Wire harness and bus bar module

Abstract

To provide a wire harness capable of suppressing rattling of a flat wiring material with respect to a case.SOLUTION: The wire harness 1 includes a flat wiring material 3 and a case 2 having a wiring path 23 for accommodating the flat wiring material, wherein the wiring path includes a bottom wall 23a facing the flat wiring material and a pair of side walls 23b disposed on both sides in a width direction with respect to the bottom wall, the flat wiring material is accommodated in the wiring path by pressing both end portions in the width direction against the pair of side walls, and a cross-sectional shape of the flat wiring material in a cross section orthogonal to an extending direction of the wiring path is a shape curved toward a depth direction D3 of the wiring path.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a wire harness and a bus bar module. [Background technology]

[0002] Conventionally, there is a busbar module having a flat wiring material. Patent Document 1 discloses a busbar module including a main body including a case, a busbar, and a flexible thin-plate electric wire, and a current sensor. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2023-009471 Summary of the Invention [Problem to be solved by the invention]

[0004] When a flat wiring material is housed in a case, it is desirable to be able to suppress rattle of the flat wiring material relative to the case.

[0005] An object of the present invention is to provide a wire harness and a bus bar module that can suppress rattle of a flat wiring material relative to a case. [Means for solving the problem]

[0006] The wire harness of the present invention comprises a flat wiring material and a case having a wiring path that accommodates the flat wiring material, wherein the wiring path has a bottom wall facing the flat wiring material and a pair of side walls arranged on both sides of the bottom wall in the width direction, and the flat wiring material is accommodated in the wiring path with both widthwise ends pressed against the pair of side walls, respectively, and the cross-sectional shape of the flat wiring material in a cross section perpendicular to the extension direction of the wiring path is a shape that is curved toward the depth direction of the wiring path. [Effects of the Invention]

[0007] In the wire harness according to the present invention, the wiring passage of the case has a bottom wall facing the flat wiring material and a pair of side walls arranged on both sides of the bottom wall in the width direction, and the flat wiring material is accommodated in the wiring passage with both ends in the width direction pressed against the pair of side walls, respectively. The cross-sectional shape of the flat wiring material in a cross section perpendicular to the extension direction of the wiring passage is a shape curved toward the depth direction of the wiring passage. According to the wire harness according to the present invention, the flat wiring material is held by the pair of side walls, thereby achieving the effect of suppressing rattling of the flat wiring material relative to the case. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram illustrating a wire harness and a bus bar module according to an embodiment. [Figure 2] FIG. 2 is a diagram showing a wire harness and a bus bar module assembled to a battery module. [Figure 3] FIG. 3 is a plan view of the flat wiring material according to the embodiment. [Figure 4] FIG. 4 is a plan view of the case according to the embodiment. [Figure 5] FIG. 5 is a perspective view of the wire harness according to the embodiment. [Figure 6] FIG. 6 is a cross-sectional view of the wire harness according to the embodiment. [Figure 7] FIG. 7 is a side view of the wire harness and the bus bar module according to the embodiment. [Figure 8] FIG. 8 is a side view of the wire harness according to the embodiment. [Figure 9] FIG. 9 is a plan view of the flat wiring material according to the embodiment. [Figure 10] FIG. 10 is a diagram showing another wire harness and a bus bar module according to the embodiment. [Figure 11]FIG. 11 is a cross-sectional view of another wire harness and a bus bar module according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a wire harness and a bus bar module according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiment. Furthermore, components in the following embodiments include those that can be easily imagined by a person skilled in the art or those that are substantially the same.

