Bus bar unit

Abstract

To improve the work efficiency related to attachment / detachment of a bus bar unit to and from equipment.SOLUTION: A bus bar unit comprises: a bus bar that includes a bolt fastening part and a connector terminal part; and a mold resin part that covers the bus bar. The mold resin part includes: a connector housing part provided so as to be opposed to a lateral face of a battery pack and separated from the lateral face in a first direction, and covering the connector terminal part; an intermediate cover part that covers an intermediate part of the bus bar extending from the connector housing part; and a projection protruding from the connector housing part toward the lateral face of the battery pack, and in contact with the lateral face of the battery pack. A fixed part fixed to the battery pack separately from the bolt fastening part is provided at the bolt fastening part side from a centroid position of the bus bar unit in a second direction, of the mold resin part.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a bus bar unit. [Background technology]

[0002] Patent Document 1 discloses an inter-terminal connection structure that electrically connects multiple devices via a current-carrying member. The combination of multiple devices is, for example, two unit cells, or a unit cell and a junction block. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2020 / 241412 Summary of the Invention [Problem to be solved by the invention]

[0004] During maintenance, inspection, or replacement of equipment, work to attach or detach a current-carrying member to the equipment may be required. The attachment work of the current-carrying member to the equipment includes the work of connecting the current-carrying member to the equipment, and the removal work of the current-carrying member to the equipment includes the work of disconnecting the current-carrying member from the equipment. In the terminal connection structure of Patent Document 1, if both ends of the current-carrying member are fastened with bolts, it may be necessary to operate each of the bolts on both ends when attaching or detaching the current-carrying member to the equipment. Therefore, there is a demand for improving the efficiency of the work involved in attaching or detaching the current-carrying member to the equipment.

[0005] Therefore, an object of the present invention is to improve the efficiency of attaching and detaching a bus bar unit to a device. [Means for solving the problem]

[0006] A bus bar unit according to the present disclosure is a bus bar unit electrically connected to a terminal of a battery pack, the bus bar including a bolt fastening portion provided at one end and electrically connected to the terminal of the battery pack by being bolt-fastened, and a connector terminal portion provided at the other end and electrically connected to a connector terminal of a mating connector, and a molded resin portion covering the bus bar, wherein the bolt fastening portion and the connector terminal portion of the bus bar are spaced apart from each other in a first direction that is a normal direction to a side surface of the battery pack and a second direction that follows the side surface of the battery pack, and the molded resin the busbar unit includes a connector housing portion that is disposed away from the side surface of the battery pack in the first direction so as to face the side surface and cover the connector terminal portion, an intermediate cover portion that covers an intermediate portion of the busbar extending from the connector housing portion, and a protrusion that protrudes from the connector housing portion toward the side surface of the battery pack and comes into contact with the side surface of the battery pack, and a fixing portion that is fixed to the battery pack separately from the bolt fastening portion is provided in the molded resin portion on the bolt fastening portion side of the center of gravity of the busbar unit in the second direction. [Effects of the Invention]

[0007] According to the present disclosure, the efficiency of the work involved in attaching and detaching a bus bar unit to a device is improved. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing a bus bar unit and a connection module including the bus bar unit according to a first embodiment. [Figure 2] FIG. 2 is a side view showing the bus bar unit and the connection module including the bus bar unit according to the first embodiment. [Figure 3] FIG. 3 is a perspective view showing the bus bar unit. [Figure 4] FIG. 4 is a plan view showing the bus bar unit. [Figure 5] FIG. 5 is a front view showing the bus bar unit. [Figure 6]FIG. 6 is a side view showing the bus bar unit. [Figure 7] FIG. 7 is a cross-sectional view taken along line VII-VII in FIG. [Figure 8] FIG. 8 is a schematic diagram showing how the bus bar unit tilts. DETAILED DESCRIPTION OF THE INVENTION

[0009] [Description of the embodiments of the present disclosure] First, embodiments of the present disclosure will be listed and described.

[0010] The bus bar unit of the present disclosure is as follows.

[0011] (1) A bus bar unit electrically connected to a terminal of a battery pack, the bus bar including a bolt fastening portion provided at one end and electrically connected to the terminal of the battery pack by being bolted, and a connector terminal portion provided at the other end and electrically connected to a connector terminal of a mating connector, and a molded resin portion covering the bus bar, wherein the bolt fastening portion and the connector terminal portion of the bus bar are spaced apart in a first direction that is a normal direction to a side surface of the battery pack and in a second direction along the side surface of the battery pack, and the molded resin portion a connector housing portion that is disposed away from the side surface of the battery pack in the first direction so as to face the side surface and cover the connector terminal portion; an intermediate cover portion that covers an intermediate portion of the bus bar extending from the connector housing portion; and a protrusion that protrudes from the connector housing portion toward the side surface of the battery pack and comes into contact with the side surface of the battery pack, and a fixing portion that is fixed to the battery pack separately from the bolt fastening portion is provided in the molded resin portion on the bolt fastening portion side of the center of gravity of the bus bar unit in the second direction.

[0012] According to the bus bar unit of (1), the other end of the bus bar is connected to the mating connector, which improves the work efficiency of attaching and detaching the bus bar unit to the device compared to when the other end of the bus bar is fastened by a bolt. Also, because the molded resin portion has a protrusion that contacts the side of the battery pack, even if the bus bar unit is pressed by the mating connector when the other end of the bus bar is connected to the connector, the other end of the bus bar unit is supported by the battery pack. This improves the work efficiency of the connector connection.

