Flexible busbar and method for manufacturing a flexible busbar

Abstract

We provide flexible busbars that can improve the appearance of products, even those with complex (non-straight) shapes, and furthermore, stabilize product quality. [Solution] The flexible busbar body 6a is formed by laminating multiple conductive material foils 1 in a flexible, non-straight shape. The flexible busbar body 6a is provided with upper fixing parts 2 and lower fixing parts 3 that fix both sides of the busbar body 6a, and a non-fixing part 4 formed between the upper fixing parts 2 and lower fixing parts 3. Furthermore, a bending fixing part 5 is formed on a part of the non-fixing part 4, and this bending fixing part 5 is formed in a location where the non-fixing part 4 does not bulge when the non-fixing part 4 is bent from the bending line S2.

Description

Technical Field

[0001] The present invention relates to a flexible bus bar and a method for manufacturing the same.

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. The flexible bus bar described in this Patent Document 1 is manufactured by laminating and fixing conductive material foils made of a thin plate-like and flexible metal such as copper that has been cut out in a predetermined shape in advance.

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 connecting energizable members using the flexible bus bar as described above, the flexible bus bar is bent from a predetermined position so as to fit the space between the members, and the energizable members are connected.

[0005] However, when the flexible busbar described above was bent from a predetermined position, there was a possibility that the laminated conductive foil would bulge and wrinkle. Flexible busbars exhibiting this phenomenon were unsightly and had problems connecting conductive components due to size mismatches, etc., resulting in inconsistent product quality. This was particularly noticeable when the flexible busbar was made into a complex shape (non-straight shape).

[0006] Therefore, in view of the above problems, the present invention aims to provide a flexible busbar and a method for manufacturing a flexible busbar that can improve the appearance even if it has a complex shape (non-straight shape), and furthermore, can stabilize the quality of the product. [Means for solving the problem]

[0007] 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.

[0008] The flexible busbar according to claim 1 comprises a flexible busbar body (6a) which is formed by laminating a plurality of conductive materials (conductive material foil 1) and is flexible in a non-straight shape, The flexible busbar body (6a) has first fixing parts (upper fixing part 2, lower fixing part 3) that fix both sides of it, In a flexible busbar (6) having a non-fixed portion (4) formed between the first fixed portion (upper fixed portion 2, lower fixed portion 3), A second fixing portion (bending fixing portion 5) is formed on a part of the non-fixed portion (4), separate from the first fixing portion (upper fixing portion 2, lower fixing portion 3), which fixes a part of the non-fixed portion (4). The second fixing portion (bending fixing portion 5) is characterized in that it is formed in a location where the non-fixing portion (4) does not bulge when the non-fixing portion (4) is bent from a predetermined position (for example, the bending line S2 shown in Figure 2(a)).

[0009] The flexible busbar according to claim 2 is characterized in that, in the flexible busbar (6) described in claim 1, the second fixing portion (bending fixing portion 5) is formed at the predetermined position (for example, the bending line S2 shown in Figure 2(a)) or at the location where the plurality of conductive materials (conductive material foil 1) bulge when the bending process is performed (for example, see Figures 4(a) and (b)).

[0010] The method for manufacturing a flexible busbar according to claim 3 includes the step of laminating a plurality of conductive materials (conductive material foil 1) (see Figures 1(a) and (b)), The process involves fixing both sides of the laminated plurality of conductive materials (conductive material foil 1) to form a first fixed portion (upper fixed portion 2, lower fixed portion 3) and an unfixed portion (4) on the plurality of conductive materials (conductive material foil 1) (see Figure 1(c)), The process involves fixing a portion of the non-fixed portion (4) to form a second fixed portion (bending fixed portion 5) that is separate from the first fixed portion (upper fixed portion 2, lower fixed portion 3) (see Figure 1(d)), The process includes cutting out a flexible busbar (6) of a predetermined shape from the plurality of conductive materials (conductive material foil 1) on which the first fixing portion (upper fixing portion 2, lower fixing portion 3), the second fixing portion (bending fixing portion 5), and the non-fixing portion (4) are formed (see Figure 2(a)), The second fixing portion (bending fixing portion 5) is characterized in that it is formed in a location where the non-fixing portion (4) does not bulge when the non-fixing portion (4) is bent from a predetermined position (for example, the bending line S2 shown in Figure 2(a)). [Effects of the Invention]

[0011] Next, the effects of the present invention will be described with reference to the reference numerals in the drawings. Note that the reference numerals in parentheses are those of embodiments described later, but the present invention is not limited thereto.

