U.S. patent application number 15/725483 was filed with the patent office on 2018-06-21 for conductor module.
The applicant listed for this patent is Yazaki Corporation. Invention is credited to Takuto Goto, Yoshiaki Ichikawa, Katsunori Sato, Takao Shoji, Shinichi Yanagihara.
Application Number | 20180175535 15/725483 |
Document ID | / |
Family ID | 62251802 |
Filed Date | 2018-06-21 |
United States Patent
Application |
20180175535 |
Kind Code |
A1 |
Sato; Katsunori ; et
al. |
June 21, 2018 |
CONDUCTOR MODULE
Abstract
A conductor module includes a busbar, an accommodation case, and
a fixing member. The accommodation case has two or more fixing
holes that pass through a fixing body first surface and a fixing
body second surface. The fixing member includes a main body and
fixing legs. The fixing legs are associated with the respective
fixing holes, and have a part of the busbar interposed
therebetween. The fixing legs are capable of plastic deformation by
external force, are inserted in the respective fixing holes from a
side of the fixing body first surface to protrude from a side of
the fixing body second surface, and, under a fixed condition in
which the busbar is fixed to the accommodation case by the fixing
member, have leading ends disposed on an outside in a radial
direction with respect to the fixing holes as viewed in an axial
direction of the fixing holes.
Inventors: |
Sato; Katsunori; (Shizuoka,
JP) ; Goto; Takuto; (Shizuoka, JP) ;
Yanagihara; Shinichi; (Shizuoka, JP) ; Ichikawa;
Yoshiaki; (Shizuoka, JP) ; Shoji; Takao;
(Shizuoka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Yazaki Corporation |
Tokyo |
|
JP |
|
|
Family ID: |
62251802 |
Appl. No.: |
15/725483 |
Filed: |
October 5, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 11/287 20130101;
H01R 11/12 20130101; H01M 2/30 20130101; H01M 10/482 20130101; H01R
13/405 20130101; H01R 11/283 20130101; Y02E 60/10 20130101 |
International
Class: |
H01R 13/405 20060101
H01R013/405; H01R 11/12 20060101 H01R011/12 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 19, 2016 |
JP |
2016-245832 |
Claims
1. A conductor module, comprising: at least one connection
conductor configured to be connected electrically with a connection
target; a fixing body to which the at least one connection
conductor is fixed; and a fixing member that fixes each of the at
least one connection conductor to the fixing body, wherein the
fixing body has two or more fixing holes that pass through a fixing
body first surface and a fixing body second surface opposite to the
fixing body first surface, the fixing member includes: a main body
having an opposed surface that faces the fixing body first surface
and that clamps, with the fixing body first surface, part of the at
least one connection conductor disposed between the opposed surface
and the fixing body first surface; and fixing legs that protrude
from the opposed surface, that are associated with the respective
fixing holes, and that have the part of the at least one connection
conductor interposed between the fixing legs, and the fixing legs
are capable of plastic deformation by an external force, are
inserted in the respective fixing holes from a side of the fixing
body first surface to protrude from a side of the fixing body
second surface, and, under a fixed condition in which the at least
one connection conductor is fixed to the fixing body by the fixing
member, have leading ends disposed on an outside in a radial
direction with respect to the fixing holes as viewed in an axial
direction of the fixing holes.
2. The conductor module according to claim 1, wherein the at least
one connection conductor includes at least one connection conductor
having through holes that pass through a conductor first surface
and a conductor second surface opposite to the conductor first
surface and that are associated with the respective fixing holes,
and the fixing legs are inserted in the through holes and the
fixing holes under the fixed condition.
3. The conductor module according to claim 2, wherein the at least
one connection conductor includes: a first connection conductor;
and a second connection conductor different from the first
connection conductor, and the second connection conductor is fixed,
using the fixing member that fixes the first connection conductor,
to the fixing body that is identical to the fixing body to which
the first connection conductor is fixed.
4. The conductor module according to claim 3, wherein the
connection target is a battery cell, and the conductor module
further comprises: a status detector including a detection
conductor that electrically connects the second connection
conductor with a status detection unit that detects a status of the
battery cell with which the second connection conductor is
electrically connected.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application claims priority to and incorporates
by reference the entire contents of Japanese Patent Application No.
2016-245832 filed in Japan on Dec. 19, 2016.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to a conductor module.
2. Description of the Related Art
[0003] A conventional conductor module is applied to a battery
module including a plurality of battery cells. The conductor module
exemplarily includes a plurality of busbars and a status detector.
The busbar is electrically connected with one of two electrode
terminals of a battery cell and with electrode terminals of two
battery cells that are adjacent to each other. The status detector
includes a detection conductor to detect voltage of each battery
cell (see, for example, Japanese Patent No. 5223607).
[0004] The conductor module further includes a connection part that
electrically connects each busbar with the detection conductor
through, for example, soldering or welding of the detection
conductor to the busbar on which the detection conductor is
disposed. In some conductor modules, the busbar with which the
detection conductor is connected is accommodated in an
accommodation space defined in an accommodation case before being
connected with the electrode terminal.
