BUSBAR MODULE

TECHNICAL FIELD

The present disclosure relates to a busbar module.

BACKGROUND ART

In the related art, a busbar module is used, for example, to be assembled to a battery assembly (that is, a battery module in which a plurality of battery cells are stacked and arranged) that is used as a driving power source mounted on an electric vehicle, a hybrid vehicle, or the like (see, for example, JP2014-220128A).

The busbar module described in JP2014-220128A includes a plurality of busbars and voltage detection lines. The busbars are stacked, and each of the busbars connects a positive electrode and a negative electrode between adjacent battery cells. The voltage detection lines are respectively connected to the plurality of busbars and monitor the battery cells. The voltage detection line is configured to bundle a plurality of electric wires. Each of the electric wires has a general structure in which a core wire is covered with an insulating sheath.

In general, the battery cells included in the battery assembly expand and contract in a stacking direction due to operating heat associated with charging and discharging, a temperature of an external environment, and the like. As a result, the battery assembly (battery module) is also deformed to expand and contract in the stacking direction of the battery cells. Further, a size of the battery assembly in the stacking direction may generally vary for manufactured battery assemblies (that is, a manufacturing variation may occur) due to an assembly tolerance when the plurality of battery cells are stacked and arranged. Therefore, the busbar module is generally designed to have a certain margin in a length of the voltage detection line in order to cope with such deformation and manufacturing variation of the battery assembly.

However, in the busbar module in the related art described above, for example, when the number of the stacked battery cells is increased for a purpose of increasing a capacity of the battery assembly, the number of the electric wires forming the voltage detection line also increases. As a result, when the voltage detection line is formed by bundling these many electric wires, a rigidity of the voltage detection line as a whole (and thus a rigidity of the busbar module) increases, and it may be difficult to improve operability (assemblability) of assembling the busbar module to the battery assembly. For the same reason, it may also be difficult for the busbar module to extend and contract to sufficiently cope with the deformation and the manufacturing variation of the battery assembly.

SUMMARY OF INVENTION

The present disclosure provides a busbar module excellent in assemblability to a battery assembly and adaptability to deformation and a manufacturing variation of the battery assembly.

According to an embodiment of the present disclosure, there is provided a busbar module to be attached to a battery assembly in which a plurality of single cells are stacked, and the busbar module includes:

- a first circuit body that is formed of a flexible substrate having a first wiring pattern and that includes a first main line portion and a first branch line portion, the first main line portion being arranged to extend along a stacking direction of the plurality of single cells, and the first branch line portion extending to branch from the first main line portion;
  - a second circuit body that is formed of a flexible substrate having second wiring pattern and that includes a second main line portion and a second branch line portion, the second main line portion being arranged to extend along the stacking direction, and the second branch line portion extending to branch from the second main line portion;
  - a busbar configured to connect to adjacent electrodes between the plurality of single cells:
  - an electronic component each attached to the first branch line portion and the second branch line portion to each connect the first wiring pattern and the second wiring pattern to the corresponding busbar; and
  - a holder extensible and contractible along the stacking direction and holding the first circuit body, the second circuit body, and the busbar, in which
  - the first wiring pattern and the second wiring pattern are electrically connected to each other at an overlapping portion of the first main line portion and the second main line portion.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view showing a busbar module according to the present embodiment;

FIG. 2 is a perspective view showing a battery assembly to which the busbar module shown in FIG. 1 is to be assembled;

FIG. 3 is a perspective view showing a procedure when a first circuit body and a second circuit body included in a circuit body shown in FIG. 1 are connected and accommodated in a holder;

FIG. 4 is a perspective view showing a state in which the first circuit body and the second circuit body included in the circuit body shown in FIG. 1 are connected and accommodated in the holder;

FIG. 5 is a perspective view showing first to third circuit bodies included in a circuit body according to a first modification (however, wiring patterns are not shown);

FIG. 6 is a perspective view showing a state in which a connection portion of a first circuit body and a connection portion of a second circuit body included in a circuit body according to a second modification are connected; and

FIG. 7 is a perspective view showing a state in which a connection portion of a first circuit body and a connection portion of a second circuit body included in a circuit body according to a third modification are connected.

DESCRIPTION OF EMBODIMENTS

Hereinafter, a busbar module 10 according to an embodiment of the present disclosure will be described with reference to the drawings. The busbar module 10 according to the present embodiment is used, for example, to be assembled to a long battery assembly 1 (a battery module in which a plurality of single cells are stacked and arranged, see FIG. 2) that is used as a driving power source mounted on an electric vehicle.

Hereinafter, for convenience of description, “front”, “rear”, “left”, “right”, “upper”, and “lower” are defined as shown in FIG. 1 and the like. A “front-rear direction”, a “left-right direction”, and an “upper-lower direction” are orthogonal to each other. The front-rear direction coincides with a stacking direction (see FIGS. 1 and 2) of a plurality of single cells 2 included in the battery assembly 1. These directions are defined for convenience of description, and do not necessarily correspond to a front-rear direction, a left-right direction, and an upper-lower direction of a vehicle when the busbar module 10 is mounted on the vehicle.

