EP2867914A1 - Fuse apparatus and manufacturing method thereof - Google Patents
Fuse apparatus and manufacturing method thereofInfo
- Publication number
- EP2867914A1 EP2867914A1 EP20130808521 EP13808521A EP2867914A1 EP 2867914 A1 EP2867914 A1 EP 2867914A1 EP 20130808521 EP20130808521 EP 20130808521 EP 13808521 A EP13808521 A EP 13808521A EP 2867914 A1 EP2867914 A1 EP 2867914A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fuse
- bus bar
- mounting portion
- lead wire
- housing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H69/00—Apparatus or processes for the manufacture of emergency protective devices
- H01H69/02—Manufacture of fuses
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
- H01H85/02—Details
- H01H85/20—Bases for supporting the fuse; Separate parts thereof
- H01H85/202—Bases for supporting the fuse; Separate parts thereof for fuses with ferrule type end contacts
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
- H01H85/02—Details
- H01H85/20—Bases for supporting the fuse; Separate parts thereof
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
- H01H85/02—Details
- H01H85/20—Bases for supporting the fuse; Separate parts thereof
- H01H85/2045—Mounting means or insulating parts of the base, e.g. covers, casings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
- H01H85/02—Details
- H01H85/0241—Structural association of a fuse and another component or apparatus
- H01H2085/025—Structural association with a binding post of a storage battery
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
- H01H85/02—Details
- H01H85/20—Bases for supporting the fuse; Separate parts thereof
- H01H2085/2075—Junction box, having holders integrated with several other holders in a particular wiring layout
- H01H2085/208—Junction box, having holders integrated with several other holders in a particular wiring layout specially adapted for vehicles
Definitions
- the present invention relates to a fuse apparatus and a manufacturing method thereof, and more particularly, to a fuse apparatus for a vehicle, the fuse apparatus especially applied to a vehicle battery pack of a high voltage, for example 450 V or more, for an electric car or a hybrid car, and a manufacturing method thereof.
- a fuse apparatus for a vehicle the fuse apparatus especially applied to a vehicle battery pack of a high voltage, for example 450 V or more, for an electric car or a hybrid car, and a manufacturing method thereof.
- a vehicle includes various electric apparatuses for driving of the vehicle and convenience for a rider.
- the electric apparatuses (hereinafter, referred to as 'electric parts') are electrically connected to a battery and a generator to be supplied with power necessary for operation.
- the electric parts are controlled by switch manipulation of a driver and electric control of a control apparatus.
- a fuse is provided on a power line of the electric parts to be heated and shorted when abnormality occurs in electric systems or an excessive current is generated by overload, thereby protecting the electric parts.
- various types of fuse are integrated and installed in a fuse box.
- the multi-connector used for a junction box in the engine room includes a bus bar assembly adapted to receive an input of control signals and distribute the control signals as multiple outputs, and a fuse connected to the bus bar assembly to interrupt a circuit in case of an excessive current and thereby protect a device and a circuit.
- a conventional multi-connector is designed to be used at a lower voltage than the high voltage for the electric car or hybrid car, fire may occur when the conventional multi-connector is used for the high voltage. Furthermore, electrical interference between circuits may be generated and shielding performance may be reduced.
- Cited reference 1 discloses a high-voltage multi-connector which includes a main housing made of an insulating material and including an input terminal and an output terminal, a bus bar assembly mounted in the main housing to form a branch circuit between the input terminal and the output terminal, a fuse connected to the bus bar assembly to be interposed in the branch circuit, a fuse cover openably mounted to a part of the main housing for connection and separation of the fuse, and an interlock switch to interrupt a current flowing to the fuse in association with opening of the fuse cover.
- Cited reference 2 discloses a fuse mounting apparatus enabling size reduction of a main body by mounting a fuse in a seating portion recessed from a lower surface of the main body.
- An aspect of the present invention provides a fuse apparatus enabling easy mass production of a high-voltage fuse of a vehicle battery pack used for an electric car or hybrid car, and a manufacturing method thereof.
- Another aspect of the present invention provides a fuse apparatus minimizing a contact resistance of a high-voltage fuse for a vehicle, and a manufacturing method thereof.
- a fuse apparatus to be connected to a housing of a vehicle battery pack which includes a plurality of battery cells, wherein the fuse apparatus includes a fuse assembly provided with a fuse including a first bus bar and a second bus bar electrically connected with the vehicle battery pack, and a first lead wire and a second lead wire, and the first lead wire and the second lead wire are inserted and fixed in the first bus bar and the second bus bar.
- the fuse may be used for a high voltage and include a body provided in a cylindrical shape and the first lead wire and the second lead wire disposed at opposite ends of the body.
- the fuse apparatus may further include a fuse mounting portion to which the first bus bar and the second bus bar are connected.
- the first bus bar and the second bus bar may be fixed by stitching to opposite ends of the fuse mounting portion.
- the fuse mounting portion may include a plurality of support members for fixing the fuse.
- the fuse apparatus may further include a housing for receiving the fuse assembly.
- the housing may include a locking recess
- the fuse mounting portion may include a raised locking portion
- the fuse assembly may be mounted to the housing through engagement between the raised locking portion and the locking recess.
- the first bus bar and the second bus bar may each include an insertion portion
- the fuse mounting portion may include insertion holes corresponding to the insertion portions
- the first bus bar and the second bus bar may be connected to the fuse mounting portion by inserting the insertion portions into the insertion holes.
- the first bus bar and the second bus bar may each include an upright terminal, and the first lead wire and the second lead wire may be passed through the support members and resistance-welded to the upright terminals.
