CN110707273B

CN110707273B - Protector and bus bar module

Info

Publication number: CN110707273B
Application number: CN201910602927.5A
Authority: CN
Inventors: 市川喜章; 牧野公利; 小林真人; 安田知司; 高松昌博
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 2018-07-10
Filing date: 2019-07-05
Publication date: 2022-06-28
Anticipated expiration: 2039-07-05
Also published as: JP2020013765A; JP6793690B2; JP6793691B2; JP2020013767A; CN110707273A; CN110707274B; JP2020013969A; JP6691178B2; JP6865722B2; JP2020013766A; JP2020014369A; CN110707274A; JP6883548B2

Abstract

A protector is configured to protect a strip-shaped flexible board provided with a wiring pattern. The protector includes: a first accommodating portion configured to accommodate a flexible board in a slidable manner in a length direction of the flexible board; a second accommodating portion configured to accommodate the flexible board at a position different from the first accommodating portion in a length direction; and a bendable coupling part connecting between the first receiving part and the second receiving part. The coupling portion is configured to allow deformation of the flexible board in a direction away from the coupling portion when the flexible board slides in a longitudinal direction with respect to the first receiving portion in a state where the coupling portion is bent.

Description

Protector and bus bar module

Technical Field

The present invention relates to a protector and a bus bar module using the same.

Background

Generally, a flexible board (FPC: flexible printed circuit board) provided with a wiring pattern is used as a wiring for connecting various electronic devices (for example, refer to patent document 1). The flexible board generally has a structure in which a thin film conductive layer constituting a wiring pattern (i.e., a circuit) of a prescribed form is sandwiched between insulating films, and is characterized by being capable of flexible deformation such as bending while maintaining electrical characteristics, in particular.

In some cases, a protector is installed to cover the flexible board in order to protect the flexible board. In these examples, for example, when the connector is mounted to the terminal portion of the flexible board and the connector is connected to an external device or the like, there are cases where the deformable range of the flexible board is limited because the protector covers the flexible board and it makes handling of the flexible board difficult.

Disclosure of Invention

The present invention has been made in view of the above circumstances, and an object thereof is to provide a protector and a bus bar module that minimize damage to the ease of handling a flexible board.

To achieve the above object, a protector and a bus bar module according to the present invention are characterized by the following [1] to [4 ]:

[1] a protector configured to protect a strip-shaped flexible board provided with a wiring pattern, the protector comprising:

a first accommodating portion configured to accommodate the flexible board in a slidable manner in a longitudinal direction of the flexible board;

a second accommodating portion configured to accommodate the flexible board at a position different from the first accommodating portion in the length direction; and

a bendable coupling part connecting between the first receiving part and the second receiving part,

Wherein the coupling portion is configured such that, when the flexible board slides in the longitudinal direction with respect to the first accommodating portion in a state in which the coupling portion is bent, deformation of the flexible board in a direction away from the coupling portion is permitted.

[2] The protector according to the above-mentioned item [1],

the coupling portion is configured to cover a plate surface of one side in a thickness direction of the flexible board between the first accommodating portion and the second accommodating portion, and is configured to expose a plate surface of the other side in the thickness direction of the flexible board to the outside.

[3] A bus bar module configured to be mounted to a battery assembly having a plurality of electric cells combined with each other in a first direction, the bus bar module comprising:

a bus bar configured to be connected to an electrode of each of the unit cells;

a circuit body configured by a belt-shaped flexible board on which a wiring pattern for connecting the bus bar and an external device is configured;

a bracket configured to support the bus bar and to be retractable in the first direction; and

the protector according to [1] or [2] above, wherein the first accommodating portion accommodates the circuit body extending from the bracket to the external device and the second accommodating portion is fixed to the bracket.

[4] The bus bar module according to the above [3], further comprising:

a cover mounted to the bracket,

wherein the protector is configured such that the first accommodating portion can be fixed to the cover in a state where the coupling portion is bent.

According to the protector of the above structure [1], when the flexible board slides with respect to the first accommodating portion in a state where the coupling portion is bent, deformation of the flexible board is not impaired by the flexible board being deformed in a direction away from the coupling portion. Therefore, handling of the flexible board can be made as easy as possible.

According to the protector of the above configuration [2], the coupling portion is configured such that one of the two plate surfaces (the plate surface on the other side) in the thickness direction of the flexible plate is exposed to the outside. In other words, the coupling portion is configured to be on one side in the thickness direction of the flexible board without impairing the deformation of the flexible board. Since this allows the flexible board to be deformed toward one side when the flexible board slides with respect to the first receiving portion in a state where the coupling board is bent, the deformation of the flexible board is not impaired, so that handling of the flexible board can be made as easy as possible.

According to the bus bar module of the above structure [3], when the circuit body (flexible board) extending from the bus bar module to the external device is connected to the external device, the protector does not easily damage the deformation of the circuit body (flexible board) and the handling of the circuit body becomes easy. Therefore, the operability of the work of connecting the bus bar module and the external device can be improved.

According to the bus bar module of the above structure [4], by fixing the protector to the cover mounted to the bracket, the cover, and the protector can be integrated. Therefore, even when the bus bar module is exposed to an external force such as vibration, relative movement of the bracket, the cover, and the protector can be suppressed, and a state in which the circuit body (flexible board) connects between the bus bar and the external device can be appropriately maintained. In addition, since the protector of the present structure does not easily impair the deformation of the circuit body even if the bracket, the cover, and the protector are integrated as described above, the workability of the work of connecting between the bus bar module and the external device is not lowered.

According to the present invention, a protector and a bus bar module are provided that minimize damage to the ease of handling a flexible board.

In the foregoing, the present invention has been described briefly. Further, details of the present invention will be further clarified by reading a mode for carrying out the present invention (hereinafter, referred to as "embodiment") described below with reference to the drawings.

Drawings

Fig. 1 is an overall perspective view of a bus bar module of the present embodiment.

Fig. 2 is a perspective view of a battery assembly mounted with a bus bar module to which the present invention is applied.

Fig. 3 is a perspective view of an end portion of the enlarged circuit body.

