Fuse unit and conductive module

Abstract

The present invention includes: a circuit protection component (30); a first terminal fitting (40) which electrically connects a first electrical connection part (41) directly to a first electrode (31) of the circuit protection component; a second terminal fitting (50) which electrically connects a second electrical connection part (51) directly to a second electrode (32) of the circuit protection component; and a housing component (70) that accommodates, in a housing chamber (70a), the first electrical connection part, the second electrical connection part, and the circuit protection component installed across the first electrical connection part and the second electrical connection part. The housing component includes a plurality of housing members (70A, 70B) which are assembled and fixed to each other to form a housing chamber therein. The plurality of housing members are molded as members separate from the first electrical connection part, the second electrical connection part, and the circuit protection component, and surround and house the first electrical connection part, the second electrical connection part, and the circuit protection component within the housing chamber.

Description

Fuse Unit and Conductive Module

[0001] The present invention relates to a fuse unit and a conductive module.

[0002] In a battery module in which a plurality of battery cells are arranged, the conductive module electrically connects the plurality of battery cells using a plurality of connection conductors. Then, the conductive module electrically connects each connection conductor to a battery monitoring unit that monitors the battery state of the battery cells using wiring components such as electric wires. For example, the following Patent Document 1 discloses this type of conductive module. In such a conductive module, a combination of a pair of connection conductors and a conductor portion of a wiring component is provided for each connection conductor, and a circuit protection component such as a fuse may be interposed between the connection conductor and the conductor portion of the wiring component in each combination. For example, the following Patent Document 2 discloses a fuse unit (composed of a chip fuse, a pair of terminal fittings, and a resin portion) applied to this conductive module.

[0003] Japanese Patent Application Laid-Open No. 2020-119651 Patent No. 7561318

[0004] By the way, a conventional fuse unit connects a chip fuse to a pair of terminal fittings in which a resin portion is insert-molded, and the order is regulated in its manufacturing process. Therefore, there is room for improvement in terms of the degree of freedom in manufacturing in the conventional fuse unit.

[0005] Therefore, an object of the present invention is to provide a fuse unit and a conductive module with a high degree of freedom in manufacturing.

[0006] The fuse unit according to the present invention includes a circuit protection component that melts a fusible portion when an overcurrent flows between a first electrical connection target and a second electrical connection target, a first terminal fitting that directly electrically connects the first electrical connection portion to the first electrode of the circuit protection component and directly or indirectly electrically connects to the first electrical connection target, a second terminal fitting that directly electrically connects the second electrical connection portion to the second electrode of the circuit protection component and directly or indirectly electrically connects to the second electrical connection target, and the first electrical The device comprises an electrical connection portion, a second electrical connection portion, and an electrically insulating housing component in which the circuit protection component installed spanning the first electrical connection portion and the second electrical connection portion is housed, wherein the housing component comprises a plurality of housing members assembled and fixed together to form the housing chamber inside, and the plurality of housing members are molded as separate members from the first electrical connection portion, the second electrical connection portion, and the circuit protection component, and surround the first electrical connection portion, the second electrical connection portion, and the circuit protection component to house them in the housing chamber.

[0007] The conductive module according to the present invention comprises a connecting conductor that is directly electrically connected to the electrode terminals of a battery cell constituting the battery module, and a fuse unit that indirectly electrically connects the connecting conductor to a battery monitoring unit that monitors the battery state of the battery cell, wherein the fuse unit comprises a circuit protection component that melts a fusible portion when an overcurrent flows between the connecting conductor and the battery monitoring unit, a first terminal fitting that directly electrically connects a first electrical connection portion to a first electrode of the circuit protection component and is directly or indirectly electrically connected to the connecting conductor, a second terminal fitting that directly electrically connects a second electrical connection portion to a second electrode of the circuit protection component and is indirectly electrically connected to the battery monitoring unit, and the second terminal fitting and the The device comprises a wiring component interposed between battery monitoring units, and an electrically insulating housing component in which the first electrical connection, the second electrical connection, and the circuit protection component installed spanning the first and second electrical connection are housed in a housing chamber, wherein the wiring component has a conductor portion that directly electrically connects one end to the second terminal fitting and the other end that directly or indirectly electrically connects to the battery monitoring unit, and the housing component comprises a plurality of housing members assembled and fixed together to form the housing chamber inside, wherein the plurality of housing members are molded as separate members from the first electrical connection, the second electrical connection, and the circuit protection component, and surround the first electrical connection, the second electrical connection, and the circuit protection component and house them in the housing chamber.

[0008] In the fuse unit according to the present invention, the multiple housing members that constitute the housing components are molded as separate components from the first electrical connection part, the second electrical connection part, and the circuit protection component, so they can be formed through multiple manufacturing processes. For example, in the fuse unit according to the present invention, it is possible to adopt a manufacturing method in which the circuit protection component is installed on the first electrical connection part and the second electrical connection part installed on the housing member, and then the circuit protection component is connected to the first electrical connection part and the second electrical connection part, or to adopt a manufacturing method in which the circuit protection component is connected to the first electrical connection part and the second electrical connection part, and then installed on the housing member. Therefore, this fuse unit has a higher degree of freedom in manufacturing compared to conventional fuse units. The conductive module according to the present invention comprises this fuse unit and can achieve the same effects as those obtained with this fuse unit.

