A busbar assembly including a busbar body formed from a wire assembly

Abstract

The present invention relates to a busbar assembly including a busbar body in the form of a wire assembly composed of a plurality of wires, and coupling portions at both ends of the busbar body for coupling with the wires. The busbar body is flexible and can be freely deformed, and has an improved cooling function.

Description

[Technical field]

[0001] This application claims the benefit of priority to Korean Patent Application No. 10-2022-0121727 filed on September 26, 2022, and all contents disclosed in the Korean Patent Application are incorporated herein by reference.

[0002] The present invention relates to a busbar assembly including a busbar body formed of a wire assembly, and more particularly to a busbar assembly including a busbar body formed of a wire assembly having an improved cooling function for preventing damage to a battery module or an electrical component due to a heat generation phenomenon. [Background technology]

[0003] A plurality of lithium secondary batteries are assembled together with a battery disconnect unit (BDU) assembly and a battery management system (BMS) to form a battery module or a battery pack. A connecting member such as a relay or a bus bar can be used to electrically connect these individual components.

[0004] Lithium secondary batteries generate heat during charging and discharging. When a connecting member such as a bus bar is heated by the heat generation, the resistance of the conductive material increases, which may cause a decrease in electrical conductivity. A vicious circle of temperature rise due to the increase in the resistance of the conductive material and the resulting increase in resistance may occur, and in the worst case, the connecting member may become inoperable.

[0005] Another problem that must be solved is that the busbar, which is used as an electrical connection means, is instead used as a heat transfer path. Ambient heat may be transferred to the power distribution device through the busbar. This may reduce the electrical conductivity of electrical components such as relays inside the power distribution device, thereby reducing the overall performance of the battery pack.

[0006] To solve the heat generation problem in battery modules and battery packs, methods are being considered to apply a cooling system using a refrigerant to the power distribution device or to cool individual components such as relays. Prediction technology to simulate temperature changes in battery packs is also being developed.

[0007] Nevertheless, cooling of the busbar itself has not yet been taken into consideration, and only a passive method of introducing a busbar with a larger capacity, i.e., a larger area, than the current required for the battery pack has been applied, rather than cooling individual busbar components.

[0008] Such a change in the structure of the bus bar not only increases manufacturing costs but also requires more space, and since it requires an increase in the size of the electrical components, it is not suitable for the current demand to increase capacity per volume or reduce the size of the battery pack.

[0009] Patent Document 1 relates to a flexible busbar for vehicles, which is configured in such a form that connection terminals are joined to both ends of a braided wire having flexibility and elasticity, three braided wires are stacked in the thickness direction of the connection terminal, and the entire outer circumference of the three braided wires is covered with a heat shrink tube.

[0010] The flexible busbar in Patent Document 1 is configured such that the braided wires are of different lengths so that when pressure is applied from the shorter side to the longer side, excessive tension is not applied to the longer side. However, because the entire braided wire is located inside a single heat-shrink tube, it is difficult for heat to be quickly dissipated when the temperature of the braided wire increases.

[0011] Patent Document 2 relates to an electrical cell connector for an accumulator or battery for the automotive industry, or an electrical high current connector for an electrical module connector, comprising a stranded wire and a solid electrical connecting piece, an end section of the braided wire being configured to be embedded in a portion of the solid electrical connecting piece.

[0012] Patent document 2 discloses that the braided wire is formed of flat strands (braided wire), round strands (braided cable, braided wire) or braided sleeving, and the braided wire can have a copper or aluminum material.

[0013] However, there is no technology presented for improving the heat generation and heat dissipation functions when using the high current connector.

[0014] As described above, there is a need for a technology that can improve heat dissipation performance in a busbar assembly without increasing the area or including a separate cooling member, and that can prevent degradation of electrical conductivity due to surrounding heat sources. [Prior art documents] [Patent documents]

[0015] [Patent Document 1] JP 2008-041330 A [Patent Document 2] Korean Patent Publication No. 10-2018-0135809 Summary of the Invention [Problem to be solved by the invention]

[0016] The present invention has been made to solve the above problems, and an object of the present invention is to provide a busbar assembly in which the surface area of ​​a busbar body is increased to improve heat dissipation and prevent damage to electrical components due to heat generated from a surrounding heat source being transferred through the busbar body. [Means for solving the problem]

[0017] To achieve this object, a busbar assembly according to the present invention may include a busbar body in the form of a wire assembly formed of a plurality of wires, and coupling portions coupled to the wires at both ends of the busbar body.

