Circuit protection unit and conductive module

Abstract

The objective is to provide a circuit protection unit and a conductive module that can properly protect the connection portion between the circuit protection component and a pair of terminal fittings. [Solution] The circuit protection unit 20 applied to the conductive module 1 is characterized by comprising: a circuit protection component 30; a first terminal fitting 40 for electrically connecting a first electrical connection part 41 to the circuit protection component 30; a second terminal fitting 50 for electrically connecting a second electrical connection part 51 to the circuit protection component 30; an insulating support member 70 formed in a plate shape on which the first electrical connection part 41 and the second electrical connection part 51 are placed; and an insulating covering resin part 80 provided on the support member 70, which encloses the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30 installed spanning the first electrical connection part 41 and the second electrical connection part 51.

Description

Technical Field

[0001] The present invention relates to a circuit protection unit and a conductive module.

Background Art

[0002] In a battery module in which a plurality of battery cells are arranged, the conductive module electrically connects the plurality of battery cells using a plurality of connection conductors. Then, the conductive module electrically connects each connection conductor to a battery monitoring unit that monitors the battery state of the battery cell using a wiring component such as an electric wire. For example, the following Patent Document 1 discloses this type of conductive module. In such a conductive module, a combination of a pair of connection conductors and a conductor portion of a wiring component is provided for each connection conductor, and a circuit protection component such as a fuse may be interposed between the connection conductor and the conductor portion of the wiring component in each combination. For example, the following Patent Document 2 discloses a circuit protection unit (composed of a chip fuse, a pair of terminal fittings, and a resin portion) applied to this conductive module.

Prior Art Documents

Patent Documents

[0006] To achieve the above objective, the circuit protection unit according to the present invention is characterized by comprising: a circuit protection component that melts a fusible part when an overcurrent flows between a first electrical connection target and a second electrical connection target; a first terminal fitting having a first electrical connection portion electrically connected to a first electrode of the circuit protection component and electrically connected to the first electrical connection target; a second terminal fitting having a second electrical connection portion electrically connected to a second electrode of the circuit protection component and electrically connected to the second electrical connection target; an insulating support member formed in the shape of a plate on which the first electrical connection portion and the second electrical connection portion are placed; and an insulating covering resin portion provided on the support member and enclosing the first electrical connection portion, the second electrical connection portion, and the circuit protection component installed spanning the first electrical connection portion and the second electrical connection portion.

[0007] To achieve the above objective, the conductive module according to the present invention comprises a connecting conductor electrically connected to the electrode terminals of a battery cell constituting the battery module, and a circuit protection unit that electrically connects the connecting conductor to a battery monitoring unit that monitors the battery state of the battery cell, wherein the circuit protection unit has a circuit protection component that melts a fusible part when an overcurrent flows between the connecting conductor and the battery monitoring unit, a first electrical connection part electrically connected to the first electrode of the circuit protection component, a first terminal fitting electrically connected to the connecting conductor, and a second electrical connection part electrically connected to the second electrode of the circuit protection component. The present invention is characterized by comprising: a second terminal fitting having a function and being electrically connected to the battery monitoring unit; a wiring component interposed between the second terminal fitting and the battery monitoring unit, having one end electrically connected to the second terminal fitting and the other end electrically connected to the battery monitoring unit, comprising a conductor portion; an insulating support member formed in a plate shape on which the first electrical connection portion and the second electrical connection portion are placed; and an insulating covering resin portion provided on the support member, enclosing the first electrical connection portion, the second electrical connection portion, and the circuit protection component installed spanning the first electrical connection portion and the second electrical connection portion. [Effects of the Invention]

[0008] The circuit protection unit and conductive module according to the present invention have the effect of properly protecting the connection portion between the circuit protection component and the pair of terminal fittings. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a perspective view showing a schematic configuration of the circuit protection unit and conductive module according to the first embodiment. [Figure 2] Figure 2 is a schematic diagram showing the general configuration of a battery module and the connecting conductors that electrically connect the electrode terminals of the battery cells constituting the battery module. [Figure 3]Figure 3 is a perspective view showing a schematic configuration of the circuit protection unit according to the first embodiment. [Figure 4] Figure 4 is a plan view illustrating the covering resin portion provided in the circuit protection unit according to the first embodiment. [Figure 5] Figure 5 is a perspective view showing the schematic configuration of the circuit protection unit according to the second embodiment. [Figure 6] Figure 6 is a perspective view showing the schematic configuration of the circuit protection unit according to the third embodiment. [Figure 7] Figure 7 is a perspective view showing a schematic configuration of the circuit protection unit according to the fourth embodiment. [Modes for carrying out the invention]

[0010] Embodiments of the present invention will be described in detail below with reference to the drawings. However, the present invention is not limited by these embodiments. Furthermore, some of the components in the following embodiments may be easily substituted or substantially identical to those that are easily substituted by those skilled in the art.

[0011] [First Embodiment] The conductive module 1 shown in Figure 1 is assembled into a battery module BM (see Figure 2) in which multiple battery cells BC are arranged, and by electrically connecting the battery module BM and a battery monitoring unit (not shown), the battery monitoring unit monitors the battery status of the battery cells BC. Furthermore, a battery pack composed of such conductive modules 1 and battery modules BM is mounted, for example, in a vehicle (BEV: Battery Electric Vehicle, HEV: Hybrid Electric Vehicle, etc.) that is equipped with a rotating machine as a power source, and supplies power to the rotating machine. Furthermore, a circuit protection unit 20 (see Figures 1 and 3) applied to such a conductive module 1 is composed of a circuit protection component 30 such as a fuse, a pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) electrically connected to the circuit protection component 30, and a support member 70 formed in a plate shape on which the pair of terminal fittings are placed. Furthermore, the circuit protection unit 20 and conductive module 1 of this embodiment are configured to properly protect the connection portion between the circuit protection component 30 and the pair of terminal fittings by providing a covering resin portion 80 on a plate-shaped support member 70. The configurations of the circuit protection unit 20 and conductive module 1 will be described in detail below with reference to Figures 1 to 4.