Fig. 4 is a perspective view showing the structure of the main line, the first branch portion, and the second branch portion constituting the circuit body.

Fig. 5 a is a perspective view showing that the second branch portion is bent in an S-shape as a whole, fig. 5B is a perspective view showing a shape that the second branch portion is deformed when the bus bar is moved relatively backward, and fig. 5C is a perspective view showing a case that the bus bar is moved relatively forward so that the second branch portion is stretched.

Fig. 6 is a perspective view showing a part of the stent.

Fig. 7 is a perspective view of the accommodating space in the bus bar accommodating part.

Fig. 8 a to 8C are perspective views showing modifications of the folded portion of the second branch portion constituting the circuit body; a of fig. 8 shows a case where the folded portion is Z-shaped as a whole, B of fig. 8 shows a case where the folded portion is C-shaped as a whole, and C of fig. 8 shows a case where the folded portion is O-shaped as a whole.

Fig. 9 a is a perspective view showing a modification of the first branch portion, and fig. 9B is a perspective view showing a modification of the branch positions of the main line and the branch line.

Fig. 10 is a perspective view enlarging the periphery of the contact position between the connection piece of the bus bar and the connection portion of the second branch portion.

Fig. 11 a is a top view around the connection position shown in fig. 10, and fig. 11B is a sectional view taken along line a-a of fig. 11 a.

Fig. 12 a corresponds to fig. 11 a and is a view of a bus bar module of a modification of the present embodiment, fig. 12B corresponds to fig. 11 a and is a view of a bus bar module of another modification of the present embodiment, and fig. 12C corresponds to fig. 11 a and is a view of a bus bar module of another modification of the present embodiment.

Fig. 13 a is a perspective view enlarging around a connection position between the connection piece of the bus bar and the connection portion of the second branch portion on the bus bar module of another modification of the present embodiment, and fig. 13B is a B-B sectional view of fig. 13 a.

Fig. 14 a is a sectional view corresponding to an upper side metal layer of the circuit body part, and fig. 14B is a sectional view corresponding to a lower side metal layer of the circuit body part.

Fig. 15 is an enlarged sectional view of the periphery of a branch portion on the circuit body shown in a of fig. 14.

Fig. 16 a is a sectional view corresponding to an upper side metal layer around the front end portion of the circuit body, and fig. 16B is a sectional view corresponding to a lower side metal layer around the front end portion of the circuit body.

Fig. 17 is a cross-sectional view of the distal end portion of the circuit body according to another modification of the present embodiment, which corresponds to B in fig. 16.

A of fig. 18 is a perspective view showing a manner in which a cover is attached to a bracket of a bus bar module, and B of fig. 18 is a perspective view showing a case in which a cover is attached to a bracket of a bus bar module.

Fig. 19 is a side view for explaining an engagement position between the holder and the cover.

Fig. 20 a is a perspective view of the cover in an installed condition, and fig. 20B is an exploded perspective view of the cover.

Fig. 21 a is a top view of the cover in an installed condition, fig. 21B is a cross-sectional view of the cover in a stretched to maximum condition corresponding to section C-C of fig. 21 a, and fig. 21C is a cross-sectional view of the cover in a contracted to minimum condition corresponding to section C-C of fig. 21 a.

Fig. 22 is a perspective view showing that the protector mounted to the circuit body exposed from the cover is fixed to the cover.

A of fig. 23 is a top view of the protector mounted to the circuit body exposed from the cover, and B of fig. 23 is a bottom view of the protector mounted to the circuit body exposed from the cover.

Fig. 24 a is a schematic view for explaining a manner in which the connector provided at the front end portion of the circuit body moves forward in a case where the protector is fixed to the cover, and fig. 24B is a schematic view for explaining a manner in which the connector provided at the front end portion of the circuit body moves backward in a case where the protector is fixed to the cover.

Detailed Description

Detailed description of the preferred embodiments

Hereinafter, a protector and a bus bar module of an embodiment of the present invention will be described with reference to the accompanying drawings. The bus bar module 10 of the present embodiment is used as a battery assembly (a battery module in which a plurality of single cells are provided for ease of assembly) that is mounted on, for example, a drive power source mounted on an electric vehicle and a hybrid vehicle.

(Structure of Battery Assembly)

First, the battery assembly 1 to which the bus bar module 10 of the present embodiment is mounted will be described. As shown in fig. 2, the battery assembly 1 is formed by linearly connecting a plurality of electric cells 2. Each single cell 2 has a positive electrode 4 and a negative electrode 5 protrudingly provided on the top of a rectangular-shaped battery main body (body) 3. The positive electrode 4 and the negative electrode 5 are disposed apart from each other on an electrode surface 6 of the battery body 3, and each is disposed to protrude vertically upward from the electrode surface 6 in a substantially cylindrical shape.

In the battery assembly 1, the cells 2 are mounted such that the positive electrodes 4 and the negative electrodes 5 of adjacent cells 2 alternate with each other in a predetermined direction (mounting direction). In the battery assembly 1, for example, the positive electrode 4 of one cell 2 corresponding to both end portions of the cells 2 connected in series is a total positive electrode, whereas the negative electrode 5 of the other cell 2 is a total negative electrode.

(integral Structure of busbar Module)

Next, the bus bar module of the present embodiment will be described. As shown in fig. 1, the bus bar module 10 includes: a circuit body 20 formed of a flexible board (FPC) and mounted with bus bars 25 connected to the positive electrodes 4 and the negative electrodes 5 of the unit cells 2 (see fig. 3); and a holder (wiring member) 30 for accommodating and holding the circuit body 20 and for mounting on the battery assembly 1.

As shown in fig. 1 and 3, the circuit body 20 has a strip-shaped main line 21 (details will be described later) provided in the mounting direction on the single cell 2 and provided with a plurality of wiring patterns. The connector 212 is attached to an end of the main line 21 via a voltage detection line 211 drawn from the main line 21. The connector 212 is connectable to a voltage detector 60 (see fig. 22) described later.

