Battery Module

TECHNICAL FIELD

The present invention relates to battery modules each having a plurality of battery cells.

BACKGROUND ART

A plurality of battery cells making up a battery module are joined to each other at their terminals via a connecting conductor called a busbar. The background art relating to this busbar includes a technique disclosed in Patent Literature 1. Patent Literature 1 describes a busbar including a copper part (701) that is laser welded to a negative electrode group and is made of a copper material, and an aluminum part (702) that is laser welded to a cell positive electrode group and is made of aluminum. This busbar is configured to linearly weld (705) these two parts made of two types of metals by an ultrasonic roller seam welding process (see paragraphs 0064, 0067 and FIG. 15).

CITATION LIST
Patent Literature

Patent Literature 1: JP 2012-515418 A

SUMMARY OF INVENTION
Technical Problem

A busbar joining the terminals of a plurality of batteries receives stress caused by vibrations applied to the battery module or a bulging of the battery cells during charging/discharging. A busbar including dissimilar metals joined as in Patent Literature 1 therefore has to be configured to keep a joint strength high so that the joint between the dissimilar metals does not peel off when stress acts on the joint between the dissimilar metals.

Solution to Problem

One of the major aims of the present application is to keep a joint strength high at the joint between dissimilar metals of a busbar.

One of typical aspects of the present invention to solve the above problems relates to a battery module including: a plurality of battery cells each having terminals; and busbars each joining the terminals of the battery cells. Each busbar has: a plurality of connection face portions each connected to a corresponding one of the terminals to be joined; a plurality of rising portions each rising from a corresponding one of the plurality of connection face portions; and a connection portion connecting the plurality of rising portions. The busbar includes a copper portion containing copper and an aluminum portion containing aluminum. A joint between the copper portion and the aluminum portion is located on the connection face portion connected to the battery terminal. The connection face portion having the joint between the copper portion and the aluminum portion is connected to the battery cell terminal that is a strong member. This increases the rigidity at the joint between the copper portion and the aluminum portion and so increases the natural frequency, thus reducing stress acting on the joint between the copper portion and the aluminum portion. This configuration therefore keeps a joint strength high at the joint between the copper portion and the aluminum portion.

According to another aspect of the present invention to solve the above problems, a battery module includes a joint between the copper portion and the aluminum portion that is located on the rising portions rising from the connection face portions, and the copper portion and the aluminum portion are partially bent in a hook shape and are joined to each other at inner faces. In this way, a partial face of the copper portion and a partial face of the aluminum portion that define the rising portion are bent in a hook shape and are joined to each other at their inner faces, and this configuration allows the joint to receive a reactive force in the direction opposite to the stress acting on the joint between the copper portion and the aluminum portion. As a result, the stress acting on the joint between the copper portion and the aluminum portion is reduced. This configuration therefore keeps a joint strength high at the joint between the copper portion and the aluminum portion.

Advantageous Effects of Invention

Major aspects of the present invention keep a joint strength high at the joint between dissimilar metals of the copper portion and the aluminum portion. This therefore enhances the resistance of the battery module against vibrations, and so provides a reliable battery module having excellent resistance.

Further features of the present invention will be clear from the following descriptions and the attached drawings. Other problems, configurations and advantageous effects also will be clear from the following descriptions of the embodiments.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view showing the appearance of a battery module according to Embodiment 1 of the present invention.

FIG. 2 is an exploded perspective view of the battery module in FIG. 1.

FIG. 3 is an enlarged cross sectional view of the major part of the battery module in FIG. 1.

FIG. 4 is a perspective view of the busbar shown in FIG. 3.

FIG. 5 is a plan view of the busbar shown in FIG. 3.

FIG. 6 is an enlarged perspective view of a module terminal of the battery module in FIG. 1.

FIG. 7 is an enlarged cross sectional view of the module terminal taken along the line VII-VII of FIG. 6.

FIG. 8 is a perspective view of a busbar having a fuse that is connected to one of the module terminals that is shown in FIG. 6.

FIG. 9 is a perspective view of a busbar that is connected to the other module terminal different from the module terminal shown in FIG. 6.

FIG. 10 is a perspective view of a busbar connecting battery cells of a battery module according to Embodiment 2 of the present invention.

FIG. 11 is a plan view of the busbar shown in FIG. 10.

FIG. 12 is a side view of the busbar shown in FIG. 10.

FIG. 13 is a perspective view of a busbar connecting battery cells of a battery module according to Embodiment 3 of the present invention.

FIG. 14 is a plan view of the busbar shown in FIG. 13.

FIG. 15 is a side view of the busbar shown in FIG. 13.

FIG. 16 is a perspective view of a busbar placed on cell terminals.

FIG. 17 is a perspective view of a busbar having a voltage detection wire joint disposed at a copper portion of the connection face portion.

FIG. 18 is a perspective view of a busbar having a voltage detection wire joint disposed at an aluminum portion of the connection face portion.

DESCRIPTION OF EMBODIMENTS

The following describes some embodiments of the present invention, with reference to the attached drawings.

The following may describe various parts of the battery module while referring to the orthogonal coordinate system having x axis, y axis, and z axis as shown in the drawings or the directional terms, such as upper, lower, left, right, front, and rear. These axes and directions are used for convenience in describing the illustrated state of the battery module, and do not limit the posture or arrangement of the battery module.

Embodiment 1

FIGS. 1 to 9 show Embodiment 1 of the present invention.

First, the configuration of a battery module 100 will be described referring to FIGS. 1 and 2. FIG. 1 is a perspective view showing the appearance of the battery module 100, and FIG. 2 is an exploded perspective view of the battery module 100.