[0005] When the busbar is to be fixed in the accommodation case, a
locking portion for locking the busbar is formed in a wall portion
that defines the accommodation space in order to restrict the
busbar from moving with respect to the accommodation case in a
direction opposite to a direction in which the busbar is inserted
into the accommodation space. Because the locking portion is
elastically deformed when the busbar is inserted, the locking
portion is extended in the direction in which the busbar is
inserted to thereby make the locking portion elastically
deformable. The foregoing necessity requires a length in the
insertion direction, specifically, height of the accommodation case
in order for the locking portion for locking the busbar to be
formed. Specifically, the fixing of the busbar in the accommodation
case has been a hindrance to reduction in height of the
accommodation case.
SUMMARY OF THE INVENTION
[0006] The present invention has been made in view of the foregoing
situation and it is an object of the present invention to provide a
conductor module capable of accomplishing miniaturization of a
fixing body that fixes a connection conductor.
[0007] In order to achieve the above mentioned object, a conductor
module according to one aspect of the present invention includes at
least one connection conductor to be connected electrically with a
connection target, a fixing body to which the at least one
connection conductor is fixed, and a fixing member that fixes each
of the at least one connection conductor to the fixing body,
wherein the fixing body has two or more fixing holes that pass
through a fixing body first surface and a fixing body second
surface opposite to the fixing body first surface, the fixing
member includes a main body having an opposed surface that faces
the fixing body first surface and that clamps, with the fixing body
first surface, part of the at least one connection conductor
disposed between the opposed surface and the fixing body first
surface, and fixing legs that protrude from the opposed surface,
that are associated with the respective fixing holes, and that have
the part of the at least one connection conductor interposed
between the fixing legs, and the fixing legs are capable of plastic
deformation by an external force, are inserted in the respective
fixing holes from a side of the fixing body first surface to
protrude from a side of the fixing body second surface, and, under
a fixed condition in which the at least one connection conductor is
fixed to the fixing body by the fixing member, have leading ends
disposed on an outside in a radial direction with respect to the
fixing holes as viewed in an axial direction of the fixing
holes.
[0008] According to another aspect of the present invention, in the
conductor module, the at least one connection conductor may include
at least one connection conductor having through holes that pass
through a conductor first surface and a conductor second surface
opposite to the conductor first surface and that are associated
with the respective fixing holes, and the fixing legs are inserted
in the through holes and the fixing holes under the fixed
condition.
[0009] According to still another aspect of the present invention,
in the conductor module, the at least one connection conductor may
include a first connection conductor, and a second connection
conductor different from the first connection conductor, and the
second connection conductor is fixed, using the fixing member that
fixes the first connection conductor, to the fixing body that is
identical to the fixing body to which the first connection
conductor is fixed.
[0010] According to still another aspect of the present invention,
in the conductor module, the connection target may be a battery
cell, and the conductor module may further include a status
detector including a detection conductor that electrically connects
the second connection conductor with a status detection unit that
detects a status of the battery cell with which the second
connection conductor is electrically connected.
[0011] The above and other objects, features, advantages and
technical and industrial significance of this invention will be
better understood by reading the following detailed description of
presently preferred embodiment of the invention, when considered in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a conductor module in an
embodiment;
[0013] FIG. 2 is a perspective view of the conductor module in the
embodiment;
[0014] FIG. 3 is an exploded perspective view of the conductor
module in the embodiment;
[0015] FIG. 4 is a cross-sectional view of the conductor module in
the embodiment; and
[0016] FIG. 5 is a cross-sectional view of the conductor module in
the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The following details a conductor module according to an
embodiment. It is noted that the embodiment is not intended to
limit the scope of the invention. The elements of the embodiment
include elements that can be replaced by, and readily apparent to,
those skilled in the art, or elements that are substantially
identical.
EMBODIMENT
[0018] The following describes a conductor module according to an
embodiment. FIG. 1 is a perspective view of the conductor module
according to the embodiment. FIG. 2 is a perspective view of the
conductor module in the embodiment. FIG. 3 is an exploded
perspective view of the conductor module in the embodiment. FIG. 4
is a cross-sectional view of the conductor module in the
embodiment. FIG. 5 is a cross-sectional view of the conductor
module in the embodiment. It is here noted that FIG. 4 is a
cross-sectional view taken along line A-A in FIG. 1 and FIG. 5 is a
cross-sectional view taken along line B-B in FIG. 1. It should
further be noted that, in each of the drawings, the X-direction
extends in an array direction along which electrode terminals and
connection conductors are arrayed in the embodiment. The
Y-direction is a width direction of the conductor module in the
embodiment and is orthogonal to the array direction. The
Z-direction is a vertical direction in the conductor module and is
orthogonal to the array direction and the width direction.
[0019] This conductor module 1 in the embodiment is to be
assembled, as illustrated in FIG. 1, with a battery module 100. The
battery module 100 has a modular configuration that includes, for
example, a plurality of battery cells 101, such as secondary
batteries, arrayed in the array direction. The battery module 100
is mounted on, for example, an electric vehicle (EV) or a hybrid
vehicle (HV, PHV) and used for supplying an electric rotating
machine as a drive source with electric power and storing
(charging) the electric power generated by the electric rotating
machine. The battery module 100, for example, includes a plurality
of battery cells 101 connected in series with each other to thereby
enable a high battery output corresponding with output requirements
of the vehicle to be obtained. The battery cells 101 are composed
of two rows of electrode terminal groups 103 that are spaced apart
from each other in the width direction and that include electrode
terminals 102 (a positive electrode terminal and a negative
electrode terminal) disposed on respective ends in the width
direction. The electrode terminal groups 103 are each composed of a
plurality of electrode terminals 102 arrayed in the array direction
in the battery module 100. In the battery module 100, one conductor
module 1 is associated and assembled with each of the electrode
terminal groups 103 and the conductor module 1 connects the
electrode terminals 102 (the positive electrode terminals and the
negative electrode terminals) of the battery cells 101 in series
with each other. The battery cells 101 in the embodiment are
disposed such that the electrode terminal 102 of a first battery
cell 101 has polarity opposite to polarity of the electrode
terminal 102 of a second battery cell 101 adjacent to the first
battery cell 101 in the array direction. In addition, the two
electrode terminal groups 103 are configured as follows.