On the side in the longitudinal direction of the main line 21 (in this example, substantially aligned with the "mounting direction" of the battery assembly 1), first branch portions 22 in a band shape extending in the direction intersecting the longitudinal direction and the thickness direction of the main line 21 (outside the main line 21 in the width direction) are provided, and at the tip of each first branch portion 22, a second branch portion 23 in a band shape extending in the direction parallel to the mounting direction of the battery body 3 is provided. The main line 21, the first branch portion 22, and the second branch portion 23 are formed of FPC. Therefore, the main line 21, the first branch portion 22, and the second branch portion 23 flexibly deform particularly in the direction orthogonal to the respective surfaces.

As shown in fig. 4 and a of fig. 5, each of the second branch portions 23 has the laminated portion 231 folded back about the axes L1 and L2 (in other words, about the axis extending in the width direction of the second branch portion 23) intersecting in the mounting direction of the battery assembly 1 (in this example, substantially coinciding with the extending direction of the second branch portion 23). In this example, each of the second branch portions 23 is bent into an S shape (including an inverted S shape) as a whole by the first laminated portion 231A folded back about the axis L1 and the second laminated portion 231B folded back about the axis L2. For this reason, the second branch portion 23 is movable in the longitudinal direction of the main line 21 (the mounting direction of the battery assembly 1), and is capable of extending and contracting in the vertical direction.

The first branch portion 22 is disposed outside the main line 21 in the same plane as the main line 21, and the second branch portion 23 is connected to the first branch portion 22. For this reason, the second branch portion 23 is disposed outside the main line 21 in the width direction, and is configured in a downward S-shape with the relative positions of the battery assembly 1 and the circuit body 20 unchanged (see a of fig. 5). Therefore, the bus bar 25 is positioned outside the main line 21 in the width direction and below the plane of the main line 21.

Further, at an end portion of the second branch portion 23 opposite to the first branch portion 22, a front end portion 232 having a surface substantially parallel to the main line 21 is provided, and at an upper surface of the front end portion 232, a connection portion 24 is provided. The lower surfaces of the connection portions 24 are disposed parallel to the lower surface of the main line 21 at different height positions, and the lower surfaces are spaced apart from each other. The upper surface of the connecting portion 24 is connected to a bus bar 25 connecting the positive electrode 4 and the negative electrode 5 of the adjacent single cell 2 in the battery assembly 1. Thereby, the second branch portion 23 is connected to the electrode of each single cell 2 via the connection portion 24 and the bus bar 25, and the voltage detection line 211 is connected to the electrode.

As shown in fig. 3 and a to C of fig. 5, the bus bar 25 has: a bus bar main body 251 which is a plate-like member formed of a conductor (e.g., made of copper) and is rectangular as a whole; and a connection piece 252 protruding from the bus bar main body 251 toward the main line 21. The bus bar main body 251 has two electrode holes 253 through which the positive electrodes 4 and the negative electrodes 5 of the adjoining single cells 2 pass. A positioning recess 254 is formed in the end of the bus bar main body 251 on the main line 21 side and the end on the opposite side, corresponding to the interval between the two electrode holes 253. Further, the connection portion 24 of the second branch portion 23 is connected to the lower surface of the connection piece 252 of the bus bar main body 251. A specific form of connection between the connection piece 252 of the bus bar 25 and the connection portion 24 of the second branch portion 23 will be described later.

The bus bar 25A provided at each end in the length direction of the main line 21 is connected to the total positive electrode or the total negative electrode, and is provided with one electrode hole 253 through which the total positive electrode or the total negative electrode passes. A power cable (not shown) that derives power from the battery assembly 1 is connected to the bus bar 25A. The internal structures of the main line 21, the first branch portion 22, and the second branch portion 23 constituting the circuit body 20 will be described later.

(Structure of the holder)

As shown in fig. 6, the bracket 30 is formed of, for example, resin, and has, at the middle in the width direction, a main line accommodating portion 31 that extends in the mounting direction of the single cells 2 and accommodates and holds the main line 21. In the main line housing section 31, main line support members 311 are provided at predetermined intervals in the longitudinal direction of the main line 21 housed therein, and the main line 21 is routed on the main line support members 311. When the main line 21, the first branch portion 22, and the second branch portion 23 have such strength that the circuit body 20 of the present example can stand by itself without being supported by the main line support member 311, the main line support member 311 does not need to be provided. However, although in this case, when the circuit body 20 cannot maintain the self-standing state for some reason, the main line supporting member 311 may be provided to provide the auxiliary supporting function. As described above, the circuit body 20 may be provided to maintain the above-described state by using the main line support member 311 or may be provided to be able to stand alone without using the main line support member 311.

On both outer sides in the width direction of the main wire accommodating portion 31, bus bar accommodating portions 32 that accommodate the bus bars 25 are provided. In the bus bar housing portion 32, a plurality of housing spaces 33 that house the bus bars 25 are provided in the mounting direction of the single cells 2. As shown in fig. 7, the adjacent accommodation spaces 33 are separated by the partition 34 to prevent contact between the adjacent bus bars 25. At each end in the longitudinal direction of the main line 21, an accommodation space 33A for accommodating a bus bar 25A connected to a power cable (not shown) is provided, and the power cable accommodation portion 36 is provided continuously with the accommodation space 33A.

As shown in fig. 7, the accommodation space 33 is a rectangular space with an open top and is partitioned by an outer wall 331 on the outer side and an inner wall 332 on the inner side in the width direction and a pair of partitions 34 on both sides in the mounting direction. One side (left side in fig. 7) of the installation direction of each partition 34 is connected to the outer wall 331 and the inner wall 332 through the expansion portion 35. As a result, the accommodating space 33 expands and contracts in the mounting direction.

The bottom end portion of the outer wall 331 and the bottom end portion of the inner wall 332 are coupled by a coupling plate 333. At the bottom end portion of the outer wall 331 and the bottom end portion of the inner wall 332, engaging claws 334 are provided on both sides with a coupling plate 333 therebetween. This enables the bus bar 25 to be held between the coupling plate 333 and the engaging claw 334. Further, on the inner side surface of the outer wall 331 and the inner side surface of the inner wall 332, a protrusion 338 protruding toward the middle is provided in the mounting direction. These protrusions 338 are fitted into the positioning recesses 254 (see a of fig. 5) of the bus bar 25 to position the bus bar 25.

