Bus bar module

Abstract

To provide a bus bar module capable of also attaining downsizing of itself while attaining downsizing of a junction block.SOLUTION: A bus bar module 10 comprises: a main body part 20 including a case 21, a bus bar 22 and a flexible thin-plate wire 23; and a current sensor part 30 for detecting a current flowing in a battery assembly 40. The current sensor part 30 includes a current sensor case 31 and a current sensor bus bar 32 electrically connected to an electric cell 41. A current detection element 37 for detecting the current, a mounting part 361 where the current detection element 37 is mounted, and a current output line 362 for outputting current data to the flexible thin-plate wire 23 are also provided. An insulation part 391 disposed between the current sensor bus bar 32 and the mounting part 361, a move regulation part 392 for regulating move of the mounting part 361 in a normal direction of a mounting surface 361a and a shield part 393 for shielding an external magnetic field are further provided.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] As this type of conventional technology, what is disclosed in Patent Document 1 has been proposed. In this Patent Document 1, a plurality of bus bars are electrically connected to a battery pack including a plurality of battery cells while being supported by a case. Further, in this Patent Document 1, a current sensor for detecting one of the plurality of bus bars is provided in the battery pack. By doing so, it is possible to eliminate the need to arrange the current sensor in the junction block and to reduce the size of the junction block.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above conventional technology, data indicating the state of the battery pack such as current is output to an external device by a conducting wire (ordinary electric wire). And when using an ordinary electric wire, it is necessary to arrange the electric wire so that it crawls along the electric wire path. At this time, since it is necessary to provide a bending R that does not break and stretch the electric wire, it is necessary to increase the space for the electric wire path.

[0005] As described above, in the above conventional technology, it is necessary to provide a space for supporting a conductor in the case that supports the bus bar, and it has been difficult to reduce the size of the bus bar module itself.

[0006] The present invention has been made in view of the problems of such prior art. The object of the present invention is to provide a bus bar module capable of miniaturizing itself while miniaturizing the junction block.

Means for Solving the Problems

[0007] A bus bar module according to an aspect of the present invention includes a case assembled to a battery assembly having a plurality of single cells, a bus bar supported by the case and electrically connected to the single cells of the battery assembly, and a flexible thin plate-shaped electric wire placed on the case, and a main body portion including the flexible thin plate-shaped electric wire, and a current sensor portion integrally provided on the main body portion for detecting a current flowing through the battery assembly, the current sensor portion including a current sensor case provided on the case, a current sensor bus bar supported by the current sensor case and electrically connected to the single cell, a current detection element for detecting a current flowing through the current sensor bus bar, a mounting portion having a mounting surface on which the current detection element is mounted, a current output line connected to the mounting portion for outputting current data to the flexible thin plate-shaped electric wire, an insulating portion disposed between the current sensor bus bar and the mounting portion, a movement restricting portion for restricting movement of the mounting portion in a normal direction of the mounting surface, and a shielding portion for blocking an external magnetic field.

Effects of the Invention

[0008] According to the present invention, it is possible to provide a bus bar module capable of miniaturizing itself while miniaturizing the junction block.

Brief Description of the Drawings

[0009]

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Embodiments for Carrying Out the Invention

[0010] Hereinafter, the bus bar module according to the present embodiment will be described in detail with reference to the drawings. Hereinafter, a bus bar module assembled to a battery module mounted on an electrified vehicle (for example, HV, PHV, EV, FCV, etc.) will be exemplified. Note that the dimensional ratios in the drawings are exaggerated for convenience of explanation and may be different from the actual ratios.

[0011] Also, hereinafter, the vertical direction of the bus bar module will be defined and described in a state where the battery module is located below and the bus bar module is located above.

[0012] As shown in FIG. 1, the bus bar module 10 according to the present embodiment is assembled on the upper part of a battery module (battery assembly) 40 to constitute a power supply device 1. This power supply device 1 is mounted and used in various electrified vehicles such as an electric vehicle that travels using an electric motor and a hybrid vehicle that travels using an engine and an electric motor in combination, and is a device that supplies power to the electric motor.

[0013] In this embodiment, the bus bar module 10 includes a main body 20, and the main body 20 includes a case 21 assembled to the battery module 40 and a bus bar 22 supported by the case 21.

[0014] The case 21 can be formed using a material having insulation properties such as synthetic resin, and extends in the horizontal direction, and includes a placement wall 211 on which a flexible thin plate-shaped wire 23 described later is placed, and a peripheral wall 212 continuously provided at the periphery of the placement wall 211 and extending in the vertical direction.