First, as preparation for describing the busbar module 10, the battery assembly 1 to which the busbar module 10 is to be attached will be described with reference to FIG. 2. As shown in FIG. 2, the battery assembly 1 is formed by stacking, in the front-rear direction, the plurality of rectangular flat plate-shaped single cells 2 each of which extends in the upper-lower direction and the left-right direction. Each of the plurality of single cells 2 includes a battery body 3 having a rectangular flat plate shape, and a positive electrode 4 and a negative electrode 5 protruding upward from both end portions in the left-right direction of an upper face 6 of the battery body 3.

In the battery assembly 1, by making positions in the left-right direction of the positive electrode 4 and the negative electrode 5 of one of the single cells 2 that are adjacent in the front-rear direction opposite to positions in the left-right direction of the positive electrode 4 and the negative electrode 5 of the other single cell 2, the plurality of single cells 2 are stacked such that the positive electrode 4 and the negative electrode 5 are alternately arranged in the front-rear direction at each of a left end portion and a right end portion of an upper face of the battery assembly 1.

Hereinafter, the busbar module 10 will be described. As shown in FIGS. 1,3, and 4, the busbar module 10 includes a long circuit body 20 (see FIGS. 1 and 3) extending in the front-rear direction, a plurality of busbars 40 (see FIG. 1) connected to a plurality of branch line portions 22 (see FIG. 3) of the circuit body 20, a plurality of electronic components 50 (see FIG. 3) mounted on the plurality of branch line portions 22, a holder 60 (see FIGS. 1 and 3) holding the circuit body 20 and the busbars 40, and a cover 70 (see FIG. 1) covering the circuit body 20. A main line portion 21 and the branch line portion 22 (see FIG. 3) of the circuit body 20 are also referred to as a “main line” and a “branch line”, respectively.

The circuit body 20 is formed of an easily bendable flexible substrate (FPC). As can be understood from FIGS. 1 and 3, the circuit body 20 includes a pair of left and right first circuit bodies 20A and a pair of left and right second circuit bodies 20B. The left and right first circuit bodies 20A are extend in the front-rear direction and are spaced apart in the left-right direction. The left and right second circuit bodies 20B are respectively connected to rear sides of the pair of left and right first circuit bodies 20A and extend in the front-rear direction. The pair of left and right first circuit bodies 20A and the pair of left and right second circuit bodies 20B are coupled in the left-right direction by a coupling portion 28 (see FIG. 1). A connector 29 (see FIG. 1) electrically connected to an external voltage detection device (not shown) or the like is mounted on a lower face of the coupling portion 28.

Each of the first circuit body 20A and the second circuit body 20B includes the strip-shaped main line portion 21 extending in the front-rear direction, and at least one (in this example, the plurality of) branch line portion 22 extending to branch outward in the left-right direction from at least one (in this example, a plurality of) portion of the main line portion 21 in the front-rear direction (see FIG. 3). In this example, the branch line portion 22 extends from the main line portion 21 in a manner of having a U-shaped curved shape. Since the branch line portion 22 has the U-shaped curved shape, flexibility of the branch line portion 22 in the front-rear, left-right, and upper-lower directions is improved. A metal contact portion 24 is provided on an upper face of a distal end portion of the branch line portion 22 to be exposed to the outside (see FIG. 3).

By connecting a circuit connection portion 23 provided at a rear end portion of the main line portion 21 of the first circuit body 20A and the circuit connection portion 23 provided at a front end portion of the main line portion 21 of the second circuit body 20B, the circuit body 20 is formed in which the main line portion 21 of the first circuit body 20A and the main line portion 21 of the second circuit body 20B continuously extend in a row in the front-rear direction. A detailed structure of the circuit connection portion 23 of each of the first circuit body 20A and the second circuit body 20B and a connection procedure between the circuit connection portions 23 will be described later.

An entire surface of each of the first circuit body 20A and the second circuit body 20B is formed of a resin layer except for a portion (see FIG. 3) in which the contact portion 24 provided on the branch line portion 22 is exposed and portions (see FIG. 3) in which contact portions 25 that are described later and that are provided on the circuit connection portion 23 are exposed. Each of the first circuit body 20A and the second circuit body 20B includes a plurality of wiring patterns 26 (see FIG. 3). The wiring pattern 26 is a copper conductor extending in a strip shape, and extends along the main line portion 21 and the branch line portion 22. Each of the first circuit body 20A and the second circuit body 20B is a so-called “single-sided flexible substrate (single-sided FPC)” having a single wiring layer. The plurality of wiring patterns 26 are arranged on the single wiring layer of each of the first circuit body 20A and the second circuit body 20B.

At a position in which the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B are connected to each other, at least one (in this example, six) wiring pattern 26 belonging to the first circuit body 20A and at least one (in this example, six) wiring pattern 26 belonging to the second circuit body 20B are respectively and independently connected to each other (see FIG. 3).

Each of the plurality of wiring patterns 26 included in the first circuit body 20A and the second circuit body 20B is electrically connected to the connector 29 mounted on the coupling portion 28 through the contact portion 24 of corresponding one of the branch line portions 22, the corresponding branch line portion 22, the main line portion 21, and the coupling portion 28 in this order. Accordingly, the contact portions 24 of the branch line portions 22 belonging to the first circuit body 20A and the second circuit body 20B are individually conductively connected to the external voltage detection device via the connector 29 mounted on the coupling portion 28.