Specifically, in a first electrode terminal group 103, the
electrode terminal 102 on a first end out of both ends in the array
direction is defined as a terminating electrode terminal and, in a
second electrode terminal group 103, the electrode terminal 102 on
a second end out of both ends in the array direction is defined as
a terminating electrode terminal having polarity opposite to
polarity of the terminating electrode terminal of the first
electrode terminal group 103. The two terminating electrode
terminals are electrically connected with each other by, for
example, an inverter. This establishes an electrical connection of
the battery module 100 with an external device.
[0020] The conductor module 1 is to connect at least a plurality of
battery cells 101 in series with each other. As illustrated in
FIGS. 1 to 5, the conductor module 1 includes a busbar 2, a power
cable terminal 3, an accommodation case 4, a fixing member 5, a
fixing member 6, a detection terminal 7, a status detector 8, and a
power cable 9. The conductor module 1 electrically connects the
busbar 2, the power cable terminal 3, and the detection terminal 7
with the electrode terminal 102 as a connection target.
[0021] The busbar 2 is a connection conductor. As illustrated in
FIGS. 1 to 5, the busbar 2 is electrically connected with a first
one of the two electrode terminals 102 of the battery cell 101. In
the embodiment, the busbar 2 constitutes a first connection
conductor. The busbar 2 is directly and electrically connected with
two electrode terminals 102 that are adjacent to each other in the
array direction and that have polarities opposite to each other in
the two battery cells 101 that are adjacent to each other in the
array direction of the electrode terminal group 103 in one row. The
busbar 2 is formed of an electrically conductive material, such as
metal, into a flat plate shape. In the embodiment, the busbar 2 is
formed into a rectangular plate shape having a longitudinal
direction extending in the array direction as viewed in the
vertical direction. The busbar 2 has terminal holes 21 and through
holes 22.
[0022] The electrode terminals 102 are inserted in the terminal
holes 21. The terminal holes 21 each pass through from a conductor
first surface 2a to a conductor second surface 2b that are opposed
to each other in the vertical direction. In the embodiment, the
busbar 2 has two terminal holes 21 associated with respective two
electrode terminals 102 that are to be connected with the busbar 2.
The two terminal holes 21 are spaced apart from each other in the
array direction. It is noted that the busbar 2 is fixed to the
electrode terminals 102 as follows. Specifically, for example,
under a condition in which the electrode terminals 102 are inserted
in the terminal holes 21 in the busbar 2, nuts not illustrated are
threadedly engaged with thread grooves in leading ends of the
electrode terminals 102 protruding from the side of the conductor
first surfaces 2a of the terminal holes 21.
[0023] Fixing legs 52 to be described later of the fixing member 5
are inserted in the through holes 22. The through holes 22 each
pass through from the conductor first surface 2a to the conductor
second surface 2b that are opposed to each other in the vertical
direction. In the embodiment, the busbar 2 has two through holes 22
associated with respective two fixing holes 43 to be described
later. The through holes 22 are spaced apart from each other in the
array direction. It is noted that the two through holes 22 are
formed across part of the detection terminal 7 disposed on the
busbar 2 in the array direction. Additionally, the two through
holes 22 are disposed, in the width direction, on the side closer
to a third accommodation space 4c to be described later than the
terminal holes 21 are.
[0024] The power cable terminal 3 is a connection conductor. As
illustrated in FIGS. 1 to 5, the power cable terminal 3 is
electrically connected with a first one of the two electrode
terminals 102 of the battery cell 101. In the embodiment, the power
cable terminal 3 constitutes a third connection conductor that is
different from the busbar 2 as the first connection conductor and
the detection terminal 7 as a second connection conductor. The
power cable terminal 3 is directly and electrically connected with
the terminating electrode terminal out of the electrode terminals
102 of the electrode terminal group 103. The power cable terminal 3
is formed of an electrically conductive material, such as metal,
into a flat plate shape. In the embodiment, the power cable
terminal 3 is formed into a rectangular plate shape having a
longitudinal direction extending in the width direction as viewed
in the vertical direction. The power cable terminal 3 is attached
to a first end of the power cable 9. The power cable terminal 3
includes a contact portion 31 and a barrel portion 32 and has a
terminal hole 33.
[0025] The contact portion 31 contacts the electrode terminal 102
as a terminating electrode terminal. The contact portion 31 has an
end on the side adjacent to the power cable 9 in the width
direction connected with the barrel portion 32. The terminal hole
33 is formed at a position near an end of the contact portion 31
opposite to the barrel portion 32.
[0026] The barrel portion 32 is directly and electrically connected
with the power cable 9. The power cable 9 establishes an electrical
connection between the battery module 100 and an external device.
