Electrical junction members and connection structures

Abstract

To provide an electrical connection member and a connection structure, capable of achieving both strength and conductivity.SOLUTION: An electrical connection member according to the present invention includes: a body having a two-layer structure including a core material formed using a material with conductivity and an outer coat coating the core material and formed using a material with higher strength than the core material; and a flat plate-like end connected to the body and comprising the core material and the outer coat.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an electrical joining member and a connection structure.

Background Art

[0002] In recent years, secondary batteries have been used as power sources for various applications. In applications that require large amounts of power, other batteries, electronic components, etc. are electrically connected by an electrical joining member called a bus bar, and used as power for large-scale power sources. Bus bars are formed using aluminum alloys for conductivity and weight reduction (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, depending on the structure employing a bus bar, strength against external loads is required. However, the bus bar described in Patent Document 1 may not satisfy the required strength. Furthermore, since conductivity is also required for the bus bar used as an electrical joining member, a bus bar that achieves both strength and conductivity is required.

[0005] The present invention has been made in view of the above, and an object thereof is to provide an electrical joining member and a connection structure capable of achieving both strength and conductivity.

Means for Solving the Problems

[0006] To solve the above-mentioned problems and achieve the objective, the electrical junction member according to the present invention is characterized by comprising a main body having a two-layer structure consisting of a core material formed using a conductive material and an outer skin that covers the core material and is formed using a material having higher strength than the core material, and a flat end portion connected to the main body and consisting of the core material and the outer skin.

[0007] Furthermore, the electrical junction member according to the present invention is characterized in that, in the above invention, the end portion of the core material is exposed to the outside.

[0008] Furthermore, the electrical junction member according to the present invention is characterized in that, in the above invention, the end portion is such that the surface of the core material exposed to the outside is located on the same plane as the end surface of the outer sheath surrounding the core material.

[0009] Furthermore, the electrical bonding member according to the present invention is characterized in that a through hole is formed at the end portion, penetrating in the thickness direction of the plate.

[0010] Furthermore, the electrical junction member according to the present invention is characterized in that the main body portion is cylindrical in shape.

[0011] Furthermore, the electrical junction member according to the present invention is characterized in that the main body portion is plate-shaped.

[0012] Furthermore, the connection structure according to the present invention is characterized by comprising: a main body having a two-layer structure consisting of a core material formed using a conductive material and an outer skin covering the core material and formed using a material having higher strength than the core material; an electrical junction member connected to the main body and having a flat end made of the core material and the outer skin; and a connecting member electrically connected to the end.

[0013] Furthermore, the connection structure according to the present invention is characterized in that, in the above invention, a through hole is formed in the end portion that penetrates in the thickness direction of the plate, the connecting member is plate-shaped and has a hole formed that penetrates in the thickness direction of the plate, and a fastening member is inserted through the through hole in the end portion and attached to the hole in the connecting member. [Effects of the Invention]

[0014] According to the present invention, it is possible to achieve both strength and conductivity in an electrical bonding member. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is a perspective view (part 1) showing a part of the configuration of a busbar according to Embodiment 1 of the present invention. [Figure 2] Figure 2 is a perspective view (part 2) showing a part of the configuration of a busbar according to Embodiment 1 of the present invention. [Figure 3] Figure 3 is a perspective view showing the configuration of the base material for manufacturing a busbar according to Embodiment 1 of the present invention. [Figure 4] Figure 4 is a perspective view showing a connection structure equipped with a busbar according to Embodiment 1 of the present invention. [Figure 5] Figure 5 is a cross-sectional view along line AA shown in Figure 3. [Figure 6] Figure 6 is a perspective view showing a part of the configuration of a busbar according to Embodiment 2 of the present invention. [Figure 7] Figure 7 is a cross-sectional view showing a connection structure equipped with a busbar according to Embodiment 2 of the present invention. [Figure 8] Figure 8 is a perspective view (part 1) showing a part of the configuration of a busbar according to Embodiment 3 of the present invention. [Figure 9] Figure 9 is a perspective view (part 2) showing a part of the configuration of a busbar according to Embodiment 3 of the present invention. [Figure 10] Figure 10 is a perspective view showing a part of the configuration of a busbar according to Embodiment 4 of the present invention. [Figure 11]FIG. 11 is a cross-sectional view showing a connection structure including a bus bar according to Embodiment 4 of the present invention. [Figure 12] FIG. 12 is a plan view showing an end configuration of a bus bar according to a modification of Embodiment 4 of the present invention. [Figure 13] FIG. 13 is a perspective view showing a partial configuration of a bus bar according to Embodiment 5 of the present invention.

