Bus bar module

Abstract

To provide a bus bar module capable of suppressing deformation of a case without increasing man-hours for assembling a cover.SOLUTION: The case 20 includes a bus bar housing row portion in which a plurality of bus bar housing portions 23A and 23B are coupled by a coupling member 24 and arranged in two rows along the stacking direction, a support plate member 25 that connects the bus bar housing portion 23A in one bus bar housing row portion and the bus bar housing portion 23B in the other bus bar housing row portion to each other, and a plurality of locking portions 27 that lock the cover by engaging with a plurality of engaging portions provided on the cover. Each of the plurality of block bodies 30 constituted by a pair of bus bar housing portion side 23A and side 23B connected to each other by the support plate member 25 is provided with one locking portion 27 disposed on one bus bar housing portion side 23A or the other bus bar housing portion side 23B so as not to be adjacent to each other along the stacking direction.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a busbar module. [Background technology]

[0002] Power supply devices mounted on various vehicles, such as electric vehicles that run using an electric motor and hybrid vehicles that run using both an engine and an electric motor, are equipped with a bus bar module having multiple bus bars connected to the electrodes of multiple unit cells.

[0003] The busbar module described in Patent Document 1 includes a busbar connected to the electrodes of multiple unit cells, a circuit body made of a flexible substrate on which a wiring pattern electrically connected to the busbar is provided to detect the voltage of the unit cells, a holder (case) that holds the busbar and is expandable and contractible along the stacking direction of the multiple unit cells, and a cover that is attached to the holder to protect the circuit body and the holder.

[0004] Furthermore, the circuit body has a strip-shaped main wire extending in the stacking direction and a strip-shaped branch wire extending so as to branch off from the main wire, and at least a portion of the branch wire has a folded-back portion and a connection portion attached to the bus bar at a location distal to the folded-back portion.

[0005] Therefore, because at least a portion of the branch wires includes a folded portion, when the battery assembly expands or contracts in the stacking direction due to thermal deformation of each cell, the folded portion of the branch wire of the circuit body bends or stretches, allowing each bus bar to move in the stacking direction of the cells.Similarly, the folding portion of the branch wire of the circuit body can bend or stretch to absorb size variations in the stacking direction of the battery assembly due to assembly tolerances of the cells. That is, the bus bar module does not require any deformation of the main wires of the circuit body, and substantially only the branch wires deform, so that it can easily accommodate expansion and contraction of the battery assembly and manufacturing variations. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2020-13767 Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the above-mentioned busbar module, when assembling the holder to a battery assembly in which multiple cells are stacked, the holder may deform in a wavy manner along the longitudinal direction, causing misalignment with each cell (electrode), which may hinder the assembly work.

[0008] That is, the holder is configured to be able to expand and contract along the stacking direction of the cells by connecting the multiple busbar housing sections that house the busbars with each other using expansion and contraction sections (connecting members), and deformation is likely to occur at the expansion and contraction sections. In particular, when the circuit body is pressed against the holder by the cover, the reaction force from the folded-back section provided on a part of the branch wire of the flexible printed circuit board acts on the seat surface of the connection section for the busbar, which makes the expansion and contraction sections prone to deformation.

[0009] To prevent such deformation of the holder, it is desirable to provide locking portions in all busbar accommodating portions that engage with engaging portions provided on the cover to lock the cover, and to hold all busbar accommodating portions with the cover assembled to the holder.

[0010] However, if locking portions for locking the cover are provided in all busbar accommodating portions, a large number of engaging portions must be locked to a large number of locking portions when assembling the cover, which increases the amount of work required by the worker.