The distal end portion of the branch line portion 22 is mounted with the electronic component 50, and is connected with an elongated flat plate-shaped metal connection terminal 41 connected to the busbar 40 (see FIG. 3 and the like). The connection terminal 41 may be a part of the substantially rectangular flat plate-shaped metal busbar 40 (see FIG. 1), or may be a member that is a separate member from the busbar 40 and is joined to the busbar 40 by soldering or the like. The electronic component 50 is typically a chip fuse. The electronic component 50 is mounted on the distal end portion of the branch line portion 22 by soldering or the like so as to connect the contact portion 24 of the branch line portion 22 with the connection terminal 41. Accordingly, in the branch line portion 22, the contact portion 24 (that is, the wiring pattern 26 extending from the contact portion 24) and the connection terminal 41 (that is, the busbar 40) are electrically connected via the electronic component 50.

The mounting of the electronic component 50 on the branch line portion 22 is individually performed on the branch line portion 22 belonging to the first circuit body 20A and the branch line portion 22 belonging to the second circuit body 20B in a state before the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B are connected to each other (that is, in a state in which each of the first circuit body 20A and the second circuit body 20B is independent). Accordingly, compared to a case in which the first circuit body 20A and the second circuit body 20B are formed of a common (single) flexible substrate, a length of each of the first circuit body 20A and the second circuit body 20B in the front-rear direction is shortened, and thus a large mounting device is not required. In other words, since the first circuit body 20A and the second circuit body 20B are separate bodies, the electronic component 50 can be appropriately mounted on the branch line portion 22 regardless of a length and a size of the long circuit body 20 obtained by connecting the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B to each other, and a manufacturing cost of the busbar module 10 can be reduced.

Hereinafter, the detailed structure of the circuit connection portion 23 of each of the first circuit body 20A and the second circuit body 20B and the connection procedure between the circuit connection portions 23 will be described. As shown in FIG. 3, on an upper face of the circuit connection portion 23 of the first circuit body 20A, a plurality of (in this example, six) the metal contact portions (pads) 25 are provided to be arranged in a manner of being spaced apart in the front-rear direction and to be exposed to the outside. The wiring patterns 26 extend from the contact portions 25, respectively. More specifically, for each of the three contact portions 25 on a front side (proximal end side of the circuit connection portion 23) among the six contact portions 25, the wiring pattern 26 extends from the contact portion 25 to one side (left side) in a width direction (left-right direction) of the main line portion 21 of the first circuit body 20A, and then extends forward. For each of the three contact portions 25 on a rear side (distal side of the circuit connection portion 23) among the six contact portions 25, the wiring pattern 26 extends from the contact portion 25 to the other side (right side) in the width direction (left-right direction) of the main line portion 21 of the first circuit body 20A, and then extends forward.

In this way, by arranging extension portions of the plurality of wiring patterns 26 extending from the plurality of contact portions 25 in a distributed manner in the left-right direction, it is possible to contribute to improvement in a degree of freedom of a pattern design of the extension portions of the wiring patterns 26 extending from the contact portions 25, miniaturization of the circuit connection portion 23 (that is, the first circuit body 20A), and the like. On the upper face of the circuit connection portion 23 of the first circuit body 20A, a metal dummy contact portion (land) 27 is provided to be exposed to the outside at one position not interfering with the contact portions 25 and the wiring patterns 26. The dummy contact portion 27 is not connected (electrically connected) to the wiring pattern 26 (that is, the busbar 40). In the circuit connection portion 23 of the first circuit body 20A, hole portions 31 penetrating in the thickness direction (upper-lower direction) of the circuit connection portion 23 are respectively formed at a plurality of positions (in this example, two positions) not interfering with the contact portions 25, the wiring patterns 26, and the dummy contact portion 27.

On a lower face of the circuit connection portion 23 of the second circuit body 20B, a plurality of (in this example, six) the metal contact portions (pads) 25 are provided to be arranged in a manner of being spaced apart in the front-rear direction and to be exposed to the outside, and correspond to the plurality of contact portions 25 of the first circuit body 20A. The wiring patterns 26 extend from the contact portions 25, respectively. More specifically, for each of the three contact portions 25 on a front side (distal end side of the circuit connection portion 23) among the six contact portions 25, the wiring pattern 26 extends from the contact portion 25 to the other side (right side) in the width direction (left-right direction) of the main line portion 21 of the second circuit body 20B, and then extends rearward. For each of the three contact portions 25 on a rear side (proximal end side of the circuit connection portion 23) among the six contact portions 25, the wiring pattern 26 extends from the contact portion 25 to one side (left side) in the width direction (left-right direction) of the main line portion 21 of the second circuit body 20B, and then extends rearward.