- the first bus bar and the second bus bar may each include a connection portion disposed at one side to contact an external connection member connected to the battery pack.
- a manufacturing method for a fuse apparatus including (a) preparing a first bus bar, a second bus bar, and a fuse mounting portion; (b) connecting the first bus bar and the second bus bar to the fuse mounting portion; (c) mounting a fuse to the fuse mounting portion; and (d) mounting a fuse assembly formed in (c) to a housing.
- (c) may include bonding lead wires of the fuse to the first bus bar and the second bus bar by resistance welding.
- (a) to (c) may be performed on a lead frame including a plurality of first bus bars and a plurality of second bus bars, and the fuse assembly is formed by cutting the lead frame corresponding to the fuse mounting portion.
- a high-voltage vehicle fuse for about 450 V or more for a vehicle battery pack used in an electric car or a hybrid car is provided. Furthermore, a contact interference of the fuse may be minimized.
- the fuse apparatus may be conveniently replaced.
- FIG. 1 is an exploded perspective view illustrating a configuration of a fuse apparatus according to an embodiment of the present invention
- FIG. 2 is an exploded perspective view illustrating a bus bar and a fuse mounting portion shown in FIG. 1;
- FIG. 3 is a perspective view of a back side of the fuse apparatus, illustrating connection relations between the bus bar and the fuse mounting portion shown in FIG. 2;
- FIG. 4 is a side view illustrating the bus bar shown in FIG. 2 connected to the fuse mounting portion;
- FIG. 5 is a perspective view illustrating connection relations between a fuse mounting portion and a housing in the fuse apparatus of FIG. 1;
- FIG. 6 is a perspective view illustrating connection relations between a bus bar and a connector of the fuse apparatus of FIG. 1;
- FIG. 7 is a perspective view illustrating the fuse apparatus of FIG. 1, being mounted to a vehicle battery pack;
- FIG. 8 is a partially cutaway perspective view illustrating connection relations between a bus bar and wiring, according to the embodiment of the present invention.
- FIG. 9 is a process view illustrating manufacturing processes of a fuse apparatus, according to an embodiment of the present invention.
- FIG. 10 is a perspective view illustrating a process of preparing a lead frame
- FIG. 11 is a perspective view illustrating a process of mounting the se mounting apparatus shown in FIG. 1;
- FIG. 12 is a perspective view illustrating a process of mounting a fuse shown in FIG. 1.
- FIGS. 1 to 5 a configuration and a manufacturing process of a fuse apparatus according to a first embodiment of the present invention will be described with reference to FIGS. 1 to 5.
- FIG. 1 is an exploded perspective view illustrating a configuration of a fuse apparatus according to an embodiment of the present invention.
- FIG. 2 is an exploded perspective view illustrating a bus bar and a fuse mounting portion shown in FIG. 1.
- FIG. 3 is a perspective view of a back side of the fuse apparatus, illustrating connection relations between the bus bar and the fuse mounting portion shown in FIG. 2.
- FIG. 4 is a side view illustrating the bus bar shown in FIG. 2 connected to the fuse mounting portion.
- FIG. 5 is a perspective view illustrating connection relations between a fuse mounting portion and a housing in the fuse apparatus of FIG. 1.
- the fuse apparatus is to be connected to a housing of a vehicle battery pack in which a plurality of battery cells are built in. As shown in FIGS. 1 and 2, the fuse apparatus includes a first bus bar 11, a second bus bar 12, a fuse mounting portion 20, a fuse 30 including a first lead wire 31 and a second lead wire 32, and a housing 40.
- the first bus bar 11 and the second bus bar 12 may be formed by stamping.
- the first bus bar 11 and the second bus bar 12 may each include an upright terminal 13 integrally bent by about 90°.
- the upright terminal 13 may include a substantial U-shape recess.
- the bus bar 11 and the second bus bar 12 may include an insertion portion 111 and 121 and a connection portion 112 and 122, respectively.
- the insertion portions 111 and 121 each include serrate portions 14 disposed on both sides, the serrate portions 14 each including a plurality of recesses for connection with the fuse mounting portion 20.
- the connection portion 112 of the first bus bar 11 is provided for electrical connection with an outside of the fuse apparatus and may be protruded to one side.
- the connection portion 122 of the second bus bar 12 mm be protruded into a substantial L shape.
- the first bus bar 11 and the second bus bar 12 may be fixed by stitching to opposite ends of the fuse mounting portion 20.
- a configuration of the first bus bar 11 and the second bus bar 12 may not be limited to the embodiment shown in FIG. 2 but be altered as necessary.
- the fuse mounting portion 20 may be formed by injection molding. As shown in FIG. 2, the fuse mounting portion 20 may include a plurality of support members for supporting the fuse 30 being inserted. As the support members, a first and second support plates 21 and 22 may be formed upright at opposite ends with respect to a width direction of the fuse mounting portion 20. The first and second support plates 21 and 22 may each include a support projection 23 formed inside to prevent separation of the inserted fuse 30. The support projection 23 may be inclined downward to ease insertion of the fuse 30. An end of the support projection 23 may be formed as a plane parallel with the fuse mounting portion 20 to fix the inserted fuse.
- the fuse mounting portion may include a pair of support plates 24 for supporting the wires 31 and 32 of the inserted fuse 30.
- the pair of support plates 24 are upright and disposed at opposite sides of the fuse mounting portion 20 with respect to a length direction.
- Each support plate 24 may include a substantial V-shape recess disposed corresponding to the U-shape recess of the upright terminal 13.
- a plurality of guide projections 25 may be formed at a lower portion of the fuse mounting portion 20 in the width direction.
- a raised locking portion 26 may be formed at a part of the guide projections 25 disposed at opposite sides.