The battery module 100 mainly includes: module terminals 101P and 101N that are external terminals; a battery cell group 10 including a plurality of battery cells 1; and busbars 2 electrically and mechanically connecting the plurality of battery cells 1 of this battery cell group 10 and electrically and mechanically connecting this battery cell group 10 with the module terminals 101P and 101N. The detailed configuration will be described later, and the most distinctive feature of this embodiment is the busbars 2 that electrically and mechanically connect the plurality of battery cells 1. The battery module 100 includes a housing 20 and an electronic circuit board not shown in addition to the components described above.

The battery cell group 10 is configured so that flattened rectangular battery cells 1, i.e., thin hexahedral or cuboid battery cells 1 having the thickness smaller than the width and the height, are stacked in the thickness direction (x-axis direction). Each battery cell 1 is a rectangular lithium-ion secondary battery, and includes a flattened rectangular cell case 1a, an electrode group and electrolyte not shown that are stored in this cell case 1a, and a pair of cell terminals 1p and 1n connecting to the electrode group and disposed on the vertically upper end face of the cell case 1a. Note here that the cell terminal 1p is a positive electrode terminal and the cell terminal 1n is a negative electrode terminal.

The cell terminals 1p and 1n of the battery cell 1 each have a substantially cuboid and three-dimensional shape that protrudes vertically from the upper end face of the cell case 1a. A resin insulating member is disposed between the cell terminal 1p. In and the cell case 1a or between the cell case 1a and the electrode group for electrical insulation. The plurality of battery cells 1 making up the battery cell group 10 are stacked while alternately reversing their direction by 180° so that the positive cell terminal 1p of one of mutually adjacent battery cells 1 and the negative cell terminal 1n of the other battery cell 1 are adjacent to each other in the stacking direction (x-axis direction).

The housing 20 has a substantially cuboid shape, having the dimension in the length direction (x-axis direction) that is larger than the dimensions in the width direction (y-axis direction) and in the height direction (z-axis direction), and holds the plurality of battery cells 1 making up the battery cell group 10. Specifically the housing 20 has a plurality of cell holders 21, a pair of end plates 22, a pair of side plates 23, an insulation cover 24, and a module cover 25.

In one example, the cell holders 21 are made of a resin material such as polybutylene terephthalate (PBT). Each cell holder 21 intervenes between mutually adjacent battery cells 1 of the plurality of battery cells 1 stacked in the thickness direction (x-axis direction), and holds these battery cells 1 to sandwich them from both sides in the thickness direction (x-axis direction). The module terminals 101P and 101N, which are external terminals of the battery module 100, are disposed at a pair of cell holders 21 that are at both ends of the battery cell group 10 in the stacking direction (x-axis direction) of the plurality of battery cells 1 making up the battery cell group 10. The module terminal 101P is a positive electrode terminal and the module terminal 101N is a negative electrode terminal.

The pair of end plates 22 includes plate members made of metal. The pair of end plates 22 is disposed at both ends of the battery cell group 10 via the pair of cell holders 21 disposed on both sides of the battery cell group 10 in the stacking direction (x-axis direction) of the plurality of battery cells 1 making up the battery cell group 10. Each of the end plates 22 as a pair has one face that is opposed to the plurality of battery cells 1 held at the cell holders 21. The other face of the end plate 22 is directed to the outside that is on the other side of the battery cell group 10, and has a fixing part 22a.

The fixing part 22a at each of the end plates 22 as a pair is substantially cylindrical, and a part of the cylindrical face protrudes outward from the outer face of the end plate 22. The cylindrical fixing part 22a has a bolt hole that is bored along the center axis parallel to the height direction (z-axis direction) of the end plate 22. This fixing part 22a of the end plate 22 is to fix the battery module 100 to an external mechanism such as a vehicle or another machine. The lower end face of this fixing part 22a of the end plate 22 is a supported face 20a of the housing 20 that is supported by the external mechanism as stated above.

That is, to fix the battery module 100 to the external mechanism, the operator may place the supported face 20a of the housing 20, which is the bottom face of each fixing part 22a of the end plates 22, on the external mechanism for supporting, and insert a bolt into the bolt hole of the fixing part 22a and screw the bolt together with an internal thread or a nut of the external mechanism for fastening. In other words, the battery module 100 is fixed to the external mechanism with the bolt, and is supported by the external mechanism at the supported faces 20a of the housing 20 that is the lower end faces of the fixing parts 22a of the end plates 22.

When the battery module 100 is mounted on a vehicle such as an electric vehicle or a hybrid vehicle, the external mechanism to fix the battery module 100 is the vehicle body of such a vehicle. Although not limited especially, when the vehicle to fix the battery module 100 is placed on a horizontal road surface, the length direction (x-axis direction) and the width direction (y-axis direction) of the housing 20 of the battery module 100 are substantially parallel to the horizontal direction, and the height direction (z-axis direction) of the housing 20 of the battery module 100 is substantially parallel to the vertical direction. In this state, the supported face 20a of the housing 20 is substantially parallel to the horizontal plane.

The pair of side plates 23 is disposed on both sides of the plurality of battery cells 1 making up the battery cell group 10 in the width direction (y-axis direction) via the cell holders 21. The side plates 23 as a pair are metal members each having a substantially rectangular shape, and are mutually opposed on both sides of the housing 20 in the width direction (y-axis direction). The side plates 23 as a pair are substantially oblongs, having the long-side direction, i.e., longitudinal direction in the stacking direction (x-axis direction) of the plurality of battery cells 1 making up the battery cell group 10 and the short-side direction, i.e., transverse direction in the height direction (z-axis direction) of the plurality of battery cells 1 making up the battery cell group 10. The pair of side plates 23 are fastened at both ends in the longitudinal direction to the pair of end plates 22 by fasteners such as rivets and bolts. The pair of side plates 23 engage with recess-like grooves of the cell holders 21 at both ends in the transverse direction.