In this way, by arranging extension portions of the plurality of wiring patterns 26 extending from the plurality of contact portions 25 in a distributed manner in the left-right direction, it is possible to contribute to improvement in a degree of freedom of a pattern design of the extension portions of the wiring patterns 26 extending from the contact portions 25, miniaturization of the circuit connection portion 23 (that is, the second circuit body 20B), and the like. On the lower face of the circuit connection portion 23 of the second circuit body 20B, the metal dummy contact portion (land) 27 is provided to be exposed to the outside at one position not interfering with the contact portions 25 and the wiring patterns 26, and corresponds to the dummy contact portion 27 of the first circuit body 20A. The dummy contact portion 27 is not connected (electrically connected) to the wiring pattern 26 (that is, the busbar 40). In the circuit connection portion 23 of the second circuit body 20B, the hole portions 31 penetrating in the thickness direction (upper-lower direction) of the circuit connection portion 23 are respectively formed at a plurality of positions (in this example, two positions) not interfering with the contact portions 25, the wiring patterns 26, and the dummy contact portion 27, and correspond to the plurality of hole portions 31 of the first circuit body 20A.

The operation of connecting the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B to each other is performed using a plurality of (in this example, two) protrusions 61a (see FIG. 3) that are provided at a plurality of (in this example, two) positions on a bottom wall of a circuit body holding portion 61 (see FIG. 3) described later of the holder 60 and that correspond to the plurality of hole portions 31 of the first circuit body 20A and the second circuit body 20B. That is, first, in a state in which the circuit connection portion 23 of the first circuit body 20A is disposed below the circuit connection portion 23 of the second circuit body 20B, each of the plurality of protrusions 61a is inserted from below into one of the plurality of hole portions 31 of the first circuit body 20A and corresponding one of the plurality of hole portions 31 of the second circuit body 20B in this order (see FIG. 4). Accordingly, the first circuit body 20A and the second circuit body 20B are accommodated in the holder 60 (circuit body holding portion 61), and a state is obtained in which the plurality of hole portions 31 of the first circuit body 20A and the plurality of hole portions 31 of the second circuit body 20B are aligned so as to overlap each other in the upper-lower direction.

Next, the plurality of contact portions 25 of the first circuit body 20A and the plurality of contact portions 25 of the second circuit body 20B are respectively and independently soldered, and the dummy contact portions 27 of the first circuit body 20A and the dummy contact portions 27 of the second circuit body 20B are soldered. Typically, the soldering can be performed by a method (so-called pulse heating method) of sandwiching a paste-like solder between the contact portions 25 arranged to face each other in the upper-lower direction and between the dummy contact portions 27 arranged to face each other in the upper-lower direction, then pressing, against a portion to be soldered, a heater chip that can heat the solder to a temperature at which the solder can be melted, and performing the soldering. The soldering may be performed by a reflow soldering method using a heating furnace. The electrical connection between the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B may be performed using a conductive adhesive instead of the soldering described above.

Accordingly, at the portion in which the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B are connected to each other, the plurality of wiring patterns 26 belonging to the first circuit body 20A and the plurality of wiring patterns 26 belonging to the second circuit body 20B are electrically connected to each other respectively and independently, and are mechanically integrated. The dummy contact portion 27 of the first circuit body 20A and the dummy contact portion 27 of the second circuit body 20B are mechanically integrated with each other using a solder, a conductive adhesive, or the like. Accordingly, the first circuit body 20A and the second circuit body 20B can be more firmly integrated.

In this way, by using the hole portion 31 of the first circuit body 20A, the hole portion 31 of the second circuit body 20B, and the protrusion 61a of the holder 60, it is possible to collectively perform an operation of accommodating the first circuit body 20A and the second circuit body 20B in the holder 60 (the circuit body holding portion 61) and an operation of electrically connecting the contact portion 25 (wiring pattern 26) of the first circuit body 20A and the contact portion 25 (wiring pattern 26) of the second circuit body 20B to each other while preventing a positional deviation or the like of both the contact portions 25 by the protrusion 61a. When an unintended external force is applied to the circuit body 20 (more specifically, the main line portion 21 of the first circuit body 20A and the main line portion 21 of the second circuit body 20B) after the connection, the external force is received by the protrusions 61a. Therefore, it is possible to prevent the external force from being applied to a connection portion of the contact portion 25 (the wiring pattern 26) of the first circuit body 20A and the contact portion 25 (the wiring pattern 26) of the second circuit body 20B. Accordingly, reliability of the electrical connection between the first circuit body 20A and the second circuit body 20B can be improved.

Next, the holder 60 will be described. The holder 60 is a resin molded product, and as shown in FIG. 1, integrally includes the pair of left and right strip-shaped circuit body holding portions 61 that are spaced apart in the left-right direction and extend in the front-rear direction, and a plurality of coupling portions 62 that couple the pair of left and right circuit body holding portions 61 in the left-right direction at a plurality of positions in the front-rear direction. The pair of left and right first circuit bodies 20A (main line portions 21 and branch line portions 22) are respectively placed on the pair of left and right circuit body holding portions 61. The pair of left and right second circuit bodies 20B (main line portions 21 and branch line portions 22) of the circuit body 20 are respectively placed on the pair of left and right circuit body holding portions 61.

Specifically, each of the pair of circuit body holding portions 61 extending in the front-rear direction includes a plurality of divided bodies (not shown) arranged side by side in the front-rear direction, and extension and contraction portions (not shown) each connecting, in the front-rear direction, the divided bodies adjacent to each other in the front-rear direction. Each of the extension and contraction portions has a shape that is easily extended and contracted in the front-rear direction due to elastic deformation. Therefore, the pair of circuit body holding portions 61 are extendable and contractible along the front-rear direction. As described above, a plurality of (two) protrusions 61a are provided on the bottom wall of the circuit body holding portion 61 (see FIG. 3).