[0018] Each of the wires may be configured in the form of a linear conductive member covered with an insulating tube.

[0019] At least one space may be provided between the wires.

[0020] The coupling part has a plurality of holes for inserting the wires, and one or more wires may be inserted into each hole for coupling. The coupling part may be polygonal or circular with a constant thickness, and the plurality of holes for coupling with the wires may be provided on a side surface of the coupling part.

[0021] The joint and wire may be joined by at least one of simple insertion, a conductive adhesive, and melting of a filler material.

[0022] The coupling portion may include a coupling means capable of simultaneously achieving electrical contact and physical fixation.

[0023] The coupling portion may include a through hole for fastening a coupling member.

[0024] The fastening members may be at least one of a bolt and nut, a bolt, a pin, and a rivet.

[0025] A first side end of the busbar body may be coupled to one first coupling portion, and a second side end of the busbar body may be coupled to one second coupling portion, wherein the wires constituting the busbar body may have a uniform length.

[0026] The busbar body may be composed of two or more small-unit wire assemblies, a first side end of the busbar body may be coupled to one first coupling portion, and a second side end of the busbar body may be coupled to a third coupling portion for each of the small-unit wire assemblies, wherein lengths of the small-unit wire assemblies may be different from each other.

[0027] The method for manufacturing the busbar assembly may include preparing a coupling part having a plurality of holes formed therein, inserting wires constituting a busbar body into the holes, and coupling the wires to the coupling part.

[0028] The wire and the joint may be joined by melting a filler metal.

[0029] The present invention includes a battery module including the busbar assembly.

[0030] Furthermore, the present invention can also be provided in the form of a combination of various means for solving the above problems. Effect of the Invention

[0031] As described above, in the busbar assembly according to the present invention, the busbar body is formed of a plurality of wires, so that the surface area of ​​the busbar body is increased, thereby improving heat dissipation.

[0032] In addition, since the wires constituting the busbar body are arranged so as not to be in close contact with each other, air convection can occur in spaces formed between the wires, thereby improving the cooling effect.

[0033] Furthermore, by configuring the wire assemblies to have different lengths or by providing a plurality of small unit wire assemblies, the degree of freedom in connection distance and position setting is high, and one-to-many connection to components can be configured. [Brief description of the drawings]

[0034] [Figure 1] FIG. 1 is a perspective view of a first embodiment of a busbar assembly according to the present invention. [Diagram 2] FIG. 2 is a partially enlarged view of FIG. [Diagram 3] FIG. 2 is an assembled perspective view of a first embodiment of a busbar assembly according to the present invention; [Figure 4]11A to 11C are perspective views of second and third embodiments of a busbar assembly according to the present invention. [Diagram 5] 4A to 4C are plan views of a portion of a busbar assembly, illustrating a manufacturing process of the busbar assembly according to the present invention in sequence. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] Hereinafter, the present invention will be described in detail with reference to the accompanying drawings, in which a person having ordinary skill in the art to which the present invention pertains can easily carry out the present invention. However, when describing the operation principle of the preferred embodiment of the present invention in detail, detailed description of related well-known functions or configurations will be omitted if it is determined that such detailed description may unnecessarily obscure the gist of the present invention.

[0036] In addition, the same reference numerals are used throughout the drawings for parts having similar functions and actions. Throughout the specification, when a part is said to be connected to another part, this includes not only the case where the part is directly connected to another part, but also the case where the part is indirectly connected via another element between the two parts. In addition, when a part includes a certain component, it does not mean that the other component is excluded, but that the part may further include the other component, unless otherwise specified.

[0037] Furthermore, descriptions that specify or limit components are applicable to all inventions and are not limited to a particular invention unless otherwise specified.

