JP4379931B2 - Power supply device and method of connecting lead wires - Google Patents

Power supply device and method of connecting lead wires Download PDF

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JP4379931B2
JP4379931B2 JP24639998A JP24639998A JP4379931B2 JP 4379931 B2 JP4379931 B2 JP 4379931B2 JP 24639998 A JP24639998 A JP 24639998A JP 24639998 A JP24639998 A JP 24639998A JP 4379931 B2 JP4379931 B2 JP 4379931B2
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power supply
terminal
cylindrical
supply device
positive electrode
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JP2000077056A (en
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村上　　茂
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Sony Corp
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Description

【０００１】
【発明の属する技術分野】
本発明は、電気自動車の駆動モータ等の装置本体に対して大電流を出力する電源装置及びこの電源装置を構成する各単電池に電圧検出線等の引き出し導線を接続する引き出し導線の接続方法に関する。
【０００２】
【従来の技術】
電気自動車等に積載され車両駆動用のモータに対し大電流を供給する電源装置は、複数個の単電池が直列に接続された組電池を内蔵して構成されている。
【０００３】
従来の電源装置は、組電池を構成する単電池間の接続が接続導体（以下、バスバーと称する。）を各単電池の端子部にネジ止めすることにより行われていた。具体的には、従来の電源装置は、一の単電池の正極部にネジ止めされたバスバーを他の単電池の負極部にネジ止めすることにより各単電池が電気的に接続されて構成されていた。電池間接続用のバスバーは、各単電池の正極部又は負極部に設けられたネジ穴、或いは正極部又は負極部に溶接されたネジ穴のついた部材にネジ止めされていた。
【０００４】
また、電源装置は、電気自動車等に積載する場合に、外部出力用のケーブルによって組電池を構成する単電池のうち終端の単電池と電気自動車等とが電気的に接続されている。従来の電源装置は、外部出力用のケーブルが組電池の終端の単電池の正極部又は負極部にネジ止めできるように端末処理が施され終端の単電池にネジ止めされていた。
【０００５】
さらに、電源装置においては、組電池を構成する各単電池の状態を観察する等のために各単電池ごとに電圧検出線等の引き出し導線を接続する場合がある。従来の電源装置においては、上述した外部出力用のケーブルと同様に、引き出し導線にもネジ止めできるように端末処理が施され、各単電池の正極部又は負極部にネジ止めによって接続されていた。
【０００６】
従来の電源装置は、上述したケーブルや引き出し導線のネジ止めがネジ穴加工やタップ立て等の処理が電池本体よりも容易なバスバー部分において行われる場合が多い。このため、従来の電源装置は、複数個の単電池がバスバーにより電気的に接続された後に、ケーブルや引き出し導線等のネジ止めが行われてが接続されていた。
【０００７】
【発明が解決しようとする課題】
しかしながら、従来の電源装置は、車両等に積載して使用した場合に、上述したようにネジ止めされた外部出力用のケーブルや引き出し導線を単電池に接続するネジ部分が振動等によって緩んでしまう場合がある。従来の電源装置においては、単電池と引き出し導線等とを接続するネジが緩むと接触抵抗が増大して長期的に安定した接続の信頼性を得ることが難しく、接続の信頼性が低いという問題があった。
【０００８】
また、従来の電源装置においては、接続される単電池又はバスバー側及び接続する引き出し導線側においてネジ止めするための様々な処理、例えば線材の端末処理や単電池又はバスバー側のネジ穴加工等を施す必要や、線材を取り付けるスペースを単電池等の側で確保する必要があった。従来の電源装置においては、上述したような端末処理等や、単電池等と引き出し導線等とをネジ止めする場合のコストや作業者の負担が増加する等の問題があった。
【０００９】
さらに、従来の電源装置は、バスバーにより各単電池を接続後に引き出し導線等をネジ止めする場合に、数本分の単電池の電位が引き出し導線等にかかり、配線作業において作業者が感電する危険性が高くなり、作業上の安全性の面で問題があった。
【００１０】
そこで、本発明は、各単電池の電極と引き出し導線との接続信頼性が高く、配線作業の際の安全性が改善された電源装置及び引き出し導線の接続方法を提供することを目的にするものである。
【００１１】
【課題を解決するための手段】
上述した目的を達成する本発明に係る電源装置は、正極側及び／又は負極側に円筒状電極端子が取り付けられた複数の単電池が組み合わされて構成される組電池と、組電池を構成する単電池を直列に接続する電池間用接続導体と、組電池の終端の単電池と外部出力端子に接続されたケーブルとを接続する終端用接続導体とを備え、終端用接続導体の一端側に単電池の正極側及び負極側に取り付けられた円筒状電極端子に接続される円筒部が形成されるとともに、他端側に平板状部が波状に折りたたまれかつ絞り込まれて形成され、円筒状電極端子と終端用接続導体の円筒部とは、溶接によって接続されている。終端用接続導体は、絞り込まれて形成された他端側と外部出力端子に接続されたケーブルとがスリーブ型の圧着端子に通され、かしめられることによりケーブルと接続されている。
