Bus bar module and method for assembling the bus bar module

Abstract

To provide a bus bar module and a method for assembling the bus bar module, capable of realizing a folding state.SOLUTION: A bus bar module 10, 10A comprises: a case 12 that is installed in a battery collector; a plurality of bus bars supported by the case and connected to each single battery; and a wiring material 4 electrically connected to the bus bar and wired to the case. The case comprises: a plurality of division cases 2A, 2B, and 2C(2) which are divided into a direction X where the signal batteries are arranged; and coupling structure bodies 5A(5), 5B(5), and 15 that rotatably couple both of adjacent division cases 2. The coupling structure is constructed so as to deviate the plurality of division cases to a folding state where the division cases are rotated so that the adjacent division cases are overlapped with each other and an expanded state where the plurality of division cases are positioned on the same plane.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a busbar module and a method for assembling the busbar module. [Background technology]

[0002] Conventionally, power supply devices mounted on various vehicles, such as electric vehicles that run using an electric motor and hybrid vehicles that run using both an engine and an electric motor, are configured by assembling a busbar module to a battery assembly made up of multiple unit cells (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2021-136162 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, busbar modules constituting conventional power supply devices tend to become larger in the direction in which the cells are arranged (longitudinal direction) due to an increase in the number of unit cells constituting the power supply device, for example, due to an increase in the amount of power required by an electric motor. Furthermore, when the busbar module becomes larger, the packaging size also becomes larger, which may increase, for example, transportation costs.

[0005] An object of the present invention is to provide a busbar module that can be put into a folded state, and a method for assembling the busbar module. [Means for solving the problem]

[0006] In order to solve the above problems and achieve the above objects, the invention described in claim 1 provides a busbar module to be assembled to a battery assembly composed of a plurality of single cells, comprising: a case installed on the battery assembly; a plurality of bus bars supported by the case and connected to each of the single cells; and wiring material electrically connected to the bus bars and arranged in the case, wherein the case comprises a plurality of split cases divided in the direction in which the single cells are arranged; and a connecting structure that rotatably connects adjacent split cases to each other, and the connecting structure is configured to rotate the split cases to displace the multiple split cases between a folded state in which the adjacent split cases overlap each other and an unfolded state in which the multiple split cases are positioned on the same plane. Effect of the Invention

[0007] According to the invention recited in claim 1, the multiple separate cases can be folded and placed on top of each other. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a plan view of a bus bar module according to one embodiment of the present invention, showing the bus bar module in an expanded state. [Diagram 2] FIG. 4 is a side view showing the bus bar module in a folded state. [Diagram 3] 4 is an enlarged perspective view showing a main part of the bus bar module in the folded state. FIG. [Figure 4] FIG. 2 is a plan view showing a connecting structure that constitutes the bus bar module. [Diagram 5] FIG. 5 is a cross-sectional view taken along line II in FIG. [Figure 6] FIG. 2A is a conceptual diagram showing the folded state, and FIG. 2B is a conceptual diagram showing the transition from the folded state to the unfolded state. [Figure 7] 4A and 4B are views showing a connecting portion that constitutes the connecting structure, in which (A) is a perspective view and (B) is a plan view. [Figure 8] 2A and 2B are diagrams showing a valley fold regulating portion (first rotation regulating portion) that constitutes the busbar module, in which (A) is a plan view and (B) is a cross-sectional view taken along line II-II of (A). [Figure 9] 3A and 3B are diagrams showing a mountain fold regulating portion (second rotation regulating portion) constituting the bus bar module, in which (A) is a plan view and (B) is a cross-sectional view taken along line III-III in (A). [Figure 10] FIG. 11 is a perspective view showing a modified example of the bus bar module. [Figure 11] FIG. 11 is a conceptual diagram showing an expanded state of the bus bar module shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment of the present invention will be described below with reference to Figs. 1 to 9. Fig. 1 is a plan view of a busbar module 10 according to an embodiment of the present invention, showing the busbar module 10 in an unfolded state. Fig. 2 is a side view showing the busbar module 10 in a folded state. Fig. 3 is an enlarged perspective view showing a main part of the busbar module 10 in the folded state. The busbar module 10 according to this embodiment is assembled on the upper surface of a battery assembly (not shown) to constitute a power supply device. The power supply device is mounted on various vehicles, such as an electric vehicle that runs using an electric motor and a hybrid vehicle that runs using both an engine and an electric motor, and supplies power to the electric motor.

[0010] The battery assembly is configured to have a plurality of unit cells. Each unit cell is configured to include a unit cell body formed in a rectangular parallelepiped shape and a pair of electrodes provided on the upper surface of the unit cell body. One of the pair of electrodes is a positive electrode and the other is a negative electrode, with the positive electrode provided at one end of the upper surface of the unit cell body and the negative electrode provided at the other end of the upper surface of the unit cell body. These multiple unit cells are stacked in one direction (X direction) and connected in series by a busbar module 10 described later.