[0038] Furthermore, throughout the description of the present invention and the claims, the singular includes the plural unless otherwise stated.

[0039] In addition, throughout the description of the present invention and the claims, unless otherwise stated, "or" includes "and." Therefore, "including A or B" means three cases: including A, including B, or including both A and B.

[0040] The invention will now be explained with reference to the drawings and in conjunction with detailed embodiments.

[0041] FIG. 1 is a perspective view of a first embodiment of a busbar assembly according to the present invention, FIG. 2 is a partially enlarged view of FIG. 1, and FIG. 3 is an assembled perspective view of the first embodiment of the busbar assembly according to the present invention.

[0042] 1 to 3, a busbar assembly according to the present invention includes a busbar body 100 in the form of a wire assembly formed of a plurality of wires 110, and coupling portions 200 coupled to the wires 110 at both ends of the busbar body 100.

[0043] Since the busbar body of the present invention is composed of a plurality of wires, the surface area of ​​the busbar body is increased and heat dissipation is improved compared to the conventional case where a rod-shaped metal plate is used. Compared to the case where heat generated from an external heat source is transferred via a metal plate, the use of a wire assembly, which has improved heat dissipation performance compared to a metal plate, reduces the heat transfer effect, thereby preventing a decrease in electrical conductivity due to an increase in temperature.

[0044] In addition, since the wires are coupled to the coupling portion while being spaced apart from each other at a predetermined interval, a space is formed between the wires where cooling can occur through air convection. Therefore, the busbar assembly according to the present invention can obtain a cooling effect due to the structural advantages of the busbar assembly without providing a separate cooling member.

[0045] The multiple wires 110 that make up the busbar body 100 are configured to have a uniform length, and a first side end of the busbar body 100 is connected to one first connecting portion 200, and a second side end of the busbar body 100 is connected to one second connecting portion 200.

[0046] The wires 110 may be circular, elliptical, or polygonal in cross section, but may be configured to have the same overall shape and uniform size. The wires 110 are not in close contact with each other, but form spaces between them, and are arranged on the same plane in the width direction of the joint. Although not shown in the drawings, some of the wires 110 may be in close contact with each other, but only in small units, and there are spaces between the wires as a whole.

[0047] The coupling part 200 is formed with a plurality of holes 210 for inserting the wires 110, and one or more wires can be inserted and coupled into each hole 210. In Figs. 1 to 3, one wire 110 is shown to be inserted into each hole 210.

[0048] The coupling part 200 may have a polygonal or circular shape with a constant thickness, and has a plurality of holes 210 on its side to which the wires 110 can be coupled. The coupling part 200 is made of a conductive material, preferably a metal.

[0049] The coupling part 200 has a plurality of holes 210 for inserting the wires 110, and the holes 210 may be formed in two or more rows at regular intervals in the thickness direction (y) and width direction (x) of the coupling part 200. Thus, the wires 110 may be coupled to the coupling part 200 in two or more layers in the thickness direction (y).

[0050] Considering that the heat dissipation improves as the surface area of ​​the wire increases, the heat dissipation effect can be increased as the wire becomes thinner.

[0051] Each of the wires may be configured with a linear conductive member 111 inside, the conductive member 111 covered with an insulating tube 112. Alternatively, the conductive member 111 may be coated with an insulating material. For example, for heat dissipation performance, a coating material including ceramic, which is an insulating material but has high heat dissipation performance, may be used. However, the portion of the end of the wire that is inserted into the coupling portion is configured so that the insulating tube is not covered and is exposed, allowing electricity to flow between the busbar body 100 and the coupling portion 200.

[0052] Although not shown in the drawings, since the busbar is not usually exposed to the outside, the wires can be made of linear conductive members without any coating. In this case, the surface area of ​​each individual wire can be reduced. Therefore, the heat dissipation performance can be increased or decreased depending on the type of coating material.

[0053] A wire 110 may be individually inserted into each hole 210 in the coupling portion 200 and coupled to the coupling portion 200, and / or multiple wires 110 may be inserted together into a single hole 210 and coupled to the coupling portion 200.