Power conductors 91 are electrically conductive and deformable. The
power conductor 91 is composed of a plurality of wires formed of,
for example, copper or aluminum, stranded together. An insulator 92
is electrically insulative and covers the power conductors 91. The
insulator 92 is elastically deformable and formed of, for example,
a synthetic resin. The barrel portion 32 includes crimped portions
32a and 32b that protrude from both ends in the width direction to
a side opposite in the vertical direction to the side of a bottom
plate 41 to be described later of the accommodation case 4. The
barrel portion 32 is curved such that the crimped portions 32a and
32b have leading ends approaching each other to thereby crimp the
power conductors 91 to the power cable terminal 3.
[0027] The terminal hole 33 receives the electrode terminal 102 as
the terminating electrode terminal inserted therein. The terminal
hole 33 passes through from a conductor first surface 3a to a
conductor second surface 3b that are opposed to each other in the
vertical direction. It is noted that the power cable terminal 3 is
fixed to the electrode terminal 102 as follows. Specifically, for
example, under a condition in which the electrode terminal 102 is
inserted in the terminal hole 33 in the power cable terminal 3, a
nut not illustrated is threadedly engaged with thread grooves in a
leading end of the electrode terminal 102 protruding from the side
of the conductor first surface 3a of the terminal hole 33.
[0028] The accommodation case 4 is a fixing body to which the
busbar 2, the power cable terminal 3, and the detection terminal 7
are fixed as illustrated in FIGS. 1 to 5. Specifically, the busbar
2, the power cable terminal 3, and the detection terminal 7 are
fixed to the same accommodation case 4 by the fixing members 5 and
6. The accommodation case 4 is electrically insulative and formed
of, for example, a synthetic resin. The accommodation case 4
includes the bottom plate 41 and a frame plate 42 and has the
fixing holes 43 and fixing holes 44.
[0029] The bottom plate 41 has a flat plate shape. The bottom plate
41 has a fixing body first surface 41a and a fixing body second
surface 41b that are opposed to each other in the vertical
direction. At least the busbar 2, the power cable terminal 3, and
the detection terminal 7 are disposed on the fixing body first
surface 41a.
[0030] The frame plate 42 defines a plurality of spaces in the
accommodation case 4 and is erected from the fixing body first
surface 41a of the bottom plate 41. In the embodiment, the frame
plate 42 is formed mainly along an outer periphery of the bottom
plate 41 to thereby define a first accommodation space 4a, a second
accommodation space 4b, and the third accommodation space 4c in the
accommodation case 4. The first accommodation space 4a accommodates
the busbar 2 and the detection terminal 7. The first accommodation
space 4a has an opening 4d that passes through from the fixing body
first surface 41a to the fixing body second surface 41b. It is
noted that the opening 4d is formed so that the terminal holes 21
are exposed to the outside of the accommodation case 4 under a
condition in which the busbar 2 is accommodated in the first
accommodation space 4a. The second accommodation space 4b
accommodates the power cable terminal 3 and is formed to be
adjacent to the first accommodation space 4a in the array
direction. The second accommodation space 4b has an opening 4e that
passes through from the fixing body first surface 41a to the fixing
body second surface 41b. The opening 4e is formed so that the
terminal hole 33 is exposed to the outside of the accommodation
case 4 under a condition in which the power cable terminal 3 is
accommodated in the second accommodation space 4b. The third
accommodation space 4c accommodates, for example, the status
detector 8 and is formed to be adjacent to the first accommodation
space 4a and the second accommodation space 4b in the width
direction. In the embodiment, the third accommodation space 4c
communicates with the first accommodation space 4a and the second
accommodation space 4b in the width direction and communicates with
the outside in the array direction.
[0031] The fixing legs 52 are to be inserted in the fixing holes
43. The fixing holes 43 pass through a portion constituting the
first accommodation space 4a of the bottom plate 41 from the fixing
body first surface 41a to the fixing body second surface 41b. In
the embodiment, two fixing holes 43 are formed to be spaced apart
in the array direction from each other in the first accommodation
space 4a. It is here noted that the two fixing holes 43 are formed
across part of the detection terminal 7 disposed on the busbar 2 in
the array direction. Additionally, the two fixing holes 43 are
disposed, in the width direction, on the side closer to the third
accommodation space 4c than the opening 4d is.
[0032] Fixing legs 62 are to be inserted in the fixing holes 44.
The fixing holes 44 pass through a portion constituting the second
accommodation space 4b of the bottom plate 41 from the fixing body
first surface 41a to the fixing body second surface 41b. In the
embodiment, two fixing holes 44 are formed to be spaced apart in
the array direction from each other in the second accommodation
space 4b. It is here noted that the two fixing holes 44 are formed
across part of the power cable terminal 3, specifically in the
embodiment, the contact portion 31 in the array direction.
Additionally, the two fixing holes 44 are disposed, in the width
direction, on the side closer to the third accommodation space 4c
than the opening 4e is.
[0033] As illustrated in FIGS. 1 to 5, the fixing member 5
integrally fixes the busbar 2 and the detection terminal 7 to the
accommodation case 4. The fixing member 5 is thermoplastic and
formed of, for example, a synthetic resin. Specifically, the fixing
member 5 is capable of plastic deformation by being heated and
subjected to external force acting thereon. The fixing member 5
includes a main body 51 and the fixing legs 52.