[0012] According to the invention of claims 1 and 3, a portion of the non-fixed portion (4) is fixed by a second fixing portion (bending fixing portion 5), and the second fixing portion (bending fixing portion 5) is formed in a location where the non-fixed portion (4) does not bulge when the non-fixed portion (4) is bent from a predetermined position (for example, the bending line S2 shown in Figure 2(a)). As a result, the phenomenon of multiple conductive materials (conductive material foil 1) bulging and wrinkling does not occur. Therefore, according to the present invention, when connecting electrically conductive members, it is possible to eliminate the inability to properly connect them due to reasons such as mismatched sizes. Therefore, according to the present invention, the quality of the product can be stabilized.

[0013] Therefore, according to the present invention, even if the shape is complex (non-straight shape), the appearance can be improved, and furthermore, the quality of the product can be stabilized.

[0014] Furthermore, according to the invention of claim 3, when manufacturing the flexible busbar (6), the quality can be stabilized, and manufacturing efficiency can be improved.

[0015] Furthermore, suitable locations where the non-adherent portion (4) does not bulge due to bending include the predetermined position described in claim 2 (for example, the bending line S2 shown in Figure 2(a)), or locations where multiple conductive materials (conductive material foil 1) bulge when bent (for example, see Figures 4(a) and (b)). [Brief explanation of the drawing]

[0016] [Figure 1] (a) to (d) are explanatory diagrams illustrating a method for manufacturing a flexible busbar according to one embodiment of the present invention. [Figure 2](a) shows a front view of a flexible bus bar manufactured by the manufacturing method according to this embodiment, and (b) is a side view when the flexible bus bar shown in (a) is bent by 90 degrees. [Figure 3] It is an explanatory diagram for explaining a method of manufacturing a plurality of flexible bus bars by the manufacturing method according to this embodiment. [Figure 4] (a) to (d) are explanatory diagrams showing modified examples of the fixing portion for bending.

Embodiment for Carrying Out the Invention

[0017] Hereinafter, a method for manufacturing 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-right directions, it refers to the up-down, left-right as viewed from the front shown in the drawing.

[0018] <Explanation of the Manufacturing Method of the Flexible Bus Bar> The manufacturing method of the flexible bus bar according to this embodiment can improve the appearance even if the shape is complex (non-straight shape), and further can stabilize the quality of the product. Specifically, it is manufactured as follows.

[0019] First, a vertically long rectangular (straight shape) conductive material foil 1 made of a thin and flexible metal such as copper as shown in Fig. 1(a) is prepared in a state where a plurality of sheets are laminated. At this time, as shown in Fig. 1(b), it is assumed that a complex shape (non-straight shape) indicated by the broken line S1 in Fig. 1(b) is cut out from the plurality of laminated conductive material foils 1. Note that at this stage, it is only assumed and not cut out yet.

[0020] Next, the upper end surface 1a of the multiple laminated conductive material foils 1 shown in Figure 1(b) is fixed by heat welding to form an upper fixed portion 2 as shown in Figure 1(c), and the lower end surface 1b of the multiple laminated conductive material foils 1 shown in Figure 1(b) is fixed by heat welding to form a lower fixed portion 3 as shown in Figure 1(c). As a result, a non-fixed portion 4 is formed between the upper fixed portion 2 and the lower fixed portion 3, as shown in Figure 1(c). This non-fixed portion 4 is flexible.

[0021] Next, as shown in Figure 1(d), the central portion of the non-adhered portion 4 of the multiple laminated conductive material foils 1 is fixed by heat welding, thereby forming a straight bending-type fixing portion 5 in the central portion of the non-adhered portion 4.

[0022] Next, in this state, the material is cut along the dashed line S1 shown in Figure 1(d), which was intended to be cut out, using a wire, press, or laser. This results in the production of a flexible busbar 6 with a complex shape (non-straight shape) as shown in Figure 2(a).

[0023] Thus, when the flexible busbar 6 manufactured as described above is bent, for example, by 90 degrees along the bending line S2 shown in Figure 2(a), the flexible busbar 6, that is, the flexible busbar body 6a, is in the state shown in Figure 2(b). At this time, the multiple laminated conductive material foils 1 do not bulge. This is due to the formation of the bending fixing portion 5.