[0011] In this embodiment, the longitudinal direction of the busbar module 10, which is the direction in which the cells constituting the battery assembly are stacked, may be referred to as the "X direction", the width direction of the busbar module 10, which is the direction in which a pair of electrodes face each other, may be referred to as the "Y direction", and a direction perpendicular to the X and Y directions may be referred to as the "Z direction". In addition, within the Z direction, the near side in the direction perpendicular to the paper surface in Fig. 1 may be referred to as the "upper Z1", and the opposite direction (the far side in the direction perpendicular to the paper surface in Fig. 1) which is the battery assembly side as viewed from the busbar module 10 may be referred to as the "lower Z2".

[0012] 1 and 2, the busbar module 10 is assembled on the upper surface of the battery assembly and includes three separate cases 2A, 2B, 2C (2), bus bars (not shown) supported by the separate cases 2 and connected to each of the cells, an FPC 4 (flexible printed circuits) connected to the bus bars and wired across the separate cases 2A, 2B, 2C, and a pair of connecting structures 5, 5 that rotatably connect adjacent separate cases 2A, 2B, 2C to each other. Each separate case 2A, 2B, 2C and the pair of connecting structures 5, 5 form a case 12 (shown in FIGS. 1 and 2).

[0013] 1 and 2, this busbar module 10 is configured to be in two forms: an unfolded state (shown in FIG. 1) in which the three split cases 2A, 2B, and 2C are positioned on the same plane, and a folded state (shown in FIG. 2) in which the three split cases 2A, 2B, and 2C are stacked in the vertical direction Z. As shown in FIG. 1, when the busbar module 10 is in the unfolded state, the first split case 2A, the second split case 2B, and the third split case 2C are arranged side by side in this order along the longitudinal direction X of the busbar module 10.

[0014] Each divided case 2 is made of insulating synthetic resin. As shown in Fig. 1, each divided case 2 includes a pair of bus bar accommodating rows 22, 22 in which a plurality of bus bar accommodating sections 22A are arranged in two rows, an insulating cover 21 that covers the bus bars accommodated in each bus bar accommodating section 22A, an FPC routing section 23, and an FPC cover 3 (routing material cover) that is supported by the FPC routing section 23 and covers the FPC portion 40. The FPC routing section 23 is located between the pair of bus bar accommodating rows 22, 22.

[0015] 3, the FPC cover 3 includes a cover body 31 formed in a rectangular plate shape, and an FPC guiding portion 32 formed by bending an end portion in the longitudinal direction X of the cover body 31 downward Z2. The cover body 31 is formed in a size capable of covering an FPC portion 40 described later.

[0016] As shown in Fig. 5 and Fig. 6(A)(B), the FPC guiding portion 32 is provided at a position facing the FPC extra length portion 41 described later, and is configured to bend the FPC extra length portion 41 downward Z2 when the busbar module 10 is displaced from the folded state to the unfolded state. That is, as shown in Fig. 6(A)(B), when the busbar module 10 is displaced from the folded state to the unfolded state, the FPC guiding portion 32 of the FPC cover 3 abuts against the FPC extra length portion 41 and is pushed downward Z2 by the FPC guiding portion 32, so that the FPC extra length portion 41 is bent downward Z2 and accommodated in the FPC accommodating portion 8. This prevents the FPC extra length portion 41 from being caught between adjacent FPC covers 3 when the busbar module 10 is displaced from the folded state to the unfolded state. Hatching showing a cross section is omitted in Fig. 5.

[0017] 1 and 5, the FPC 4 integrally comprises three FPC portions 40, 40, 40 (only two are shown in FIG. 5) arranged in each separate case 2, and a pair of FPC extra length portions 41, 41 (shown in FIG. 1) provided between adjacent FPC portions 40. As shown in FIG. 1, the FPC 4 is configured to have a continuous length from one end to the other end in the longitudinal direction X of the busbar module 10, and is arranged across each separate case 2A, 2B, 2C. The FPC 4 is connected to each busbar at each FPC portion 40, and one end 4R (shown in FIGS. 1 and 2) in the longitudinal direction X of the FPC 4 is connected to a control device (not shown) including a voltage monitoring unit that detects the voltage of each cell and a temperature monitoring unit that detects the temperature of each cell.

[0018] Each FPC portion 40 is configured to have a length that allows it to be routed in each separate case 2, and is housed in the FPC routing portion 23 of each separate case 2 so as to face the upper surface of the battery assembly.