[0013] (2) In the busbar unit of (1), the intermediate cover portion may have a first cover portion extending from the connector housing portion and a second cover portion extending in a direction intersecting the first cover portion, the molded resin portion may include a first connecting portion connecting the second cover portion and the connector housing portion, and the fixing portion may protrude from the first connecting portion. This makes it difficult for the connector housing portion to deform when the other end of the busbar is connected to the connector, improving the efficiency of the connector connection work.

[0014] (3) In the busbar unit of (2), the molded resin portion may include a second connecting portion that connects the first connecting portion and the first cover portion, and may be made of fiber-reinforced plastic. Thus, even if the molded resin portion is made of fiber-reinforced plastic, the presence of the first connecting portion and the second connecting portion increases the flow path of the fiber-reinforced plastic during molding of the molded resin portion, and the direction of the fibers contained in the fiber-reinforced plastic can be dispersed.

[0015] (4) In the busbar unit of any one of (1) to (3), the molded resin portion may include a notch extending between the fixing portion and an end of the intermediate cover portion on the bolt fastening portion side, thereby dispersing stress applied to the busbar unit from the battery pack when the battery pack expands.

[0016] (5) In the busbar unit of any one of (1) to (4), the molded resin portion may be provided with a rotation suppressing portion that, when the bolt fastening portion is not fastened by a bolt and the fixing portion is not fixed, prevents the busbar unit from tilting toward the connector housing portion by engaging with a receiving portion provided on the side surface of the battery pack. Since the other end of the busbar is configured to be connected to a connector, the other end of the busbar may be left unsupported when the bolt fastening portion at one end of the busbar is not fastened. Even in this case, the rotation suppressing portion, by engaging with the receiving portion of the battery pack, prevents the busbar unit from tilting toward the connector housing portion when the bolt fastening portion at one end is not fastened, thereby improving the efficiency of the bolt operation at the one end.

[0017] [Details of the embodiments of the present disclosure] Specific examples of busbar units according to the present disclosure will be described below with reference to the drawings. Note that the present 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.

[0018] [Embodiment 1] The bus bar unit according to the first embodiment will be described below. Fig. 1 is a perspective view showing a bus bar unit 30 according to the first embodiment and a connection module 100 including the bus bar unit 30. Fig. 2 is a side view showing the bus bar unit 30 according to the first embodiment and a connection module 100 including the bus bar unit 30.

[0019] The busbar unit 30 is electrically connected to the terminal 13A of the battery pack 10. The busbar unit 30 is also electrically connected to the connector terminal 23 of the mating connector 20. The busbar unit 30 is interposed between the battery pack 10 and the mating connector 20, and electrically connects the terminal 13A of the battery pack 10 to the connector terminal 23 of the mating connector 20. In the present disclosure, the battery pack 10, the mating connector 20, and the busbar unit 30 connected together are referred to as a connection module 100. Note that Figures 1 and 2 show the busbar unit 30 and the mating connector 20 in a disassembled state, with the busbar unit 30 not connected. The battery pack 10 and the mating connector 20, which are connected to the busbar unit 30, will be described first.

[0020] The battery pack 10 includes multiple cell batteries 11, connecting conductors 14, and a housing 15. Each cell battery 11 has a battery body 12 and multiple terminals 13. The battery body 12 is a portion that stores electric charge. The multiple terminals 13 are provided on the battery body 12 to connect the battery body 12 to an electrical device, and have a positive terminal and a negative terminal. The multiple cell batteries 11 are connected in series, for example, via connecting conductors 14. The connecting conductors 14 connect the positive terminals and negative terminals of adjacent cell batteries 11. The terminals 13 and connecting conductors 14 may be of any type. In this example, the terminals 13 are stud bolts 13. The connecting conductors 14 are metal plates with holes through which the stud bolts 13 pass. The housing 15 holds the multiple cell batteries 11. The multiple cell batteries 11 are held and integrated by the housing 15.

[0021] The terminal 13A of the battery pack 10 connected to the busbar unit 30 is located on the top surface 15a of the battery pack 10. Here, the terminal 13A is the terminal 13A of the cell battery 11 located at the end of the multiple cell batteries 11 connected in series. As described above, the terminal 13 of the cell battery 11 is a stud bolt, and therefore the terminal 13A of the battery pack 10 connected to the busbar unit 30 is also a stud bolt. However, the terminal of the battery pack connected to the busbar unit 30 may be a terminal provided separately from the terminal 13 of the cell battery 11 and electrically connected to the terminal 13 of the cell battery 11. Alternatively, the terminal of the battery pack connected to the busbar unit 30 may be a metal plate with a hole for passing a bolt.

[0022] Fixing bolts 16 are also provided on the top surface 15a of the battery pack 10. The fixing bolts 16 protrude in the same direction as the stud bolts 13A. The fixing bolts 16 are bolts for fixing the busbar unit 30. The fixing bolts 16 do not electrically connect the cell battery 11 to the busbar 40 in the busbar unit 30. Here, the portion of the top surface 15a of the battery pack 10 where the fixing bolts 16 are provided is lower than the portion of the top surface 15a of the battery pack 10 where the stud bolts 13A are provided. Here, a step is created between the portion of the top surface 15a of the battery pack 10 where the fixing bolts 16 are provided and the portion of the top surface 15a of the battery pack 10 where the stud bolts 13A are provided.

[0023] As shown in Fig. 2, a receiving portion 17 is provided on the side surface 15b of the battery pack 10. Most of the busbar unit 30, excluding the portion fastened to the stud bolt 13A and the portion fastened to the fixing bolt 16, is disposed in a position facing the side surface 15b. The receiving portion 17 comes into contact with the busbar unit 30 to prevent the busbar unit 30 from rotating. The receiving portion 17 protrudes outward from the surrounding portion of the side surface 15b.