[0009] Figure 1 is a perspective view showing the fuse unit and conductive module of the embodiment. Figure 2 is a schematic diagram showing the battery module together with the busbar. Figure 3 is a perspective view showing the fuse unit of the embodiment. Figure 4 is an exploded perspective view showing the fuse unit of the embodiment. Figure 5 is an exploded perspective view of the fuse unit of the embodiment from a different angle. Figure 6 is a plan view illustrating the covering resin part. Figure 7 is a plan view illustrating a modified form of the housing component.

[0010] Embodiments of the fuse unit and conductive module according to the present invention will be described in detail below with reference to the drawings. However, the present invention is not limited to these embodiments.

[0011] [Embodiment] One embodiment of the fuse unit and conductive module according to the present invention will be described with reference to Figures 1 to 7.

[0012] Reference numeral 1 in Figure 1 indicates a conductive module of this embodiment. This conductive module 1 is assembled into a battery module BM (Figure 2) in which a plurality of battery cells BC are arranged, and electrically connects the plurality of battery cells BC in the battery module BM. Furthermore, this conductive module 1 electrically connects the battery module BM to a battery monitoring unit (not shown), causing the battery monitoring unit to monitor the battery state of the battery cells BC. This conductive module 1, together with the battery module BM, constitutes a battery pack. A battery pack is, for example, mounted on a vehicle (BEV: Battery Electric Vehicle, HEV: Hybrid Electric Vehicle, etc.) that is equipped with a rotating machine as a power source, and is used to supply power to that rotating machine, etc.

[0013] A battery cell BC comprises a cell body BCa and positive and negative electrode terminals BCb (Figure 2). In a battery module BM, multiple of these battery cells BC are arranged in a single row along the arrangement direction. The battery module BM comprises one electrode terminal group BCc, where one electrode terminal BCb of the multiple battery cells BC is arranged along the arrangement direction, and the other electrode terminal group BCc, where the other electrode terminal BCb of the multiple battery cells BC is arranged along the arrangement direction (Figure 2).

[0014] The battery cell BC shown here is formed in a rectangular shape with a cell body BCa having six outer wall surfaces. In multiple battery cells BC, adjacent cell bodies BCa are arranged with one outer wall surface facing the other in the arrangement direction. For example, in a battery cell BC, the positive and negative electrode terminals BCb are arranged on one of the six outer wall surfaces of the cell body BCa, or on two of the six outer wall surfaces of the cell body BCa. In this example, each battery cell BC has the positive and negative electrode terminals BCb on one of the six outer wall surfaces of the cell body BCa (Figure 2). Therefore, in the battery module BM, two groups of electrode terminals BCc are provided on a single plane (Figure 2).

[0015] The electrode terminal BCb shown here is formed into a flat plate shape, and the connecting conductor 10, described later, is directly electrically connected to it by laser welding or the like (Figure 2). However, the electrode terminal BCb may be formed into a pole column shape with a male screw portion. In this case, the connecting conductor 10 is screwed into the male screw portion of the electrode terminal BCb by screwing a female screw member into it.

[0016] The conductive module 1 includes a connecting conductor 10 that is directly electrically connected to the electrode terminal BCb of the battery cell BC that constitutes the battery module BM (Figures 1 and 2).

[0017] The connecting conductor 10 is formed from a conductive material such as metal. This connecting conductor 10 is a metal plate-shaped conductive component called a busbar, and is, for example, press-formed using a metal plate as the base material. The connecting conductor 10 shown here is formed into a rectangular flat plate shape.

[0018] The conductive module 1 includes, as connecting conductors 10, for example, one that is directly electrically connected to adjacent electrode terminals BCb of a pair of battery cells BC in the battery module BM, one that is directly electrically connected to the electrode terminal BCb that forms the total negative electrode in the battery module BM, and one that is directly electrically connected to the electrode terminal BCb that forms the total positive electrode in the battery module BM.

[0019] The conductive module 1 includes a fuse unit 20 that indirectly electrically connects the connecting conductor 10 to the battery monitoring unit (Figures 1 and 3 to 5). This fuse unit 20 indirectly electrically connects the connecting conductor 10, which is the first electrical connection target, and the battery monitoring unit, which is the second electrical connection target, and cuts off the current when an overcurrent flows between them. This fuse unit 20 is provided for each connecting conductor 10.

[0020] The fuse unit 20 includes a circuit protection component 30 that melts a fusible portion when an overcurrent flows between the connecting conductor 10 and the battery monitoring unit (Figures 3 to 5). This circuit protection component 30 includes a first electrode 31 and a second electrode 32 positioned with their fusible portions in between (Figures 3 to 5). The first electrode 31 and the second electrode 32 are positioned in a straight line at one end and the other end of the circuit protection component 30.

[0021] The circuit protection component 30 may be configured as, for example, a chip fuse having a fusible portion, or as a pattern fuse in which a wiring pattern having a fusible portion is provided on a printed circuit board (for example, a flexible printed circuit board). The circuit protection component 30 shown here is configured as a rectangular chip fuse. The first electrode 31 is provided at one end of the circuit protection component 30, extending across five outer wall surfaces. The second electrode 32 is provided at the other end of the circuit protection component 30, extending across five outer wall surfaces.