【００１２】
また、本発明に係る電源装置は、上述した終端用接続導体の一端側に単電池の正極側及び／又は負極側に取り付けられた円筒状電極端子に接続される円筒部が形成されるとともに、他端側に平板状部が形成され、この平板状部の一辺に沿ってケーブルが挿入されるチューブ状部が形成され、円筒状電極端子と終端用接続導体の円筒部とは、溶接によって接続されている。終端用接続導体は、チューブ状部の外側から少なくとも１個の圧着部材でかしめられることによりケーブルと接続されている。
【００１３】
本発明に係る引き出し導線の接続方法は、単電池の正極側及び負極側に取り付けられた円筒状電極端子と引き出し導線又は引き出し導線が接続された棒状の圧着端子とを溶接電極によって上記円筒状部材の内側と外側から挟み込んで加圧することにより上記単電池の各電極に引き出し導線を接続する。
【００１４】
上述した構成を有する本発明に係る電源装置によれば、終端用接続導体に単電池の円筒状電極端子と同様の円筒部が形成されるため、終端用接続導体に単電池が嵌合されかつその嵌合部において内側と外側から加圧することにより溶接可能とされる。本発明に係る電源装置は、終端用接続導体と単電池とが上述したように溶接可能とされることにより、終端用接続導体に接続された外部出力用のケーブルとの接続の信頼性が向上する。また、本発明に係る引き出し導線の接続方法によれば、複数の単電池が電気的に接続される前の各単電池と引き出し導線又は引き出し導線が接続された棒状圧着端子とが溶接により接続されるため、煩雑な配線作業による感電事故の防止を可能とする。
【００１５】
【発明の実施の形態】
以下、本発明に係る電源装置及び引き出し導線の接続方法の具体的な実施の形態について図面を参照しながら詳細に説明する。電源装置１は、図１及び図２に示すように、複数個の単電池２が組み合わされてなる組電池３と、組電池３の両端子側にはめ込まれる電池保持枠４とを備えて構成される。なお、本実施の形態においては、電源装置１を電気自動車に積載され、車両を駆動するモータの駆動用電源として使用されるものとして説明する。
【００１６】
単電池２は、図３に示すように、円筒状の外装缶５の一端側に正極端子を兼ねる正極カバー６が取り付けられるとともに、他端側に負極端子を兼ねる負極カップ７が取り付けられている。正極カバー６は、円形の平板状部材の中央部が立ち上がって円筒状に形成され、外装缶５の正極側の開口部に組み付けられている。負極カップ７は、円筒状に形成され、外装缶５の負極側の中央部に取り付けられる。
【００１７】
組電池３は、図２に示すように、複数個の単電池２が正極と負極とが交互に隣接するように配置されている。組電池３は、図１に示すように、各単電池２の正極カバー６及び負極カップ７が電池保持枠４に形成された孔部８内に位置するように配置され、保持されている。
【００１８】
組電池３は、図１及び図２に示すように、各単電池２が電池間用バスバー９によって接続される。電池間用バスバー９は、中央部が一段高く形成された平板状の部材であり、中央部よりも低く位置する両端側に単電池２の正極カバー６又は負極カップ７が接続されるバスバー円筒部１０がそれぞれ形成されている。
【００１９】
電池間用バスバー９は、組電池３を構成する複数の単電池２のうち隣接する一方の単電池２の正極カバー６と他方の単電池２の負極カップ７とがバスバー円筒部１０にはめ込まれることにより複数個の単電池２を直列に接続する。このように、組電池３は、複数の単電池２が電池間用バスバー９によって直列に接続されて構成される。なお、単電池２の正極カバー６又は負極カップ７と電池缶用バスバー９とは、後述するようにバスバー円筒部１０内に正極カバー６又は負極カップ７がはめ込まれた後に溶接されて接続される。
【００２０】
組電池３は、図１に示すように、直列に接続された単電池２の両端、すなわち終端の単電池２の正極カバー６又は負極カップ７に終端用バスバー１１が接続される。終端用バスバー１１は、組電池３と図示を省略する外部出力端子に接続されたケーブル１２とを接続する。組電池３は、ケーブル１２によってを介して電気自動車の駆動源であるモータと接続される。
【００２１】
ケーブル１２は、銅線であり、可撓性に富み絶縁部材により被覆されている。なお、電源装置１は、上述したようなケーブル１２に代えて銅製の棒材等を終端用バスバー１１と外部出力端子との接続に使用してもよい。
【００２２】
終端用バスバー１１は、図４（ａ）に示すように、一端側に終端の単電池２の正極カバー６又は負極カップ７に接続されるバスバー円筒部１０が形成される。また、終端用バスバー１１は、図４（ｂ）及び（ｃ）に示すように、他端側が波状に折りたたまれた波状部１１ａと、波状部１１ａの端部が絞り込まれてなる接続部１１ｂにより形成されている。終端用バスバー１１は、波状部１１ａと接続部１１ａとで形成され他端側がケーブル１２と接続されることにより、ケーブル１２との接続部において大きな表面積が確保できるとともに、波状部１１ａがフィンとして作用するため、放電時において効率よく放熱し得る。
【００２３】
電源装置１は、図１に示すように、終端用バスバー１１の接続部１１ｂがスリーブ型圧着端子１３の一端側に挿入されるとともに、ケーブル１２がスリーブ型圧着端子１３の他端側に挿入される。電源装置１は、スリーブ型圧着端子１３の終端用バスバー１１の接続部１１ａとケーブル１２とが挿入された部分がそれぞれかしめられることにより、終端用バスバー１１とケーブル１２とが電気的に接続される。
【００２４】