The insulation cover 24 is a plate member made of resin such as PBT having an electrical insulating property. The insulation cover 24 is opposed to the upper end face of each cell case 1a having the cell terminals 1p and 1n of the battery cell 1. The insulation cover 24 has openings to expose the upper end faces of the cell terminals 1p and 1n of the plurality of battery cells 1 and a partition wall for insulation between the cell terminals 1p and 1n of the mutually adjacent battery cells 1 and between the mutually adjacent busbars 2. The partition wall of the insulation cover 24 is disposed so as to surround the cell terminals 1p and 1n of the battery cells 1 and the busbars 2. Various types of electric wiring are placed on the insulation cover 24 to connect to the battery cell group 10 and the electronic circuit board.

The electronic circuit board not shown is disposed between the insulation cover 24 and the module cover 25, i.e., on the insulation cover 24 on the other side of the battery cell group 10 in the height direction of the housing 20, and electrically connects to the busbars 2 via connecting conductors such as leading wiring and printed wiring and to a temperature sensor (thermistor) to detect the temperatures of the battery cells 1.

The busbars 2 are connecting conductors that electrically and mechanically connect the plurality of battery cells 1 of the battery cell group 10 and electrically and mechanically connect the battery cell group 10 with the module terminals 101P and 101N.

The busbars 2 electrically and mechanically connecting the plurality of battery cells 1 of the battery cell group 10 are a plurality of busbars 2A that electrically and mechanically connect the battery cells 1. These busbars 2A are joined by welding to the upper end faces of the cell terminals 1p and 1n of the plurality of battery cells 1 of the battery cell group 10 that are exposed through the openings of the insulation cover 24. Each busbar 2A electrically connects the cell terminal 1p of one of mutually adjacent battery cells 1 in the stacking direction and the cell terminal 1n of the other battery cell 1, so as to electrically connect all of the battery cells 1 of the battery cell group 10 in series.

The busbars 2 connecting the battery cell group 10 with the module terminals 101P and 101N are a pair of busbars 2B disposed at both ends of the battery cell group 10 in the stacking direction of the battery cells. One of the busbars 2B as a pair electrically and mechanically connects to the cell terminal 1p of one of the pair of battery cells 1 disposed at both ends of the plurality of battery cells 1 in the stacking direction. The other busbar 2B electrically and mechanically connects to the cell terminal 1n of the other of the pair of battery cells 1 disposed at both ends of the plurality of battery cells 1 in the stacking direction.

One end of one of the busbars 2B as a pair is joined by welding to the upper end face of the cell terminal 1p of one of the battery cells 1, and the other end is fastened to the module terminal 101P disposed at one of the ends of the battery cell group 10 in the stacking direction of the battery cells with a fastener such as a rivet or a bolt. One end of the other of the busbars 2B as a pair is joined by welding to the upper end face of the cell terminal 1n of one of the battery cells 1, and the other end is fastened to the module terminal 101N disposed at the other end of the battery cell group 10 in the stacking direction with a fastener such as a rivet or a bolt.

The module cover 25 is a plate member made of resin such as PBT having an electrical insulating property. The module cover 25 is disposed at the upper end of the housing 20 on the other side of the battery cell group 10 in the height direction (z-axis direction) of the housing 20 so as to cover the insulation cover 24 and the electronic circuit board. The module cover 25 has terminal covers 25a at the positions corresponding to the module terminals 101P and 101N so as to cover the module terminals 101P and 101N from the above. The module cover 25 is fixed to the upper part of the insulation cover 24 by engaging hooks 24b disposed at the frame 24a of the insulation cover 24 with the side edge of the module cover 25.

The battery module 100 having the above-stated configuration has the module terminals 101P and 101N that electrically connect to an external electric generator or electric motor via an inverter as a power converter, and so exchanges electricity with such an external electric generator or electric motor via the inverter.

Next the following describes the configuration of the busbars 2 in details.

First, the configuration of the busbars 2A will be described in details referring to FIGS. 3 and 5. FIG. 3 is an enlarged cross-sectional view of the battery module 100, FIG. 4 is a perspective view of the busbar 2A, and FIG. 5 is a plan view of the busbar 2A. As described above, the battery module 100 of the present embodiment has the most distinctive feature in the structure of the busbar 2A.

As shown in FIG. 3, the busbar 2A is a connecting conductor electrically and mechanically connecting the cell terminal 1p of one of the adjacent battery cells 1 in the stacking direction of the battery cells and the cell terminal 1n of the other battery cell, and is also a dissimilar metal junction structure formed by joining a copper portion 2e containing copper and an aluminum portion 2f containing aluminum.

The busbar 2A has a pair of connection face portions 2c1 and 2c2, and a bridge portion 2d joining this pair of connection face portions 2c1 and 2c2.

Of the pair of connection face portions 2c1 and 2c2, the connection face portion 2c1 to be joined to the cell terminal 1p is a flat rectangular portion formed only with the aluminum portion 2f, and is disposed on the top surface of the cell terminal 1p and joined by laser welding. For the laser welding, laser is applied to the surface of the connection face portion 2c1 so as to move the laser along a positioning hole 2z of the connection face portion 2c1 (see FIGS. 4 and 5) with the cell terminal 1p and circumferentially around the solid portion outside the positioning hole 2z to join the cell terminal 1p and the connection face portion 2c1.

