Connection structure for external connection bus bar and connection method for external connection bus bar

Abstract

A connection structure for an external connection bus bar configured to connect the external connection bus bar to an external connection electrode terminal of a power storage element stack including power storage elements including electrode terminals. The connection structure includes: the external connection bus bar including one end part to be connected to the external connection electrode terminal; a receiving connector that houses the external connection bus bar and is fixed to the power storage element stack, and that includes a connector terminal to be connected to the external connection bus bar and to connect the external connection bus bar to an outside; and a fixing member that is provided to one end of the power storage element stack and fixes the receiving connector. The external connection bus bar includes a flexible part that is configured to expand and contract in a direction where the power storage elements are arranged.

Claims

1. A connection structure for an external connection bus bar configured to connect the external connection bus bar to an external connection electrode terminal of a power storage element stack formed by arranging a plurality of power storage elements including electrode terminals of a positive electrode and a negative electrode, the connection structure comprising: the external connection bus bar including one end part to be connected to the external connection electrode terminal; a receiving connector that houses the external connection bus bar and is fixed to the power storage element stack, and that includes a connector terminal to be connected to the external connection bus bar and to connect the external connection bus bar to an outside; and a fixing member that is provided to one end of the power storage element stack and fixes the receiving connector, wherein the external connection bus bar includes a flexible part that is configured to expand and contract in a direction where the power storage elements are arranged.

2. The connection structure for the external connection bus bar according to claim 1, wherein: the external connection electrode terminal includes a bolt terminal; the external connection bus bar includes an insertion hole at the one end part, the insertion hole into which the bolt terminal is inserted; and the insertion hole has an oval shape that is long in the direction where the power storage elements are arranged.

3. The connection structure for the external connection bus bar according to claim 1, wherein: the fixing member includes a fixing hole configured to fix the receiving connector; the receiving connector includes a penetration hole communicating with the fixing hole, the penetration hole allowing a bolt that is to be fitted to the fixing hole to pass therethrough; and the penetration hole is larger in diameter than the fixing hole.

4. The connection structure for the external connection bus bar according to claim 1, further comprising an external connection bus bar protector that holds the one end part of the external connection bus bar, wherein the external connection bus bar protector includes: a first positioning part that positions the external connection bus bar in a vertical direction; and a second positioning part that positions the external connection bus bar in a width direction.

5. A connection method for an external connection bus bar configured to connect the external connection bus bar to an external connection electrode terminal of a power storage element stack formed by arranging a plurality of power storage elements including electrode terminals of a positive electrode and a negative electrode, the connection method comprising: preparing the external connection bus bar that includes one end part to be connected to the external connection electrode terminal and includes a flexible part that is configured to expand and contract in a direction where the power storage elements are arranged, and a receiving connector that houses the external connection bus bar and is fixed to the power storage element stack and that includes a connector terminal to be connected to the external connection bus bar and to connect the external connection bus bar to an outside; connecting the external connection bus bar to the external connection electrode terminal in a state where the external connection bus bar is housed in the receiving connector; and fixing the receiving connector to the power storage element stack by using expansion and contraction of the flexible part.

6. The connection method for the external connection bus bar according to claim 5, further comprising preparing an external connection bus bar protector that holds the one end part of the external connection bus bar and includes a positioning part that positions the external connection bus bar, connecting the external connection bus bar to the external connection electrode terminal further comprising: causing the external connection bus bar protector to hold the one end part of the external connection bus bar and temporarily fixing the receiving connector to the fixing member of the power storage element stack to temporarily position the receiving connector in the direction where the power storage elements are arranged; positioning the one end part of the external connection bus bar in a width direction and a vertical direction using the positioning part; and connecting the one end part of the external connection bus bar to the external connection electrode terminal, and fixing the receiving connector to the power storage element stack further comprising when the receiving connector is fixed to the fixing member, positioning the receiving connector in the direction where the power storage elements are arranged by using the expansion and contraction of the flexible part of the external connection bus bar.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic perspective view of a power storage module according to one embodiment.