For each of the pair of left and right circuit body holding portions 61, a busbar holding portion 64 (see FIG. 1) is integrally provided to be adjacent to the outside in the left-right direction in each of the plurality of divided bodies arranged in the front-rear direction. That is, the plurality of busbar holding portions 64 are arranged side by side in the front-rear direction on the outer side in the left-right direction of each of the pair of left and right circuit body holding portions 61. Since each of the busbar holding portions 64 is provided in corresponding one of the divided bodies, an interval in the front-rear direction between the busbar holding portions 64 adjacent to each other in the front-rear direction can be changed by a function of the extension and contraction portion.

The busbar 40 is accommodated in corresponding one of the busbar holding portions 64. When the holder 60 is attached to the battery assembly 1, the busbar 40 accommodated in the busbar holding portion 64 is conductively connected to the corresponding positive electrode 4 and negative electrode 5 that are adjacent to each other in the front-rear direction on the upper face of the battery assembly 1.

Next, the cover 70 will be described. The cover 70, which is a resin molded product, functions to cover the circuit bodies 20, that is, the first circuit bodies 20A (main line portions 21 and branch line portions 22) and the second circuit bodies 20B (main line portions 21 and branch line portions 22) placed on the pair of left and right circuit body holding portions 61 of the holder 60 which are long in the front-rear direction (see FIG. 1). Therefore, as shown in FIG. 1, the cover 70 has a strip shape formed to be long in the front-rear direction.

In an attachment completion state in which the busbar module 10 has been attached to the battery assembly 1, in the battery assembly 1, the plurality of stacked single cells 2 are electrically connected in series via the plurality of busbars 40. The busbar 40 is conductively connected to the external voltage detection device via the electronic component 50 mounted on corresponding one of the branch line portions 22, the wiring pattern 26 extending from the corresponding branch line portion 22 (contact portion 24), and the connector 29 mounted on the coupling portion 28, in this order. Accordingly, a voltage (potential) of the busbar 40 can be individually detected by the external voltage detection device. When an excessive current equal to or greater than a rated current flows in the electronic component 50 for some reason, a fuse function of the electronic component 50 will be exerted, and thus an electrical connection between the busbar 40 and the wiring pattern 26 is cut off by the electronic component 50. Accordingly, the excessive current is prevented from flowing into the external voltage detection device, so that the external voltage detection device can be protected.

In a use state of the battery assembly 1 to which the busbar module 10 has been attached, each of the single cells 2 included in the battery assembly 1 may expand or contract in the stacking direction (the front-rear direction) due to operating heat associated with charging and discharging, a temperature of an external environment, and the like. As a result, the battery assembly 1 may deform to expand and contract in the stacking direction (front-rear direction). Further, a size of the battery assembly 1 in the stacking direction (front-rear direction) may vary for the manufactured battery assemblies 1 (a manufacturing variation may occur) due to an assembly tolerance when the plurality of single cells 2 are stacked and arranged.

In this regard, in the busbar module 10, even when the extension and contraction of the battery assembly 1 in the stacking direction (front-rear direction) due to the thermal deformation of each single cell 2 and the manufacturing variation of the battery assembly 1 occur, the extension and contraction due to the thermal deformation and the manufacturing variation of the battery assembly 1 can be easily absorbed since each of the plurality of extension and contraction portions of the holder 60 extends and contracts in the front-rear direction and each branch line portion 22 formed of the flexible substrate is easily bent.

As described above, according to the busbar module 10 of the present embodiment, the first circuit body 20A and the second circuit body 20B (main lines) formed of the flexible substrates are integrated by electrically connecting the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B to each other at an overlapping portion (the circuit connection portions 23) of the main line portion 21 of the first circuit body 20A and the main line portion 21 of the second circuit body 20B. In other words, the first circuit body 20A and the second circuit body 20B are electrically connected. The branch line portions 22 (branch lines) extend to branch from the main line portion 21 of the first circuit body 20A and the main line portion 21 of the second circuit body 20B. Therefore, when the battery assembly 1 expands and contracts in the stacking direction (front-rear direction) due to the thermal deformation of each of the single cells 2, each of the busbars 40 can move in the stacking direction of the single cells 2 by bending or the like of the branch line. Similarly, by the bending or the like of the branch line, a variation in the size of the battery assembly 1 in the stacking direction (front-rear direction) due to the assembly tolerance of the single cells 2 can be absorbed. In other words, the busbar module 10 according to the present embodiment can easily cope with the expansion and contraction and the manufacturing variation of the battery assembly 1 due to the deformation of the branch line. Here, in general, even when the flexible substrate includes a large number of circuit structures, the flexible substrate is easily and flexibly deformed with a much smaller force than an electric wire used in the busbar module in the related art described above. Therefore, assemblability to the battery assembly 1 is improved. Accordingly, the busbar module 10 according to the present embodiment is more excellent in the assemblability to the battery assembly 1 and adaptability to the deformation and the manufacturing variation of the battery assembly 1 than the busbar module in the related art described above.