The connection face portion 2c2 to be joined to the negative cell terminal 1n is a substantially flat rectangular portion where the copper portion 2e and the aluminum portion 2f are overlapped in the overlapping direction (z-axis direction) with the cell terminal 1n, and the copper portion 2e is joined to the cell terminal In by laser welding. The copper portion 2e defines a flat rectangular plate portion, and a pair of arms 2f1 projecting parallel to each other from a flat portion 2g as a rising portion are overlapped on the flat portion for joining. The connection face portion 2c2 is a dissimilar metal joining portion where the pair of arms 2f1 including the aluminum portions 2f are overlapped for joining on the flat rectangular portion including the copper portion 2e (on the opposite side of the cell terminal 1n), that is, on the flat portion.

The pair of arms 2f1 is formed by cutting out a central portion in the transverse direction (y-axis direction) of the aluminum portion 2f, which projects from a bridge portion 2d toward the connection face portion 2c2, from the projecting end toward the bridge portion 2d. The pair of arms 2f1 defines a recess 2f2, which is a recessed portion of the flat plate and is recessed toward the bridge portion 2d, therebetween so as to expose the copper portion 2e including the positioning hole 2z.

The aluminum portion 2f of the connection face portion 2c2 is a molded product of a rectangular flat plate that is recessed toward the bridge portion 2d. The aluminum portion 2f overlaps only on a part of both ends of the rectangular flat copper portion 2e in the transverse direction (y-axis direction) and on the end of the rectangular flat copper portion 2e close to the bridge portion 2d to expose the other portion of the copper portion 2e. The copper portion 2e of the connection face portion 2c2 therefore can be joined to the cell terminal 1n by laser welding. For the laser welding, laser is applied to the surface of the copper portion 2e at the connection face portion 2c2 so as to move the laser along the positioning hole 2z of the copper portion 2e of the connection face portion 2c2 (see FIGS. 4 and 5) with the cell terminal 1n and circumferentially around the solid portion outside the positioning hole 2z to join the cell terminal 1n and the copper portion 2e of the connection face portion 2c2.

Ultrasonic joining is used for joining the copper portion 2e and the aluminum portion 2f at the connection face portion 2c2, that is, the flat portion of the copper portion 2e and the pair of arms 2f1 of the aluminum portion 2f. In this embodiment, the overlapping portions with the aluminum portions 2f at both ends of the rectangular flat copper portion 2e in the transverse direction (y-axis direction) are the joints 2x by ultrasonic joining. For the ultrasonic joining, a face of the copper portion 2e on the opposite side of the aluminum portion 2f is placed on an anvil, and a horn is applied to the surface of the aluminum portion 2f on the opposite side of the copper portion 2e so as to apply ultrasonic vibrations to the overlapping portion of the copper portion 2e and the aluminum portion 2f for joining of the copper portion 2e and the aluminum portion 2f. The surface of the copper portion 2e or the aluminum portion 2f or both surfaces, which are to be ultrasonically joined, may undergo the coating processing such as tin or nickel plating.

In this way, this embodiment includes the joint 2x of the copper portion 2e and the aluminum portion 2f formed at the connection face portion 2c2. Such a joint 2x of the copper portion 2e and the aluminum portion 2f formed at the connection face portion 2c2 increases the rigidity of the joint 2x of the copper portion 2e and the aluminum portion 2f and so increases the natural frequency, because the cell terminal 1n is a strong member. The present embodiment therefore reduces stress acting on the joint 2x between the copper portion 2e and the aluminum portion 2f due to vibrations of the battery module 100 or the like, and so keeps the joint strength high at the joint 2x between the copper portion 2e and the aluminum portion 2f. The present embodiment therefore enhances the resistance of the battery module 100 against vibrations and the like, and provides a reliable battery module 100.

The bridge portion 2d is an inverted U-shaped portion formed only with the aluminum portion 2f, and has a pair of flat portions 2g (they may be called rising portions) rising vertically or at a steep angle upward from the bridge portion 2d-side ends of the aluminum portions 2f that define the connection face portions 2c1 and 2c2, and a folded portion 2h (they may be called a connection portion) joining between the pair of flat portions 2g. The folded portion 2h is curved in an arch shape.

The copper portion 2e defining the connection face portion 2c2 that is exposed from the aluminum portion 2f has an end portion of the rectangular flat copper portion 2e projecting in the direction opposite to the bridge portion 2d. This end portion serves a detection conductor to detect the voltage, and is provided as a voltage detection wire joint 2y where lead wiring (not shown) for voltage detection is joined by brazing or ultrasonic welding. The voltage detection wire joint 2y may be located at the aluminum portion 2f defining the connection face portion 2c1.

In another example as shown in FIGS. 17 and 18, a terminal for joining voltage detection wiring may extend out as the voltage detection wire joint 2y from the aluminum portion 2f defining the connection face portion 2c1 or the copper portion 2e defining the connection face portion 2c2, and lead wiring for voltage detection (not shown) may be joined to this extended terminal by brazing or ultrasonic welding. The extended terminal and the lead wiring may be connected with a terminal including an elastic member for connecting them under pressure.

Next, the configuration of the busbars 2B will be described in detail referring to FIGS. 6 to 9. FIG. 6 is an enlarged perspective view of the battery module 100 in FIG. 1. FIG. 7 is an enlarged cross-sectional view taken along the line VII-VII of FIG. 6. FIG. 8 is a perspective view of the busbar 2B connected to the module terminal 101N in FIG. 6, and FIG. 9 is a perspective view of the busbar 2B connected to the module terminal 101P. FIG. 6 is a cutaway view of a terminal cover, which is a part of the module cover 25. This embodiment has a feature in that the busbar 2B connected to the module terminal 101N includes a fuse 2a, which is the smallest portion in volume in the current path, and has a space S below the fuse 2a of the busbar 2B for dropping the melted fuse 2a. The term “below” refers to vertically below when the battery module 100 is placed so that the supported face 20a of the housing 20 is horizontal. The fuse 2a may be disposed in the busbar 2B connected to the module terminal 101P.