[0019] One of the pair of connecting structures 5, 5 (hereinafter sometimes referred to as the first connecting structure 5A) rotatably connects the first separate case 2A and the second separate case 2B as shown in Figs. 1 and 2, and the other (hereinafter sometimes referred to as the second connecting structure 5B) rotatably connects the second separate case 2B and the third separate case 2C as shown in Figs. 1 and 2. The pair of connecting structures 5A, 5B are configured to have the same function or structure. Below, only the first connecting structure 5A will be described, and a detailed description of the second connecting structure 5B will be omitted.

[0020] As shown in Figures 4 and 5, the first connecting structure 5A, 5 comprises a pair of shaft portions 50, 50 formed in a cylindrical shape and extending in the width direction Y of the busbar module 10, and a connecting portion 6 journaled by the pair of shaft portions 50, 50.

[0021] As shown in Figure 4, one of the pair of shaft portions 50, 50 is supported by the first separate case 2A and extends in the width direction Y of the busbar module 10, and the other is supported by the second separate case 2B and extends in the width direction Y.

[0022] As shown in Figures 7(A) and (B), the connecting portion 6 comprises a connecting portion main body 61 having a rectangular shape when viewed in a plane, and a pair of support portions 62, 62 provided at both ends of the connecting portion main body 61 and supporting the pair of shaft portions 50, 50, respectively.

[0023] 7(A) and 7(B), the connecting portion main body 61 integrally includes a pitch absorbing portion 7 formed to be elastically deformable in the longitudinal direction X of the busbar module 10, and an FPC accommodating portion 8 that accommodates the FPC excess length portion 41. The pitch absorbing portion 7 and the FPC accommodating portion 8 are arranged side by side in the width direction Y of the busbar module 10.

[0024] As shown in FIGS. 7(A) and 7(B), the pitch absorbing portion 7 includes an absorbing portion main body 70 and a pair of flat plate-like one-side plate portions 71, 71 that are continuous with the absorbing portion main body 70 and each of the pivot supports 62.

[0025] As shown in Fig. 7(A), the absorbent body 70 is configured to have a plurality of one-side arcuate portions 7A. Each one-side arcuate portion 7A is formed in an arc shape that protrudes downward Z2. In addition, in the absorbent body 70, the multiple one-side arcuate portions 7A are arranged side by side in the width direction Y at intervals. That is, one-side slits 7B for reducing the rigidity of the absorbent body 70 are formed between the multiple one-side arcuate portions 7A. This allows the absorbent body 70 to be elastically deformed (stretched and contracted) with a small force.

[0026] As shown in Figures 7(A) and (B), the FPC accommodating section 8 comprises an accommodating section main body 80 that accommodates the FPC excess length portion 41, and a pair of flat, plate-shaped other side plate portions 81, 81 that are continuous with the accommodating section main body 80 and each of the support portions 62.

[0027] As shown in Fig. 7(B), the accommodating section main body 80 is configured to have a plurality of other-side arc-shaped portions 8A. Each other-side arc-shaped portion 8A is formed in an arc shape that protrudes downward Z2. The circumferential length of the accommodating section main body 80 is formed to be longer than the length of the FPC excess length portion 41, and the FPC excess length portion 41 is configured to be able to be accommodated in the accommodating section main body 80 when the busbar module 10 is in the deployed state. In addition, in the accommodating section main body 80, the plurality of other-side arc-shaped portions 8A are arranged side by side in the width direction Y at intervals. That is, other-side slits 8B are formed between the plurality of other-side arc-shaped portions 8A.

[0028] This accommodating section main body 80 is provided at a position facing the FPC guiding section 32 in the up-down direction Z when the busbar module 10 is in the unfolded state. That is, the FPC excess length section 41 pressed downward Z2 by the FPC guiding section 32 is accommodated inside the accommodating section main body 80 in a curved arc state.

[0029] Each of the shaft support portions 62 is formed in a C-shape capable of supporting the pair of shaft portions 50, 50, and is provided extending in the width direction Y of the busbar module 10.

[0030] When the first separate case 2A and the second separate case 2B are connected by such a first connecting structure 5A, the pair of axial supports 62, 62 provided on the connecting portion 6 are brought close to the pair of shaft portions 50, 50. Each axial support portion 62 fits into each shaft portion 50, and each axial support portion 62 is supported by each shaft portion 50. In this way, the first separate case 2A and the second separate case 2B are rotatably connected by the first connecting structure 5A. Similarly, when the second separate case 2B and the third separate case 2C are connected by the second connecting structure 5B, the pair of axial supports 62, 62 provided on the connecting portion 6 are brought close to the pair of shaft portions 50, 50. In this way, the second separate case 2B and the third separate case 2C are rotatably connected by the second connecting structure 5B.