Further, according to the busbar module 10 of the present embodiment, the first circuit body 20A and the second circuit body 20B are prepared as separate bodies and then electrically connected to each other. Therefore, compared to a case in which the first circuit body 20A and the second circuit body 20B are formed of a single continuous flexible substrate, the length of each of the first circuit body 20A and the second circuit body 20B in the stacking direction (front-rear direction) is shortened. Therefore, a dedicated large-sized mounting device is not required when the electronic component 50 is attached (that is, mounted) to the branch line portion 22. In other words, even when a length and a size of a final main line obtained by connecting the first circuit body 20A and the second circuit body 20B are not suitable for a general (general-purpose) mounting device, the first circuit body 20A and the second circuit body 20B may be connected to each other after the electronic component 50 is appropriately mounted on the branch line portion 22 using the general (general-purpose) mounting device for each of the first circuit body 20A and the second circuit body 20B. Therefore, the manufacturing cost of the busbar module 10 can be reduced.

According to the busbar module 10 of the present embodiment, by aligning the hole portion 31 of the first circuit body 20A and the hole portion 31 of the second circuit body 20B to be overlapped with each other (for example, by inserting the protrusion 61a as in this example or a rod-shaped fixture into the hole portion 31 of the first circuit body 20A and the hole portion 31 of the second circuit body 20B), it is possible to prevent the positional deviation or the like between the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B when both the wiring patterns 26 are electrically connected to each other (for example, soldered). Accordingly, the reliability of the electrical connection between the first circuit body 20A and the second circuit body 20B can be improved.

According to the busbar module 10 of the present embodiment, the holder 60 has the protrusion 61a that is inserted into the hole portion 31 of the first circuit body 20A and the hole portion 31 of the second circuit body 20B. Accordingly, it is possible to collectively perform the operation of accommodating the first circuit body 20A and the second circuit body 20B in the holder 60 and the operation of electrically connecting the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B to each other while regulating the positions of both the wiring patterns 26 by the protrusion 61a. When an unintended external force is applied to the main lines (the first circuit body 20A and the second circuit body 20B) after the connection, the external force is received by the protrusion 61a. Therefore, it is possible to prevent the external force from being applied to the connection portion of the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B. Accordingly, the reliability of the electrical connection between the first circuit body 20A and the second circuit body 20B can be improved.

According to the busbar module 10 of the present embodiment, the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B are conductively joined to each other by a conductive joining material. Accordingly, in addition to electrically connecting the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B, the first circuit body 20A and the second circuit body 20B are also mechanically integrated.

According to the busbar module 10 of the present embodiment, in addition to joining the wiring pattern 26 of the first circuit body 20A and the wiring pattern 26 of the second circuit body 20B, the dummy contact portion 27 of the first circuit body 20A and the dummy contact portion 27 of the second circuit body 20B are joined to each other. Accordingly, the first circuit body 20A and the second circuit body 20B can be more firmly integrated.

The present disclosure is not limited to the embodiment described above, and various modifications can be applied within the scope of the present disclosure. For example, the present disclosure is not limited to the embodiment described above, but modifications, improvements, and the like can be appropriately made. In addition, materials, shapes, sizes, numbers, arrangement positions, or the like of components in the embodiment described above are freely selected and are not limited as long as the present disclosure can be implemented.

In the above embodiment, each of the first circuit body 20A and the second circuit body 20B is the so-called single-sided flexible substrate (single-sided FPC) having the single wiring layer. The circuit body 20 is configured by connecting the circuit connection portion 23 provided at the rear end portion of the first circuit body 20A and the circuit connection portion 23 provided at the front end portion of the second circuit body 20B.

In contrast, as in a first modification shown in FIG. 5, the circuit body 20 may be configured by connecting the circuit connection portion 23 provided at the rear end portion of the first circuit body 20A and the circuit connection portion 23 provided at the front end portion of the second circuit body 20B, and connecting the circuit connection portion 23 provided at a rear end portion of the second circuit body 20B and the circuit connection portion 23 provided at a front end portion of the third circuit body 20C. Here, each of the first circuit body 20A and the third circuit body 20C may be a so-called single-sided flexible substrate (single-sided FPC) having a single wiring layer. The second circuit body 20B may be a so-called double-sided flexible substrate (double-sided FPC) having a plurality of wiring layers.

In the second circuit body 20B, one part of the wiring patterns 26 is arranged in one wiring layer, and the other part of the wiring patterns 26 is arranged in the other wiring layer. The one part and the other part of the wiring patterns 26 are in an interlayer connection. An arrangement order of the wiring patterns 26 in the width direction (left-right direction) of the second circuit body 20B in the one wiring layer is different from an arrangement order of the wiring patterns 26 in the width direction (left-right direction) of the second circuit body 20B in the other wiring layer. Accordingly, an arrangement order of the wiring patterns 26 in the first circuit body 20A and an arrangement order of the wiring patterns 26 in the third circuit body 20C can be replaced with any order by the second circuit body 20B (for example, replaced with a potential order of the busbars 40 to which the wiring patterns 26 are connected). Accordingly, the manufacturing cost of the busbar module 10 can be reduced as compared with a case in which the first circuit body 20A, the second circuit body 20B, and the third circuit body 20C are entirely formed of a double-sided flexible substrate.