[0034] Part of the busbar 2 and the detection terminal 7 are
sandwiched in the vertical direction between the main body 51 and
the fixing body first surface 41a. The detection terminal 7
contacts the main body 51. In the embodiment, the main body 51 has
a substantially flat plate shape having a longitudinal direction
extending in the array direction when viewed in the vertical
direction. The main body 51 is formed into an arcuate shape curved
toward the side of the third accommodation space 4c in the width
direction. The main body 51 has an opposed surface 51a that faces
the conductor first surface 2a and a conductor first surface 7a to
be described later. The opposed surface 51a is formed such that,
under a fixed condition in which the fixing member 5 fixes the
busbar 2 and the detection terminal 7 to the accommodation case 4,
portions thereof between respective both ends and a center in the
array direction are in contact with the conductor first surface 7a,
resulting in the part of the busbar 2 and the detection terminal 7
being sandwiched between the opposed surface 51a and the fixing
body first surface 41a. The main body 51 is formed to have the
center in the array direction protruding toward a side opposite to
the conductor first surface 7a in the vertical direction and is
formed such that a portion of the opposed surface 51a facing the
protruding portion in the vertical direction is spaced away from
the conductor first surface 7a. Specifically, the main body 51 has
a status detector inserting space 51b (hereinafter referred to
simply as a "space 51b") defined by the opposed surface 51a and the
conductor first surface 7a at the center in the array direction.
The space 51b is formed into a substantially semi-arcuate shape as
viewed in the width direction and communicates with the outside in
the width direction. When viewed in the vertical direction, the
main body 51 is formed to cover part of the detection terminal 7
via the busbar 2 disposed on the fixing body first surface 41a,
specifically in the embodiment, part of a barrel portion 72 to be
described later.
[0035] The fixing legs 52 are inserted in the fixing holes 43 and,
under the fixed condition, are restricted from being pulled out of
the fixing holes 43. The fixing legs 52 are formed to protrude from
the opposed surface 51a of the main body 51 toward the side of the
fixing body first surface 41a in the vertical direction. In the
embodiment, two fixing legs 52 are formed to be associated with the
respective fixing holes 43 in the accommodation case 4. The fixing
legs 52 are formed to be spaced away from each other in the array
direction. Under the fixed condition, part of the detection
terminal 7 is disposed between the two fixing legs 52. The fixing
legs 52 are inserted in the through holes 22 in the busbar 2 from
the side of the conductor first surface 2a and further inserted in
the fixing holes 43 from the side of the fixing body first surface
41a, to thereby have leading ends 52a protruding to the side of the
fixing body second surface 41b. The fixing legs 52, before being
fixed in place, specifically, before the external force acts
thereon with heat being applied at the same time, are formed into
cylindrical shapes including the leading ends 52a as illustrated in
FIG. 3. The fixing legs 52 each have a length in the vertical
direction set to be longer than a total depth in the vertical
direction of the through holes 22 and the fixing holes 43. The
fixing legs 52 are formed, under the fixed condition, so as to have
the leading ends 52a disposed on the outside in a radial direction
with respect to the fixing holes 43 when viewed in an axial
direction of the fixing holes 43, specifically, when viewed in the
vertical direction. In the embodiment, the fixing legs 52 are each
formed such that, under the fixed condition, the leading end 52a is
formed into a hemispherical shape having a circumference of a
diameter greater than a diameter of the fixing hole 43 when viewed
in the vertical direction as illustrated in FIG. 4. Specifically,
each of the leading ends 52a is disposed, when viewed in the
vertical direction, so as to surround the circumference of the
fixing hole 43.
[0036] As illustrated in FIGS. 1 to 5, the fixing member 6 fixes
the power cable terminal 3 to the accommodation case 4. The fixing
member 6 is thermoplastic and is formed of, for example, a
synthetic resin. Specifically, the fixing member 6 is capable of
plastic deformation by being heated and subjected to external force
acting thereon. The fixing member 6 includes a main body 61 and the
fixing legs 62. The fixing member 6 has a basic configuration
identical to a basic configuration of the fixing member 5.
[0037] Part of the power cable terminal 3 is sandwiched in the
vertical direction between the main body 61 and the fixing body
first surface 41a. The power cable terminal 3 contacts the main
body 61. In the embodiment, the main body 61 has a substantially
flat plate shape. When viewed in the vertical direction, the main
body 61 has a substantially rhombic shape having a longitudinal
direction extending in the array direction. The main body 61 has an
opposed surface 61a that faces the conductor first surface 3a. The
opposed surface 61a is formed such that, under a fixed condition in
which the fixing member 6 fixes the power cable terminal 3 to the
accommodation case 4, portions thereof near respective both ends in
the array direction are in contact with the conductor first surface
3a, resulting in the part of the power cable terminal 3 being
sandwiched between the opposed surface 61a and the fixing body
first surface 41a. The main body 61 is formed to have a center in
the array direction protruding toward a side opposite to the
conductor first surface 3a in the vertical direction and is formed
such that a portion of the opposed surface 61a facing the
protruding portion in the vertical direction is spaced away from
the conductor first surface 3a. Specifically, the main body 61 has
a status detector inserting space 61b (hereinafter referred to
simply as a "space 61b") defined by the opposed surface 61a and the
conductor first surface 3a at the center in the array direction.