- the pair of support plates 24 may each include an insertion hole 27 disposed at an outside and recessed by a depth corresponding to a length of the insertion portions 111 and 121, to insert the first bus bar 11 and the second bus bar 12.
- a structure corresponding to the serrate portion 14 of the first bus bar 11 and the second bus bar 12 is formed inside the insertion holes 27, so that the first bus bar 11 and the second bus bar 12 being inserted are prevented from separating.
- a maintaining projection 28 may be formed in the pair of support plates 24 to securely fix the fuse 30 in the inserted state, as shown in FIG. 2.
- Connection between the first and second bus bars 11 and 12 and the fuse mounting portion 20 may be easily performed by simply inserting the serrate portions 14 formed at the first bus bar 11 and the second bus bar 12 in the insertion holes 27 of the fuse mounting portion 20.
- the fuse 30 including the first and second lead wires 31 and 32 is mounted to the fuse mounting portion 20.
- Mounting of the fuse 30 may be performed by inserting a fuse body between the first support plate 21 and the second support plate 22 and inserting the first and second lead wires 31 and 32 in the U-shape recess of the upright terminal 13 and the V-shape recess of the maintaining plate 24.
- resistance welding may be performed with respect to the upright terminal 13 and the first and second lead wires 31 and 32 provided at the first and second bus bars 11 and 12, so as to minimize a contact interference.
- the embodiment of the present invention is described in such manner that resistance welding is performed, the present invention is not limited thereto and general electrical welding may also be applied.
- a fuse assembly as shown in FIG. 1 may be completed by mounting the fuse 30.
- the fuse assembly may be mounted to the housing 40 as shown in FIGS. 1 to 5.
- the fuse 30 may be used to protect electric and electronic circuits, as a fuse for an output, for example 500 VAC and 400 VCD, of a vehicle battery pack 100 mounted in an electric car or a hybrid car.
- a main body of the fuse 30 may be made of ceramic and a cap of the fuse 30 may be nickel-plated.
- the first and second lead wires 31 and 32 may include tin-plated copper.
- the housing 40 may include a first insertion portion 41 to receive the first bus bar 11, a first guide projection 42 to maintain the connection portion 112 to be exposed out of the housing 40, a plurality of second guide projections 43 to guide the plurality of guide projections 25 during insertion of the fuse mounting portion 20, a second insertion portion 44 to receive the second bus bar 12, and a locking recess 45 to be engaged with and thereby fix the raised locking portion 26 to prevent separation of the fuse assembly.
- An outside of the first insertion portion 41 may function as a locking projection fixed to the housing of the battery pack 100 when the fuse apparatus is mounted to the vehicle battery pack 100.
- the fuse apparatus may be structured by fitting the fuse assembly along with the first insertion portion 41, the first guide projection 42, and the second guide projections 43 of the housing 40 and by engaging the raised locking portion 26 with the locking recess 45.
- the fuse mounting portion 20 and the housing 40 may be made of an insulating material, for example plastic or synthetic resin, for insulation with the first and second bus bars 11 and 12, the connector, and the like.
- the fuse apparatus structured as aforementioned may be mounted to the vehicle battery pack as shown in FIGS. 6 and 7.
- FIG. 6 is a perspective view illustrating connection relations between a bus bar and a connector of the fuse apparatus of FIG. 1.
- FIG. 7 is a perspective view illustrating the fuse apparatus of FIG. 1, being mounted to a vehicle battery pack 100.
- FIG. 8 is a partially cutaway perspective view illustrating connection relations between a bus bar and wiring 60 according to an embodiment of the present invention.
- the first bus bar 11 is fit in a connection terminal 51 of a connector 50 provided at the vehicle battery pack 100.
- the second bus bar 12 may be connected to the wiring 60 as shown in FIG. 8.
- the housing 40 may include a wiring guide portion 46 to guide insertion of the wiring 60.
- the wiring 60 may be inserted through the wiring guide portion 46 and connected to the second bus bar 12. Connection between the second bus bar 12 and the wiring 60 may be achieved by a general electrical connection method.
- FIG. 9 is a process view illustrating manufacturing processes of a fuse apparatus, according to an embodiment of the present invention.
- first and second bus bars 11 and 12 and the fuse mounting portion 20 as shown in FIG. 2 are prepared in operation S10.
- the first and second bus bars 11 and 12 may be formed by stamping.
- the upright terminal 13 may be formed by bending the first and second bus bars 11 and 12 by about 90°.
- the fuse mounting portion 20 may be formed by injection molding.
- the first and second bus bars 11 and 12 are connected to the fuse mounting portion 20 in operation S20. Connection between the first and second bus bars 11 and 12 and the fuse mounting portion 20 may be achieved easily by inserting the insertion portions 111 and 121 of the first and second bus bars 11 and 12 in the insertion holes 27 formed at the outside of the pair of support plates 24 of the fuse mounting portion 20, as shown in FIG. 3.
- Operation S30 may include a process of performing resistance welding with respect to the upright terminals 13 formed at the first and second bus bars 11 and 12 and with respect to the first and second lead wires 31 and 32.
- the fuse assembly formed in operation S30 may be mounted to the housing 40 as shown in FIGS. 1 and 5, thereby completing the fuse apparatus as shown in FIG. 6 in operation S40.
- operations S20 to S40 may be performed by an automated process.
- FIG. 10 is a perspective view illustrating a process of preparing a lead frame.
- FIG. 11 is a perspective view illustrating a process of mounting the fuse mounting apparatus shown in FIG. 1; and
- FIG. 12 is a perspective view illustrating a process of mounting a fuse shown in FIG. 1.