[0015] On the other hand, as shown in FIG. 1, the battery module 40 includes a plurality of single cells 41, and the plurality of single cells 41 are arranged in a row along one direction. As such a single cell 41, for example, a lithium battery can be used. By arranging the single cells 41 in one direction, the battery module 40 has one stacked portion 40A in which the single cells 41 are arranged in one direction. Note that the battery module 40 may have a plurality of stacked portions 40A.

[0016] The bus bar 22 is electrically connected to the single cells 41 of the battery module 40 while being supported by the case 21, and the plurality of single cells 41 are connected in series or in parallel. In this embodiment, the main body 20 includes a plurality of bus bars 22, and each bus bar 22 is respectively housed in a bus bar housing portion 214 formed in the case 21. Note that a plurality of bus bar housing portions 214 are formed along one direction on both sides in the width direction (a direction orthogonal to the one direction and the vertical direction) of the case 21, and an insulating wall 213 is formed between the bus bar housing portions 214 adjacent to each other in the one direction. By doing so, it is possible to prevent the bus bars 22 adjacent to each other in the one direction from short-circuiting.

[0017] Also, in this embodiment, each single cell 41 includes a battery body 410 formed in a rectangular parallelepiped shape, and the single cells 41 are arranged in a state where the long sides of the upper surfaces of the battery bodies 410 are in contact with each other. On the upper surface of the battery body 410, a positive terminal 411 and a negative terminal 412 protruding upward (the side where the case 21 is assembled) are provided. Then, by inserting the positive terminal 411 and the negative terminal 412 into insertion holes 22a formed in the bus bar 22, the bus bar 22 is electrically connected to the single cells 41 of the battery module 40.

[0018] Specifically, the plurality of single cells 41 are arranged such that the positive terminals 411 and the negative terminals 412 are alternately arranged along one direction. That is, the plurality of single cells 41 are arranged to be aligned in one direction in a state of being alternately inverted.

[0019] Also, the bus bar 22 is formed in a plate shape using a conductive material. In this embodiment, the bus bar 22 includes a plurality of connection bus bars 221 that connect adjacent single cells 41, and two lead-out bus bars 222 that are connected to one single cell 41 and are electrically connected to a power source or the like (not shown).

[0020] Then, as shown in FIG. 5, two insertion holes 221a are formed in each of the plurality of connection bus bars 221, and the positive terminal 411 and the negative terminal 412 of adjacent single cells 41 are inserted into the two insertion holes 221a of each connection bus bar 221. Also, insertion holes 222a are respectively formed in the two lead-out bus bars 222. One lead-out bus bar 222 is connected to the positive terminal 411 of the single cell 41 arranged at one end in one direction, and one lead-out bus bar 222 is connected to the negative terminal 412 of the single cell 41 arranged at the other end in one direction.

[0021] By doing so, a plurality of single cells 41 are connected in series by the bus bar 22. That is, in a state where a plurality of single cells 41 having positive terminals 411 and negative terminals 412 are stacked in a row with alternating reverse polarities, adjacent single cells 41 are electrically connected by the bus bar 22, so that the plurality of single cells 41 are connected in series. Note that it is also possible to form sets by arranging a plurality of adjacent single cells (for example, 3 to 5 etc.) with their terminal polarities aligned, and connecting the plurality of sets in series.

[0022] Furthermore, in the present embodiment, the main body 20 includes a voltage sensor 25 for detecting the voltage of the single cell 41 and a temperature sensor 26 for detecting the temperature of the single cell 41, and the voltage sensor 25 and the temperature sensor 26 are held by the case 21. Then, the voltage data and temperature data detected by the voltage sensor 25 and the temperature sensor 26 are output to the FPC (Flexible Printed Circuit board: flexible thin plate-shaped electric wire) 23. Thus, in the present embodiment, the main body 20 includes the FPC (Flexible Printed Circuit board: flexible thin plate-shaped electric wire) 23 as an electric wire for outputting the state (voltage and temperature) of the battery module 40. By using the FPC (Flexible Printed Circuit board: flexible thin plate-shaped electric wire) 23, the degree of freedom in arranging electronic components is improved, and the height of the bus bar module 10 assembled to the battery module 40 can be reduced.

[0023] In the present embodiment, as shown in FIG. 3, the FPC 23 includes a main body portion 231. The FPC 23 also includes a voltage output line 232 for outputting the voltage data of the single cell 41 detected by the voltage sensor 25 to the main body portion 231, and a temperature output line 233 for outputting the temperature data of the single cell 41 detected by the temperature sensor 26 to the main body portion 231. In the present embodiment, the voltage output line 232 and the temperature output line 233 are also flexible thin plate-shaped electric wires. The voltage sensor 25 is connected to the tip of the voltage output line 232, and the temperature sensor 26 is connected to the tip of the temperature output line 233.