[0012] In this embodiment, as shown in Figure 2, the battery cell BC is formed in a rectangular shape with a cell body BCa having six outer wall surfaces. The battery cells BC are arranged so that their outer wall surfaces face each other, and the positive and negative electrode terminals BCb are provided on one of the six outer wall surfaces of the cell body BCa. Therefore, in this embodiment, the battery module BM has two electrode terminal groups BCc arranged on a single plane, each consisting of multiple electrode terminals BCb aligned along the arrangement direction of the battery cells BC.

[0013] Furthermore, as shown in Figure 2, the electrode terminal BCb in this embodiment is formed in a flat plate shape. The electrode terminal BCb is electrically connected to the connecting conductor 10, which will be described later, by joining the connecting conductor 10 to the electrode terminal BCb by laser welding or the like, as shown in Figure 2. The electrode terminal BCb may also be formed in a pole column shape with a male screw portion. In this case, the electrode terminal BCb and the connecting conductor 10 are electrically connected by screwing a female screw member into the male screw portion of the electrode terminal BCb and fixing the connecting conductor 10 to the electrode terminal BCb with screws.

[0014] In the following explanation, of the three intersecting directions, the first direction is referred to as the "axial direction X," the second direction as the "width direction Y," and the third direction as the "height direction Z." Here, the axial direction X, the width direction Y, and the height direction Z are mutually orthogonal. The axial direction X typically corresponds to the direction connecting the first electrical connection part 41 of the first terminal fitting 40 and the second electrical connection part 51 of the second terminal fitting 50, the extending direction of the support member 70, etc. The width direction Y corresponds to the width direction of the first electrical connection part 41, the width direction of the second electrical connection part 51, the width direction of the support member 70, etc. The height direction Z typically corresponds to the thickness direction of the first electrical connection part 41, the thickness direction of the second electrical connection part 51, the thickness direction of the support member 70, etc.

[0015] As shown in Figure 1, the conductive module 1 includes a connecting conductor 10 that is electrically connected to the electrode terminal BCb of the battery cell BC that constitutes the battery module BM, and a circuit protection unit 20 that electrically connects the connecting conductor 10 to a battery monitoring unit (not shown) that monitors the battery state of the battery cell BC.

[0016] The connection conductor 10 is a conductive component formed of a material having conductivity such as metal. The connection conductor 10 in the present embodiment is a plate-shaped conductive component made of metal called a bus bar. For example, by press-forming a metal plate according to the shape corresponding to each part, each part is integrally formed. As shown in FIGS. 1 and 2, the connection conductor 10 is formed in a rectangular flat plate shape and is joined to the electrode terminals BCb of the battery cells BC arranged adjacent to each other, thereby electrically connecting the battery cells BC to each other.

[0017] As shown in FIGS. 3 and 4, the circuit protection unit 20 includes a circuit protection component 30 that melts and cuts a fusible part when an overcurrent flows between the connection conductor 10 as the first electrical connection object and the battery monitoring unit as the second electrical connection object, a first terminal fitting 40 and a second terminal fitting 50 that are electrically connected to the circuit protection component 30, and a wiring component 60 that is interposed between the second terminal fitting 50 and the battery monitoring unit. Further, as shown in FIGS. 3 and 4, the circuit protection unit 20 includes a support member 70 on which the first electrical connection portion 41 of the first terminal fitting 40 and the second electrical connection portion 51 of the second terminal fitting 50 are placed, and a coating resin portion 80 that is provided on the support member 70 and wraps the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 installed across the first electrical connection portion 41 and the second electrical connection portion 51.

[0018] The circuit protection component 30 is a component that protects an electrical device by melting and cutting itself to cut off the circuit when an overcurrent flows through the electrical circuit. The circuit protection component 30 in the present embodiment is a cubic chip fuse having a fusible part, and includes a first electrode 31 that is electrically connected to the first terminal fitting 40 arranged on the connection conductor 10 side and a second electrode 32 that is electrically connected to the second terminal fitting 50 arranged on the battery monitoring unit side, as shown in FIGS. 3 and 4.

[0019] The first electrode 31 is an electrode provided on one end side of the circuit protection component 30 in the axial direction X, and the second electrode 32 is an electrode provided on the other end side of the circuit protection component 30 in the axial direction X, that is, on the opposite side of the first electrode 31 in the axial direction X. In the circuit protection component 30 of the present embodiment, the first electrode 31 and the second electrode 32 are linearly arranged along the axial direction X, and the first electrode 31 is electrically connected to the first terminal fitting 40, and the second electrode 32 is electrically connected to the second terminal fitting 50, so that the first terminal fitting 40 and the second terminal fitting 50 can be linearly connected along the axial direction X.

[0020] Note that the circuit protection component 30 may be configured as a chip fuse having a fusible part, or may be configured as a pattern fuse in which a wiring pattern having a fusible part is provided on a printed board (for example, a flexible printed board).

[0021] The first terminal fitting 40 is a conductive component formed of a material having conductivity such as metal. The first terminal fitting 40 in the present embodiment is a plate-shaped component made of metal. For example, each part is integrally formed by pressing a metal plate into a shape corresponding to each part. As shown in FIGS. 3 and 4, the first terminal fitting 40 includes a first electrical connection part 41 that is electrically connected to the first electrode 31 of the circuit protection component 30, and a first electrical connection object connection part that is electrically connected to a first electrical connection object. In the present embodiment, the first electrical connection object connection part will be described as a conductor connection part 42.

