A busbar assembly including a busbar body formed from a wire assembly.

Abstract

The present invention relates to a busbar assembly including a busbar body in the form of a wire assembly composed of a plurality of wires, and coupling portions at both ends of the busbar body for coupling with the wires. The busbar body is flexible and can be freely deformed, and has an improved cooling function.

Description

[Technical Field]

[0001] This application claims the benefit of priority based on Korean Patent Application No. 10-2022-0121727, filed September 26, 2022, and all contents disclosed in the Korean Patent Application are incorporated herein by reference.

[0002] The present invention relates to a busbar assembly including a busbar body formed of a wire assembly, and more particularly to a busbar assembly including a busbar body formed of a wire assembly with improved cooling function for preventing damage to battery modules and electrical components due to heat generation. [Background technology]

[0003] A plurality of lithium secondary batteries are assembled together with a battery disconnect unit (BDU) assembly and a battery management system (BMS) to form a battery module or a battery pack. Connecting members such as relays or bus bars can be used to electrically connect these individual components.

[0004] Lithium secondary batteries generate heat during charging and discharging. When this heat heats up connecting members such as bus bars, the resistance of the conductive material increases, which can lead to a decrease in electrical conductivity. This can create a vicious cycle of temperature rise due to the increased resistance of the conductive material, and in the worst case, can cause the connecting members to become inoperable.

[0005] Another issue that must be resolved is that the busbar, which is intended as an electrical connection means, is instead used as a heat transfer path. Surrounding heat can be transferred to the power distribution device through the busbar. This can reduce the electrical performance of electrical components, such as relays, inside the power distribution device, and can degrade the overall performance of the battery pack.

[0006] To solve the heat generation problem in battery modules and battery packs, methods are being considered, such as applying a cooling system using a refrigerant to the power distribution device or cooling individual components such as relays. Prediction technology for simulating temperature changes in battery packs is also being developed.

[0007] Nevertheless, cooling of the busbar itself has not yet been considered, and rather than cooling individual busbar components, only a passive method of introducing a busbar with a larger capacity, i.e., a larger area, than the current required for the battery pack has been applied.

[0008] Such a change in the busbar structure not only increases manufacturing costs but also requires more space, which is incompatible with current demands for increasing capacity per volume or reducing the size of the battery pack, since it requires an increase in the size of the electrical components.

[0009] Patent Document 1 relates to a flexible bus bar for vehicles, which is configured in a form in which connection terminals are connected to both ends of a braided wire that is flexible and stretchable, three braided wires are stacked in the thickness direction of the connection terminal, and the entire outer circumference of the three braided wires is covered with a heat-shrinkable tube.

[0010] The flexible busbar in Patent Document 1 is configured such that the braided wires are of different lengths so that excessive tension is not applied to the longer side when pressed from the shorter side to the longer side. However, since the entire braided wire is located within a single heat-shrinkable tube, it is difficult to quickly dissipate heat when the temperature of the braided wire increases.

[0011] Patent Document 2 relates to an electrical cell connector for a storage battery or battery for the automotive industry, or an electrical high current connector for an electrical module connector, which has a braided wire and a solid electrical connecting piece, and an end section of the braided wire is configured to be embedded in a part of the solid electrical connecting piece.

[0012] Patent document 2 discloses that the braided wire is formed of flat strands (braided wire), round strands (braided cable, braided wire) or braided sleeving, and the braided wire can have a copper or aluminum material.

[0013] However, no technology is presented for improving the heat generation and heat dissipation function when using the high current connector.

[0014] As such, there is a need for a technology that can improve heat dissipation performance in a busbar assembly without increasing the area or including a separate cooling member, and that can prevent degradation of electrical conductivity due to surrounding heat sources. [Prior art documents] [Patent documents]

[0015] [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-041330 [Patent Document 2] Korean Patent Publication No. 10-2018-0135809 Summary of the Invention [Problem to be solved by the invention]

[0016] The present invention has been made to solve the above problems, and an object of the present invention is to provide a busbar assembly that increases the surface area of ​​a busbar body to improve heat dissipation and prevent damage to electrical components due to heat generated from surrounding heat sources being transferred through the busbar body. [Means for solving the problem]

[0017] To achieve this object, the busbar assembly according to the present invention may include a busbar body in the form of a wire assembly including a plurality of wires, and coupling portions coupled to the wires at both ends of the busbar body.

