Manufacturing method for flexible busbars

Abstract

We provide flexible busbars that not only improve the appearance but also stabilize the quality of the product. [Solution] The flexible busbar 1 comprises a flexible busbar body 2 and left fixing parts 2a1 and right fixing parts 2b1 that fix both sides of the flexible busbar body 2. When bending the flexible busbar body 2 from the bending line S1, a bending fixing part 2d including the bending line S1 is formed on the flexible busbar body 2, separate from the left fixing part 2a1 and right fixing part 2b1.

Description

Technical Field

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

Background Art

[0002] Generally, when connecting energizable members (for example, batteries mounted in electric vehicles, hybrid cars, etc.), it is known to use a flexible bus bar. As such a flexible bus bar, for example, the one described in Patent Document 1 is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, when bending the above flexible bus bar, there were the following problems. This will be specifically described with reference to FIGS. 4 and 5.

[0005] As shown in FIG. 4(a), a conventional flexible bus bar 100 includes a horizontally long rectangular flexible bus bar body 101. This flexible bus bar body 101 is formed by laminating a conductive material foil 102 made of a thin plate-like and flexible metal such as copper, as shown in FIG. 4(b). Note that the flexible bus bar body 101 formed in this way can conduct a large current.

[0006] Thus, as shown in Figure 4(a), the flexible busbar body 101 configured in this way has its left side 101a fixed to form a left fixed portion 101a1, and its right side 101b fixed to form a right fixed portion 101b1. As a result, as shown in Figure 4(a), an unfixed portion 101c is formed between the left fixed portion 101a1 and the right fixed portion 101b1. Therefore, the flexible busbar 100 shown in Figure 4(a) is formed in this way. The unfixed portion 101c is flexible.

[0007] Thus, when the flexible busbar 100 formed in this manner is bent 90 degrees along the bending line S100 shown in Figure 4(a), it becomes as shown in Figure 4(b). That is, as shown in Figure 4(b), since the non-adherent portion 101c is involved in the 90-degree bending process, when the conductive material foil 102 located on the outermost circumferential surface 101ca side of the non-adherent portion 101c and the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-adherent portion 101c are bent 90 degrees along the bending line S100 shown in Figure 4(a), a distance difference occurs, resulting in an inner-outer difference. Therefore, as shown in Figures 4(a) and 4(b), when the left fixing portion 101a1 and the right fixing portion 101b1 are formed, the difference between the inside and outside causes the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c to bulge and wrinkle, as shown in Figure 4(b). Flexible busbars 100 that exhibit this phenomenon have an unsightly appearance and pose a problem in that they cannot be properly connected to electrically conductive components (for example, batteries installed in electric vehicles or hybrid cars) due to size incompatibility.

[0008] Therefore, in order to solve the above-mentioned problems, the method shown in Figure 5 can be considered.

[0009] In other words, as shown in Figure 5(a), only the left side 101a of the flexible busbar body 101 is fixed to form the left fixed portion 101a1. Then, in this state, when it is bent 90 degrees along the bending line S101 shown in Figure 5(a), it will be in the state shown in Figure 5(b). In other words, as shown in Figure 5(b), since the non-fixed portion 101c is involved in the 90-degree bending process, when the conductive material foil 102 located on the outermost circumferential surface 101ca side of the non-fixed portion 101c and the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c are bent 90 degrees along the bending line S101 shown in Figure 5(a). However, as shown in Figure 5(b), since the right-side fixed portion 101b1 shown in Figure 3 is not formed, the length of the conductive material foil 102 located on the outermost circumferential surface 101ca side of the non-fixed portion 101c becomes longer, and the length gradually decreases towards the conductive material foil 102 located on the innermost circumferential surface 101cb side of the non-fixed portion 101c. This prevents the wrinkled phenomenon shown in Figure 4(b) from occurring.