The space 61b is formed into a substantially semi-arcuate shape as
viewed in the width direction and communicates with the outside in
the width direction. When viewed in the vertical direction, the
main body 61 is formed to cover part of the contact portion 31 of
the power cable terminal 3 disposed on the fixing body first
surface 41a.
[0038] The fixing legs 62 are inserted in the fixing holes 44 and,
under the fixed condition, are restricted from being pulled out of
the fixing holes 44. The fixing legs 62 are formed to protrude from
the opposed surface 61a of the main body 61 toward the side of the
fixing body first surface 41a in the vertical direction. In the
embodiment, two fixing legs 62 are formed to be associated with the
respective fixing holes 44 in the accommodation case 4. The fixing
legs 62 are formed to be spaced away from each other in the array
direction. Under the fixed condition, part of the power cable
terminal 3 is disposed between the two fixing legs 62. The fixing
legs 62 are inserted in the fixing holes 44 from the side of the
fixing body first surface 41a, to thereby have leading ends 62a
protruding to the side of the fixing body second surface 41b. The
fixing legs 62, before being fixed in place, specifically, before
the external force acts thereon with heat being applied at the same
time, are formed into cylindrical shapes including the leading ends
62a as illustrated in FIG. 3. The fixing legs 62 each have a length
in the vertical direction set to be longer than a depth in the
vertical direction of the fixing holes 44. The fixing legs 62 are
formed, under the fixed condition, so as to have the leading ends
62a disposed on the outside in a radial direction with respect to
the fixing holes 44 when viewed in an axial direction of the fixing
holes 44, specifically, when viewed in the vertical direction. In
the embodiment, the fixing legs 62 are each formed such that, under
the fixed condition, the leading end 62a is formed into a
hemispherical shape having a circumference of a diameter greater
than a diameter of the fixing hole 44 when viewed in the vertical
direction as illustrated in FIG. 5. Specifically, each of the
leading ends 62a is disposed, when viewed in the vertical
direction, so as to surround the circumference of the fixing hole
44.
[0039] The detection terminal 7 is a connection conductor. As
illustrated in FIGS. 1 to 5, the detection terminal 7 is
electrically connected with one of the two electrode terminals 102
of the battery cell 101. In the embodiment, the detection terminal
7 is a second connection conductor different from the busbar 2 as
the first connection conductor. The detection terminal 7 is
directly and electrically connected with one of the two electrode
terminals 102 with which the busbar 2 is directly and electrically
connected. The detection terminal 7 is formed of an electrically
conductive material, such as metal, into a flat plate shape. In the
embodiment, the detection terminal 7 is formed, when viewed in the
vertical direction, into a plate shape having a longitudinal
direction extending in the width direction and having a width in
the array direction narrower on the side of the third accommodation
space 4c than on the side of the first accommodation space 4a. The
detection terminal 7 is attached with a first end of the status
detector 8 and includes a contact portion 71 and the barrel portion
72 and has a terminal hole 73.
[0040] The contact portion 71 contacts the electrode terminal 102.
The contact portion 71 has a first end in the width direction on
the side of the power cable 9 connected with the barrel portion 72.
The terminal hole 73 is formed at a position near a second end
opposite to the first end.
[0041] The barrel portion 72 is directly and electrically connected
with the status detector 8. The barrel portion 72 includes a pair
of insulator crimping portions 72a and 72b and a pair of conductor
crimping portions 72c and 72d, the pairs formed on respective ends
in the width direction. The pair of insulator crimping portions 72a
and 72b and the pair of conductor crimping portions 72c and 72d
protrude to the side opposite to the bottom plate 41 in the
vertical direction. The pair of insulator crimping portions 72a and
72b is formed on the side closer to the third accommodation space
4c in the width direction with respect to the pair of conductor
crimping portions 72c and 72d. In the barrel portion 72, the
insulator crimping portions 72a and 72b have leading ends curved to
approach each other to thereby crimp an insulator 82 to be
described later of the status detector 8 onto the detection
terminal 7 and the conductor crimping portions 72c and 72d have
leading ends curved to approach each other to thereby crimp a
detection conductor 81 to be described later of the status detector
8 onto the detection terminal 7.
[0042] The terminal hole 73 receives the electrode terminal 102 as
a terminating electrode terminal inserted therein. The terminal
hole 73 passes through from the conductor first surface 7a to a
conductor second surface 7b that are opposed to each other in the
vertical direction. It is noted that the detection terminal 7 is
fixed to the electrode terminal 102 together with the busbar 2 as
follows. Specifically, for example, under a condition in which the
electrode terminal 102 is inserted in the terminal hole 73, a nut
not illustrated is threadedly engaged with thread grooves in the
leading end of the electrode terminal 102 protruding from the side
of the conductor first surface 7a of the terminal hole 73.
[0043] The status detector 8 electrically connects the electrode
terminal 102 with a battery module monitoring unit 200 via the
detection terminal 7 as illustrated in FIGS. 1 to 5. Specifically,
the conductor module 1 detects via the status detector 8 a status
of the battery cell 101 connected with the detection terminal 7,
specifically in the embodiment, voltage information and outputs the
voltage information to the battery module monitoring unit 200. The
battery module monitoring unit 200 represents a status detection
device detecting the status of each battery cell 101. The battery
module monitoring unit 200, for example, monitors the status of
each battery cell 101 using the voltage information and notifies an
operator who detects a fault in the battery cell 101 of a fault.