The inner wall 332 is provided with a cut-out portion 336 corresponding to the cut-out portion 336, and a support plate 337 is provided to protrude inward. Therefore, the connection piece 252 of the bus bar 25 accommodated in the accommodation space 33 is supported by the support plate 337.

Further, on each side of the coupling direction of the coupling plate 333, a space 335 is provided. As a result, the positive electrode 4 and the negative electrode 5 of the single cell 2 can be exposed from the space 335 to the inside of the accommodating space 33 so that they can be connected to the electrode holes 253 of the bus bar 25 accommodated in the accommodating space 33. Instead of the coupling plate 333, a bottom plate having cutout portions or holes corresponding to the positive electrode 4 and the negative electrode 5 of the single cell 2 may also be provided.

As shown in fig. 1, the holder 30 accommodates and holds a portion of the circuit body 20 from the front end portion of the main line 21 to which the connector 212 is attached to a position behind a predetermined length (in other words, a portion of the circuit body 20 in a range where at least the branch positions of the main line 21 and the first branch portion 22 exist). In other words, a portion (hereinafter, referred to as an "exposed portion 213") from the front end of the main line 21 to which the connector 212 is mounted to a prescribed length is not accommodated in the cradle 30 but is exposed from the cradle 30.

(action of busbar Module)

Next, the operation of the bus bar module 10 will be described. A of fig. 5 shows a case where the second branch line is bent in an S shape as a whole, B of fig. 5 shows a case where the second branch line is slightly stretched backward, and C of fig. 5 shows a case where the second branch line is stretched forward.

As described above, the main line 21 is routed on the main line support member 311 of the cradle 30 and can move upward and in the longitudinal direction. Further, the bus bar 25 is fixed to the inside of the accommodating space 33 of the bracket 30, the accommodating space 33 being movable in the length direction of the main line 21. The main line 21 and the bus bar 25 are connected by the second branch portion 23 bent in an S-shape (see a of fig. 5).

Although the relative positions of the battery assembly 1 and the circuit body 20 are changed due to, for example, deformation of the battery assembly 1 in this state, and it changes the relative positions of the main wire 21 and the bus bar 25, the change (displacement) in the relative positions can be absorbed by bending and stretching of the second branch portion 23. Likewise, although the dimension in the mounting direction of the battery assembly 1 differs between the manufactured battery assemblies 1 due to the assembly tolerance of the plurality of single cells 2, the manufacturing variation can be absorbed by the bending and stretching of the second branch portion 23.

More specifically, B of fig. 5 shows a case where the bus bar 25 is slightly displaced rearward (rightward in B of fig. 5) with respect to the main line 21. In this case, the S shape of the folded portion 231 of the second branch portion 23 is deformed to allow the displacement of the bus bar 25. Further, C of fig. 5 represents a case where the bus bar 25 is greatly shifted forward (leftward in C of fig. 5) with respect to the main line 21. In this case, the S shape of the folded portion 231 of the second branch portion 23 stretches to allow displacement of the bus bar 25. Although not shown, when the main line 21 is moved upward or downward to change the position with respect to the bus bar 25, the S shape of the folded portion 231 is stretched in the vertical direction to allow the change of the relative position.

In the above embodiment, the case where the folded portion 231 of the second branch portion 23 is bent into an S shape (including an inverted S shape) as a whole has been described. In addition, as shown in a of fig. 8, the folded portion 231 may be folded in a Z shape (including an inverted Z shape) as a whole. Further, as shown in B of fig. 8, the folded portion 231 may be folded into a C shape as a whole (including an inverted C shape). Further, as shown in C of fig. 8, the folded portion 231 may be formed in an O shape as a whole. In the example shown in C of fig. 8, the

branch lines

22 and 23 may be formed such that the lower surface of the main line 21 and the lower surface of the connection portion 24 are in the same plane as each other as required.

For example, in the above-described embodiment, the case where the first branch portion 22 extends in the same plane as the main line 21 is described; however, as shown in a of fig. 9, the first branch portion 22 may be disposed in a direction intersecting with the lower surface of the main line 21 (for example, a direction downward perpendicular to the main line 21 in a of fig. 9). Further, for example, in the above-described embodiment, the case where the first branch portion 22 branches from the side portion of the main line 21 is described, and as shown in B of fig. 9, the opening 29 may be provided in a central portion different from the side portion of the main line 21 so that the first branch portion 22 branches from the central portion of the main line 21.

(internal construction of Main line and Branch line constituting Circuit body)

Next, referring to fig. 11B and A, B and 17 of fig. 14, the internal structure of the main line 21, the first branch portion 22, and the second branch portion 23 constituting the circuit body 20 will be described.

As described above, the main line 21, the first branch portion 22, and the second branch portion 23 constituting the circuit body 20 are formed of FPCs. As shown in B of fig. 11, the circuit body 20 (constituted by FPC) is formed of a resin layer 201, and an upper side metal layer 203a and a lower side metal layer 203B sandwiched by the resin layer 201. Typically, the resin layer 201 is made of polyimide, and the upper side metal layer 203a and the lower side metal layer 203b are made of copper (Cu). As described later, in the present embodiment, the circuit body 20 is supported by the bus bar 25, and a reinforcing plate for suppressing deformation, such as bending, of the circuit body 20, which is generally required, may be omitted. In practice, the circuit body 20 is provided with an adhesive layer (not shown) that tightly fixes these layers. However, for convenience of explanation, the illustration of the adhesive layer is omitted in B of fig. 11.

An upper metal layer 203a located above (front side) the center in the thickness direction of the resin layer 201 and a lower metal layer 203b located below (rear side) the center in the thickness direction of the resin layer 201 are embedded in the resin layer 201. The upper metal layer 203a and the lower metal layer 203b are separated from each other in the thickness direction of the resin layer 201 with the resin layer 201 interposed therebetween. That is, the upper metal layer 203a and the lower metal layer 203b are insulated from each other.