[0022] The fuse unit 20 includes a first terminal fitting 40 and a second terminal fitting 50 that are directly electrically connected to the circuit protection component 30 (Figures 3 to 5). The first terminal fitting 40 and the second terminal fitting 50 are formed from a conductive material such as metal. For example, the first terminal fitting 40 and the second terminal fitting 50 are press-formed using a metal plate as the base material.

[0023] The first terminal fitting 40 has a first electrical connection portion 41 that directly electrically connects to the first electrode 31 of the circuit protection component 30 (Figures 3 to 5). One of the four outer wall surfaces of the first electrode 31, which are arranged in the circumferential direction, rests on this first electrical connection portion 41, and the first electrode 31 is directly electrically connected by laser welding, soldering, or the like. Therefore, the first electrical connection portion 41 is formed in a flat plate shape with a plane on which the outer wall surface of the first electrode 31 rests. The first electrical connection portion 41 shown here is formed in a convex flat plate shape, and the outer wall surface of the first electrode 31 rests on this convex narrow portion. In this first electrical connection portion 41, the narrow portion becomes a contact portion 41a with the first electrode 31, and this contact portion 41a and the first electrode 31 are directly electrically connected (Figures 3 to 5).

[0024] Furthermore, the first terminal fitting 40 has a conductor connection portion 42 that is electrically connected to the connecting conductor 10 directly or indirectly (Figures 3 to 5). This conductor connection portion 42 is formed in a flat plate shape and is placed on the connecting conductor 10 with its planes overlapping. This conductor connection portion 42 is then electrically connected to the connecting conductor 10 directly by laser welding, ultrasonic bonding, or the like. The conductor connection portion 42 shown here is formed in a rectangular flat plate shape.

[0025] The first terminal fitting 40 shown here is formed into a single flat plate shape with the first electrical connection portion 41 and the conductor connection portion 42 adjacent to each other.

[0026] The second terminal fitting 50 has a second electrical connection portion 51 that directly electrically connects to the second electrode 32 of the circuit protection component 30 (Figures 3 to 5). One of the four outer wall surfaces of the second electrode 32, which are arranged in the circumferential direction, rests on this second electrical connection portion 51, and the second electrode 32 is directly electrically connected by laser welding, soldering, or the like. Therefore, the second electrical connection portion 51 is formed in a flat plate shape with a surface on which the outer wall surface of the second electrode 32 rests. The second electrical connection portion 51 shown here is formed in a convex flat plate shape, and the outer wall surface of the second electrode 32 rests on this convex narrow portion. In this second electrical connection portion 51, the narrow portion becomes the contact portion 51a with the second electrode 32, and this contact portion 51a and the second electrode 32 are directly electrically connected (Figures 3 to 5).

[0027] Furthermore, the second terminal fitting 50 is indirectly electrically connected to the battery monitoring unit. The fuse unit 20 includes a wiring component 60 interposed between the second terminal fitting 50 and the battery monitoring unit (Figures 3 to 5), and the second terminal fitting 50 is indirectly electrically connected to the battery monitoring unit via this wiring component 60. The second terminal fitting 50 has a wiring connection portion 52 that is directly electrically connected to this wiring component 60 (Figures 3 to 5).

[0028] The wiring component 60 has a conductor portion 61 that is directly electrically connected at one end to the second terminal fitting 50 and at the other end to the battery monitoring unit directly or indirectly (Figures 3 and 4). The wiring component 60 also has an electrically insulating coating 62 that covers at least one end of the conductor portion 61 on the side facing the battery monitoring unit (Figures 3 to 5). The wiring component 60 shown here is a linear conductor having a linearly formed conductor portion 61. Specifically, the wiring component 60 is an electric wire in which the core wire as the conductor portion 61 is covered with an electrically insulating coating 62, and the wiring connection portion 52 is directly electrically connected to one end of the conductor portion 61 at its terminal.

[0029] For example, in the case of the wiring component 60, the insulating coating 62 is stripped off at its end to expose one end of the conductor portion 61. In this case, the wiring connection portion 52 can be a crimping portion formed to crimp one end of the conductor portion 61 (i.e., the core wire at the end of the electric wire). Alternatively, for example, the wiring component 60 may be one in which the insulating coating 62 covers one end of the conductor portion 61 at its end. In this case, the wiring connection portion 52 can be a pair of crimping blades formed by making an incision in the insulating coating 62 at the end of the wiring component 60 to clamp one end of the conductor portion 61 (the core wire at the end of the electric wire). The wiring connection portion 52 shown here is formed as a crimping portion.

[0030] The second terminal fitting 50 shown here has a second electrical connection part 51 and a wiring connection part 52 adjacent to each other. The wiring connection part 52 allows the wiring component 60 to be pulled out in the direction adjacent to it and along the direction of the second electrical connection part 51.

[0031] The wiring component 60 may be a flat wiring material such as a flexible printed circuit board in which the conductor portion 61 is formed as a wiring pattern (not shown). In this case, the wiring component 60 has a conductor portion 61 formed for each second terminal fitting 50 in the multiple fuse units 20, and one end of the conductor portion 61 is provided at the end of the branch portion branched off from the main body for each second terminal fitting 50. One end of the conductor portion 61 is electrically connected directly to the wiring connection portion 52, for example, by laser welding or soldering.