[0031] 1, case 12 is provided with a valley fold restricting portion 9A (first rotation restricting portion) that restricts the rotation direction of first separate case 2A and second separate case 2B, and a mountain fold restricting portion 9B (second rotation restricting portion) that restricts the rotation direction of second separate case 2B and third separate case 2C. Mountain fold restricting portion 9B restricts rotation in the opposite direction to that of valley fold restricting portion 9A. This makes it possible to restrict rotation in an unintended direction when busbar module 10 is changed from an unfolded state to a folded state.

[0032] As shown in FIG. 1, the valley fold regulating portion 9A is provided at the end opposite the first connecting structure 5A in the width direction Y of the busbar module 10, and is provided at a position adjacent to the first connecting structure 5A in the longitudinal direction X of the busbar module 10.

[0033] As shown in Figures 8(A) and (B), the valley fold regulating portion 9A comprises an L-shaped valley fold first regulating piece 91 protruding from the first separate case 2A toward the second separate case 2B, and a valley fold second regulating piece 92 protruding from the second separate case 2B toward the first separate case 2A and abutting the valley fold first regulating piece 91.

[0034] As shown in Figure 8 (B), the first valley fold restricting piece 91 is configured in an L-shape and has a valley fold opposing portion 93 that protrudes from the first separate case 2A toward the second separate case 2B, and a valley fold extending portion 94 that bends from the end of the valley fold opposing portion 93 and extends downward Z2.

[0035] As shown in Figure 8 (B), when the busbar module 10 is in an unfolded state, this valley fold regulating portion 9A is arranged so that the valley fold opposing portion 93 of the first valley fold regulating piece 91 faces the upper side Z1 of the second valley fold regulating piece 92, and the valley fold extension portion 94 is arranged so as to be able to abut against the second valley fold regulating piece 92.

[0036] In addition, as shown in Figures 8(A) and (B), when the busbar module 10 is in an unfolded state, the valley fold extension portion 94 of the first valley fold regulating piece 91 abuts against the second valley fold regulating piece 92, regulating the top surfaces of the first and second separate cases 2A and 2B from rotating in a valley shape so as to approach each other, and allowing the bottom surfaces of the first and second separate cases 2A and 2B to rotate in a mountain shape so as to approach each other.

[0037] As shown in FIG. 1, the mountain fold regulating portion 9B is provided at the end opposite the second connecting structure 5B in the width direction Y of the busbar module 10, and is provided at a position adjacent to the second connecting structure 5B in the longitudinal direction X of the busbar module 10.

[0038] As shown in Figures 9(A) and (B), the mountain fold control portion 9B comprises an L-shaped mountain fold first control piece 95 protruding from the second separate case 2B toward the third separate case 2C, and a mountain fold second control piece 96 protruding from the third separate case 2C toward the second separate case 2B and abutting the mountain fold first control piece 95.

[0039] As shown in Figure 9 (B), the first mountain fold restricting piece 95 is configured in an L-shape and has a mountain fold opposing portion 97 that protrudes from the second separate case 2B toward the third separate case 2C, and a mountain fold extending portion 98 that bends and extends downward Z2 from the end of the mountain fold opposing portion 97.

[0040] As shown in Figure 9 (B), when the busbar module 10 is in an unfolded state, this type of mountain fold control portion 9B is arranged so that the mountain fold opposing portion 97 of the first mountain fold control piece 95 faces the downward side Z2 of the second mountain fold control piece 96, and the first mountain fold control piece 95 is arranged so as to be able to abut against the second mountain fold control piece 96.

[0041] In addition, as shown in Figures 9(A) and (B), when the busbar module 10 is in an unfolded state, the first mountain fold restricting piece 95 abuts the second mountain fold restricting piece 96, restricting the bottom surfaces of the second separate case 2B and the third separate case 2C from rotating in a mountain shape so as to approach each other, and allowing the top surfaces of the second separate case 2B and the third separate case 2C to rotate in a valley shape so as to approach each other.

[0042] When assembling such a bus bar module 10, each bus bar is accommodated in each bus bar accommodating portion 22A of each split case 2. In addition, a pair of axial supports 62, 62 provided on the connecting portion 6 of the first connecting structure 5A are brought close to the pair of shaft portions 50, 50. Each axial support portion 62 fits into each shaft portion 50, and each axial support portion 62 is axially supported by each shaft portion 50, thereby connecting the first split case 2A and the second split case 2B. In addition, a pair of axial supports 62, 62 provided on the connecting portion 6 of the second connecting structure 5B are brought close to the pair of shaft portions 50, 50. Each axial support portion 62 fits into each shaft portion 50, and each axial support portion 62 is axially supported by each shaft portion 50, thereby connecting the second split case 2B and the third split case 2C.