First, the configuration of the busbar 2B1 connected to the module terminal 101N is described in details with reference to FIGS. 6 to 8.

The busbar 2B1 has a pair of connection face portions 2c1 and 2c2 that are placed side by side in the x-axis direction, and a bridge portion 2d extending from these connection face portions in the y-axis direction so as to join this pair of connection face portions 2c1 and 2c2 outside of these connection face portions.

The connection face portions 2c1 and 2c2 are rectangular flat plates. The connection face portion 2c1 to be connected to the module terminal 101N and the connection face portion 2c2 to be connected to the cell terminal 1n are different in height in the z-axis direction. In the present embodiment, the connection face portion 2c1 is located higher than the connection face portion 2c2. The height of the connection face portion 2c1 and the connection face portion 2c2 may be the same, or their relationship in height may be reversed.

The bridge portion 2d is a bent portion in the direction (y-axis direction) to intersect the connection face portions 2c1 and 2c2. More particularly, the bridge portion 2d includes a U-shaped first bridge portion 2d1, a U-shaped second bridge portion 2d2 placed lateral of the first bridge portion 2d1 in the x-axis direction, and the fuse 2a connecting between the two bridge portions in the x-axis direction. The first bridge portion 2d1 and the second bridge portion 2d2 are the same in height in the height direction (z-axis direction) of the battery cells 1.

The first bridge portion 2d1 includes a pair of flat portions 2g1 horizontally placed in the z-axis direction and a folded portion 2h1 (this may be called a connection portion) joining the pair of flat portions 2g1. The folded portion 2h1 is curved in an arch shape. The flat portion 2g1 connected to the connection face portion 2c1 and the flat portion 2g1 connected to the fuse 2a face each other in the Z-axis direction, and they are connected by the folded portion 2h1 at their ends on the opposite side of the connection face portion 2c1. The bridge 2d-side end of the connection face portion 2c1 and the connection surface portion 2c1-side end of the lower flat portion 2g1 in the z-axis direction of the pair of flat portions 2g1 are connected by a flat bridge 2w (this may be called a rising portion) extending (rising) in the z-axis direction.

The second bridge portion 2d2 includes a pair of flat portions 2g2 horizontally placed in the z-axis direction and a folded portion 2h2 (this may be called a connection portion) joining the pair of flat portions 2g2. The folded portion 2h2 is curved in an arch shape. The flat portion 2g2 connected to the connection face portion 2c2 and the flat portion 2g2 connected to the fuse 2a face each other in the z-axis direction, and they are connected by the folded portion 2h2 at their ends on the opposite side of the connection face portion 2c2. Of the pair of flat portions 2g2, the lower flat portion 2g2 in the z-axis direction has a connection face portion 2c2-side end connected to the bridge portion 2d-side end of the connection face portion 2c2 in such a manner that the connection face portion 2c2-side end extends horizontally in the y-axis direction toward the connection face portion 2c2.

The fuse 2a-side end of the upper flat portion 2g1 in the z-axis direction of the pair of flat portions 2g1 and the fuse 2a-side end of the upper flat portion 2g2 in the z-axis direction of the pair of flat portions 2g2 are connected by the fuse 2a. The current path between the first bridge portion 2d1 and the second bridge portion 2d2 includes only the fuse 2a, which has a smaller current carrying area than those of the first bridge portion 2d1 and the second bridge portion 2d2, and is the smallest volume current path in the busbar 2B1. With this configuration. when an excessive current flows through the busbar 2B1, the current density and temperature due to heat generation in the fuse 2a will be the highest in the busbar 2B1. When the temperature due to the heat generation exceeds the melting point temperature of the material of the fuse 2a, the fuse 2a blows the fastest in the busbar 2B1. This allows the current path of busbar 2B1 to be interrupted.

The busbar 2B1 is a dissimilar metal joint structure formed by joining the copper portion 2e containing copper and the aluminum portion 2f containing aluminum. Clad joining is used to join these dissimilar metals, and so the busbar 2B1 may be referred to as a clad busbar. In this embodiment, the connection face portions 2c1 and 2c2 and the bridge portion 2w are the copper portions 2e, and the bridge portion 2d is the aluminum portion 2f. A part of the bridge portion 2d (e.g., the upper flat portion 2g1 in the z-axis direction of the pair of flat portions 2g1, the upper flat portion 2g2 in the z-axis direction of the pair of flat portions 2g2, and the fuse 2a) may be the aluminum portions 2f, and the remaining may be the copper portions 2e.

This embodiment includes the folded parts 2h due to the space in the insulation cover 24 to store the busbar. In another embodiment having a larger space to store the busbar, the folded parts 2h may be omitted.

When the battery module is designed so that the module terminal 101N and the cell terminal 1n are at the same height, the bridge portion 2w also can be omitted.

The space S to allow the melted fuse 2a to fall is defined by the battery cell 1 and the housing 20. Specifically the space S below the fuse 2a is an internal space of the housing 20 defined by the cell terminal 1p or 1n and the cell case 1a of the battery cell 1 and the cell holder 21 of the housing 20. The space S faces the lower face of the busbar 2B1 opposed to the battery cell 1. The space S has a depth that is equal to or longer than the height of the cell terminal 1n in the direction (z-axis direction) perpendicular to the supported face 20a of the housing 20 and has a sufficiently large volume compared to the volume of the fuse 2a. If excessive current flows through the busbar 2B1 and the metal of the fuse 2a melts, the melted metal material of the fuse 2a falls down into the space S below the fuse 2a due to the action of gravity. This prevents the melted metal material from forming a new current path between the positive cell terminal 1p and the negative cell terminal 1n of the battery cell 1, thereby improving the safety of the battery module 100.