[0024] In addition, the FPC 23 is provided with a connector 23a. The voltage data of the single battery 41 detected by the voltage sensor 25 and the temperature data of the single battery 41 detected by the temperature sensor 26 are output from the FPC 23 through the connector 23a to the ECU (Electrical Control Unit).

[0025] Also, in the present embodiment, as shown in FIG. 4, a voltage sensor housing portion 215 and a temperature sensor housing portion 216 are formed in the case 21. By housing the voltage sensor 25 in the voltage sensor housing portion 215 and the temperature sensor 26 in the temperature sensor housing portion 216, the voltage sensor 25 and the temperature sensor 26 are supported by the case 21.

[0026] In addition, in the present embodiment, the main body portion 20 includes a lid body 24, and by attaching the lid body 24 to the case 21, the FPC 23 is held between the lid body 24 and the mounting wall 211 of the case 21.

[0027] Specifically, engaging protrusions 211a and positioning protrusions 211b are formed on the mounting wall 211 of the case 21 so as to protrude upward, and insertion holes 231a into which the engaging protrusions 211a and the positioning protrusions 211b are inserted are formed in the main body portion 231 of the FPC 23. Then, with the engaging protrusions 211a and the positioning protrusions 211b inserted into the insertion holes 231a, the FPC 23 is placed on the upper part of the mounting wall 211.

[0028] Also, an engaging hole 24a with which the engaging protrusion 211a engages and an insertion hole 24b into which the positioning protrusion 211b is inserted are formed in the lid body 24. Then, with the positioning protrusion 211b inserted into the insertion hole 24b, the lid body 24 is attached to the case 21 by engaging the engaging protrusion 211a with the engaging hole 24a.

[0029] In this way, in the present embodiment, the FPC 23 is placed from above the case 21, and the lid body 24 is attached to the case 21 from above, so that the FPC 23 is held by the case 21.

[0030] Here, in the present embodiment, the bus bar module 10 is integrally provided on the main body portion 20 so as to include a current sensor portion 30 that detects the current flowing through the battery module 40, thereby achieving miniaturization of the junction block.

[0031] This current sensor portion 30 includes a current sensor case 31 provided in the case 21, and a current sensor bus bar 32 supported by the current sensor case 31 and electrically connected to the single cell 41.

[0032] In the present embodiment, the current sensor case 31 is continuously provided on the other end side in one direction of the case 21, and is formed using a portion that would be a dead space of the case 21 when the current sensor portion 30 is not provided. By doing so, it is possible to suppress the case 21 from becoming larger.

[0033] Also, in the present embodiment, the current sensor case 31 includes a bottom wall 311 and a pair of side walls 312 continuously provided on both sides in the width direction (a direction orthogonal to one direction and the vertical direction) of the bottom wall 311. And the current sensor bus bar 32 is arranged in the space surrounded by the bottom wall 311 and the pair of side walls 312. Further, pressing projections 312a are respectively formed on the pair of side walls 312, and the current sensor bus bar 32 is prevented from coming off by these pressing projections 312a. By doing so, the current sensor bus bar 32 is supported in a state where it is suppressed from coming off from the current sensor case 31 in the current sensor case 31.

[0034] Also, an engagement hole 312b is formed in the side wall 312, and a second engagement projection 342b formed on the peripheral wall 342 of a lower case 34 described later is engaged with this engagement hole 312b.

[0035] Furthermore, in the present embodiment, a shield plate insertion hole 3121 is formed in the side wall 312, and a shield plate 38 is inserted into the shield plate insertion hole 3121 from the lower side and fixed to the current sensor case 31.

[0036] In the present embodiment, the shield plate 38 can be formed of a magnetic material such as metal, and includes a bottom wall 381 disposed below the bottom wall 311 and a pair of side walls 382 continuously provided on both sides in the width direction (a direction orthogonal to the one direction and the vertical direction) of the bottom wall 381. And, engaging holes 382a are respectively formed in the pair of side walls 382, and engaging protrusions 3121a formed in the side wall 312 and existing in the shield plate insertion hole 3121 are inserted into the engaging holes 382a. By doing so, the shield plate 38 is fixed to the current sensor case 31.

[0037] In the present embodiment, the pair of side walls 382 of the shield plate 38 are made to function as a shield portion 393 that blocks an external magnetic field. Further, by connecting the pair of side walls 382 with the bottom wall 381, it also functions as an amplification portion 394 that amplifies the magnetic field generated by the current flowing through the current sensor bus bar 32 and transmits it to the Hall IC 37 described later.

[0038] And, a current sensor module 33 is assembled to the current sensor case 31 in which the current sensor bus bar 32 is disposed.