(2) FIG. 2 is a partial plan view illustrating an external connection part of a power storage module.

(3) FIG. 3 is a schematic partial cross-sectional view taken along line A-A in FIG. 2.

(4) FIG. 4 is a perspective view of a receiving connector.

(5) FIG. 5 is a plan view of the receiving connector.

(6) FIG. 6 is a partial perspective view illustrating a connection structure for an external connection bus bar.

(7) FIG. 7 is a schematic partial cross-sectional view of FIG. 3 excluding a female connector.

(8) FIG. 8 is a side view of the power storage module.

(9) FIG. 9 is a partial cross-sectional view taken along line B-B in FIG. 8.

(10) FIG. 10 is a partial perspective view for describing a connection method for an external connection bus bar.

(11) FIG. 11 is a partial perspective view for describing the connection method for an external connection bus bar.

(12) FIG. 12 is a partial perspective view for describing the connection method for an external connection bus bar.

DETAILED DESCRIPTION

Embodiment

(13) One embodiment of the technology described herein is described with reference to FIG. 1 to FIG. 12.

(14) As illustrated in FIG. 1, a power storage module M1 includes a power storage element stack 10 in which a plurality of power storage elements 11 are arranged, a stack fixing member 12, a connection module 20, an external connection receiving connector 30, and a connection structure 50 for an external connection bus bar.

(15) The power storage module M1 is used for, for example, a driving source of a vehicle such as an electric vehicle or a hybrid vehicle. In the description below, a plurality of members that is the same may be denoted by one reference sign and the reference signs and description of the other members may be omitted.

1. Power Storage Element Stack

(16) The power storage element stack 10 to which the connection module 20 according to the present embodiment is attached is formed by arranging a plurality of (twelve in the present embodiment) power storage elements 11 as illustrated in FIG. 1.

(17) The power storage element 11 includes an electrode terminal part 13A of a positive electrode and an electrode terminal part 13B of a negative electrode that project vertically from an upper surface of a main body part with a flat rectangular parallelepiped shape in which a power storage component that is not shown is housed.

(18) Each electrode terminal part 13 (13A, 13B) includes a terminal board 15 with a plate-like shape, and an electrode terminal 14 (14A, 14B) with a cylindrical shape that projects upward from the terminal board 15. Each electrode terminal 14 is inserted into a terminal insertion hole 22 of a bus bar 21 (see FIG. 11). To a side wall part of the electrode terminal 14, a screw thread (not shown) to which a nut 17 is fitted is formed. That is to say, the electrode terminal 14 is a bolt terminal in the present embodiment.

(19) The positive electrode terminal 14A on the front side (arrow-Y1 side) of the power storage element 11 that is on a right end (end on arrow-X1 side) in FIG. 1 corresponds to an external connection positive electrode terminal (external connection electrode terminal) 14Aout, and the negative electrode terminal 14B on the front side (arrow-Y1 side) of the power storage element 11 that is on a left end (end on arrow-X2 side) in FIG. 1 corresponds to an external connection negative electrode terminal (external connection electrode terminal) 14Bout. In the description below, the positive electrode terminal 14A and the negative electrode terminal 14B are simply referred to as the electrode terminal 14 unless they need to be distinguished.

(20) When the bus bar 21 inserted to the electrode terminal 14 and the terminal board 15 are in contact with each other, the bus bar 21 and the electrode terminal 14 are in electric connection. A plurality of the power storage elements 11 is disposed such that the electrode terminals 14 that are adjacent in the left-right direction (arrow-X direction) in FIG. 1 have opposite polarities.

(21) Outside the power storage elements 11 at both ends of the power storage element stack 10, a stack fixing member (one example of fixing member) 12 is provided to fix the power storage element stack 10. The stack fixing member 12 includes, for example, a first fixing member 12A formed of a strong and thick metal plate, and a second fixing member 12B formed of a thin insulating material and covering the first fixing member 12A.