With the configuration of the busbar 2B1 of this embodiment, the fuse 2a can be located farther from the cell terminal 1n. This prevents a melted metal material from forming a new current path between the positive cell terminal 1p and the negative cell terminal 1n of the battery cell 1 more reliably, and so further improves the safety of the battery module 100.

Next, the configuration of the busbar 2B2 connected to the module terminal 101P will be described in detail referring to FIG. 9.

The busbar 2B2 has a pair of connection face portions 2c1 and 2c2 that are placed side by side in the x-axis direction, and a bridge portion 2d joining this pair of connection face portions 2c1 and 2c2.

The connection face portions 2c1 and 2c2 are rectangular flat plates. The connection face portion 2c1 to be connected to the module terminal 101P and the connection face portion 2c2 to be connected to the cell terminal 1p are different in height in the z-axis direction. In the present embodiment, the connection face portion 2c1 is located higher than the connection face portion 2c2. The height of the connection face portion 2c1 and the connection face portion 2c2 may be the same, or their relationship in height may be reversed.

The bridge portion 2d is a flat rectangular portion that is bent (rising) in the direction (z-axis direction) that intersects the connection face portions 2c1 and 2c2, and may be called a rising portion.

The busbar 2B2 is a dissimilar metal joint structure formed by joining a copper portion 2e containing copper and an aluminum portion 2f containing aluminum. Clad joining is used to join these dissimilar metals, and so the busbar 2B2 may be referred to as a clad busbar. In this embodiment, a part from the connection face portion 2c1 to a part of the bridge portion 2d is the copper portion 2e, and a part from the connection face portion 2c2 to the part of the bridge portion 2d is the aluminum portion 2f.

Embodiment 2

FIGS. 10 to 12 show Embodiment 2 of the present invention.

Similarly to Embodiment 1, this embodiment is for keeping a joint strength high at the joint 2x between the copper portion 2e and the aluminum portion 2f of the busbar 2A, and its structure is different from that of Embodiment 1. FIG. 10 is a perspective view of the busbar 2A. FIG. 11 is a plan view of the busbar 2A, and FIG. 12 is a side view of the busbar 2A. The configuration of the battery module is the same as that of Embodiment 1 except for the busbar 2A, and the following describes differences from Embodiment 1 only.

The busbar 2A is a connecting conductor electrically and mechanically connecting the cell terminal 1p of one of the adjacent battery cells 1 in the stacking direction of the battery cells and the cell terminal 1n of the other battery cell, and is also a dissimilar metal junction structure formed by joining a copper portion 2e containing copper and an aluminum portion 2f containing aluminum.

As shown in FIG. 10, the busbar 2A has a pair of connection face portions 2c1 and 2c2, and a bridge portion 2d joining this pair of connection face portions 2c1 and 2c2.

Of the pair of connection face portions 2c1 and 2c2, the connection face portion 2c1 to be joined to the cell terminal 1p is a flat rectangular portion formed only with the aluminum portion 2f, and is disposed on the top surface of the cell terminal 1p and joined by laser welding. For the laser welding, laser is applied to the surface of the connection face portion 2c1 so as to move the laser along the positioning hole 2z of the connection face portion 2c1 (see FIGS. 10 and 11) with the cell terminal 1p and circumferentially around the solid portion outside the positioning hole 2z to join the cell terminal 1p and the connection face portion 2c1.

The connection face portion 2c2 to be joined to the negative cell terminal 1n is a flat rectangular portion formed with the copper portion 2e only, and is disposed on the top surface of the cell terminal 1n and joined by laser welding. For the laser welding, laser is applied to the surface of the connection face portion 2c2 so as to move the laser along the positioning hole 2z of the connection face portion 2c2 (see FIGS. 10 and 11) with the cell terminal 1n and circumferentially around the solid portion outside the positioning hole 2z to join the cell terminal 1n and the connection face portion 2c2.

The bridge portion 2d is an inverted U-shaped portion formed with the copper portion 2e and the aluminum portion 2f, and has a flat portion 2g (this may be called a rising portion) rising vertically or at a steep angle upward from the bridge portion 2d side-end of the aluminum portion 2f that defines the connection face portions 2c1, a flat portion 2v opposed to the flat portion 2g in the x-axis direction, and a folded portion 2h (this may be called a connection portion) joining between the flat portions 2g and 2v.

The folded portion 2h is curved in an arch shape. The flat portion 2g and the folded portion 2h include the aluminum portions 2f, and the flat portion 2v includes the joining of the copper portion 2e and the aluminum portion 2f. The flat portion 2v is a dissimilar metal joining portion where the copper portion 2e and the aluminum portion 2f are overlapped for joining. The flat portion 2v in this embodiment corresponds to one of the rising portions described in the claims. and the flat portion 2g corresponds to the other rising portion described in the claims.

The flat portion 2g has a shape having a cutout at the center of a rectangular flat plate in the y-axis direction, and includes two portions at both ends in the y-axis direction that extend upwardly in the z-axis direction from the bridge portion 2d-side end of the connection face portion 2c1. Similarly, the folded portion 2h has a cutout at the center in the y-axis direction, and has both ends in the y-axis direction that extend toward the flat portion 2v. This exposes the inside of the bridge portion 2d, especially the inside of the central portion in the y-axis direction. In other words, the flat portion 2g and the folded portion 2h have the cutouts that expose a flat rectangular portion 2e1.

The flat portion 2v is an overlapping portion of the flat rectangular portion 2e1 (first flat rectangular portion) rising vertically or at a steep angle upward from the bridge portion 2d side-end of the copper portion 2e of the connection face portion 2c2 and a flat rectangular portion 2f3 (second flat rectangular portion) extending downward in the z-axis direction from the folded portion 2h, where these flat rectangular portions are overlapped at their inner faces in the x-axis direction. In other words, this is the overlapping portion of the inner faces of the two members that are bent in a hook shape. The flat rectangular portion 2f3 is continuous to the folded portion 2h, and the side face opposed to the flat portion 2g is overlapped and joined to the connection face portion 2c2-side side face of the flat rectangular portion 2e1.