[0018] Each of the wires may be configured in the form of a linear conductive member covered with an insulating tube.

[0019] At least one space may be provided between the wires.

[0020] The coupling part may have a plurality of holes formed therein for inserting the wires, and one or more wires may be inserted into each hole for coupling. The coupling part may be polygonal or circular with a uniform thickness, and the plurality of holes for coupling with the wires may be formed on its side.

[0021] The joint and wire may be joined by at least one of simple insertion, conductive adhesive, and melting of a filler material.

[0022] The coupling portion may include coupling means that can simultaneously achieve electrical contact and physical fixation.

[0023] The coupling portion may include a through hole for fastening a coupling member.

[0024] The fastening member may be at least one of a bolt and nut, a bolt, a pin, and a rivet.

[0025] A first side end of the busbar body may be coupled to one first coupling portion, and a second side end of the busbar body may be coupled to one second coupling portion, wherein the wires constituting the busbar body may have a uniform length.

[0026] The busbar body may be formed of two or more small-unit wire assemblies, with a first side end of the busbar body coupled to one first coupling portion and a second side end of the busbar body coupled to a third coupling portion for each small-unit wire assemblies, wherein the lengths of the small-unit wire assemblies may be different from each other.

[0027] The method for manufacturing the busbar assembly may include preparing a coupling part having a plurality of holes formed therein; inserting wires constituting a busbar body into the holes; and coupling the wires to the coupling part.

[0028] The wire and the joint may be joined by melting a filler metal.

[0029] The present invention includes a battery module including the busbar assembly.

[0030] Furthermore, the present invention can also be provided in the form of various combinations of means for solving the above problems. [Effects of the Invention]

[0031] As described above, in the busbar assembly according to the present invention, the busbar body is formed of a plurality of wires, so that the surface area of ​​the busbar body is increased, thereby improving heat dissipation.

[0032] In addition, since the wires constituting the busbar body are arranged so as not to be in close contact with each other, air convection can occur in the spaces formed between the wires, thereby improving the cooling effect.

[0033] Furthermore, by configuring the wire assemblies to have different lengths or by providing multiple small unit wire assemblies, there is a high degree of freedom in the connection distance and position setting, and it is possible to configure one-to-many connection to components. [Brief explanation of the drawings]

[0034] [Figure 1] 1 is a perspective view of a first embodiment of a busbar assembly according to the present invention; [Figure 2] FIG. 2 is a partially enlarged view of FIG. [Figure 3] 1 is an assembled perspective view of a first embodiment of a busbar assembly according to the present invention; [Figure 4]10A and 10B are perspective views of second and third embodiments of the busbar assembly according to the present invention. [Figure 5] 1A to 1C are plan views of a portion of a busbar assembly illustrating a manufacturing process of the busbar assembly according to the present invention in sequence. DETAILED DESCRIPTION OF THE INVENTION

[0035] Hereinafter, with reference to the accompanying drawings, a detailed description will be given of an embodiment of the present invention that will enable a person of ordinary skill in the art to easily carry out the present invention. However, in describing the operation principle of the preferred embodiment of the present invention in detail, detailed description of related well-known functions or configurations will be omitted if it is determined that such detailed description may unnecessarily obscure the gist of the present invention.

[0036] Furthermore, the same reference numerals are used throughout the drawings for parts having similar functions and actions. Throughout the specification, when a part is said to be connected to another part, this includes not only a direct connection but also an indirect connection via another element therebetween. Furthermore, unless otherwise specified, "including a certain element" does not mean that other elements are excluded, but that other elements may also be included.