(22) The stack fixing member 12 is also used to fix the external connection receiving connector 30 to be described below. Therefore, the first fixing member 12A and the second fixing member 12B include a pair of screw holes (one example of fixing holes) 18 for fastening the external connection receiving connector 30 with a bolt. In addition, the second fixing member 12B includes a pair of engaging pieces 19 for engaging with and fixing the external connection receiving connector 30 (see FIG. 9 and FIG. 10).

(23) Although not shown, the power storage element stack 10 together with the stack fixing member 12 are fastened and fixed by a fastening band that is provided in the periphery, for example. Note that the configuration of the stack fixing member 12 is not limited to the above structure. For example, the first fixing member 12A and the second fixing member 12B may be formed by one fixing member.

2. Connection Module

(24) The connection module 20 is attached to the power storage element stack 10 along a direction (arrow-X direction) where the power storage elements 11 are arranged, and has a function of electrically connecting the plurality of power storage elements 11 as illustrated in FIG. 1. The connection module 20 includes a first bus bar module 20A and a second bus bar module 20B.

(25) Each bus bar module (20A, 20B) includes a plurality of bus bars 21, a plurality of protectors 25 that holds the bus bars 21 in an insulated state, and linking parts 26 that link the protectors 25 as illustrated in FIG. 1.

(26) On an upper surface of the plurality of power storage elements 11, the first bus bar module 20A is attached at one end part (end part in arrow-Y1 direction in FIG. 1) in a direction (arrow-Y direction in FIG. 1) that is perpendicular to the direction where the plurality of power storage elements 11 is arranged as illustrated in FIG. 1. On the other hand, on the upper surface of the plurality of power storage elements 11, the second bus bar module 20B is attached to the other end part (end part in arrow-Y2 direction in FIG. 1) that is opposite to the one end part as illustrated in FIG. 1.

(27) Note that the first bus bar module 20A and the second bus bar module 20B are different only in their both end parts. That is to say, at a left end of the first bus bar module 20A (end part in arrow-X2 direction in FIG. 1), an external connection bus bar protector 27 for an external connection bus bar 32 to be described below is provided.

(28) On each of opposite wall parts of the external connection bus bar protectors 27, two positioning claws 27A (one example of first positioning part) with flexibility are provided, which are therefore provided four in total to the wall parts, in order to position the external connection bus bar 32 in a vertical direction (arrow-Z direction in FIG. 1) as illustrated in FIG. 2. On each of the same wall parts, two positioning ribs 27B (one example of second positioning part) are provided, which are therefore provided four in total to the wall parts, in order to position the external connection bus bar 32 in a width direction (arrow-Y direction in FIG. 1) as illustrated in FIG. 2.

(29) With these positioning claws 27A and positioning ribs 27B, a flat plate part (one end part) 32P of the external connection bus bar can be fixed to a predetermined position. Therefore, the external connection bus bar 32 can be connected to the external connection negative electrode terminal 14Bout more stably. This also contributes to the higher reliability in connecting between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout. The configuration of the first positioning part is not limited to the positioning claw 27A and the configuration of the second positioning part is not limited to the positioning rib 27B.

(30) The bus bar 21 connects between the positive electrode terminal 14A and the negative electrode terminal 14B of the adjacent power storage elements 11. The bus bar 21 is formed of metal such as copper, copper alloy, stainless steel (SUS), or aluminum, and a pair of terminal insertion holes 22 (see FIG. 11) into which the electrode terminal 14 is inserted is formed to penetrate.

3. External Connection Receiving Connector

(31) The external connection receiving connector (hereinafter simply referred to as receiving connector) 30 is a male connector, and includes a connector housing 31, the external connection bus bar 32, a male connector terminal 33, a bus bar holding part 34, a fixing part 35, an engaging claw 36, an engaging part 37, and the like as illustrated in FIG. 4 and FIG. 5.