[0039] In the present embodiment, the current sensor module 33 includes a Hall IC (current detection element) 37 that detects the current flowing through the current sensor bus bar 32, and a mounting portion 361 having a mounting surface 361a on which the Hall IC (current detection element) 37 is mounted. In the present embodiment, a surface mount type Hall IC 37 is used as the Hall IC 37. The Hall IC 37 includes a main body portion 371 and lead wires 372, and the Hall IC 37 is mounted on the mounting portion 361 by connecting the lead wires 372 to conductors exposed on the mounting surface 361a of the mounting portion 361.

[0040] Also, the current sensor unit 30 is connected to the mounting unit 361 and includes a current output line 362 that outputs current data to the FPC (flexible thin-plate-shaped electric wire) 23. This current output line 362 is connected to the FPC (flexible thin-plate-shaped electric wire) 23 via a connection connector 362a (see FIG. 3).

[0041] Here, in the present embodiment, the mounting unit 361 and the current output line 362 are provided on a single FPC (flexible thin-plate-shaped current sensor wire) 36. That is, in the present embodiment, the mounting unit 361 and the current output line 362 are made flexible. Therefore, in the present embodiment, the mounting unit 361 on which the Hall IC (current detection element) 37 is mounted is sandwiched between the lower case (first module case) 34 and the upper case (second module case) 35. By doing so, it is possible to suppress the mounting unit 361 from being bent when it is arranged in the current sensor case 31.

[0042] Specifically, the lower case 34 includes a bottom wall 341 that functions as an insulating portion 391 and a peripheral wall 342 continuously provided on the bottom wall 341, and two positioning protrusions 341a protruding upward are formed on the upper surface of the bottom wall 341. On the other hand, two insertion holes 361b into which the positioning protrusions 341a are respectively inserted are formed in the mounting unit 361 of the FPC (flexible thin-plate-shaped current sensor wire) 36. Then, with the positioning protrusions 341a inserted into the insertion holes 361b, the FPC (flexible thin-plate-shaped current sensor wire) 36 is placed on the lower case 34. By doing so, it is possible to suppress the mounting unit 361 from being displaced in the horizontal direction. In the present embodiment, the positioning protrusions 341a are formed in a tapered shape with a reduced diameter toward the upper side to facilitate insertion into the insertion holes 361b.

[0043] Then, by attaching the upper case 35 to the lower case 34 on which the mounting unit 361 is placed in a state where the displacement in the horizontal direction is suppressed, the movement of the mounting unit 361 in the normal direction of the mounting surface 361a is also restricted.

[0044] Specifically, the upper case 35 includes a top wall 351 and a peripheral wall 352, and a pressing rib 3511 that protrudes downward on the lower surface of the top wall 351 to press the mounting portion 361 is formed. An insertion hole 3511a is formed in the pressing rib 3511 so as to open downward, and when the upper case 35 is attached to the lower case 34, the positioning projection 341a is inserted into the insertion hole 3511a. Then, in a state where the positioning projection 341a is inserted into the insertion hole 3511a, the end face (pressing surface) 3511b of the pressing rib 3511 contacts the mounting surface 361a of the mounting portion 361 to press the mounting portion 361 downward. By doing so, the movement of the mounting portion 361 in the normal direction of the mounting surface 361a is also restricted. In this way, in the present embodiment, the pressing rib 3511 has a function as a movement restricting portion 392 that restricts the movement of the mounting portion 361 in the normal direction of the mounting surface 361a.

[0045] Note that a first engaging projection 342a is formed on the peripheral wall 342 of the lower case 34, and an engaging hole 352a is formed on the peripheral wall 352 of the upper case 35. Then, by engaging the first engaging projection 342a formed on the peripheral wall 342 of the lower case 34 with the engaging hole 352a formed on the peripheral wall 352 of the upper case 35, the upper case 35 is assembled to the lower case 34.

[0046] In this way, in the present embodiment, the current sensor unit 30 includes an insulating portion 391 disposed between the current sensor bus bar 32 and the mounting portion 361. Further, the current sensor unit 30 includes a movement restricting portion 392 that restricts the movement of the mounting portion 361 in the normal direction of the mounting surface 361a, and a shielding portion 393 that blocks an external magnetic field. Furthermore, the current sensor unit 30 includes an amplifying portion 394 that amplifies the magnetic field generated by the current flowing through the current sensor bus bar 32 and transmits it to the Hall IC 37.

[0047] Also, in the present embodiment, while attaching the current sensor unit 30 to the main body unit 20 of the bus bar module 10, current data is output from the current output line 362 to the FPC (flexible thin-plate-shaped electric wire) 23. By doing so, the current data detected by the current sensor unit 30 is taken into the FPC (flexible thin-plate-shaped electric wire) 23. In this way, the current sensor circuit can be integrated into the FPC (flexible thin-plate-shaped electric wire) 23, and the configuration can be simplified.

