Multilayer Divergence Type Busbar and Method of Manufacturing the Same

Abstract

The present invention relates to a multilayer divergence type busbar that is easy to manufacture and has various shapes and a method of manufacturing the same. The divergence type busbar is configured such that at least two conductive layers are stacked and some of the conductive layers are divided and diverged at a divergence point.

Claims

1. A divergence type busbar, comprising: at least two conductive layers stacked, some of the conductive layers being divided and diverged from one another at a divergence point.

2. The divergence type busbar according to claim 1, wherein the divergence point is a parallel connection section at which members electrically connected to each other by the conductive layers are configured to have an identical voltage.

3. The divergence type busbar according to claim 2, wherein a number of the conductive layers diverged from one another at the parallel connection section is configured to provide a different current to at least one of the members.

4. The divergence type busbar according to claim 3, wherein the number of the conductive layers is calculated by an equation:
Number of conductive layers=desired current of each conductive layer/sum of desired current of all conductive layers

5. The divergence type busbar according to claim 1, wherein the conductive layers have an identical length.

6. The divergence type busbar according to claim 1, wherein the conductive layers have holes are formed in opposite ends thereof.

7. The divergence type busbar according to claim 1, wherein some of the conductive layers are folded and diverged from one another.

8. The divergence type busbar according to claim 1, wherein each conductive layer is made of a thin and flexible material.

9. The divergence type busbar according to claim 8, wherein each conductive layer is made of copper.

10. A battery module comprising the divergence type busbar according to claim 1.

11. A battery pack comprising the divergence type busbar according to claim 1.

12. A method of manufacturing a divergence type busbar, the method comprising: stacking at least two conductive layers with one another; welding a first end of each of the conductive layers together and forming a hole extending through the first end that has been welded; folding some of the conductive layers relative to the first end to form at least one divergence path; and welding a second end of each of the divergence paths and forming a hole extending through the second end of each of the divergence paths.

13. The method according to claim 12, further comprising cutting the second end of each of the divergence paths after repeating the folding at least once.

Description

DESCRIPTION OF DRAWINGS

[0030] FIG. 1 is a top view of a conventional busbar for parallel connection.

[0031] FIG. 2 is a top view of a divergence type busbar according to the present invention.

[0032] FIG. 3 is a side view of the divergence type busbar according to the present invention.

[0033] FIG. 4 is a top view of the divergence type busbar according to the present invention before divergence.

[0034] FIG. 5 is a top view of the divergence type busbar according to the present invention after first divergence.

[0035] FIG. 6 is a top view of the divergence type busbar according to the present invention after second divergence.

[0036] FIG. 7 is a top view of a divergence type busbar according to another embodiment of the present invention.

BEST MODE

[0037] Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings such that the preferred embodiments of the present invention can be easily implemented by a person having ordinary skill in the art to which the present invention pertains. In describing the principle of operation of the preferred embodiments of the present invention in detail, however, a detailed description of known functions and configurations incorporated herein will be omitted when the same may obscure the subject matter of the present invention.

[0038] In addition, the same reference numbers will be used throughout the drawings to refer to parts that perform similar functions or operations. In the case in which one part is said to be connected to another part throughout the specification, not only may the one part be directly connected to the other part, but also, the one part may be indirectly connected to the other part via a further part. In addition, that a certain element is included does not mean that other elements are excluded, but means that such elements may be further included unless mentioned otherwise.

[0039] In addition, a description to embody elements through limitation or addition may be applied to all inventions, unless particularly restricted, and does not limit a specific invention.

[0040] Also, in the description of the invention and the claims of the present application, singular forms are intended to include plural forms unless mentioned otherwise.

[0041] Also, in the description of the invention and the claims of the present application, “or” includes “and” unless mentioned otherwise. Therefore, “including A or B” means three cases, namely, the case including A, the case including B, and the case including A and B.

[0042] FIG. 2 is a top view of a divergence type busbar according to the present invention, and FIG. 3 is a side view of the divergence type busbar according to the present invention.

[0043] The divergence type busbar 100 according to the present invention includes a stem portion 110 connected to an energy supply portion configured to supply main energy to the divergence type busbar 100 and a branch portion 120 protruding from the stem portion 110, the branch portion being configured to transmit energy supplied from the energy supply portion in parallel.

[0044] As shown in FIG. 3, the divergence type busbar 100 according to the present invention is configured such that two or more conductive layers are stacked.

