Busbar module
10959324 ยท 2021-03-23
Assignee
Inventors
Cpc classification
H05K2201/10272
ELECTRICITY
B60R16/033
PERFORMING OPERATIONS; TRANSPORTING
H01M10/425
ELECTRICITY
H05K1/0265
ELECTRICITY
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M50/507
ELECTRICITY
H05K1/189
ELECTRICITY
H01M2220/20
ELECTRICITY
H01M10/4207
ELECTRICITY
International classification
Abstract
A busbar module includes: a circuit body having a flexible circuit board; busbars; and a holder. The circuit body has: a band-shaped main strip to be located to extend in a stacking direction of cells; a band-shaped first branch strip branched from the main strip and extending toward a corresponding busbar; and a second branch strip branched from the main strip and extending toward an external device. The first branch strip has: a bent portion extending in the stacking direction and having a bent shape around an axis crossing the stacking direction; and a busbar connection portion disposed closer to an end of the first branch strip than the bent portion and connected to the corresponding busbar. The second branch strip has a device connection portion to be connected to the external device.
Claims
1. A busbar module to be attached to a battery assembly having a stack of a plurality of cells and to connect the plurality of cells to an external device, the busbar module comprising: a circuit body having a flexible circuit board including a wiring pattern; a plurality of busbars to be connected to corresponding electrodes of the plurality of cells; and a holder holding the busbars and being extendable in a stacking direction of the plurality of cells, the circuit body comprising: a band-shaped main strip to be located to extend in the stacking direction; a band-shaped first branch strip branched from the main strip and extending toward a corresponding busbar among the plurality of the busbars; and a second branch strip branched from the main strip and extending toward the external device, the first branch strip comprising: a bent portion extending in the stacking direction and having a bent shape around an axis intersecting the stacking direction; and a busbar connection portion disposed closer to an end of the first branch strip than the bent portion and connected to the corresponding busbar, wherein the bent portion includes portions at a different height than the main strip and the busbar connection portion, the second branch strip comprising: a device connection portion to be connected to the external device.
2. The busbar module according to claim 1, wherein at least a part of the second branch strip extends in the stacking direction and has a bent shape around the axis intersecting the stacking direction.
3. The busbar module according to claim 1, wherein the second branch strip branches off the main strip from a side edge of the main strip or from inside area of the main strip.
4. The busbar module according to claim 1, wherein the first branch strip extends from the main strip toward one side in a thickness direction of the main strip, the second branch strip extends from the main strip toward the other side in the thickness direction of the main strip.
5. The busbar module according to claim 1, wherein the device connection portion has a connector structure to be connected to a counterpart connector of the external device or a board connection structure to be connected to a circuit board of the external device.
6. A busbar module to be attached to a battery assembly having a stack of a plurality of cells and to connect the plurality of cells to an external device, the busbar module comprising: a circuit body having a flexible circuit board including a wiring pattern; a plurality of busbars to be connected to corresponding electrodes of the plurality of cells; and a holder holding the busbars and being extendable in a stacking direction of the plurality of cells, the circuit body comprising: a band-shaped main strip to be located to extend in the stacking direction; a band-shaped first branch strip branched from the main strip and extending toward a corresponding busbar among the plurality of the busbars; and a second branch strip branched from the main strip and extending toward the external device, the first branch strip comprising: a bent portion extending in the stacking direction and having a bent shape around an axis intersecting the stacking direction; and a busbar connection portion disposed closer to an end of the first branch strip than the bent portion and connected to the corresponding busbar, the second branch strip comprising: a device connection portion to be connected to the external device, wherein at least a part of the second branch strip has a bent shape around the axis intersecting the stacking direction, and wherein the second branch strip branches off the main strip from inside area of the main strip.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
Embodiment
(12) A busbar module 10 according to an embodiment of the present invention will be hereinafter described with reference to the drawings. The busbar module 10 according to the embodiment is used being attached to a battery assembly (i.e., a battery module in which plural cells are laid on each other) that is a drive power source installed in an electric vehicle, a hybrid vehicle, or the like.
(13) (Configuration of Battery Assembly 1)
(14) First, a battery assembly 1 to which the busbar module 10 according to the embodiment is to be attached will be described. As shown in
(15) The battery assembly 1 is configured by laying the cells 2 on each other in a preset direction (stacking direction) in such a manner that the positive electrodes 4 and the negative electrodes 5 of the cells 2 are arranged alternately. The positive electrode 4 of one of end cells 2 located at the two respective ends of the series connection of the cells 2 of the battery assembly 1 serves as an assembly positive electrode and the negative electrode 5 of the other end cell 2 serves as an assembly negative electrode.