また、電源装置１は、終端の単電池２と外部出力用のケーブル１２とが、図５（ａ）及び（ｂ）に示すような終端用バスバー２０によって接続されるものでもよい。終端用バスバー２０は、一端側にバスバー円筒部１０が形成されるとともに、他端側の平板状部の一辺に沿ってケーブル１２が挿通されるチューブ状部２１が形成される。終端用バスバー２０は、ケーブル１２が挿通されたチューブ状部２１の外側にコネクタ２２を嵌合させてチューブ状部２１をかしめることにより、ケーブル１２を圧着する。終端用バスバー２０は、チューブ状部２１が形成されることによりケーブル１２との接続部においける表面積が大きくなり、電源装置１の放電時において効率よく放熱し得る。なお、終端用バスバー２０においては、ケーブル１２を圧着するコネクタ２２が少なくとも１個使用されていればよい。
【００２５】
電源装置１は、上述した構成を有する終端用バスバー１１、２０によって外部出力用のケーブル１２が接続されることにより、終端用バスバー１１、２０に形成されたバスバー円筒部１０に終端の単電池２の正極カバー６又は負極カップ７が溶接可能とされる。このため、電源装置１は、終端の単電池と外部出力用のケーブル１２との接続がネジ止めによる接続の如く電気自動車に積載した際に生じる振動等により緩むことが無く、高い信頼性を得ることができる。また、電源装置１は、単電池２側等にネジ穴加工やネジ締め等の工程が不要とされるためコストを削減できるとともに、製造上の負担が減少する。
【００２６】
上述したような構成を有する電源装置１は、図１に示すように、組電池３を構成する各単電池２の正極カバー６或いは負極カップ７に、終端の単電池２については正極カバー６及び負極カップ７に電圧検出線１４が接続される。電圧検出線１４は、銅線がビニール等の絶縁部材によって被覆されたものであり、各単電池２の出力電圧を検出する。電源装置１は、電圧検出線１４によって検出された各単電池２の出力電圧が図示を省略するコントローラ基板に送られ、各単電池２に異常がないか等が判断される。
【００２７】
電源装置１は、電池缶用バスバー９によって各単電池２が直列に接続される前に、電圧検出線１４が正極カバー６又は負極カップ７に溶接されて接続される。以下、電圧検出線１４を各単電池２の正極カバー６又は負極カップ７に接続する方法について説明する。
【００２８】
電圧検出線１４は、単電池２に接続される前に、接続端側のビニール被覆が数ｍｍ、例えば断面積が０．３ｍｍ2の銅線である電圧検出線１４の場合、１ｍｍ乃至２ｍｍ程度剥がされて銅線を露出させる。
【００２９】
電源装置１は、図６に示すように、単電池２の正極側に取り付けられた正極カバー６が円筒状に形成されているため、銅線が露出した電圧検出線１４の一端と単電池２の正極カバー６とが正極カバー６の内側と外側から溶接電極１５によって挟み込まれる。溶接電極１５は、正極カバー６の内側にクロム銅電極１５ａが配設され、電圧検出線１４側にタングステン電極１５ｂが配設される。溶接電極１５は、タングステン電極１５ｂの発熱を利用して電圧検出線１４を正極カバー６に溶接している。
【００３０】
電圧検出線１４と単電池２の正極カバー６とは、溶接電極１５により挟み込まれた後に１００Ｎ乃至２００Ｎ（１０ｋｇｆ乃至２０ｋｇｆ）程度の力で図６中矢印Ａ1方向及び矢印Ａ2方向に加圧される。このとき、電圧検出線１４と溶接電極１５との重なりは、少なすぎると銅線が融ける場合があり、多すぎると接合がうまくいかない場合があるため１ｍｍ程度が適当である。電圧検出線１４と溶接電極１５とは、重なりが１ｍｍより長い場合、溶接電極１５の容量を上げれば溶接は可能であるが、電圧検出線１４を接続する場合、溶接部分に流れる電流値が小さいので、やはり１ｍｍ程度が適当である。
【００３１】
電源装置１においては、電圧検出線１４を正極カバー６に直接溶接電極１５によって接続した場合、電圧検出線１４が動くと溶接された部分の線材が破断するおそれがある。このため、電源装置１は、電圧検出線１４の一部に接着剤等の樹脂コーティングが施され、溶接部の線材が動かないように電池保持枠４に固定され、線材の破断が防止される。
【００３２】
また、電源装置１は、上述したように、電圧検出線１４を直接単電池２の正極カバー６に溶接せずに、図７に示すように、棒状圧着端子１６を介して正極カバー６に溶接してもよい。 棒状圧着端子１６は、一端に導線が露出した電圧検出線１４が接続されるとともに、他端が正極カバー６に押し当てられ溶接電極１５によって溶接される。
【００３３】
電源装置１は、図７に示すように、正極カバー６側に配設されたクロム銅電極１５ａと棒状圧着端子１６側に配設されたタングステン電極１５ｂによって図７中矢印Ａ1方向及び矢印Ａ2方向に加圧されて溶接される。
【００３４】
電圧検出線１４は、棒状圧着端子１６を介して正極カバー６に溶接されることにより、振動等により線材の破断が防止される。なお、電圧検出線１４は、絶縁部材によって被覆されている部分が棒状圧着端子１６のかしめ部１６ａにおいてかしめられて取り付けられているため、振動等による棒状圧着端子１６との取付部分における線材の破断も防止される。
【００３５】
以上、電圧検出線１４を単電池２に取り付けられた正極カバー６に溶接する方法について説明したが、正極カバー６と同様に円筒形に形成された負極カップ７も正極カバー６と同じように溶接電極１５によって溶接が可能であることは勿論である。
【００３６】
なお、電源装置１は、電圧検出線１４の代わりに予め線材が配線されたフレキシブルプリント基板（図示は省略）を使用することにより、線材の引き回し作業が大幅に簡易化されるとともに、線材と単電池２との溶接部の位置決めが予め基板によってなされるため溶接の自動化が容易に達成できる。
【００３７】
電源装置１は、上述したように、電圧検出線１４と単電池２とを溶接によって接続するため、従来行われていたネジ止めによる接続に比して電気自動車に積載した場合の振動等によって生じるよりネジの緩みがないため、接続の信頼性が向上するとともに、電圧検出線１４の接続端側の端末処理にかかる端子代や加工代等のコストの削減や作業時の負担を減少させることができる。