- a lead frame 10 including a first and second bus bars 11 and 12 is prepared in operation S10.
- the lead frame 10 may be implemented by a general process of forming a lead frame.
- An upright terminal 13 may be formed at the first and second bus bars 11 and 12, respectively, by die process or press process.
- a substantial U-shape recess may be formed at the upright terminals 13.
- a serrate portion 14 including a plurality of recesses for molding with the fuse mounting portion 20, which will be described later, may be formed at opposite sides of the first and second bus bars 11 and 12.
- FIG. 10 illustrates an example in which three first bus bars 11 and second bus bars 12 are included respectively, the present invention is not limited to the example. The number of first and second bus bars 11 and 12 may be varied according to use.
- the fuse mounting portion 20 is mounted to the first and second bus bars 11 and 12.
- connection between the first and second bus bars 11 and 12 and the fuse mounting portion 20 is performed by insert molding.
- the insert molding is performed such that the serrate portions 14 formed at the first and second bus bars 11 and 12 are inserted in the fuse mounting portion 20. Accordingly, the fuse mounting portion 20 may be mounted on the first and second bus bars 11 and 12.
- a fuse 30 including first and second lead wires 31 and 32 is mounted to the fuse mounting portion 20. Resistance welding may be performed with respect to the upright terminal 13 and the first and second lead wires 31 and 32 provided at the first and second bus bars 11 and 12.
- the fuse assembly is completed by mounting the fuse 30.
- the fuse assembly is cut in the lead frame 10 and thereby manufactured as a single product. That is, the fuse assembly is manufactured by cutting the lead frame 10 corresponding to the fuse mounting portion 20.
- the vehicle fuse apparatus may be applied to a vehicle using about 450 V or more.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Fuses (AREA)
- Battery Mounting, Suspending (AREA)
Abstract
Description
- The present invention relates to a fuse apparatus and a manufacturing method thereof, and more particularly, to a fuse apparatus for a vehicle, the fuse apparatus especially applied to a vehicle battery pack of a high voltage, for example 450 V or more, for an electric car or a hybrid car, and a manufacturing method thereof.
- Generally, a vehicle includes various electric apparatuses for driving of the vehicle and convenience for a rider. The electric apparatuses (hereinafter, referred to as 'electric parts') are electrically connected to a battery and a generator to be supplied with power necessary for operation. The electric parts are controlled by switch manipulation of a driver and electric control of a control apparatus.
- A fuse is provided on a power line of the electric parts to be heated and shorted when abnormality occurs in electric systems or an excessive current is generated by overload, thereby protecting the electric parts. For convenient management, various types of fuse are integrated and installed in a fuse box.
- With development of an electric car or hybrid car using a high voltage and according to downsizing of an engine room of these days, demands for a multi-connector for distributing power or control signals to various electric parts in the car are increasing. In general, the multi-connector used for a junction box in the engine room includes a bus bar assembly adapted to receive an input of control signals and distribute the control signals as multiple outputs, and a fuse connected to the bus bar assembly to interrupt a circuit in case of an excessive current and thereby protect a device and a circuit.
- However, since a conventional multi-connector is designed to be used at a lower voltage than the high voltage for the electric car or hybrid car, fire may occur when the conventional multi-connector is used for the high voltage. Furthermore, electrical interference between circuits may be generated and shielding performance may be reduced.
- Example technologies for solving the foregoing limits are disclosed in cite references 1 and 2.
- Cited reference 1 discloses a high-voltage multi-connector which includes a main housing made of an insulating material and including an input terminal and an output terminal, a bus bar assembly mounted in the main housing to form a branch circuit between the input terminal and the output terminal, a fuse connected to the bus bar assembly to be interposed in the branch circuit, a fuse cover openably mounted to a part of the main housing for connection and separation of the fuse, and an interlock switch to interrupt a current flowing to the fuse in association with opening of the fuse cover.
- Cited reference 2 discloses a fuse mounting apparatus enabling size reduction of a main body by mounting a fuse in a seating portion recessed from a lower surface of the main body.
-
- Cited references
- Patent documents
- (Cited reference 0001) KR Patent Publication No. 2011-0037217 (laid-open on April 13, 2011)
- (Cited reference 0002) KR Utility Model Publication No. 2012-0004040 (laid-open on June 8, 2012)
- However, a high-voltage fuse for a vehicle battery pack is not disclosed in the foregoing conventional arts.
- In addition, according to the conventional fuse apparatus as described above, replacement of the fuse is inconvenient and manufacturing process of the fuse mounting apparatus is complicated.
- An aspect of the present invention provides a fuse apparatus enabling easy mass production of a high-voltage fuse of a vehicle battery pack used for an electric car or hybrid car, and a manufacturing method thereof.
- Another aspect of the present invention provides a fuse apparatus minimizing a contact resistance of a high-voltage fuse for a vehicle, and a manufacturing method thereof.
- According to an aspect of the present invention, there is provided a fuse apparatus to be connected to a housing of a vehicle battery pack which includes a plurality of battery cells, wherein the fuse apparatus includes a fuse assembly provided with a fuse including a first bus bar and a second bus bar electrically connected with the vehicle battery pack, and a first lead wire and a second lead wire, and the first lead wire and the second lead wire are inserted and fixed in the first bus bar and the second bus bar.
- The fuse may be used for a high voltage and include a body provided in a cylindrical shape and the first lead wire and the second lead wire disposed at opposite ends of the body.
- The fuse apparatus may further include a fuse mounting portion to which the first bus bar and the second bus bar are connected.
- The first bus bar and the second bus bar may be fixed by stitching to opposite ends of the fuse mounting portion.