[0010] [Embodiment] An embodiment will be described with reference to FIGS. 1 to 11. The embodiment relates to a wire harness and a busbar module. FIG. 1 is a diagram showing the wire harness and the busbar module of the embodiment. FIG. 2 is a diagram showing the wire harness and the busbar module assembled to a battery module. FIG. 3 is a plan view of a flat wiring material according to the embodiment. FIG. 4 is a plan view of a case according to the embodiment. FIG. 5 is a perspective view of the wire harness according to the embodiment. FIG. 6 is a cross-sectional view of the wire harness according to the embodiment. FIG. 7 is a side view of the wire harness and the busbar module according to the embodiment. FIG. 8 is a side view of the wire harness according to the embodiment. FIG. 9 is a plan view of the flat wiring material according to the embodiment. FIG. 10 is a diagram showing another wire harness and the busbar module according to the embodiment. FIG. 11 is a cross-sectional view of another wire harness and the busbar module according to the embodiment. FIG. 6 shows a cross section taken along line VI-VI of FIG. 1. FIG. 11 shows a cross section taken along line XI-XI of FIG. 10.

[0011] As shown in Fig. 1, the wire harness 1 of this embodiment includes a case 2 and a flat wiring material 3. The illustrated case 2 is configured to accommodate and hold a plurality of bus bars 10. The wire harness 1 can be combined with the bus bars 10 to form a bus bar module 200.

[0012] As shown in Fig. 2, the wire harness 1 and the bus bar module 200 can be applied to a battery module 110 of a battery pack 100. The battery module 110 has a plurality of battery cells 120 arranged in an arrangement direction AR. The battery pack 100 is mounted as a power source in a vehicle such as an electric vehicle or a hybrid electric vehicle.

[0013] The busbar 10 is a conductor formed of a conductive metal plate and is fixed to the electrode of the battery cell 120. The busbar 10 connects, for example, two adjacent battery cells 120 in series. The flat wiring material 3 connects multiple busbars 10 to a monitoring device 130 of the battery pack 100. The flat wiring material 3 may connect a thermistor arranged in the battery cell 120 to the monitoring device 130. The monitoring device 130 is a device that monitors the conditions of the battery cell 120, such as the voltage and temperature.

[0014] The flat wiring material 3 is connected to the monitoring device 130, for example, via a connector. As shown in FIG. 1, the flat wiring material 3 has a plurality of detection lines 9. The flat wiring material 3 is, for example, a flexible printed circuit board. The flexible printed circuit board has a base film, a coverlay, and a conductive layer. The base film and coverlay are flexible insulating resin layers. The conductive layer is sandwiched between the base film and the coverlay for protection. The conductive layer is, for example, a conductive metal foil, and has a plurality of circuit patterns including the detection lines 9. The detection lines 9 are connected to the circuit of the monitoring device 130.

[0015] The detection wire 9 is connected to the bus bar 10 via a chip fuse 6 mounted on the flat wiring material 3. The chip fuse 6 is a protective component that protects the circuit. In the wire harness 1 of this embodiment, a plate member 4 is interposed between the chip fuse 6 and the bus bar 10. The plate member 4 is connected to the bus bar 10 by welding or the like, and electrically connects the chip fuse 6 and the bus bar 10. The plate member 4 of this embodiment is arranged on the flat wiring material 3 as a voltage detection terminal that detects the voltage of the battery cell 120.

[0016] As shown in FIG. 3, the flat wiring material 3 has a main line 30 and multiple branch portions 31. The main line 30 has a longitudinal direction L and a width direction W. The shape of the main line 30 in a plan view is, for example, rectangular. Multiple detection lines 9 extend on the main line 30 along the longitudinal direction L. The main line 30 has a width Wd1. The branch portions 31 branch off from edges of the main line 30 in the width direction W. In this embodiment, the branch portions 31 extend from the main line 30 in the width direction W. At least one detection line 9 is arranged on the branch portion 31.

[0017] The conductive layer of the flat wiring material 3 has pads 32, 33 provided on the branch portion 31. The chip fuse 6 is connected to the pair of pads 32 by solder or the like. The chip fuse 6 mounted on the flat wiring material 3 is interposed between the detection wire 9 and the pads 33. The plate member 4 is connected to the pair of pads 33 by solder or the like. In other words, the plate member 4 is connected to the detection wire 9 via the chip fuse 6.