[0022] As shown in Figure 3, the first electrical connection portion 41 is formed in the shape of a rectangular flat plate. The width (length in the width direction Y) of the first electrical connection portion 41 is set to a length that can be placed on the support member 70, which will be described later, and is configured to be narrower than the width (length in the width direction Y) of the support member 70. In this embodiment, as shown in Figure 3, the width (length in the width direction Y) of the first electrical connection portion 41 is configured to be the same as the width (length in the width direction Y) of the conductor connection portion 42. Furthermore, as shown in Figures 3 and 4, when the first electrode 31 of the circuit protection component 30 is placed on the surface of the first electrical connection portion 41 while it is placed on the support member 70, the first electrode 31 is joined to the circuit protection component 30 by laser welding, soldering, or the like, thereby electrically connecting the first electrical connection portion 41 to the circuit protection component 30.

[0023] As shown in Figures 3 and 4, the conductor connection portion 42 is formed in the shape of a rectangular flat plate. Therefore, the conductor connection portion 42 is placed on the connecting conductor 10 so that their planes overlap, and the connecting conductor 10 is joined by laser welding, ultrasonic bonding, or the like, thereby electrically connecting with the connecting conductor 10, which is the first object to be electrically connected. Also, as shown in Figures 3 and 4, since the first electrical connection portion 41 and the conductor connection portion 42 described above are provided adjacent to each other, the first terminal fitting 40 is formed in the shape of a rectangular flat plate.

[0024] The second terminal fitting 50 is a conductive component formed from a conductive material such as metal. In this embodiment, the second terminal fitting 50 is a component formed three-dimensionally from a metal plate-like material. For example, each part is integrally formed by press-forming a metal plate to the shape corresponding to each part. As shown in Figures 3 and 4, the second terminal fitting 50 includes a second electrical connection part 51 that is electrically connected to the second electrode 32 of the circuit protection component 30, and a second electrical connection target connection part that is electrically connected to a second electrical connection target. In this embodiment, the second electrical connection target connection part will be referred to as the wiring connection part 52.

[0025] As shown in Figure 4, the second electrical connection portion 51 is formed in the shape of a rectangular flat plate. The width (length in the width direction Y) of the second electrical connection portion 51 is set to a length that can be placed on the support member 70, which will be described later, and is configured to be narrower than the width (length in the width direction Y) of the support member 70. Furthermore, as shown in Figures 3 and 4, when the second electrode 32 of the circuit protection component 30 is placed on the surface of the second electrical connection portion 51 while it is placed on the support member 70, the second electrode 32 is joined to the circuit protection component 30 by laser welding, soldering, or the like, thereby electrically connecting the second electrical connection portion 51 to the circuit protection component 30.

[0026] As shown in Figure 3, the wiring connection portion 52 is formed in a cylindrical shape, and the conductor portion 61 of the wiring component 60, which will be described later, is crimped to it, thereby electrically connecting it to the wiring component 60, which is the second object to be electrically connected. Also, as shown in Figure 3, since the second electrical connection portion 51 and the wiring connection portion 52 described above are provided adjacent to each other, the second terminal fitting 50 can pull out the wiring component 60 along the axial direction X, which is the direction in which the second electrical connection portion 51 and the wiring connection portion 52 are adjacent, that is, the direction in which the second electrical connection portion 51 and the wiring connection portion 52 extend. The shape of the wiring connection portion 52 may be cylindrical as shown in Figure 3, etc., or it may be composed of a pair of barrel pieces.

[0027] As shown in Figure 3, the wiring component 60 is an insulated wire comprising a conductive portion 61 (core wire) which has conductivity and is electrically connected at one end to the second terminal fitting 50 and at the other end to the battery monitoring unit, and an insulating coating portion 62 which has insulating properties, with the conductive portion 61 covered by the insulating coating portion 62. The conductive portion 61 here refers to a plurality of conductive strands. The insulating coating portion 62 is formed by extruding an insulating resin material (such as PP, PVC, or cross-linked PE, which is appropriately selected considering abrasion resistance, chemical resistance, heat resistance, etc.). The conductive portion 61 may also be made by twisting together a plurality of strands 11a or by bundling together a plurality of strands 11a.

[0028] Furthermore, as shown in Figure 3, the wiring component 60 extends linearly along the axial direction X, and the cross-sectional shape of the conductor portion 61 (the cross-sectional shape in the direction intersecting the axial direction X, which is the direction in which the wiring component 60 extends) is approximately circular, and the cross-sectional shape of the insulating coating portion 62 is approximately annular, resulting in an overall approximately circular cross-sectional shape. In addition, at least one end of the wiring component 60, the insulating coating portion 62 is stripped off, and the exposed conductor portion where the conductor portion 61 is exposed from the end of the insulating coating portion 62 is crimped to the wiring connection portion 52 of the second terminal fitting 50, thereby electrically connecting one end of the conductor portion 61 to the wiring connection portion 52. Note that the wiring component 60 may be a flat wiring material such as a flexible printed circuit board in which the conductor portion 61 is formed as a wiring pattern.

[0029] The support member 70 is made of an insulating material such as synthetic resin and supports the connection portion between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50), that is, the portion where the first electrode 31 of the circuit protection component 30 is connected to the first electrical connection portion 41 of the first terminal fitting 40, and the portion where the second electrode 32 of the circuit protection component 30 is connected to the second electrical connection portion 51 of the second terminal fitting 50.

[0030] As shown in Figures 3 and 4, the support member 70 is a plate-shaped member that extends along the axial direction X and the width direction Y, with the height direction Z being the plate thickness direction. The support member 70 in this embodiment is formed in the shape of a rectangular flat plate and is provided with an installation surface 71 on which the first electrical connection portion 41 of the first terminal fitting 40 and the second electrical connection portion 51 of the second terminal fitting 50 are placed (see Figure 4). Therefore, in this embodiment, the support member 70 can be placed on the installation surface 71, with the circuit protection component 30 placed on the first electrical connection portion 41 of the first terminal fitting 40 and the second electrical connection portion 51 of the second terminal fitting 50, thereby providing space for the portion where the first electrode 31 of the circuit protection component 30 is connected to the first electrical connection portion 41 of the first terminal fitting 40 and the portion where the second electrode 32 of the circuit protection component 30 is connected to the second electrical connection portion 51 of the second terminal fitting 50.