As shown in a of fig. 14 and a of 16, the upper metal layer 203a forms an upper wiring pattern 204a which is a part of the above-described plurality of wiring patterns, an upper dummy pattern 205a which is independent of the upper wiring pattern 204a, and the above-described connection 24 which is independent of the upper wiring pattern 204 a.

As shown in B of fig. 14 and B of 16, the lower metal layer 203B forms a lower wiring pattern 204B of the remaining part of the above-described plurality of wiring patterns and a lower dummy pattern 205B independent of the lower wiring pattern 204B. The respective upper wiring patterns 204a and lower wiring patterns 204B are communicated in the thickness direction of the circuit body 20 via respective through holes 206 (see a of fig. 14, B of fig. 14, a of fig. 16, and B of fig. 16) so as to be electrically continuous with each other.

As shown in fig. 14 a, 14B, 16 a, and 16B, of the plurality of first branch portions 22 and second branch portions 23 provided on both sides of the main line 21 in the width direction, the corresponding upper wiring patterns 204a continuously extend from the vicinity of the rear end portion of the second branch portion 23 to the connector 212 connected to the front end portion of the circuit body 20 via the first and

second branch portions

22 and 23 and the main line 21 to the connector 212 connected to the front end portion of the circuit body 20, with respect to the first and

second branch portions

22 and 23 on one side in the width direction (the right side in fig. 14 a and 14B), whereby the first and

second branch portions

22 and 23 are electrically connected to the connector 212.

On the other hand, in the first and

second branch portions

22 and 23, with respect to the first and

second branch portions

22 and 23 on the other side in the width direction (the left side in B of a and 14 of fig. 14), first, as shown in a of fig. 14, the corresponding upper wiring pattern 204a extends from near the trailing end portion of the second branch portion 23 to the through hole 206 near the first branch portion 22 on the main line 21 via the first and

second branch portions

22 and 23. And as shown in B of fig. 14, the respective lower wiring patterns 204B extend from the through-holes 206 to the through-holes 206 near the connector 212 on the main line 21 (see B of fig. 16). Further, as shown in a of fig. 16, the respective upper wiring patterns 204a extend from the through-holes 206 to the connector 212, whereby the first and

second branch portions

22 and 23 are connected to the connector 212 so as to be electrically continuous. That is, at the portion of the main line 21 connected to the connector 212, the upper wiring patterns 204a corresponding to all of the first and

second branch portions

22 and 23 provided on both sides in the width direction are connected to the connector 212 (see B of fig. 16), and there are no lower wiring patterns 204B connected to the connector 212 (see B of fig. 16).

By using both the upper metal layer 203a and the lower metal layer 203b as described above to thereby gather the upper wiring patterns 204a and the lower wiring patterns 204b to the connector 212, the plurality of wirings extending from the plurality of bus bars 25a can be connected to the connector 212 while being rearranged in an order corresponding to the arrangement order of the single cells 2 (see fig. 2). That is, the wiring patterns may be arranged in order of potential.

As shown in a of fig. 14, B of fig. 14, a of fig. 16, and B of fig. 16, the upper dummy pattern 205a and the lower dummy pattern 205B are mainly formed in almost all areas of the area occupied by the upper wiring pattern 204a and the lower wiring pattern 204B, out of the portion of the main line 21 accommodated in the support 30 (i.e., the portion excluding the exposed portion 213). The upper dummy patterns 205a and the upper wiring patterns 204a, and the lower dummy patterns 205b and the lower wiring patterns 204b are arranged to be separated from each other so as not to be electrically continuous. The upper dummy pattern 205a and the lower dummy pattern 205b are mainly disposed in order that the rigidity of the portion of the main line 21 accommodated in the support 30 (i.e., the portion excluding the exposed portion 213) is higher than the rigidity of the first and

second branch portions

22 and 23.

Further, as shown in B of fig. 16, the lower dummy pattern 205B (hereinafter, referred to as "connector connection portion dummy pattern 207" in particular) is formed in a prescribed area in the length direction of the portion connected between the main line 21 and the connector 212, and substantially the entire area in the width direction. In other words, the connector connection portion dummy pattern 207 is provided in multiple layers with respect to the upper wiring patterns 204a connected to the connector 212.

Since the plurality of upper wiring patterns 204a are densely connected to the connector 212 as described above, the contact points between the terminals built into the connector 212 and the upper wiring patterns 204a also become dense. For this reason, heat caused by contact resistance at each contact point is concentrated in a narrow space of the connector 212. It is desirable to release this heat to the outside of the connector 212. In this regard, since the connector connection portion dummy pattern 207 made of metal has high thermal conductivity, heat in the connector 212 can be released to the outside through the connector connection portion dummy pattern 207. Therefore, by providing the connector connection portion dummy pattern 207, the performance of releasing heat from the connector 212 can be higher than that of a mode in which the connector connection portion dummy pattern 207 is not provided. In addition, since the rigidity of the connection portion of the main line 21 with the connector 212 can be higher than in a mode in which the connector connection dummy pattern 207 is not provided by providing the connector connection dummy pattern 207, for example, the contact point separation between the terminal and the upper wiring pattern 204a due to the deformation, such as bending, of the main line 21 can be suppressed.

In the example shown in B of fig. 16, the edge 207a of the connector connection portion dummy pattern 207 on the rear side (the side opposite to the side connected to the connector 212) has a linear shape. This makes the manufacture of the connector connection portion dummy pattern 207 relatively easy. In contrast, as shown in fig. 17, the rim 207a may have a corrugated shape. Thereby, the occurrence of stress concentration in the connector connecting portion dummy pattern 207 can be avoided as much as possible when the main line 21 of the circuit body 20 is deformed.

Next, as shown in a of fig. 14, the connection portion 24 is formed at the trailing end portion of each of the second branch portions 23 of all the first and

second branch portions

22 and 23 provided on both sides in the width direction of the main line 21. As shown in fig. 15, the connection portion 24 is provided apart from the trailing end portion 26 of the upper wiring pattern 204a on the second branch portion 23. As described later, the bus bar 25 is connected to the connecting portion 24 and the chip fuse 50 is arranged to bridge between the tail end portion 26 and the connecting portion 24 (see fig. 10 and the like), whereby the bus bar 25 and the connector 212 are connected for electrical continuity.