[0032] In this fuse unit 20, the first electrical connection portion 41 of the first terminal fitting 40 and the second electrical connection portion 51 of the second terminal fitting 50 are arranged on the same plane with a predetermined distance between them. This predetermined distance is the distance between the first electrode 31 and the second electrode 32 in the circuit protection component 30 (in other words, the electrode pitch). Therefore, the first terminal fitting 40 and the second terminal fitting 50 are positioned so that the distance between the first electrical connection portion 41 and the second electrical connection portion 51 matches the electrode pitch between the first electrode 31 and the second electrode 32. The circuit protection component 30 is installed straddling the first electrical connection portion 41 and the second electrical connection portion 51. Here, the first terminal fitting 40 and the second terminal fitting 50 are positioned so that the distance between the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51 matches the electrode pitch between the first electrode 31 and the second electrode 32. Therefore, the circuit protection component 30 is installed spanning the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51.

[0033] Furthermore, the first terminal fitting 40 shown here is arranged so that the adjacent directions of the first electrical connection part 41 and the conductor connection part 42 are aligned in the opposing arrangement direction of the respective contact parts 41a and 51a. The second terminal fitting 50 shown here is arranged so that the adjacent directions of the second electrical connection part 51 and the wiring connection part 52 are aligned in the opposing arrangement direction of the respective contact parts 41a and 51a.

[0034] The fuse unit 20 includes an electrically insulating housing component 70 that houses the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30 (Figures 3 to 5). This housing component 70 is provided with a housing chamber 70a that houses the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30 (Figure 5).

[0035] The housing component 70 comprises a plurality of housing members that are assembled and fixed together to form a housing chamber 70a inside. These plurality of housing members are molded from an electrically insulating material such as synthetic resin. The plurality of housing members are molded as separate components from the first electrical connection part 41, the second electrical connection part 51 and the circuit protection component 30, and surround the first electrical connection part 41, the second electrical connection part 51 and the circuit protection component 30 to house them in the housing chamber 70a.

[0036] Specifically, the housing component 70 shown here includes, as its multiple housing members, a first housing member 70A and a second housing member 70B that house the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30 by sandwiching them between each other and housing them in the housing chamber 70a (Figures 3 to 5).

[0037] The first housing member 70A is provided with an installation surface 71 on which the first electrical connection part 41 and the second electrical connection part 51 are placed (Figures 3 and 4). The circuit protection component 30 is placed on the first electrical connection part 41 and the second electrical connection part 51 which are placed on this installation surface 71. For example, this first housing member 70A is molded as a base member on which the first electrical connection part 41 and the second electrical connection part 51 are placed on the installation surface 71. The first housing member 70A shown here is molded in a rectangular flat plate shape.

[0038] The second housing member 70B is molded as a cover member that covers the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30 at the position where it is assembled to the first housing member 70A, which serves as the base member.

[0039] The second housing member 70B has a lid portion 72 that, when assembled, is positioned opposite the installation surface 71 of the first housing member 70A, with the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 in between (Figures 4 and 5). The lid portion 72 shown here is formed in a rectangular flat plate shape and is positioned parallel to the installation surface 71 of the first housing member 70A when assembled.

[0040] Furthermore, the second housing member 70B has a pair of first side wall portions 73 that are suspended from the lid portion 72 and are positioned opposite each other with a gap between them in the direction of the opposing arrangement of the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51 (Figures 4 and 5). The first side wall portions 73 shown here are formed in a rectangular flat plate shape and, when assembled, the edge of the leading edge abuts against the installation surface 71 of the first housing member 70A. However, the leading edge of one of the first side wall portions 73 has a first notch 73a formed therein that allows the conductor connection portion 42 side of the first electrical connection portion 41 to be pulled out of the housing chamber 70a (Figure 5). Furthermore, the leading edge of the other first side wall portion 73 has a second notch 73b formed therein that allows the wiring connection portion 52 side of the second electrical connection portion 51 to be pulled out of the housing chamber 70a (Figures 4 and 5).

[0041] Furthermore, the second housing member 70B is suspended from the lid 72 and has a pair of second side wall portions 74 that are spaced apart from each other in directions perpendicular to the opposing arrangement direction of the lid 72 and the first housing member 70A and the opposing arrangement direction of their respective contact portions 41a and 51a (Figures 4 and 5). The second side wall portions 74 shown here are formed in a rectangular flat plate shape and, at the completed assembly position, the edges of the leading edges abut against the installation surface 71 of the first housing member 70A.

[0042] The second housing member 70B has an internal space enclosed by its lid portion 72, a pair of first side wall portions 73, and a pair of second side wall portions 74. In the housing component 70, when the first housing member 70A and the second housing member 70B are assembled to the final position, the opening of the internal space of the second housing member 70B is closed by the first housing member 70A, and that internal space becomes the housing chamber 70a.

[0043] For example, in this housing component 70, the leading edges of the pair of first side wall portions 73 and the leading edges of the pair of second side wall portions 74 are fixed to the installation surface 71 of the first housing member 70A by heat welding or the like at the completed assembly position.