[0054] In order to facilitate the formation of spacing between the wires, it is preferred that one wire 110 is inserted into each hole 210 of the coupling portion 200 for coupling.

[0055] Here, the wire 110 can be connected to the hole 210 of the connecting portion 200 by at least one of simple insertion, application of a conductive adhesive, and melting of a filler metal.

[0056] For example, when the wires are joined to the holes of the joint using the filler metal melting method, the process can be performed by adding the filler metal to the end of each wire, inserting the wires with the filler metal into the holes of the joint, and brazing the wires, or by adding the filler metal inside the holes of the joint, inserting the wires into the holes, and brazing the wires.

[0057] The size of the coupling portion 200 and the number of holes formed in the coupling portion and the size D of the holes can be changed depending on the current specifications of the electrical components to which the busbar assembly is coupled, the number of wires required, and the wire thickness, and the coupling portion can be used with wires coupled to only some of the holes.

[0058] Meanwhile, in order to keep the wires 110 spaced apart from each other, a thin intermediate fixing part may be added to the middle of the busbar body, and the intermediate fixing part may have holes disposed on the sides thereof, similar to the hole 210 of Fig. 3. The wires 110 coupled to the holes 210 of the coupling part 200 may pass through each hole of the intermediate fixing part in the same manner.

[0059] The coupling part 200 may include a coupling means capable of simultaneously achieving electrical contact and physical fixation. For example, the coupling part 200 may have a through hole 220 penetrating in a thickness direction for fastening a coupling member. A part to be coupled to the coupling part 200 is disposed on one side of the coupling part 200. In this case, the through holes for fastening the coupling members are disposed to match each other, and at least one of a bolt, a pin, and a rivet is inserted through the through hole 220, and then the coupling part and the part may be coupled to each other by fastening with a nut or a fastening member or by performing a riveting operation.

[0060] Alternatively, if the coupling part 200 does not have a through hole, a conductive adhesive may be applied to the coupling surface of the coupling part, or a fastening hook or fixture may be provided on the coupling part to fasten it to another component, or the entire coupling part may be inserted into a groove provided on the other component to attach it.

[0061] FIG. 4 is a perspective view of a second and third embodiment of a busbar assembly according to the present invention.

[0062] Referring to FIG. 4, FIG. 4(a) shows a busbar assembly according to a second embodiment, and FIG. 4(b) shows a busbar assembly according to a third embodiment.

[0063] In the busbar assembly according to the second embodiment and the busbar assembly according to the third embodiment, the busbar body 100 is composed of two small unit wire assemblies. A first side end of the busbar body 100 is coupled to one first coupling part 200, and a second side end of the busbar body 100 is coupled to a third coupling part 200 for each small unit wire assemblies.

[0064] In a single small-unit wire assembly, the wire is coupled to the first coupling part 200 and the third coupling part 200 so that they are spaced apart from each other on the same plane, and the different small-unit assemblies coupled to the first coupling part may all be disposed and coupled on the same plane, or each small-unit assemblies may be coupled so that they are disposed on different planes.

[0065] The third connecting portion may be smaller in size than the first connecting portion, or the third connecting portion may be the same as the first connecting portion.

[0066] When the busbar body is formed of small-unit wire assemblies, a single component can be electrically connected to multiple components, thereby reducing the number of busbar assemblies. As a result, the number of connectors to which the busbar assemblies are coupled in the electrical component can be reduced by the number of busbar assemblies reduced, so that the area required for electrical connection can be used for other functions, and various electrical connection circuit configurations can be formed.

[0067] In the busbar assembly according to the second embodiment, the lengths of the small unit wire assemblies are different from each other, so that even if the distance between the 3-1 electrical component to which the third coupling part is coupled and the 1st electrical component to which the first coupling part is coupled is different from the distance between the 3-2 electrical component to which the third coupling part is coupled and the 1st electrical component to which the first coupling part is coupled, it is possible to form an electrical connection between them using a single busbar assembly.

[0068] FIG. 5 is a plan view of a portion of a busbar assembly showing a sequence of steps for manufacturing the busbar assembly according to the present invention.