[0011] The present invention has been made in consideration of the above-mentioned circumstances, and an object of the present invention is to provide a bus bar module that can suppress deformation of the case without increasing the number of steps required for assembling the cover. [Means for solving the problem]

[0012] The above object of the present invention can be achieved by the following configuration. a case to be assembled to a battery assembly in which a plurality of unit cells are stacked; a plurality of bus bars supported by the case and connected to electrodes of the unit cells in the battery assembly; a circuit body made of a flexible substrate having a wiring pattern electrically connected to the bus bars; and a cover assembled to the case to protect the circuit body, The case is a busbar accommodating row portion in which a plurality of busbar accommodating sections for accommodating the busbars are connected to each other by expandable and contractible connecting members and arranged in two rows along the stacking direction of the unit cells; a support plate member connecting the busbar accommodating portions in one of the busbar accommodating row portions to the busbar accommodating portions in the other of the busbar accommodating row portions; a plurality of locking portions that lock the cover by respectively engaging with a plurality of engaging portions provided on the cover; each of the plurality of block bodies formed by a set of the busbar accommodating portions connected to each other by the support plate member is provided with one of the locking portions arranged in one of the busbar accommodating portions or the other busbar accommodating portion so as not to be adjacent to each other in the stacking direction; Busbar module. [Effects of the Invention]

[0013] According to the present invention, it is possible to provide a bus bar module that can suppress deformation of the case without increasing the number of steps required for assembling the cover.

[0014] The present invention has been briefly described above. The details of the present invention will become clearer by reading the following detailed description of the invention (hereinafter referred to as "embodiments") with reference to the accompanying drawings. [Brief explanation of the drawings]

[0015] [Figure 1]FIG. 1 is an overall perspective view of a bus bar module according to one embodiment of the present invention. [Figure 2] FIG. 2 is an enlarged exploded perspective view of a portion of the bus bar module shown in FIG. [Figure 3] FIG. 3 is a perspective view of a part of the circuit body shown in FIG. 2 as viewed from below. [Figure 4] FIG. 4 is a plan view of the case and cover of the bus bar module according to this embodiment. [Figure 5] FIG. 5 is an enlarged view of a portion A of the cover shown in FIG. [Figure 6] FIG. 6 is an enlarged view of a portion B of the cover shown in FIG. [Figure 7] FIG. 7 is a cross-sectional view of a main part showing the locking portion of the case engaged with the engaging portion of the cover. [Figure 8] FIG. 8 is a cross-sectional view of a main part showing a state in which a connection portion provided at the tip of a branch line branched from a main line of a circuit body is attached to a bus bar. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Fig. 1 is an overall perspective view of a busbar module according to one embodiment of the present invention. Fig. 2 is an enlarged exploded perspective view of a portion of the busbar module shown in Fig. 1. Fig. 3 is a perspective view of a portion of the circuit body shown in Fig. 2 viewed from below.

[0017] As shown in Figures 1 to 3, the busbar module 10 of this embodiment includes a case 20 that is assembled to the battery assembly 1, a plurality of busbars 60 supported by the case 20, a circuit body 40 made up of a flexible printed circuit (FPC) having wiring patterns that are electrically connected to each of the busbars 60, and a cover 50 that is assembled to the case 20 and protects the circuit body 40.

[0018] The busbar module 10 constitutes a power supply device when assembled on top of the battery assembly 1. The power supply device is mounted on various vehicles, such as electric vehicles that run using an electric motor and hybrid vehicles that run using both an engine and an electric motor, and supplies power to the electric motor.

[0019] The battery assembly 1 is a battery assembly made up of a plurality of cells 3 stacked in a row along one direction. Each cell 3 is formed in a rectangular parallelepiped shape and has a pair of electrodes 5 protruding from one end and the other end of the top surface. One of the pair of electrodes 5 is a positive electrode and the other is a negative electrode. In the battery assembly 1, the poles of the electrodes 5 of the adjacent cells 3 are aligned, and the bus bar module 10 connects the plurality of cells 3 in series with bus bars 60.

[0020] 2 and 3, the circuit body 40 of this embodiment is arranged on each cell 3 along the stacking direction X, and has a strip-shaped main line 41 having a wiring pattern (voltage detection line) electrically connected to the bus bar 60. A connector 44 is attached to the end of the main line 41, and connects a voltage detection line drawn from the main line 41 to a voltage detection device (not shown).