[0031] The covering resin portion 80 encloses the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51, thereby suppressing current flow between the first electrical connection portion 41 and the second electrical connection portion 51. Furthermore, the covering resin portion 80 can also function as a fixing member that secures the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51 to the support member 70 by being fixed to the support member 70. The covering resin portion 80 is composed of a solidified material obtained by hardening a liquid resin material (so-called potting material) that is dripped onto the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51, thereby enclosing them. Furthermore, it is desirable to use a resin material with a viscosity that can remain around the circuit protection component 30, the first electrical connection part 41, and the second electrical connection part 51 from the time it is dropped onto the support member 70 until it hardens, so as to enclose the circuit protection component 30, the first electrical connection part 41, and the second electrical connection part 51 that are placed on the support member 70.

[0032] Furthermore, the support member 70 described above can function as a member on which the connection portion between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) can be placed. Alternatively, for example, a pair of positioning pins can be provided on the support member 70 side, and positioning holes can be provided on the terminal fitting side (first terminal fitting 40 and second terminal fitting 50), and the positioning pins can be inserted into the positioning holes to determine the positional relationship between the first terminal fitting 40 and the second terminal fitting 50 (such as the distance between the first terminal fitting 40 and the second terminal fitting 50). In addition, the support member 70 can also function as a member that can absorb heat generated at the connection portion between the circuit protection component 30 and the pair of terminal fittings and dissipate it to the outside, thereby preventing heat from accumulating at the connection portion. Therefore, by providing a covering resin part 80 on the plate-shaped support member 70, the circuit protection unit 20 of this embodiment can improve the degree of freedom in manufacturing compared to conventional circuit protection units, and can protect the connection portion between the circuit protection component 30 and the pair of terminal fittings in a more appropriate state.

[0033] Furthermore, the conductive module 1 described above includes, in addition to the connecting conductor 10 and the circuit protection unit 20, an insulating housing component (hereinafter referred to as "module housing component") 90 in which the circuit protection unit 20 is housed (see Figure 1). As shown in Figure 1, the module housing component 90 is composed of a housing chamber (hereinafter referred to as "conductor housing chamber") 90a for housing the connecting conductor 10 and a housing chamber (hereinafter referred to as "unit housing chamber") 90b for housing the circuit protection unit 20. A conductor housing chamber 90a is provided for each connecting conductor 10 connected to a plurality of electrode terminals BCb constituting the electrode terminal group BCc. If the wiring component 60 of the circuit protection unit 20 is made up of electric wires, the electric wires provided for each circuit protection unit 20 are routed to the battery monitoring unit side in the unit housing chamber 90b. The ends of the wiring component 60 routed to the battery monitoring unit side are connected to a connector CN. Therefore, the wiring component 60 is electrically connected to the battery monitoring unit via the connector CN. If the wiring component 60 is a flat cable, the unit housing chamber 90b houses flat cable components having conductors that are connected to the second terminal fittings 50 of the multiple circuit protection units 20 (not shown).

[0034] Furthermore, the module housing component 90 includes a first housing member (hereinafter referred to as the "first module housing member") 90A (see Figure 1) and a second housing member (hereinafter referred to as the "second module housing member"; not shown) which are assembled and fixed together to form a plurality of conductor housing chambers 90a and unit housing chambers 90b inside. The first module housing member 90A and the second module housing member are each made of an insulating material such as synthetic resin. The first module housing member 90A is provided with a space for forming the plurality of conductor housing chambers 90a and unit housing chambers 90b at the assembly completion position with the second module housing member. The second module housing member is molded as a cover member that covers the openings of each space.

[0035] The conductive module 1 described above comprises a connecting conductor 10 that is electrically connected to the electrode terminal BCb of the battery cell BC constituting the battery module BM, and a circuit protection unit 20 that electrically connects the connecting conductor 10 to a battery monitoring unit that monitors the battery state of the battery cell BC. The circuit protection unit 20 also comprises a circuit protection component 30 that melts a fusible part when an overcurrent flows between the connecting conductor 10 and the battery monitoring unit, a first electrical connection part 41 that is electrically connected to the first electrode 31 of the circuit protection component 30 and a first terminal fitting 40 that is electrically connected to the connecting conductor 10, a second electrical connection part 51 that is electrically connected to the second electrode 32 of the circuit protection component 30 and a second terminal fitting 50 that is electrically connected to the battery monitoring unit, and the second terminal fitting 50 and the battery monitoring unit The wiring component 60 is interposed between the two, and includes a conductor portion 61, one end of which is electrically connected to the second terminal fitting 50 and the other end of which is electrically connected to the battery monitoring unit; a support member 70 which is insulating, formed in a plate shape, on which the first electrical connection portion 41 and the second electrical connection portion 51 are placed; and a covering resin portion 80 which is insulating, provided on the support member 70, and encloses the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 which is installed spanning the first electrical connection portion 41 and the second electrical connection portion 51.

[0036] With this configuration, the circuit protection unit 20 and the conductive module 1 can reduce material costs compared to conventional circuit protection units in which the connection between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) is surrounded from four directions by a frame-shaped resin part, by placing the connection between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) on a plate-shaped support member 70. Furthermore, the circuit protection unit 20 and the conductive module 1 cover only the lower side of the pair of terminal fittings (opposite side from the circuit protection component 30) with the plate-shaped support member 70. As a result, compared to conventional circuit protection units in which the connection between the circuit protection component 30 and the pair of terminal fittings is surrounded from four directions by a frame-shaped resin part, heat generated at the connection between the circuit protection component 30 and the pair of terminal fittings can be dissipated more efficiently, thus further suppressing heat buildup at the connection. Furthermore, the circuit protection unit 20 and the conductive module 1 can suppress current flow between the first electrical connection 41 and the second electrical connection 51, or fix the circuit protection component 30, the first electrical connection 41, and the second electrical connection 51 to the support member 70, by providing a covering resin portion 80 on the plate-shaped support member 70. Therefore, the circuit protection unit 20 and the conductive module 1 of this embodiment can properly protect the connection portion between the circuit protection component 30 and the pair of terminal fittings.