- The fuse mounting portion may include a plurality of support members for fixing the fuse.
- The fuse apparatus may further include a housing for receiving the fuse assembly.
- The housing may include a locking recess, the fuse mounting portion may include a raised locking portion, and the fuse assembly may be mounted to the housing through engagement between the raised locking portion and the locking recess.
- The first bus bar and the second bus bar may each include an insertion portion, the fuse mounting portion may include insertion holes corresponding to the insertion portions, and the first bus bar and the second bus bar may be connected to the fuse mounting portion by inserting the insertion portions into the insertion holes.
- The first bus bar and the second bus bar may each include an upright terminal, and the first lead wire and the second lead wire may be passed through the support members and resistance-welded to the upright terminals.
- The first bus bar and the second bus bar may each include a connection portion disposed at one side to contact an external connection member connected to the battery pack.
- According to an aspect of the present invention, there is provided a manufacturing method for a fuse apparatus, the method including (a) preparing a first bus bar, a second bus bar, and a fuse mounting portion; (b) connecting the first bus bar and the second bus bar to the fuse mounting portion; (c) mounting a fuse to the fuse mounting portion; and (d) mounting a fuse assembly formed in (c) to a housing.
- (c) may include bonding lead wires of the fuse to the first bus bar and the second bus bar by resistance welding.
- (b) and (c) may be performed by an automated process.
- (a) to (c) may be performed on a lead frame including a plurality of first bus bars and a plurality of second bus bars, and the fuse assembly is formed by cutting the lead frame corresponding to the fuse mounting portion.
- As aforementioned, according to a fuse apparatus and a manufacturing method thereof in accordance with an embodiment of the present invention, a high-voltage vehicle fuse for about 450 V or more for a vehicle battery pack used in an electric car or a hybrid car is provided. Furthermore, a contact interference of the fuse may be minimized.
- In addition, according to the fuse apparatus and the manufacturing method thereof, mass production of the fuse apparatus may be conveniently performed.
- Also, according to the fuse apparatus and the manufacturing method thereof, the fuse apparatus may be conveniently replaced.
- FIG. 1 is an exploded perspective view illustrating a configuration of a fuse apparatus according to an embodiment of the present invention;
- FIG. 2 is an exploded perspective view illustrating a bus bar and a fuse mounting portion shown in FIG. 1;
- FIG. 3 is a perspective view of a back side of the fuse apparatus, illustrating connection relations between the bus bar and the fuse mounting portion shown in FIG. 2;
- FIG. 4 is a side view illustrating the bus bar shown in FIG. 2 connected to the fuse mounting portion;
- FIG. 5 is a perspective view illustrating connection relations between a fuse mounting portion and a housing in the fuse apparatus of FIG. 1;
- FIG. 6 is a perspective view illustrating connection relations between a bus bar and a connector of the fuse apparatus of FIG. 1;
- FIG. 7 is a perspective view illustrating the fuse apparatus of FIG. 1, being mounted to a vehicle battery pack;
- FIG. 8 is a partially cutaway perspective view illustrating connection relations between a bus bar and wiring, according to the embodiment of the present invention;
- FIG. 9 is a process view illustrating manufacturing processes of a fuse apparatus, according to an embodiment of the present invention;
- FIG. 10 is a perspective view illustrating a process of preparing a lead frame;
- FIG. 11 is a perspective view illustrating a process of mounting the se mounting apparatus shown in FIG. 1; and
- FIG. 12 is a perspective view illustrating a process of mounting a fuse shown in FIG. 1.
- Other objects and features of the invention will become apparent upon reading the following detailed description and upon reference to the drawings.
- Hereinafter, a configuration and a manufacturing process of a fuse apparatus according to a first embodiment of the present invention will be described with reference to FIGS. 1 to 5.
- FIG. 1 is an exploded perspective view illustrating a configuration of a fuse apparatus according to an embodiment of the present invention. FIG. 2 is an exploded perspective view illustrating a bus bar and a fuse mounting portion shown in FIG. 1. FIG. 3 is a perspective view of a back side of the fuse apparatus, illustrating connection relations between the bus bar and the fuse mounting portion shown in FIG. 2. FIG. 4 is a side view illustrating the bus bar shown in FIG. 2 connected to the fuse mounting portion. FIG. 5 is a perspective view illustrating connection relations between a fuse mounting portion and a housing in the fuse apparatus of FIG. 1.
- The fuse apparatus according to the embodiment of the present invention is to be connected to a housing of a vehicle battery pack in which a plurality of battery cells are built in. As shown in FIGS. 1 and 2, the fuse apparatus includes a first bus bar 11, a second bus bar 12, a fuse mounting portion 20, a fuse 30 including a first lead wire 31 and a second lead wire 32, and a housing 40.
- The first bus bar 11 and the second bus bar 12 may be formed by stamping. The first bus bar 11 and the second bus bar 12 may each include an upright terminal 13 integrally bent by about 90°. The upright terminal 13 may include a substantial U-shape recess.
- In addition, the bus bar 11 and the second bus bar 12 may include an insertion portion 111 and 121 and a connection portion 112 and 122, respectively. As shown in FIG. 2, the insertion portions 111 and 121 each include serrate portions 14 disposed on both sides, the serrate portions 14 each including a plurality of recesses for connection with the fuse mounting portion 20. The connection portion 112 of the first bus bar 11 is provided for electrical connection with an outside of the fuse apparatus and may be protruded to one side. The connection portion 122 of the second bus bar 12 mm be protruded into a substantial L shape. The first bus bar 11 and the second bus bar 12 may be fixed by stitching to opposite ends of the fuse mounting portion 20.
