminal, the second intermediate terminal, and the end terminal.

[0010] According to the battery module disclosed herein, a battery cell with a pair of electrode tabs protruding on both sides in a direction intersecting the arrangement direction of at least three (first to third) battery cells is constructed. Furthermore, the connection terminals constituting the current path connecting the first to third battery cells in series are a base terminal, an end terminal, and a plurality of intermediate terminals. Adjacent battery cells are connected via the plurality of intermediate terminals, and the end-side connection portion is connected to the circuit board, thereby enabling the formation of first and second voltage detection lines. Therefore, both the current path and the voltage detection line can be formed via the connection terminals. This provides a battery module that reduces the number of components and operating time.

[0011] Furthermore, the following operations can be performed: battery cells are sequentially overlapped from the base end to the end in the battery cell arrangement direction, while simultaneously making necessary connection terminals conductively connected to the electrode tabs of each battery cell. This simplifies the battery module assembly process and automates the assembly procedure. Incidentally, in this specification, "flange-shaped" includes not only a shape that extends outwards along the entire circumference of the protrusion, but also a shape that extends outwards from a portion of the outer periphery of the protrusion towards the outer periphery of the protrusion.

[0012] Furthermore, by adding one or more units such as two battery cells and a first intermediate terminal and a second intermediate terminal that connect them in series, it is possible to similarly configure a battery module that connects three or more battery cells in series and can detect the voltage of each battery cell.

[0013] (2) Based on (1) above, it is preferable that the protrusions of the base terminal, the first intermediate terminal, the second intermediate terminal and the end terminal are each covered by an insulating member. Since the protrusions of each connecting terminal are covered by an insulating member, the protrusions can be used as current paths and voltage detection lines, while the protrusions stably pass through the electrode tabs of each battery cell in a non-energized state.

[0014] (3) Based on (1) or (2) above, preferably, the battery module comprises: a power supply unit having the power input side conductor, the power output side conductor, and the grounding wire; and a battery unit having the battery cell, the electrode tab, and the connection terminal, wherein the power supply unit and the battery unit overlap, and the power input side conductor is connected to the power output side conductor via a relay. When the battery module of this disclosure is used as an auxiliary battery, if the main battery is functioning normally, the power input side conductor and the power output side conductor are kept in a non-connected state by means of a relay, thereby enabling the voltage state of each battery cell to be detected and the battery module to be charged simultaneously. Furthermore, when the main battery fails, the power input side conductor and the power output side conductor are connected by means of a relay, thereby making the end-side connection of the base terminal connected to the power output side conductor, thereby enabling the power of the battery module to be output to the necessary equipment via the power output side conductor.

[0015] (4) Based on (3) above, preferably, the relay includes: a bridging bus, disposed between the power input conductor and the power output conductor; an input-side semiconductor relay connected to the power input conductor and the bridging bus to switch on / off the energization between the power input conductor and the bridging bus; and an output-side semiconductor relay connected to the power output conductor and the bridging bus to switch on / off the energization between the power output conductor and the bridging bus. The conductive route for connecting the input conductor and the output conductor via the semiconductor relay uses the bridging bus, thus enabling the conduction of large currents. Furthermore, by using the bridging bus, heat dissipation is superior compared to using thick copper foil on the printed circuit board, allowing for advantageous dissipation of Joule heat during energization.

[0016] (Details of the embodiments disclosed herein) Hereinafter, specific examples of the battery module of this disclosure will be described with reference to the accompanying drawings. Furthermore, this disclosure is not limited to these examples, but is defined by the claims and is intended to include all modifications within the meaning and scope of the claims and their equivalents.

[0017] (Implementation Method 1) The following uses Figures 1 to 19 The battery module 10 of Embodiment 1 of this disclosure will be described. The battery module 10 of Embodiment 1 is used as an emergency power source, for example, to enable minimal operations such as driving, steering, and parking even when the power supply to an electric vehicle or hybrid vehicle fails, and is also used as an energy storage module. Therefore, the battery module 10 has a structure in which a plurality of rechargeable and dischargeable battery cells 12 are arranged in an array. Furthermore, although the battery module 10 can be arranged in any orientation, below, we will assume that the top is the orientation. Figure 3 The top and bottom of the middle are Figure 3 The bottom and left of the middle are Figure 2 The top and right sides are Figure 2 The bottom and front of the middle are Figure 2 The left and rear of the middle are Figure 2 The description will be provided on the right side of the diagram. Furthermore, in the following description, for multiple identical components, only some components will be labeled with reference numerals, and for other components, reference numerals may sometimes be omitted.

[0018] (Battery Module 10) The battery module 10 includes: at least three battery cells 12 arranged in series; a pair of electrode tabs 14, 14 (+-side electrode tab 14a and --side electrode tab 14b) disposed in each battery cell 12; and a plurality of connection terminals 18 connected to each electrode tab 14a, 14b to form a current path 16 connecting the at least three battery cells 12. In the battery module 10 of Embodiment 1, the three battery cells 12 are arranged in a vertical direction, including a first battery cell 12a, a second battery cell 12b, and a third battery cell 12c arranged sequentially from the base end side (lower side) to the end side (upper side) in the arrangement direction. Each battery cell 12a to 12c is of the same shape, and each battery cell 12a to 12c is provided with a +-side electrode tab 14a and a --side electrode tab 14b of the same shape. The electrode tabs 14a and 14b on the + and - sides mentioned above protrude from each battery cell 12a to 12c on both sides in the cross direction (orthogonal direction and front-back direction in Embodiment 1) that intersects with the arrangement direction of each battery cell 12a to 12c.

[0019] Furthermore, among the three battery cells 12a to 12c arranged vertically, the central second battery cell 12b is positioned with its orientation rotated 180 degrees around a central axis extending vertically. Consequently, the second battery cell 12b is positioned 180 degrees opposite to the first and third battery cells 12a and 12c in the aforementioned cross direction (front-back direction). As a result, the positive electrode protrusion 14a of the first and third battery cells 12a and 12c and the negative electrode protrusion 14b of the second battery cell 12b are respectively positioned on one side (front side) of the aforementioned cross direction. Conversely, the negative electrode protrusion 14b of the first and third battery cells 12a and 12c and the positive electrode protrusion 14a of the second battery cell 12b are respectively positioned on the other side (rear side) of the aforementioned cross direction. Furthermore, the + and - electrode tabs 14a and 14b disposed on the aforementioned side are connected using the connecting terminal 18, and the + and - electrode tabs 14a and 14b disposed on the other side are connected using the connecting terminal 18, thereby connecting the three individual battery cells 12a to 12c in series.

[0020] In addition, as Figure 5 As shown, the battery module 10 of Embodiment 1 includes a power supply unit 20 and a battery unit 22. The power supply unit 20 is fixed from above to overlap with the battery unit 22, thereby constituting the battery module 10. Also as... Figure 6 As shown, each of the aforementioned battery cells 12a to 12c, each of the electrode tabs 14a and 14b, and each of the connecting terminals 18 are included in the battery cell section 22.

[0021] (Battery cell 12 (first to third battery cells 12a to 12c)) Each battery cell 12 (first to third battery cells 12a to 12c) has the same shape, and is generally flat with a predetermined width and length. Each battery cell 12a to 12c uses, for example, a known capacitor (energy storage element), therefore, a description of its specific structure is omitted. Each battery cell 12a to 12c has a rectangular flat body portion 24 that, when viewed from above, has a predetermined width and length. The aforementioned +-side and --side electrode protrusions 14a and 14b protrude from each body portion 24 in the rear-to-rear direction. Each body portion 24 extends in the horizontal direction (a direction orthogonal to the vertical direction) and is arranged with its rear-to-rear dimension larger than its left-to-right dimension.

[0022] (Electrode tabs 14 (+ side and - side electrode tabs 14a, 14b)) The +-side and --side electrode protrusions 14a and 14b are both approximately rectangular in shape when viewed from above, and are formed to approximately the same size. Furthermore, each of the aforementioned electrode protrusions 14a and 14b is provided with a terminal insertion hole 26 for the aforementioned connecting terminals 18 to be inserted. As will be described later, in Embodiment 1, since four connecting terminals 18 are provided (base terminal 28, end terminal 30, first intermediate terminal 32 which serves as a plurality of intermediate terminals, and second intermediate terminal 34), four terminal insertion holes 26 are provided, with two terminal insertion holes 26 provided in each of the +-side and --side electrode protrusions 14a and 14b.

[0023] Specifically, the +-side electrode tab 14a is provided with a first terminal insertion hole 26a and a second terminal insertion hole 26b, which are spaced apart from each other in the left-right direction. Similarly, the --side electrode tab 14b is provided with a third terminal insertion hole 26c and a fourth terminal insertion hole 26d, which are also spaced apart from each other in the left-right direction. Therefore, in the +-side and --side electrode tabs 14a and 14b, which are spaced apart in the front-back direction, the first terminal insertion hole 26a and the third terminal insertion hole 26c are spaced apart from each other in the front-back direction, and the second terminal insertion hole 26b and the fourth terminal insertion hole 26d are also spaced apart from each other in the front-back direction.