[0037] [Second Embodiment] Next, the circuit protection unit 20A and conductive module 1A according to the second embodiment shown in Figure 5 will be described. The circuit protection unit 20A and conductive module 1A differ from the circuit protection unit 20 and conductive module 1 described above in terms of the configuration of the covering resin portion 80. In the second embodiment, the same reference numerals are used for components that are the same as in the first embodiment, and their detailed descriptions are omitted.

[0038] Specifically, the circuit protection unit 20A applied to the conductive module 1A differs from the circuit protection unit 20 in that the covering resin portion 80A provided on the plate-shaped support member 70 is made of UV-curing resin.

[0039] The covering resin portion 80A, similar to the covering resin portion 80 described above, encloses the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51, thereby suppressing current flow between the first electrical connection portion 41 and the second electrical connection portion 51. Furthermore, by fixing the covering resin portion 80A to the support member 70, it can also function as a fixing member that secures the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51 on the support member 70.

[0040] The UV-curing resin constituting the coating resin portion 80A is a resin that hardens when irradiated with ultraviolet (UV) light. Therefore, when UV light is irradiated immediately after the resin is dropped to envelop the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51, it has the characteristic of being less likely to drip from the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51. In addition, since UV-curing resin is a resin with a relatively fast curing speed, the time from when it is dropped to envelop the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51 until it hardens can be shortened.

[0041] As described above, the conductive module 1A according to the second embodiment includes a connecting conductor 10 that is electrically connected to the electrode terminal BCb of the battery cell BC constituting the battery module BM, and a circuit protection unit 20A that electrically connects the connecting conductor 10 to a battery monitoring unit that monitors the battery state of the battery cell BC. The circuit protection unit 20A also includes a circuit protection component 30 that melts a fusible part when an overcurrent flows between the connecting conductor 10 and the battery monitoring unit, a first electrical connection part 41 that is electrically connected to the first electrode 31 of the circuit protection component 30 and a first terminal fitting 40 that is electrically connected to the connecting conductor 10, a second electrical connection part 51 that is electrically connected to the second electrode 32 of the circuit protection component 30 and a second terminal fitting 50 that is electrically connected to the battery monitoring unit, and the second terminal fitting 50 and the battery monitoring unit The wiring component 60 is interposed between the two, and includes a conductor portion 61, one end of which is electrically connected to the second terminal fitting 50 and the other end of which is electrically connected to the battery monitoring unit; a support member 70 which is insulating, formed in a plate shape, on which the first electrical connection portion 41 and the second electrical connection portion 51 are placed; and a covering resin portion 80A which is insulating, provided on the support member 70, and encloses the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 which is installed spanning the first electrical connection portion 41 and the second electrical connection portion 51. The covering resin portion 80A is made of a UV-curing resin that hardens when irradiated with ultraviolet light.

[0042] With this configuration, the circuit protection unit 20A and the conductive module 1A have a coating resin portion 80A made of UV-curing resin. By curing the liquid resin material remaining around the first electrical connection portion 41 and the second electrical connection portion 51, which are installed on the plate-shaped support member 70, and the circuit protection component 30, which is installed spanning the first electrical connection portion 41 and the second electrical connection portion 51, in a short time using ultraviolet light, the connection portion between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) can be more properly encased. Furthermore, the circuit protection unit 20A and the conductive module 1A can fix the coating resin portion 80A to the support member 70 in a short time, thereby fixing the circuit protection component 30, the first electrical connection portion 41 and the second electrical connection portion 51 on the support member 70 in a more proper state. Therefore, the circuit protection unit 20A and the conductive module 1A can more properly protect the connection portion between the circuit protection component 30 and the pair of terminal fittings.

[0043] [Third Embodiment] Next, the circuit protection unit 20B and conductive module 1B according to the third embodiment shown in Figure 6 will be described. The circuit protection unit 20B and conductive module 1B differ from the circuit protection units 20, 20A and conductive modules 1, 1A in that they further include a tubular member that covers the portion in which the connection portion of the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) is enclosed by the covering resin portion 80. In the third embodiment, the same reference numerals are used for components that are the same as those in the first and second embodiments, and their detailed descriptions are omitted.

[0044] Specifically, the circuit protection unit 20B applied to the conductive module 1B differs from the circuit protection units 20, 20A and conductive modules 1, 1A in that it further includes a heat-shrinkable tube 100 that shrinks when heat is applied, and which houses a first electrical connection part 41, a second electrical connection part 51, a circuit protection component 30, a support member 70, and a covering resin part 80 on its inside.

[0045] The heat shrink tubing 100 is made of an insulating material such as synthetic resin and houses the first electrical connection part 41, the second electrical connection part 51, the circuit protection component 30, the support member 70, and the covering resin part 80 on its inside. The covering resin part 80 protects the portion where the circuit protection component 30, the first electrical connection part 41, and the second electrical connection part 51 are encased, in other words, the portion where the circuit protection component 30 and the connection parts of the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) are encased by the covering resin part 80 from external factors such as water droplets and dust.

[0046] The heat shrink tubing 100 is formed in a cylindrical shape. The cross-sectional shape of the heat shrink tubing 100 before shrinking (the cross-sectional shape in the direction intersecting the axial direction X, which is the direction in which the heat shrink tubing 100 extends) is approximately circular, and the inner diameter of the heat shrink tubing 100 before shrinking is set to a size that can accommodate the first electrical connection part 41, the second electrical connection part 51, the circuit protection component 30, the support member 70, and the covering resin part 80. Furthermore, the length of the heat shrink tubing 100 before shrinking (length in the axial direction X) is set to be longer than the length of the support member 70 (length in the axial direction X).