- A configuration of the first bus bar 11 and the second bus bar 12 may not be limited to the embodiment shown in FIG. 2 but be altered as necessary.
- The fuse mounting portion 20 may be formed by injection molding. As shown in FIG. 2, the fuse mounting portion 20 may include a plurality of support members for supporting the fuse 30 being inserted. As the support members, a first and second support plates 21 and 22 may be formed upright at opposite ends with respect to a width direction of the fuse mounting portion 20. The first and second support plates 21 and 22 may each include a support projection 23 formed inside to prevent separation of the inserted fuse 30. The support projection 23 may be inclined downward to ease insertion of the fuse 30. An end of the support projection 23 may be formed as a plane parallel with the fuse mounting portion 20 to fix the inserted fuse.
- Additionally, the fuse mounting portion may include a pair of support plates 24 for supporting the wires 31 and 32 of the inserted fuse 30. The pair of support plates 24 are upright and disposed at opposite sides of the fuse mounting portion 20 with respect to a length direction. Each support plate 24 may include a substantial V-shape recess disposed corresponding to the U-shape recess of the upright terminal 13.
- A plurality of guide projections 25 may be formed at a lower portion of the fuse mounting portion 20 in the width direction. A raised locking portion 26 may be formed at a part of the guide projections 25 disposed at opposite sides. In addition, the pair of support plates 24 may each include an insertion hole 27 disposed at an outside and recessed by a depth corresponding to a length of the insertion portions 111 and 121, to insert the first bus bar 11 and the second bus bar 12. A structure corresponding to the serrate portion 14 of the first bus bar 11 and the second bus bar 12 is formed inside the insertion holes 27, so that the first bus bar 11 and the second bus bar 12 being inserted are prevented from separating.
- Additionally, a maintaining projection 28 may be formed in the pair of support plates 24 to securely fix the fuse 30 in the inserted state, as shown in FIG. 2.
- Connection between the first and second bus bars 11 and 12 and the fuse mounting portion 20 may be easily performed by simply inserting the serrate portions 14 formed at the first bus bar 11 and the second bus bar 12 in the insertion holes 27 of the fuse mounting portion 20.
- Next, the fuse 30 including the first and second lead wires 31 and 32 is mounted to the fuse mounting portion 20.
- Mounting of the fuse 30 may be performed by inserting a fuse body between the first support plate 21 and the second support plate 22 and inserting the first and second lead wires 31 and 32 in the U-shape recess of the upright terminal 13 and the V-shape recess of the maintaining plate 24. Next, resistance welding may be performed with respect to the upright terminal 13 and the first and second lead wires 31 and 32 provided at the first and second bus bars 11 and 12, so as to minimize a contact interference. Although the embodiment of the present invention is described in such manner that resistance welding is performed, the present invention is not limited thereto and general electrical welding may also be applied.
- Thus, a fuse assembly as shown in FIG. 1 may be completed by mounting the fuse 30. The fuse assembly may be mounted to the housing 40 as shown in FIGS. 1 to 5.
- The fuse 30 may be used to protect electric and electronic circuits, as a fuse for an output, for example 500 VAC and 400 VCD, of a vehicle battery pack 100 mounted in an electric car or a hybrid car. A main body of the fuse 30 may be made of ceramic and a cap of the fuse 30 may be nickel-plated. The first and second lead wires 31 and 32 may include tin-plated copper.
- As shown in FIGS. 1 and 5, the housing 40 may include a first insertion portion 41 to receive the first bus bar 11, a first guide projection 42 to maintain the connection portion 112 to be exposed out of the housing 40, a plurality of second guide projections 43 to guide the plurality of guide projections 25 during insertion of the fuse mounting portion 20, a second insertion portion 44 to receive the second bus bar 12, and a locking recess 45 to be engaged with and thereby fix the raised locking portion 26 to prevent separation of the fuse assembly. An outside of the first insertion portion 41 may function as a locking projection fixed to the housing of the battery pack 100 when the fuse apparatus is mounted to the vehicle battery pack 100.
- That is, as shown in FIGS. 1 to 5, the fuse apparatus may be structured by fitting the fuse assembly along with the first insertion portion 41, the first guide projection 42, and the second guide projections 43 of the housing 40 and by engaging the raised locking portion 26 with the locking recess 45.
- In addition, the fuse mounting portion 20 and the housing 40 may be made of an insulating material, for example plastic or synthetic resin, for insulation with the first and second bus bars 11 and 12, the connector, and the like.
- The fuse apparatus structured as aforementioned may be mounted to the vehicle battery pack as shown in FIGS. 6 and 7.
- FIG. 6 is a perspective view illustrating connection relations between a bus bar and a connector of the fuse apparatus of FIG. 1. FIG. 7 is a perspective view illustrating the fuse apparatus of FIG. 1, being mounted to a vehicle battery pack 100. FIG. 8 is a partially cutaway perspective view illustrating connection relations between a bus bar and wiring 60 according to an embodiment of the present invention.
- As shown in FIG. 6, in the fuse apparatus, the first bus bar 11 is fit in a connection terminal 51 of a connector 50 provided at the vehicle battery pack 100. The second bus bar 12 may be connected to the wiring 60 as shown in FIG. 8. The housing 40 may include a wiring guide portion 46 to guide insertion of the wiring 60. The wiring 60 may be inserted through the wiring guide portion 46 and connected to the second bus bar 12. Connection between the second bus bar 12 and the wiring 60 may be achieved by a general electrical connection method.
- Next, a manufacturing process for a fuse apparatus according to a first embodiment of the present invention will be described with reference to FIG. 9.