[0043] Thereafter, each FPC portion 40 of the FPC 4 is routed to the FPC routing portion 23 of each of the split cases 2A, 2B, 2C, and the FPC cover 3 is attached to the FPC routing portion 23. In this manner, the assembly of the busbar module 10 is completed. In the assembled busbar module 10, the FPC 4 is routed across each of the split cases 2A, 2B, 2C, and each FPC portion 40 of the FPC 4 is electrically connected to the bus bars accommodated in each busbar accommodating portion 22A.

[0044] When such a busbar module 10 is in an unfolded state, the first separate case 2A, the second separate case 2B and the third separate case 2C are connected to each other by the respective connecting structures 5A, 5B and are located on the same plane as each other, as shown in Fig. 1. In addition, in the unfolded state, the pitch absorbing portions 7 constituting the respective connecting structures 5A, 5B are in their natural state and are not elastically deformed before being assembled into the battery assembly, and the FPC extra length portion 41 is curved so as to protrude downward Z2 and is accommodated in the FPC accommodating portion 8.

[0045] In addition, when the busbar module 10 is in an unfolded state, the first valley fold regulating piece 91 of the valley fold regulating portion 9A is provided at a position abutting or close to (a position where it can abut) the second valley fold regulating piece 92, and the first mountain fold regulating piece 95 of the mountain fold regulating portion 9B is provided at a position abutting or close to (a position where it can abut) the second mountain fold regulating piece 96.

[0046] Next, when the busbar module 10 is changed from the unfolded state to the folded state, the first separate case 2A and the second separate case 2B are rotated into a mountain shape by the first connecting structure 5A. At this time, the valley fold restricting portion 9A restricts the first separate case 2A and the second separate case 2B from rotating into a valley shape. As the rotation progresses, the bottom surfaces of the first separate case 2A and the second separate case 2B are brought closer to each other, and the second separate case 2B is stacked below the first separate case 2A at Z2.

[0047] The second separate case 2B and the third separate case 2C are rotated into a valley shape by the second connecting structure 5B. At this time, the mountain fold restricting portion 9B restricts the second separate case 2B and the third separate case 2C from rotating into a mountain shape. As the rotation progresses, the top surfaces of the second separate case 2B and the third separate case 2C are brought closer to each other, and the third separate case 2C is stacked below the second separate case 2B at Z2. In this way, the busbar module 10 is in a folded state.

[0048] Next, when assembling the busbar module 10 on the upper surface of the battery assembly, the end 2Ca of the third separate case 2C is brought close to a reference position located at one end of the battery assembly in the longitudinal direction X when the busbar module 10 is in a folded state, and positioned (positioning step). As a result, the third separate case 2C is placed on the upper surface of the battery assembly.

[0049] Thereafter, the second separate case 2B is rotated by the second connecting structure 5B so as to move away from the third separate case 2C, and the first separate case 2A is rotated by the first connecting structure 5A so as to move away from the second separate case 2B.

[0050] As the rotation progresses, the FPC guide portion 32 of the FPC cover 3 comes into contact with the FPC extra length portion 41, and the FPC extra length portion 41 is pushed downward Z2 by the FPC guide portion 32, so that the FPC extra length portion 41 is curved downward Z2 and accommodated in the FPC accommodation portion 8. As the rotation progresses further, the second separate case 2B and the first separate case 2A are brought closer to the upper surface of the battery assembly. After this, the second separate case 2B is placed in a predetermined position of the battery assembly, and the first separate case 2A is placed in a predetermined position of the battery assembly (installation process). At this time, the pitch absorbing portions 7 of the connection structures 5A and 5B are elastically deformed and expand and contract in the longitudinal direction X, so that the pitch absorbing portions 7 absorb the tolerance of the arrangement pitch of the electrodes between the unit cells. After this, the bus bars and the electrodes of the unit cells are electrically connected, and the bus bars are covered with the insulating cover 21. In this manner, the assembly of the bus bar module 10 to the battery assembly is completed.

[0051] According to the above-mentioned embodiment, each connecting structure 5A, 5B is configured to rotate the separate cases 2A, 2B, 2C to displace the separate cases 2 between a folded state in which adjacent separate cases 2A, 2B, 2C overlap each other, and an unfolded state in which the separate cases 2A, 2B, 2C are located on the same plane. This allows the separate cases 2A, 2B, 2C to be folded in a state in which they overlap each other by the connecting structures 5A, 5B, and therefore the packaging size can be reduced in the folded state. This can prevent an increase in transportation costs, etc.