[0048] Also, in the present embodiment, the FPC (flexible thin-plate-shaped electric wire) 23 is used. By doing so, a circuit for outputting data indicating the state (such as current, voltage, temperature, etc.) of the battery module (battery assembly) 40 can be integrated into the FPC (flexible thin-plate-shaped electric wire) 23. As a result, it becomes possible to reduce the weight of the bus bar module 10 itself.

[0049] Also, if the FPC (flexible thin-plate-shaped electric wire) 23 is used, the current data can be directly output from the FPC (flexible thin-plate-shaped electric wire) 23. Therefore, there is no need to provide a space for connector connection as in the case of using a rigid substrate, and it becomes possible to further reduce the size of the bus bar module 10.

[0050] Next, an example of the assembly method of the current sensor unit 30 will be described with reference to FIGS. 12 to 15.

[0051] First, as shown in FIG. 12, a current sensor bus bar 32 is arranged on the bottom wall 311 of the current sensor case 31. Specifically, while accommodating in the bus bar housing portion 214 of the case 21 the portion to which the negative terminal 412 of the lead-out bus bar 222, to which the current sensor bus bar 32 extends, is connected, the current sensor bus bar 32 is arranged on the current sensor case 31 extending from the case 21. At this time, the current sensor bus bar 32 is pushed in so as to be positioned below the pressing projection 312a (on the side of the bottom wall 311), and the pressing projection 312a prevents the current sensor bus bar 32 from coming off.

[0052] Next, a Hall IC 37 is mounted on the mounting portion 361 of the FPC 36. Then, as shown in FIG. 13, the FPC 36 on which the Hall IC 37 is mounted is placed on the bottom wall 341 of the lower case 34. At this time, the positioning projection 341a formed on the bottom wall 341 of the lower case 34 is inserted into the insertion hole 361b formed in the mounting portion 361 of the FPC 36, and the mounting portion 361 (Hall IC 37) is positioned by the positioning projection 341a.

[0053] Next, as shown in FIG. 14, the upper case 35 is assembled to the lower case 34 to form the current sensor module 33. Specifically, the upper case 35 is assembled to the lower case 34 by engaging the first engaging projection 342a formed on the peripheral wall 342 of the lower case 34 with the engaging hole 352a formed on the peripheral wall 352 of the upper case 35. At this time, the positioning projection 341a is inserted into the insertion hole 3511a of the pressing rib 3511 formed on the top wall 351 of the upper case 35, and the end face 3511b of the pressing rib 3511 presses the mounting surface 361a of the mounting portion 361. By doing so, the mounting portion 361 (Hall IC 37) is restricted from moving in the vertical direction (the normal direction of the mounting surface 361a).

[0054] Next, as shown in FIG. 15, assemble the current sensor module 33 to the current sensor case 31 in which the current sensor bus bar 32 is arranged with the bottom wall 341 of the lower case 34 positioned downward. Specifically, the current sensor module 33 is assembled to the current sensor case 31 by engaging the second engaging projection 342b formed on the peripheral wall 342 of the lower case 34 with the engaging hole 312b formed on the side wall 312 of the current sensor case 31.

[0055] Finally, assemble the shield plate 38 to the current sensor case 31. Specifically, the shield plate 38 is assembled to the current sensor case 31 by inserting the side wall 382 of the shield plate 38 into the shield plate insertion hole 3121 formed on the side wall 312 of the current sensor case 31. At this time, the engaging projection 3121a formed in the shield plate insertion hole 3121 on the side wall 312 of the current sensor case 31 is engaged with the engaging hole 382a formed on the side wall 382 of the shield plate 38.

[0056] By doing so, the current sensor unit 30 as shown in FIG. 6 is integrally provided on the main body unit 20. Note that the above method is merely an example, and the current sensor unit 30 can be assembled in various ways. For example, the step of arranging the current sensor bus bar 32 on the bottom wall 311 of the current sensor case 31 can be carried out during the process of forming the current sensor module 33, or after the process of forming the current sensor module 33. Also, the step of assembling the shield plate 38 to the current sensor case 31 does not necessarily have to be the last step, and it can be carried out before, after, or during the process of forming the current sensor module 33.

[0057] In this embodiment, an example of mounting the surface mount type hall IC 37 on the FPC 36 is illustrated. However, as shown in FIGS. 16 to 18, it is also possible to mount the through-hole mount type hall IC 37 on the FPC 36.

[0058] Note that the current sensor unit 30 shown in FIGS. 16 to 18 includes the same components as those in the above embodiment. Therefore, hereinafter, the same reference numerals are given to those similar components, and redundant explanations are omitted.

[0059] In the current sensor unit 30 shown in FIGS. 16 to 18, as the current detection element, a Hall IC 37 including a main body portion 371 and a lead wire 372 that protrudes downward from the lower surface of the main body portion and is inserted into a through hole formed in a rigid substrate is used.