[0024] Furthermore, as mentioned above, among the battery cells 12a to 12c, the second battery cell 12b is arranged with its front-to-back orientation rotated 180 degrees. Therefore, on the front left side, the fourth terminal insertion hole 26d in the second battery cell 12b is located between the first terminal insertion holes 26a in the first and third battery cells 12a and 12c, and the aforementioned first terminal insertion holes 26a and fourth terminal insertion holes 26d are coaxially arranged in the vertical direction. Similarly, on the front right side, the third terminal insertion hole 26c is located between the second terminal insertion holes 26b on both the upper and lower sides, and the aforementioned second terminal insertion holes 26b and third terminal insertion holes 26c are coaxially arranged in the vertical direction.

[0025] Additionally, on the rear left side, the second terminal through hole 26b is located between the third terminal through holes 26c on both the upper and lower sides, and the aforementioned third terminal through holes 26c and second terminal through holes 26b are coaxially arranged in the vertical direction. Furthermore, on the rear right side, the first terminal through hole 26a is located between the fourth terminal through holes 26d on both the upper and lower sides, and the aforementioned fourth terminal through holes 26d and first terminal through holes 26a are coaxially arranged in the vertical direction.

[0026] In Embodiment 1, among the first to fourth terminal through holes 26a to 26d, the first, third, and fourth terminal through holes 26a, 26c, and 26d are formed with approximately equal inner diameters, and the second terminal through hole 26b is formed with an inner diameter smaller than that of the first, third, and fourth terminal through holes 26a, 26c, and 26d. Therefore, on the front left side, each of the first terminal through holes 26a and the fourth terminal through holes 26d is arranged with approximately equal inner diameters and coaxially, and on the rear right side, each of the fourth terminal through holes 26d and the first terminal through hole 26a is arranged with approximately equal inner diameters and coaxially. On the front right side and the rear left side, at the location where the second terminal through hole 26b is formed, its inner diameter is smaller than that of the third terminal through hole 26c.

[0027] In particular, in Embodiment 1, the inner diameters of the first, third, and fourth terminal insertion holes 26a, 26c, and 26d are equal to or slightly larger than the outer diameter φα of the large-diameter portion of the insulating member 42 in the base terminal 28 and the end terminal 30, as well as the protrusion 36 in the first intermediate terminal 32 and the second intermediate terminal 34. Furthermore, the inner diameter of the second terminal insertion hole 26b is equal to or slightly larger than the outer diameter φβ of the small-diameter portion of the protrusion 36 in the first intermediate terminal 32 and the second intermediate terminal 34.

[0028] (Connection terminal 18) The connection terminal 18 includes: a base terminal 28 disposed on the base end side (lower side) in the arrangement direction (vertical direction) of each battery cell 12a-12c; an end terminal 30 disposed on the end side (upper side) in the arrangement direction; and a plurality of first intermediate terminals 32 and second intermediate terminals 34 disposed in the middle portion in the arrangement direction as intermediate terminals. The base terminal 28, end terminal 30, and first and second intermediate terminals 32 and 34 are as described above. Figures 7-10 As shown.

[0029] (Base terminal 28 and end terminal 30) like Figure 7 and Figure 10 As shown, the base terminal 28 and the end terminal 30 each include: a protrusion 36 extending from the base side to the end side in the arrangement direction of each battery cell 12a to 12c; a base-side connecting portion 38 extending in a flange shape from the base side (lower side) of the protrusion 36 to the outer periphery of the protrusion 36; and an end-side connecting portion 40 provided on the end side (upper side) of the protrusion 36. The aforementioned base terminal 28 and end terminal 30 are formed of metals with excellent conductivity, such as copper (including copper alloys) or aluminum (including aluminum alloys).

[0030] The protrusion 36 is a cylindrical portion with a circular cross-section, having a predetermined diameter and length (vertical dimension). The base terminal 28 and the end terminal 30 have approximately equal diameters in their respective protrusions 36, and the protrusion 36 of the base terminal 28 has a longer length than the protrusion 36 of the end terminal 30. Furthermore, the base-side connecting portions 38 of the base terminal 28 and the end terminal 30 are approximately identical in shape, having approximately equal diameters and vertical dimensions. Thus, the base terminal 28 has a predetermined length L1 (see reference). Figure 7 Furthermore, the end terminal 30 has a shorter length dimension L2 than the base terminal 28 (see reference). Figure 10 ).

[0031] Furthermore, the protrusions 36 of both the base terminal 28 and the end terminal 30 are covered by insulating members 42. The insulating members 42 are cylindrical components, for example, formed of synthetic resin. The length dimension (vertical dimension) of each insulating member 42 is slightly shorter than the length dimension of the protrusions 36. Each protrusion 36 is covered by the insulating member 42 along its approximately full length, except for the end portion (upper portion) of each protrusion 36. The portion of each protrusion 36 not covered by the insulating member 42 is the end-side connecting portion 40. In other words, in both the base terminal 28 and the end terminal 30, the end-side connecting portion 40 protrudes upwards from the insulating member 42.

[0032] Furthermore, the outer diameter of each insulating member 42 is smaller than the diameter of each base-end connecting portion 38. Therefore, when each protrusion 36 is covered by the insulating member 42, the upper surface of each base-end connecting portion 38 is not covered by the insulating member 42, and the annular area is exposed to the outside. That is, in the base terminal 28 and the end terminal 30, the end-end connecting portions 40 and 38 at both ends are not covered by the insulating member 42, allowing for electrical connection. However, in the base terminal 28 and the end terminal 30, the middle portion in the vertical direction is covered by the insulating member 42, preventing electrical connection. Additionally, the insulating members 42 in the base terminal 28 and the insulating members 42 in the end terminal 30 have approximately equal outer diameters φα (see reference). Figure 7 , 10 With each protrusion 36 in the base terminal 28 and the end terminal 30 covered by the insulating member 42, the middle portions in the vertical direction of the base terminal 28 and the end terminal 30 have approximately equal outer diameter dimensions φα.

[0033] As described below, the base-side connection portion 38 of the base terminal 28 is electrically connected to the positive electrode tab 14a of the first battery cell 12a, which is disposed on one side (front side) of the aforementioned cross direction. The end-side connection portion 40 of the base terminal 28 is inserted into the base terminal connection hole 92 and electrically connected to the power input conductor 58. The protrusion portion 36 of the base terminal 28 passes through the other electrode tabs 14 (the negative electrode tab 14b of the second battery cell 12b and the positive electrode tab 14a of the third battery cell 12c) on one side (front side) of the aforementioned cross direction in an insulated state. In addition, the base-side connection portion 38 of the end terminal 30 is electrically connected to the negative electrode tab 14b of the third battery cell 12c, which is disposed on the other side (rear side) of the aforementioned cross direction. The end-side connection portion 40 of the end terminal 30 is inserted into the end terminal connection hole 98 and electrically connected to the ground wire 62.

[0034] (First and second intermediate terminals 32 and 34) like Figure 8 , 9As shown, the first and second intermediate terminals 32 and 34, like the base terminal 28 and the end terminal 30, each include a protrusion 36, a base-side connecting portion 38, and an end-side connecting portion 40. The first and second intermediate terminals 32 and 34 can be formed of the same material as the base terminal 28 and the end terminal 30. Furthermore, the first and second intermediate terminals 32 and 34 include an intermediate connecting portion 44 disposed between the base-side connecting portion 38 and the end-side connecting portion 40 and extending outwards in a flange-like manner towards the outer periphery of the protrusion 36. Specifically, each protrusion 36 in the first and second intermediate terminals 32 and 34 is configured as a stepped cylindrical shape, with the upper portion of each protrusion 36 having a smaller diameter than the lower portion. Thus, a stepped surface 46 extending in a ring shape is formed in the middle portion of each protrusion 36 in the vertical direction.

[0035] Furthermore, in each of the protrusions 36 of the first and second intermediate terminals 32 and 34, the portion with a smaller diameter that is above each stepped surface 46 is covered by the insulating member 42, just like the base terminal 28 and the end terminal 30. The outer diameter φβ of the insulating member 42 in the first and second intermediate terminals 32 and 34 (refer to...) Figure 8 , 9 The outer diameter of each stepped surface 46 is smaller than that of the portion of each protrusion 36 that is larger than the portion of each stepped surface 46 located below it. Thus, the insulating member 42 coincides with the upper surface of the inner periphery of each stepped surface 46, but the annular region of the outer periphery of each stepped surface 46 is exposed to the outside without being covered by the insulating member 42, allowing for electrical connection. The aforementioned intermediate connection portion 44 is formed by the portion of each stepped surface 46 that is exposed to the outside without being covered by the insulating member 42.

[0036] Furthermore, like the base terminal 28 and the end terminal 30, the insulating members 42 in the first and second intermediate terminals 32 and 34 do not reach the upper portion of each protrusion 36, and the upper portion of each protrusion 36 protrudes upward from each insulating member 42. Therefore, in the first and second intermediate terminals 32 and 34, the end-side connection portion 40 is also formed by the portion of the upper portion of each protrusion 36 that is not covered by each insulating member 42.