[0052] In addition, in the folded state, the busbar module 10 is arranged in a Z-shape with the first separate case 2A, the second separate case 2B, and the third separate case 2C stacked in that order on the downward Z2 (direction approaching the battery assembly). With this, when installing the busbar module 10 on the battery assembly, the third separate case 2C is brought close to the battery assembly while in the folded state, and the busbar module 10 is installed on the battery assembly using the end 2Ca of the third separate case 2C as a reference for positioning with respect to the battery assembly, thereby enabling the busbar module 10 to be installed on the battery assembly with good workability.

[0053] Furthermore, case 12 has valley fold restricting portion 9A (first rotation restricting portion) that restricts the rotation direction of first separate case 2A and second separate case 2B, and mountain fold restricting portion 9B (second rotation restricting portion) that restricts the rotation direction of second separate case 2B and third separate case 2C, and mountain fold restricting portion 9B restricts rotation in the opposite direction to valley fold restricting portion 9A. This makes it possible to restrict rotation in an unintended direction when busbar module 10 is changed from an unfolded state to a folded state.

[0054] The connecting portion 6 has a pitch absorbing portion 7 that is expandable in the longitudinal direction X of the busbar module 10 (the direction in which the unit cells are arranged), and the pitch absorbing portion 7 has a plurality of one-side arc-shaped portions 7A (absorbing members) that protrude downward Z2 (toward the battery assembly) in the unfolded state, and the plurality of one-side arc-shaped portions 7A are arranged side by side at intervals (one-side slits 7B). That is, one-side slits 7B for reducing the rigidity of the absorbing portion main body 70 are formed between the plurality of one-side arc-shaped portions 7A. According to this, when the unfolded busbar module 10 is installed in the battery assembly, the pitch absorbing portion 7 elastically deforms in the longitudinal direction X of the busbar module 10 and expands and contracts in the longitudinal direction X, so that the pitch absorbing portion 7 can absorb the tolerance of the arrangement pitch of the electrodes of the unit cells. Furthermore, since the pitch absorption portion 7 has one-side slits 7B provided between multiple one-side arc-shaped portions 7A, the pitch absorption portion 7 can be deformed (expanded and contracted) with a small force, so that the busbar module 10 can be installed on the battery assembly with good workability while absorbing tolerances.

[0055] Furthermore, the connecting portion 6 has an FPC accommodating portion 8 (routing material accommodating portion) capable of accommodating the FPC excess portion 41, and the FPC accommodating portion 8 is formed in an arc shape that protrudes downward Z1 (towards the battery assembly) in the unfolded state. With this, when the busbar module 10 is in the unfolded state, the FPC excess portion 41 of the FPC 4 is accommodated in the FPC accommodating portion 8, so that the FPC excess portion 41 does not interfere with other components and the FPC excess portion 41 can be protected.

[0056] Moreover, the FPC cover 3 includes a plate-shaped cover main body 31, and an FPC guiding portion 32 (guiding portion) provided at an end of the cover main body 31 for guiding an FPC excess length portion 41 (excess length portion) into the FPC accommodating portion 8 (routing material accommodating portion), the FPC guiding portion 32 being formed by bending from the cover main body 31 toward the FPC accommodating portion 8, and configured to come into contact with the FPC excess length portion 41 and push the FPC excess length portion 41 into the FPC accommodating portion 8 when changing from the folded state to the unfolded state. With this, the FPC excess length portion 41 is pushed in by the FPC guiding portion 32, so that the FPC excess length portion 41 can be accommodated in the FPC accommodating portion 8.

[0057] Furthermore, a busbar module assembling method for assembling the busbar module 10 to the battery assembly includes a positioning step of positioning the busbar module 10 by bringing the end 2Ca of the third separate case 2C close to an end of the battery assembly in a folded state, and an installation step of rotating the second separate case 2B and the first separate case 2A with the pair of connecting structures 5A, 5B in a state in which the busbar module 10 is positioned in the battery assembly, and installing the second separate case 2B and the first separate case 2A to the battery assembly. According to this, when installing the busbar module 10 in the battery assembly, the third separate case 2C is brought close to the battery assembly in the folded state, and the busbar module 10 is installed in the battery assembly using the end 2Ca of the third separate case 2C as a reference for positioning with respect to the battery assembly, thereby making it possible to install the busbar module 10 in the battery assembly with good workability.

[0058] The present invention is not limited to the above-described embodiment, but includes other configurations that can achieve the object of the present invention, and the following modifications are also included in the present invention.