Additionally, the battery module monitoring unit 200 can output the
acquired voltage information to a battery ECU that controls the
battery module 100. The battery ECU performs charge and discharge
control of the battery module 100 on the basis of the voltage
information. The status detector 8 includes the detection conductor
81 and the insulator 82. In the embodiment, the status detector 8
is a wire corresponding to the busbar 2 and is integrally molded so
as to cover the detection conductor 81 in the insulator 82.
[0044] The detection conductor 81 electrically connects the
detection terminal 7 with the battery module monitoring unit 200.
The detection conductor 81 is electrically conductive and
deformable and is composed of a plurality of wires formed of, for
example, copper or aluminum, stranded together. The detection
conductor 81 has a first end directly and electrically connected
with the conductor first surface 7a and a second end electrically
connected with the battery module monitoring unit 200 via a
connector not illustrated. Part of the insulator 82 covering the
first end of the detection conductor 81 is peeled off in advance to
cause the first end of the detection conductor 81 to be exposed to
the outside from a leading end of the insulator 82.
[0045] The insulator 82 covers the detection conductor 81. The
insulator 82 is electrically insulative and elastically deformable.
The insulator 82 is formed of, for example, a synthetic resin. The
insulator 82 is formed to extend in the array direction. The
insulator 82 is bent from the array direction in the width
direction and disposed on the conductor first surface 7a.
[0046] The following describes an assembly procedure for the
conductor module 1. It is noted that the following assembly
procedure assumes that the power cable 9 is electrically connected
with the power cable terminal 3 in advance and that the detection
terminal 7 is electrically connected with the status detector 8 in
advance. As illustrated in FIG. 3, an assembly operator first
disposes the busbar 2 with respect to the accommodation case 4 such
that the conductor second surface 2b faces the fixing body first
surface 41a in the first accommodation space 4a and such that the
through holes 22 in the busbar 2 are aligned with the respective
fixing holes 43 in the vertical direction. The assembly operator
brings the busbar 2 near to the accommodation case 4, causing the
conductor second surface 2b to be in contact with the fixing body
first surface 41a. At this time, the through holes 22 communicate
with the respective fixing holes 43. The assembly operator next
places the detection terminal 7 on the conductor first surface 2a
of the busbar 2 so that part of the detection terminal 7 is
disposed between the through holes 22. At this time, the detection
terminal 7 is accommodated in the first accommodation space 4a and
the status detector 8 is accommodated in the third accommodation
space 4c. The assembly operator then disposes the fixing member 5
with respect to the busbar 2 such that the opposed surface 51a
faces the conductor first surface 2a and such that the fixing legs
52 of the fixing member 5 are aligned with the respective through
holes 22 in the busbar 2 in the vertical direction. At this time,
the conductor first surface 7a of the detection terminal 7 placed
on the conductor first surface 2a of the busbar 2 faces the opposed
surface 51a. The assembly operator then brings the fixing member 5
close to the busbar 2 in the vertical direction. At this time, the
fixing legs 52 are inserted in the respective through holes 22 from
the conductor first surface 2a side and into the respective fixing
holes 43, thus protruding from the fixing body second surface 41b
side. Additionally, the main body 51 contacts the detection
terminal 7 under a condition in which the main body 51 presses the
detection terminal 7 and the busbar 2 against the fixing body first
surface 41a. Next, the power cable terminal 3 and the accommodation
case 4 are disposed such that the power cable terminal 3 is
disposed between the fixing holes 44 and such that the conductor
second surface 3b faces the fixing body first surface 41a in the
second accommodation space 4b. Next, the assembly operator brings
the power cable terminal 3 close to the accommodation case 4 so
that the conductor second surface 3b contacts the fixing body first
surface 41a. Then, the assembly operator disposes the fixing member
6 with respect to the accommodation case 4 such that the opposed
surface 61a faces the fixing body first surface 41a and such that
the fixing legs 62 of the fixing member 6 are aligned with the
respective fixing holes 44 in the vertical direction. Then, the
assembly operator brings the fixing member 6 close to the
accommodation case 4 in the vertical direction. At this time, the
fixing legs 62 are inserted in the respective fixing holes 44 from
the fixing body first surface 41a side and protrude from the fixing
body second surface 41b side. Additionally, the main body 61
contacts the power cable terminal 3 under a condition in which the
main body 61 presses the power cable terminal 3 against the fixing
body first surface 41a. Then, the assembly operator applies
external force toward the accommodation case 4 side in the vertical
direction, while heating the fixing legs 52 and 62 protruding from
the fixing body second surface 41b of the accommodation case 4. For
example, under a condition in which a mold having formed therein in
advance a transfer surface identical to shapes of the leading ends
52a and 62a under the fixed condition is heated, the assembly
operator presses the leading ends 52a and 62a before the fixed
condition toward the accommodation case 4 side in the vertical
direction. The foregoing step causes the leading ends 52a and 62a
of the fixing legs 52 and 62 to be elastically deformed so as to
surround the circumferences of the fixing holes 43 and 44. When
cooled thereafter, the leading ends 52a and 62a maintain the
deformed conditions at room temperature. The electrode terminals
102 are then inserted in the terminal holes, 21, 33, and 73 exposed
outside the accommodation case 4 through the openings 4d, 4e, and
are electrically connected with the busbar 2, the power cable
terminal 3, and the detection terminal 7, respectively, to thereby
assemble the conductor module 1 with the battery module 100. This
completes the assembly of the conductor module 1 and the fixed
condition is achieved in which the busbar 2, the power cable
terminal 3, and the detection terminal 7 are fixed to the
accommodation case 4 by the fixing members 5 and 6.