[0037] Furthermore, each protrusion 36 in the first and second intermediate terminals 32 and 34 also has a predetermined diameter and length (vertical dimension). Additionally, each base-side connecting portion 38 in the first and second intermediate terminals 32 and 34 is formed with a shape substantially the same as that of each base-side connecting portion 38 in the base terminal 28 and the end terminal 30, and each base-side connecting portion 38 has a diameter and vertical dimension that are substantially equal to each other. Specifically, the outer diameter of the portion of each protrusion 36 in the first and second intermediate terminals 32 and 34 that is set to a larger diameter than each stepped surface 46 is substantially equal to the outer diameter φα of each insulating member 42 in the base terminal 28 and the end terminal 30. Furthermore, as described above, the outer diameter φβ of each insulating member 42 in the first and second intermediate terminals 32 and 34 is smaller than the outer diameter φα of each stepped surface 46 (the outer diameter of each insulating member 42 in the base terminal 28 and the end terminal 30). Furthermore, the length of the first intermediate terminal 32 is approximately equal to the length of the base terminal 28 and is set as L1, and the length of the second intermediate terminal 34 is L3 (refer to...). Figure 9 The length L1 of the base terminal 28 and the first intermediate terminal 32 is set to the length L2 of the end terminal 30 (L2 < L3 < L1).

[0038] In the first and second intermediate terminals 32 and 34, as described above, the portion of each protrusion 36 that is set to a smaller diameter above each stepped surface 46 is covered by each insulating member 42, making electrical connection impossible. However, in the first and second intermediate terminals 32 and 34, in addition to the base-side connection portion 38 and the end-side connection portion 40, electrical connection can also be made in the intermediate connection portion 44.

[0039] As described below, the base-side connection portion 38 of the first intermediate terminal 32 is electrically connected to the other (rear) side electrode tab 14b of the first battery cell 12a, which is disposed in the aforementioned cross direction. The protrusion portion 36 of the first intermediate terminal 32 is configured such that its upper portion passes through the other (rear) side electrode tab 14a of the second battery cell 12b, which is disposed in the aforementioned cross direction, in an insulated state, while the intermediate connection portion 44 is electrically connected to the side electrode tab 14a of the second battery cell 12b. The end-side connection portion 40 of the first intermediate terminal 32 is inserted into the first intermediate terminal connection hole 116 in the circuit board 72 and electrically connected to the electrical circuit in the circuit board 72. The first intermediate terminal 32 forms the first voltage detection line 118 through the electrical connection as described above.

[0040] Furthermore, the base-side connection portion 38 of the second intermediate terminal 34 is electrically connected to the one-side electrode tab 14b of the second battery cell 12b disposed on one side (front side) of the aforementioned cross direction. The protrusion portion 36 of the second intermediate terminal 34 is configured such that its upper portion passes through the positive-side electrode tab 14a of the third battery cell 12c disposed on one side (front side) of the aforementioned cross direction in an insulated state, while the intermediate connection portion 44 is electrically connected to the positive-side electrode tab 14a of the third battery cell 12c. The end-side connection portion 40 of the second intermediate terminal 34 is inserted into the second intermediate terminal connection hole 114 in the circuit board 72 and electrically connected to the electrical circuit in the circuit board 72. The second intermediate terminal 34 forms the second voltage detection line 119 through the electrical connection as described above.

[0041] (Power supply unit 20) As previously described, the battery module 10 of Embodiment 1 is configured to include a power supply unit 20. Also as... Figure 5 As shown, the power supply unit 20 comprises a substrate assembly 48 and a heat sink 50. Specifically, the substrate assembly 48 and the heat sink 50 overlap with each other via a heat sink 52, and the outer periphery of the substrate assembly 48 is bonded to the heat sink 50 via a waterproof adhesive 54. The heat sink 50 is formed of a metal with good thermal conductivity and has a plurality of upwardly protruding fins 56. In addition, a through hole 57 extending in the thickness direction (vertical direction) is formed in the rear portion of the heat sink 50, and the substrate connector 120, described later, is exposed to the outside through the through hole 57 when the battery module 10 is assembled. In particular, the power supply unit 20 of Embodiment 1, as described later, includes a power input side conductor 58, a power output side conductor 60, and a ground wire 62 constituting the substrate assembly 48.

[0042] Furthermore, known heat-conducting components with good thermal conductivity can be used as heat sinks 52. In Embodiment 1, three heat sinks 52 are provided, and each heat sink 52 overlaps with the power input side conductor 58 (especially the input side bus 80 constituting the power input side conductor 58), the power output side conductor 60 (especially the output side bus 84 constituting the power output side conductor 60), and the bridging bus 66 disposed between the power input side conductor 58 and the power output side conductor 60, which are provided in the substrate assembly 48 (described later). The heat sinks 52 are preferably disposed in a compressed state between the substrate assembly 48 and the heat sink 50 in the vertical direction.

[0043] (Substrate assembly 48) Also Figure 11As shown, the substrate assembly 48 includes: a power input conductor 58 connected to the positive side of each of the three battery cells 12a-12c connected in series; a power output conductor 60 connected to the negative side; and a grounding wire 62 for grounding the aforementioned current path 16 (e.g., connecting it to earth). Additionally, the substrate assembly 48 includes a relay 64, through which the power input conductor 58 and the power output conductor 60 are connected.

[0044] The relay 64 in Embodiment 1 includes: a bridging bus 66 disposed between the power input side conductor 58 and the power output side conductor 60; an input-side semiconductor relay 68 connected to the power input side conductor 58 and the bridging bus 66 to switch the energization between them; and an output-side semiconductor relay 70 connected to the power output side conductor 60 and the bridging bus 66 to switch the energization between them. Furthermore, the substrate assembly 48 includes a circuit board 72, which has an input-side conductive path 74 and an output-side conductive path 76 on one side (the lower surface of the battery module 10 in its assembled state) for connecting the aforementioned input-side semiconductor relay 68 and output-side semiconductor relay 70, respectively.

[0045] (Power input conductor 58, power output conductor 60 and grounding wire 62) Also Figure 12 As shown, the power input side conductor 58 is composed of an input side stud 78 and an input side bus 80. The power input side conductor 58 is connected to external wires or the like for charging each battery cell 12a-12c. The power output side conductor 60 is composed of an output side stud 82 and an output side bus 84. Furthermore, the grounding wire 62 is composed of a grounding side stud 86 and a grounding bus 88.

[0046] Specifically, the input-side busbar 80 is a generally rectangular plate-shaped component extending in the front-rear direction, with a bolt insertion hole 90 formed at its front end for inserting an input-side stud 78. Additionally, a base terminal connection hole 92 is formed at the front end of the input-side busbar 80, allowing it to connect to the base terminal 28 via an end-side connecting portion 40, as described later. Both the bolt insertion hole 90 and the base terminal connection hole 92 extend through the input-side busbar 80 in the thickness direction (vertical direction) and are spaced apart from each other in the left-right direction. Furthermore, the output-side busbar 84 is a generally rectangular plate-shaped component extending in the front-rear direction, with a bolt insertion hole 94 formed at its front end for inserting an output-side stud 82, extending through the output-side busbar 84 in the thickness direction (vertical direction).

[0047] Furthermore, the grounding busbar 88 is a generally rectangular plate-shaped component extending in the left-right direction, with a bolt insertion hole 96 formed at its right end for inserting a grounding-side stud 86. Additionally, an end terminal connection hole 98 is formed at the left end of the grounding busbar 88, allowing it to connect to the end terminal 30 by inserting the end-side connection portion 40 as described later. Both the bolt insertion hole 96 and the end terminal connection hole 98 are formed through the grounding busbar 88 along its thickness direction (vertical direction).

[0048] The aforementioned input-side stud 78 and input-side busbar 80 are connected by inserting the shaft portion of the input-side stud 78 from below into the bolt insertion hole 90, thereby forming a power input-side conductor 58. As described later, the base terminal 28 is electrically connected to the power input-side conductor 58 by connecting the base terminal connection hole 92 in the power input-side conductor 58 to the end-side connection portion 40 in the base terminal 28, thus forming an input-side voltage detection line 99. Furthermore, the ground-side stud 86 and ground busbar 88 are connected by inserting the shaft portion of the ground-side stud 86 from below into the bolt insertion hole 96, thereby forming a ground wire 62. As described later, the end terminal 30 is electrically connected to the ground wire 62 by connecting the end terminal connection hole 98 in the ground wire 62 to the end-side connection portion 40 in the end terminal 30, thus forming a ground-side voltage detection line 100. Furthermore, the output-side stud 82 and the output-side busbar 84 are connected by inserting the shaft portion of the output-side stud 82 from below into the bolt insertion hole 94, thereby forming the power output-side conductor 60. The aforementioned power input-side conductor 58, power output-side conductor 60, and ground wire 62 are held by a frame-like frame 101. The frame 101 is, for example, formed of synthetic resin.

[0049] In Embodiment 1, the frame 101 is formed, for example, as an integrally molded part 102 having a power input side conductor 58, a power output side conductor 60, and a ground wire 62. That is, when molding the frame 101, resin material is injected into the frame 101 while the power input side conductor 58, the power output side conductor 60, and the ground wire 62 are placed in the molding cavity, thereby forming an integrally molded part 102 having a power input side conductor 58, a power output side conductor 60, and a ground wire 62.

[0050] Also Figure 12As shown, in the integrally molded part 102, the input-side stud 78, the output-side stud 82, and the ground-side stud 86 protrude upwards. Each of these studs 78, 82, and 86 protrudes outwards (upwards) in the assembled state of the battery module 10, functioning as an external connection part for connecting to external wires, etc. Furthermore, in the integrally molded part 102, the base terminal connection hole 92 in the power input-side conductor 58 and the end terminal connection hole 98 in the ground wire 62 are located on the inner periphery of the frame 101, which is frame-shaped, and open to both sides in the upward and downward directions. Additionally, in the integrally molded part 102, portions of the input-side busbar 80 and the output-side busbar 84 are located on the inner periphery of the frame 101, and the regions of the input-side and output-side busesbars 80 and 84 extending in the front-back direction are exposed outwards on the inner periphery of the frame 101.