[0021] Furthermore, strip-shaped branch wires 43 extending in a direction intersecting the longitudinal direction of the main wires 41 are provided on both opening edges 42a extending in the longitudinal direction of the multiple rectangular openings 42 formed in the widthwise center along the stacking direction X of the main wires 41. The branch wires 43 extend from the opening edges 42a so as to branch off from the main wires 41, and have folded-back portions 45 that are folded back downward toward the outside of the width direction of the main wires 41. These main wires 41 and branch wires 43 are made of FPC, and therefore can be flexibly deformed, particularly in a direction perpendicular to their respective surfaces.

[0022] Furthermore, a connection portion 47 to be attached to bus bar 60 is provided on the underside of the tip portion of branch wire 43 folded back downward by folding back portion 45. This connection portion 47 is attached to bus bar 60 via a flat terminal 49 that is electrically connected to bus bar 60.

[0023] The bus bar 60 of this embodiment is a plate-shaped member made of conductive metal that is connected to the electrodes 5 of the cells 3 in the battery assembly 1. As shown in Fig. 2, the bus bar 60 is provided with two electrode holes 61, 61 through which the electrodes 5, 5 of adjacent cells 3 are passed, and a terminal connection portion 63 to which a terminal 49 attached to the tip of the branch wire 43 is electrically connected.

[0024] The case 20 of this embodiment is integrally molded from, for example, an insulating synthetic resin, etc. The case 20 has busbar accommodating row portions 21A, 21B in which a plurality of busbar accommodating portions 23A, 23B for accommodating the busbars 60 are arranged in two rows along the stacking direction X of the unit cells.

[0025] Furthermore, as shown in Figures 4 to 6, the case 20 has a plurality of support plate members 25 that connect the busbar accommodating section 23A in one busbar accommodating row section 21A to the busbar accommodating section 23A in the other busbar accommodating row section 21B, and a plurality of locking sections 27 that lock the cover 50 by respectively engaging with a plurality of engaging sections 53 provided on the cover 50.

[0026] The bus bar accommodating portions 23A (23B) arranged in a row along the stacking direction X of the unit cells are connected to each other by connecting members 24 that are extendable and contractible. The connecting member 24 is a hinge that has a semi-cylindrical shape with a C-shaped cross section and is elastically deformable. A pair of both edges of the connecting member 24 are connected to opposing peripheral wall portions of the adjacent busbar accommodating portions 23A (23B), respectively. The connecting member 24 elastically deforms to decrease or increase the distance between the adjacent busbar accommodating portions 23A (23B), thereby absorbing shape errors of the cells 3, the case 20, etc. This absorbing effect can improve the assembly ease of the power supply device.

[0027] Furthermore, the support plate member 25 of this embodiment is formed in a crank shape that is extendable and contractible in a direction intersecting the stacking direction X. A set of busbar accommodating portions 23A, 23B connected to each other by the support plate member 25 and the support plate member 25 constitute a plurality of block bodies 30.

[0028] In this embodiment, the plurality of locking portions 27 are provided on each block body 30 one by one to engage with a plurality of engaging portions 53 provided on both longitudinal sides of the cover 50, which will be described later. The locking portions 27 provided on each block body 30 are arranged in one busbar accommodating portion 23A or the other busbar accommodating portion 23B so as not to be adjacent to each other along the stacking direction X.

[0029] That is, the plurality of locking portions 27 are provided one by one on the block body 30, whose rigidity is increased by connecting a pair of busbar accommodating portions 23A, 23B to each other with the support plate member 25, and are arranged in a staggered pattern in the stacking direction X by being arranged in the busbar accommodating portion 23A or the busbar accommodating portion 23B so as not to be adjacent to each other in the stacking direction X.

[0030] 6, depending on the structure of case 20, a standalone busbar accommodating portion 23C, which cannot be used to form block body 30 with support plate member 25, may be generated in the middle of the longitudinal direction of case 20. Therefore, a single locking portion 27 is provided in standalone busbar accommodating portion 23C that is not connected to support plate member 25.