[0059] In the above-described embodiment, the connecting portion body 61 of the connecting portion 6 is configured to include the pitch absorbing portion 7 elastically deformable in the longitudinal direction X of the busbar module 10 and the FPC accommodating portion 8 that accommodates the FPC extra length portion 41, but the present invention is not limited thereto. As shown in FIG. 10, the connecting structure 15 in the busbar module 10A may include a pair of shaft portions 50, 50 provided on the adjacent separate cases 2A(2), 2B(2), respectively, and a connecting portion 16 pivotally supported by the pair of shaft portions 50, 50. FIG. 10 is a perspective view showing a modified example of the busbar module 10. FIG. 11 is a conceptual diagram showing the busbar module 10A in an expanded state. The FPC 4 and the FPC cover 3 are omitted in FIG. 10.

[0060] As shown in Figure 10, one of the pair of shaft portions 50, 50 is supported by a pair of first protruding pieces 24, 24 (only one is shown in Figure 10) protruding from the first separate case 2A and extends in the width direction Y of the busbar module 10, and the other is supported by a pair of second protruding pieces 25, 25 protruding from the second separate case 2B and extends in the width direction Y.

[0061] 10, a connecting portion main body 161 constituting the connecting portion 16 may be formed in a flat plate shape. In this case, a pair of pivot supports 62, 62 may be provided on the lower side Z2 (the side closer to the battery assembly) of the connecting portion main body 161 when the busbar module 10A is in the unfolded state. This makes it possible to realize a structure in which the separate cases 2A, 2B, 2C can be displaced between a folded state in which the separate cases 2A, 2B, 2C overlap each other and an unfolded state in which the separate cases 2A, 2B, 2C are located on the same plane.

[0062] 11, in the case where the connecting portion main body 161 is formed in a flat plate shape, the FPC protection portion 132 (protection portion) may be provided at a position facing the FPC excess portion 41 when the busbar module 10A is in the unfolded state, and may be configured to be able to cover the FPC excess portion 41 in a state where the FPC excess portion 41 is curved upward Z1 (in a direction away from the battery assembly). That is, as shown in FIG. 11, the FPC protection portion 132 may be configured to have an oblique extension portion 33 continuing from the cover main body 131, a rising portion 34 continuing from the oblique extension portion 33 and rising upward Z1, and a cover facing portion 35 continuing from the rising portion 34 and facing the connecting portion main body 161. According to this, when the busbar module 10A is in an unfolded state, the FPC excess portion 41 is covered by each FPC protection portion 132 of the adjacent split cases 2A, 2B, so that the FPC excess portion 41 does not interfere with other components and the FPC excess portion 41 can be protected.

[0063] In the above-described embodiment, each of the connecting structures 5A, 5B includes a pair of shafts 50, 50 and a connecting portion 6 pivotally supported by the pair of shafts 50, 50, and is configured to rotate the adjacent split cases 2, 2 on two axes, but the present invention is not limited to this. Each connecting structure may be configured to include one shaft provided on the split case 2 on one side and a connecting portion pivotally supported by the one shaft. In this case, one end of the connecting portion may be pivotally supported by the shaft portion, and the other end may be fixed to the split case 2 on the other side so as not to rotate, and the split case located on the one end side of the connecting portion may be pivoted on one axis. Alternatively, each connecting structure may be configured in a hinge shape including one shaft extending in the width direction Y and a pair of connecting portions pivotally supported by the one shaft portion. In this case, each connecting portion may be configured such that one end is pivotally supported on a single shaft portion and the other end is fixed non-rotatably to a pair of adjacent split cases 2, 2, thereby allowing the adjacent split cases 2, 2 to rotate on a single shaft.

[0064] In the above-described embodiment, the wiring material is made of the FPC 4, but the present invention is not limited to this. The wiring material may be made of a covered electric wire.

[0065] In addition, the best configurations and methods for implementing the present invention are disclosed in the above description, but the present invention is not limited thereto. That is, the present invention has been mainly illustrated and described with reference to specific embodiments, but those skilled in the art can make various modifications to the above-described embodiments in terms of shape, material, quantity, and other detailed configurations without departing from the scope of the technical idea and purpose of the present invention. Therefore, the descriptions limiting the shapes, materials, etc. disclosed above are illustrative descriptions for the purpose of facilitating understanding of the present invention, and do not limit the present invention, and therefore descriptions of the names of components that are free of some or all of the limitations on the shapes, materials, etc. are included in the present invention. [Explanation of symbols]