[0051] (Relay 64) As previously described, relay 64 includes a bridging bus 66, an input-side semiconductor relay 68, and an output-side semiconductor relay 70. In Embodiment 1, the bridging bus 66 has an input-side protrusion 104 connected to the aforementioned input-side conductive path 74 and an output-side protrusion 106 connected to the output-side conductive path 76. Specifically, the bridging bus 66 is formed of a metal with excellent conductivity, as... Figure 13 As shown, the base portion 108 is configured as a generally rectangular plate. Furthermore, in the base portion 108, the input side protrusion 104 and the output side protrusion 106 are provided in such a way that they protrude to one side (below the assembled state of the battery module 10) in the plate thickness direction (vertical direction).

[0052] In Embodiment 1, a plurality of input-side protrusions 104 and a plurality of output-side protrusions 106 are respectively provided in the bridging bus 66. Specifically, in Embodiment 1, at the left end of the base portion 108, the plurality of input-side protrusions 104 are spaced apart from each other in the front-rear direction, and at the right end of the base portion 108, the plurality of output-side protrusions 106 are spaced apart from each other in the front-rear direction. Each of the aforementioned input-side protrusions 104 and each of the output-side protrusions 106 has a generally elongated oval shape when viewed from above (projection in the vertical direction) and has a predetermined protrusion height.

[0053] As the input-side semiconductor relay 68 and the output-side semiconductor relay 70, known metal oxide semiconductor field-effect transistors (MOSFETs) can be used, and power MOSFETs designed to handle high currents are particularly suitable. Although the specific construction of the input-side semiconductor relay 68 and the output-side semiconductor relay 70 is omitted above, both the input-side semiconductor relay 68 and the output-side semiconductor relay 70 have a gate terminal, a drain terminal, and a source terminal.

[0054] (Circuit board 72) The circuit board 72 is, for example, a known rigid printed circuit board, arranged to extend in a horizontal direction (orthogonal to the vertical direction). Electrical circuitry (not shown) is printed on at least one surface of the circuit board 72 in the thickness direction (vertical direction) (the lower surface of the battery module 10 in its assembled state). In Embodiment 1, as in... Figure 13 As shown, when viewed from above, the circuit board 72 is generally rectangular in shape, and its shape is designed to roughly correspond to the inner periphery of the integrally formed part 102. Specifically, the circuit board 72 is formed such that its front-to-back dimension is larger than its left-to-right dimension, and a through hole 110 is formed in the middle portion of the circuit board 72 in the front-to-back direction, extending through the circuit board 72 along the thickness direction. In Embodiment 1, a plurality of through holes 110 are formed, and each through hole 110 is spaced apart from each other in the front-to-back direction.

[0055] The circuit board 72, as described below, can be assembled into the integral molded part 102. The aforementioned plurality of through holes 110 are provided in the portion of the circuit board 72 located between the input-side busbar 80 and the output-side busbar 84. Particularly in Embodiment 1, in the portion of the circuit board 72 near the input-side busbar 80 (i.e., the left end of the middle portion in the front-rear direction of the circuit board 72), the plurality of input-side through holes 110a are spaced apart from each other in the front-rear direction. Furthermore, in the portion of the circuit board 72 near the output-side busbar 84 (i.e., the right end of the middle portion in the front-rear direction of the circuit board 72), the plurality of output-side through holes 110b are spaced apart from each other in the front-rear direction.

[0056] Furthermore, copper foil pads are formed around each of the input-side and output-side through-holes 110a and 110b. Multiple pads formed around each input-side through-hole 110a constitute an input-side conductive path 74, and multiple pads formed around each output-side through-hole 110b constitute an output-side conductive path 76. Specifically, a resist layer (not shown) is provided on the surface of the circuit board 72 (e.g., both sides in the thickness direction). Multiple through-holes provided in the resist layer expose at least one side of the circuit board 72 in the thickness direction. Furthermore, the input-side and output-side conductive paths 74 and 76 are constructed using the aforementioned multiple pad portions. By merging the source terminals and gate terminals of the input-side and output-side semiconductor relays 68 and 70 with the multiple pad portions and performing soft soldering, the input-side and output-side conductive paths 74 and 76 can be electrically connected to the input-side and output-side semiconductor relays 68 and 70.

[0057] Furthermore, the aforementioned input-side conductive path 74 and output-side conductive path 76 are connected via the aforementioned bridging bus 66. Specifically, with respect to the other side of the circuit board 72 in the thickness direction (the upper surface of the battery module 10 in its assembled state), coinciding with the bridging bus 66, each input-side protrusion 104 in the bridging bus 66 is inserted into each input-side through hole 110a, and each output-side protrusion 106 in the bridging bus 66 is inserted into each output-side through hole 110b. Thus, on one side of the circuit board 72 (the lower surface of the battery module 10 in its assembled state), the protruding end faces of each input-side protrusion 104 and each output-side protrusion 106 are exposed. In other words, the protruding end faces of each input-side protrusion 104 are exposed at the plurality of pad portions constituting the input-side conductive path 74, and the protruding end faces of each output-side protrusion 106 are exposed at the plurality of pad portions constituting the output-side conductive path 76. In this state, it is preferable that the protruding end faces of each pad portion and each input side and each output side protrusion 104, 106 are located on the same plane.

[0058] And, as well as Figure 14 As shown, relative to each pad portion constituting the input-side conductive path 74 and the output-side conductive path 76, a bonding piece 112 made of copper foil or the like is overlapped from one side of the circuit board 72 (below the assembled state of the battery module 10), and each pad portion is welded to the protruding end face of each input-side and output-side protrusion 104, 106 using a method such as laser welding. Thus, the input-side conductive path 74 and the output-side conductive path 76 are electrically connected via a bridging bus 66.

[0059] Furthermore, a second intermediate terminal connection hole 114 is formed at the front end of the circuit board 72, extending through the thickness direction (vertical direction) of the circuit board 72. This second intermediate terminal connection hole 114 is connected to the second intermediate terminal 34 by inserting the end-side connection portion 40 of the aforementioned second intermediate terminal 34. Additionally, a first intermediate terminal connection hole 116 is formed at the rear end of the circuit board 72, extending through the thickness direction of the circuit board 72. This first intermediate terminal connection hole 116 is connected to the first intermediate terminal 32 by inserting the end-side connection portion 40 of the aforementioned first intermediate terminal 32. Furthermore, when the circuit board 72 is assembled on the integrally formed member 102, the base terminal connection hole 92 and the second intermediate terminal connection hole 114 are located separated from each other in the left-right direction at the front end portion of the assembly, and the end terminal connection hole 98 and the first intermediate terminal connection hole 116 are located separated from each other in the left-right direction at the rear end portion.

[0060] Furthermore, the connection between the second intermediate terminal connection hole 114 and the end-side connection portion 40 in the second intermediate terminal 34, and the connection between the first intermediate terminal connection hole 116 and the end-side connection portion 40 in the first intermediate terminal 32, are achieved by welding using the same bonding piece 117 as the bonding piece 112 described above. That is, the end-side connection portion 40 in the second intermediate terminal 34 is inserted into the second intermediate terminal connection hole 114 from below, so that the upper end surface of the end-side connection portion 40 is exposed on the upper surface of the circuit board 72. Preferably, the upper end surface of the end-side connection portion 40 is on the same plane as the upper surface of the circuit board 72. The bonding piece 117 is then overlapped with the second intermediate terminal connection hole 114 from above and welded using methods such as laser welding, thereby electrically connecting the second intermediate terminal connection hole 114 and the end-side connection portion 40 in the second intermediate terminal 34. The electrical connection between the first intermediate terminal connection hole 116 and the end-side connection portion 40 in the first intermediate terminal 32 is achieved in the same way. As described below, the first voltage detection line 118 is formed by connecting the end-side connection portion 40 in the first intermediate terminal 32 to the first intermediate terminal connection hole 116 in the circuit board 72. Similarly, the second voltage detection line 119 is formed by connecting the end-side connection portion 40 in the second intermediate terminal 34 to the second intermediate terminal connection hole 114 in the circuit board 72.

[0061] In Embodiment 1, a substrate connector 120 is mounted on the upper surface (other side) of the circuit board 72. This substrate connector 120 is electrically connected to an electrical circuit (not shown) on the circuit board 72. Furthermore, the electrical circuit on the circuit board 72 is also electrically connected to the first intermediate terminal connection hole 116 and the second intermediate terminal connection hole 114. Thus, the first and second voltage detection lines 118 and 119 are electrically connected to the substrate connector 120 via the electrical circuit (not shown) on the circuit board 72. In the assembled state of the battery module 10, the substrate connector 120 is exposed to the outside through a through hole 57 in the heat sink 50. By connecting external wires or the like to the substrate connector 120, the first and second voltage detection lines 118 and 119 can be connected to external wires or the like. As a result, the voltage at a predetermined location in the current path 16 can be detected (detected) using an external device via the first and second voltage detection lines 118 and 119.