[0031] The main wires 41 of the circuit body 40 are arranged in the longitudinal direction above a plurality of support plate members 25 disposed in the widthwise central portions of the two busbar accommodating array portions 21A, 21B. Note that the circuit body 40 of this example may or may not be supported by the support plate members 25, as long as the main wires 41 and the branch wires 43 have sufficient strength to maintain a self-supporting state.

[0032] The cover 50 of this embodiment is integrally molded from, for example, an insulating synthetic resin. As shown in Fig. 2, the cover 50 is attached from above to the case 20 housing the circuit body 40 so as to cover the circuit body 40 in order to protect the circuit body 40. With the cover 50 attached to the case 20, the connector 44 attached to the end of the circuit body 40 is exposed to the outside from the space covered by the case 20 and the cover 50 (see Fig. 1).

[0033] As shown in Fig. 4, the cover 50 has a rectangular flat top plate 51 and a plurality of engagement portions 53 provided on both longitudinal sides of the top plate. As shown in Fig. 7, the cover 50 is attached to the case 20 by engaging the corresponding locking portions 27 of the case 20 with the engagement portions 53 of the cover 50.

[0034] At this time, as shown in FIG. 8, the circuit body 40 is pressed against the case 20 side by the cover 50, and the reaction force of the folded portion 45 provided on a part of the branch line 43 made of FPC is applied to the seat surface (underside) of the terminal 49 for the bus bar 60, and the reaction force of the folded portion 45 is also applied to the bus bar accommodating portions 23A, 23B that accommodate the bus bar 60.

[0035] Here, the locking portions 27 of the case 20 are provided on each block body 30, the rigidity of which is increased by connecting a pair of busbar accommodating portions 23A, 23B to each other with a support plate member 25. Therefore, in the busbar module 10 of this embodiment, the cover 50 attached to the case 20 can hold the busbar accommodating portions 23A, 23B via the block body 30.

[0036] Furthermore, in the busbar module 10 of this embodiment, the locking portions 27 of the case 20 that engage with the locking portions 53 of the cover 50 are provided one by one on each of the block bodies 30 with increased rigidity, and the number of locking portions 53 of the cover 50 that engage with the locking portions 27 of the case 20 can be reduced by half compared to when locking portions 27 are provided in all of the busbar accommodating portions 23A, 23B. As a result, according to the bus bar module 10 of this embodiment, the number of steps required for assembling the cover 50 can be reduced.

[0037] Therefore, according to the busbar module 10 of this embodiment, the multiple locking portions 27 of the case 20, which are arranged in a staggered pattern along the stacking direction X to lock the cover 50, hold the busbar accommodating portions 23A, 23B via the block bodies 30, thereby suppressing deformation of the connecting members 24 that respectively connect the busbar accommodating portions 23A, 23A and the busbar accommodating portions 23B, 23B, and thereby suppressing wavy deformation of the case 20 along the longitudinal direction. As a result, when the busbar module 10 is assembled to the battery assembly 1, the case 20 is less likely to become misaligned with the cells 3 (electrodes 5), and assembly work is less likely to be hindered.

[0038] Furthermore, in the busbar module 10 of this embodiment, the circuit body 40 includes a strip-shaped main wire 41 arranged to extend along the stacking direction, a strip-shaped branch wire 43 extending from the main wire 41 so as to branch off from the main wire 41 and having a folded portion 45 at least in part, and a connection portion 47 provided at the tip of the branch wire 43 and attached to the busbar 60.

[0039] Therefore, when each cell 3 repeatedly expands and contracts in the thickness direction (stacking direction) or when the position of the cell 3 varies among manufactured battery assemblies 1 due to assembly tolerances of the cell 3, the folded-back portions 45 of the branch wires 43 bend and expand, allowing each bus bar 60 to move in the thickness direction of the cell 3. In other words, the bus bar module 10 does not require any deformation of the main wires 41 of the circuit body 40, and substantially only the branch wires 43 deform, making it possible to easily accommodate expansion and contraction of the battery assembly 1 and manufacturing variations.