[0060] Then, as shown in FIG. 17, it is mounted on the mounting portion 361 of the FPC 36 in a state where the through-hole mounting type Hall IC 37 is placed horizontally (a state where the lead wire 372 protrudes horizontally).

[0061] Furthermore, the current sensor module 33 is formed by holding the FPC 36 on which the through-hole mounting type Hall IC 37 is mounted on the mounting portion 361 with the lower case 34 and the upper case 35.

[0062] Here, in the current sensor unit 30 shown in FIGS. 16 to 18, since the through-hole mounting type Hall IC 37 is placed horizontally, it is assembled to the current sensor case 31 in a state where the current sensor module 33 is rotated 90 degrees. By doing so, the magnetic field generated in the current sensor bus bar 32 can be detected by the through-hole mounting type Hall IC 37.

[0063] Therefore, in the current sensor unit 30 shown in FIGS. 16 to 18, an engaging protrusion 351a is formed on the top wall 351 of the upper case 35. Then, the current sensor module 33 is assembled to the current sensor case 31 by engaging the engaging protrusion 351a with an engaging hole 312b formed in the side wall 312 of the current sensor case 31. At this time, the lower portions of the peripheral wall 342 of the lower case 34 and the peripheral wall 352 of the upper case 35 function as the insulating portion 391.

[0064] Even with such a configuration, the same operations and effects as those of the bus bar module 10 shown in the above embodiment can be achieved. That is, even when the Hall IC 37, which is attached to a substrate on which through holes are formed and used, is attached to a member such as the FPC 36 on which through holes cannot be formed, the same functions can be obtained by rotating it by 90 degrees.

[0065] [Operations and Effects] Hereinafter, the characteristic configurations of the bus bar modules shown in the above embodiment and its modified examples and the effects obtained thereby will be described.

[0066] The bus bar module 10 shown in the above embodiment and its modified examples includes a main body portion 20. This main body portion 20 includes a case 21 that is assembled to a battery module (battery assembly) 40 having a plurality of single cells 41, and a bus bar 22 that is supported by the case 21 and electrically connected to the single cells 41 of the battery module (battery assembly) 40. Further, the main body portion 20 includes an FPC (flexible thin plate-shaped electric wire) 23 placed on the case 21.

[0067] Further, the bus bar module 10 includes a current sensor portion 30 that is provided integrally with the main body portion 20 and detects a current flowing through the battery module (battery assembly) 40.

[0068] This current sensor portion 30 includes a current sensor case 31 provided on the case 21, and a current sensor bus bar 32 that is supported by the current sensor case 31 and electrically connected to the single cell 41. Further, the current sensor portion 30 includes a Hall IC (current detection element) 37 that detects a current flowing through the current sensor bus bar 32, and a mounting portion 361 having a mounting surface 361a on which the Hall IC (current detection element) 37 is mounted. Also, the current sensor portion 30 includes a current output line 362 that is connected to the mounting portion 361 and outputs current data to the FPC (flexible thin plate-shaped electric wire) 23.

[0069] The current sensor unit 30 includes an insulating portion 391 disposed between the current sensor bus bar 32 and the mounting portion 361, a movement restricting portion 392 that restricts the movement of the mounting portion 361 in the normal direction of the mounting surface 361a, and a shielding portion 393 that blocks an external magnetic field.

[0070] In this way, if the current sensor unit 30 is integrally provided in the main body portion 20 of the bus bar module 10, it is not necessary to arrange the current sensor in the junction block, so that the junction block can be miniaturized.

[0071] Furthermore, by using the FPC (flexible thin plate-shaped electric wire) 23, it becomes possible to solve the following problems that occur when using a normal electric wire.

[0072] First, when using a normal electric wire, it is necessary to arrange the electric wire so that it crawls along the electric wire path. At this time, since it is necessary to provide a bending R that does not break and stretch the electric wire, it is necessary to increase the space for the electric wire path.

[0073] In addition, since there is a concern of disconnection even if the electric wire strongly interferes with other components, an extra length of the electric wire is required, and there is a possibility that the bus bar module becomes larger.

[0074] In addition, when the bus bar module uses an electric wire, after assembling the case 21 to the battery module (battery assembly) 40, it is necessary to pass the electric wire through the space for the electric wire path, which is time-consuming during the assembly work.

[0075] On the other hand, since the thickness of the FPC (flexible thin plate-shaped electric wire) 23 is about 1 / 5 of the diameter of a normal electric wire, when using the FPC (flexible thin plate-shaped electric wire) 23, the space for the electric wire path can be made smaller. As a result, the bus bar module 10 can be made thinner.

