Manufacturing method for flexible busbars

Abstract

We provide flexible busbars that not only improve the appearance but also stabilize the quality of the product. [Solution] The flexible busbar 1 comprises a flexible busbar body 2 and left fixing parts 2a1 and right fixing parts 2b1 that fix both sides of the flexible busbar body 2. When bending the flexible busbar body 2 from the bending line S1, a bending fixing part 2d including the bending line S1 is formed on the flexible busbar body 2, separate from the left fixing part 2a1 and right fixing part 2b1.

Description

Technical Field

[0001] The present invention relates to a flexible bus bar.

Background Art

[0002] Generally, when connecting energizable members (for example, batteries mounted on electric vehicles, hybrid cars, etc.), it is known to use a flexible bus bar. As such a flexible bus bar, for example, the one described in Patent Document 1 is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, when bending the flexible bus bar as described above, there were the following problems. This will be specifically described with reference to FIGS. 4 and 5.

[0005] As shown in FIG. 4(a), the conventional flexible bus bar 100 includes a horizontally long rectangular flexible bus bar body 101. This flexible bus bar body 101 is formed by laminating a conductive material foil 102 made of a thin plate-like and flexible metal such as copper, as shown in FIG. 4(b). Note that the flexible bus bar body 101 formed in this way can conduct a large current.

[0006] Thus, as shown in Figure 4(a), the flexible busbar body 101 configured in this way has its left side 101a fixed to form a left fixed portion 101a1, and its right side 101b fixed to form a right fixed portion 101b1. As a result, as shown in Figure 4(a), an unfixed portion 101c is formed between the left fixed portion 101a1 and the right fixed portion 101b1. Therefore, the flexible busbar 100 shown in Figure 4(a) is formed in this way. The unfixed portion 101c is flexible.

[0007] Thus, when the flexible busbar 100 formed in this manner is bent 90 degrees along the bending line S100 shown in Figure 4(a), it becomes as shown in Figure 4(b). That is, as shown in Figure 4(b), since the non-adherent portion 101c is involved in the 90-degree bending process, when the conductive material foil 102 located on the outermost circumferential surface 101ca side of the non-adherent portion 101c and the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-adherent portion 101c are bent 90 degrees along the bending line S100 shown in Figure 4(a), a distance difference occurs, resulting in an inner-outer difference. Therefore, as shown in Figures 4(a) and 4(b), when the left fixing portion 101a1 and the right fixing portion 101b1 are formed, the difference between the inside and outside causes the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c to bulge and wrinkle, as shown in Figure 4(b). Flexible busbars 100 that exhibit this phenomenon have an unsightly appearance and pose a problem in that they cannot be properly connected to electrically conductive components (for example, batteries installed in electric vehicles or hybrid cars) due to size incompatibility.

[0008] Therefore, in order to solve the above-mentioned problems, the method shown in Figure 5 can be considered.

[0009] In other words, as shown in Figure 5(a), only the left side 101a of the flexible busbar body 101 is fixed to form the left fixed portion 101a1. Then, in this state, when it is bent 90 degrees along the bending line S101 shown in Figure 5(a), it will be in the state shown in Figure 5(b). In other words, as shown in Figure 5(b), since the non-fixed portion 101c is involved in the 90-degree bending process, when the conductive material foil 102 located on the outermost circumferential surface 101ca side of the non-fixed portion 101c and the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c are bent 90 degrees along the bending line S101 shown in Figure 5(a). However, as shown in Figure 5(b), since the right-side fixed portion 101b1 shown in Figure 3 is not formed, the length of the conductive material foil 102 located on the outermost circumferential surface 101ca side of the non-fixed portion 101c becomes longer, and the length gradually decreases towards the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c. This prevents the wrinkled phenomenon shown in Figure 4(b) from occurring.