[0018] As shown in Fig. 4, the case 2 has a case body 20, a cover body 21, and a hinge portion 22. The case 2 is molded from, for example, an insulating synthetic resin. In this embodiment, the case body 20, the cover body 21, and the hinge portion 22 are molded integrally. The cover body 21 is connected to the case body 20 via the flexible hinge portion 22.

[0019] The case body 20 has a wiring path 23, a plurality of holding portions 24, and a plurality of support walls 25. The wiring path 23 is a passage that accommodates the main wire 30 of the flat wiring material 3. The extension direction D1 of the wiring path 23 is the longitudinal direction of the case 2. The holding portion 24 holds and accommodates the bus bar 10. The holding portion 24 has a rectangular frame shape and has a locking protrusion that locks the bus bar 10. The plurality of holding portions 24 are arranged along the wiring path 23 and are aligned in the extension direction D1.

[0020] The support wall 25 supports the branch portion 31 of the flat wiring material 3. The support wall 25 branches off from the wiring path 23 in a width direction D2 perpendicular to the extension direction D1. The support wall 25 protrudes from the wiring path 23 toward the side opposite to the cover body 21, and is arranged along the retaining portion 24.

[0021] The wiring path 23 has a bottom wall 23a and a pair of side walls 23b. The bottom wall 23a is a wall portion facing the main wire 30 of the flat wiring material 3. The bottom wall 23a extends along the extension direction D1. The shape of the wiring path 23 in a plan view is rectangular. The bottom wall 23a is provided from one end of the case body 20 to the other end. The pair of side walls 23b are arranged on both sides of the bottom wall 23a in the width direction D2. The pair of side walls 23b face each other in the width direction D2. The wiring path 23 has a width Wd2. The width Wd2 is the distance between one side wall 23b and the other side wall 23b. The width Wd2 of the wiring path 23 is narrower than the width Wd1 of the main wire 30.

[0022] The cover body 21 has a first cover 26 that covers the wiring path 23 and a plurality of second covers 27. The first cover 26 has a rectangular shape in a plan view. The first cover 26 is connected to the side wall 23b of the wiring path 23 via a hinge portion 22. The second cover 27 covers the support wall 25 of the case main body 20. The second cover 27 extends from the first cover 26 in the width direction D2. The plurality of second covers 27 are lined up in the extension direction D1.

[0023] In the wire harness 1 of this embodiment, as will be described below, the flat wiring material 3 is press-fitted into the wiring passage 23. This suppresses rattle of the flat wiring material 3 relative to the case 2.

[0024] As shown in Figures 5 and 6, the side walls 23b are erected from the ends of the bottom wall 23a in the width direction D2. The main wire 30 of the flat wiring material 3 is accommodated in the wiring path 23 in a curved state. The bottom wall 23a of the wiring path 23 faces the main wire 30 in the depth direction D3. The main wire 30 is accommodated in the wiring path 23 with both widthwise ends 30e pressed against the pair of side walls 23b, respectively. That is, the main wire 30 is accommodated in the wiring path 23 with one end 30e pressed against one side wall 23b and the other end 30e pressed against the other side wall 23b. Therefore, the main wire 30 is sandwiched from both sides in the width direction D2 by the pair of side walls 23b.

[0025] The cross-sectional shape of the main wire 30 in a cross section perpendicular to the extension direction D1 of the wiring path 23 is a shape curved toward the depth direction D3 of the wiring path 23. In the flat wiring material 3 shown in Figures 5 and 6, the main wire 30 has a shape curved toward the bottom wall 23a. That is, the central portion 30c in the width direction is curved so as to be convex toward the bottom wall 23a relative to both end portions 30e.

[0026] The widthwise end portion 30e of the main wire 30 is supported by the side wall 23b, thereby suppressing rattle of the flat wiring material 3. The side wall 23b can suppress rattle of the flat wiring material 3 in the width direction D2, for example. The side wall 23b can also suppress rattle of the flat wiring material 3 in the depth direction D3. The main wire 30 may be accommodated in the wiring passage 23 with the widthwise central portion 30c in contact with the bottom wall 23a. In this case, the bottom wall 23a supports the central portion 30c and can suppress rattle of the flat wiring material 3 in the depth direction D3.