[0047] As described above, the heat shrink tubing 100 shrinks when subjected to a heat treatment. Therefore, when the heat shrink tubing 100 is subjected to a heat treatment using a heat gun or other heat-applying tool, it deforms to match the shape of the support member 70 located inside and the covering resin portion 80 provided on the support member 70, and adheres tightly to the support member 70 and the covering resin portion 80.

[0048] Thus, the conductive module 1B according to the third embodiment includes a connecting conductor 10 that is electrically connected to the electrode terminal BCb of the battery cell BC constituting the battery module BM, and a circuit protection unit 20B that electrically connects the connecting conductor 10 to a battery monitoring unit that monitors the battery state of the battery cell BC. The circuit protection unit 20B also includes a circuit protection component 30 that melts a fusible part when an overcurrent flows between the connecting conductor 10 and the battery monitoring unit, a first electrical connection part 41 that is electrically connected to the first electrode 31 of the circuit protection component 30 and a first terminal fitting 40 that is electrically connected to the connecting conductor 10, a second electrical connection part 51 that is electrically connected to the second electrode 32 of the circuit protection component 30 and a second terminal fitting 50 that is electrically connected to the battery monitoring unit, and the second terminal fitting 50 and the battery monitoring unit The wiring component 60 is interposed between the terminals and includes a conductor portion 61, one end of which is electrically connected to the second terminal fitting 50 and the other end of which is electrically connected to the battery monitoring unit; a support member 70 which is insulating, formed in a plate shape, on which the first electrical connection portion 41 and the second electrical connection portion 51 are placed; and a covering resin portion 80 which is insulating, provided on the support member 70, and encloses the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 which is installed spanning the first electrical connection portion 41 and the second electrical connection portion 51. Furthermore, the circuit protection unit 20B is insulating, formed in a cylindrical shape, and contains a heat-shrinkable tube 100 that shrinks when heat is applied, housing the first electrical connection part 41, the second electrical connection part 51, the circuit protection component 30, the support member 70, and the covering resin part 80 inside. The heat-shrinkable tube 100 shrinks when heated and adheres tightly to the support member 70 and the covering resin part 80 provided on the support member.

[0049] With this configuration, the circuit protection unit 20B and the conductive module 1B shrink the heat shrink tube 100 by heat treatment, causing it to adhere tightly to the plate-shaped support member 70 housed inside the heat shrink tube 100 and the covering resin portion 80 provided on the support member 70. This allows the covering resin portion 80 to protect the portion of the connection between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) that is encased in the heat shrink tube 100. Therefore, the circuit protection unit 20B and the conductive module 1B can protect the connection between the circuit protection component 30 and the pair of terminal fittings with two components, the covering resin portion 80 and the heat shrink tube 100, thus providing more appropriate protection for the connection between the circuit protection component 30 and the pair of terminal fittings. Furthermore, by ensuring the heat shrink tubing 100 is tightly attached to the support member 70 and the covering resin part 80, the circuit protection unit 20B and the conductive module 1B can prevent heat from a heat gun or the like from being applied to the connection portion between the circuit protection component 30 and the pair of terminal fittings when the heat shrink tubing 100 is heat-treated. In addition, by ensuring the heat shrink tubing 100 is tightly attached to the support member 70 and the covering resin part 80, the circuit protection unit 20B and the conductive module 1B can absorb the heat generated at the connection portion between the circuit protection component 30 and the pair of terminal fittings via the heat shrink tubing 100 and dissipate it to the outside, thereby further suppressing heat buildup at the connection portion. Moreover, by using the heat shrink tubing 100 as a tubular member that covers the portion where the connection portion between the circuit protection component 30 and the pair of terminal fittings is enclosed by the covering resin part 80, the circuit protection unit 20B and the conductive module 1B can reuse existing products, thereby improving productivity and reducing manufacturing costs. Therefore, the circuit protection unit 20B and the conductive module 1B can more effectively protect the connection between the circuit protection component 30 and the pair of terminal fittings.

[0050] [Fourth Embodiment] Next, the circuit protection unit 20C and conductive module 1C according to the fourth embodiment shown in Figure 7 will be described. The circuit protection unit 20C and conductive module 1C differ from the circuit protection units 20, 20A and conductive modules 1, 1A in that they further include a tube member that covers the portion in which the connection portion of the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) is enclosed by the covering resin portion 80. Furthermore, the circuit protection unit 20C and conductive module 1C also differ from the circuit protection unit 20B and conductive module 1B in terms of the configuration of the tube member. In the fourth embodiment, the same reference numerals are used for components that are the same as those in the first, second, and third embodiments, and their detailed descriptions are omitted.

[0051] Specifically, the circuit protection unit 20C applied to the conductive module 1C differs from the circuit protection units 20, 20A, 20B and conductive modules 1, 1A, 1B in that it further comprises a rigid tube 110 that houses a first electrical connection part 41, a second electrical connection part 51, a circuit protection component 30, a support member 70, and a covering resin part 80 on its inside.

[0052] The rigid tube 110 is formed from an insulating material such as synthetic resin, and houses the first electrical connection part 41, the second electrical connection part 51, the circuit protection component 30, the support member 70, and the covering resin part 80 inside. The covering resin part 80 protects the portion where the circuit protection component 30, the first electrical connection part 41, and the second electrical connection part 51 are encased, in other words, the portion where the connection part of the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) is encased by the covering resin part 80 from external factors such as water droplets and dust. In this embodiment, the rigid tube 110 is a corrugated tube.