(32) The connector housing 31 includes a housing part 21A. In the housing part 21A, the male connector terminal 33 is provided (see FIG. 7), and a female connector 40 is inserted into the housing part 21A (see FIG. 3). When the female connector 40 is inserted, the male connector terminal 33 and a female connector terminal (not shown) of the female connector 40 are connected electrically.

(33) The external connection bus bar 32 is bent to have an L-like shape (see FIG. 3), and is formed of metal such as copper, copper alloy, stainless steel (SUS), or aluminum like the bus bar 21. The external connection bus bar 32 includes an insertion hole 32A, a flexible part 32B, and the flat plate part 32P as illustrated in FIG. 3. A lower end part of the external connection bus bar 32 is bonded to an end of the male connector terminal 33 as illustrated in FIG. 4.

(34) The insertion hole 32A is provided to the flat plate part 32P of the external connection bus bar 32, and has an oval opening shape (planar shape) that is long in the direction where the power storage elements 11 are arranged (arrow-X direction in FIG. 1). When the external connection bus bar 32 inserted to the external connection negative electrode terminal 14Bout through the insertion hole 32A is in contact with the terminal board 15, the external connection bus bar 32 and the external connection negative electrode terminal 14Bout are in electric connection. Here, since the insertion hole 32A has the oval shape, the product tolerance of the power storage elements 11 and the like in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1) can be absorbed when the external connection bus bar 32 is connected to the external connection negative electrode terminal (external connection electrode terminal) 14Bout. Note that the opening shape of the insertion hole 32A is not limited to the oval shape and may be a circular shape, for example.

(35) The flexible part 32B is formed by deforming the external connection bus bar 32 with a thin plate shape into a wave-like shape (see FIG. 4). The flexible part 32B is configured to expand and contract in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1), and when the receiving connector 30 is fixed to the power storage element stack 10, the flexible part 32B expands and contracts to absorb the product tolerance of the power storage elements 11 and the like.

(36) The fixing parts 35 are provided as a pair (see FIG. 8), and each fixing part 35 is provided with a bolt penetration hole 35A into which a bolt 38 (see FIG. 2, etc.) can be inserted. Here, the bolt penetration hole 35A is larger in diameter than the screw hole 18 as illustrated in FIG. 9. Therefore, when the receiving connector 30 is fixed to the stack fixing member 12 with the bolt 38, the fixing position can be set flexibly. Thus, for example, backlash of the receiving connector 30 that is due to the product tolerance in fixing the receiving connector 30 can be absorbed. The configuration is not limited thereto. In another example, the bolt penetration hole 35A and the screw hole 18 may have the same diameter.

(37) With the engaging claw 36, an engaging part 42 of the female connector 40 is engaged (see FIG. 3). The engaging parts 37 are provided as a pair (see FIG. 8), and each engaging part 37 is, when temporarily fixing the receiving connector 30, hooked by the engaging piece 19 of the second fixing member 12B. Thus, the receiving connector 30 is temporarily fixed.

4. Connection Structure for External Connection Bus Bar

(38) Next, description is made of the connection structure 50 for an external connection bus bar, which corresponds to a structure of connecting the external connection bus bar 32 to the external connection negative electrode terminal 14Bout of the power storage element stack 10.

(39) The connection structure 50 for an external connection bus bar is formed by some of the components of the power storage module M1 that are: the external connection negative electrode terminal 14Bout of the power storage element stack 10, the external connection bus bar protector 27 of the connection module 20, the receiving connector 30, the external connection bus bar 32, the stack fixing member 12, a bolt 39, and the like as illustrated in FIG. 6.

5. Connection Method for External Connection Bus Bar

(40) Next, description is made of a method of connecting the external connection bus bar 32 to the external connection negative electrode terminal 14Bout with reference to FIG. 6, and FIG. 10 to FIG. 12.

(41) The connection method for an external connection bus bar broadly includes a bus bar connecting step of connecting the external connection bus bar 32 to the external connection negative electrode terminal 14Bout in a state where the external connection bus bar 32 is housed in the receiving connector 30, and a connector fixing step of fixing the receiving connector 30 to the power storage element stack 10 using the expansion and contraction of the flexible part 32B.