[0027] The flat wiring material 3 is housed in the case 2 with, for example, the bus bars 10 connected thereto. In this case, a chip fuse 6 and a plate member 4 are mounted on each branch portion 31, and the plate member 4 is joined to the bus bars 10. The multiple bus bars 10 are housed in the corresponding holding portions 24, respectively, and the main wires 30 of the flat wiring material 3 are pushed into the wiring path 23. The assembly work of the flat wiring material 3 and the bus bars 10 into the case 2 is performed, for example, by a worker. The worker pushes the main wires 30 of the flat wiring material 3 into the wiring path 23 while bending them. When the main wire 30 is pushed into the wiring path 23, both end portions 30e of the main wire 30 are pressed against the side walls 23b, respectively, and are supported by the side walls 23b.

[0028] The flat wiring material 3 may be connected to the bus bar 10 after being housed in the case 2. In this case, a chip fuse 6 and a plate member 4 are mounted in advance on each branch portion 31. The plate member 4 is joined to the bus bar 10 held by the case 2, for example. The assembling work of the bus bar 10 to the case 2 and the assembling work of the flat wiring material 3 to the case 2 are performed, for example, by a worker.

[0029] After the flat wiring material 3 is accommodated in the wiring passage 23, the cover body 21 is closed. FIG. 7 shows the cover body 21 in a closed state. The first cover 26 of the cover body 21 faces the bottom wall 23a and the main wire 30 of the flat wiring material 3 in the depth direction D3. The first cover 26 covers the wiring passage 23 and forms an accommodation space 29. The accommodation space 29 is a space that accommodates the main wire 30 of the flat wiring material 3 and is surrounded by the first cover 26, the bottom wall 23a, and a pair of side walls 23b. The first cover 26 restricts movement of the main wire 30 to prevent the main wire 30 from protruding from the wiring passage 23. By positioning the main wire 30 inside the wiring passage 23, the first cover 26 can maintain the curved shape of the main wire 30.

[0030] The busbar module 200 is assembled to the battery module 110 with the cover body 21 of the case 2 closed. As shown in Fig. 5 , the case 2 has engagement portions 20a and 20b that engage with the battery module 110. The engagement portions 20a and 20b protrude from the case main body 20 along the depth direction D3. The engagement portions 20a and 20b engage with, for example, the end plates of the battery module 110 to fix the case main body 20 to the battery module 110.

[0031] 7, the battery module 110 has a vertical side surface 110a. The side surface 110a is a surface that follows the vertical direction of the vehicle when the battery pack 100 is mounted on the vehicle. The busbar module 200 is assembled to the battery module 110 so that the bottom wall 23a faces the vertical side surface 110a. In this case, the width direction D2 of the wiring path 23 is the vertical direction, and the pair of side walls 23b face each other in the vertical direction.

[0032] The main wire 30 of the flat wiring material 3 is supported by the side walls 23b from both the vertical and horizontal sides. This suppresses rattle of the flat wiring material 3 due to vertical vibrations. Furthermore, the side walls 23b hold the main wire 30 and can suppress rattle of the flat wiring material 3 due to horizontal vibrations. For example, rattle of the flat wiring material 3 due to vibrations in the depth direction D3 is suppressed.

[0033] 8 shows an example of the curved shape of the flat wiring material 3 housed in the wiring path 23. The main wire 30 housed in the wiring path 23 may have a shape curved toward the side opposite to the bottom wall 23a. In this case, the cross-sectional shape of the main wire 30 in a cross section perpendicular to the extension direction D1 is a curved shape in which both end portions 30e are located on the bottom wall 23a side relative to the central portion 30c. The main wire 30 may be housed in the wiring path 23 with the central portion 30c in contact with the first cover 26.

[0034] The flat wiring material 3 may have an expanded portion 34 in a part of the main wire 30. Figure 9 shows a flat wiring material 3 having an expanded portion 34. The expanded portion 34 is provided on both sides of the main wire 30 in the width direction W. That is, in the part having the expanded portion 34, both ends of the main wire 30 in the width direction W protrude toward the width direction W. The shape of the expanded portion 34 in a plan view is, for example, rectangular or trapezoidal.