- FIG. 9 is a process view illustrating manufacturing processes of a fuse apparatus, according to an embodiment of the present invention.
- First, the first and second bus bars 11 and 12 and the fuse mounting portion 20 as shown in FIG. 2 are prepared in operation S10. As aforementioned, the first and second bus bars 11 and 12 may be formed by stamping. The upright terminal 13 may be formed by bending the first and second bus bars 11 and 12 by about 90°. The fuse mounting portion 20 may be formed by injection molding.
- As shown in FIG. 3, the first and second bus bars 11 and 12 are connected to the fuse mounting portion 20 in operation S20. Connection between the first and second bus bars 11 and 12 and the fuse mounting portion 20 may be achieved easily by inserting the insertion portions 111 and 121 of the first and second bus bars 11 and 12 in the insertion holes 27 formed at the outside of the pair of support plates 24 of the fuse mounting portion 20, as shown in FIG. 3.
- Next, the fuse 30 including the first and second lead wires 31 and 32 is mounted to the fuse mounting portion 20 in operation S30. Operation S30 may include a process of performing resistance welding with respect to the upright terminals 13 formed at the first and second bus bars 11 and 12 and with respect to the first and second lead wires 31 and 32.
- Next, the fuse assembly formed in operation S30 may be mounted to the housing 40 as shown in FIGS. 1 and 5, thereby completing the fuse apparatus as shown in FIG. 6 in operation S40.
- Here, operations S20 to S40 may be performed by an automated process.
- A second embodiment of the present invention will be described with reference to FIGS. 10 to 12.
- FIG. 10 is a perspective view illustrating a process of preparing a lead frame. FIG. 11 is a perspective view illustrating a process of mounting the fuse mounting apparatus shown in FIG. 1; and FIG. 12 is a perspective view illustrating a process of mounting a fuse shown in FIG. 1.
- As shown in FIG. 10, first, a lead frame 10 including a first and second bus bars 11 and 12 is prepared in operation S10. The lead frame 10 may be implemented by a general process of forming a lead frame. An upright terminal 13 may be formed at the first and second bus bars 11 and 12, respectively, by die process or press process. A substantial U-shape recess may be formed at the upright terminals 13.
- A serrate portion 14 including a plurality of recesses for molding with the fuse mounting portion 20, which will be described later, may be formed at opposite sides of the first and second bus bars 11 and 12.
- Although FIG. 10 illustrates an example in which three first bus bars 11 and second bus bars 12 are included respectively, the present invention is not limited to the example. The number of first and second bus bars 11 and 12 may be varied according to use.
- Next, as shown in FIG. 11, the fuse mounting portion 20 is mounted to the first and second bus bars 11 and 12.
- Since the fuse mounting portion 20 is configured in the same manner as in the first embodiment except the insertion holes 27, a same description will not be repeated. That is, connection between the first and second bus bars 11 and 12 and the fuse mounting portion 20 is performed by insert molding. In detail, the insert molding is performed such that the serrate portions 14 formed at the first and second bus bars 11 and 12 are inserted in the fuse mounting portion 20. Accordingly, the fuse mounting portion 20 may be mounted on the first and second bus bars 11 and 12.
- Next, as shown in FIG. 12, a fuse 30 including first and second lead wires 31 and 32 is mounted to the fuse mounting portion 20. Resistance welding may be performed with respect to the upright terminal 13 and the first and second lead wires 31 and 32 provided at the first and second bus bars 11 and 12.
- Thus, the fuse assembly is completed by mounting the fuse 30. The fuse assembly is cut in the lead frame 10 and thereby manufactured as a single product. That is, the fuse assembly is manufactured by cutting the lead frame 10 corresponding to the fuse mounting portion 20.
- Next, by mounting the fuse assembly to the housing as shown in FIGS. 1 and 5, the fuse apparatus according to the first embodiment may be completed.
- Although a few embodiments of the present invention have been shown and described, the present invention is not limited to the described embodiments. Instead, it would be appreciated by those skilled in the art that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
- Using a vehicle fuse apparatus and a manufacturing method thereof according to an embodiment of the present invention, the vehicle fuse apparatus may be applied to a vehicle using about 450 V or more.
Claims (14)
- A fuse apparatus to be connected to a housing of a vehicle battery pack which includes a plurality of battery cells, whereinthe fuse apparatus comprises a fuse assembly provided with a fuse comprising a first bus bar and a second bus bar electrically connected with the vehicle battery pack, and a first lead wire and a second lead wire, andthe first lead wire and the second lead wire are inserted and fixed in the first bus bar and the second bus bar.
- The fuse apparatus of claim 1, wherein the fuse is used for a high voltage and comprises a body provided in a cylindrical shape and the first lead wire and the second lead wire disposed at opposite ends of the body.
- The fuse apparatus of claim 1, further comprising a fuse mounting portion to which the first bus bar and the second bus bar are connected.
- The fuse apparatus of claim 3, wherein the first bus bar and the second bus bar are fixed by stitching to opposite ends of the fuse mounting portion.
- The fuse apparatus of claim 3, wherein the fuse mounting portion comprises a plurality of support members for fixing the fuse.
- The fuse apparatus of claim 3, further comprising a housing for receiving the fuse assembly.
- The fuse apparatus of claim 6, whereinthe housing comprises a locking recess,the fuse mounting portion comprises a raised locking portion, andthe fuse assembly is mounted to the housing through engagement between the raised locking portion and the locking recess.
- The fuse apparatus of claim 4, whereinthe first bus bar and the second bus bar each comprise an insertion portion,the fuse mounting portion comprises insertion holes corresponding to the insertion portions, andthe first bus bar and the second bus bar are connected to the fuse mounting portion by inserting the insertion portions into the insertion holes.