[0044] Also, for example, the first housing member 70A and the second housing member 70B are preferably formed and fixed in a shape that can eliminate the gap between them at the assembly completion position so that the accommodation chamber 70a becomes a sealed space at the assembly completion position. Thereby, this fuse unit 20 can suppress the intrusion of liquid, dust, etc. into the accommodation chamber 70a, and thus can suppress the deterioration of quality and durability due to the intrusion of such liquid, etc.

[0045] Here, between the installation surface 71 of the first housing member 70A and the first electrical connection portion 41, a first positioning structure 75A for positioning the first electrical connection portion 41 with respect to the installation surface 71 is provided (FIGS. 3 to 5). And between the installation surface 71 of the first housing member 70A and the second electrical connection portion 51, a second positioning structure 75B for positioning the second electrical connection portion 51 with respect to the installation surface 71 is provided (FIGS. 3 to 5). The first positioning structure 75A and the second positioning structure 75B position the first electrical connection portion 41 and the second electrical connection portion 51 by adjusting the interval between the contact portion 41a of the first electrical connection portion 41 and the contact portion 51a of the second electrical connection portion 51 to match the electrode pitch between the first electrode 31 and the second electrode 32.

[0046] For example, the first positioning structure 75A is composed of a first positioning pin 71a vertically provided from the installation surface 71 of the first housing member 70A and a first positioning hole 41b provided in the first electrical connection portion 41 into which the first positioning pin 71a is inserted (FIGS. 4 and 5). In the first positioning structure 75A shown here, the first positioning pin 71a is formed in a cylindrical shape, and the first positioning hole 41b is formed as a circular through-hole. However, in the first positioning structure 75A, in order to suppress the rotation of the first positioning pin 71a around the axis in the first terminal fitting 40, for example, it is desirable to form the first positioning pin 71a in a prismatic shape and form the first positioning hole 41b as a rectangular through-hole.

[0047] Further, the second positioning structure 75B is composed of a second positioning pin 71b vertically provided from the installation surface 71 of the first housing member 70A, and a second positioning hole 51b provided in the second electrical connection portion 51 for fitting the second positioning pin 71b (FIGS. 4 and 5). In the second positioning structure 75B shown here, the second positioning pin 71b is formed in a cylindrical shape, and the second positioning hole 51b is formed as a circular through-hole. However, in the second positioning structure 75B, in order to prevent rotation of the second positioning pin 71b around the axis in the second terminal fitting 50, for example, it is desirable to form the second positioning pin 71b in a prismatic shape and form the second positioning hole 51b as a rectangular through-hole.

[0048] For example, in this fuse unit 20, the first electrical connection portion 41 and the second electrical connection portion 51 are installed on the installation surface 71 of the first housing member 70A. The first electrical connection portion 41 and the second electrical connection portion 51 are adjusted by the first positioning structure 75A and the second positioning structure 75B so that the intervals between the respective contact portions 41a, 51a match the electrode pitch between the first electrode 31 and the second electrode 32. Therefore, in the fuse unit 20, by installing the circuit protection component 30 on the respective contact portions 41a, 51a of the first electrical connection portion 41 and the second electrical connection portion 51, the first electrode 31 of the circuit protection component 30 can be placed on the contact portion 41a of the first electrical connection portion 41, and the second electrode 32 of the circuit protection component 30 can be placed on the contact portion 51a of the second electrical connection portion 51. In this fuse unit 20, the contact portion 41a of the first electrode 31 and the first electrical connection portion 41 is directly electrically connected by laser welding, soldering, or the like, and the contact portion 51a of the second electrode 32 and the second electrical connection portion 51 is directly electrically connected by laser welding, soldering, or the like.

[0049] In this fuse unit 20, the first housing member 70A serves as a base member, and there is no wall or other structure covering the area around the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30 installed on the mounting surface 71. Therefore, in this fuse unit 20, a laser irradiator or soldering iron can be brought close to the contact part 41a of the first electrode 31 and the first electrical connection part 41, and to the contact part 51a of the second electrode 32 and the second electrical connection part 51 from various directions. Laser light can be irradiated from any direction between the first electrode 31 and the contact part 41a and between the second electrode 32 and the contact part 51a, and soldering can be performed between them with a soldering iron from any direction. Consequently, this fuse unit 20 can increase the degree of freedom in manufacturing when directly electrically connecting the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30.

[0050] Next, in this fuse unit 20, the second housing member 70B is placed over the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30, and the first housing member 70A and the second housing member 70B in the completed assembly position are fixed by heat welding or the like. Here, it is assumed that the wiring component 60 is pre-connected to the wiring connection part 52 of the second terminal fitting 50.

[0051] On the other hand, this fuse unit 20 can also be formed through the following manufacturing process.

[0052] For example, in this manufacturing process, a jig is used that has two pins positioned at a distance between a first positioning pin 71a and a second positioning pin 71b (not shown). In the fuse unit 20, the first electrical connection part 41 and the second electrical connection part 51 are aligned and installed in the jig by inserting each of the pins into the first positioning hole 41b and the second positioning hole 51b, respectively. Then, in the fuse unit 20, the circuit protection component 30 is installed on the contact parts 41a, 51a of the first electrical connection part 41 and the second electrical connection part 51, respectively, with the first electrode 31 of the circuit protection component 30 resting on the contact part 41a of the first electrical connection part 41, and the second electrode 32 of the circuit protection component 30 resting on the contact part 51a of the second electrical connection part 51. Subsequently, in this fuse unit 20, the contact portion 41a of the first electrode 31 and the first electrical connection portion 41 are directly electrically connected by laser welding, soldering, or the like, and the contact portion 51a of the second electrode 32 and the second electrical connection portion 51 are directly electrically connected by laser welding, soldering, or the like.