[0010] Then, as shown in Figure 5(c), the right side 101b of the flexible busbar body 101 is fixed to form the right fixing portion 101b1. At this time, in order to align the end face of the right fixing portion 101b1 (the right side 101b of the flexible busbar body 101) as shown in Figure 5(c), the right fixing portion 101b1 is cut along the cutting line S102. As a result, the flexible busbar 100 can be bent 90 degrees along the bending line S101 shown in Figure 5(a) without the wrinkles that occur as shown in Figure 4(b).

[0011] However, this approach not only increases the number of cutting steps but also increases the likelihood of product variation, potentially leading to inconsistent product quality.

[0012] Therefore, in view of the above problems, the present invention aims to provide a flexible busbar that can not only improve the appearance but also stabilize the quality of the product. [Means for solving the problem]

[0013] The object of the present invention described above is achieved by the following means. The reference numerals in parentheses indicate the embodiments described later, but the present invention is not limited thereto.

[0014] A method for manufacturing a flexible busbar according to claim 1 comprises a flexible busbar body (2) and The flexible busbar body (2) has first fixing parts (left fixing part 2a1, right fixing part 2b1) that fix both sides of the body, Multiple second fixing parts (bending fixing parts 2d) are provided at positions spaced apart from the first fixing part (left fixing part 2a1, right fixing part 2b1), In a method for manufacturing a flexible busbar (1) having, The second fixing portion is, When bending the flexible busbar body (2) from a predetermined position (bending line S1) located at a position separated from the first fixing portion, it is essential that each of the multiple predetermined positions includes the predetermined position (bending line S1), separate from the first fixing portion (left fixing portion 2a1, right fixing portion 2b1). Before Formed on the flexible busbar body (2) And so, The flexible busbar body (2), other than those bent from the aforementioned multiple predetermined positions, is characterized by being formed in a straight line.

[0016] Claim 2 Flexible bus bar Manufacturing method The above claim 1 Flexible bus bar (1) as described above Manufacturing method In this invention, the first fixing portion (left fixing portion 2a1, right fixing portion 2b1) and the second fixing portion (bending fixing portion 2d) are characterized by being formed by heat welding. [Effects of the Invention]

[0017] Next, the effects of the present invention will be described with reference to the reference numerals in the drawings. Note that the reference numerals in parentheses are those of embodiments described later, but the present invention is not limited thereto.

[0018] According to the invention according to claim 1, This is a position separated from the first fixing part (left fixing part 2a1, right fixing part 2b1). From a predetermined position (bending line S1) of the flexible bus bar body (2), each When performing bending processing, place It is necessary to form the second fixing part (bending fixing part २d) on the flexible bus bar body (2) at the predetermined position (bending line S1). so that it includes The flexible bus bar body (2) other than the one bent from the predetermined position is formed in a straight line. Thereby, multiple Even if it is bent from a predetermined position (bending line S1) of the flexible bus bar body (2), a flexible part of the flexible bus bar body (2) (for example, a non-fixed part (2c) as shown in FIG. 1) is not affected. This is a position separated from the first fixing part (left fixing part 2a1, right fixing part 2b1). From a predetermined position (bending line S1) of the flexible bus bar body (2), each Even if it is bent, a flexible part of the flexible bus bar body (2) (for example, a non-fixed part (2c) as shown in FIG. 1) is not affected. Furthermore, it enables more complex bending processes.

[0019] Therefore, according to the present invention, not only can the appearance be improved, but also the quality of the product can be stabilized.

[0020] Further, according to the present invention, since the second fixing part (bending fixing part २d) is formed only in the part including the predetermined position (bending line S1), the flexibility of the flexible part of the flexible bus bar body (2) (for example, the non-fixed part (2c) as shown in FIG. 1) can be maximally exerted.

[0022] Claim 2 According to the invention according to claim, when heat is applied to the flexible bus bar (1) used with solder or the like, there is no possibility of melting. Furthermore, there is no possibility that the resistance value required for the flexible bus bar (1) cannot be obtained due to the influence of members used for solder or the like.