[0035] In the main wire 30, the width Wd1 of the portion having the widened portion 34 is larger than the width Wd3 of the portion not having the widened portion 34. The width Wd1 of the portion having the widened portion 34 is larger than the width Wd2 of the wiring path 23. The width Wd3 of the portion not having the widened portion 34 is smaller than the width Wd2 of the wiring path 23, for example. The flat wiring material 3 illustrated in FIG. 9 has widened portions 34 arranged at multiple locations on the main wire 30. The widened portions 34 are arranged, for example, between two adjacent branch portions 31. The multiple widened portions 34 may be arranged at equal intervals along the longitudinal direction L.

[0036] The main wire 30 is accommodated in the wiring passage 23 by pressing the widened portions 34 at both ends in the width direction W against the pair of side walls 23b, respectively. By pressing multiple points of the main wire 30 into the wiring passage 23, rattle of the flat wiring material 3 is appropriately suppressed.

[0037] 10 and 11 show a case 2 having a locking portion 28. The locking portion 28 is configured to lock the flat wiring material 3 and suppress rattle of the flat wiring material 3. The locking portion 28 in FIGS. 10 and 11 is disposed in the wiring path 23 of the case 2. More specifically, the locking portion 28 is a protrusion protruding from a pair of side walls 23b.

[0038] 10, a plurality of locking portions 28 are arranged at intervals along the extension direction D1 on each side wall 23b. The locking portions 28 are arranged, for example, between two adjacent support walls 25. The locking portion 28 arranged on one side wall 23b and the locking portion 28 arranged on the other side wall 23b face each other in the width direction D2.

[0039] As shown in FIG. 11 , the locking portion 28 protrudes from the inner wall surface of the side wall 23b in the width direction D2. The locking portion 28 protrudes from the tip of the side wall 23b. The locking portion 28 has a locking surface 28a facing the bottom wall 23a. The main wire 30 of the flat wiring material 3 is accommodated in the wiring path 23 so as to curve toward the bottom wall 23a. The locking portion 28 locks the end 30e of the main wire 30 with the locking surface 28a. The case 2 having the locking portion 28 can stabilize the posture of the main wire 30 by locking the end 30e of the main wire 30. In addition, the locking portion 28 can restrict movement of the main wire 30 to prevent the main wire 30 from protruding from the wiring path 23.

[0040] The main wire 30 may be inserted into the wiring path 23 so that the central portion 30c in the width direction is in contact with the bottom wall 23a and both end portions 30e are locked by the locking portions 28. In this case, both end portions 30e and the central portion 30c of the main wire 30 are supported, thereby effectively suppressing rattle of the flat wiring material 3. When the flat wiring material 3 has an enlarged portion 34, it is preferable that the locking portions 28 are provided at positions where the enlarged portion 34 can be locked.

[0041] The location where locking portion 28 is provided is not limited to side wall 23b. Case 2 may have locking portion 28 provided on cover body 21, for example. In this case, locking portion 28 may be a protrusion that protrudes from first cover 26 toward bottom wall 23a.

[0042] As described above, the wire harness 1 of this embodiment includes the flat wiring material 3 and the case 2. The case 2 includes the wiring path 23 that accommodates the flat wiring material 3. The wiring path 23 includes a bottom wall 23a facing the flat wiring material 3 and a pair of side walls 23b arranged on both sides of the bottom wall 23a in the width direction D2. The flat wiring material 3 is accommodated in the wiring path 23 with both widthwise ends 30e pressed against the pair of side walls 23b, respectively. The cross-sectional shape of the flat wiring material 3 in a cross section perpendicular to the extension direction D1 of the wiring path 23 is curved toward the depth direction D3 of the wiring path 23. By pressing both ends 30e of the curved flat wiring material 3 against the side walls 23b, rattling of the flat wiring material 3 in the wiring path 23 is suppressed.