In the above embodiment, in each of the circuit connection portions 23 of the first circuit body 20A and the second circuit body 20B, the plurality of contact portions 25 are arranged in a manner of being spaced apart in the front-rear direction (longitudinal direction of the circuit body 20).

In contrast, as in a second modification shown in FIG. 6, in each of the circuit connection portions 23 of the first circuit body 20A and the second circuit body 20B, the plurality of contact portions 25 may be arranged in a manner of being spaced apart in the left-right direction (width direction of the circuit body 20). In the second modification, the circuit body 20 is configured by joining the contact portion 25 exposed on a lower face of the circuit connection portion 23 of the first circuit body 20A and the contact portion 25 exposed on the lower face of the circuit connection portion 23 of the second circuit body 20B to each other in a state in which both the circuit connection portions 23 are bent such that the lower face of the circuit connection portion 23 of the first circuit body 20A and the lower face of the circuit connection portion 23 of the second circuit body 20B face each other in the front-rear direction.

As in a third modification shown in FIG. 7, in each of the circuit connection portions 23 of the first circuit body 20A and the second circuit body 20B, the plurality of contact portions 25 may be arranged in a manner of being spaced apart in the left-right direction (width direction of the circuit body 20). In the third modification, the circuit body 20 is configured by joining the contact portion 25 exposed on the upper face of the circuit connection portion 23 of the first circuit body 20A and the contact portion 25 exposed on the lower face of the circuit connection portion 23 of the second circuit body 20B to each other in a state in which the circuit connection portion 23 of the first circuit body 20A is disposed so as to overlap a lower side of the circuit connection portion 23 of the second circuit body 20B. In the third modification, a plurality of connection points between the contact portions 25 of the first circuit body 20A and the contact portions 25 of the second circuit body 20B are arranged in a manner of being spaced apart in the left-right direction. A slit-shaped through hole 71 penetrating the circuit connection portion 23 of the first circuit body 20A and the circuit connection portion 23 of the second circuit body 20B in the thickness direction (upper-lower direction) is provided between adjacent connection points. Even when the busbar module 10 is temporarily exposed to water or the like, it is possible to prevent, by the through holes 71, a short circuit between the adjacent connection points due to moisture or the like.

Here, in the embodiment of the present disclosure described above, a busbar module (10) is a busbar module (10) to be attached to a battery assembly (1) in which a plurality of single cells (2) are stacked, the busbar module (10) including:

- a first circuit body (20A) that is formed of a flexible substrate having a first wiring pattern (26) and that includes a first main line portion (21) and a first branch line portion (22), the first main line portion (21) being arranged to extend along a stacking direction of the plurality of single cells (2), and the first branch line portion (22) extending to branch from the first main line portion (21);
- a second circuit body (20B) that is formed of a flexible substrate having second wiring pattern (26) and that includes a second main line portion (21) and a second branch line portion (22), the second main line portion (21) being arranged to extend along the stacking direction, and the second branch line portion (22) extending to branch from the second main line portion (21),
- a busbar (40) configured to connect to adjacent electrodes (4, 5) between the plurality of single cells (2),
- an electronic component (50) each attached to the first branch line portion (22) and the second branch line portion (22) to each connect the first wiring pattern (26) and the second wiring pattern (26) to the corresponding busbar (40), and
- a holder (60) extensible and contractible along the stacking direction and holding the first circuit body (20A), the second circuit body (20B), and the busbar (40), in which
- the first wiring pattern (26) and the second wiring pattern (26) are electrically connected to each other at an overlapping portion (23) of the first main line portion (21) and the second main line portion (21).

According to the busbar module having the above configuration, the first circuit body and the second circuit body (hereinafter also referred to as “main lines”) formed of the flexible substrates are integrated by electrically connecting the first wiring pattern and the second wiring pattern at the overlapping portion of the first main line portion of the first circuit body and the second main line portion of the second circuit body. In other words, the first circuit body and the second circuit body are electrically connected to each other. The first branch line portion and the second branch line portion (hereinafter also referred to as “branch lines”) extend to respectively branch from the first main line portion and the second main line portion. Therefore, when the battery assembly expands and contracts in the stacking direction due to the thermal deformation of each of the single cells, each of the busbars can move in the stacking direction of the single cells by bending or the like of the branch line. Similarly, by the bending or the like of the branch line, the variation in the size of the battery assembly in the stacking direction due to the assembly tolerance of the single cells can be absorbed. In other words, the busbar module having the present configuration can easily cope with the extension and contraction and the manufacturing variation of the battery assembly by the deformation of the branch line. Here, in general, even when the flexible substrate includes a large number of circuit structures, the flexible substrate is easily and flexibly deformed with a much smaller force than an electric wire used in the busbar module in the related art described above. Therefore, the assemblability to the battery assembly is improved. Accordingly, the busbar module having the present configuration is more excellent in the assemblability to the battery assembly and the adaptability to the deformation and the manufacturing variation of the battery assembly than the busbar module in the related art described above.