Embodiments for Carrying Out the Invention

[0016] Hereinafter, embodiments for carrying out the present invention (hereinafter referred to as "embodiments") will be described with reference to the accompanying drawings. Note that the drawings are schematic, and the relationships between the thickness and width of each part, the ratio of the thickness of each part, etc. may be different from the actual ones, and there may be parts where the dimensional relationships and ratios are different between the drawings.

[0017] (Embodiment 1) FIGS. 1 and 2 are perspective views showing a partial configuration of a bus bar according to Embodiment 1 of the present invention. FIGS. 1 and 2 show the bus bar in different viewing directions. FIG. 1 is a perspective view of the bus bar viewed from above, and FIG. 2 is a perspective view of the bus bar viewed from below.

[0018] The bus bar 1 includes a columnar main body portion 10 and end portions provided on the main body portion respectively. In FIGS. 1 and 2, an end portion 11 provided at one end of the main body portion 10 is shown. Hereinafter, the end portion 11 provided on one side of the main body portion 10 will be described, but the other end portion also has the same configuration as this end portion 11.

[0019] The busbar 1 has a concentric two-layer structure, with both the main body 10 and the end portion 11 consisting of a core material and an outer shell made of aluminum alloys with different compositions. The core material of the busbar 1 is made of a highly conductive material, such as an A1000 series aluminum alloy. The outer shell of the busbar 1 covers the core material and is made of a material with strength, corrosion resistance, and heat resistance, such as an A2000 series, A3000 series, A4000 series, A5000 series, A6000 series, and A7000 series aluminum alloy. Busbar 1 electrically conducts electricity between the connected components at both ends.

[0020] In this specification, high conductivity means an IACS (International Annealed Copper Standard) conductivity of 60 IACS% or higher. Furthermore, the strength is preferably 85 MPa or higher in tensile strength, and more preferably 205 MPa or higher.

[0021] The main body 10 is cylindrical in shape, composed of the core material described above and an outer shell that covers the core material.

[0022] The end portion 11 is plate-shaped. The end portion 11 has a terminal portion 12 to be attached to the object to be joined, and a connecting portion 13 provided between the main body portion 10 and the terminal portion 12. In addition, a through hole 14 is formed in the end portion 11 in the thickness direction, passing through the terminal portion 12. Hereinafter, "main surface" refers to the surface with the largest area of ​​the plate-shaped member. The thickness direction corresponds to the direction that connects the two main surfaces formed on opposite sides of the plate-shaped member by the shortest distance.

[0023] The terminal portion 12 is flat and has a conductive portion 21 made of a core material and a covering portion 22 made of an outer material that covers a part of the conductive portion 21. The covering portion 22 has an opening 22a that exposes one main surface of the conductive portion 21 to the outside. In this embodiment 1, the surface of the conductive portion 21 that is exposed to the outside is the end face of the covering portion 22 (outer skin) surrounding the conductive portion 21, and is located on the same plane as the end face where the opening 22a is formed (here, the face that is in the same orientation as the exposed portion of the conductive portion 21). Note that in Figures 1 and 2, the conductive portion 21 is exposed at the end of the end portion 11 opposite to the side connected to the connection portion 13, but the conductive portion 21 may also be covered by the covering portion 22.

[0024] The connecting portion 13 extends in a fan shape from the end of the main body portion 10 and connects to the terminal portion 12. The connecting portion 13 is composed of a core material and an outer sheath, similar to the main body portion 10.

[0025] Next, the manufacturing of the busbar 1 will be described with reference to Figure 3. Figure 3 is a perspective view showing the structure of the base material for manufacturing the busbar according to Embodiment 1 of the present invention. The busbar 1 is manufactured using the base material 100 shown in Figure 3. The base material 100 has a concentric two-layer structure consisting of a core material 101 formed using an A1000 series aluminum alloy and an outer shell 102 that covers the core material and is made of a material having strength, corrosion resistance and heat resistance, for example, an A6000 series aluminum alloy.