[0010] Then, as shown in Figure 5(c), the right side 101b of the flexible busbar body 101 is fixed to form the right fixing portion 101b1. At this time, in order to align the end face of the right fixing portion 101b1 (the right side 101b of the flexible busbar body 101) as shown in Figure 5(c), the right fixing portion 101b1 is cut along the cutting line S102. As a result, the flexible busbar 100 can be bent 90 degrees along the bending line S101 shown in Figure 5(a) without the wrinkles that occur as shown in Figure 4(b).

[0011] However, this approach not only increases the number of cutting steps but also increases the likelihood of product variation, potentially leading to inconsistent product quality.

[0012] Therefore, in view of the above problems, the present invention aims to provide a flexible busbar that can not only improve the appearance but also stabilize the quality of the product. [Means for solving the problem]

[0013] The object of the present invention described above is achieved by the following means. The reference numerals in parentheses indicate the embodiments described later, but the present invention is not limited thereto.

[0014] The flexible busbar according to claim 1 comprises a flexible busbar body (2) and A flexible busbar (1) having first fixing parts (left fixing part 2a1, right fixing part 2b1) that fix both sides of the flexible busbar body (2), The flexible busbar body (2) is characterized in that, when bending it from a predetermined position (bending line S1), a second fixing part (bending fixing part 2d) including the predetermined position (bending line S1) is formed on the flexible busbar body (2), separate from the first fixing part (left fixing part 2a1, right fixing part 2b1).

[0015] The flexible busbar according to claim 2 is characterized in that, in the flexible busbar (1) described in claim 1, when bending the flexible busbar body (2) from a plurality of predetermined positions, a second fixing portion (bending fixing portion 2d) is formed on the flexible busbar body (2) separately from the first fixing portion (left fixing portion 2a1, right fixing portion 2b1), such that each of the plurality of predetermined positions includes the plurality of predetermined positions.

[0016] The flexible bus bar according to claim 3 is characterized in that, in the flexible bus bar (1) described in claim 1 or 2, the first fixing portion (left fixing portion 2a1, right fixing portion 2b1) and the second fixing portion (bending fixing portion 2d) are formed by heat welding. [Effects of the Invention]

[0017] Next, the effects of the present invention will be described with reference numerals in the drawings. The reference numerals in parentheses are those of the embodiments described later, but the present invention is not limited thereto.

[0018] According to the invention of claim 1, when bending from a predetermined position (bending line S1) of the flexible bus bar body (2), a second fixing portion (bending fixing portion 2d) including the predetermined position (bending line S1) is formed on the flexible bus bar body (2). Thereby, even if bending is performed from a predetermined position (bending line S1) of the flexible bus bar body (2), a flexible portion of the flexible bus bar body (2) (for example, the non-fixing portion (2c) as shown in FIG. 1) is not affected.

[0019] Therefore, according to the present invention, not only can the appearance be improved, but also the quality of the product can be stabilized.

[0020] Also, according to the present invention, since only the second fixing portion (bending fixing portion 2d) is formed in the portion including the predetermined position (bending line S1), the flexibility of the flexible portion of the flexible bus bar body (2) (for example, the non-fixing portion (2c) as shown in FIG. 1) can be maximally exerted.

[0021] According to the invention of claim 2, if the second fixing portion (bending fixing portion 2d) is formed on the flexible bus bar body (2) such that a plurality of predetermined positions are included in each of the plurality of predetermined positions, complex bending processing becomes possible.

[0022] According to the invention of claim 3, when heat is applied to the flexible bus bar (1) used for solder or brazing, etc., there is no possibility of melting. Furthermore, there is no possibility that the resistance value required for the flexible bus bar (1) cannot be obtained due to the influence of members used for solder or the like.