[0062] (Battery cell section 22) Also Figure 6As shown, the battery unit 22 includes the aforementioned first to third battery cells 12a to 12c, first to third battery housings 121a to 121c that respectively house each battery cell 12a to 12c, and a frame 122 that houses the battery cells 12a to 12c and the battery housings 121a to 121c. Furthermore, the battery unit 22 includes connection terminals 18 (base terminal 28, end terminal 30, first intermediate terminal 32, and second intermediate terminal 34), through which the battery cells 12a to 12c housed in the battery housings 121a to 121c are connected.

[0063] Each battery casing 121a to 121c is formed with the same shape, and each is generally box-shaped with an upward opening. Each battery casing 121a to 121c is formed of an insulating synthetic resin and is sized to accommodate each battery cell 12a to 12c. That is, each battery casing 121a to 121c is generally rectangular in shape when viewed from above, and is arranged with its front-to-back dimension larger than its left-to-right dimension. Each battery casing 121a to 121c has a generally rectangular bottom wall portion 124 that is larger than each battery cell 12a to 12c, and has a peripheral wall portion 126 that protrudes upward from the outer periphery of the bottom wall portion 124.

[0064] Each of the battery housings 121a to 121c has a bottomed circular recess 128 formed at both ends along its length (front-to-back direction) to accommodate the base-side connection portion 38 of each connection terminal 18. The inner diameter of the circular recess 128 is the same as or slightly larger than the outer diameter of each base-side connection portion 38. Specifically, two circular recesses 128 are formed at the front and rear ends of each of the battery housings 121a to 121c, for a total of four circular recesses 128 in each of the battery housings 121a to 121c. More specifically, a first circular recess 128a is formed on the left side and a second circular recess 128b is formed on the right side of the front end of each of the battery housings 121a to 121c, and the first and second circular recesses 128a and 128b are separated from each other in the left-right direction. In addition, a third circular recess 128c is formed on the left side of the rear end of each battery casing 121a to 121c and a fourth circular recess 128d is formed on the right side. The third and fourth circular recesses 128c and 128d are separated from each other in the left-right direction.

[0065] A through hole 129 extending vertically through the bottom of each circular recess 128 is formed in the central portion of the bottom. The inner diameter of each through hole 129 is the same as or slightly larger than the outer diameter of the larger diameter portion of each connecting terminal 18 (the outer diameter of the insulating member 42 in the base terminal 28 and the end terminal 30, and the outer diameter of the larger diameter portion of the protrusion 36 in the first intermediate terminal 32 and the second intermediate terminal 34), and smaller than the outer diameter of each base-side connecting portion 38. Thus, each connecting terminal 18 is configured to accommodate each base-side connecting portion 38 in each circular recess 128a to 128d and to allow insertion through the through hole 129 located above each circular recess 128a to 128d.

[0066] Furthermore, each battery cell 12a-12c has a buffer member 130 overlapping the bottom wall portion 124 of each battery casing 121a-121c, and each battery cell 12a-12c is housed in each battery casing 121a-121c with the buffer member 130 provided on each bottom wall portion 124. In other words, each buffer member 130 is provided between the main body portion 24 of each battery cell 12a-12c and the opposing surface of the bottom wall portion 124 of each battery casing 121a-121c. The aforementioned buffer member 130 is formed of an elastic element such as rubber or an elastomer, and is preferably disposed in a substantially compressed state between the main body portion 24 and the bottom wall portion 124 in the vertical direction.

[0067] Furthermore, with each battery cell 12a-12c housed in each battery casing 121a-121c, the covers 132 are overlapped from above to cover the upper openings of each battery casing 121a-121c. Each cover 132 is a generally rectangular plate-shaped component that can cover the upper opening of each battery casing 121a-121c, and is made of, for example, synthetic resin. In each cover 132, first to fourth circular insertion holes 134a-134d are formed at positions corresponding to the first to fourth circular recesses 128a-128d of each battery casing 121a-121c, for insertion of each connecting terminal 18 (base terminal 28, first intermediate terminal 32, second intermediate terminal 34, and end terminal 30).

[0068] Furthermore, on the lower surface of each cover 132 and around the periphery of each circular insertion hole 134a-134d, a generally cylindrical electrode tab abutment portion 136 protruding downwards is provided. That is, each of the circular insertion holes 134a-134d is configured to include the inner hole of each electrode tab abutment portion 136. The inner diameter of each of the circular insertion holes 134a-134d is approximately equal to the inner diameter of each of the circular recesses 128a-128d, and is the same as or slightly larger than the outer diameter of each base-side connection portion 38 in each connection terminal 18. Thus, with each battery cell 12a to 12c housed in each battery casing 121a to 121c and each connecting terminal 18 positioned at an appropriate position in each circular recess 128a to 128d, and each cover 132 overlapped from above, each connecting terminal 18 is inserted into each circular insertion hole 134a to 134d in each cover 132.

[0069] Furthermore, the lower surface of each electrode tab abutting portion 136 abuts against the portion surrounding the terminal insertion hole 26 in each electrode tab 14 (+ side electrode tab 14a and - side electrode tab 14b) and presses it from above, so that each electrode tab 14 is in close contact with the upper surface of the base end side connecting portion 38 in each connecting terminal 18. With each connecting terminal 18 inserted through each circular insertion hole 134a-134d, the portion surrounding each terminal insertion hole 26a-26d in each electrode tab 14 is exposed upwards through each circular insertion hole 134a-134d. Therefore, the portion surrounding each terminal insertion hole 26a-26d can be welded to the upper surface of each base end side connecting portion 38 from above through each circular insertion hole 134a-134d. In addition, each battery casing 121a-121c and each cover 132 can be fixed to each other by bonding, welding, pressing or interlocking (not shown), or they can be left unfixed.

[0070] Furthermore, the frame 122 is generally box-shaped with an upward opening (having an upward opening portion 138), and is formed from a rigid material such as metal or synthetic resin. Viewed from above, the frame 122 is generally rectangular and has a bottom wall portion 140 that is larger than each battery casing 121a-121c. Additionally, an upwardly protruding peripheral wall portion 142 is provided on the outer periphery of the bottom wall portion 140. Furthermore, with the first to third battery cells 12a-12c and the first to third battery casings 121a-121c housed in the frame 122, a [transportation method] is used to [transport] the battery cells from above the cover 132 in the third battery casing 121c. Figure 18 The waterproof adhesive 144 shown is used to overlap the aforementioned power unit section 20 to cover the upper opening 138 in the frame 122, thereby constituting the battery module 10 of Embodiment 1.

[0071] (Assembly process of battery module 10) Next, especially showing Figures 12-19 This will illustrate a specific example of the assembly process of the battery module 10. However, the assembly process of the battery module 10 is not limited to the description below.

[0072] First, such as Figure 12 As shown, with the input-side stud 78, input-side busbar 80, output-side stud 82, output-side busbar 84, grounding-side stud 86, and grounding busbar 88 installed in the molding chamber of the frame 101, resin material of the frame 101 is injected into the molding chamber to perform molding, thereby obtaining an integrally molded part 102 of the frame 101 that integrally has a power input-side conductor 58, a power output-side conductor 60, and a grounding wire 62.

[0073] After that, as Figure 13 As shown, the circuit board 72 is assembled from one side of the integral molded part 102 in the thickness direction (the lower surface side of the battery module 10 in the assembled state), and the jumper bus 66 is assembled from the other side of the circuit board 72 in the thickness direction (the upper side of the battery module 10 in the assembled state). Furthermore, the integral molded part 102 and the circuit board 72 can be fixed using known fixing methods, such as adhesive bonding or thread fastening. The jumper bus 66 is assembled relative to the circuit board 72 by inserting the input-side and output-side protrusions 104 and 106 of the jumper bus 66 into the input-side and output-side through holes 110a and 110b respectively provided in the circuit board 72. The input-side and output-side protrusions 104 and 106 can be inserted into the input-side and output-side through holes 110a and 110b in a substantially pressed-in state. By inserting the aforementioned input-side and output-side protrusions 104 and 106 into the input-side and output-side through holes 110a and 110b, the protruding end faces of the input-side and output-side protrusions 104 and 106 are exposed on one side of the circuit board 72. Specifically, the protruding end faces of the input-side and output-side protrusions 104 and 106 are located on the same plane as one side of the circuit board 72. Furthermore, in Figure 13 In the process, the integrally formed part 102 and other components are formed from... Figure 12 The state shown is flipped upside down. Additionally, the substrate connector 120 can be mounted on the circuit board 72 at any time.

[0074] Then, as Figure 14As shown, with the protruding end faces of each input-side protrusion 104 exposed from the center of each pad constituting the input-side conductive path 74, the bonding tab 112 is overlapped with each pad and welded using laser welding or the like. Similarly, with the protruding end faces of each output-side protrusion 106 exposed from the center of each pad constituting the output-side conductive path 76, the bonding tab is overlapped with each pad and welded using laser welding or the like. Thus, as Figure 14 As shown in the central figure, the input-side conductor 74 and the output-side conductor 76 are connected via a bridging bus 66. Then, as... Figure 14 As shown in the right figure, each input-side semiconductor relay 68 is mounted across the input-side conductive path 74 and the input-side bus 80 in the power input-side conductor 58, and each output-side semiconductor relay 70 is mounted across the output-side conductive path 76 and the output-side bus 84 in the power output-side conductor 60. Specifically, the source and gate terminals of each input-side semiconductor relay 68 are aligned with the input-side conductive path 74, and the drain terminal of each input-side semiconductor relay 68 is aligned with the input-side bus 80, thereby performing reflow soldering. Similarly, the source and gate terminals of each output-side semiconductor relay 70 are aligned with the output-side conductive path 76, and the drain terminal of each output-side semiconductor relay 70 is aligned with the output-side bus 84, thereby performing reflow soldering. Thus, the power input-side conductor 58 and the power output-side conductor 60 are electrically connected via each input-side semiconductor relay 68, each output-side semiconductor relay 70, and the bridging bus 66. Figure 14 The assembly shown in the right image is flipped up and down to form... Figure 5 The substrate assembly 48 shown is shown in the figure.