(16) (Overall Structure of Busbar Module 10)
(17) Next, the busbar module 10 according to the embodiment will be described. As shown in
(18) As shown in
(19) Busbar branch strips 201 each of which consists of a first branch portion 22 and a second branch portion 23 are connected to side edges, extending parallel with the longitudinal direction (substantially coincident with the stacking direction of the battery assembly 1) of the main strip 21, of the main strip 21. More specifically, band-shaped first branch portions 22 extending in the direction that crosses the longitudinal direction and the thickness direction of the main strip 21 (i.e., outward in the width direction of the main strip 21) are connected to the side edges of the main strip 21. Band-shaped second branch portions 23 extend from the tips of the first branch portions 22, respectively, in parallel with the stacking direction of the battery main bodies 3. The main strip 21, the first branch portions 22, and the second branch portions 23 are an FPC and hence can be deformed flexibly particularly in the direction that is perpendicular to their planes.
(20) As shown in
(21) The first branch portions 22 are located outside the main strip 21 in the same plane as the main strip 21, and the second branch portions 23 are connected to the respective first branch portions 22. Thus, the second branch portions 23 are located outside the main strip 21 in its width direction and extend generally downward so as to assume an S shape in a state that there is no deviation between the battery assembly 1 and the circuit body 20 (see
(22) An end portion, opposite to the first branch portion 22, of each second branch portion 23 is a tip portion 232 having a plane that is approximately parallel with the main strip 21, and a connection portion 24 is attached to the top surface of the tip portion 232. The bottom surface of the connection portion 24 is parallel with and at a different height as the bottom surface of the main strip 21, and hence these bottom surfaces are spaced from each other. The top surface of the connection portion 24 is connected to a busbar 25 that connects a positive electrode 4 and a negative electrode 5 of adjacent cells 2 of the battery assembly 1. Since the second branch portion 23 is thus connected to the electrodes 4 and 5 of those cells 2 via the connection portion 24 and the busbar 25, the associated voltage detection line 211 is connected to the electrodes 4 and 5.
(23) As shown in
(24) Busbars 25A that are located at the two respective ends of the main strip 21 in its longitudinal direction are connected to the assembly positive electrode or the assembly negative electrode and are each formed with one electrode hole 253 through which the assembly positive electrode or the assembly negative electrode is to be inserted. Power cables (not shown) for extracting power from the battery assembly 1 are connected to the respective busbars 25A.
(25) (Structure of Holder 30)
(26) As shown in
(27) Two busbar housing portions 32 for housing the busbars 25 are provided outside the main strip housing portion 31 in the width direction. Each busbar housing portion 32 is provided with plural housing spaces 33 which are to house respective busbars 25 and are arranged in the stacking direction of the cells 2. As also shown in
(28) As shown in
(29) Bottom end portions of the outer wall 331 and the inner wall 332 are connected to each other by a connection plate 333. The bottom end portions of the outer wall 331 and the inner wall 332 are formed with lock nails 334 inside, whereby a busbar 25 can be held between the connection plate 333 and the lock nails 334. Projections 338 project inward from the inner side surfaces of the outer wall 331 and the inner wall 332 at the centers in the stacking direction, respectively. The projections 338 serve to position the associated busbar 25 by fitting into the respective positioning recesses 254 (see
(30) The inner wall 332 is formed with a cut 336 and a support plate 337 projects inward at a position corresponding to the cut 336. As a result, the connection piece 255 of the busbar 25 housed in the housing space 33 is supported by the support plate 337.
(31) The connection plate 333 is formed with spaces 335 on the two respective sides of the center in the stacking direction. Thus, the positive electrode 4 and the negative electrode 5 of the cells 2 can be exposed in the housing space 33 through the respective spaces 335 and can be connected to the electrode holes 253 of the busbar 25 housed in the housing space 33. A bottom plate may be provided in place of the connection plate 333 so as to be formed with cuts or holes corresponding to the positive electrode 4 and the negative electrode 5 of the cells 2, respectively.
(32) As shown in
(33) (Operation of Busbar Module 10)
(34) Next, a description will be made of how the busbar module 10 operates.
(35) As described above, the main strip 21 is put on the main strip support members 311 of the holder 30 and hence can move upward and in the longitudinal direction. Although the busbars 25 are housed in the respective housing spaces 33, the housing spaces 33 can move in the longitudinal direction of the main strip 21. The main strip 21 is connected to the busbars 25 via the respective second branch portion 23 which are bent in an S shape (see
(36) Even if, for example, the battery assembly 1 is deformed in this state and the relative positional relationship between the battery assembly 1 and the circuit body 20 is changed and the relative positional relationships between the main strip 21 and the busbars 25 are thereby changed, the changes (deviations) in the relative positional relationships can be absorbed by bending or stretching of the second branch portions 23. Likewise, even if the size of the battery assembly 1 in its stacking direction varies from one battery assembly 1 manufactured to another due to an assembling allowance of the plurality of cells 2, that manufacture dispersion can be absorbed by bending or stretching of the second branch portions 23.