[0069] Referring to FIG. 5, the method includes the steps of preparing a coupling portion 200 having a plurality of holes 210 formed therein (FIG. 5(a)), inserting wires constituting the busbar body 100 into the holes 210 (FIG. 5(c)), and coupling the wires to the coupling portion 200 (FIG. 5(d)).

[0070] Specifically, a method of joining the wire and the joint portion can be a method of melting a filler material 300. Here, prior to joining the wire constituting the busbar body 100 to the joint portion 200, a process of adding the filler material 300 to the hole 210 of the joint portion 200 as shown in Fig. 5(b) can be included. Alternatively, a process of adding the filler material to the end of the wire to be inserted into the hole 210 of the joint portion 200 can be included.

[0071] As shown in (c) of FIG. 5, the busbar body 100 is inserted into the hole 210 of the joint portion 200, and then, as shown in (d) of FIG. 5, brazing is performed by heating the peripheral portion 400 of the hole 210 of the joint portion, thereby joining the busbar body 100 to the joint portion 200.

[0072] For example, silver (Ag) can be used as the filler metal, and the heating temperature of the peripheral portion 400 can be set to a temperature range that is higher than the melting temperature of silver but lower than the melting temperature of the wire and the joint.

[0073] By using the busbar assembly manufactured in this manner, a battery module in which electrical connections are formed between electrical components inside the battery module can be manufactured, or electrical connections can be formed between the battery module and its external peripheral components.

[0074] The present invention provides a busbar assembly that exhibits excellent cooling effect through a large surface area of ​​the busbar body and spaces between wires without requiring a separate cooling member.

[0075] Those skilled in the art will appreciate that various applications and modifications within the scope of the present invention will be possible based on the above content. [Explanation of symbols]

[0076] 100 Busbar body 110 Wire 111 Conductive materials 112 Insulating tube 200 Joint, 1st joint, 2nd joint, 3rd joint 210 holes 220 Through Hole 300 Filler metal 400 Periphery

Claims

1. A busbar body in the form of a wire assembly formed of a plurality of wires; a coupling portion that is coupled to the wire at each end of the busbar body; The busbar assembly includes:

2. The busbar assembly according to claim 1 , wherein each of the wires is configured as a linear conductive member covered with an insulating tube.

3. The assembly of claim 1 , wherein the wires are spaced apart by at least one space.

4. The coupling portion has a plurality of holes formed therein for inserting the wires therethrough; The busbar assembly according to claim 1 , wherein one or more of the wires are inserted into and coupled to each of the holes.

5. 5. The busbar assembly of claim 4, wherein the coupling portion and the wire are coupled by at least one of simple insertion, a conductive adhesive, and dissolving a filler material.

6. The busbar assembly according to claim 1 , wherein the coupling portion comprises a coupling means capable of simultaneously achieving electrical contact and physical fixation.

7. The busbar assembly according to claim 6 , wherein the coupling portion includes a through hole for fastening a coupling member.

8. The busbar assembly of claim 7 , wherein the fastening members are at least one of a bolt and nut, a bolt, a pin, and a rivet.

9. The busbar assembly of claim 1 , wherein a first side end of the busbar body is coupled to a first coupling portion and a second side end of the busbar body is coupled to a second coupling portion.

10. The busbar assembly according to claim 9 , wherein the wires constituting the busbar body have a uniform length.

11. the busbar body is composed of two or more small unit wire assemblies, 2. The busbar assembly of claim 1, wherein a first side end of the busbar body is coupled to one first coupling portion, and a second side end of the busbar body is coupled to a third coupling portion for each of the small-unit wire assemblies.

12. The busbar assembly of claim 11 , wherein the two or more sub-unit wire assemblies have different lengths.

13. A method for manufacturing a busbar assembly according to any one of claims 1 to 12, comprising the steps of: providing the coupling member having a plurality of holes formed therein; inserting the wire constituting the busbar body into the hole; coupling the wire to the coupling portion; A method for manufacturing a busbar assembly comprising:

14. The method of claim 13, wherein the wire and the joint are joined by melting a filler metal.

15. A battery module comprising the busbar assembly according to any one of claims 1 to 12.

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