[0053] The rigid tube 110 is formed in a cylindrical shape. The cross-sectional shape of the rigid tube 110 (the cross-sectional shape in the direction intersecting the axial direction X, which is the direction in which the rigid tube 110 extends) is approximately circular, and the inner diameter of the rigid tube 110 is set to a size that can accommodate the first electrical connection part 41, the second electrical connection part 51, the circuit protection component 30, the support member 70, and the covering resin part 80. Furthermore, the length of the rigid tube 110 (length in the axial direction X) is set to be longer than the length of the support member 70 (length in the axial direction X).

[0054] The rigid tube 110 has annular protrusions 111 formed on its outer surface along the circumferential direction, and multiple protrusions 111 are provided along the extending direction of the rigid tube 110 to form a bellows-like shape. Therefore, the rigid tube 110 is composed of protrusions 111 that project toward the outer circumferential surface and recesses that project toward the inner circumferential surface. In addition, the rigid tube 110 is flexible and deforms into an elliptical shape or the like to match the height and width of the support member 70 housed inside or the covering resin part 80 provided on the support member 70.

[0055] Thus, the conductive module 1C according to the fourth embodiment includes a connecting conductor 10 that is electrically connected to the electrode terminal BCb of the battery cell BC constituting the battery module BM, and a circuit protection unit 20C that electrically connects the connecting conductor 10 to a battery monitoring unit that monitors the battery state of the battery cell BC. The circuit protection unit 20C also includes a circuit protection component 30 that melts a fusible part when an overcurrent flows between the connecting conductor 10 and the battery monitoring unit, a first electrical connection part 41 that is electrically connected to the first electrode 31 of the circuit protection component 30 and a first terminal fitting 40 that is electrically connected to the connecting conductor 10, a second electrical connection part 51 that is electrically connected to the second electrode 32 of the circuit protection component 30 and a second terminal fitting 50 that is electrically connected to the battery monitoring unit, and the second terminal fitting 50 and the battery monitoring unit The wiring component 60 is interposed between the terminals and includes a conductor portion 61, one end of which is electrically connected to the second terminal fitting 50 and the other end of which is electrically connected to the battery monitoring unit; a support member 70 which is insulating, formed in a plate shape, on which the first electrical connection portion 41 and the second electrical connection portion 51 are placed; and a covering resin portion 80 which is insulating, provided on the support member 70, and encloses the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 which is installed spanning the first electrical connection portion 41 and the second electrical connection portion 51. The circuit protection unit 20C further includes a rigid tube 110 which is insulating, formed in a cylindrical shape, and houses the first electrical connection portion 41, the second electrical connection portion 51, the circuit protection component 30, the support member 70, and the covering resin portion 80 on its inside.

[0056] With this configuration, the circuit protection unit 20C and the conductive module 1C can surround the plate-shaped support member 70 and the covering resin portion 80 provided on the support member 70 with a rigid tube 110. Therefore, the portion of the connection between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) that is encased by the covering resin portion 80 can be protected. As a result, the circuit protection unit 20C and the conductive module 1C can protect the connection between the circuit protection component 30 and the pair of terminal fittings with two components, the covering resin portion 80 and the rigid tube 110, thus providing more appropriate protection for the connection between the circuit protection component 30 and the pair of terminal fittings. Furthermore, the circuit protection unit 20C and the conductive module 1C can absorb heat generated at the connection between the circuit protection component 30 and the pair of terminal fittings and dissipate it to the outside through the openings 112 (a pair of openings 112 that open along the axial direction X) of the cylindrical rigid tube 110, thereby further suppressing heat buildup at the connection. Furthermore, by using a corrugated tube as the rigid tube 110 in the circuit protection unit 20C and the conductive module 1C, the surface area in contact with the external fluid can be increased by the uneven surface 111 of the corrugated tube, thereby further suppressing heat buildup at the connection point. In addition, by using the rigid tube 110 as the tube member that covers the portion where the connection point between the circuit protection component 30 and the pair of terminal fittings is enclosed by the covering resin portion 80 in the circuit protection unit 20C and the conductive module 1C, existing products can be reused, thereby improving productivity and reducing manufacturing costs. Therefore, the circuit protection unit 20C and the conductive module 1C can more effectively protect the connection point between the circuit protection component 30 and the pair of terminal fittings.

[0057] Furthermore, the circuit protection units 20, 20A, 20B, 20C and conductive modules 1, 1A, 1B, 1C according to the embodiments of the present invention described above are not limited to the embodiments described above, and various modifications are possible within the scope of the claims.

[0058] For example, the shape of the support member 70 is not particularly limited to a rectangular shape as shown in Figure 3. The shape of the support member 70 may be, for example, a polygon or an ellipse, which is composed of straight and curved lines.

[0059] Furthermore, the support member 70 may be formed integrally with the first module housing member 90A.

[0060] Furthermore, the rigid tube 110 is not limited to a corrugated tube. The rigid tube 110 may be, for example, a tube member that is not formed in a bellows shape (e.g., a twisted tube).

[0061] Furthermore, the circuit protection units 20, 20A, 20B, and 20C may be applied to, for example, an electrical junction box. The circuit protection units 20, 20A, and 20B can be installed at any position on the electrical circuit.

[0062] Furthermore, the circuit protection units 20, 20A, 20B, 20C and the conductive modules 1, 1A, 1B, 1C according to this embodiment may be configured by appropriately combining the components of the embodiment described above.

[0063] [Reference example of a second embodiment] As a reference example of the second embodiment, the circuit protection unit 20A and the conductive module 1A may be configured without a support member 70 in some cases, for example, when the positional relationship between the first terminal fitting 40 and the second terminal fitting 50 is already fixed during the manufacturing process. In this case, the circuit protection unit 20A and the conductive module 1A include a circuit protection component 30, a first terminal fitting 40, a second terminal fitting 50, a wiring component 60, and a covering resin part 80A. Even in this case, the circuit protection unit 20A and the conductive module 1A according to the reference example may be able to properly encase the connection portion between the circuit protection component 30 and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) by curing the liquid resin material remaining around the circuit protection component 30 and the first electrical connection part 41 and the second electrical connection part 51 in a short time using ultraviolet light. Therefore, the circuit protection unit 20A and conductive module 1A in the reference example can properly protect the connection portion between the circuit protection component 30 and the pair of terminal fittings.