In this embodiment, the flat rectangular portion 2f3 extends over the upper end of the rising flat rectangular portion 2e1 and falls down there, so that they overlap in the x-axis direction. The busbar may have this configuration at the flat portion 2g. In this case, the flat rectangular portion of the copper portion 2e extends over the upper end of the flat rectangular portion of the aluminum portion 2f that rises upward from the aluminum portion, and falls down there, so that they overlap in the x-axis direction.

Similarly to Embodiment 1, the copper portion 2e and the aluminum portion 2f are joined by ultrasonic joining. In this embodiment, the joint 2x between the copper portion 2e and the aluminum portion 2f is located at the center part in the y-axis direction of the overlapping portion between the flat rectangular portion 2e1 and the flat rectangular portion 2f3. For the ultrasonic joining, an anvil is applied to one of the surfaces of the flat rectangular portion 2e1 on the opposite side of the flat rectangular portion 2f3 and the flat rectangular portion 2f3 on the opposite side of the flat rectangular portion 2e1 and at the center part in the y-axis direction, and a horn is applied to the surface of the other so as to apply ultrasonic vibrations to the overlapping portion of the flat rectangular portion 2e1 and the flat rectangular portion 2f3 for joining of the copper portion 2e and the aluminum portion 2f. The surface of the copper portion 2e or the aluminum portion 2f or both surfaces, which are to be ultrasonically joined, may undergo the coating processing such as tin or nickel plating.

In this way, this embodiment includes the joint 2x of the copper portion 2e and the aluminum portion 2f formed at the bridge portion 2d. At the bridge portion 2d, the flat rectangular portion 2e1 and the flat rectangular portion 2f3 are bent into a hook shape and are boned at their opposed inner surfaces. If stress acts on the busbar in the direction of tearing off the copper portion 2e and the aluminum portion 2f, this joining structure receives a pressurizing force to bring these portions into contact, and the elastic force at their bending portions acts on the joint 2x of the copper portion 2e and the aluminum portion 2f as the reaction force in the direction opposite to the direction of the stress acting on the joint 2x of the copper portion 2e and the aluminum portion 2f. As a result, the stress acting on the joint 2x between the copper portion 2e and the aluminum portion 2f is reduced.

This means that if stress acts in the direction of separating the connection face portions 2c1 and 2c2 in the x-axis direction, a force will act on the busbar in a direction to bring the flat rectangular portion 2e1 of the copper portion 2e and the flat rectangular portion 2f3 of the aluminum portion 2f into contact under pressure. This embodiment therefore keeps a joint strength high at the joint 2x of the copper portion 2e and the aluminum portion 2f. Similarly to Embodiment 1, the present embodiment therefore improves the resistance of the battery module against vibrations and the like, and provides a reliable battery module.

A voltage detection wire joint may be disposed at either surface of the connection face portions 2c1 and 2c2. A terminal for connecting voltage detection wiring may extend out from either the connection face portion 2c1 or 2c2, and lead wiring for voltage detection (not shown) may be joined to this extended terminal by brazing or ultrasonic welding. The extended terminal and the lead wiring may be connected with a terminal including an elastic member for connecting them under pressure.

Embodiment 3

FIGS. 13 to 16 show Embodiment 3 of the present invention.

Similarly to Embodiment 1, this embodiment is for keeping a joint strength high at the joint 2x between the copper portion 2e and the aluminum portion 2f of the busbar 2A, and its structure is different from that of Embodiment 1. FIG. 13 is a perspective view of the busbar 2A, FIG. 14 is a plan view of the busbar 2A, FIG. 15 is a side view of the busbar 2A, and FIG. 16 is a perspective view of the busbar 2A placed on cell terminals. The configuration of the battery module is the same as that of Embodiment 1 except for the busbar 2A, and the following describes differences from Embodiment 1 only.

As shown in FIG. 16, the busbar 2A is a connecting conductor electrically and mechanically connecting the cell terminal 1p of one of the adjacent battery cells 1 in the stacking direction of the battery cells and the cell terminal 1n of the other battery cell, and is also a dissimilar metal junction structure formed by joining a copper portion 2e containing copper and an aluminum portion 2f containing aluminum.

As shown in FIG. 13, the busbar 2A has a pair of connection face portions 2c1 and 2c2, and a bridge portion 2d joining this pair of connection face portions 2c1 and 2c2.

Of the pair of connection face portions 2c1 and 2c2, the connection face portion 2c1 to be joined to the cell terminal 1p is a flat rectangular portion formed only with the aluminum portion 2f, and is disposed on the top surface of the cell terminal 1p and joined by laser welding. For the laser welding, laser is applied to the surface of the connection face portion 2c1 so as to move the laser along the positioning hole 2z of the connection face portion 2c1 (see FIGS. 13 and 14) with the cell terminal 1p and circumferentially around the solid portion outside the positioning hole 2z to join the cell terminal 1p and the connection face portion 2c1.

The connection face portion 2c2 to be joined to the negative cell terminal 1n is a substantially flat rectangular portion having a U-shaped part at each of the both ends in the longitudinal direction (x-axis direction) of the copper portion 2e so that the aluminum portion 2f is caught in the U-shaped parts of the copper portion 2e and is overlapped in the overlapping direction (z-axis direction) with the cell terminal 1n, and the copper portion 2e is joined to the cell terminal 1n by laser welding. In other words, the connection face portion 2c2 is a dissimilar metal joining portion where the flat recessed part of the aluminum portion 2f that is recessed toward the bridge portion 2d is overlapped on the flat rectangular portion of the copper portion 2e (on the opposite side of the cell terminal 1n).