[0066] 10, 10A busbar module 12 cases 2A(2) First separate case 2B(2) Second Separate Case 2C(2) Third Separate Case 2Ca End of the third separate case 9A Valley fold regulating part (first rotation regulating part) 9B Mountain fold regulating portion (second rotation regulating portion) 3, 13 FPC cover (wiring material cover) 31 Cover body 32 FPC guiding part (guiding part) 132 Protection Department (Protection Department) 4 FPC (roping material) 40 Multiple FPC parts (routing material parts) 41 FPC extra length (extra length) 5A(5) First connected structure (connected structure) 5B(5) Second connected structure (connected structure) 15 Connected structure 50, 50 Pair of shafts 6, 16 Connection part 61, 161 Connection body 62, 62 Pair of pivot supports 7 Pitch absorbing section 7A One side arc-shaped portion (absorption member) 7B One side slit (spacing) 8 FPC storage section (wiring material storage section) X: Longitudinal direction of the busbar module (direction in which the cells are lined up) Z1 Upward (away from the battery assembly) Z2 Downward (closer to the battery assembly)

Claims

1. A busbar module that is assembled to a battery assembly composed of a plurality of single cells, a case installed in the battery assembly; a plurality of bus bars supported by the case and connected to each of the unit cells; A wiring material electrically connected to the bus bar and wired to the case, the case includes a plurality of split cases that are split in a direction in which the cells are arranged, and a connecting structure that rotatably connects adjacent split cases to each other, a connecting structure configured to rotate the split cases to displace the multiple split cases between a folded state in which adjacent split cases overlap each other and an unfolded state in which the multiple split cases are positioned on the same plane.

2. the plurality of split cases include a first split case, a second split case and a third split case, a pair of the connection structures are provided, and the first separate case, the second separate case, and the third separate case are connected in this order by the pair of connection structures; 2. The busbar module according to claim 1, wherein in the folded state, the first separate case, the second separate case, and the third separate case are stacked in this order in a Z-shape in a direction approaching the battery assembly.

3. the case has a first rotation restricting portion that restricts a rotation direction of the first separate case and the second separate case, and a second rotation restricting portion that restricts a rotation direction of the second separate case and the third separate case, The busbar module according to claim 2 , wherein the second rotation restricting portion restricts rotation in a direction opposite to that of the first rotation restricting portion.

4. the connecting structure includes a pair of shaft portions provided on the adjacent separate cases, and a connecting portion journaled to the pair of shaft portions, the connecting portion has a pitch absorbing portion that is elastically deformable in a direction in which the unit cells are arranged, 2. The busbar module according to claim 1, wherein the pitch absorbing portion has a plurality of absorbing members that protrude toward the battery assembly in the deployed state, and the plurality of absorbing members are arranged side by side at intervals from each other.

5. the connecting structure includes a pair of shaft portions provided on the adjacent separate cases, and a connecting portion journaled to the pair of shaft portions, The wiring material includes a plurality of wiring material portions that are wired to each of the separate cases, and an excess portion that is provided between the plurality of wiring material portions and faces the connecting structure, The connecting portion has an arc-shaped wiring material accommodating portion capable of accommodating the excess portion, The busbar module according to claim 1 or 4, wherein the wiring material accommodating portion is provided so as to protrude toward the battery assembly in the deployed state.

6. A wiring material cover is provided which is supported by the split case and covers at least each of the wiring material portions, The wiring material cover includes a plate-shaped cover body and a guide portion provided at an end of the cover body to push the excess portion into the wiring material storage portion, The guide portion is formed by bending from the cover body toward the wiring material storage portion, The busbar module according to claim 5, characterized in that, when the busbar module is changed from the folded state to the unfolded state, the busbar module is configured to abut against the excess portion and push the excess portion into the wiring material accommodating portion.

7. the connecting structure includes a pair of shaft portions provided on the adjacent separate cases, and a connecting portion journaled to the pair of shaft portions, The connecting portion includes a connecting portion main body and a pair of shaft support portions provided on the connecting portion main body and supporting the pair of shaft portions, respectively. The connecting portion body is formed in a flat plate shape, 2 . The busbar module according to claim 1 , wherein the pair of pivot support portions are provided on a side of the connecting portion body closer to the battery assembly in the deployed state.

8. The wiring material includes a plurality of wiring material portions that are wired to each of the separate cases, and an excess portion that is provided between the plurality of wiring material portions and faces the connecting structure, A wiring material cover is provided which is supported by the split case and covers at least each of the wiring material portions, The wiring material cover includes a plate-shaped cover body and a protective portion provided at an end of the cover body to cover and protect the excess portion, The busbar module according to claim 7 , wherein the protection portion is bent in a direction away from the connecting portion main body and configured to cover the excess portion in the deployed state.

9. A busbar module assembling method for assembling the busbar module according to claim 2 to the battery assembly, comprising the steps of: a positioning step of positioning the busbar module by bringing an end of the third separate case away from the second separate case close to an end of the battery assembly in the folded state; and an installation step of rotating the second split case and the first split case using the pair of connecting structures with the busbar module positioned on the battery assembly, thereby installing the second split case and the first split case on the battery assembly.

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