(42) In accordance with this method, the external connection bus bar 32 is connected to the outside, such as a connection cable 45, through the male connector terminal 33 of the receiving connector 30 that is fixed to the power storage element stack 10 (specifically, stack fixing member 12) (see FIG. 2). Therefore, as compared to a case in which the connection cable 45 is directly connected to the external connection bus bar 32, a part of vibration from the vehicle that is applied to the connection part between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout is absorbed by the receiving connector 30, and thus, the vibration from the vehicle is reduced.

(43) In addition, when the receiving connector 30 is fixed to the stack fixing member 12, the tolerance between the power storage element 11 and the first fixing member 12A that is caused by the product tolerance of the power storage element 11 can be absorbed by the flexible part 32B of the external connection bus bar 32. Accordingly, the stress is applied less to the connection part. By reducing the vibration from the vehicle and the stress on the connection part between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout in this manner, the reliability of the connection between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout of the power storage element can be increased.

(44) In the connection method for an external connection bus bar, the bus bar connecting step may further include: a connector temporarily fixing step of causing the prepared external connection bus bar protector 27 to hold the flat plate part (one end part) 32P of the external connection bus bar and temporarily fixing the receiving connector 30 to the stack fixing member 12 of the power storage element stack to temporarily position the receiving connector in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1); a bus bar positioning step of positioning the flat plate part 32P of the external connection bus bar in a width direction (arrow-Y direction in FIG. 1) and a vertical direction (arrow-Z direction in FIG. 1) using the positioning parts (27A, 27B); and a bus bar connecting step of connecting the flat plate part 32P of the external connection bus bar to the external connection negative electrode terminal 14Bout. In this case, the connector fixing step may include a connector positioning step of, when the receiving connector 30 is fixed to the stack fixing member 12, positioning the receiving connector in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1) by using the expansion and contraction of the flexible part 32B of the external connection bus bar 32.

(45) In this case, while the receiving connector 30 is temporarily fixed, the external connection bus bar 32 is positioned and then connected to the external connection negative electrode terminal 14Bout (external connection electrode terminal); therefore, the external connection bus bar 32 and the external connection negative electrode terminal 14Bout can be connected correctly at a predetermined place. In addition, the receiving connector 30 can be fixed at a desired position while the backlash due to the product tolerance is absorbed using the expansion and contraction of the flexible part 32B of the external connection bus bar.

(46) In the connection method for an external connection bus bar, more specifically, in a state where the connection module 20 is attached to the upper surface of the power storage element stack 10 (see FIG. 10), first, the external connection negative electrode terminal 14Bout is inserted into the insertion hole 32A of the external connection bus bar 32 housed in the receiving connector 30. In this insertion, the positioning claw 27A is displaced with the flat plate part 32P of the external connection bus bar 32 in contact with the positioning claw 27A. Thus, the flat plate part 32P of the external connection bus bar 32 is placed on the terminal board 15 below the positioning claw 27A.

(47) In the bus bar positioning step, a cutoff part 32K of the external connection bus bar 32 or the like is brought into contact with the positioning rib 27B. A pair of engaging parts 37 of the receiving connector 30 is hooked by a pair of engaging pieces 19 of the second fixing member 12B. Here, the position of the receiving connector 30 in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1) is temporarily determined. Thus, the connector temporarily fixing step of temporarily fixing the receiving connector 30 to the power storage element stack 10 (specifically, second fixing member 12B) so as to temporarily position the receiving connector 30 in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1) is completed. FIG. 11 illustrates a state where the receiving connector 30 is temporarily fixed.

(48) Next, in the state where the receiving connector 30 is temporarily fixed, the bus bar 21 is bonded to the terminal board 15 by fastening the electrode terminal 14 of each power storage element 11 of the power storage element stack 10 with the nut 17 and moreover the external connection bus bar 32 is bonded to the terminal board 15 by fastening the external connection negative electrode terminal 14Bout with the nut 17. Thus, the external connection bus bar 32 is positioned in the vertical direction (arrow-Z direction in FIG. 1) and in the width direction (arrow-Y direction in FIG. 1) (bus bar positioning step).