[0040] When the cover 50 is attached to the case 20, the circuit body 40 is pressed against the case 20 by the cover 50, and the reaction force of the folded portion 45 provided on a part of the branch wire 43 acts on the busbar 60, and the reaction force of the folded portion 45 also acts on the busbar accommodating portions 23A, 23B that accommodate the busbar 60. However, as described above, the busbar module 10 can suppress deformation of the connecting member 24 and thereby suppress deformation of the case 20 by using the cover 50 attached to the case 20 to hold the busbar accommodating portions 23A, 23B via the block body 30, which has increased rigidity.

[0041] Furthermore, in the busbar module 10 of this embodiment, the support plate member 25 of the case 20 is formed in a crank shape that is expandable and contractible in a direction intersecting the stacking direction X. Therefore, when each cell 3 repeatedly expands and contracts in the width direction (direction intersecting the stacking direction), the crank-shaped support plate member 25 expands and contracts, allowing each busbar accommodating portion 23A, 23B to move in the width direction of the cell 3. In other words, the case 20 can easily accommodate expansion and contraction of the cell 3 in the width direction and manufacturing variations.

[0042] Furthermore, in the busbar module 10 of this embodiment, one locking portion 27 is provided in each busbar accommodating portion 23C that is not connected to the support plate member 25. Therefore, even in a case 20 structure in which a single busbar accommodating portion 23C that cannot form a block body 30 using the support plate member 25 is located in the middle of the case 20 in the longitudinal direction, the busbar accommodating portion 23C can be held by the locking portion 27 of the cover 50 attached to the case 20.

[0043] The present invention is not limited to the above-described embodiments, and can be appropriately modified, improved, etc. Furthermore, the material, shape, size, number, location, etc. of each component in the above-described embodiments are arbitrary and not limited as long as they can achieve the present invention.

[0044] Here, the features of the embodiments of the busbar module according to the present invention described above will be briefly summarized and listed below in [1] to [4]. [1] A battery assembly (1) including a case (20) assembled to a battery assembly (1) in which a plurality of cells (3) are stacked; bus bars (60) supported by the case (20) and connected to electrodes (5) of the cells (3) in the battery assembly (1); a circuit body (40) made of a flexible substrate having a wiring pattern electrically connected to each of the bus bars (60); and a cover (50) assembled to the case (20) to protect the circuit body (40); The case (20) is a plurality of busbar accommodating sections (23A, 23B, 23C) for accommodating the busbars (60) are connected to each other by extendable connecting members (24), and busbar accommodating row sections (21A, 21B) are arranged in two rows along the stacking direction (X) of the cells (3); a support plate member (25) connecting the busbar accommodating portion (23A) in one of the busbar accommodating row portions (21A) and the busbar accommodating portion (23B) in the other busbar accommodating row portion (21B) to each other; a plurality of locking portions (27) that lock the cover (50) by respectively engaging with a plurality of engaging portions (53) provided on the cover (50); In each of a plurality of block bodies (30) formed by a set of the bus bar accommodating portions (23A, 23B) connected to each other by the support plate member (25), one of the locking portions (27) is disposed in one of the bus bar accommodating portions (23A) or the other bus bar accommodating portion (23B) so as not to be adjacent to each other along the stacking direction (X). Busbar module (10).

[0045] According to the busbar module (10) having the configuration [1] above, the locking portions (27) of the case (20) that engage with the locking portions (53) of the cover (50) are provided one by one on each of the block bodies (30) with increased rigidity, and the number of the locking portions (53) of the cover (50) that engage with the locking portions (27) of the case (20) can be reduced by half compared to when locking portions (27) are provided in all of the busbar accommodating portions (23A, 23B). Furthermore, the multiple locking portions (27) of the case (20), which are arranged in a staggered pattern along the stacking direction (X) to lock the cover (50), hold the busbar accommodating portions (23A, 23B) via the block bodies (30), thereby suppressing deformation of the connecting members (24) connecting the busbar accommodating portions (23A, 23A) and the busbar accommodating portions (23B, 23B), respectively, and thus suppressing wavy deformation of the case (20) along the longitudinal direction.