The aluminum portion 2f at the connection face portion 2c2 has a pair of arms 2f1. The pair of arms 2f1 is formed by cutting out a central portion of the aluminum portion 2f in the transverse direction (y-axis direction), which projects from a bridge portion 2d toward the connection face portion 2c2, from the projecting end toward the bridge portion 2d. The pair of arms 2f1 defines a recess 2f2, which is a recessed portion of the flat plate that is recessed toward the bridge portion 2d, therebetween so as to expose the copper portion 2e including the positioning hole 2z.

The copper portion 2e of the connection face portion 2c2 has bases 2e3 and claws 2e2 facing each of the pair of arms 2f1 from one side and the other side of the overlapping direction. The bases 2e3 of the copper portion 2e are spaced apart from each other in the transverse direction and at both ends in the longitudinal direction to form pairs. The claws 2e2 of the copper portion 2e are formed by raising center parts in the transverse direction at both ends in the longitudinal direction to separate them from the cell terminal 1n located on one side in the overlapping direction relative to the bases 2e3, so that the arms 2f1 are insertable into gaps between the claws 2e2 and the bases 2e3.

The aluminum portion 2f of the connection face portion 2c2 is a molded product of a rectangular flat plate that is recessed toward the bridge portion 2d. The aluminum portion 2f overlaps only on a part of both ends of the rectangular flat copper portion 2e in the transverse direction (y-axis direction) and on the end of the rectangular flat copper portion 2e close to the bridge portion 2d to expose the other portion of the copper portion 2e. The copper portion 2e of the connection face portion 2c2 therefore can be joined to the cell terminal 1n by laser welding. For the laser welding, laser is applied to the surface of the copper portion 2e at the connection face portion 2c2 so as to move the laser along the positioning hole 2z of the copper portion 2e of the connection face portion 2c2 (see FIGS. 13 and 14) with the cell terminal 1n and circumferentially around the solid portion outside the positioning hole 2z to join the cell terminal 1n and the copper portion 2e of the connection face portion 2c2.

The copper portion 2e and the aluminum portion 2f (the pair of arms 2f1) at the connection face portion 2c2 are joined by ultrasonic joining. In this embodiment, the overlapping portions with the aluminum portions 2f at the U-shaped flat portions located at both ends of the rectangular flat copper portion 2e in the transverse direction (y-axis direction), i.e., the overlapping portions of the arms 2f1 of the aluminum portion 2f with the claws 2e2 of the copper portion 2e are the joints 2x by ultrasonic joining. For the ultrasonic joining, the face of the copper portion 2e opposed to the aluminum portion 2f is placed on an anvil, and a horn is applied to the surface of the aluminum portion 2f on the opposite side of the copper portion 2e so as to apply ultrasonic vibrations to the overlapping portion of the copper portion 2e and the aluminum portion 2f for joining of the copper portion 2e and the aluminum portion 2f. The surface of the copper portion 2e or the aluminum portion 2f or both surfaces, which are to be ultrasonically joined, may undergo the coating processing such as tin or nickel plating.

In this way, this embodiment includes the copper portion 2e, a part of which has a U-shaped portion that sandwiches the aluminum portion 2e2 from above and below for overlapping, so as to form the joint 2x between the arms 2f1 and the claws 2e2. The copper portion 2e is joined by laser to the cell terminal 1n, which is also made of copper, and they can be joined strongly because it is a copper-to-copper join. If external pressure is applied to the aluminum portion 2f in the upward direction, the joint becomes stronger, and if external pressure is applied to the aluminum portion 2f in the downward direction, the joint 2x does not bend downward because the cell terminal 1n under the aluminum portion 2f provides support. This embodiment therefore keeps a joint strength high at the joint 2x of the copper portion 2e and the aluminum portion 2f. Similarly to Embodiment 1, the present embodiment therefore improves the resistance of the battery module against vibrations and the like, and provides a reliable battery module.

That is a detailed description of the embodiments of the present disclosure. The present disclosure is not limited to the above-stated embodiments, and the design may be modified variously without departing from the spirits of the present disclosure. For instance, the entire detailed configuration of the embodiments described above for explanatory convenience is not always necessary for the present invention. A part of one embodiment may be replaced with the configuration of another embodiment, or the configuration of one embodiment may be added to the configuration of another embodiment. A part of the configuration of each embodiment may include another configuration that is added, or may be deleted or replaced with another configuration.

REFERENCE SIGNS LIST

- 1 Battery cell
- 1
  p Cell terminal
- 1
  n Cell terminal
- 2 Busbar
- 2A Busbar
- 2B1(2B) Busbar
- 2B2(2B) Busbar
- 2
  a Fuse
- 2
  c
  1 Connection face portion
- 2
  c
  2 Connection face portion
- 2
  d Bridge portion
- 2
  d
  1 First bridge portion
- 2
  d
  2 Second bridge portion
- 2
  e Copper portion
- 2
  f Aluminum portion
- 2
  g Flat portion
- 2
  h Folded portion
- 2
  v Flat portion
- 2
  w Bridge portion
- 2
  x Joint
- 2
  y Voltage detection wire joint
- 2
  z Positioning hole
- 10 Battery cell group
- 100 Battery module
- 20 Housing
- 20
  a Supported face
- 101P Module terminal
- 101N Module terminal
- S Space

	Number	Date	Country
Parent	17287029	Apr 2021	US
Child	18660664		US

Battery Module

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CPC

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Abstract

Description

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Priority Claims (1)

CROSS REFERENCE TO RELATED APPLICATIONS

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