[0045] The conductive layer may be made of a conductive material. As an example, the conductive layer may be made of at least one of copper, a copper alloy, nickel, a nickel alloy, and aluminum. Specifically, the copper alloy may include 60 or more weight % of copper. More specifically, the copper alloy may include 90 or more weight % of copper. In addition, the copper alloy may include the remaining weight % of at least one selected from the group consisting of nickel, silicon, tin, iron, zinc, magnesium, phosphorus, chromium, and zirconium, in addition to the specified weight % of copper. For example, the copper alloy may include 90 or more weight % of copper, less than 10 weight % of zinc, less than 10 weight % of chromium, and less than 5 weight % of zirconium. Also, in another embodiment, the copper alloy may include 90 or more weight % of copper, less than 5 weight % of nickel, less than 1 weight % of silicon, less than 1 weight % of tin, 1 or less weight % of iron, 1 or less weight % of zinc, 0.1 or less weight % of magnesium, 0.1 or less weight % of phosphorus, and 0.1 or less weight % of zirconium. However, the divergence type busbar 100 is not limited to the copper alloy. All metal alloys including nickel, aluminum, gold, and silver as main ingredients are applicable, and all materials having high electrical conductivity, such as conductive rubber, a gold-silver nanocomposite manufactured by mixing silver nanowires, the surfaces of which are wrapped with gold, with poly(styrene-butadiene-styrene) (SBS), and carbon nanotubes, and a carbon-rubber composite, may be used.

[0046] The conductive layer may be made of a flexible material. Since the conductive layer is made of a flexible material, the divergence type busbar 100 according to the present invention is not damaged even though some layers are folded. As an example, the conductive layer may be made of a metal having a thickness of 0.2 mm to 0.25 mm based on copper (C1100, 1/4H). If the conductive layer is too thin, the conductive layer may be damaged when a portion of the conductive layer is diverged. If the conductive layer is too thick, it is not possible to diverge the conductive layer into a desired shape, and therefore it is not possible to form variously shaped busbars.

[0047] In addition, the conductive layer may have a tensile elongation of 10% to 25% and a strength of 215 N/mm.sup.2 to 275 N/mm.sup.2. If the tensile elongation of the conductive layer is less than 10%, it may be difficult to diverge the conductive layer. If the tensile elongation of the conductive layer is greater than 25%, the busbar constituted by the conductive layer may not be fixed in a desire shape. Also, if the strength of the conductive layer is less than 215 N/mm.sup.2, the conductive layer may be damaged when the conductive layer is diverged. If the strength of the conductive layer is greater than 275 N/mm.sup.2, it may be difficult to diverge the conductive layer. As an example, the conductive layer may be made of a metal, such as copper, a copper alloy, or aluminum.

[0048] The conductive layer is folded at a divergence point A to form a branch portion 120, as shown in FIG. 2. The branch portion 120 may have a shape shown in FIG. 2 in which the branch portion is divided into two branches from the same divergence point A, or may have a branch shape in which the branch portion is divided into branches from different divergence points A.

[0049] The divergence point A may be a parallel connection section at which members electrically connected to each other by the diverged conductive layers are connected to each other so as to have the same voltage. The branch portions 120 divided by the divergence point A may be formed so as to have desired current specification in order to supply specific power to desired portions.

[0050] To this end, the respective conductive layers may be formed so as to have the same thickness, and the number of the conductive layers forming the diverged portions, i.e. the branch portions 120, may be set based on current specification.

[0051] As an example, the number of the conductive layers that are diverged may be calculated by the following equation.

Number of conductive layers=current specification of each diverged conductive layer/sum of current specifications of all conductive layers

[0052] On the assumption that current specification of the all conductive layers is 150A, a first branch portion 121 has a current specification of 100A, a second branch portion 122 has a current specification of 30A, and a third branch portion 123 has a current specification of 20A, as an example to which the above equation is applied, the above equation may be calculated, and this may be converted into a constant so as to be used. Ten conductive layers may be disposed at the first branch portion 121, three conductive layers may be disposed at the second branch portion 122, and two conductive layers may be disposed at the third branch portion 123.

[0053] The divergence type busbar according to the present invention has an advantage in that several conductive layers are divided and diverged, whereby it is possible to accurately divide the current specification, as described above.

[0054] Alternatively, the thicknesses of the diverged conductive layers may be changed so as to be different from each other, whereby the thickness of each branch portion 120 may be set based on the current specification of the diverged conductive layers.

[0055] Each branch portion 120 of the conductive layer may be formed by folding a portion of the conductive layer at the stem portion 110.

[0056] FIGS. 4 to 6 show a process of folding a portion of the conductive layer.

[0057] FIG. 4 is a top view of the divergence type busbar according to the present invention before divergence, FIG. 5 is a top view of the divergence type busbar according to the present invention after first divergence, and FIG. 6 is a top view of the divergence type busbar according to the present invention after second divergence.

[0058] Before divergence, the divergence type busbar 100 according to the present invention is configured to have a structure in which layers of a conductive layer are stacked such that only the stem portion 110 is present, as shown in FIG. 4.

[0059] Although all of the conductive layers may have the same length, the lengths of the conductive layers may be set to be different from each other in consideration of the fact that a portion of the conductive layer constituting the divergence type busbar 100 is folded.