As shown in fig. 15, a narrow portion 27 in which the width (i.e., the cross-sectional area) of the wiring pattern is relatively small is formed in the upper wiring pattern 204a of the second branch portion 23. Therefore, although an overcurrent flows through a particular wiring pattern for various reasons and the chip fuse 50 is not operated, the narrow portion 27 corresponding to the wiring pattern is preferentially blown out than the remaining portion of the upper side wiring pattern 204a due to joule heat caused by the overcurrent. Therefore, the remaining portion of the upper wiring pattern 204a (particularly, the portion where the upper wiring pattern 204a is dense on the main line 21) is fused, whereby adverse effects on peripheral wiring and the like can be suppressed. Since the melted narrowed portion 27 is trapped in the resin layer 201, scattering to the vicinity of the metal constituting the narrowed portion 27 can be suppressed.

(concrete form of connection between connecting piece of bus bar and connecting part of branch line)

Next, a specific form of connection between the connection piece 252 of the bus bar 25 and the connection portion 24 of the second branch portion 23 will be described with reference to fig. 10, fig. 11 a, and fig. 11B.

As shown in fig. 10, a of fig. 11, and B of fig. 11, on the upper surface of the leading end portion 232 of the second branch portion 23, in the regions corresponding to the connection portion 24 and the tail end portion 26, the resin layer 201 (see B of fig. 11) constituting the circuit body 20 is removed. As a result, the substantially U-shaped connecting portion 24 and the rectangular trailing end portion 26 are exposed on the upper surface of the leading end portion 232, and the top is open.

The connecting piece 252 of the bus bar 25 is constituted by a first portion 252a extending inward (the main line 21 side) from the bus bar main body 251 in the width direction, and a pair of

second portions

252b and 252c extending rearward from the leading end portion and the base end portion of the first portion 252 a. As a result, the connecting piece 252 has a substantially U-shape that opens rearward corresponding to the shape of the exposed connecting portion 24.

The connecting piece 252 (which has a first portion 252a and

second portions

252b and 252c) is fixed to the entire area of the upper surface of the exposed connecting portion 24 so that the substantially U-shaped shapes overlap each other. In this example, this fixing is performed by using solder H. As a result, the connection portion 24 and the bus bar 25 are connected so as to be electrically continuous, and by utilizing the rigidity of the connection piece 252, a region (deformation restricting region) R in which deformation, for example, bending, of the second branch portion 23 is restricted is formed in a rectangular portion sandwiched by the pair of

second portions

252b and 252 c.

In the deformation restricting region R, the chip fuse 50 is mounted so as to bridge between the tail end portion 26 and the connecting portion 24. Specifically, one electrode on both end portions of the chip fuse 50 is fixed to the exposed connecting portion 24, and the other is fixed to the exposed tail end portion 26. In the present example, this fixing is performed by using solder H. As a result, the connection portion 24 (thus, the bus bar 25) and the tail end portion 26 (thus, the connector 212) are connected so as to be electrically continuous.

As described above, the deformation restricting region R is formed by the connection piece 252 of the bus bar 25, and the chip fuse 50 is mounted in this region. Therefore, deformation of the second branch portion 23 in the mounting region of the chip fuse 50 can be suppressed without providing a reinforcing plate or the like.

As shown in a of fig. 12, the connection piece 252 may have an L shape in which the second portion 252c is omitted from the pattern shown in a of fig. 11. In addition, as shown in B of fig. 12, the connecting piece 252 may also have a rectangular shape in which a third portion 252d coupling front ends of the pair of second portions 252B and 252c is further provided in the pattern shown in a of fig. 11. Further, as shown in C of fig. 12, the connecting piece 252 may be constituted by two

first portions

252a and 252e from the bus bar main body 251. In either mode, since the chip fuse 50 is mounted in the deformation restricting region R utilizing the rigidity of the connecting piece 252, the deformation of the second branch portion 23 in the mounting region of the chip fuse 50 is suppressed.

Further, as shown in a of fig. 13 and B of 13, by using a structure in which the height of the connection piece 252 (which has the first portion 252a and the second portions 252B and 252c) is greater than the height of the chip fuse 50 (see B of fig. 11), the potting member 28 may be disposed to cover the chip fuse 50 at the deformation restricting region R formed by the connection piece 252 such that it is separated from the outside.

As described above, by covering the potting material 28 of the chip fuse 50, the waterproof performance of the chip fuse 50 and the electric contacts near the chip fuse 50 can be improved. Further, by solidifying potting material 28 in a state of being in close contact with the surface of distal end portion 232, deformation of second branch portion 23 can be further suppressed by utilizing the rigidity of potting material 28. It is desirable that the potting member 28 is provided to fill the entire deformation restricting region R formed by the connection piece 252 of the bus bar 25.

(cover to mount bracket)

Next, the cover 40 attached to the bracket 30 will be described with reference to a of fig. 18 and AC of B to 21 of 18. As shown in a of fig. 18 and B of fig. 18, a cover 40 made of resin is attached from above to the bracket 30 accommodating the circuit body 20 to cover the circuit body 20 to protect the circuit body 20. In the case of mounting the cover 40 to the bracket 30, the exposed portion 213 of the circuit body 20 is exposed to the outside from the space covered by the bracket 30 and the cover 40 (see B of fig. 18).

As described above, the holder 30 is extendable and retractable in the front-rear direction (the mounting direction of the battery assembly 1). For this reason, it is desirable that the cover 40 is also configured to be stretchable in the front-rear direction. In this regard, the cover 40 is formed of two parts (i.e., a front side part 41 and a rear side part 42) arranged in the front-rear direction, and the front side part 41 and the rear side part 42 are coupled to be movable in the front-rear direction with respect to each other. Hereinafter, specific structures of the front side portion 41 and the rear side portion 42 will be described.

As shown in fig. 20 a and 20B, the front portion 41 is substantially formed by a top plate 411 having a rectangular flat plate shape and a pair of side plates 412 that hang down from both sides in the width direction of the top plate 411. The rear portion 42 is also formed of a top plate 421 having a substantially rectangular flat plate shape and a pair of side plates 422 that hang down from both sides in the width direction of the top plate 421.