[0026] The busbar 1 is manufactured by flattening the end of the base material 100 to form a flat plate, removing a portion of the outer shell 102, and forming through holes (corresponding to through holes 14) that penetrate in the thickness direction of the plate.

[0027] Next, a connection structure in which the busbar 1 is fastened to the connection target will be described with reference to Figures 4 and 5. Figure 4 is a perspective view showing a connection structure comprising a busbar according to Embodiment 1 of the present invention. Figure 5 is a cross-sectional view taken along line AA shown in Figure 3. The connection structure 2 shown in Figures 4 and 5 consists of the busbar 1 described above, a connection member 30 to be connected, and a fastening member 40 that fastens the busbar 1 and the connection member 30 together.

[0028] The connecting member 30 is a terminal provided on batteries, electronic components, etc., and is a single thread made of a conductive lead or the like. The connecting member 30 has a hole 30a that screws into the fastening member 40. In Figure 5, the hole 30a is shown as penetrating in the thickness direction of the plate, but it may also have a closed-end shape as long as the fastening member 40 can be attached.

[0029] The fastening member 40 is a conductive bolt having a head portion 41 and a shaft portion 42.

[0030] The connecting member 30 and the fastening member 40 each have, for example, screw threads that can be threaded into each other. In addition to threading, they may also be joined by welding or a combination of threading and welding.

[0031] In connection structure 2, the fastening member 40 fastens the end portion 11 between the connecting member 30 and the head 41 by screwing the fastening member 40 into the connecting member 30. At this time, the connecting member 30 comes into contact with the conductive portion 21 that is exposed at the end portion 11. As a result, the conductive portion 21 and the connecting member 30 are electrically connected. Similarly, on the other end of the busbar 1, for example, a member is connected and fastened by a fastening member. In this connection structure 2, the busbar 1 (conductive portion 21) relays the electrical conductivity between the members (connecting member 30) connected at both ends. At this time, current flows between the busbar 1 and the connecting member 30, but by forming the fastening member 40 (shaft portion 42) from a conductive material, electrical conductivity can be made through the fastening member 40. Note that the fastening member 40 does not have to be conductive as long as conductivity is ensured between the conductive portion 21 and the connecting member 30.

[0032] In the first embodiment described above, the busbar 1 is composed of a conductive core material and a high-strength outer sheath covering the core material. The flat end portion 11 exposes a part of the conductive portion 21 made of the core material, and this exposed conductive portion 21 contacts the member to be connected to ensure electrical conductivity. According to the first embodiment, the combination of the core material and the outer sheath makes it possible to achieve both strength and conductivity in the electrical joint member.

[0033] Furthermore, in Embodiment 1, at the flat end portion 11, the exposed portion of the planar conductive portion 21 comes into contact with the member to be connected, thus ensuring a large contact area for electrical conductivity and enabling stable current flow.

[0034] In Embodiment 1, the core material and outer sheath were described as having a concentric two-layer structure, but they may also have an eccentric two-layer structure. When using an eccentric two-layer busbar as wiring material, it is conceivable to bend the busbar, and durability can be increased by reducing the thickness of the outer sheath on the inside of the bend. In this case, it is preferable that the thickness on the mechanical fastening side of the terminal portion is thicker.

[0035] (Embodiment 2) Next, Embodiment 2 will be described with reference to Figures 6 and 7. Figure 6 is a perspective view showing a part of the configuration of a busbar according to Embodiment 2 of the present invention. Busbar 1A according to Embodiment 2 is provided with end 11A instead of end 11 according to Embodiment 1. The configuration of the main body 10 and other parts is the same as in Embodiment 1. The same reference numerals are used for components that are the same as in Embodiment 1.

[0036] The end portion 11A is plate-shaped. The end portion 11A has a terminal portion 12A to be attached to the object to be joined, and a connecting portion 13 provided between the main body portion 10 and the terminal portion 12A. In addition, a through hole 14 is formed in the end portion 11A in the thickness direction, passing through the terminal portion 12A.