Brief Description of the Drawings

[0023] [Figure 1] (a) is a plan view of a flexible bus bar according to an embodiment of the present invention, and (b) is a side view when the flexible bus bar according to the embodiment is bent by 90 degrees. [Figure 2]This is a side view of a flexible busbar according to the same embodiment, when it has been bent into a stepped shape. [Figure 3] This is a side view of the flexible busbar according to the same embodiment when it has been bent into a U-shape. [Figure 4] (a) is a plan view of a conventional flexible busbar, and (b) is a side view of the flexible busbar in (a) after it has been bent at a 90-degree angle. [Figure 5] (a) is a plan view of a conventional flexible busbar, (b) is a side view of the flexible busbar in (a) after it has been bent at a 90-degree angle, and (c) is an explanatory diagram illustrating the cutting process. [Modes for carrying out the invention]

[0024] A flexible busbar according to one embodiment of the present invention will be described in detail below with reference to the drawings. In the following description, when the directions of up, down, left, and right are indicated, they refer to the up, down, left, and right directions as viewed from the front as shown in the drawings.

[0025] <Overview of Flexible Busbars> The flexible busbar 1 according to this embodiment is capable of bending in a way that not only prevents wrinkles from forming but also stabilizes the quality of the product. Specifically, the flexible busbar 1 shown in Figure 1 comprises a flexible busbar body 2.

[0026] <Description of the Flexible Busbar> As shown in Figure 1(a), the flexible busbar body 2 is formed in a horizontally elongated rectangular shape in plan view, and as shown in Figure 1(b), it is formed by laminating thin, flexible conductive material foils 3 made of metal such as copper. The flexible busbar body 2 formed in this manner can carry large currents.

[0027] Thus, as shown in Figure 1(a), the flexible busbar body 2 configured in this way has its left side 2a fixed by heat welding to form a left fixed portion 2a1, and its right side 2b fixed by heat welding to form a right fixed portion 2b1. As a result, as shown in Figure 1(a), a non-fixed portion 2c is formed between the left fixed portion 2a1 and the right fixed portion 2b1, and this non-fixed portion 2c is flexible.

[0028] Therefore, the flexible busbar 1 is constructed in this manner.

[0029] <Explanation of the bending process for flexible busbars> Incidentally, as shown in Figure 1(a), the non-fixed portion 2c has a bending fixing portion 2d formed on the left side of the center, separate from the left fixing portion 2a1 and the right fixing portion 2b1, which is fixed by heat welding. As shown in Figure 1(a), this bending fixing portion 2d includes the bending line S1 when the flexible busbar body 2 is bent by 90 degrees.

[0030] Thus, by forming such a bending fixing portion 2d, when the flexible busbar 1, that is, the flexible busbar body 2, is bent along the bending line S1 shown in Figure 1(a), it will be in the state shown in Figure 1(b). In other words, as shown in Figure 1(b), this bending process does not create a distance difference, or an in-outside difference, between the conductive material foil 3 located on the outermost surface 2ca side and the conductive material foil 3 located on the innermost surface 2cb side of the non-fixed portion 2c. In other words, as shown in Figure 1(b), the flexible portion of the non-fixed portion 2c is not involved in the bending process due to the bending fixing portion 2d, and is therefore not affected by the bending process. As a result, no distance difference, or an in-outside difference, occurs. Therefore, the phenomenon of wrinkles forming on the conductive material foil 3 located on the innermost surface 2cb side, as shown in Figure 4(b), which would occur due to a distance difference, or an in-outside difference, does not occur.

[0031] Furthermore, there is no need to perform cutting to align the end face of the right fixing portion 2b1 (the right side 2b of the flexible busbar body 2), as shown in Figure 5(c), which occurs due to the difference in distance, i.e., the difference between the inside and outside.

[0032] Therefore, according to the embodiment described above, there is no distance difference, or inverse difference, between the conductive material foil 3 located on the outermost surface 2ca side and the conductive material foil 3 located on the innermost surface 2cb side of the non-adhered portion 2c. As a result, the phenomenon of wrinkling that occurs in the conventional method does not occur, and problems such as an increase in cutting steps, increased product variation, and potential instability in product quality do not arise.