[0024] Here, Figure 1 shows the X direction, Y direction, and Z direction, which are orthogonal to one another. The X direction is a normal direction to the side surface 15b on which the receiving portion 17 is provided, and is an example of a first direction. The Y direction is a direction along the side surface 15b, and is an example of a second direction. Here, the Y direction is a direction along the side surface 15b that is orthogonal to the protruding direction of the stud bolt 13A. The Z direction is the protruding direction of the stud bolt 13A and the fixing bolt 16. The X direction, Y direction, and Z direction corresponding to Figure 1 are also shown in Figure 2 and the subsequent figures.

[0025] The mating connector 20 includes a connector housing 21 and connector terminals 23 (see FIG. 7 ). For example, the connector housing 21 is made of insulating resin, and the connector terminals 23 are made of conductive metal. The connector housing 21 holds the connector terminals 23. A lock receiving portion 22 is provided on a side surface of the connector housing 21. When the mating connector 20 is connected to the bus bar unit 30, the lock receiving portion 22 is locked to a locking portion 52 provided on the bus bar unit 30. Here, the lock receiving portion 22 has a locking piece 22a that locks to the locking portion 52, and an operating portion 22b that deforms the locking piece 22a so as to move away from the locking portion 52 when unlocking. One end of the connector terminal 23 is connected to the bus bar unit 30. One end of the electric wire 24 is connected to the other end of the connector terminal 23. The connector terminal 23 and the electric wire 24 are connected by crimping, pressure welding, welding, or the like.

[0026] The electric wire 24 is, for example, a coated electric wire having a conductor core wire and an insulating coating. The conductor core wire is, for example, a twisted wire in which a plurality of metal wires are twisted. The insulating coating covers the conductor core wire. The other end of the electric wire 24 is connected to an electric device other than the battery pack 10. For example, a connection terminal or a connector is provided at the other end of the electric wire 24, and the connection terminal or connector is connected to the other electric device. Such an electric device is not particularly limited, and may be, for example, a battery pack having the same configuration as the battery pack 10 and provided separately from the battery pack 10. Alternatively, for example, the electric device may be a busbar unit having the same configuration as the busbar unit 30 and provided in the other battery pack. Alternatively, for example, the electric device may be a junction box or the like.

[0027] The electric wire 24 is easier to bend than, for example, the bus bar 40 in the bus bar unit 30. The presence of the electric wire 24 between the battery pack 10 and another electrical device increases the degree of freedom in the positional relationship between the battery pack 10 and the other electrical device in the vehicle. Furthermore, if a design change occurs in the positional relationship between the battery pack 10 and the other electrical device, this can be accommodated by bending the electric wire 24 without having to change the design of other components.

[0028] <Busbar unit> The busbar unit 30 will be described in more detail with further reference to Figs. 3 to 7. Fig. 3 is a perspective view of the busbar unit 30. Figs. 1 and 3 are perspective views seen from different viewpoints. Fig. 4 is a plan view of the busbar unit 30. Fig. 5 is a front view of the busbar unit 30. Fig. 6 is a side view of the busbar unit 30. Fig. 6 shows the side opposite to that of Fig. 2. Fig. 7 is a cross-sectional view taken along line VII-VII in Fig. 4. Note that in Figs. 4 to 6, the battery pack 10 is shown by imaginary lines. Furthermore, in Fig. 7, the mating connector 20 is shown by solid lines.

[0029] The busbar unit 30 includes a busbar 40 and a molded resin portion 50. The molded resin portion 50 is formed by insert molding using the busbar 40 as an insert component. In this embodiment, the molded resin portion 50 includes not only the busbar 40 but also a collar 70 as an insert component. The collar 70 is a member for reinforcing the fixing portion 60 in the molded resin portion 50. The collar 70 may be press-fitted into the molded resin portion 50 later. Alternatively, the collar 70 may be omitted.

[0030] The bus bar 40 includes a bolt fastening portion 41 and a connector terminal portion 42. The bolt fastening portion 41 is provided at one end of the bus bar 40. The bolt fastening portion 41 is fastened to the terminal 13A of the battery pack 10 with a bolt and electrically connected to the terminal 13A. The connector terminal portion 42 is provided at the other end of the bus bar 40. The connector terminal portion 42 is electrically connected to the connector terminal 23 of the mating connector 20. The bolt fastening portion 41 and the connector terminal portion 42 are provided separately from each other in the X direction and the Y direction.

[0031] In busbar 40, the portions from bolt fastening portion 41 to connector terminal portion 42 are formed by a single plate material. This plate material is made of metal and is formed as a long plate with a flat cross section whose thickness dimension is smaller than its width dimension and which continues in the extension direction. Busbar 40 has bent portions 43A, 43B, 43C, and 43D where the plate material is bent in the thickness direction. Bent portions 43A, 43B, 43C, and 43D are provided in this order from connector terminal portion 42 toward bolt fastening portion 41. At bent portions 43A, 43B, and 43C, the plate material is bent by 90 degrees in the thickness direction. At bent portion 43D, the plate material is bent so as to be offset in the thickness direction.

[0032] The portion of the busbar 40 closer to the other end than the bent portion 43A is defined as a connector terminal portion 42. The connector terminal portion 42 extends from the bent portion 43A in the Z direction. The portion of the busbar 40 closer to one end than the bent portion 43D is defined as a bolt fastening portion 41. The bolt fastening portion 41 extends from the bent portion 43D in the X direction. The portion of the busbar 40 between the bent portion 43A and the bent portion 43D is defined as an intermediate portion 44. Here, the intermediate portion 44 has a first intermediate portion 44A, a second intermediate portion 44B, and a third intermediate portion 44C.