Brief Description of the Drawings

[0023] ]> [Figure 1](a) is a plan view of a flexible bus bar according to an embodiment of the present invention, and (b) is a side view when the flexible bus bar according to the same embodiment is bent at 90 degrees. [Figure 2] It is a side view when the flexible bus bar according to the same embodiment is bent in a stepped shape. [Figure 3] It is a side view when the flexible bus bar according to the same embodiment is bent into a U-shape. [Figure 4] (a) is a plan view of a conventional flexible bus bar, and (b) is a side view when the flexible bus bar in (a) is bent at 90 degrees. [Figure 5] (a) is a plan view of a conventional flexible bus bar, (b) is a side view when the flexible bus bar in (a) is bent at 9 degrees, and (c) is an explanatory view for explaining the state of cutting.

Mode for Carrying Out the Invention

[0024] Hereinafter, a flexible bus bar according to an embodiment of the present invention will be specifically described with reference to the drawings. In the following description, when indicating the up, down, left, and right directions, it refers to the up, down, left, and right as viewed from the front of the drawing.

[0025] <Schematic Explanation of Flexible Bus Bar> The flexible bus bar 1 according to the present embodiment can not only prevent the phenomenon of wrinkling but also enable bending processing that can stabilize the quality of the product. Specifically, the flexible bus bar 1 shown in FIG. 1 includes a flexible bus bar main body 2.

[0026] <Explanation of Flexible Bus Bar Main Body> As shown in Figure 1(a), the flexible busbar body 2 is formed in a horizontally elongated rectangular shape in plan view, and as shown in Figure 1(b), it is formed by laminating thin, flexible conductive material foils 3 made of metal such as copper. The flexible busbar body 2 formed in this manner can carry large currents.

[0027] Thus, as shown in Figure 1(a), the flexible busbar body 2 configured in this way has its left side 2a fixed by heat welding to form a left fixed portion 2a1, and its right side 2b fixed by heat welding to form a right fixed portion 2b1. As a result, as shown in Figure 1(a), a non-fixed portion 2c is formed between the left fixed portion 2a1 and the right fixed portion 2b1, and this non-fixed portion 2c is flexible.

[0028] Therefore, the flexible busbar 1 is constructed in this manner.

[0029] <Explanation of the bending process for flexible busbars> Incidentally, as shown in Figure 1(a), the non-fixed portion 2c has a bending fixing portion 2d formed on the left side of the center, separate from the left fixing portion 2a1 and the right fixing portion 2b1, which is fixed by heat welding. As shown in Figure 1(a), this bending fixing portion 2d includes the bending line S1 when the flexible busbar body 2 is bent by 90 degrees.

[0030] Thus, by forming such a bending fixing portion 2d, when the flexible busbar 1, that is, the flexible busbar body 2, is bent along the bending line S1 shown in Figure 1(a), it will be in the state shown in Figure 1(b). In other words, as shown in Figure 1(b), this bending process does not create a distance difference, or an in-outside difference, between the conductive material foil 3 located on the outermost surface 2ca side and the conductive material foil 3 located on the innermost surface 2cb side of the non-fixed portion 2c. In other words, as shown in Figure 1(b), the flexible portion of the non-fixed portion 2c is not involved in the bending process due to the bending fixing portion 2d, and is therefore not affected by the bending process. As a result, no distance difference, or an in-outside difference, occurs. Therefore, the phenomenon of wrinkles forming on the conductive material foil 3 located on the innermost surface 2cb side, as shown in Figure 4(b), which would occur due to a distance difference, or an in-outside difference, does not occur.

[0031] Furthermore, there is no need to perform cutting to align the end face of the right fixing portion 2b1 (the right side 2b of the flexible busbar body 2), as shown in Figure 5(c), which occurs due to the difference in distance, i.e., the difference between the inside and outside.

[0032] Therefore, according to the embodiment described above, there is no distance difference, or inverse difference, between the conductive material foil 3 located on the outermost surface 2ca side and the conductive material foil 3 located on the innermost surface 2cb side of the non-adhered portion 2c. As a result, the phenomenon of wrinkling that occurs in the conventional method does not occur, and problems such as an increase in cutting steps, increased product variation, and potential instability in product quality do not arise.