(37) This will be described below more specifically.
(38) In the above-described embodiment, the bent portion 231 of each second branch portion 23 is bent so as to assume an S shape (or inverted S shape) as a whole. Alternatively, as shown in
(39) Although in the above embodiment each first branch portion 22 is in the same plane as the main strip 21, as shown in
(40) (Modifications of Connection Between Circuit Body 20 and External Device)
(41) In the embodiment, as described above with reference to
(42) In the following, modifications of the connection between the circuit body 20 and the voltage detection device (external device) will be described with reference to
(43) As shown in
(44) The main strip 21, the first branch portion 42, and the second branch portion 43 are an FPC. Thus, as in the case shown in
(45) More specifically, like the second branch portion 23 of each busbar branch strip 201, the second branch portion 43 of the device branch strip 401 is bent in an S shape (or an inverted S shape) as a whole. Thus, the second branch portion 43 can move in the longitudinal direction of the main strip 21 (i.e., the stacking direction of the battery assembly 1) and extend and contract in the top-bottom direction. Furthermore, the first branch portion 42 of the device branch strip 401 is disposed outside the main strip 21 in the same plane and the second branch portion 43 is connected to the first branch portion 42. Thus, the second branch portion 43 is located outside the main strip 21 in its width direction and assumes an S shape (erected upward) in a state that the relative positional relationship between the voltage detection device and the circuit body 20 is not varied.
(46) (Modifications of Device Branch Strip 401)
(47) In the example shown in
(48) The position of the device branch strip 401 may be determined as appropriate taking the positional relationship between the busbar module 10 and the voltage detection device and other factors into consideration.
Main Advantages of Embodiment
(49) As described above, in the busbar module 10 according to the embodiment, the circuit body 20 which is a flexible circuit board (FPC) is composed of the band-shaped main strip 21, the band-shaped busbar branch strips 201 which branch off the main strip 21, and the device branch strip 401. Each of the busbar branch strips 201 connected to the respective busbars 25 includes the bent portion 231 which is bent along axes that cross the stacking direction of the plurality of cells 2. With this configuration, when the battery assembly 1 extends or contracts in its stacking direction due to thermal deformation of each cell 2, each busbar 25 can move in the stacking direction of the cells 2 because the bent portion 231 of each busbar branch strip 201 of the circuit body 20 is bent or stretched. Likewise, dispersion of the size of the battery assembly 1 in its stacking direction due to an assembling allowance of each cell 2 can be absorbed by bending or stretching of the bent portions 231 of the busbar branch strips 201 of the circuit body 20. In other words, the busbar module 10 having this configuration can easily accommodate expansion/contraction and manufacture dispersion of the battery assembly 1 by deformation of substantially only the busbar branch strips 201 with no deformation of the main strip 21 of the circuit body 20.
(50) Furthermore, the busbar module 10 having this configuration can flexibly accommodate external devices having various structures or installed at various locations by determining, as appropriate, a position where the device branch strip 401 to be connected to an external device (e.g., voltage detection device (not shown)) branches off the main strip 21 according to an installation location of the external device or its structure (e.g., a position of a connector of the external device).
(51) In general, even in the case where a flexible circuit board includes a number of circuit structures, it can be deformed flexibly by a much weaker force than the electric wires used in the above-described conventional busbar module. Thus, the ease of attachment of the circuit body 20 to the battery assembly 1 is increased remarkably.
(52) As such, the busbar module 10 having this configuration is higher in the ease of attachment to the battery assembly 1 and the followability to deformation and manufacture dispersion of the battery assembly 1 and is also higher in the degree of freedom of selection of an installation location and a structure of an external device than the above-described conventional busbar module.
(53) Like each busbar branch strip 201 connected to the associated busbar 25, the device branch strip 401 to be connected to the external device has a shape obtained by being bent along an axis that crosses the stacking direction of the plurality of cells 2. Thus, the busbar module 10 can flexibly accommodate external devices that are different from each other in installation location or structure. Furthermore, since the device branch strip 401 is bent and stretched, work of connecting the device branch strip 401 to the external device (e.g., work of fitting the connector 51 provided at the end of the device branch strip 401 to a connector of the external device) is made easier and hence work of connecting the busbar module 10 to the external device can be increased in efficiency. Incidentally, as in the case of each busbar branch strip 201, even when the device branch strip 401 is bent or stretched, substantially only the device branch strip 401 is deformed with no deformation of the main strip 21 of the circuit body 20.