- The fuse apparatus of claim 5, whereinthe first bus bar and the second bus bar each comprise an upright terminal, andthe first lead wire and the second lead wire are passed through the support members and resistance-welded to the upright terminals.
- The fuse apparatus of claim 8 or claim 9, wherein the first bus bar and the second bus bar each comprise a connection portion disposed at one side to contact an external connection member connected to the battery pack.
- A manufacturing method for a fuse apparatus, the method comprising:(a) preparing a first bus bar, a second bus bar, and a fuse mounting portion;(b) connecting the first bus bar and the second bus bar to the fuse mounting portion;(c) mounting a fuse to the fuse mounting portion, thereby forming a fuse assembly; and(d) mounting the fuse assembly to a housing.
- The method of claim 11, wherein (c) comprises bonding lead wires of the fuse to the first bus bar and the second bus bar by resistance welding.
- The method of claim 11, wherein (b) and (c) are performed by an automated process.
- The method of claim 11, wherein (a) to (c) are performed on a lead frame including a plurality of first bus bars and a plurality of second bus bars, and the fuse assembly is formed by cutting the lead frame corresponding to the fuse mounting portion.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1020120071189A KR101873066B1 (en) | 2012-06-29 | 2012-06-29 | Fuse apparatus and manufacturing method thereof |
PCT/KR2013/005386 WO2014003353A1 (en) | 2012-06-29 | 2013-06-19 | Fuse apparatus and manufacturing method thereof |
Publications (3)
Publication Number | Publication Date |
---|---|
EP2867914A1 true EP2867914A1 (en) | 2015-05-06 |
EP2867914A4 EP2867914A4 (en) | 2016-03-09 |
EP2867914B1 EP2867914B1 (en) | 2017-08-09 |
Family
ID=49783444
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP13808521.2A Active EP2867914B1 (en) | 2012-06-29 | 2013-06-19 | Fuse apparatus and manufacturing method thereof |
Country Status (4)
Country | Link |
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EP (1) | EP2867914B1 (en) |
KR (1) | KR101873066B1 (en) |
CN (1) | CN104603905B (en) |
WO (1) | WO2014003353A1 (en) |
Families Citing this family (5)
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KR101529835B1 (en) * | 2014-12-16 | 2015-06-29 | 스마트전자 주식회사 | Fuse resistor and manufacturing method thereof |
US10044022B2 (en) | 2015-10-28 | 2018-08-07 | Ford Global Technologies, Llc | Finger proof fuse retention |
KR101864290B1 (en) * | 2017-03-06 | 2018-06-04 | 영화테크(주) | Assembly Structure of Inter Connected Board Module for High Voltage Battery |
KR102379227B1 (en) * | 2018-12-26 | 2022-03-24 | 주식회사 엘지에너지솔루션 | Battery module, battery pack comprising the battery module and vehicle comprising the battery pack |
CN110774903B (en) * | 2019-11-25 | 2024-05-28 | 威马智慧出行科技(上海)有限公司 | Battery pack device and automobile |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2738486A (en) * | 1953-12-28 | 1956-03-13 | Howard M Wadsworth | Universal mounting clip |
BE639102A (en) * | 1962-12-18 | |||
FR2393505A1 (en) | 1977-06-02 | 1978-12-29 | Ast Ind Sarl | Printed circuit support for e.g. electrical fuse, diode etc. - uses two conductor drilled printed circuit plate with fitting clips |
JP3566573B2 (en) | 1999-03-01 | 2004-09-15 | 矢崎総業株式会社 | Power shut-off device |
US6162097A (en) * | 1999-09-17 | 2000-12-19 | Liang; Shih-Tsung | Fuse box |
JP2002204518A (en) * | 2001-01-09 | 2002-07-19 | Auto Network Gijutsu Kenkyusho:Kk | Bus-bar connecting structure |
JP2003031108A (en) * | 2001-07-16 | 2003-01-31 | Yazaki Corp | Installation structure of fuse |
JP2003203552A (en) * | 2002-01-09 | 2003-07-18 | Matsushita Electric Ind Co Ltd | Fuse and method of manufacture |
KR20110037217A (en) | 2009-10-06 | 2011-04-13 | 엘에스전선 주식회사 | High voltage multi connector |
KR20110107169A (en) * | 2010-03-24 | 2011-09-30 | 한국단자공업 주식회사 | Multi fuse |
KR200455204Y1 (en) * | 2010-04-19 | 2011-08-23 | 오리셀 주식회사 | Housing device for high voltage fuse |
KR20120004040A (en) | 2010-07-06 | 2012-01-12 | 삼성전자주식회사 | Plasma generating apparatus |
KR20120004040U (en) | 2010-11-30 | 2012-06-08 | 한국단자공업 주식회사 | Fuse mounting apparatus |
-
2012
- 2012-06-29 KR KR1020120071189A patent/KR101873066B1/en active IP Right Grant
-
2013
- 2013-06-19 EP EP13808521.2A patent/EP2867914B1/en active Active
- 2013-06-19 CN CN201380034556.6A patent/CN104603905B/en active Active
- 2013-06-19 WO PCT/KR2013/005386 patent/WO2014003353A1/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
KR20140003871A (en) | 2014-01-10 |
EP2867914A4 (en) | 2016-03-09 |
KR101873066B1 (en) | 2018-06-29 |
CN104603905A (en) | 2015-05-06 |
EP2867914B1 (en) | 2017-08-09 |
CN104603905B (en) | 2017-06-30 |
WO2014003353A1 (en) | 2014-01-03 |
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