【００３８】
また、電圧検出線１４は、単電池２との接続が電池間用バスバー９によって複数の単電池２が直列に接続される前に行われる。このため、電源装置１においては、電圧検出線１４溶接時に単電池２の１本分の電位がかかるだけであり、作業者の感電の危険が減少し、作業面における安全性が向上する。
【００３９】
なお、電源装置１においては、終端用バスバー１１、２０と単電池２の正極カバー６及び負極カップ７とが円筒形に形成されているため、終端用バスバー１１、２０と各単電池２電極とが電圧検出線と同様の方法によって溶接することが可能である。
【００４０】
【発明の効果】
以上詳細に説明したように、本発明に係る電源装置によれば、表面積の大きな終端用バスバーと終端の単電池とが溶接されて接続されているため、大電流が流れる場合であっても効率よく放熱を行うことができる。また、本発明に係る電源装置によれば、終端用バスバーと外部出力用のケーブルとの接続信頼性が高いため、電源装置全体としても高い接続信頼性を得ることができる。
【００４１】
本発明に係る引き出し導線の接続方法によれば、単電池の正極カバー又は負極カップに直接又は棒状の圧着端子を介して電圧検出線等の引き出し導線が溶接されるため、従来のネジ止めによる接続のように電気自動車等に積載した際に生じる振動等によりネジが緩む心配が無く長期的に安定した高い接続信頼性を得ることができる。また、本発明に係る引き出し導線の接続方法によれば、電池間用バスバーによって単電池が直列に接続される以前に引き出し導線の接続を行うため、作業者が感電する危険性が低く、作業面における安全性を向上させることができる。
【図面の簡単な説明】
【図１】電源装置の平面図である。
【図２】電源装置の側面図である。
【図３】単電池の一部切欠き縦断面図である。
【図４】（ａ）は、終端用バスバーの平面図であり、（ｂ）は、終端用バスバーのＡ−Ａ断面図であり、（ｃ）は、終端用バスバーのＢ−Ｂ断面図である。
【図５】（ａ）は、他の実施の形態にかかる終端用バスバーの平面図であり、（ｂ）は、他の実施の形態にかかる終端用バスバーの断面図である。
【図６】電圧検出線と単電池の正極カバーとの接続方法を説明するための図である。
【図７】電圧検出線が取り付けられた圧着端子と単電池の正極カバーとの接続方法を説明するための図である。
【符号の説明】
１ 電源装置，２ 単電池，３ 組電池，４ 電池保持枠，６ 正極カバー，７ 負極カップ，９ 電池間用バスバー，１０ バスバー円筒部，１１、２０ 終端用バスバー，１２ ケーブル，１３ スリーブ型圧着端子，１４ 電圧検出線，１５ 溶接電極，１６ 棒状圧着端子，２１ チューブ状部，２２ コネクタ[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a power supply device that outputs a large current to a main body of a device such as a drive motor of an electric vehicle, and a connection method of a lead wire for connecting a lead wire such as a voltage detection line to each unit cell constituting the power supply device. .
[0002]
[Prior art]
2. Description of the Related Art A power supply device that supplies a large current to a motor for driving a vehicle mounted on an electric vehicle or the like includes a battery pack in which a plurality of single cells are connected in series.
[0003]
In the conventional power supply apparatus, the connection between the cells constituting the assembled battery is performed by screwing a connection conductor (hereinafter referred to as a bus bar) to the terminal portion of each cell. Specifically, a conventional power supply device is configured such that each unit cell is electrically connected by screwing a bus bar screwed to the positive electrode part of one unit cell to the negative electrode part of another unit cell. It was. The bus bar for battery connection is screwed to a screw hole provided in the positive electrode part or the negative electrode part of each unit cell, or a member having a screw hole welded to the positive electrode part or the negative electrode part.