As shown in fig. 19, the side plate portion 412 of the front side portion 41 and the side plate portion 422 of the rear side portion 42 are provided with a plurality of engaging portions 43 so as to correspond to the engaging portions 37 provided at a plurality of positions on both sides in the front-rear direction of the bracket 30 (see fig. 1 and 6). The engaging portions 37 of the respective brackets 30 and the engaging portions 43 of the cover 40 are engaged with each other, so that the cover 40 (the front side portion 41 and the rear side portion 42) is mounted to the brackets 30.

As shown in a of fig. 20 and B of fig. 20, in the top plate portion 411 of the front side portion 41, an engagement hole (through hole) 413 is formed in a central portion in the width direction near a rear end portion (a portion coupled to the rear side portion 42). Further, at the rear end portion of the top plate portion 411, at the center portion in the width direction, a first coupling plate portion 414 is formed at a position slightly lower than the top plate portion 411, and at both sides in the width direction of the first coupling plate portion 414, a pair of second coupling plate portions 415 flush with the top plate portion 411 are formed.

In the top plate portion 421 of the rear side portion 42, a tongue piece 423 is formed to protrude forward from a central portion in the width direction of a front end portion (a position coupled to the front side portion 41). A projection 423a projecting upward is formed at the center of the upper surface of the tongue piece 423. Further, at the front end portion of the top plate portion 421, a first coupling plate portion 424 flush with the top plate portion 421 is formed at the central portion in the width direction, and at both sides of the first coupling plate portion 424 in the width direction, a pair of second coupling plate portions 425 are formed at positions slightly lower than the top plate portion 421.

In a state where the front side portion 41 and the rear side portion 42 are coupled together, as shown in a of fig. 20 and 21, the tongue piece 423 of the rear side portion 42 enters a vertical gap between the top plate portion 411 of the front side portion 41 and the first coupling plate portion 414, and the protrusion 423a of the tongue piece 423 is located in the engagement hole 413. Further, the first coupling plate portion 414 enters below the first coupling plate portion 424, and the pair of second coupling plate portions 415 enter above the pair of second coupling plate portions 425, and thus, the first coupling plate portion 414 and the first coupling plate portion 424 partially overlap each other, and the pair of second coupling plate portions 415 and the pair of second coupling plate portions 425 partially overlap each other.

In a state where the front side portion 41 and the rear side portion 42 are coupled together, the front side portion 41 and the rear side portion 42 are stretchable in the front-rear direction until the projection 423a shown in B of fig. 21 abuts against the rear side end of the engaging hole 413, and contractible in the front-rear direction until the front end portion 423B of the tongue piece 423 abuts against the stopper wall 417 provided on the lower surface of the top plate portion 411 of the front side portion 41 shown in C of fig. 21.

Thus, the cover 40 formed by the front side 41 and the rear side 42 coupled together is configured to be retractable. As a result, the cover 40 is also stretched and contracted as the holder 30 is stretched and contracted, so that the assemblability for the battery assembly 1 and the adaptability to manufacturing variations are improved, the circuit body 20 and the bus bar 25 are protected from the outside.

Further, even if the front side portion 41 and the rear side portion 42 are located at any position within the telescopic range, the first coupling plate portion 414 and the first coupling plate portion 424 partially overlap each other, and the pair of second coupling plate portions 415 and the pair of second coupling plate portions 425 partially overlap each other. That is, even if the front side portion 41 and the rear side portion 42 are located at any position within the telescopic range, the portion coupling the front side portion 41 and the rear side portion 42 is closed, and the inside and the outside of the cover 40 are not communicated. As a result, even if the lid 40 is stretched or contracted, the state of the external protection circuit body 20 and the bus bar 25 can be maintained.

Further, since the cover 40 is configured to be able to expand and contract, the degree of absorbing manufacturing variations and the like at the engaging portion 37 of the bracket 30 and the engaging portion 43 of the cover 40 may be set lower than the manner in which the cover 40 cannot be stretched or contracted. As a result, the engaging portion 37 of the bracket 30 and the engaging portion 43 of the cover 40 can be made small.

(protector fixed to cover)

Next, referring to a of fig. 22 to 24 and B of 24, the protector 70 fixed to the cover 40 is described. The protector 70 made of resin is provided at the exposed portion 213 of the circuit body 20 so as to protect the exposed portion 213 of the circuit body 20.

As shown in a of fig. 23 and B of fig. 23, the protector 70 is formed of a base end side accommodating portion 71, a leading end side accommodating portion 72, and a coupling portion 73. The base end side accommodating portion 71 has a rectangular plate shape. The base end side accommodating portion 71 is attached and fixed to the front end portion 38 of the bracket 30 accommodating the circuit body 20 from above so as to cover the base portion of the exposed portion 213 of the circuit body 20 by the engaging portions 71a on both sides in the width direction. Therefore, the base portion of the exposed portion 213 of the circuit body 20 is accommodated slidably in the longitudinal direction by the base end side accommodating portion 71 and the front end portion 38 of the holder 30.

The distal-end-side accommodating portion 72 is formed of an upper portion 72a and a lower portion 72b having a rectangular plate shape. The upper side portion 72a and the lower side portion 72b are attached to each other by sandwiching the longitudinal center portion of the exposed portion 213 of the circuit body 20 between the upper side portion 72a and the lower side portion 72b by the engaging portions 72c on both sides in the width direction. Therefore, the central portion of the exposed portion 213 of the circuit body 20 is accommodated slidably in the longitudinal direction by the front end side accommodating portion 72 formed by the upper side portion 72a and the lower side portion 72 b.

The coupling portion 73 is formed of a plurality of (in this example, 3) bendable bands that couple the upper side portions 72a of the base end side accommodating portion 71 and the leading end side accommodating portion 72.