[0024] In other words, by forming the bending fixing portion 5, this bending process will prevent a distance difference, or inward / outward difference, from occurring between the conductive material foil 1 located on the outermost circumferential surface 4a side and the conductive material foil 1 located on the innermost circumferential surface 4b side of the non-fixed portion 4, as shown in Figure 2(b). Therefore, when the flexible busbar 6 described above is bent from a predetermined position, the phenomenon of the laminated conductive material foil 1 bulging and wrinkling is thought to be caused by this distance difference, or inward / outward difference.

[0025] Therefore, by forming the bending-adhering portion 5 as in this embodiment, as shown in Figure 2(b), the flexible portion of the non-adhering portion 4 does not participate in the bending process and is therefore not affected by the bending process. As a result, no distance difference, i.e., an inner-outer difference, occurs. Consequently, the phenomenon of the conductive material foil 1 swelling and wrinkling caused by the distance difference, i.e., an inner-outer difference, does not occur.

[0026] Therefore, according to the embodiment described above, there is no distance difference, or inward / outward difference, between the conductive material foil 1 located on the outermost circumferential surface 4a side and the conductive material foil 1 located on the innermost circumferential surface 4b side of the non-adhered portion 4. As a result, the phenomenon of the conductive material foil 1 swelling and wrinkling due to the inward / outward difference, as in the conventional method, does not occur. Therefore, according to this embodiment, it is possible to eliminate the inability to properly connect electrically conductive members due to reasons such as mismatched sizes. Thus, according to this embodiment, the quality of the product can be stabilized.

[0027] Therefore, according to this embodiment, even if the shape is complex (non-straight shape), the appearance can be improved, and furthermore, the quality of the product can be stabilized.

[0028] <Explanation of variations> It should be noted that the shapes and other features 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, although this embodiment shows an example of manufacturing one flexible busbar 6, it is also possible to manufacture multiple flexible busbars 6 together. This will be explained in detail with reference to Figure 3.

[0029] Prepare a stack of multiple thin, flexible conductive material foils 1A made of a metal such as copper, arranged in a horizontally elongated rectangular shape (straight shape), as shown in Figure 3(a). At this stage, as shown in Figure 3(b), it is assumed that multiple complex shapes (non-straight shapes) will be cut out from the stacked conductive material foils 1A, as indicated by the dashed line S1 in Figure 3(b). Note that at this stage, this is only an assumption and no cutting has been done yet.

[0030] Next, the upper end surface 1Aa side of the multiple laminated conductive material foils 1A shown in Figure 3(b) is fixed by heat welding to form the upper fixed portion 2 as shown in Figure 3(c), and the lower end surface 1Ab side of the multiple laminated conductive material foils 1 shown in Figure 3(b) is fixed by heat welding to form the lower fixed portion 3 as shown in Figure 3(c). As a result, a non-fixed portion 4 is formed between the upper fixed portion 2 and the lower fixed portion 3, as shown in Figure 3(c). This non-fixed portion 4 is flexible.

[0031] Next, as shown in Figure 3(d), the central portion of the non-adhered portion 4 of the multiple laminated conductive material foils 1A is fixed by heat welding, thereby forming a straight bending-type fixing portion 5 in the central portion of the non-adhered portion 4.

[0032] Next, in this state, the material is cut along the multiple dashed lines S1 shown in Figure 3(d), which were intended to be cut out, using a wire, press, or laser. This results in the production of multiple flexible busbars 6 as shown in Figure 2(a).

[0033] Therefore, even with this method, as described above, it is possible to improve the appearance of the product, even if it has a complex shape (non-straight shape), and furthermore, to stabilize the quality of the product.

[0034] Furthermore, because multiple pieces can be cut at once, manufacturing time can be reduced.

[0035] Furthermore, in this embodiment, an example is shown in which multiple laminated conductive material foils 1 are fixed together (upper fixing portion 2 and lower fixing portion 3 shown in Figure 1(c), and bending fixing portion 5 shown in Figure 1(d)) and then cut out. However, the invention is not limited to this, and the following method may also be used. That is, each conductive material foil 1 may be cut into a complex shape (non-straight shape) as shown by the dashed line S1 in Figure 1(d), and then multiple of these cut conductive material foils 1 may be laminated together and fixed together (upper fixing portion 2 and lower fixing portion 3 shown in Figure 1(c), and bending fixing portion 5 shown in Figure 1(d)) to manufacture a flexible busbar 6 as shown in Figure 2(a).