[0004]
In addition, when the power supply device is mounted on an electric vehicle or the like, a terminal unit cell and an electric vehicle or the like among the unit cells constituting the assembled battery are electrically connected by an external output cable. In the conventional power supply device, terminal processing is performed so that the external output cable can be screwed to the positive electrode portion or the negative electrode portion of the cell at the end of the assembled battery, and is screwed to the cell at the end.
[0005]
Furthermore, in the power supply device, a lead conductor such as a voltage detection line may be connected to each unit cell in order to observe the state of each unit cell constituting the assembled battery. In the conventional power supply device, like the above-described external output cable, terminal treatment is performed so that the lead wire can also be screwed, and connected to the positive electrode portion or the negative electrode portion of each unit cell by screwing. .
[0006]
In the conventional power supply device, the above-described screwing of the cable and the lead wire is often performed at the bus bar portion where the processing such as screw hole processing and tapping is easier than the battery body. For this reason, the conventional power supply apparatus is connected after a plurality of single cells are electrically connected by a bus bar and then screwed with a cable, a lead wire, or the like.
[0007]
[Problems to be solved by the invention]
However, when the conventional power supply device is used while being loaded on a vehicle or the like, the screw portion for connecting the external output cable and the lead-out lead wire, which are screwed as described above, to the unit cell is loosened by vibration or the like. There is a case. In conventional power supply devices, if the screws connecting the cells and the lead wires are loosened, the contact resistance increases, making it difficult to obtain stable connection reliability over the long term, and the connection reliability is low was there.
[0008]
Further, in the conventional power supply device, various processes for screwing on the connected unit cell or bus bar side and the connected lead wire side, for example, terminal processing of the wire material or screw hole processing on the unit cell or bus bar side, etc. It was necessary to secure the space for attaching the wire on the side of the unit cell or the like. In the conventional power supply device, there are problems such as the above-described terminal processing and the like, and the cost and the burden on the operator when the single cell or the like and the lead wire are screwed.
[0009]
Furthermore, in the case of conventional power supply devices, when each lead cell is connected with a bus bar and the lead wire is screwed, the potential of several cells is applied to the lead wire, etc. There was a problem in terms of work safety.
[0010]
SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a power supply device and a connection method for a lead conductor, in which the connection reliability between the electrode of each unit cell and the lead conductor is high, and the safety during wiring work is improved. It is.
[0011]
[Means for Solving the Problems]
The power supply device according to the present invention that achieves the above-described object constitutes an assembled battery, and an assembled battery configured by combining a plurality of single cells having cylindrical electrode terminals attached to the positive electrode side and / or the negative electrode side. and connecting between batteries conductor connecting the unit cells in series, and a termination connection conductor for connecting the cable connected to the unit cell and the external output terminal of the end of the battery pack, one end of the terminal connection conductors A cylindrical electrode connected to cylindrical electrode terminals attached to the positive electrode side and the negative electrode side of the unit cell is formed, and a flat plate part is folded and squeezed into the other end side to form a cylindrical electrode. The terminal and the cylindrical portion of the terminal connection conductor are connected by welding . The terminating connection conductor is connected to the cable by passing the other end side formed by being squeezed and the cable connected to the external output terminal through a sleeve-type crimp terminal and caulking.
[0012]
Further, in the power supply device according to the present invention, a cylindrical portion connected to the cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side of the unit cell is formed on one end side of the above-described termination connection conductor, A flat plate portion is formed on the other end side, and a tube-like portion into which a cable is inserted is formed along one side of the flat plate portion . The cylindrical electrode terminal and the cylindrical portion of the terminal connection conductor are connected by welding. Has been . The terminal connection conductor is connected to the cable by caulking with at least one crimping member from the outside of the tubular portion.
[0013]
The lead wire connecting method according to the present invention includes a cylindrical electrode terminal attached to a positive electrode side and a negative electrode side of a battery cell and a rod-like crimp terminal to which the lead wire or the lead wire is connected by a welding electrode. The lead wires are connected to the respective electrodes of the unit cell by being pressed from the inside and outside of the battery.
[0014]
According to the power supply device of the present invention having the above-described configuration, since the cylindrical portion similar to the cylindrical electrode terminal of the unit cell is formed in the termination connection conductor, the unit cell is fitted into the termination connection conductor and Welding is possible by applying pressure from the inside and outside at the fitting portion. In the power supply device according to the present invention, the termination connection conductor and the single cell can be welded as described above, thereby improving the reliability of connection with the external output cable connected to the termination connection conductor. To do. Further, according to the lead wire connecting method according to the present invention, each single cell before the plurality of single cells are electrically connected to the lead wire or the rod-like crimp terminal to which the lead wire is connected is connected by welding. Therefore, it is possible to prevent an electric shock accident due to complicated wiring work.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, specific embodiments of a power supply device and a lead wire connecting method according to the present invention will be described in detail with reference to the drawings. As shown in FIGS. 1 and 2, the power supply device 1 includes an assembled battery 3 in which a plurality of single cells 2 are combined, and a battery holding frame 4 that is fitted to both terminals of the assembled battery 3. Is done. In the present embodiment, description will be made assuming that power supply device 1 is mounted on an electric vehicle and used as a driving power source for a motor that drives the vehicle.