[0076] Thus, if the bus bar module 10 is as described in the above embodiment and its modifications, it is possible to reduce the size of the junction block while also reducing the size of the bus bar module 10 itself.

[0077] In addition, since the FPC (flexible thin plate-shaped wire) 23 can be assembled to the case 21 simply by placing it on the upper part of the case 21, the assembly workability can be further improved.

[0078] Also, in the bus bar module 10 described in the above embodiment and its modifications, while the current sensor unit 30 is attached to the main body unit 20 of the bus bar module 10, current data is output from the current output line 362 to the FPC (flexible thin plate-shaped wire) 23. In this way, if the current data detected by the current sensor unit 30 is taken into the FPC (flexible thin plate-shaped wire) 23, the current sensor circuit can be integrated into the FPC (flexible thin plate-shaped wire) 23, and the configuration can be simplified.

[0079] Moreover, if the FPC (flexible thin plate-shaped wire) 23 is used, a circuit for outputting data indicating the state (such as current, voltage, temperature, etc.) of the battery module (battery assembly) 40 can be integrated into the FPC (flexible thin plate-shaped wire) 23. As a result, it becomes possible to reduce the weight of the bus bar module 10 itself.

[0080] Furthermore, if the FPC (flexible thin plate-shaped wire) 23 is used, the current data can be directly output from the FPC (flexible thin plate-shaped wire) 23. Therefore, there is no need to provide a space for connector connection as in the case of using a rigid substrate, and it becomes possible to further reduce the size of the bus bar module 10.

[0081] Further, in the bus bar module 10 shown in the above embodiment and its modified examples, an insulating portion 391 is disposed between the bus bar 32 for current sensor and the mounting portion 361. By doing so, it becomes possible to more surely prevent the bus bar 32 for current sensor and the mounting portion 361 from short - circuiting.

[0082] Further, in the bus bar module 10 shown in the above embodiment and its modified examples, the current sensor unit 30 includes a movement restricting portion 392 that restricts the movement of the mounting portion 361 in the normal direction of the mounting surface 361a. By doing so, it becomes possible to more surely suppress the deflection and displacement of the mounting portion 361, and it becomes possible to more easily position the Hall IC (current detection element) 37.

[0083] Further, in the bus bar module 10 shown in the above embodiment and its modified examples, the current sensor unit 30 includes a shielding portion 393 that blocks an external magnetic field. By doing so, it is possible to suppress the Hall IC (current detection element) 37 from being affected by an external magnetic field, and it becomes possible to further improve the current detection accuracy.

[0084] Further, the battery module (battery assembly) 40 may have a stacked portion 40A in which the single cells 41 are arranged in one direction, and the bus bar 32 for current sensor may be electrically connected to the single cell 41 disposed at one - end portion of the stacked portion 40A in one direction.

[0085] By doing so, even when a plurality of single cells 41 are arranged without gaps, it is not necessary to shift the current sensor unit 30 in the thickness direction of the main body portion 20 (the direction facing the battery module 40) in order to avoid interference with the battery module (battery assembly) 40. As a result, it becomes possible to reduce the size of the battery module (battery assembly) 40 without sacrificing the output, and it becomes possible to reduce the height of the bus bar module 10.

[0086] At this time, if the current sensor unit 30 is provided using the dead space formed in the main body unit 20, further miniaturization of the bus bar module 10 can be achieved.

[0087] Further, the current sensor unit 30 may include an FPC (flexible thin plate-shaped current sensor wire) 36, and a mounting portion 361 and a current output line 362 may be provided on the FPC (flexible thin plate-shaped current sensor wire) 36.

[0088] In this way, the current sensor unit 30 can be formed without using a rigid substrate, and there is no need to provide connector terminals for connecting wires to the substrate, so that it is possible to save space and reduce the height of the current sensor unit 30.

[0089] Further, the current sensor unit 30 may include a current sensor module 33 assembled in a current sensor case 31. Further, this current sensor module 33 may include a lower case (first module case) 34 provided with an insulating portion 391 and an upper case (second module case) 35 provided with a movement restricting portion 392 and assembled to the lower case 34. Then, the Hall IC (current detection element) 37, the mounting portion 361, and the current output line 362 may be held by the lower case (first module case) 34 and the upper case (second module case) 35.

[0090] In this way, it becomes possible to assemble the current sensor unit 30 more easily. At this time, when the current sensor module 33 is formed using the FPC 36, it is possible to suppress the FPC (flexible thin plate-shaped current sensor wire) 36 from being bent when assembling it to the current sensor case 31. That is, it becomes possible to more reliably suppress the Hall IC (current detection element) 37 from being displaced when the current sensor module 33 is assembled to the current sensor case 31.