[0075] Next, as Figures 7-10 As shown, insulating members 42 are inserted externally into each of the protrusions 36 constituting the base terminal 28, the end terminal 30, the first intermediate terminal 32, and the second intermediate terminal 34 to form the base terminal 28, the end terminal 30, the first intermediate terminal 32, and the second intermediate terminal 34. Furthermore, as... Figure 15 As shown, the buffer 130 is attached to the bottom wall 124 of the first battery housing 121a, for example, using double-sided tape. Furthermore, the base-side connecting portion 38 of the base terminal 28 is inserted into the first circular recess 128a in the first battery housing 121a, causing the base terminal 28 to be positioned in an upward protruding state. Similarly, the base-side connecting portion 38 of the first intermediate terminal 32 is inserted into the third circular recess 128c, causing the first intermediate terminal 32 to be positioned in an upward protruding state.

[0076] Next, the first battery cell 12a is brought close to the first battery casing 121a from above, and the base terminal 28 and the first intermediate terminal 32 are inserted into the first terminal insertion hole 26a and the third terminal insertion hole 26c, thereby aligning the main body 24 of the first battery cell 12a with the buffer member 130 in the vertical direction. Then, the cover 132 is brought close to the first battery cell 12a from above, and the base terminal 28 and the first intermediate terminal 32 are inserted into the first circular insertion hole 134a and the third circular insertion hole 134c, using the cover 132 to cover the upper opening of the first battery casing 121a. In this state, the electrode tabs 136 protruding downwards from the cover 132 press the portions surrounding the first terminal insertion hole 26a and the third terminal insertion hole 26c onto the upper surfaces of the base-side connecting portions 38 of the base terminal 28 and the first intermediate terminal 32. Furthermore, in this state, the upper portions of the base terminal 28 and the first intermediate terminal 32 protrude upwards from the first circular through-hole 134a and the third circular through-hole 134c, causing the portions surrounding the first terminal through-hole 26a and the third terminal through-hole 26c to be exposed upwards. This allows the first battery cell 12a to be housed between the first battery casing 121a and the cover 132.

[0077] Then, as Figure 15 As shown in the right figure, the first battery casing 121a, which houses the first battery cell 12a, is housed within the frame 122 such that it overlaps with the bottom wall 124 of the frame 122. Then, the portion surrounding the first terminal insertion hole 26a that overlaps with the base-side connection portion 38 of the base terminal 28 is welded using laser welding or the like via the first circular insertion hole 134a. Similarly, the portion surrounding the third terminal insertion hole 26c that overlaps with the base-side connection portion 38 of the first intermediate terminal 32 is welded using laser welding or the like via the third circular insertion hole 134c. The welded portions are then... Figure 3 , 4 The downward-pointing black triangle indicates this. Thus, the base terminal 28 and the first intermediate terminal 32 are electrically connected to the first battery cell 12a. Furthermore, by performing laser welding via the aforementioned first and third circular through-holes 134a and 134c, it is possible to prevent spatter (parts of molten metal flying off) generated during laser welding from adhering to the outer casing of the first battery cell 12a and causing damage to it.

[0078] Next, as Figure 16As shown, the buffer 130 is attached to the bottom wall 124 of the second battery housing 121b, and the base-side connecting portion 38 of the second intermediate terminal 34 is inserted into the second circular recess 128b, so that the second intermediate terminal 34 is positioned in a protruding upward state. Then, the second battery cell 12b is brought close to the second battery housing 121b from above, and the second intermediate terminal 34 is inserted into the third terminal insertion hole 26c. The upper opening of the second battery housing 121b is covered by the cover 132. In this state, similarly as described above, the electrode tab abutment portion 136 in the cover 132 presses the portion around the third terminal insertion hole 26c against the upper surface of the base-side connecting portion 38 in the second intermediate terminal 34. Furthermore, in this state, the upper portion of the second intermediate terminal 34 protrudes upward from the second circular insertion hole 134b, and the portion around the third terminal insertion hole 26c is exposed upward through the second circular insertion hole 134b. Thus, the second battery cell 12b is housed between the second battery casing 121b and the cover 132.

[0079] Then, as Figure 16 As shown in the right figure, the second battery housing 121b, which houses the second battery cell 12b, is housed within the frame 122, overlapping the cover 132 in the first battery housing 121a. At this time, the upper portion of the base terminal 28, protruding upwards from the first battery housing 121a, passes through the through hole 129, the fourth terminal insertion hole 26d, and the first circular insertion hole 134a in the cover 132, protruding upwards from the second battery housing 121b. Similarly, the upper portion of the first intermediate terminal 32, protruding upwards from the first battery housing 121a, passes through the through hole 129 in the second battery housing 121b, but the portion around the second terminal insertion hole 26b rests on the intermediate connecting portion 44 of the first intermediate terminal 32. Furthermore, the portion of the upper part of the first intermediate terminal 32 that is configured with a small diameter protrudes upward toward the second battery housing 121b through the second terminal insertion hole 26b and the third circular insertion hole 134c in the cover 132.

[0080] Next, the portion surrounding the third terminal through-hole 26c and overlapping the base-side connection portion 38 of the second intermediate terminal 34 is welded using laser welding or the like via the second circular through-hole 134b. Additionally, the portion surrounding the second terminal through-hole 26b and overlapping the intermediate connection portion 44 of the first intermediate terminal 32 is welded using laser welding or the like via the third circular through-hole 134c. The welded portions are then... Figure 3 , 4The downward-pointing black triangle indicates this. Thus, the first intermediate terminal 32 and the second intermediate terminal 34 are electrically connected relative to the second battery cell 12b. Furthermore, since an insulating member 42 is provided in the portion of the base terminal 28 that penetrates the second battery housing 121b, the base terminal 28 is not electrically connected to the second battery cell 12b. Additionally, laser welding is performed via the second and third circular through holes 134b and 134c as described above, thereby preventing the scattering of spatter.

[0081] Next, as Figure 17 As shown, the buffer 130 is attached to the bottom wall 124 of the third battery housing 121c, and the base-side connecting portion 38 of the end terminal 30 is inserted into the fourth circular recess 128d, so that the end terminal 30 is positioned in a protruding upward state. Then, the third battery cell 12c is brought close to the third battery housing 121c from above, and the end terminal 30 is inserted into the fourth terminal insertion hole 26d. The upper opening of the third battery housing 121c is covered by the cover 132. In this state, similarly as described above, the electrode tab abutment portion 136 in the cover 132 presses the portion around the fourth terminal insertion hole 26d against the upper surface of the base-side connecting portion 38 in the end terminal 30. Furthermore, in this state, the upper portion of the end terminal 30 protrudes upward from the fourth circular insertion hole 134d, exposing the portion around the fourth terminal insertion hole 26d upward through the fourth circular insertion hole 134d. Thus, the third battery cell 12c is housed between the third battery casing 121c and the cover 132.

[0082] Then, as Figure 17As shown in the right figure, the third battery housing 121c, which houses the third battery cell 12c, is housed within the frame 122, overlapping the cover 132 in the second battery housing 121b. At this time, the upper portion of the base terminal 28, protruding upwards from the second battery housing 121b, passes through the through hole 129 in the third battery housing 121c, the first terminal insertion hole 26a, and the first circular insertion hole 134a in the cover 132, protruding upwards from the third battery housing 121c. Similarly, the upper portion of the first intermediate terminal 32, protruding upwards from the second battery housing 121b, passes through the through hole 129 in the third battery housing 121c, the third terminal insertion hole 26c, and the third circular insertion hole 134c in the cover 132, protruding upwards from the third battery housing 121c. Furthermore, the upper portion of the second intermediate terminal 34, which protrudes upward from the second battery housing 121b, passes through the through hole 129 in the third battery housing 121c and protrudes upward, while the portion around the second terminal insertion hole 26b rests on the intermediate connecting portion 44 of the second intermediate terminal 34. Also, the portion of the upper portion of the second intermediate terminal 34 that is configured with a small diameter passes through the second terminal insertion hole 26b and the second circular insertion hole 134b in the cover 132 and protrudes upward into the third battery housing 121c.

[0083] Next, the portion surrounding the fourth terminal through-hole 26d and overlapping the base-side connection portion 38 in the end terminal 30 is welded using laser welding or the like via the fourth circular through-hole 134d. Additionally, the portion surrounding the second terminal through-hole 26b and overlapping the intermediate connection portion 44 in the second intermediate terminal 34 is welded using laser welding or the like via the second circular through-hole 134b. The welded portions are then... Figure 3 , 4 The downward-pointing black triangle indicates this. Thus, the second intermediate terminal 34 and the end terminal 30 are electrically connected to the third battery cell 12c. Furthermore, since insulating members 42 are provided in the portions of the base terminal 28 and the first intermediate terminal 32 that penetrate the third battery housing 121c, the base terminal 28 and the first intermediate terminal 32 are not electrically connected to the third battery cell 12c. Additionally, by performing laser welding via the second and fourth circular through holes 134b and 134d as described above, the scattering of spatter is prevented.