[0060] In the divergence type busbar 100 according to the present invention, (S1) at least two conductive layers are stacked, and (S2) one end of each of the stacked conductive layers is welded and a stem portion connection hole 131 is formed.

[0061] The conductive layers of the divergence type busbar 100 may be mechanically fastened to each other, or the divergence type busbar 100 may be integrally formed by ultrasonic welding or laser welding.

[0062] In the case in which one end of the stem portion 110 is welded, as described above, the conductive layers may be fixed so as not to move when the stacked conductive layers are diverged. Also, in the case in which the stem portion connection hole 131 is formed in one end of the stem portion 110, the stem portion connection hole 131 may be used to fix the divergence type busbar 100 when diverged or to fix the divergence type busbar 100 to a battery module, a battery pack, or another member.

[0063] In the divergence type busbar 100, a portion of the stem portion 110 at which the several conductive layers are stacked is folded or divided into several layers to form branch portions 120.

[0064] The branch portions 120 may be formed at the same divergence point A, as shown in FIG. 2, or the second branch portion 122 may be formed without divergence and the first branch portion 121 and the third branch portion 123 may be diverged from different divergence points A to form the branch portions 120, as shown in FIG. 5.

[0065] At this time, in the divergence type busbar 100, the already diverged branch portion 120, i.e. the first branch portion 121, may be diverged again to form a diverged branch portion 121(a), as shown in FIG. 6. At this time, the first branch portion 121 must be made of at least two layers in order to form the diverged branch portion 121(a).

[0066] In the divergence type busbar 100 according to the present invention, (S3) some of the conductive layers may be folded to form one or more divergence paths, and (S4) one end of each divergence path may be welded and then a hole may be formed. At this time, the hole may be a branch portion connection hole 132, which is used to connect the busbar to a battery module, a battery pack, or another member.

[0067] By welding, a single divergence type busbar 100 may be formed, and the diverged conductive layers of the branch portion 120 of the divergence type busbar 100 may be fixed.

[0068] At this time, opposite ends of the divergence type busbar 100 may have the same length. The reason for this is that it is necessary to dispose a device, a battery module, or a battery pack using the divergence type busbar 100 at a constant position. Also, in order to form the divergence type busbar 100 so as to have a constant length, the respective conductive layers of the divergence type busbar 100 may be stacked so as to have different lengths, or (S4-0) a process of cutting the other end of each divergence path so as to satisfy design conditions may be performed after (S3) the process of folding some of the conductive layers of the divergence type busbar 100 to form one or more divergence paths is performed at least once. In the case in which the end of each divergence path is cut, as described above, there is an advantage in that all conductive layers of the divergence type busbar 100 are formed so as to have the same length and are easily diverged.

[0069] FIG. 7 is a top view of a divergence type busbar according to another embodiment of the present invention.

[0070] As can be seen from FIG. 7, the divergence type busbar 200 according to the other embodiment of the present invention may be configured such that the conductive layers are stacked side by side, unlike FIGS. 3 and 2.

[0071] At this time, the stem portion 210 may be configured such that a width part of a metal portion made of a conductive metal, which is formed in a stacking direction, has a constant width, whereas a thickness part, which is not formed in the stacking direction, is thin. As a result, it is possible to obtain a busbar having a constant thickness and width.

[0072] In the divergence type busbar 200, branch portions 220 may be formed by bending the conductive layers stacked side by side at the stem portion 210 into a predetermined shape.

[0073] When the conductive layers of the divergence type busbar 200 are stacked side by side, it is possible to easily form the branch portions 220 of the divergence type busbar 200, and a concern of resistance increase as the result of the conductive layers being folded due to formation of the branch portions 220 may be reduced.

[0074] The entirety of the divergence type busbar 200 according to the other embodiment of the present invention may be welded after divergence. The reason for this is that it is necessary to reduce a concern of the divergence type busbar 200 being separated due to stacking side by side.

[0075] The divergence type busbar according to the present invention may be included in a battery module or a battery pack. In addition, the divergence type busbar according to the present invention may be used in various devices to connect the devices to each other in parallel.

[0076] Those skilled in the art to which the present invention pertains will appreciate that various applications and modifications are possible within the category of the present invention based on the above description.

DESCRIPTION OF REFERENCE SYMBOLS

[0077] 1: Busbar for parallel connection [0078] 100, 200: Divergence type busbars [0079] 10, 110, 210: Stem portions [0080] 20, 120, 220: Branch portions [0081] 21, 121, 221: First branch portions [0082] 121(a): Diverged branch portion [0083] 22, 122, 222: Second branch portions [0084] 23, 123, 223: Third branch portions [0085] 130: Connection hole [0086] 131: Stem portion connection hole [0087] 132: Branch portion connection hole [0088] A: Divergence point [0089] A′: Second divergence point