As shown in fig. 22, in a case where the exposed portion 213 of the circuit body 20 is folded from the base thereof toward the upper surface of the cover 40, the connector 212 located at the front end of the exposed portion 213 is connected to the connector connection portion 61 of the voltage detector 60 disposed on the upper surface of the cover 40. In this case, the coupling portion 73 of the protector 70 is bent, and the front end side accommodating portion 72 is fixed to the upper surface of the cover 40 by engaging the engaging portions 72d (see also B of a and 23 of fig. 23) on both sides in the width direction thereof to the engaging portion 416 (see also B of a and 20 of fig. 20, and the like) of the cover 40.

As shown in fig. 24 a and 24B, in the case where the coupling portion 73 is bent and the front end side accommodating portion 72 is fixed to the upper surface of the cover 40, by sliding the circuit body 20 relative to the front end side accommodating portion 72, the circuit body 20 can also be deformed in a direction separating from the coupling portion 73. That is, the deformation of the circuit body 20 is not prevented. For this reason, not only the connector 212 is movable in the front-rear direction with respect to the cover 40 but also handling of the circuit body 20 can be facilitated.

(main influence of the present embodiment)

According to the protector 70 of the present embodiment, when the circuit body 20 (flexible board) slides with respect to the front end side accommodating portion 72 in a state where the coupling portion 73 is bent, deformation of the circuit body 20 is not impaired by the circuit body 20 being deformed in a direction separating from the coupling portion 73. As a result, the circuit body 20 can be handled as easily as possible. In particular, the coupling portion 73 is configured not to impair deformation of the circuit body 20 on one side in the thickness direction of the circuit body 20. This allows the circuit body 20 to be deformed to one side when the circuit body 20 slides with respect to the front end side receiving portion 72 in a state where the coupling portion 73 is bent, without impairing the deformation of the circuit body 20, so that handling of the circuit body 20 is made as easy as possible.

Further, according to the bus bar module 10 of the present embodiment, when the circuit body 20 extending from the bus bar module 10 to the voltage detector 60 is connected to the voltage detector 60, the protector 70 does not easily damage the deformation of the circuit body 20 and the handling of the circuit body 20 becomes easy. Therefore, the workability of the work of connecting the bus bar module 10 and the voltage detector 60 can be enhanced.

Further, by fixing the protector 70 to the cover 40 attached to the bracket 30, the cover 40, and the protector 70 can be integrated. Therefore, even when the bus bar module 10 is exposed to an external force such as vibration, the relative movement of the bracket 30, the cover 40, and the protector 70 can be suppressed, so that the state in which the circuit body 20 is connected between the bus bar 25 and the voltage detector 60 can be appropriately maintained.

< other mode >

The present invention is not limited to the above-described embodiments, and various modified examples may be adopted within the scope of the present invention. For example, the present invention is not limited to the above-described embodiments, and may be appropriately modified, improved, or the like. In addition, the materials, shapes, sizes, numbers, placement positions, and the like of the constituent elements in the above-described embodiments are arbitrary as long as the present invention can be implemented, and are not limited thereto.

Now, the features of the above-described embodiments of the protector and the bus bar module according to the present invention are briefly summarized and listed as the following [1] to [4 ]:

[1] a protector (70) configured to protect a band-shaped flexible board (20) provided with a wiring pattern (204a, 204b), the protector (70) comprising:

a first accommodating portion (72) configured to accommodate the flexible board (20) in a slidable manner in a longitudinal direction of the flexible board (20);

a second housing portion (71) configured to house the flexible board (20) at a position different from the first housing portion (72) in a length direction; and

a bendable coupling part (73) connecting between the first receiving part (72) and the second receiving part (71),

wherein the coupling portion (73) is configured such that, when the flexible board (20) slides in the longitudinal direction with respect to the first housing portion (72) in a state in which the coupling portion (73) is bent, deformation of the flexible board (20) in a direction away from the coupling portion (73) is permitted.

[2] The protector (70) according to the above [1],

the coupling portion (73) is configured to cover a plate surface of one side in a thickness direction of the flexible board (20) between the first accommodating portion (72) and the second accommodating portion (71), and is configured to expose a plate surface of the other side in the thickness direction of the flexible board (20) to the outside.

[3] A bus bar module (10) configured to be mounted to a battery assembly having a plurality of electric cells combined with each other in a first direction, the bus bar module comprising:

a bus bar (25) configured to be connected to an electrode of each of the unit cells;

a circuit body (20) configured by a belt-shaped flexible board (20) on which wiring patterns (204a, 204b) for connecting the bus bar (25) and an external device are configured;

a bracket (30) configured to support the bus bar (25) and to be retractable in the first direction; and

the protector (70) according to the above [1] or [2], configured such that the first accommodation portion (72) accommodates the circuit body extending from the bracket (30) to the external device and the second accommodation portion (71) is fixed to the bracket (30).

[4] The bus bar module according to the above [3], further comprising:

A cover (40) mounted to the bracket (30),

wherein the protector (70) is configured such that the first accommodating portion (72) can be fixed to the cover (40) in a state in which the coupling portion (73) is bent.

Claims

1. A protector configured to protect a strip-shaped flexible board provided with a wiring pattern, the protector comprising:

a bendable coupling part connected between the first receiving part and the second receiving part,

wherein the coupling portion is configured to allow the flexible board between the first accommodating portion and the second accommodating portion to be deformed in a direction away from the coupling portion by sliding the flexible board relative to the first accommodating portion in the longitudinal direction of the flexible board and a direction in which the flexible board is inserted into the first accommodating portion in a state in which the coupling portion is bent, and

wherein the first accommodating portion is held at a predetermined position with respect to the second accommodating portion.

2. The protector of claim 1, wherein

3. A bus bar module configured to be mounted to a battery assembly having a plurality of electric cells combined with each other in a first direction, the bus bar module comprising:

a bus bar configured to be connected to an electrode of each of the unit cells;

a circuit body configured by a strip-shaped flexible board configured with a wiring pattern for connecting the bus bar and an external device;

the protector of claim 1 or 2, configured such that the first accommodating portion accommodates the circuit body extending from the bracket to the external device and the second accommodating portion is fixed to the bracket.

4. The bus bar module according to claim 3, further comprising:

a cover mounted to the bracket,