[0084] Thus, with the first to third battery cells 12a to 12c housed in the frame 122, as follows: Figure 18As shown, the aforementioned substrate assembly 48 is overlapped from above the cover 132 in the third battery housing 121c via a waterproof adhesive 144, thereby housing the substrate assembly 48 within the frame 122 and fixing it to the cover 132 of the third battery housing 121c. Consequently, the end-side connection portion 40 of the base terminal 28 protruding upward from the third battery housing 121c is inserted into the base terminal connection hole 92 of the substrate assembly 48, electrically connecting the base terminal 28 to the power input conductor 58. Similarly, the end-side connection portion 40 of the end terminal 30 protruding upward from the third battery housing 121c is inserted into the end terminal connection hole 98 of the substrate assembly 48, electrically connecting the end terminal 30 to the power output conductor 60. Furthermore, the end-side connection portion 40 of the first intermediate terminal 32 protruding upward from the third battery housing 121c is inserted into the first intermediate terminal connection hole 116 of the substrate assembly 48. Furthermore, the end-side connection portion 40 of the second intermediate terminal 34, which protrudes upward from the third battery casing 121c, is inserted into the second intermediate terminal connection hole 114 of the substrate assembly 48. In this state, the upper end surfaces of the end-side connection portions 40 of the base terminal 28, the end terminal 30, and the first and second intermediate terminals 32 and 34 are located on the same plane as the upper surface of the circuit board 72.

[0085] And, as Figure 18 As shown, at the connection point between the end-side connecting portion 40 of the first intermediate terminal 32 and the first intermediate terminal connecting hole 116, the bonding piece 117 is overlapped from above and welded using laser welding or the like. This electrically connects the first intermediate terminal 32 to the electrical circuitry in the circuit board 72. Similarly, at the connection point between the end-side connecting portion 40 of the second intermediate terminal 34 and the second intermediate terminal connecting hole 114, the bonding piece 117 is overlapped from above and welded using laser welding or the like. This electrically connects the second intermediate terminal 34 to the electrical circuitry in the circuit board 72. The welded portions are then... Figure 3 , 4 The downward-pointing black triangle in the image represents this.

[0086] After that, as Figure 19 As shown, heat sinks 52 are overlapped on the input bus 80, output bus 84, and bridging bus 66 of the substrate assembly 48, respectively. A waterproof adhesive 54 is applied to the outer periphery of the substrate assembly 48 to bond the heat sink 50 to the top of the substrate assembly 48. At this time, the substrate connector 120 on the circuit board 72 protrudes outward (upward) through the through-hole 57 in the heat sink 50. Thus, the process is completed. Figures 1-4 Battery module 10 shown.

[0087] In the battery module 10 manufactured as described above, the base terminal 28 and the first intermediate terminal 32 are electrically connected to the first battery cell 12a. The base terminal 28 is connected to the power input side conductor 58 via the base terminal connection hole 92, and the power input side conductor 58 can be connected to external wires or the like via the input side stud 78. The first intermediate terminal 32 is electrically connected to the first battery cell 12a and also to the second battery cell 12b, and the end-side connection portion 40 is electrically connected to the substrate connector 120 in the circuit board 72 via the connection hole 116 of the first intermediate terminal. The first intermediate terminal 32 and the second intermediate terminal 34 are electrically connected to the second battery cell 12b. The second intermediate terminal 34 is electrically connected to the second battery cell 12b and also to the third battery cell 12c, and the end-side connection portion 40 is electrically connected to the substrate connector 120 in the circuit board 72 via the connection hole 114 of the second intermediate terminal. The second intermediate terminal 34 and the end terminal 30 are electrically connected to the third battery cell 12c. The end terminal 30 is connected to the grounding wire 62 through the end terminal connection hole 98, and the grounding wire 62 can be connected to external wires, etc. via the grounding side stud 86.

[0088] In addition, the input bus 80 in the power input side conductor 58 is electrically connected to the output bus 84 in the power output side conductor 60 via the input side semiconductor relay 68, the input side conductive path 74, the bridging bus 66, the output side conductive path 76, and the output side semiconductor relay 70.

[0089] In summary, in the battery module 10 of Embodiment 1, each battery cell 12a to 12c is connected in series via each connection terminal 18 (base terminal 28, end terminal 30, first intermediate terminal 32, and second intermediate terminal 34). The base terminal 28 is electrically connected to the input-side stud 78, and the end terminal 30 is electrically connected to the ground-side stud 86. Thus, the current path 16 from the input-side stud 78 to the ground-side stud 86 is configured to include the series-connected battery cells 12a to 12c and each connection terminal 18. Furthermore, the base terminal 28, end terminal 30, and first and second intermediate terminals 32 and 34 in this current path 16 have input-side voltage detection lines 99, ground-side voltage detection lines 100, and first and second voltage detection lines 118 and 119 branching from the current path 16. The voltages on both sides of each battery cell 12a to 12c can be detected via the aforementioned voltage detection lines 99, 100, 118, and 119.

[0090] Furthermore, the input-side conductive path 74 and the output-side conductive path 76 are electrically connected via the input-side semiconductor relay 68, the bridging bus 66, and the output-side semiconductor relay 70. The input-side and output-side semiconductor relays 68 and 70 are used to switch the energization of the input-side conductive path 74 and the output-side conductive path 76 via the bridging bus 66. Under normal conditions, by setting the input-side and output-side semiconductor relays 68 and 70 to the off state, a current path 16 is formed from the input-side stud 78 to the ground-side stud 86 as described above. On the other hand, when the main power supply fails, power input from the input side becomes impossible. Furthermore, by setting the input-side and output-side semiconductor relays 68 and 70 to the on state, a current path 16 is formed from the ground-side stud 86 to the base terminal 28, and then via the input-side bus 80, the input-side semiconductor relay 68, the bridging bus 66, the output-side semiconductor relay 70, and the output-side bus 84 to the output-side stud 82. Thus, power is output through external wires or the like connected to the output-side stud 82.

[0091] More specifically, under normal conditions, current flows through the aforementioned current path 16 from the input-side stud 78 to the ground-side stud 86, thereby charging each battery cell 12a-12c. In the input-side voltage detection line 99 and the ground-side voltage detection line 100, voltage can be detected via external wires connected to the input-side stud 78 and the ground-side stud 86, respectively. Furthermore, in the first and second voltage detection lines 118 and 119, voltage can be detected via external wires connected to the substrate connector 120, respectively. On the other hand, when the main power supply fails, current flows through the aforementioned current path 16 from the ground-side stud 86 to the output-side stud 82, thereby releasing the electrical energy of each charged battery cell 12a-12c. In this state, in addition to the external wires connected to the ground-side stud 86 and the substrate connector 120, the voltage at a predetermined position in the current path 16 can also be detected via external wires connected to the output-side stud 82, respectively.

[0092] According to the battery module 10 of Embodiment 1 with the above-described structure, the base terminal 28, the end terminal 30, the first intermediate terminal 32, and the second intermediate terminal 34 are used as connection terminals 18, thereby allowing the individual battery cells 12a to 12c to be connected in series via the aforementioned terminals 28, 30, 32, and 34. Furthermore, under normal conditions, the first and second voltage detection lines 118 and 119 are formed via the first and second intermediate terminals 32 and 34, and the voltage is detected from the input-side stud 78 and the ground-side stud 86 via the base terminal 28 and the end terminal 30, thereby allowing the voltage at both sides of each battery cell 12a to 12c to be measured. This allows confirmation of whether the charging is balanced among the battery cells 12a to 12c, and enables approximately uniform charging among the battery cells 12a to 12c. Furthermore, in the event of a main power failure, in addition to the first and second voltage detection lines 118 and 119 and the grounding stud 86, voltage is also detected from the output stud 82. This allows for the measurement of the voltage at both sides of each battery cell 12a-12c, enabling monitoring of the heat dissipation status of each battery cell 12a-12c. In other words, both the connection of each battery cell 12a-12c and voltage detection can be achieved through terminals 28, 30, 32, and 34, thereby reducing the number of components and operating time.

[0093] In particular, the protruding portions 36 of the base terminal 28, the end terminal 30, and the first and second intermediate terminals 32 and 34 are each covered by the insulating member 42 for a predetermined length, preventing electrical connection. Therefore, in each of the terminals 28, 30, 32, and 34, the portions that are not intended to be connected to the individual battery cells 12a-12c can be covered by the insulating member 42 to prevent electrical connection, while the portions that are intended to be connected to the individual battery cells 12a-12c are exposed through the insulating member 42 to allow electrical connection. Furthermore, by achieving electrical connection at predetermined locations in each of the terminals 28, 30, 32, and 34, the individual battery cells 12a-12c can be sequentially assembled into the frame 122 from bottom to top while housed within the battery casings 121a-121c. This improves the manufacturing efficiency of the battery module 10. In particular, by making the portions of the base terminal 28, the end terminal 30, and the first and second intermediate terminals 32 and 34 that constitute the current path 16 larger in diameter, a battery module 10 capable of handling large currents can be provided.