[0091] [Others] As described above, although the present embodiment has been explained, the present embodiment is not limited to these, and various modifications are possible within the scope of the gist of the present embodiment.

[0092] For example, in the above-described embodiment and its modification, the bus bar 32 for the current sensor is illustrated as being electrically connected to the single cell 41 disposed at one end in one direction of the stacked portion 40A. However, the bus bar module 10 is not limited to such a configuration. For example, it is also possible to electrically connect the bus bar 32 for the current sensor to the single cell 41 in the middle of the stacked portion 40A. In this case, if the single cells 41 are arranged so that a gap is formed at the site where the current sensor portion 30 is formed, it is possible to reduce the height of the bus bar module 10. Such a configuration can be obtained, for example, by removing one of the single cells 41 arranged side by side in one direction, arranging the bus bar 32 for the current sensor in that space while electrically connecting it to the adjacent single cells 41, and arranging the current sensor module 33 thereon.

[0093] Also, it is possible to provide the current sensor portion 30 above or below the case 21. That is, the site where the current sensor portion 30 is formed can be various sites of the case 21.

[0094] Also, in the above-described embodiment and its modification, the insulating portion 391 is illustrated as being provided separately from the current sensor case 31, but the insulating portion 391 may be integrally formed with the current sensor case 31. Such a configuration can be obtained, for example, by forming the insulating portion 391 so that a space (horizontal hole) is formed between the bottom wall 311 while being continuously provided on the side walls 312 facing each other of the current sensor case 31. In this case, when assembling the current sensor portion 30, the bus bar 32 for the current sensor is slid in the space (horizontal hole).

[0095] In addition, in the above-described embodiment and its modifications, an example is shown in which an FPC (flexible thin-plate-shaped current sensor wire) 36 provided with a mounting portion 361 and a current output line 362 is used. However, the bus bar module 10 is not limited to such a configuration. For example, a configuration in which a rigid substrate such as a multilayer circuit board is used as the mounting portion 361 is also possible. In this case, an ordinary wire can be used as the current output line 362, or a flexible thin-plate-shaped wire can also be used.

[0096] It is also possible to reinforce the mounting portion 361 to make it rigid while using the FPC (flexible thin-plate-shaped current sensor wire) 36 provided with the mounting portion 361 and the current output line 362.

[0097] It is also possible to use a bus bar module in which the above-described configurations are appropriately combined.

[0098] In addition, the case of the main body, the bus bar, and other detailed specifications (shape, size, layout, etc.) can also be appropriately changed.

Explanation of Reference Numerals

[0099] 10 Bus bar module 20 Main body 21 Case 22 Bus bar 23 FPC (flexible thin-plate-shaped wire) 30 Current sensor unit 31 Current sensor case 32 Current sensor bus bar 33 Current sensor module 34 Lower case (first module case) 35 Upper case (second module case) 36 FPC (flexible thin-plate-shaped current sensor wire) 361 Mounting portion 361a Mounting surface 362 Current output line 37 Hall IC (current detection element) 391 Insulating part 392 Movement control part 393 Shielding part 40 Battery module (battery assembly) 40A Laminated part 41 Single cell

Claims

1. A main body portion including a case assembled to a battery assembly having a plurality of single cells, a bus bar supported by the case and electrically connected to the single cells of the battery assembly, and a flexible thin plate-shaped wire placed on the case; A current sensor portion integrally provided on the main body portion for detecting a current flowing through the battery assembly; Comprising; The current sensor portion includes: A current sensor case provided on the case; A current sensor bus bar supported by the current sensor case and electrically connected to the single cell; A current detection element for detecting a current flowing through the current sensor bus bar; A mounting portion having a mounting surface on which the current detection element is mounted; A current output line connected to the mounting portion and outputting current data to the flexible thin plate-shaped wire; An insulating portion disposed between the current sensor bus bar and the mounting portion; A movement restricting portion for restricting movement of the mounting portion in a normal direction of the mounting surface; A shielding portion for blocking an external magnetic field; Comprising; A bus bar module.

2. The battery assembly has a stacked portion in which the single cells are arranged in one direction, The current sensor bus bar is electrically connected to the single cell disposed at an end of the stacked portion in the one direction. The bus bar module according to Claim 1.

3. The current sensor portion includes a flexible thin plate-shaped current sensor wire, The mounting portion and the current output line are provided on the flexible thin plate-shaped current sensor wire. The bus bar module according to Claim 1 or Claim 2.

4. The current sensor portion includes a current sensor module assembled to the current sensor case, The current sensor module includes: A first module case provided with the insulating portion; A second module case provided with the movement restricting portion and assembled to the first module case; The current detection element, the mounting portion, and the current output line held by the first module case and the second module case. Comprising; The bus bar module according to any one of Claims 1 to 3.

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