[0037] The terminal portion 12A is flat and has a conductive portion 21 made of a core material and a covering portion 22A made of an outer sheath material that covers a part of the conductive portion 21. The covering portion 22A has an opening 22b that exposes a part of one main surface of the conductive portion 21 to the outside. The covering portion 22A covers a part of the outer edge side of the main surface of the conductive portion 21. In this embodiment 2, the surface of the conductive portion 21 that is exposed to the outside is the end face of the covering portion 22A (outer sheath) surrounding the conductive portion 21, and is located on a plane different from the end face where the opening 22b is formed (here, the face with the same orientation as the exposed portion of the conductive portion 21), and is located inside the said end face.

[0038] The busbar 1A is manufactured using the base material 100 described above, by crushing the end of the base material 100 to form a flat plate, removing a portion of the outer shell 102, and forming through holes (corresponding to through holes 14) that penetrate in the thickness direction of the plate.

[0039] Next, a connection structure in which the busbar 1A is fastened to the connection target will be described with reference to Figure 7. Figure 7 is a cross-sectional view showing a connection structure equipped with a busbar according to Embodiment 2 of the present invention. Figure 7 corresponds to the cross-sectional view along line AA shown in Figure 3. The connection structure 2A shown in Figure 7 is composed of the busbar 1A described above, the connection member 30 to be connected, and a fastening member 40 that fastens the busbar 1A and the connection member 30. In Embodiment 2, the inner circumferential surface of the through hole 14 and the fastening member 40 are in contact.

[0040] In connection structure 2A, the fastening member 40 fastens the end portion 11A between the connecting member 30 and the head portion 41 by screwing the fastening member 40 into the connecting member 30. At this time, a portion of the covering portion 22A is interposed between the conductive portion 21 and the connecting member 30, so the conductive portion 21 and the connecting member 30 do not come into direct contact. Therefore, in connection structure 2A, the conductive portion 21 and the connecting member 30 are electrically connected via the fastening member 40 (shaft portion 42).

[0041] In the second embodiment described above, the busbar 1A is composed of a conductive core material and a high-strength outer sheath covering the core material, and the flat end portion 11A is electrically connected to the member to be connected via a fastening member 40. According to the second embodiment, the combination of the core material and the outer sheath makes it possible to achieve both strength and conductivity in the electrical joint member.

[0042] (Embodiment 3) Next, Embodiment 3 will be described with reference to Figures 8 and 9. Figures 8 and 9 are perspective views showing a part of the configuration of a busbar according to Embodiment 3 of the present invention. Figures 8 and 9 show the busbar from different directions. Figure 8 is a perspective view of the busbar from above, and Figure 9 is a perspective view of the busbar from below. Components similar to those in Embodiment 1 are denoted by the same reference numerals.

[0043] The busbar 1B according to Embodiment 3 comprises a plate-shaped main body 10A and ends provided on the main body 10A. Figures 8 and 9 show the end 11B provided on one end of the main body 10A. The end 11B provided on one end of the main body 10A will be described below, but the other end has the same configuration as this end 11B.

[0044] The busbar 1B extends in a plate-like shape, with a portion of its end notched. Furthermore, both the main body 10A and the end portion 11B of the busbar 1B have a concentric two-layer structure composed of the core material and outer sheath described above.

[0045] The main body 10A is plate-shaped and is composed of the core material described above and an outer shell that covers the core material.

[0046] The end portion 11B is plate-shaped. The end portion 11B has a terminal portion 12 to be attached to the object to be joined, and a connecting portion 13A provided between the main body portion 10A and the terminal portion 12. In addition, a through hole 14 is formed in the end portion 11B in the thickness direction, passing through the terminal portion 12.

[0047] The connecting portion 13A extends in a plate-like shape from the end of the main body portion 10A and connects to the terminal portion 12. The connecting portion 13, like the main body portion 10, is composed of a core material and an outer sheath.

[0048] Busbar 1B is manufactured using a plate-shaped base material consisting of the core material and outer shell described above, by removing a portion of the outer shell at the end of the base material and forming through holes (corresponding to through holes 14) that penetrate in the thickness direction of the plate.