[0053] In the fuse unit 20, the first electrical connection portion 41 and the second electrical connection portion 51, to which the circuit protection component 30 is connected, are installed on the mounting surface 71 of the first housing member 70A. The first electrical connection portion 41 and the second electrical connection portion 51 are positioned using the first positioning structure 75A and the second positioning structure 75B, respectively, so that the spacing between their respective contact portions 41a and 51a matches the electrode pitch of the first electrode 31 and the second electrode 32, as in the manufacturing configuration described above. In this fuse unit 20, the second housing member 70B is placed over the first electrical connection portion 41, the second electrical connection portion 51 and the circuit protection component 30, and the first housing member 70A and the second housing member 70B are fixed in the completed assembly position by heat welding or the like. Here, it is assumed that the wiring component 60 is pre-connected to the wiring connection portion 52 of the second terminal fitting 50.

[0054] In this fuse unit 20, the first electrical connection 41, the second electrical connection 51, and the circuit protection component 30 are exposed within the housing chamber 70a. Therefore, this fuse unit 20 is equipped with an electrically insulating resin covering portion 76 that encloses the circuit protection component 30, the first electrical connection 41, and the second electrical connection 51 within the housing chamber 70a (Figure 6). This resin covering portion 76 encloses the circuit protection component 30, the first electrical connection 41, and the second electrical connection 51, thereby suppressing current flow between the first electrical connection 41 and the second electrical connection 51. For example, even if condensation occurs within the housing chamber 70a, this resin covering portion 76 can suppress short circuits within the housing chamber 70a caused by the condensed water. Furthermore, by fixing the covering resin portion 76 to the installation surface 71 of the first housing member 70A, it can also function as a fixing member that secures the first electrical connection portion 41, the second electrical connection portion 51, and the circuit protection component 30 to the first housing member 70A within the housing chamber 70a.

[0055] For example, the covering resin portion 76 is a solidified form of liquid resin material (so-called potting material) supplied by dripping or other means so as to enclose the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51. In this case, first, liquid potting material is supplied to the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51 which are installed on the installation surface 71 of the first housing member 70A. Then, depending on the properties of the potting material, the potting material is irradiated with ultraviolet light or heated to form the covering resin portion 76 by curing the potting material. Since the covering resin portion 76 goes through such a manufacturing process, it is desirable to use a liquid potting material with a viscosity that allows it to remain on the installation surface 71 until it hardens, so that the liquid potting material does not flow out from the installation surface 71 of the first housing member 70A, which serves as a base member, before it hardens.

[0056] In the case of UV-curing potting material, it is necessary to bring the UV irradiator close to the liquid potting material. In this fuse unit 20, the first housing member 70A serves as a base member, and there is no wall or other structure covering the area around the supplied liquid potting material. Therefore, in this fuse unit 20, the UV irradiator can be brought close to the liquid potting material from various directions on the installation surface 71 of the first housing member 70A, and UV light can be irradiated onto the liquid potting material from any direction. Consequently, this fuse unit 20 can increase the degree of freedom in manufacturing when forming the coating resin part 76.

[0057] Furthermore, for example, the covering resin portion 76 may be a solidified material that fills the housing chamber 70a and encloses the circuit protection component 30, the first electrical connection portion 41, and the second electrical connection portion 51. In this case, for example, a supply hole (not shown) for supplying liquid resin material to the inside (housing chamber 70a) of the first housing member 70A and the second housing member 70B at the completed assembly position is provided in either the first housing member 70A or the second housing member 70B. If there is no gap between the first housing member 70A and the second housing member 70B at the completed assembly position (in other words, if the housing chamber 70a is airtight), then an air vent hole (not shown) is provided in either the first housing member 70A or the second housing member 70B to release gas from inside the housing chamber 70a to the outside while the liquid resin material is being supplied. In this case, liquid resin material is supplied through the supply hole to fill the inside (storage chamber 70a) of the first storage member 70A and the second storage member 70B at the completed assembly position, and this resin material is hardened to form the covering resin part 76. If there is a gap between the first storage member 70A and the second storage member 70B at the completed assembly position (in other words, if the airtightness of the storage chamber 70a is low), or if the supply hole or air vent hole has to be provided, for example, vertically downward, and there is a concern that the liquid resin material may leak out of the storage chamber 70a, it is desirable to form the covering resin part 76 using a liquid resin material with a viscosity that can be kept in the storage chamber 70a until it hardens.

[0058] The conductive module 1 includes an electrically insulating housing component (hereinafter referred to as the "module housing component") 80 that houses the fuse unit 20, along with the connecting conductor 10 (Figure 1). The module housing component 80 is provided with a housing chamber (hereinafter referred to as the "conductor housing chamber") 80a for housing the connecting conductor 10 and a housing chamber (hereinafter referred to as the "unit housing chamber") 80b for housing the fuse unit 20 (Figure 1).