[0016]
As shown in FIG. 3, the unit cell 2 has a positive electrode cover 6 that also serves as a positive electrode terminal attached to one end side of a cylindrical outer can 5, and a negative electrode cup 7 that also serves as a negative electrode terminal attached to the other end side. . The positive electrode cover 6 is formed in a cylindrical shape with a central portion of a circular flat plate member rising, and is assembled to an opening on the positive electrode side of the outer can 5. The negative electrode cup 7 is formed in a cylindrical shape and is attached to the central portion of the outer can 5 on the negative electrode side.
[0017]
As shown in FIG. 2, the assembled battery 3 has a plurality of single cells 2 arranged so that positive electrodes and negative electrodes are alternately adjacent to each other. As shown in FIG. 1, the assembled battery 3 is arranged and held so that the positive electrode cover 6 and the negative electrode cup 7 of each unit cell 2 are positioned in the hole 8 formed in the battery holding frame 4.
[0018]
As shown in FIGS. 1 and 2, the unit cell 2 is connected to the battery pack 3 by inter-battery bus bars 9. The inter-battery bus bar 9 is a flat plate member whose central portion is formed one step higher, and a bus bar cylindrical portion in which the positive electrode cover 6 or the negative electrode cup 7 of the unit cell 2 is connected to both ends located lower than the central portion. 10 are formed.
[0019]
In the inter-battery bus bar 9, the positive electrode cover 6 of one adjacent unit cell 2 and the negative electrode cup 7 of the other unit cell 2 among the plurality of unit cells 2 constituting the assembled battery 3 are fitted in the bus bar cylindrical portion 10. Thus, the plurality of single cells 2 are connected in series. Thus, the assembled battery 3 is configured by connecting a plurality of single cells 2 in series by the inter-battery bus bar 9. The positive electrode cover 6 or the negative electrode cup 7 of the unit cell 2 and the battery can bus bar 9 are welded and connected after the positive electrode cover 6 or the negative electrode cup 7 is fitted in the bus bar cylindrical portion 10 as will be described later. .
[0020]
As shown in FIG. 1, the assembled battery 3 has terminal bus bars 11 connected to both ends of the unit cells 2 connected in series, that is, to the positive electrode cover 6 or the negative electrode cup 7 of the terminal unit cell 2. The terminal bus bar 11 connects the assembled battery 3 and a cable 12 connected to an external output terminal (not shown). The assembled battery 3 is connected via a cable 12 to a motor that is a drive source of the electric vehicle.
[0021]
The cable 12 is a copper wire and is covered with an insulating member that is rich in flexibility. The power supply device 1 may use a copper bar or the like for the connection between the terminating bus bar 11 and the external output terminal instead of the cable 12 as described above.
[0022]
As shown in FIG. 4A, the terminal bus bar 11 is formed with a bus bar cylindrical portion 10 connected to the positive electrode cover 6 or the negative electrode cup 7 of the terminal cell 2 at one end. Further, as shown in FIGS. 4B and 4C, the terminating bus bar 11 includes a corrugated portion 11a in which the other end is folded in a corrugated manner and a connecting portion 11b formed by narrowing the end of the corrugated portion 11a. Is formed. The terminating bus bar 11 is formed by the waved portion 11a and the connecting portion 11a, and the other end side is connected to the cable 12, so that a large surface area can be secured at the connecting portion with the cable 12, and the waved portion 11a acts as a fin. Therefore, heat can be radiated efficiently during discharge.
[0023]
As shown in FIG. 1, in the power supply device 1, the connection portion 11 b of the termination bus bar 11 is inserted into one end side of the sleeve-type crimp terminal 13, and the cable 12 is inserted into the other end side of the sleeve-type crimp terminal 13. The In the power supply device 1, the terminal bus bar 11 and the cable 12 are electrically connected to each other by caulking the connection portion 11 a of the terminal bus bar 11 and the cable 12 inserted into the sleeve-type crimp terminal 13. .
[0024]
Further, the power supply device 1 may be configured such that the terminal cell 2 and the external output cable 12 are connected by a terminal bus bar 20 as shown in FIGS. 5 (a) and 5 (b). The terminal bus bar 20 has a bus bar cylindrical portion 10 formed on one end side and a tube-shaped portion 21 into which the cable 12 is inserted along one side of the flat plate portion on the other end side. The terminal bus bar 20 crimps the cable 12 by fitting the connector 22 on the outside of the tube-like portion 21 through which the cable 12 is inserted and crimping the tube-like portion 21. The terminal bus bar 20 has a large surface area at the connection portion with the cable 12 due to the formation of the tube-shaped portion 21, and can efficiently dissipate heat when the power supply device 1 is discharged. In the termination bus bar 20, it is sufficient that at least one connector 22 for crimping the cable 12 is used.
[0025]
In the power supply device 1, when the external output cable 12 is connected by the terminating bus bars 11 and 20 having the above-described configuration, the terminating cell 2 is connected to the bus bar cylindrical portion 10 formed in the terminating bus bars 11 and 20. The positive electrode cover 6 or the negative electrode cup 7 can be welded. For this reason, the power supply device 1 does not loosen due to vibration or the like that occurs when the terminal cell and the external output cable 12 are loaded on an electric vehicle, such as a connection by screwing, and obtains high reliability. be able to. Moreover, since the power supply device 1 does not require a process such as screw hole machining or screw tightening on the unit cell 2 side or the like, the power supply device 1 can reduce the cost and the manufacturing burden.