[0043] The flat wiring material 3 of this embodiment has a main wire 30 and branch portions 31 branching from the main wire 30. In this case, the flat wiring material 3 is accommodated in the wiring passage 23, for example, by pressing both widthwise end portions 30e of the main wire 30 against the pair of side walls 23b, respectively. Since the main wire 30 is supported from both sides by the side walls 23b, rattling of the flat wiring material 3 is suppressed.

[0044] The case 2 may have locking portions 28 that lock both widthwise ends 30e of the flat wiring material 3 housed in the wiring passage 23. In this case, the cross-sectional shape of the flat wiring material 3 in a cross section perpendicular to the extension direction D1 of the wiring passage 23 is a shape that curves toward the bottom wall 23a. By locking both ends 30e by the locking portions 28, rattling of the flat wiring material 3 is suppressed.

[0045] The locking portions 28 are, for example, protrusions protruding from the pair of side walls 23b. In this case, the locking portions 28 can lock both end portions 30e of the flat wiring material 3 press-fitted into the wiring passage 23, thereby stabilizing the posture of the flat wiring material 3.

[0046] The busbar module 200 of this embodiment includes a wire harness 1 and a busbar 10 held by a case 2 and connected to a flat wiring material 3. The busbar module 200 is assembled to the battery module 110 so that the bottom wall 23a faces the vertical side surface 110a of the battery module 110. When the bottom wall 23a of the wiring path 23 faces the vertical side surface 110a, rattle of the flat wiring material 3 is likely to occur if the flat wiring material 3 is not held. In the busbar module 200 of this embodiment, rattle of the flat wiring material 3 is suppressed by holding the flat wiring material 3 by a pair of side walls 23b.

[0047] The flat wiring material 3 is not limited to a flexible printed circuit board, but may be a flexible flat cable (FFC) or other elastically deformable plate-like wiring material.

[0048] The contents disclosed in the above embodiments can be implemented in appropriate combinations. [Explanation of symbols]

[0049] 1: Wire harness 2: Case 3: Flat wiring material, 4: Plate material 6: Chip fuse, 9: Detection line 10: Bus bar 20: Case body, 21: Cover body, 22: Hinge part 23: Cabling path, 23a: Bottom wall, 23b: Side wall 24: holding portion, 25: support wall, 26: first cover, 27: second cover 28: Locking part 30: Main line, 30c: Center, 30e: End 31: Branch, 32, 33: Pad 100: Battery pack, 110: Battery module, 120: Battery cell 130: Monitoring device 200: Busbar module D1: Extension direction, D2: Width direction, D3: Depth direction L: Longitudinal direction, W: Width direction Wd1: Width of main line, Wd2: Width of cable routing

Claims

1. Flat cable ties and A case having a wiring path that accommodates the flat wiring material; Equipped with The wiring path has a bottom wall facing the flat wiring material and a pair of side walls arranged on both sides of the bottom wall in the width direction, The flat wiring material is accommodated in the wiring path with both widthwise ends pressed against the pair of side walls, The cross-sectional shape of the flat wiring material in a cross section perpendicular to the extension direction of the wiring path is a shape curved toward the depth direction of the wiring path. A wire harness characterized by:

2. The flat wiring material has a trunk line and a branch portion branching from the trunk line, The flat wiring material is accommodated in the wiring path by pressing both widthwise ends of the main wire against the pair of side walls. The wire harness according to claim 1 .

3. The case has a locking portion that locks both widthwise ends of the flat wiring material accommodated in the wiring path, The cross-sectional shape of the flat wiring material in a cross section perpendicular to the extension direction of the wiring path is a shape curved toward the bottom wall. The wire harness according to claim 1 .

4. The locking portions are protrusions protruding from the pair of side walls. The wire harness according to claim 3 .

5. The wire harness according to claim 1; a bus bar held by the case and connected to the flat wiring material; Equipped with The bottom wall is attached to the battery module so as to face the side surfaces of the battery module in the vertical direction. Busbar module.

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