[0037] Furthermore, descriptions that specify or add elements are applicable to all inventions unless otherwise specified, and are not limited to a particular invention.

[0038] Furthermore, throughout the description of the present invention and the claims, the singular includes the plural unless otherwise stated.

[0039] Furthermore, throughout the description of the present invention and the claims, unless otherwise specified, "or" includes "and." Therefore, "including A or B" means three cases: including A, including B, or including both A and B.

[0040] The invention will now be explained with reference to the drawings and in conjunction with detailed embodiments.

[0041] FIG. 1 is a perspective view of a first embodiment of a busbar assembly according to the present invention, FIG. 2 is a partially enlarged view of FIG. 1, and FIG. 3 is an assembled perspective view of the first embodiment of the busbar assembly according to the present invention.

[0042] 1 to 3, the busbar assembly according to the present invention includes a busbar body 100 in the form of a wire assembly made up of a plurality of wires 110, and coupling portions 200 coupled to the wires 110 at both ends of the busbar body 100.

[0043] In the present invention, the busbar body is made up of multiple wires, which increases the surface area of ​​the busbar body and improves heat dissipation compared to conventional methods that use rod-shaped metal plates. Compared to heat generated from an external heat source being transferred through a metal plate, the use of a wire assembly, which has improved heat dissipation properties compared to a metal plate, reduces the heat transfer effect, preventing a decrease in electrical conductivity due to an increase in temperature.

[0044] In addition, since the wires are spaced apart from each other and connected to the connecting portion, a space is formed between the wires where cooling by air convection can occur. Therefore, the bus bar assembly according to the present invention can obtain a cooling effect due to the structural advantages of the bus bar assembly without requiring a separate cooling member.

[0045] The multiple wires 110 that make up the busbar body 100 are configured to have a uniform length, and a first side end of the busbar body 100 is connected to one first connecting portion 200, and a second side end of the busbar body 100 is connected to one second connecting portion 200.

[0046] The wires 110 may have a circular, elliptical, or polygonal cross section, but may be configured to have the same overall shape and uniform size. The wires 110 are not in close contact with each other, but form spaces between them and are arranged on the same plane in the width direction of the joint. Although not shown in the drawings, some of the wires 110 may be in close contact with each other, but only in small units, and there will be spaces between the wires as a whole.

[0047] The coupling part 200 is formed with a plurality of holes 210 for inserting the wires 110, and one or more wires can be inserted and coupled into each hole 210. In FIGS. 1 to 3, one wire 110 is shown inserted into each hole 210.

[0048] The connecting part 200 may have a polygonal or circular shape with a uniform thickness, and has a plurality of holes 210 on its side that can be connected to the wires 110. The connecting part 200 is made of a conductive material, preferably metal.

[0049] The coupling part 200 is formed with a plurality of holes 210 for inserting the wires 110, and the holes 210 may be formed in two or more rows at regular intervals in the thickness direction (y) and width direction (x) of the coupling part 200. Therefore, the wires 110 may be coupled to the coupling part 200 in two or more layers in the thickness direction (y).

[0050] Considering that the heat dissipation efficiency improves as the surface area of ​​the wire increases, the heat dissipation effect can be increased as the wire becomes thinner.

[0051] Each wire may have a linear conductive member 111 inside, covered with an insulating tube 112. Alternatively, the conductive member 111 may be coated with an insulating material. For example, a coating material containing ceramic, which is an insulating material with high heat dissipation performance, may be used to improve heat dissipation performance. However, the end of the wire that is inserted into the coupling portion is exposed without being covered with the insulating tube, allowing current to flow between the busbar body 100 and the coupling portion 200.

[0052] Although not shown in the drawings, since the busbar is usually not exposed to the outside, the wires can be made of linear conductive members without any coating. In this case, the surface area of ​​each individual wire can be reduced. Therefore, the heat dissipation performance can be improved or reduced depending on the type of coating material.

[0053] A single wire 110 may be individually inserted into each hole 210 in the coupling portion 200 and coupled to the coupling portion 200, and / or multiple wires 110 may be inserted together into a single hole 210 and coupled to the coupling portion 200.