[0059] For example, this module housing component 80 has a conductor housing chamber 80a for each connecting conductor 10 connected to each electrode terminal BCb of the electrode terminal group BCc. On the other hand, this module housing component 80 has a unit housing chamber 80b in which the fuse units 20 for each connecting conductor 10 are housed together.

[0060] In the unit housing chamber 80b, the wiring components 60 (wires) of each fuse unit 20 are routed to the battery monitoring unit. The other end of each wiring component 60 (wire) that is routed to the battery monitoring unit is connected to a connector 65 (Figure 1). Each wiring component 60 (wire) is indirectly electrically connected to the battery monitoring unit via this connector 65.

[0061] Furthermore, if the wiring component 60 is a flat wiring material, the unit housing chamber 80b houses the wiring component 60 (flat wiring material) having a conductor portion 61 connected to the second terminal fitting 50 of each fuse unit 20 (not shown).

[0062] The module housing component 80 comprises a first housing member (hereinafter referred to as the "first module housing member") 80A (Figure 1) and a second housing member (hereinafter referred to as the "second module housing member"; not shown) which are assembled and fixed together to form a plurality of conductor housing chambers 80a and unit housing chambers 80b inside. The first module housing member 80A and the second module housing member are molded from an electrically insulating material such as synthetic resin.

[0063] The first module housing member 80A is provided with spaces for forming multiple conductor housing chambers 80a and unit housing chambers 80b at the assembly completion position with the second module housing member. The second module housing member is molded as a cover member that covers the openings of each of these spaces.

[0064] In the fuse unit 20 of this embodiment described above, the multiple housing members (first housing member 70A, second housing member 70B) that make up the housing component 70 are molded as separate components from the first electrical connection part 41, the second electrical connection part 51, and the circuit protection component 30, so they can be formed through the multiple manufacturing processes described above. For example, in the fuse unit 20 shown here, it is possible to adopt a manufacturing method in which the circuit protection component 30 is installed on the first electrical connection part 41 and the second electrical connection part 51 which are installed on the mounting surface 71 of the first housing member 70A, and then the circuit protection component 30 is connected to the first electrical connection part 41 and the second electrical connection part 51, or to adopt a manufacturing method in which the circuit protection component 30 is connected to the first electrical connection part 41 and the second electrical connection part 51 and then installed on the mounting surface 71 of the first housing member 70A. Therefore, this fuse unit 20 has a higher degree of freedom in manufacturing compared to conventional fuse units. The conductive module 1 of this embodiment is equipped with this fuse unit 20 and can achieve the same effects as those obtained with this fuse unit 20.

[0065] Incidentally, in this fuse unit 20 and conductive module 1, the function of the first housing member 70A may be shared with the first module housing member 80A. In this case, the first module housing member 80A is provided with an installation surface 71, a first positioning pin 71a of the first positioning structure 75A, and a second positioning pin 71b of the second positioning structure 75B. As a result, the fuse unit 20 and conductive module 1 do not require the first housing member 70A, which reduces the number of parts and manufacturing steps, and thus contributes to cost reduction.

[0066] Furthermore, in this fuse unit 20 and conductive module 1, the function of the second housing member 70B may be shared with the second module housing member. As a result, the fuse unit 20 and conductive module 1 do not require the second housing member 70B, which reduces the number of parts and manufacturing steps, and thus contributes to cost reduction.

[0067] Furthermore, in this fuse unit 20 and conductive module 1, the function of the first housing member 70A may be shared with the first module housing member 80A as described above, and the function of the second housing member 70B may be shared with the second module housing member. As a result, the fuse unit 20 and conductive module 1 do not require the first housing member 70A and the second housing member 70B, which reduces the number of parts and manufacturing processes, and thus contributes to cost reduction.

[0068] In the housing component 70 shown above, the first housing member 70A and the second housing member 70B are separate components. In the fuse unit 20, this housing component 70 may be replaced with the following housing component 170 (Figure 7).

[0069] This housing component 170 has connecting portions 170C connected to the first housing member 70A and the second housing member 70B shown above (Figure 7), and the first housing member 70A, the second housing member 70B, and the connecting portion 170C are molded as a single integrated component.

[0070] The connecting portion 170C displaces the relative positions of the first housing member 70A and the second housing member 70B between a first state in which the first electrical connection portion 41 and the second electrical connection portion 51 can be installed on the installation surface 71 of the first housing member 70A, and a second state in which the housing chamber 70a is formed. The first state is the state in which the installation surface 71 of the first housing member 70A is exposed, in other words, it refers to the open state of the first housing member 70A and the second housing member 70B. The second state is the state in which the installation surface 71 of the first housing member 70A is covered by the second housing member 70B, in other words, it refers to the closed state of the first housing member 70A and the second housing member 70B. For example, the connecting portion 170C shown here is formed as a so-called living hinge.

[0071] When the first housing member 70A and the second housing member 70B are assembled in the second state (closed state), the housing component 170 is fixed, for example, by heat welding or the like to the mounting surface 71 of the first housing member 70A, at the tip edges of the pair of first side wall portions 73 and the tip edges of the pair of second side wall portions 74.

[0072] By using this housing component 170, the fuse unit 20 and the conductive module 1 can reduce the number of parts compared to when the housing component 70 is used, thus contributing to cost reduction.