[0049] The connection structure to which the busbar 1B is fastened is similar to the connection structure 2 of Embodiment 1, in which the busbar 1B and the connecting member 30 are fastened together by a fastening member 40. In this case, the connecting member 30 comes into contact with the conductive portion 21 that is exposed at the end portion 11B. As a result, the conductive portion 21 and the connecting member 30 are electrically connected.

[0050] In the embodiment 3 described above, the busbar 1B is composed of a conductive core material and a high-strength outer sheath covering the core material, and the flat end portion 11B is electrically connected to the member to be connected via a fastening member 40. According to embodiment 3, the combination of the core material and the outer sheath makes it possible to achieve both strength and conductivity in the electrical joint member.

[0051] (Embodiment 4) Next, Embodiment 4 will be described with reference to Figures 10 and 11. Figure 11 is a perspective view showing a part of the configuration of a busbar according to Embodiment 4 of the present invention. The busbar 1C according to Embodiment 4 has an end 11C instead of the end 11 according to Embodiment 1. The configuration of the main body 10 and the like is the same as in Embodiment 1. The same reference numerals are used for components that are the same as in Embodiment 1.

[0052] The end portion 11C is plate-shaped. The end portion 11C has a terminal portion 12B to be attached to the object to be joined, and a connecting portion 13 provided between the main body portion 10 and the terminal portion 12B. In addition, a through hole 14 is formed in the end portion 11C in the thickness direction, passing through the terminal portion 12.

[0053] The terminal portion 12B is flat and has a conductive portion 21 made of a core material and a covering portion 22B made of an outer sheath material that covers the conductive portion 21.

[0054] The busbar 1C is manufactured using the base material 100 described above, by crushing the end of the base material 100 to form a flat plate, removing a portion of the outer shell 102, and forming through holes (corresponding to through holes 14) that penetrate in the thickness direction of the plate.

[0055] Next, a connection structure in which the busbar 1C is fastened to the connection target will be described with reference to Figure 11. Figure 11 is a cross-sectional view showing a connection structure equipped with a busbar according to Embodiment 4 of the present invention. Figure 11 corresponds to the cross-sectional view along line AA shown in Figure 3. The connection structure 2B shown in Figure 11 is composed of the busbar 1C described above, the connection member 30 to be connected, and a fastening member 40 that fastens the busbar 1C and the connection member 30.

[0056] In connection structure 2B, the fastening member 40 fastens the end portion 11C between the connecting member 30 and the head portion 41 by screwing the fastening member 40 into the connecting member 30. At this time, the covering portion 22B is interposed between the conductive portion 21 and the connecting member 30, so the conductive portion 21 and the connecting member 30 do not come into direct contact. Therefore, in connection structure 2B, the conductive portion 21 and the connecting member 30 are electrically connected via the fastening member 40 (shaft portion 42).

[0057] In the embodiment 4 described above, the busbar 1C is composed of a conductive core material and a high-strength outer sheath covering the core material, and the flat end portion 11C is electrically connected to the member to be connected via a fastening member 40. According to embodiment 4, the combination of the core material and the outer sheath makes it possible to achieve both strength and conductivity in the electrical joint member.

[0058] (Modified version of Embodiment 4) Next, a modified example of Embodiment 4 of the present invention will be described with reference to Figure 12. Figure 12 is a plan view showing the end configuration of a busbar according to a modified example of Embodiment 4 of the present invention. The busbar according to this modified example is equipped with an end 11D instead of the end 11C according to Embodiment 4.

[0059] The end portion 11D is plate-shaped. The end portion 11D has a terminal portion 12C to be attached to the object to be joined, and a connecting portion 13 (see, for example, Figure 10) provided between the main body portion 10 and the terminal portion 12C. In addition, a through hole 14 is formed in the end portion 11D in the thickness direction, passing through the terminal portion 12C (see, for example, Figure 10).

[0060] The terminal portion 12C has a shape in which the main surface is flat and the side surface adjacent to the main surface is arc-shaped. Specifically, the terminal portion 12C is flat, made of a core material, and has a conductive portion 21A on its side surface and a covering portion 22C made of an outer sheath material that covers the conductive portion 21A.