[0033] The portion of the bus bar 40 between the bent portions 43A and 43B is defined as a first intermediate portion 44A. The first intermediate portion 44A extends from the bent portion 43A in the Y direction, then changes its extending direction to the X direction just before the bent portion 43B, and reaches the bent portion 43B. The portion of the bus bar 40 between the bent portions 43B and 43C is defined as a second intermediate portion 44B. The second intermediate portion 44B extends from the bent portion 43B in the Z direction to reach the bent portion 43C. The portion of the bus bar 40 between the bent portions 43C and 43D is defined as a third intermediate portion 44C. The third intermediate portion 44C extends from the bent portion 43C in the X direction, then changes its extending direction just before the bent portion 43D, and reaches the bent portion 43D, and reaches the bent portion 43D.

[0034] In the bus bar 40, the number, positions, and bending manner of the bent portions are not limited to those described above, and can be set as appropriate.

[0035] The molded resin portion 50 includes a connector housing portion 51 , an intermediate cover portion 53 , a protrusion 55 , a first connecting portion 56 , a second connecting portion 57 , a fixing portion 60 , and a notch 61 .

[0036] The connector housing portion 51 covers the connector terminal portion 42. The connector housing portion 51 is disposed opposite the side surface 15b of the battery pack 10 and spaced apart from the side surface 15b in the X direction. The bent portion 43A is located within the connector housing portion 51. The connector housing portion 51 is provided with a mating recess 51A into which the tip of the mating connector 20 fits. The mating recess 51A is a hole that continues in the Z direction. The mating recess 51A opens on the top surface of the connector housing portion 51. The tip of the connector terminal portion 42 protrudes into the mating recess 51A from the bottom surface located opposite the opening of the mating recess 51A. The bus bar 40 extends outward from the connector housing portion 51 midway from the bent portion 43A toward the bent portion 43B. Here, the bus bar 40 extends outward from the connector housing portion 51 near the bent portion 43A. In the Z direction, the bus bar 40 extends from an end portion of the connector housing portion 51 opposite to the end portion where the opening of the fitting recess 51A is provided.

[0037] The intermediate cover portion 53 covers the intermediate portion 44 of the bus bar 40 extending from the connector housing portion 51. The intermediate cover portion 53 has a first cover portion 53A, a second cover portion 53B, and a third cover portion 53C. The first cover portion 53A extends from the connector housing portion 51. The second cover portion 53B extends in a direction (here, the Z direction) intersecting with the extension direction (here, the Y direction) of the portion of the first cover portion 53A extending from the connector housing portion 51. The third cover portion 53C extends in a direction (here, the X direction) intersecting with the second cover portion 53B. Here, the first cover portion 53A covers a portion of the first intermediate portion 44A of the bus bar 40 that is located outside the connector housing portion 51. The second cover portion 53B covers the second intermediate portion 44B of the bus bar 40. The third cover portion 53C covers a portion of the third intermediate portion 44C of the bus bar 40 that is closer to the bent portion 43C. The connecting portion between the first cover portion 53A and the second cover portion 53B covers the bent portion 43B, and the connecting portion between the second cover portion 53B and the third cover portion 53C covers the bent portion 43C. A part of the third intermediate portion 44C of the busbar 40 that is closer to the bent portion 43D and the bolt fastening portion 41 are not covered by the molded resin portion 50.

[0038] 2, the protrusion 55 protrudes in the X direction from the connector housing portion 51 toward the side surface 15b of the battery pack 10. The protrusion 55 comes into contact with the side surface 15b of the battery pack 10 when the busbar unit 30 is attached to the battery pack 10. The protrusion 55 extends from the end of the connector housing portion 51 in the Z direction where the opening of the fitting recess 51A is provided.

[0039] The first connecting portion 56 connects the connector housing portion 51 to a portion of the intermediate cover portion 53 that is distant from the connector housing portion 51. Here, the first connecting portion 56 connects the second cover portion 53B to the connector housing portion 51. Here, there is only one first connecting portion 56. The first connecting portion 56 extends linearly parallel to the Y direction. The first connecting portion 56 extends from an end of the connector housing portion 51 in the Z direction where the opening of the fitting recess 51A is provided. The first connecting portion 56 and the first cover portion 53A extend parallel to each other from the connector housing portion 51 along the Y direction. The portion of the first cover portion 53A that extends from the connector housing portion 51 in the Y direction is separated from the first connecting portion 56 in the X and Z directions. The first connecting portion 56 is connected to the side surface 15b of the connector housing portion 51 from which the protrusion 55 protrudes. The tip of the first connecting portion 56 is also connected to the protrusion 55.

[0040] The second connecting portion 57 connects a portion of the intermediate cover portion 53 closer to the connector housing portion 51 than the intersection with the first connecting portion 56 to an intermediate portion of the first connecting portion 56. Here, the second connecting portion 57 connects the first cover portion 53A to the first connecting portion 56. Here, there is only one second connecting portion 57. The second connecting portion 57 extends in a straight line parallel to the Z direction. As clearly shown in FIG. 5, the second connecting portion 57 is located closer to the second cover portion 53B than the center between the connector housing portion 51 and the second cover portion 53B in the Y direction. In the Y direction, the fixing portion 60 is located between the second cover portion 53B and the second connecting portion 57.