[0054] In order to facilitate the formation of spacing between the wires, it is preferable that one wire 110 is inserted into each hole 210 of the coupling part 200 and coupled.

[0055] Here, the wire 110 can be connected to the hole 210 of the connecting portion 200 by at least one of simple insertion, application of a conductive adhesive, and melting of a filler material.

[0056] For example, when joining wires to holes in a joint using a filler metal melting method, the process can be performed by adding filler metal to the end of each wire, inserting the wires with the filler metal into the holes in the joint, and then brazing them, or by adding filler metal inside the holes in the joint, inserting the wires into the holes, and then brazing them.

[0057] The size of the coupling portion 200, the number of holes formed in the coupling portion, and the size D of the holes can be changed depending on the current specifications of the electrical components to which the busbar assembly is coupled, the number of wires required, and the wire thickness, and the coupling portion can be used with wires coupled to only some of the holes.

[0058] Meanwhile, in order to maintain the wires 110 spaced apart from one another, a thin intermediate fixing part may be added to the middle of the busbar body, with holes formed on the sides, similar to the hole 210 in Fig. 3. The wires 110 coupled to the holes 210 of the coupling part 200 may pass through each hole of the intermediate fixing part in the same manner.

[0059] The coupling part 200 may include a coupling means capable of simultaneously achieving electrical contact and physical fixation. For example, the coupling part 200 may have a through-hole 220 penetrating the thickness direction for fastening a coupling member. A component to be coupled to the coupling part 200 is disposed on one side of the coupling part 200. In this case, the through-holes for fastening the coupling members are aligned with each other, and at least one of a bolt, a pin, and a rivet is inserted through the through-hole 220, and then the coupling part and the component may be coupled by fastening with a nut or a fastener, or by performing a riveting operation.

[0060] Alternatively, if the coupling part 200 does not have a through hole, a conductive adhesive may be applied to the coupling surface of the coupling part, or a fastening hook or fixture may be provided on the coupling part to fasten it to another part, or the entire coupling part may be inserted into a groove provided on the other part to attach it.

[0061] FIG. 4 is a perspective view of a second and third embodiment of the busbar assembly according to the present invention.

[0062] Referring to FIG. 4, (a) of FIG. 4 shows a busbar assembly according to a second embodiment, and (b) of FIG. 4 shows a busbar assembly according to a third embodiment.

[0063] In the busbar assemblies according to the second and third embodiments, the busbar body 100 is composed of two small-unit wire assemblies. A first side end of the busbar body 100 is coupled to one first coupling part 200, and a second side end of the busbar body 100 is coupled to a third coupling part 200 for each small-unit wire assemblies.

[0064] In a single small-unit wire assembly, the wire is connected to the first connecting part 200 and the third connecting part 200 so that they are spaced apart from each other on the same plane, and different small-unit assemblies connected to the first connecting part may all be arranged and connected on the same plane, or each small-unit assemblies may be arranged and connected on a different plane.

[0065] The third connecting portion may be smaller than the first connecting portion, or the third connecting portion may be the same as the first connecting portion.

[0066] When a busbar body is formed using small-unit wire assemblies, a single component can be electrically connected to multiple components, thereby reducing the number of busbar assemblies. This reduces the number of connectors to which the busbar assemblies are connected in the electrical component, allowing the area required for electrical connection to be used for other functions, thereby enabling a variety of electrical connection circuit configurations to be formed.

[0067] In the busbar assembly according to the second embodiment, the lengths of the small-unit wire assemblies are different from each other, so even if the distance between the 3-1 electrical component to which the third coupling part is coupled and the 1st electrical component to which the first coupling part is coupled is different from the distance between the 3-2 electrical component to which the third coupling part is coupled and the 1st electrical component to which the first coupling part is coupled, an electrical connection can be formed between them using a single busbar assembly.

[0068] 5A to 5C are plan views of a portion of a busbar assembly showing the steps of manufacturing the busbar assembly according to the present invention.