[0061] As described above in this modified example, even when the side surface of the end is arc-shaped, the combination of the core material and the outer sheath described above makes it possible to achieve both strength and conductivity in the electrical bonding member, similar to Embodiment 4.

[0062] (Embodiment 5) Next, Embodiment 5 will be described with reference to Figure 13. Figure 13 is a perspective view showing a part of the configuration of a busbar according to Embodiment 5 of the present invention. The busbar 1D according to Embodiment 5 has an end 11E instead of the end 11 according to Embodiment 1. The configuration of the main body 10 and the like is the same as in Embodiment 1. The same reference numerals are used for components that are the same as in Embodiment 1.

[0063] The end portion 11E is plate-shaped. The end portion 11E has a terminal portion 12 that is attached to the object to be joined, and a connecting portion 13 provided between the main body portion 10 and the terminal portion 12. Furthermore, the end portion 11E is configured so that the through hole 14 described above is not formed therein.

[0064] The busbar 1D is manufactured using the base material 100 described above, by crushing the end of the base material 100 to form a flat plate, and removing a portion of the outer shell 102.

[0065] The connection structure to which the busbar 1D is connected to the target is formed by joining the end 11E of the busbar 1D and the connecting member 30 by welding or by clamping and fixing them with a clip or the like. In this case, the connecting member 30 comes into contact with the conductive part 21 exposed at the end 11E, or is electrically connected to the conductive part 21 via a conductive bonding agent (e.g., solder). As a result, the conductive part 21 and the connecting member 30 are electrically connected.

[0066] In Embodiment 5 described above, the busbar 1D is composed of a conductive core material and a high-strength outer sheath covering the core material, and the flat end portion 11E is electrically connected to the member to be connected. According to Embodiment 5, the combination of the core material and the outer sheath makes it possible to achieve both strength and conductivity in the electrical joint member.

[0067] While embodiments for carrying out the present invention have been described so far, the present invention should not be limited to the embodiments described above.

[0068] Thus, the present invention may include various embodiments not described herein, and various design modifications can be made without departing from the technical idea specified by the claims.

[0069] As described above, the electrical bonding member and connection structure according to the present invention are suitable for achieving both strength and conductivity. [Explanation of Symbols]

[0070] 1. 1A~1D Busbar 2, 2A, 2B Connection Structure 10, 10A Main Unit 11, 11A~11E end 12, 12A~12C terminal section 13, 13A connection 14 Through holes 21, 21A conductive part 22, 22A~22C Covering 22a, 22b opening 30 Connecting Members 30a hole 40 Fastening members 100 Base material 101 Core material 102 Hull

Claims

1. The main body has a two-layer structure consisting of a core material formed from a first aluminum alloy having conductivity, and an outer shell formed from a second aluminum alloy having higher strength than the first aluminum alloy that covers the core material. A flat end portion connected to the main body, consisting of the core material and the outer shell, An electrical junction member characterized by comprising:

2. In part of the end portion, the core material is exposed to the outside. The electrical bonding member according to feature 1.

3. The end portion is such that the surface of the core material exposed to the outside lies on the same plane as the end face of the outer shell surrounding the core material. The electrical junction member according to feature 2.

4. A through hole is formed at the end portion, extending through in the thickness direction of the plate. An electrical joining member according to any one of features 1 to 3.

5. The main body is cylindrical in shape. An electrical joining member according to any one of features 1 to 4.

6. The main body is plate-shaped, An electrical joining member according to any one of features 1 to 4.

7. An electrical junction member having a two-layer structure consisting of a core material formed from a first conductive aluminum alloy and an outer shell formed from a second aluminum alloy having higher strength than the first aluminum alloy covering the core material, and a flat plate-shaped end portion connected to the main body and consisting of the core material and the outer shell, A connecting member that is electrically connected to the end portion, A connection structure characterized by comprising the above.

8. A through hole is formed at the end portion, extending through in the thickness direction of the plate. The connecting member is plate-shaped and has holes that penetrate in the thickness direction. A fastening member inserted through the through hole of the end and attached to the hole of the connecting member, The connection structure according to claim 7, further comprising the features.

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