[0064] [Reference example of the third embodiment] Furthermore, as a reference example of the third embodiment, the circuit protection unit 20B and the conductive module 1B may, in some cases, be configured without the support member 70 and the covering resin part 80, depending on the situation such as when the first electrical connection part 41 and the second electrical connection part 51 are insulated by other means, or the installation position of each part constituting the circuit protection unit 20B. In other words, in this case, the circuit protection unit 20B and the conductive module 1B include a circuit protection component 30, a first terminal fitting 40, a second terminal fitting 50, a wiring component 60, and a heat shrink tube 100. Even in this case, the circuit protection unit 20B and the conductive module 1B according to the reference example may be able to protect the connection portion of the circuit protection component 30 housed inside and the pair of terminal fittings (first terminal fitting 40 and second terminal fitting 50) by making the heat shrink tube 100 tightly adhere to the circuit protection component 30, the first electrical connection part 41, and the second electrical connection part 51. Furthermore, the circuit protection unit 20B and conductive module 1B according to the reference example may be able to suppress heat buildup at the connection point between the circuit protection component 30 and the pair of terminal fittings via the heat shrink tubing 100. Therefore, the circuit protection unit 20B and conductive module 1B according to the reference example can properly protect the connection point between the circuit protection component 30 and the pair of terminal fittings.

[0065] [Reference example of the fourth embodiment] Furthermore, as a reference example of the fourth embodiment, the circuit protection unit 20C and the conductive module 1C may, in some cases, be configured without the support member 70 and the covering resin part 80, depending on the situation such as when the first electrical connection part 41 and the second electrical connection part 51 are insulated by other means, or the installation position of each part constituting the circuit protection unit 20C. In this case, the circuit protection unit 20C and the conductive module 1C include a circuit protection component 30, a first terminal fitting 40, a second terminal fitting 50, a wiring component 60, and a rigid tube 110. Even in this case, the circuit protection unit 20C and the conductive module 1C according to the reference example may be able to suppress heat buildup at the connection part between the circuit protection component 30 and the pair of terminal fittings through the opening 112 of the cylindrical rigid tube 110. Furthermore, in the circuit protection unit 20C and conductive module 1C according to the reference example, by using a corrugated tube as the rigid tube 110, the surface area in contact with the external fluid can be increased by the uneven portion 111 of the corrugated tube, which may suppress heat buildup at the connection point. Therefore, the circuit protection unit 20C and conductive module 1C according to the reference example can properly protect the connection point between the circuit protection component 30 and the pair of terminal fittings. [Explanation of Symbols]

[0066] 1, 1A, 1B, 1C Conductive Modules 10 Connecting conductors 20, 20A, 20B, 20C Circuit Protection Units 30 Circuit protection components 40. First terminal fitting 41. First electrical connection section 50. Second terminal fitting 51 Second electrical connection 60 Wiring Components 61 Conductor section 70 Support member 80 Coated resin part BC battery cell BCb electrode terminal BM Battery Module X-axis direction Y width direction Z (height direction)

Claims

1. A circuit protection component that melts a fusible part when an overcurrent flows between the first electrical connection target and the second electrical connection target, A first electrical connection portion is electrically connected to the first electrode of the circuit protection component, and a first terminal fitting is electrically connected to the first object to be electrically connected, A second electrical connection portion is electrically connected to the second electrode of the circuit protection component, and a second terminal fitting is electrically connected to the second object to be electrically connected, A support member having insulating properties, formed in a plate shape, on which the first electrical connection portion and the second electrical connection portion are placed, The present invention is characterized by comprising an insulating resin portion that is provided on the support member and encloses the first electrical connection portion, the second electrical connection portion, and the circuit protection component installed spanning the first electrical connection portion and the second electrical connection portion, Circuit protection unit.

2. The aforementioned coating resin portion is made of a UV-curing resin that hardens when irradiated with ultraviolet light. The circuit protection unit according to claim 1.

3. It is an insulating, cylindrical, heat-shrinkable tube that houses the first electrical connection part, the second electrical connection part, the circuit protection component, the support member, and the covering resin part on its inside, and shrinks when heat is applied. The heat-shrinkable tube shrinks when subjected to heat treatment and adheres tightly to the support member and the covering resin portion provided on the support member. The circuit protection unit according to claim 1.

4. It is insulating, formed in a cylindrical shape, and further comprises a rigid tube that houses the first electrical connection part, the second electrical connection part, the circuit protection component, the support member, and the covering resin part on its inside. The circuit protection unit according to claim 1.

5. A connecting conductor that is electrically connected to the electrode terminals of the battery cells that make up the battery module, The system includes a circuit protection unit that electrically connects the connecting conductor to a battery monitoring unit that monitors the battery state of the battery cell, The circuit protection unit is A circuit protection component that melts a fusible part when an overcurrent flows between the connecting conductor and the battery monitoring unit, The circuit protection component has a first electrical connection portion that is electrically connected to the first electrode, and a first terminal fitting that is electrically connected to the connecting conductor, The circuit protection component has a second electrical connection portion that is electrically connected to the second electrode, and a second terminal fitting that is electrically connected to the battery monitoring unit, A wiring component comprising a conductor portion interposed between the second terminal fitting and the battery monitoring unit, with one end electrically connected to the second terminal fitting and the other end electrically connected to the battery monitoring unit, A support member having insulating properties, formed in a plate shape, on which the first electrical connection portion and the second electrical connection portion are placed, The present invention is characterized by comprising an insulating resin portion that is provided on the support member and encloses the first electrical connection portion, the second electrical connection portion, and the circuit protection component installed spanning the first electrical connection portion and the second electrical connection portion, Conductive module.

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