[0033] Therefore, according to this embodiment, not only can the appearance be improved, but the quality of the product can also be stabilized.

[0034] Furthermore, according to this embodiment, since the bending-fixed portion 2d is formed only in the portion located at the bending line S1 shown in Figure 1(a), the influence of the flexibility of the non-fixed portion 2c can be minimized. Therefore, the flexibility of the non-fixed portion 2c can be maximized.

[0035] Furthermore, by forming the bending fixing portion 2d as described above, complex bending processes as shown in Figures 2 and 3 become possible. Specifically, as shown in Figure 2, when bending the flexible busbar 1, that is, the flexible busbar body 2, to form a stepped shape, bending fixing portions 2d should be formed at the bending portion (the portion indicated by the dashed lines X1 and X2 in Figure 2). Similarly, as shown in Figure 3, when bending the flexible busbar 1, that is, the flexible busbar body 2, to form a U-shape, bending fixing portions 2d should be formed at the bending portion (the portion indicated by the dashed lines X3 and X4 in Figure 3). As a result, even with complex bending processes, there is no distance difference, i.e., an in-out-out difference, between the conductive material foil 3 located on the outermost circumferential surface 2ca side and the conductive material foil 3 located on the innermost circumferential surface 2cb side of the non-fixed portion 2c, thus preventing the wrinkles that occur in conventional designs. Furthermore, since there is no need to perform cutting to align the end face of the right fixing portion 2b1 (the right side 2b of the flexible busbar body 2), as shown in Figure 5(c), which occurs due to the difference in distance, i.e., the difference between the inside and outside, problems such as increased cutting steps, product variations, and potential instability in product quality do not occur.

[0036] Therefore, by forming bending fixing parts 2d in the parts to be bent (the parts indicated by dashed lines X1 and X2 in Figure 2, and the parts indicated by dashed lines X3 and X4 in Figure 3), not only can the appearance be improved, but the quality of the product can be stabilized, and furthermore, complex bending processes can be performed.

[0037] <Explanation of variations> It should be noted that the shapes shown in this embodiment are merely examples, and various modifications and changes are possible within the scope of the gist of the present invention as described in the claims. For example, in this embodiment, an example is shown in which the left fixing portion 2a1, the right fixing portion 2b1, and the bending fixing portion 2d are formed by heat welding, but it is not limited to this, and they may also be formed using solder or the like. However, heat welding is preferred. This is because if they are formed using solder or the like, the solder used in the solder may melt when heat is applied to the flexible busbar 1, and furthermore, the resistance value required for the flexible busbar 1 may not be obtained due to the influence of the materials used in the solder or the like. For this reason, heat welding is preferred.

[0038] Furthermore, although this embodiment describes the bending process using 90 degrees as an example, it is of course not limited to this and can be applied to various bending angles such as 80 degrees or 100 degrees. [Explanation of Symbols]

[0039] 1 Flexible bus bar 2 Flexible busbar body 2a1 Left fixing part (first fixing part) 2b1 Right fixing part (first fixing part) 2c Non-adhesive part 2d Folding fastening part (second fastening part) S1 Folding line (predetermined position)

Claims

1. Flexible busbar body, The first fixing portion secures both sides of the flexible busbar body, A method for manufacturing a flexible busbar having a plurality of second fixing portions provided at positions spaced apart from the first fixing portion, When bending the flexible busbar body from a predetermined position on the flexible busbar body that is spaced apart from the first fixing portion, the second fixing portion is always formed on the flexible busbar body separately from the first fixing portion, such that each of the plurality of predetermined positions includes the predetermined position. A method for manufacturing a flexible busbar, in which the flexible busbar body other than that which has been bent from the plurality of predetermined positions is formed in a straight line.

2. A method for manufacturing a flexible bus bar according to claim 1, wherein the first fixing portion and the second fixing portion are formed by heat welding.

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