[0036] However, as shown in this embodiment, it is preferable to fix multiple laminated conductive material foils 1 together (upper fixing portion 2 and lower fixing portion 3 shown in Figure 1(c), and bending fixing portion 5 shown in Figure 1(d)) before cutting them out. If the conductive material foils 1 are cut out one by one and then fixed, misalignment may occur during lamination, potentially resulting in unstable quality and reduced manufacturing efficiency when producing flexible busbars 6 as shown in Figure 2(a). Therefore, it is preferable to fix multiple laminated conductive material foils 1 together (upper fixing portion 2 and lower fixing portion 3 shown in Figure 1(c), and bending fixing portion 5 shown in Figure 1(d)) before cutting them out.

[0037] Furthermore, in this embodiment, an example is shown in which the upper fixing portion 2, the lower fixing portion 3, and the bending fixing portion 5 are formed by heat welding. However, the method is not limited to this, and they may also be formed using solder or the like. Nevertheless, 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 6, and furthermore, the resistance value required for the flexible busbar 6 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, in this embodiment, an example is shown in which a bending fixing portion 5 is formed in the central part of the non-fixed portion 4. However, it is not limited to this, and the bending fixing portion 5 can be formed anywhere on the non-fixed portion 4 as long as it is formed in a location where the non-fixed portion 4 does not bulge when the non-fixed portion 4 of the flexible busbar body 6a is bent. For example, as shown in Figure 4(a), when the non-fixed portion 4 is bent, a bending fixing portion 5A may be formed at the corner where bulging is likely to occur due to the difference in distance between the inner and outer parts. Also, the bending fixing portion 5B may be formed in a triangular shape as shown in Figure 4(b), rather than a rectangular shape as shown in Figure 4(a). In other words, the shape can be anything. On the other hand, as shown in Figure 4(c), a bending fixing portion 5C may be formed in an inclined shape from the upper right to the lower left in the figure, connecting the upper fixing portion 2 and the lower fixing portion 3.

[0039] Furthermore, instead of forming the bending fastening portions 5 and 5C continuously as described above, the bending fastening portions 5D may be formed at intervals, as shown in Figure 4(d). Alternatively, any combination of the bending fastening portions 5, 5A to 5D described above may be used to form the portions.

[0040] In other words, when the non-fixed portion 4 of the flexible busbar body 6a is bent, it is sufficient to form the non-fixed portion 4 in a location where it does not bulge as a result of the bending process; therefore, the size and shape of the fixing portion for bending can be any.

[0041] 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]

[0042] 1. Conductive material foil (conductive material) 2 Upper fixing part (first fixing part) 3. Lower fixing part (first fixing part) 4 Non-fixed part 5. Folding fastening part (second fastening part) 6 Flexible busbars S2 Folding line (predetermined position)

Claims

1. A flexible busbar body, which has a flexible, non-straight shape and is formed by laminating multiple conductive materials, The first fixing portion secures both sides of the flexible busbar body, A flexible busbar having non-fixed portions formed between the first fixed portions, A second fixing portion is formed on a part of the non-fixed portion, separate from the first fixing portion, to fix the part of the non-fixed portion. The second fixing portion is a flexible busbar formed in a location where the non-fixing portion does not bulge when the non-fixing portion is bent from a predetermined position.

2. The flexible bus bar according to claim 1, wherein the second fixing portion is formed at the predetermined position or at the location where the plurality of conductive materials bulge when the bending process is performed.

3. A process of laminating multiple conductive materials, A step of fixing both sides of the stacked plurality of conductive materials to form a first fixed portion and an unfixed portion in the plurality of conductive materials, A step of fixing a part of the non-fixed portion to form a second fixed portion separate from the first fixed portion, The process includes cutting out a flexible busbar of a predetermined shape from the plurality of conductive materials on which the first fixed portion, the second fixed portion, and the non-fixed portion are formed, A method for manufacturing a flexible busbar, wherein the second fixing portion is formed in a location where the non-fixed portion does not bulge when the non-fixed portion is bent from a predetermined position.

Images