[0094] In embodiment 1, the power input side conductor 58 and the power output side conductor 60 are connected via a relay 64. By providing such a relay 64, the connection between the power input side conductor 58 and the power output side conductor 60 can be switched between normal operation and mains power failure.

[0095] In particular, in embodiment 1, the relay 64 is configured to include input-side and output-side semiconductor relays 68 and 70, and a bridging bus 66. That is, the input-side semiconductor relay 68 and the output-side semiconductor relay 70 are connected via the bridging bus 66 rather than simply via the electrical circuitry of the circuit board 72, thereby enabling stable handling of large currents.

[0096] The input-side and output-side conductive paths 74 and 76 in the circuit board 72 have input-side and output-side through holes 110a and 110b, and the bridging bus 66 has input-side and output-side protrusions 104 and 106. By inserting the input-side and output-side protrusions 104 and 106 into the input-side and output-side through holes 110a and 110b and soldering them with bonding pads 112, the input-side and output-side conductive paths 74 and 76 can be electrically connected to the bridging bus 66. This allows for a stable electrical connection between the input-side and output-side conductive paths 74 and 76 via the bridging bus 66. Furthermore, the input-side and output-side semiconductor relays 68 and 70 generate heat when energized with a large current; however, heat sinks 50 are superimposed on the input-side and output-side buses 80 and 84 and the bridging bus 66 connected to the input-side and output-side semiconductor relays 68 and 70 via heat sinks 52. Therefore, the heat generated by the input and output semiconductor relays 68 and 70 can be dissipated through the heat sink 50.

[0097] (Modified example) The above detailed description of Embodiment 1, as a specific example of this disclosure, is not limited to these specific descriptions. Modifications and improvements within the scope of achieving the purpose of this disclosure are included in this disclosure. For example, modifications of the embodiments as described below are also included within the technical scope of this disclosure.

[0098] (1) In the above embodiment, the upper portions of the first and second intermediate terminals 32 and 34 are set to have a smaller diameter than the lower portions, but this is not a limitation. As mentioned above, the base terminal 28, the end terminal 30, and the lower portions of the first and second intermediate terminals 32 and 34 constitute the current path 16, and it is preferable to have a larger diameter to enable the passage of a large current. On the other hand, the upper portions of the first and second intermediate terminals 32 and 34 are provided for voltage detection purposes, so they can be set to have a smaller diameter. This also enables the first and second intermediate terminals to be lightweight, etc., but the protrusions in the first and second intermediate terminals can also have a relatively large outer diameter, just like the base terminal and the end terminal, and are set to a roughly constant outer diameter throughout their entire length. In addition, by making the upper portion of the first and second intermediate terminals smaller than the lower portion and making the inner diameter of the terminal insertion hole in the electrode tab different, as in the above embodiment, misassembly when connecting individual battery cells in series can be prevented. Furthermore, when the battery module of this disclosure is not used for high current applications, the base terminal, the end terminal, and the first and second intermediate terminals can all be configured with relatively small diameters. Additionally, in this case, the relay installed in the battery module does not necessarily need to be a semiconductor relay.

[0099] (2) The battery module 10 in the above embodiment is provided with three battery cells 12 (first to third battery cells 12a to 12c), but in the battery module of this disclosure, the number of battery cells is not limited to three, for example, it can be four or more. For example, the battery module may also have a first battery cell, multiple second battery cells and a third battery cell. Explanation of reference numerals in the attached figures

[0100] 10 battery modules 12 battery cells 12a First Cell 12b second cell 12c third battery cell 14 electrode tabs 14a+ side electrode protrusion 14b - Side electrode protrusion 16 Current Paths 18 connection terminals 20 Power Supply Units 22 Battery Cell Section 24 main body sections 26-terminal through hole 26a First terminal insertion hole 26b Second Terminal Through Hole 26c Third Terminal Through Hole 26d fourth terminal through hole 28 base terminals 30 end terminal 32 First intermediate terminal (intermediate terminal) 34 Second intermediate terminal (intermediate terminal) 36 protruding parts 38 Base end side connection part 40 End-side connection part 42 Insulating Components 44 Intermediate connecting part 46-step surface 48 substrate assembly 50 radiator 52 heatsinks 54 Waterproof Adhesive 56 fins 57 Through Hole 58 power input side conductor 60 power output side conductor 62 grounding wire 64 relays 66 jumper busbar 68-input-side semiconductor relay 70 Output-side semiconductor relay 72 Circuit Board 74 Input Side Conductive Circuit 76 Output Side Conductor Circuit 78 Input Side Studs 80 Input Side Bus 82 Output Side Studs 84 Output side bus 86 Grounding Side Stud 88 grounding busbar 90 bolt through hole 92 base terminal connection hole 94 and 96 bolts through holes 98 end terminal connection hole 99 Input side voltage detection line 100 Grounding Side Voltage Detection Line 101 Framework 102 One-piece molded part 104 Input Side Convex 106 Output Side Protrusion 108 base part 110 through hole 110a Input Side Through Hole 110b Output Side Through Hole 112 joint piece 114 Second intermediate terminal connection hole 116 First intermediate terminal connection hole 117 joint piece 118 First Voltage Detection Line 119 Second Voltage Detection Line 120 baseboard connector 121a First Battery Casing 121b Second Battery Casing 121c third battery casing 122 frame 124 bottom wall 126 circumference wall 128 circular recesses 128a First circular recess 128b Second circular recess 128c Third circular recess 128d Fourth Circular Recess 129 through holes 130 buffer 132 masks 134a First circular through hole 134b Second Circular Through Hole 134c Third Circular Through Hole 134d Fourth Circular Through Hole 136 Electrode Protrusion Contact Part 138 opening above 140 bottom wall 142nd week wall 144 Waterproof Adhesive

Claims

1. A battery module, comprising: At least three battery cells are arranged in a series connection. A pair of electrode tabs are disposed in each of the battery cells; as well as Multiple connection terminals are connected to the electrode tabs to form a current path connecting the at least three battery cells, wherein... The pair of electrode tabs protrude from each of the battery cells on both sides in the intersecting direction that intersects with the arrangement direction of the plurality of battery cells. The at least three battery cells include a first battery cell, a second battery cell, and a third battery cell arranged sequentially from the base end side to the end side in the arrangement direction. The connection terminal includes a base terminal, an end terminal, and multiple intermediate terminals. The base terminal and the end terminal each include: a protrusion extending from the base side to the end side in the arrangement direction; a base-side connecting portion extending in a flange shape from the base side of the protrusion toward the outer periphery of the protrusion; and an end-side connecting portion disposed on the end side of the protrusion. Each of the intermediate terminals includes the protruding portion, the base-side connecting portion, the end-side connecting portion, and the intermediate connecting portion. The intermediate connecting portion is disposed between the base-side connecting portion and the end-side connecting portion and extends outward in a flange shape towards the outer periphery of the protruding portion. The base terminal is configured such that the base-side connection portion is electrically connected to the electrode tab on one side of the first battery cell in the crossing direction, the end-side connection portion is electrically connected to the power input side conductor, and the protruding portion penetrates the electrode tabs on one side of the other battery cells in an insulated state. The end terminal is configured such that the base-side connection portion is electrically connected to the electrode protrusion on the other side of the cross direction of the third battery cell, and the end-side connection portion is electrically connected to the grounding wire. The plurality of intermediate terminals include a first intermediate terminal and a second intermediate terminal. The first intermediate terminal is configured such that the base-side connection portion is electrically connected to the electrode tab on the other side of the crossing direction of the first battery cell, and while the protruding portion passes through the electrode tab on the other side of the crossing direction of the second battery cell in an insulated state, the intermediate connection portion is electrically connected to the electrode tab on the other side of the crossing direction of the second battery cell, and the end-side connection portion is connected to the circuit board, thereby forming a first voltage detection line. The second intermediate terminal is configured such that the base-side connection portion is electrically connected to the electrode tab on one side of the cross direction of the second battery cell, and the protruding portion passes through the electrode tab on one side of the cross direction of the third battery cell in an insulated state, while the intermediate connection portion is electrically connected to the electrode tab on one side of the cross direction of the third battery cell, and the end-side connection portion is connected to the circuit board, thereby forming a second voltage detection line. The current path connecting the first battery cell to the third battery cell in series is formed by the base terminal, the first intermediate terminal, the second intermediate terminal, and the end terminal.

2. The battery module according to claim 1, wherein, The protrusions of the base terminal, the first intermediate terminal, the second intermediate terminal, and the end terminal are each covered by an insulating member.

3. The battery module according to claim 1 or 2, wherein, The battery module has the following features: The power supply unit includes the power input conductor, the power output conductor, and the grounding wire; and The battery cell section includes the battery cell, the electrode tabs, and the connection terminals. The power supply unit section overlaps with the battery unit section. The power input conductor is connected to the power output conductor via a relay.

4. The battery module according to claim 3, wherein, The relay includes: A bridging bus is configured between the power input side conductor and the power output side conductor; An input-side semiconductor relay, connected to the power input-side conductor and the bridging bus, is used to switch the energized connection between the power input-side conductor and the bridging bus; and An output-side semiconductor relay is connected to the power output-side conductor and the bridging bus to switch the power supply between the power output-side conductor and the bridging bus on / off.

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