[0047] As described above, the conductor module 1 in the embodiment
incorporates the fixing members 5 and 6 to fix the busbar 2, the
power cable terminal 3, and the detection terminal 7 to the
accommodation case 4 under the fixed condition. Specifically, the
conductor module 1 fixes the busbar 2, the power cable terminal 3,
and the detection terminal 7 to the accommodation case 4 using
another element instead of the accommodation case 4. Thus, when the
busbar 2, the power cable terminal 3, and the detection terminal 7
are to be fixed by the accommodation case 4, the accommodation case
4 does not require a function to fix the busbar 2, the power cable
terminal 3, and the detection terminal 7. Thus, the conductor
module 1 is required only to form, in the accommodation case 4, a
space (the first accommodation space 4a and the second
accommodation space 4b) having a total length in the vertical
direction of the connection conductors (the busbar 2, the power
cable terminal 3, and the detection terminal 7) and the fixing
members 5 and 6, so that reduction in height of the accommodation
case 4 can be promoted. The foregoing feature enables the conductor
module 1 to achieve reduction in size.
[0048] In the conductor module 1 in the embodiment, the busbar 2 is
fixed by the fixing member 5 to the accommodation case 4 under a
condition in which the fixing legs 52 are inserted in the
respective through holes 22 in the busbar 2. Thus, the conductor
module 1 enables the busbar 2 to be reliably fixed to the
accommodation case 4, compared with a case in which the busbar 2 is
fixed to the accommodation case 4 by the fixing member 5 through
part of the busbar 2 being simply sandwiched between the fixing
legs 52. In addition, the busbar 2 can be restricted from moving
relative to the accommodation case 4 in the array direction and the
width direction, so that the busbar 2 can be reliably positioned
with respect to the accommodation case 4.
[0049] In the conductor module 1 in the embodiment, the busbar 2
and the detection terminal 7 are simultaneously fixed to the
accommodation case 4 by the fixing member 5. Thus, the conductor
module 1 enables a plurality of different connection conductors
laminated one on top of another to be fixed to the accommodation
case 4 by a single fixing member 5. Thus, the conductor module 1
enables a greater number of connection conductors 2, 3, and 7 to be
fixed to the accommodation case 4 by a smaller number of fixing
members 5 and 6.
[0050] In the conductor module 1 in the embodiment, the busbar 2
and the detection terminal 7 to be fixed to a single electrode
terminal 102 are fixed to the accommodation case 4 by a single
fixing member 5. This arrangement enables the busbar 2 and the
detection terminal 7 fixed to the accommodation case 4 to establish
an electrical connection with an adjacent electrode terminal 102
and to establish an electrical connection between the electrode
terminal 102 and the battery module monitoring unit 200.
[0051] The conductor module 1 in the embodiment has been described
for a case in which one set of the busbar 2 and the detection
terminal 7 is accommodated in the accommodation case 4. The case is
nonetheless illustrative only and not limiting. The accommodation
case 4 may include a plurality of first accommodation spaces 4a
defined therein and arrayed in the array direction. Each of the
first accommodation spaces 4a then may accommodate a busbar 2 and a
detection terminal 7, and the busbar 2 and the detection terminal 7
may then be fixed to the accommodation case 4 by the fixing member
5.
[0052] The conductor module 1 in the embodiment has been described
for a case in which the busbar 2 and the detection terminal 7 are
fixed to the accommodation case 4 by the fixing member 5. The case
is nonetheless illustrative only and not limiting. The first
accommodation space 4a may accommodate only the busbar 2, and only
the busbar 2 may then be fixed to the accommodation case 4 by the
fixing member 5. In this case, the opposed surface 51a of the
fixing member 5 contacts the conductor first surface 2a of the
busbar 2.
[0053] In the conductor module 1 in the embodiment, the fixing
members 5 and 6 have been each described to be formed of a
synthetic resin capable of plastic deformation by external force.
The material is nonetheless illustrative only and not limiting.
Metal capable of plastic deformation, such as aluminum or iron
having electrical conductivity, may be used to form the fixing
members 5 and 6. In this case, the fixing legs 52 and 62 are each
bent in directions to approach each other as viewed in the width
direction under the fixed condition, to thereby contact the fixing
body second surface 41b. Specifically, the fixing legs 52 and 62
may have the respective leading ends 52a and 62a bent inwardly.
[0054] In the conductor module 1 in the embodiment, the
accommodation case 4 has been described as the fixing body. The
arrangement is, however, illustrative only and not limiting, and a
flexible flat cable (FFC) or a flexible printed wiring board (FPC)
may be used.
[0055] The conductor module in the aspect of the present embodiment
includes the fixing member to fix the connection conductor to the
fixing body. Thus, the fixing body does not require a function to
fix the busbar. The aspect of the present embodiment can thus
achieve an effect of promoting reduction in size.
[0056] Although the invention has been described with respect to
the specific embodiment for a complete and clear disclosure, the
appended claims are not to be thus limited but are to be construed
as embodying all modifications and alternative constructions that
may occur to one skilled in the art that fairly fall within the
basic teaching herein set forth.
* * * * *