[0041] Here, the second connecting portion 57 has a connecting body 57A and a rib 57B. The connecting body 57A connects the first cover portion 53A and the first connecting portion 56. The rib 57B protrudes toward the battery pack 10 in the X direction further than the connecting body 57A. In the X direction, the protruding dimension of the rib 57B is smaller than the protrusion 55. As clearly shown in FIG. 3 , the rib 57B protrudes toward the battery pack 10 in the X direction further than the first connecting portion 56. The upper end of the rib 57B in the Z direction reaches the middle portion 44 of the first connecting portion 56.

[0042] The connector housing 51, the first cover 53A, the second cover 53B, and the first connecting portion 56 are connected to form a closed ring. The molded resin portion 50 has an opening surrounded by the connector housing 51, the first cover 53A, the second cover 53B, and the first connecting portion 56. The opening is divided into two by the second connecting portion 57. The molded resin portion 50 has an opening surrounded by the connector housing 51, the first cover 53A, the second connecting portion 57, and the first connecting portion 56, and an opening surrounded by the first cover 53A, the second cover 53B, the first connecting portion 56, and the second connecting portion 57.

[0043] The thickness dimension (dimension along the X direction) of the first connecting portion 56 is greater than the thickness dimension (dimension along the Y direction) of the second connecting portion 57. The thickness dimension (dimension along the X direction) of the first connecting portion 56 is the same as the thickness dimension of the intermediate covering portion 53 (for example, the dimension along the Z direction of the first covering portion 53A). The width dimension (dimension along the Z direction) of the first connecting portion 56 is smaller than the width dimension of the intermediate covering portion 53 (for example, the dimension along the Y direction of the second covering portion 53B).

[0044] The fixing portion 60 is fixed to the battery pack 10 separately from the bolt fastening portion 41. The fixing portion 60 is provided on the molded resin portion 50 closer to the bolt fastening portion 41 than the center of gravity of the bus bar unit 30 in the Y direction. In other words, the center of gravity of the bus bar unit 30 in the Y direction is located closer to the connector housing portion 51 than the fixing portion 60. The fixing portion 60 protrudes from the first coupling portion 56.

[0045] A rotation suppressing portion is provided in the molded resin portion 50. Here, the rib 57B functions as the rotation suppressing portion. The rotation suppressing portion 57B is caught on a receiving portion 17 provided on the side surface 15b of the battery pack 10. The rotation suppressing portion 57B suppresses the busbar unit 30 from tilting toward the connector housing portion 51 when the bolt fastening portion 41 is not fastened with a bolt and the fixing portion 60 is not fixed. Here, the rotation suppressing portion 57B is provided on the second connecting portion 57. The rib 57B is caught on the receiving portion 17 and functions as the rotation suppressing portion 57B.

[0046] In this embodiment, a rib 58 parallel to the rib 57B is provided on the second cover portion 53B. The rib 58 protrudes toward the battery pack 10 in the X direction beyond the second cover portion 53B. The upper end of the rib 58 in the Z direction reaches the underside of the third cover portion 53C. The dimension of the rib 58 in the Y direction is smaller than the dimension of the second cover portion 53B in the Y direction. One rib 58 is provided at the center of the second cover portion 53B in the Y direction. Multiple ribs 58 may be provided. The protruding dimension of the rib 58 in the X direction is smaller than the protrusion 55 and the same as the protruding dimension of the rib 57B. The ribs 57B and 58 do not reach the side surface 15b of the battery pack 10. Note that when the battery pack 10 expands due to heat or the like, the side surface 15b of the battery pack 10 may come into contact with the ribs 57B and 58. Even in this case, the ribs 57B and 58 are thin, so that the battery pack 10 is less susceptible to expansion due to heat or the like.

[0047] The notch 61 extends between the fixing portion 60 and the end of the intermediate cover portion 53 on the bolt fastening portion 41 side. Here, the third cover portion 53C and the fixing portion 60 are completely separated by the notch 61. The portion of the second cover portion 53B on the third cover portion 53C side and the fixing portion 60 are also completely separated by the notch 61. In the Z direction, the notch 61 reaches the upper surface of the first coupling portion 56. In the Z direction, the notch 61 does not reach the height of the upper surface of the connector housing portion 51. The width dimension (dimension along the Z direction) of the coupling portion of the first coupling portion 56 with the second cover portion 53B is larger than the width dimension (dimension along the Z direction) of the coupling portion of the first coupling portion 56 with the connector housing portion 51. The width dimension (dimension along the Y direction) of the notch 61 is larger than the thickness dimension (dimension along the Y direction) of the second coupling portion 57.

[0048] The molded resin part 50 is made of fiber reinforced plastics (FRP). The fibers contained in the fiber reinforced plastic are not particularly limited, but may be, for example, glass fibers. The base resin of the fiber reinforced plastic is not particularly limited, but may be, for example, polybutylene terephthalate (PBT).

[0049] The molded resin part 50 is formed by pouring a material (here, molten resin containing fiber) into a mold. A gate mark for pouring the material into the mold remains on the molded resin part 50. In the example shown in FIG. 5, the gate mark 62 is provided on the first cover part 53A. In the example shown in FIG. 5, the gate mark 62 is provided on the surface of the first cover part 53A opposite to the surface connected to the second connecting part 57. Of course, the position of the gate mark 62 is not limited to this and can be set as appropriate.