[0026]
As shown in FIG. 1, the power supply device 1 having the above-described configuration includes a positive electrode cover 6 or a negative electrode cup 7 of each cell 2 constituting the assembled battery 3, and a positive electrode cover 6 and a terminal cell 2 for the terminal cell 2. A voltage detection line 14 is connected to the negative electrode cup 7. The voltage detection line 14 is a copper wire covered with an insulating member such as vinyl, and detects the output voltage of each unit cell 2. In the power supply device 1, the output voltage of each cell 2 detected by the voltage detection line 14 is sent to a controller board (not shown), and it is determined whether each cell 2 is normal.
[0027]
In the power supply device 1, the voltage detection wires 14 are welded to the positive electrode cover 6 or the negative electrode cup 7 before the individual cells 2 are connected in series by the battery can bus bar 9. Hereinafter, a method of connecting the voltage detection line 14 to the positive electrode cover 6 or the negative electrode cup 7 of each unit cell 2 will be described.
[0028]
Before the voltage detection line 14 is connected to the unit cell 2, in the case of the voltage detection line 14 which is a copper wire having a vinyl coating on the connection end side of several mm, for example, a cross-sectional area of 0.3 mm 2 , about 1 mm to 2 mm. The copper wire is exposed by peeling off.
[0029]
As shown in FIG. 6, the power supply device 1 has a positive electrode cover 6 attached to the positive electrode side of the unit cell 2 in a cylindrical shape, so that one end of the voltage detection line 14 where the copper wire is exposed and the unit cell 2. The positive electrode cover 6 is sandwiched by the welding electrode 15 from the inside and the outside of the positive electrode cover 6. As for the welding electrode 15, the chromium copper electrode 15a is arrange | positioned inside the positive electrode cover 6, and the tungsten electrode 15b is arrange | positioned at the voltage detection line 14 side. The welding electrode 15 uses the heat generated by the tungsten electrode 15b to weld the voltage detection line 14 to the positive electrode cover 6.
[0030]
The voltage detection line 14 and the positive electrode cover 6 of the single battery 2 are pressed in the directions of arrows A 1 and A 2 in FIG. 6 with a force of about 100 N to 200 N (10 kgf to 20 kgf) after being sandwiched between the welding electrodes 15. Is done. At this time, if the overlap between the voltage detection line 14 and the welding electrode 15 is too small, the copper wire may melt, and if it is too large, the joining may not be successful. If the overlap between the voltage detection line 14 and the welding electrode 15 is longer than 1 mm, welding is possible if the capacity of the welding electrode 15 is increased. However, when the voltage detection line 14 is connected, the current value flowing through the welded portion is small. Therefore, about 1 mm is still appropriate.
[0031]
In the power supply device 1, when the voltage detection line 14 is directly connected to the positive electrode cover 6 by the welding electrode 15, there is a possibility that the welded portion of the wire rod is broken when the voltage detection line 14 moves. For this reason, the power supply device 1 is applied to a part of the voltage detection wire 14 with a resin coating such as an adhesive, and is fixed to the battery holding frame 4 so that the wire rod of the welded portion does not move, thereby preventing breakage of the wire rod. .
[0032]
Further, as described above, the power supply device 1 does not weld the voltage detection line 14 directly to the positive electrode cover 6 of the unit cell 2 but welds it to the positive electrode cover 6 via the rod-shaped crimp terminal 16 as shown in FIG. May be. The rod-shaped crimp terminal 16 is connected to the voltage detection line 14 with the conducting wire exposed at one end, and the other end is pressed against the positive electrode cover 6 and welded by the welding electrode 15.
[0033]
Power supply unit 1, as shown in FIG. 7, FIG. 7 in the arrow A 1 direction by chromium copper disposed on the positive electrode cover 6 side electrode 15a and the rod disposed in the crimp terminal 16 side tungsten electrodes 15b and arrow A Pressurized in two directions and welded.
[0034]
The voltage detection wire 14 is welded to the positive electrode cover 6 via the bar-shaped crimp terminal 16, thereby preventing the wire from being broken by vibration or the like. The voltage detection wire 14 is attached by being caulked at the caulking portion 16a of the bar-like crimp terminal 16 at the portion covered with the insulating member, so that the wire rod breaks at the attachment portion with the rod-like crimp terminal 16 due to vibration or the like. Is also prevented.
[0035]
Although the method for welding the voltage detection wire 14 to the positive electrode cover 6 attached to the unit cell 2 has been described above, the negative electrode cup 7 formed in a cylindrical shape similarly to the positive electrode cover 6 is also welded in the same manner as the positive electrode cover 6. Of course, welding is possible by the electrode 15.
[0036]
Note that the power supply device 1 uses a flexible printed circuit board (not shown) on which a wire is pre-wired instead of the voltage detection line 14, thereby greatly simplifying the wire drawing operation and also making the wire and the wire simpler. Since positioning of the welded portion with the battery 2 is made in advance by the substrate, automation of welding can be easily achieved.
[0037]
As described above, since the power supply device 1 connects the voltage detection line 14 and the single battery 2 by welding, the power supply device 1 is generated by vibration or the like when loaded on an electric vehicle as compared with the conventional connection by screwing. Since there is no loosening of the screw, the reliability of the connection is improved, and the cost for the terminal cost and processing cost for the terminal processing on the connection end side of the voltage detection line 14 can be reduced and the burden during the work can be reduced. it can.