[0073] Furthermore, the storage components 70 and 170 may be configured such that a space for a storage chamber 70a is provided in the first storage member 70A, and the opening of this space is covered by the second storage member 70B, which acts as a cover member. In this case, the first storage member 70A has a bottom portion provided with an installation surface 71, a first positioning pin 71a, and a second positioning pin 71b, and a plurality of side wall portions extending vertically from this bottom portion, and the space enclosed by this bottom portion and the plurality of side wall portions is used as the storage chamber 70a. The second storage member 70B is, for example, formed into a flat plate shape and covers the opening formed between the ends in the vertical direction of the plurality of side wall portions of the first storage member 70A.

[0074] 1 Conductive module 10 Connecting conductor 20 Fuse unit 30 Circuit protection component 31 First electrode 32 Second electrode 40 First terminal fitting 41 First electrical connection part 41a Contact part 50 Second terminal fitting 51 Second electrical connection part 51a Contact part 60 Wiring component 61 Conductor part 70, 170 Housing component 70a Housing chamber 70A First housing member (housing member) 70B Second housing member (housing member) 71 Installation surface 75A First positioning structure 75B Second positioning structure 76 Covering resin part 170C Connecting part BC Battery cell BCb Electrode terminal BM Battery module

Claims

1. A circuit protection component that melts a fusible portion when an overcurrent flows between a first electrical connection target and a second electrical connection target; a first terminal fitting that directly electrically connects a first electrical connection portion to a first electrode of the circuit protection component and directly or indirectly electrically connects to the first electrical connection target; a second terminal fitting that directly electrically connects a second electrical connection portion to a second electrode of the circuit protection component and directly or indirectly electrically connects to the second electrical connection target; and an electrically insulating housing component in which the first electrical connection portion, the second electrical connection portion, and the circuit protection component installed spanning the first and second electrical connection portions are housed in a housing chamber, wherein the housing component comprises a plurality of housing members assembled and fixed together to form the housing chamber inside, A fuse unit characterized in that the plurality of housing members are molded as separate members from the first electrical connection portion, the second electrical connection portion, and the circuit protection component, and surround the first electrical connection portion, the second electrical connection portion, and the circuit protection component and house them in the housing chamber.

2. The fuse unit according to claim 1, wherein the housing component comprises a plurality of housing members, a first housing member and a second housing member, which house the first electrical connection portion, the second electrical connection portion and the circuit protection component by sandwiching them between each other and housing them in the housing chamber, the first housing member is provided with an installation surface on which the first electrical connection portion and the second electrical connection portion are placed, a first positioning structure is provided between the installation surface and the first electrical connection portion to position the first electrical connection portion relative to the installation surface, and a second positioning structure is provided between the installation surface and the second electrical connection portion to position the first electrical connection portion and the second electrical connection portion in accordance with the electrode pitch between the first electrode and the second electrode, the distance between the contact portion with the first electrode in the first electrical connection portion and the contact portion with the second electrode in the second electrical connection portion.

3. The fuse unit according to claim 2, wherein the first housing member is molded as a base member on which the first electrical connection portion and the second electrical connection portion are placed on the mounting surface.

4. The fuse unit according to claim 2, wherein the housing component has connecting portions connected to the first housing member and the second housing member, and the connecting portions displace the relative positions between the first housing member and the second housing member between a first state in which the first electrical connection portion and the second electrical connection portion can be installed on the installation surface and a second state in which the housing chamber is formed.

5. The fuse unit according to claim 1, 2, 3, or 4, further comprising a wiring component interposed between the second terminal fitting and the second object to be electrically connected, wherein the wiring component has a conductor portion that directly electrically connects one end to the second terminal fitting and directly or indirectly electrically connects the other end to the second object to be electrically connected.

6. The fuse unit according to claim 1, 2, 3, or 4, further comprising an electrically insulating covering resin portion enclosing the circuit protection component, the first electrical connection portion, and the second electrical connection portion.

7. A battery module comprising: a connecting conductor that is directly electrically connected to the electrode terminals of battery cells constituting the battery module; and a fuse unit that indirectly electrically connects the connecting conductor to a battery monitoring unit that monitors the battery state of the battery cells, wherein the fuse unit comprises: a circuit protection component that melts a fusible portion when an overcurrent flows between the connecting conductor and the battery monitoring unit; a first terminal fitting that directly electrically connects a first electrical connection portion to a first electrode of the circuit protection component and is directly or indirectly electrically connected to the connecting conductor; a second terminal fitting that directly electrically connects a second electrical connection portion to a second electrode of the circuit protection component and is indirectly electrically connected to the battery monitoring unit; a wiring component interposed between the second terminal fitting and the battery monitoring unit; and an electrically insulating housing component in which the first electrical connection portion, the second electrical connection portion, and the circuit protection component installed spanning the first and second electrical connection portions are housed in a housing chamber. The conductive module is characterized in that the wiring component has a conductor portion that is directly electrically connected at one end to the second terminal fitting and at the other end that is directly or indirectly electrically connected to the battery monitoring unit, the housing component comprises a plurality of housing members that are assembled and fixed together to form the housing chamber inside, and the plurality of housing members are molded as separate members from the first electrical connection part, the second electrical connection part and the circuit protection component, and surround the first electrical connection part, the second electrical connection part and the circuit protection component and house them in the housing chamber.

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