[0050] The fibers flow through the mold together with the molten resin, and when the flow of the molten resin stops, the flow of the fibers also stops. The molten resin hardens, fixing the orientation of the fibers. Therefore, typically, the fibers contained in fiber-reinforced plastic are extended in the direction of the flow of the molten resin within the molded resin portion 50. In this embodiment, within the mold, the portions that will become the intermediate cover portion 53, as well as the first connecting portion 56 and the second connecting portion 57, become flow paths for the molten resin. Therefore, the branching of the flow path makes it difficult for the orientation of the fibers to align in a fixed direction. This prevents the molded resin portion 50 made of fiber-reinforced plastic from cracking in a specific direction. For example, this specific direction is a direction in which the cracks run along the direction in which the fibers extend.

[0051] Furthermore, molten resin containing fibers is generally more difficult to flow than molten resin that does not contain fibers, and therefore is less likely to spread throughout the mold. In this embodiment, as shown in Fig. 5, second connecting portion 57 is provided near gate mark 62, and therefore, as a flow path for the material immediately after it enters the mold from the gate, in addition to a flow path corresponding to first cover portion 53A, a flow path corresponding to second connecting portion 57 exists. This makes it easier for the material to spread throughout the mold.

[0052] The mold for molding the molded resin part 50 includes an upper mold and a lower mold. Here, the upper mold and the lower mold are punched from above and below in the Z direction. The molded resin part 50 is formed in a shape that does not have portions that face each other across a space in the Z direction (portions that become so-called undercuts). For example, in the X direction, the first cover part 53A and the first connecting part 56 are spaced apart from each other, thereby preventing the first cover part 53A and the first connecting part 56 from becoming undercuts. Furthermore, in the Y direction, the rib 57B and the fixing part 60 of the second connecting part 57 are spaced apart from each other, thereby preventing the rib 57B and the fixing part 60 from becoming undercuts.

[0053] When molding the molded resin part 50, the insert parts (here, the bus bar 40 and the collar 70) are held between the upper and lower dies. Furthermore, here, the first intermediate part 44A of the bus bar 40 is held by a positioning pin. Positioning pin recesses 63, which are marks of the positioning pins, remain in the first cover part 53A of the molded resin part 50. The positioning pins are provided above and below the bus bar 40 in the Z direction. The positioning pin recesses 63 remain in the first cover part 53A of the molded resin part 50 on the surface facing upward in the Z direction and on the surface facing downward. A plurality of positioning pin recesses 63 are provided along the extension direction of the first cover part 53A.

[0054] <Attaching and detaching the battery pack and bus bar unit> The attachment and detachment (mounting and detaching) of the battery pack 10 and the bus bar unit 30 will be described in more detail.

[0055] When attaching the battery pack 10 and the bus bar unit 30, the worker first moves the bus bar unit 30 relative to the battery pack 10 in the Z direction, and passes the stud bolt 13A through the bolt fastening portion 41 and the fixing bolt 16 through the fixing portion 60 (see FIG. 5 ). After this, the worker takes a fastening jig such as a wrench and a nut 80, and uses the fastening jig to fasten the nut 80 to each of the stud bolt 13A and the fixing bolt 16. At this time, the worker can remove both hands from the bus bar unit 30 in order to take the nut 80 and the fastening jig.

[0056] The center of gravity of the busbar unit 30 is located closer to the connector housing 51 than the fixing portion 60 in the Y direction. Therefore, if rotation is not restricted by the rotation restricting portion 57B and the receiving portion 17, the busbar unit 30 may tilt toward the connector housing 51 when the worker removes both hands from the busbar unit 30 before fastening the bolt, as shown in FIG. 8 . If the fixing portion 60 is closer to the center of gravity in the Y direction than the bolt fastening portion 41, the busbar unit 30 tilts and rotates around the contact point between the fixing portion 60 and the fixing bolt 16. If the busbar unit 30 tilts too much, the bolt fastening portion 41 may come off the stud bolt 13A. Therefore, the worker may need to correct the tilt of the busbar unit 30 before fastening the nut 80. Note that FIG. 8 is a schematic diagram showing how the busbar unit 30 tilts, and an example is shown in which the receiving portion 17 is not provided on the battery pack 10.

[0057] In contrast, in the bus bar unit 30 of this embodiment, rotation is restricted by the rotation restricting portion 57B and the receiving portion 17, so even if the worker removes both hands from the bus bar unit 30 before fastening the bolt, the bus bar unit 30 tends to maintain the correct posture, as shown in Fig. 5. Therefore, after removing the nut 80 and the fastening jig, the worker can continue fastening the nut 80 without having to correct the posture of the bus bar unit 30.

[0058] When removing the bus bar unit 30 from the battery pack 10, if rotation is not restricted by the rotation restricting portion 57B and the receiving portion 17, and the worker removes both hands from the bus bar unit 30 after the nut 80 has been removed, the bus bar unit 30 may tilt toward the connector housing portion 51, as shown in Fig. 8 . At this time, the fixing portion 60 and the fixing bolt 16 press against each other in the Y direction. Therefore, when the bus bar unit 30 is moved in the Z direction to remove it from the battery pack 10, the fixing portion 60 and the fixing bolt 16 may rub against each other strongly.

[0059] In contrast, in the bus bar unit 30 of this embodiment, rotation is restricted by the rotation restricting portion 57B and the receiving portion 17. Therefore, even if the worker removes both hands from the bus bar unit 30 after the nut 80 is removed, the bus bar unit 30 tends to maintain the correct posture, as shown in Fig. 5. Therefore, even if the worker moves the bus bar unit 30 in the Z direction after removing the nut 80, there is little risk of the fixing portion 60 and the fixing bolt 16 rubbing strongly against each other. This makes it easier to remove the bus bar unit 30 from the battery pack 10.