[0033] Therefore, according to this embodiment, not only can the appearance be improved, but the quality of the product can also be stabilized.

[0034] Furthermore, according to this embodiment, since the bending-fixed portion 2d is formed only in the portion located at the bending line S1 shown in Figure 1(a), the influence of the flexibility of the non-fixed portion 2c can be minimized. Therefore, the flexibility of the non-fixed portion 2c can be maximized.

[0035] Furthermore, by forming the bending fixing portion 2d as described above, complex bending processes as shown in Figures 2 and 3 become possible. Specifically, as shown in Figure 2, when bending the flexible busbar 1, that is, the flexible busbar body 2, to form a stepped shape, bending fixing portions 2d should be formed at the bending portion (the portion indicated by the dashed lines X1 and X2 in Figure 2). Similarly, as shown in Figure 3, when bending the flexible busbar 1, that is, the flexible busbar body 2, to form a U-shape, bending fixing portions 2d should be formed at the bending portion (the portion indicated by the dashed lines X3 and X4 in Figure 3). As a result, even with complex bending processes, there is no distance difference, i.e., an in-out-out difference, between the conductive material foil 3 located on the outermost circumferential surface 2ca side and the conductive material foil 3 located on the innermost circumferential surface 2cb side of the non-fixed portion 2c, thus preventing the wrinkles that occur in conventional designs. Furthermore, since there is no need to perform cutting to align the end face of the right fixing portion 2b1 (the right side 2b of the flexible busbar body 2), as shown in Figure 5(c), which occurs due to the difference in distance, i.e., the difference between the inside and outside, problems such as increased cutting steps, product variations, and potential instability in product quality do not occur.

[0036] Therefore, by forming bending fixing parts 2d in the parts to be bent (the parts indicated by dashed lines X1 and X2 in Figure 2, and the parts indicated by dashed lines X3 and X4 in Figure 3), not only can the appearance be improved, but the quality of the product can be stabilized, and furthermore, complex bending processes can be performed.

[0037] <Explanation of variations> It should be noted that the shapes shown in this embodiment are merely examples, and various modifications and changes are possible within the scope of the gist of the present invention as described in the claims. For example, in this embodiment, an example is shown in which the left fixing portion 2a1, the right fixing portion 2b1, and the bending fixing portion 2d are formed by heat welding, but it is not limited to this, and they may also be formed using solder or the like. However, heat welding is preferred. This is because if they are formed using solder or the like, the solder used in the solder may melt when heat is applied to the flexible busbar 1, and furthermore, the resistance value required for the flexible busbar 1 may not be obtained due to the influence of the materials used in the solder or the like. For this reason, heat welding is preferred.

[0038] Furthermore, although this embodiment describes the bending process using 90 degrees as an example, it is of course not limited to this and can be applied to various bending angles such as 80 degrees or 100 degrees. [Explanation of Symbols]

[0039] 1 Flexible bus bar 2 Flexible busbar body 2a1 Left fixing part (first fixing part) 2b1 Right fixing part (first fixing part) 2c Non-fixed part 2d Folding fastening part (second fastening part) S1 Folding line (predetermined position)

Claims

1. Flexible busbar body, A flexible busbar having a first fixing portion that fixes both sides of the flexible busbar body, A flexible busbar in which, when bending the flexible busbar body from a predetermined position, a second fixing portion including the predetermined position is formed on the flexible busbar body, separate from the first fixing portion.

2. The flexible busbar according to claim 1, wherein, when bending the flexible busbar body from a plurality of predetermined positions, a second fixing portion is formed on the flexible busbar body, separate from the first fixing portion, such that each of the plurality of predetermined positions includes the plurality of predetermined positions.

3. The flexible bus bar according to claim 1 or 2, wherein the first fixing portion and the second fixing portion are formed by heat welding.

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