(54) The device branch strip 401 branches off the main strip 21 from a side edge of the main strip 21 or from inside the main strip 21 and then extends toward the external device. This structure makes it possible to accommodate, more flexibly, external devices that are different from each other in installation location or structure. Where the device branch strip 401 branches off the main strip 21 from a side edge of the main strip 21, the device branch strip 401 may be formed so as to, for example, either extend from the side edge in the width direction of the main strip 21 or extend in the thickness direction of the main strip 21 from an edge of a cut that is formed so as to have an opening in the side edge. Where the device branch strip 401 branches off the main strip 21 from inside the main strip 21, the device branch strip 401 may be formed so as to, for example, extend in the thickness direction of the main strip 21 from an edge of an opening formed inside the main strip 21.
(55) Each of the busbar branch strips 201 and the device branch strip 401 extend in the thickness direction of the main strip 21 toward the opposite sides. With this measure, the device branch strip 401 can be prevented from interfering with the busbar branch strips 201 by, for example, disposing the battery assembly 1 under the busbar module 10 and disposing the external device above the busbar module 10.
(56) Furthermore, the device branch strip 401 has the connector 51 as a device connection portion that can be connected to a counterpart connector of the external device. The device branch strip 401 may have, for example, a structure that can be connected directly to a circuit board of the external device, instead of the connector 51. In this manner, the device branch strip 401 can be connected to various kinds of external devices.
Other Embodiments
(57) The invention is not limited to the above embodiment and various modifications, improvements, etc. can be made as appropriate within the scope of the invention. The materials, shapes, sets of dimensions, numbers, locations, etc. of the respective constituent elements of the above embodiment are not limited to those disclosed but can be determined in desired manners as long as the invention can be implemented.
(58) Features of the above-described busbar module 10 according to the embodiment of the invention will be summarized below concisely in the form of items [1] to [5]:
(59) [1] A busbar module (10) to be attached to a battery assembly (1) having a stack of a plurality of cells (2) and to connect the plurality of the cells (2) to an external device, the busbar module (10) comprising:
(60) a circuit body (20) having a flexible circuit board including a wiring pattern; a plurality of busbars (25) to be connected to corresponding electrodes of the plurality of the cells (2); and a holder (30) holding the busbars (25) and being extendable in a stacking direction of the plurality of the cells (2),
(61) the circuit body (20) having:
(62) a band-shaped main strip (21) to be located to extend in the stacking direction;
(63) a band-shaped first branch strip (201) branched from the main strip (21) and extending toward a corresponding busbar among the plurality of the busbars (25); and
(64) a second branch strip (401) branched from the main strip (21) and extending toward the external device,
(65) the first branch strip (201) having:
(66) a bent portion (231) extending in the stacking direction and having a bent shape around an axis crossing the stacking direction; and
(67) a busbar connection portion (24) disposed closer to an end of the first branch strip (201) than the bent portion (231) and connected to the corresponding busbar,
(68) the second branch strip (401) having
(69) a device connection portion (51) to be connected to the external device.
(70) [2] The busbar module (10) according to the item [1], wherein
(71) at least a part of the second branch strip (401) extends in the stacking direction and has a bent shape around the axis crossing the stacking direction.
(72) [3] The busbar module (10) according to the item [1] or the item [2], wherein
(73) the second branch strip (401) branches off the main strip (21) from a side edge of the main strip (21) or from inside area of the main strip (21).
(74) [4] The busbar module (10) according to any one of the item [1] to the item [3], wherein
(75) the first branch strip (201) extends from the main strip (21) toward one side in the thickness direction of the main strip (21),
(76) the second branch strip (401) extends from the main strip (21) toward the other side in the thickness direction of the main strip (21).
(77) [5] The busbar module (10) according to any one of the item [1] to the item [4], wherein
(78) the device connection portion (51) has a connector structure to be connected to a counterpart connector of the external device or a board connection structure to be connected to a circuit board of the external device.
REFERENCE SIGNS LIST
(79) 1: Battery assembly 2: Cell 3: Battery main body (main body) 4: Positive electrode 5: Negative electrode 10: Busbar module 20: Circuit body 21: Main strip 22: First branch portion (first branch strip) 23: Second branch portion (first branch strip) 201: Busbar branch strip 231: Bent portion 231A: First bent portion 231B: Second bent portion 24: Connection portion (busbar connection portion) 25: Busbar 30: Holder 42: First branch portion (second branch strip) 43: Second branch portion (second branch strip) 401: Device branch strip 51: Connector (device connection portion) L: Axis