[0069] Referring to FIG. 5, the method includes the steps of preparing a connecting portion 200 having a plurality of holes 210 formed therein (FIG. 5(a)), inserting wires constituting the busbar body 100 into the holes 210 (FIG. 5(c)), and connecting the wires to the connecting portion 200 (FIG. 5(d)).

[0070] Specifically, a method of joining the wire and the joint portion can be a method of melting a filler material 300. Here, prior to joining the wire constituting the busbar body 100 to the joint portion 200, a process of adding the filler material 300 to the hole 210 of the joint portion 200, as shown in Fig. 5(b), can be included. Alternatively, a process of adding the filler material to the end of the wire to be inserted into the hole 210 of the joint portion 200 can be included.

[0071] As shown in (c) of FIG. 5, the busbar body 100 is inserted into the hole 210 of the joining portion 200, and then, as shown in (d) of FIG. 5, the busbar body 100 can be joined to the joining portion 200 by performing brazing by heating the peripheral portion 400 of the hole 210 of the joining portion.

[0072] For example, silver (Ag) can be used as the filler metal, and the heating temperature of the peripheral portion 400 can be set to a temperature range higher than the melting temperature of silver but lower than the melting temperature of the wire and the joint.

[0073] Using the bus bar assembly manufactured in this manner, a battery module can be manufactured in which electrical connections are formed between electrical components inside the battery module, or electrical connections can be formed between the battery module and its external peripheral components.

[0074] The present invention provides a busbar assembly that exhibits excellent cooling effect through the large surface area of ​​the busbar body and the spacing between wires without requiring a separate cooling member.

[0075] Those skilled in the art will be able to make various applications and modifications within the scope of the present invention based on the above content. [Explanation of symbols]

[0076] 100 Busbar body 110 Wire 111 Conductive material 112 Insulating tube 200 Joint, 1st joint, 2nd joint, 3rd joint 210 holes 220 Through Hole 300 Filler metal 400 Periphery

Claims

1. a busbar body in the form of a wire assembly made up of a plurality of wires; a coupling portion that is coupled to the wire at each end of the busbar body; Including, the busbar body is composed of two or more small unit wire assemblies, a first side end of the busbar body is coupled to one first coupling portion, and a second side end of the busbar body is coupled to a third coupling portion for each of the small-unit wire assemblies.

2. The busbar assembly according to claim 1 , wherein each of the wires is configured as a linear conductive member covered with an insulating tube.

3. The busbar assembly according to claim 1 , wherein at least one space is provided between the wires.

4. The coupling portion has a plurality of holes formed therein for inserting the wires therethrough, The busbar assembly according to claim 1 , wherein one or more of the wires are inserted into and coupled to each of the holes.

5. The busbar assembly of claim 4 , wherein the coupling portion and the wire are coupled by at least one of simple insertion, a conductive adhesive, and melting of a filler material.

6. The busbar assembly according to claim 1 , wherein the coupling portion comprises coupling means capable of simultaneously achieving electrical contact and physical fixation.

7. The busbar assembly according to claim 6 , wherein the coupling portion includes a through hole for fastening a coupling member.

8. The busbar assembly according to claim 7 , wherein the fastening members are at least one of a bolt and nut, a bolt, a pin, and a rivet.

9. The busbar assembly according to claim 1 , wherein the wires constituting the busbar body have a uniform length.

10. The busbar assembly according to claim 1 , wherein the two or more small-unit wire assemblies have different lengths.

11. A method for manufacturing a busbar assembly according to any one of claims 1 to 10, comprising: preparing the coupling part having a plurality of holes formed therein; inserting the wire constituting the busbar body into the hole; coupling the wire to the coupling portion; A method for manufacturing a busbar assembly, comprising:

12. The method for manufacturing a busbar assembly according to claim 11, wherein the wire and the joint are joined by melting a filler metal.

13. A battery module comprising the busbar assembly according to any one of claims 1 to 10.

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