[0060] The rotation inhibiting portion 57B and the receiving portion 17 may be in contact with each other when the battery pack 10 and the bus bar unit 30 are in the correct mounting position. The rotation inhibiting portion 57B and the receiving portion 17 may be in contact with each other when the battery pack 10 and the bus bar unit 30 are in a position that is slightly tilted from the correct mounting position. In this case, the tilt of the bus bar unit 30 may be such that the bolt fastening portion 41 does not come off the stud bolt 13A, the nut 80 can be attached to the tip of the stud bolt 13A, and the tilt can be corrected to the correct position by fastening the nut 80.

[0061] <Attaching and detaching the busbar unit to the mating connector> The attachment and detachment of the bus bar unit 30 to and from the mating connector 20 will be described more specifically.

[0062] The description will be given assuming that the attachment of busbar unit 30 to mating connector 20 is performed after busbar unit 30 is attached to battery pack 10. The mating connector 20 is attached by moving along the Z direction relative to busbar unit 30 in the direction of arrow A1 in Figures 1 and 2 (here, a direction parallel to the Z direction) so that the tip of mating connector 20 fits into mating recess 51A.

[0063] At this time, the direction of movement of the mating connector 20 may be shifted in the X direction from the direction of arrow A1, as shown by arrow A2 or arrow A3 in Figure 2. In this case, the force of inserting the mating connector 20 into the connector housing portion 51 may act as a force that rotates the connector housing portion 51 around the Y axis. Even in this case, in the bus bar unit 30 of this embodiment, the protrusions 55 are supported in contact with the side surface 15b of the battery pack 10, so that even if a force that rotates the connector housing portion 51 around the Y axis is applied from the mating connector 20 to the connector housing portion 51, the rotation of the connector housing portion 51 is suppressed. This makes it easy to attach the bus bar unit 30 and the mating connector 20.

[0064] Similarly, when removing the bus bar unit 30 from the mating connector 20, the direction of the force that pulls the mating connector 20 out of the connector housing portion 51 may be shifted in the X direction. In this case, the force that pulls the mating connector 20 out of the connector housing portion 51 may act as a force that rotates the connector housing portion 51 around the Y axis. Even in this case, in the bus bar unit 30 of this embodiment, the protrusions 55 are supported in contact with the side surface 15b of the battery pack 10, so that even if a force that rotates the connector housing portion 51 around the Y axis is applied from the mating connector 20 to the connector housing portion 51, the rotation of the connector housing portion 51 is suppressed. This makes it easy to remove the bus bar unit 30 from the mating connector 20.

[0065] The contact between the protrusion 55 and the side surface 15b of the battery pack 10 also serves to prevent the busbar unit 30 from rotating around the Y axis when the battery pack 10 and the busbar unit 30 are attached or detached and the bolts are not fastened. In other words, the center of gravity in the X direction of the busbar unit 30 is located closer to the connector housing part 51 than the fixing part 60. Therefore, without contact between the protrusion 55 and the side surface 15b of the battery pack 10, the busbar unit 30 may rotate around the Y axis so that the connector housing part 51 drops when the bolts are not fastened. The contact between the protrusion 55 and the side surface 15b of the battery pack 10 prevents this rotation.

[0066] <Effects, etc.> With the busbar unit 30 configured as described above, the other end of the busbar 40 is connected to the mating connector 20. This improves the work efficiency of attaching and detaching the busbar unit 30 to a device, compared to when the other end of the busbar 40 is connected to the bolt-fastening portion 41 like the one end. Furthermore, the molded resin portion 50 is provided with the protrusion 55 that contacts the side surface 15b of the battery pack 10. Therefore, even if the busbar unit 30 is pressed by the mating connector 20 when the other end of the busbar 40 is connected to the connector, the other end of the busbar unit 30 is supported by the battery pack 10. This improves the work efficiency of connecting the connector. Furthermore, the contact between the protrusion 55 and the side surface 15b of the battery pack 10 makes it difficult for the busbar unit 30 to rotate around the Y-axis, causing the connector housing portion 51 to drop, when the bolts are not fastened.

[0067] Furthermore, intermediate cover portion 53 has first cover portion 53A extending from connector housing portion 51 and second cover portion 53B extending in a direction intersecting first cover portion 53A, molded resin portion 50 includes first connecting portion 56 connecting second cover portion 53B to connector housing portion 51, and fixing portion 60 protrudes from first connecting portion 56. This makes connector housing portion 51 less likely to deform when the other end of busbar 40 is connected to the connector, improving the efficiency of the connector connection process.

[0068] Furthermore, molded resin portion 50 includes second connecting portion 57 connecting first connecting portion 56 and first cover portion 53A, and is made of fiber-reinforced plastic. When molded resin portion 50 is made of fiber-reinforced plastic, fibers flow within the mold along with the softened resin during molding of the molded resin portion. At this time, even if molded resin portion 50 is made of fiber-reinforced plastic, the presence of first connecting portion 56 and second connecting portion 57 increases the flow path of the fiber-reinforced plastic during molding of molded resin portion 50, and the direction of the fibers contained in the fiber-reinforced plastic can be dispersed. This makes it possible to prevent molded resin portion 50 from cracking in a specific direction.

[0069] Furthermore, the molded resin part 50 includes a notch 61 extending between the fixing part 60 and the end part of the intermediate cover part 53 on the bolt fastening part 41 side. This allows the stress applied from the battery pack 10 to the busbar unit 30 when the battery pack 10 expands due to heat or the like to be dispersed.