According to the busbar module having the above configuration, the first circuit body and the second circuit body are prepared as separate bodies and then electrically connected to each other. Therefore, compared to a case in which the first circuit body and the second circuit body are formed of a single continuous flexible substrate, a length of each of the first circuit body and the second circuit body in the stacking direction is shortened. Therefore, a dedicated large-sized mounting device is not required when the electronic components are attached (that is, mounted) to the first branch line portion and the second branch line portion. In other words, even when the length and the size of the final main line obtained by connecting the first circuit body and the second circuit body are not suitable for a general (general-purpose) mounting device, the first circuit body and the second circuit body may be connected to each other after the electronic component is appropriately mounted on the branch circuit body using the general (general-purpose) mounting device for each of the first circuit body and the second circuit body. Therefore, the manufacturing cost of the busbar module can be reduced.

The first circuit body (20A) may have a first hole portion (31) penetrating the first circuit body (20A) in a thickness direction,

- the second circuit body (20B) may have a second hole portion (31) penetrating the second circuit body (20B) in the thickness direction, and
- the first wiring pattern (26) and the second wiring pattern (26) may be electrically connected to each other in a state where the first hole portion (31) and the second hole portion (31) are aligned to overlap each other.

According to the busbar module having the above configuration, by aligning the first hole portion of the first circuit body and the second hole portion of the second circuit body to be overlapped with each other (for example, by inserting the rod-shaped fixture into the first hole portion and the second hole portion), it is possible to prevent a positional deviation or the like between the first wiring pattern and the second wiring pattern when both the wiring patterns are electrically connected (for example, soldered). Accordingly, the reliability of the electrical connection between the first circuit body and the second circuit body can be improved.

The first circuit body (20A) may have a single wiring layer, and may be configured such that the first wiring pattern (26) is arranged in the single wiring layer,

- the second circuit body (20B) may have a plurality of wiring layers, the second wiring pattern (26) may include a plurality of second wiring patterns (26), and the second circuit body (20B) may be configured such that one part of the second wiring patterns (26) is arranged in one wiring layer and the other part of the second wiring patterns (26) is arranged in the other wiring layer,
- the one part and the other part of the second wiring patterns (26) may be in an interlayer connection, and
- an arrangement order of the second wiring patterns (26) in a width direction of the second circuit body (20B) in the one wiring layer may be different from an arrangement order of the second wiring patterns (26) in the width direction of the second circuit body (20B) in the other wiring layer.

According to the busbar module having the above configuration, the first circuit body is the circuit body (for example, the single-sided flexible substrate) having the single wiring layer, and the second circuit body is the circuit body (for example, the double-sided flexible substrate) having the plurality of wiring layers. In the second circuit body, the arrangement order of the second wiring patterns in the width direction in the one wiring layer is different from the arrangement order of the second wiring patterns in the width direction in the other wiring layer. Therefore, for example, the arrangement order of the first wiring patterns in the first circuit body can be replaced with any order by the second circuit body (for example, replaced with the potential order of the busbars to which the respective wirings included the first wiring patterns are connected). Accordingly, the manufacturing cost of the busbar module can be reduced as compared with a case in which the first circuit body and the second circuit body are entirely formed of a circuit body having a plurality of wiring layers.

The holder (60) may include a protrusion (61a) inserted into the first hole portion (31) and the second hole portion (31).

According to the busbar module having the above configuration, the holder has the protrusion that is inserted into the first hole portion of the first circuit body and the second hole portion of the second circuit body. Accordingly, it is possible to collectively perform the operation of accommodating the first circuit body and the second circuit body in the holder and the operation of electrically connecting the wiring pattern of the first circuit body and the wiring pattern of the second circuit body to each other while regulating the positions of both the wiring patterns by the protrusion. When an unintended external force is applied to the main lines (the first circuit body and the second circuit body) after the connection, the external force is received by the protrusion. Therefore, it is possible to prevent the external force from being applied to the connection portion of the wiring pattern of the first circuit body and the wiring pattern of the second circuit body. Accordingly, the reliability of the electrical connection between the first circuit body and the second circuit body can be improved.

The first wiring pattern (26) and the second wiring pattern (26) may be conductively joined by a conductive joining material.

According to the busbar module having the above configuration, the first wiring pattern and the second wiring pattern are conductively joined by the conductive joining material. Accordingly, in addition to electrically connecting the wiring pattern of the first circuit body and the wiring pattern of the second circuit body, the first circuit body and the second circuit body are also mechanically integrated. Examples of the conductive joining material include a solder and a conductive adhesive.

The first circuit body (20A) may have a first dummy wiring pattern (27) that is not connected to the busbar (40),

- the second circuit body (20B) may have a second dummy wiring pattern (27) that is not connected to the busbar (40), and
- the first dummy wiring pattern (27) and the second dummy wiring pattern (27) may be joined.

According to the busbar module having the above configuration, in addition to joining the first wiring pattern and the second wiring pattern, the first dummy wiring pattern of the first circuit body and the second dummy wiring pattern of the second circuit body are joined. Accordingly, the first circuit body and the second circuit body can be more firmly integrated.

The present application is based on a Japanese patent application (Japanese Patent Application No. 2022-192291) filed on Nov. 30, 2022, and the contents thereof are incorporated herein by reference.

	Number	Date	Country
Parent	PCT/JP2023/041351	Nov 2023	WO
Child	19042007		US

BUSBAR MODULE

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CPC

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Abstract

Description

Claims

Priority Claims (1)

CROSS-REFERENCE TO RELATED APPLICATIONS

Continuations (1)