[0046] [2] The circuit body (40) A strip-shaped main line (41) arranged to extend along the stacking direction (X); a belt-shaped branch line (43) extending from the main line (41) so as to branch off from the main line (41) and having at least a folded-back portion (45) in a part thereof; a connection portion (47) provided at the tip of the branch wire (43) and attached to the bus bar (60), The busbar module (10) according to [1] above.

[0047] According to the busbar module (10) having the configuration [2] above, no deformation is required in the main wires (41) of the circuit body (40), and substantially only the branch wires (43) are deformed, so that it is possible to easily accommodate expansion and contraction of the battery assembly (1) and manufacturing variations. When the cover (50) is attached to the case (20), the circuit body (40) is pressed against the case (20) by the cover (50), and the reaction force of the folded portion (45) provided on a part of the branch wire (43) is applied to the busbar accommodating portions (23A, 23B) that accommodate the busbars (60). However, the cover (50) attached to the case (20) holds the busbar accommodating portions (23A, 23B) via the block body (30) with increased rigidity, thereby suppressing deformation of the connecting member (24) and thus deformation of the case (20).

[0048] [3] The support plate member (25) is It is formed in a crank shape that can expand and contract in a direction intersecting the stacking direction (X), The busbar module (10) according to [1] above.

[0049] According to the busbar module (10) having the configuration [3] above, when each cell (3) repeatedly expands and contracts in the width direction (direction intersecting the stacking direction (X)), the crank-shaped support plate member (25) expands and contracts, and each busbar accommodating portion (23A, 23B) can move in the width direction of the cell (3). In other words, the case (20) can easily accommodate expansion and contraction of the cell (3) in the width direction and manufacturing variations.

[0050] [4] The bus bar accommodating portion (23C) to which the support plate member (25) is not connected is provided with one locking portion (27). The bus bar module (10) according to any one of the above [1] to [3].

[0051] According to the busbar module (10) having the configuration [4] above, even in the case (20) structure in which a single busbar accommodating portion (23C) that cannot be used to form a block body (30) using the support plate member (25) is located in the middle of the case (20) in the longitudinal direction, the busbar accommodating portion (23C) can be held by the engaging portion (53) of the cover (50) attached to the case (20). [Explanation of symbols]

[0052] 1...Battery assembly 3...Double cell 5...Electrode 10...Busbar module 20…case 21A... Busbar storage section 21B... Busbar storage section 23A...Busbar housing 23B...Busbar housing 23C...Busbar housing 24...Connecting member 25...Support plate member 27...Latching part 30...Block letters 40...Circuit body 50...Cover 60...busbar 53...Engagement portion X: stacking direction

Claims

1. a case to be assembled to a battery assembly in which a plurality of unit cells are stacked; bus bars supported by the case and connected to electrodes of the unit cells in the battery assembly; a circuit body made of a flexible substrate having wiring patterns electrically connected to the bus bars; and a cover assembled to the case to protect the circuit body, The case is a busbar accommodating row portion in which a plurality of busbar accommodating sections for accommodating the busbars are connected to each other by expandable and contractible connecting members and arranged in two rows along the stacking direction of the unit cells; a support plate member connecting the busbar accommodating portions in one of the busbar accommodating row portions to the busbar accommodating portions in the other of the busbar accommodating row portions; a plurality of locking portions that lock the cover by respectively engaging with a plurality of engaging portions provided on the cover; each of the plurality of block bodies formed by a set of the busbar accommodating portions connected to each other by the support plate member is provided with one of the locking portions arranged in one of the busbar accommodating portions or the other of the busbar accommodating portions so as not to be adjacent to each other in the stacking direction; Busbar module.

2. The circuit body is a strip-shaped main line arranged to extend along the stacking direction; a band-shaped branch line extending from the main line so as to branch off from the main line and having at least a folded-back portion; a connection portion provided at a tip end of the branch wire and attached to the bus bar, The busbar module according to claim 1 .

3. The support plate member is It is formed in a crank shape that can expand and contract in a direction intersecting the stacking direction, The busbar module according to claim 1 .

4. The bus bar accommodating portion to which the support plate member is not connected is provided with one of the locking portions. The busbar module according to any one of claims 1 to 3.

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