(49) Here, the insertion hole 32A of the external connection bus bar 32 is a long hole that is long in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1). The product tolerance of the power storage elements 11 and the like in the state where the receiving connector 30 is fixed by the second fixing member 12B is absorbed and the external connection bus bar 32 is fixed. This state is shown in FIG. 12. In this state, the bolt penetration hole 35A communicates with the screw hole 18 (see FIG. 9).

(50) Next, as illustrated in FIG. 6, the bolt 39 is inserted into the bolt penetration hole 35A of the fixing part 35 of the receiving connector, and the bolt 39 is screwed into the screw hole 18 of the stack fixing member 12. Thus, the receiving connector 30 is fixed to the power storage element stack 10 through the stack fixing member 12 (connector fixing step). In this case, due to the difference in position from the temporary fixing, stress is generated in the direction where the power storage elements are arranged (arrow-X direction in FIG. 1) and the stress is applied to the connection part between the external connection bus bar 32 and the terminal board 15. This stress, however, is absorbed by the expansion and contraction of the flexible part 32B of the external connection bus bar 32.

(51) The order of steps in the connection method is not limited to the order described above, and for example, the bus bar positioning step and the connector positioning step may be opposite. That is to say, the connector fixing step may be performed before the bus bar positioning step.

6. Effects of the Present Embodiment

(52) The external connection bus bar 32 is connected to the connection cable (external connection member) 45 through the male connector terminal 33 of the receiving connector 30 fixed to the stack fixing member 12. Therefore, as compared to the case in which the connection cable 45 is directly connected to the external connection bus bar 32, apart of the vibration from the vehicle that is applied to the connection part between the external connection bus bar 32 and the external connection negative electrode terminal (external connection electrode terminal) 14Bout is absorbed by the receiving connector 30, and the vibration from the vehicle that is applied to the connection part is reduced.

(53) When the receiving connector 30 is fixed to the stack fixing member 12, the flexible part 32B of the external connection bus bar can absorb the tolerance between the power storage element 11 and the stack fixing member 12 that is caused by the product tolerance of the power storage element 11. Thus, the stress on the connection part can be reduced. By reducing the vibration from the vehicle and the stress on the connection part between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout in this manner, the reliability of the connection between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout of the power storage element 11 can be increased.

(54) In this case, in the structure in which the external connection bus bar 32 is connected by bolt fastening to the external connection negative electrode terminal (external connection electrode terminal) 14Bout, the reliability of the connection between the external connection bus bar 32 and the external connection negative electrode terminal 14Bout against the vibration from the vehicle can be increased.

OTHER EMBODIMENTS

(55) The technology described herein is not limited to the embodiment described above and with reference to the drawings. The following embodiments may be included in the technical scope.

(56) (1) In the above embodiment, the external connection negative electrode terminal 14Bout is the cylindrical terminal (bolt terminal) and the external connection bus bar 32 is bonded to the external connection negative electrode terminal 14Bout with the nut 17; however, the structure is not limited to this example. In another example, the external connection negative electrode terminal 14Bout may be a plate-shaped electrode, and the external connection bus bar 32 may be welded with a laser to the plate-shaped electrode. That is to say, the present application is also employed in a configuration in which the external connection bus bar is welded with a laser to the plate-shaped electrode.

(57) (2) In regard to the connection configuration (connection structure) of the external connection bus bar 32, the external connection bus bar 32 is connected to the external connection negative electrode terminal 14Bout in the above embodiment; however, the structure is not limited to this example. That is to say, the present application is also employed in a configuration in which the external connection bus bar 32 is connected to the external connection positive electrode terminal 14Aout, or a configuration in which the external connection bus bar 32 is connected to the external connection positive electrode terminal 14Aout and the external connection negative electrode terminal 14Bout.