[0070] Furthermore, the molded resin portion 50 is provided with a rotation suppressing portion 57B that prevents the bus bar unit 30 from tilting toward the connector housing portion 51 when the bolt fastening portion 41 is not bolted and the fixing portion 60 is not fixed by engaging with a receiving portion 17 provided on the side surface 15b of the battery pack 10. The bus bar unit 30 of the present disclosure is configured so that the other end of the bus bar 40 is connected to a connector, and therefore, when the bolt fastening portion 41 at one end of the bus bar 40 is not fastened, the other end of the bus bar 40 may not be supported. Even in this case, the rotation suppressing portion 57B is engaged with the receiving portion 17 of the battery pack 10, thereby preventing the bus bar unit 30 from tilting toward the connector housing portion 51 when the bolt fastening portion 41 at one end is not fastened, thereby improving the work efficiency of operating the bolt at one end.

[0071] [Note] Up to this point, it has been described that the molded resin part 50 includes the first connecting part 56 and that the fixing part 60 protrudes from the first connecting part 56, but this is not a required configuration. For example, the molded resin part 50 does not have to include the first connecting part 56. Furthermore, even if the molded resin part 50 includes the first connecting part 56, the fixing part 60 does not have to protrude from the first connecting part 56. For example, the fixing part 60 may protrude from the second cover part 53B. In this case, the fixing part 60 may be farther from the center of gravity of the molded resin part 50 in the Y direction than the bolt fastening part 41.

[0072] Furthermore, although molded resin part 50 has been described up to this point as including second connecting part 57 and being made of fiber-reinforced plastic, this is not a required configuration. For example, molded resin part 50 does not have to include second connecting part 57. Furthermore, for example, molded resin part 50 may be made of a resin that does not contain fibers.

[0073] Furthermore, although molded resin part 50 has been described as including notch 61, this is not an essential configuration. Molded resin part 50 may not include notch 61, and fixing part 60 and third cover part 53C may be directly connected to each other.

[0074] Furthermore, although it has been described above that the molded resin part 50 is provided with the rotation suppressing part 57B, this is not an essential configuration. The molded resin part 50 does not have to be provided with the rotation suppressing part 57B. Even if the molded resin part 50 is provided with the rotation suppressing part 57B, it is not an essential configuration that the rotation suppressing part 57B is the above-mentioned rib 57B. The rotation suppressing part may be provided at a position other than the rib 57B, and for example, the protrusion 55 or the rib 58 may function as the rotation suppressing part.

[0075] The configurations described in the above embodiments and modifications can be combined as appropriate as long as they are not mutually contradictory. [Explanation of symbols]

[0076] 10 Battery pack 11 cell battery 12 Battery body 13, 13A terminal (stud bolt) 14 Connecting conductor 15 Case 15a Top side 15b Side 16 Fixing bolt 17 Receiving Department 20 Mating connector 21 Connector housing 22 Lock receiving part 22a Lock piece 22b Operation section 23 Connector terminal 24 Electric wire 30 Busbar unit 40 Bus Bar 41 Bolt fastening part 42 Connector terminal 43A, 43B, 43C, 43D bends 44 Middle section 44A First Intermediate Section 44B 2nd intermediate part 44C 3rd intermediate part 50 Molded resin part 51 Connector housing 51A Mating recess 52 Rock Club 53 Intermediate cover 53A First Cover 53B Second cover part 53C Third Cover 55 Protrusion 56 1st connection part 57 2nd connection part 57A Connecting body 57B Rib (rotation prevention part) 58 Ribs 60 Fixed part 61 Notch 62 Gate Remains 63 Positioning pin recess 70 colors 80 Nut 100 Connection Modules

Claims

1. A busbar unit electrically connected to a terminal of a battery pack, a bus bar including a bolt fastening portion provided at one end and electrically connected to the terminal of the battery pack by being bolt fastened thereto, and a connector terminal portion provided at the other end and electrically connected to a connector terminal of a mating connector; a molded resin portion covering the bus bar; Equipped with the bolt fastening portion and the connector terminal portion of the bus bar are spaced apart from each other in a first direction that is a normal direction to a side surface of the battery pack and in a second direction that is along the side surface of the battery pack, the molded resin portion includes a connector housing portion that is spaced apart from the side surface of the battery pack in the first direction so as to face the side surface and cover the connector terminal portion, an intermediate cover portion that covers an intermediate portion of the bus bar extending from the connector housing portion, and a protrusion that protrudes from the connector housing portion toward the side surface of the battery pack and comes into contact with the side surface of the battery pack, a fixing portion that is fixed to the battery pack separately from the bolt fastening portion is provided in the molded resin portion on the bolt fastening portion side of the center of gravity of the bus bar unit in the second direction.

2. The bus bar unit according to claim 1, the intermediate cover portion has a first cover portion extending from the connector housing portion and a second cover portion extending in a direction intersecting the first cover portion, the molded resin portion includes a first connecting portion that connects the second cover portion and the connector housing portion, The fixing portion protrudes from the first connecting portion.

3. The bus bar unit according to claim 2, the molded resin portion includes a second connecting portion that connects the first connecting portion and the first cover portion, and is made of fiber reinforced plastic.

4. The bus bar unit according to any one of claims 1 to 3, The molded resin portion includes a notch extending between the fixing portion and an end portion of the intermediate cover portion on the bolt fastening portion side.

5. The bus bar unit according to any one of claims 1 to 3, The molded resin portion is provided with a rotation suppression portion that prevents the busbar unit from tilting toward the connector housing portion when the bolt fastening portion is not bolted and the fixing portion is not fixed by catching on a receiving portion provided on the side of the battery pack.

Images