[0038]
The voltage detection line 14 is connected to the single battery 2 before the plurality of single batteries 2 are connected in series by the inter-battery bus bar 9. For this reason, in the power supply device 1, only the potential of the single cell 2 is applied when the voltage detection line 14 is welded, and the risk of an operator's electric shock is reduced and the safety on the work surface is improved.
[0039]
In the power supply device 1, the termination bus bars 11, 20 and the positive electrode cover 6 and the negative electrode cup 7 of the unit cell 2 are formed in a cylindrical shape, so that the termination bus bars 11, 20, each unit cell two electrode, Can be welded by the same method as the voltage detection line.
[0040]
【The invention's effect】
As described above in detail, according to the power supply device of the present invention, the termination bus bar having a large surface area and the termination unit cell are welded and connected, so that even when a large current flows, the efficiency is improved. It can dissipate heat well. Moreover, according to the power supply device according to the present invention, since the connection reliability between the termination bus bar and the cable for external output is high, high connection reliability can be obtained as the entire power supply device.
[0041]
According to the connection method of the lead wire according to the present invention, since the lead wire such as the voltage detection wire is welded directly or via the rod-shaped crimp terminal to the positive electrode cover or the negative electrode cup of the unit cell, the connection by the conventional screwing Thus, there is no fear that the screws will loosen due to vibrations or the like generated when loaded on an electric vehicle or the like, and high connection reliability that is stable over the long term can be obtained. Further, according to the connection method of the lead conductor according to the present invention, since the lead conductor is connected before the cells are connected in series by the inter-battery bus bar, the risk of electric shock to the operator is low and the work surface is reduced. Safety can be improved.
[Brief description of the drawings]
FIG. 1 is a plan view of a power supply device.
FIG. 2 is a side view of the power supply device.
FIG. 3 is a partially cutaway longitudinal sectional view of a unit cell.
4A is a plan view of a termination bus bar, FIG. 4B is a sectional view taken along line AA of the termination bus bar, and FIG. 4C is a sectional view taken along line BB of the termination bus bar; is there.
FIG. 5A is a plan view of a termination bus bar according to another embodiment, and FIG. 5B is a cross-sectional view of the termination bus bar according to another embodiment.
FIG. 6 is a diagram for explaining a connection method between a voltage detection line and a positive cover of a unit cell.
FIG. 7 is a diagram for explaining a method of connecting a crimp terminal to which a voltage detection line is attached and a positive electrode cover of a unit cell.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Power supply device, 2 cell, 3 assembled battery, 4 battery holding frame, 6 positive electrode cover, 7 negative electrode cup, 9 battery bus bar, 10 bus bar cylindrical part, 11, 20 terminal bus bar, 12 cable, 13 sleeve type crimp Terminal, 14 Voltage detection line, 15 Welding electrode, 16 Bar-shaped crimp terminal, 21 Tube-shaped part, 22 Connector

Claims (7)

正極側及び／又は負極側に円筒状電極端子が取り付けられた複数の単電池が組み合わされて構成される組電池と、
上記組電池を構成する単電池を直列に接続する電池間用接続導体と、
上記組電池の終端の単電池と外部出力端子に接続されたケーブルとを接続する終端用接続導体とを備え、
上記終端用接続導体は、一端側に上記単電池の正極側及び／又は負極側に取り付けられた円筒状電極端子に接続される円筒部が形成されるとともに、他端側は、平板状部が波状に折りたたまれかつ絞り込まれて上記ケーブルと接続され、
上記円筒状電極端子と上記終端用接続導体の円筒部とは、溶接によって接続されている電源装置。An assembled battery configured by combining a plurality of cells each having a cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side;
An inter-battery connection conductor for connecting in series the cells constituting the assembled battery;
A terminating connection conductor for connecting the cell at the end of the assembled battery and a cable connected to the external output terminal ;
The terminating connection conductor has a cylindrical portion connected to a cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side of the unit cell on one end side, and a flat plate portion on the other end side. Folded and squeezed into a wave and connected to the cable ,
The power supply device in which the cylindrical electrode terminal and the cylindrical portion of the terminal connection conductor are connected by welding . 上記終端用接続導体は、絞り込まれた他端側と上記外部出力端子に接続されたケーブルとがスリーブ型の圧着端子にそれぞれ通されかしめられることにより上記ケーブルと接続されている請求項１に記載の電源装置。The terminating connection conductor according to claim 1 that is connected with the cable by a narrowed end side and the connected to the external output terminal cable is swaged passed respective crimp terminal sleeve type Power supply. 正極側及び／又は負極側に円筒状電極端子が取り付けられた複数の単電池が組み合わされて構成される組電池と、
上記組電池を構成する単電池を直列に接続する電池間用接続導体と、
上記組電池の終端の単電池と外部出力端子に接続されたケーブルとを接続する終端用接続導体とを備え、
上記終端用接続導体は、一端側に上記単電池の正極側及び／又は負極側に取り付けられた円筒状電極端子に接続される円筒部が形成されるとともに、他端側に平板状部が形成され、この平板状部の一辺に沿って上記ケーブルが挿入されるチューブ状部が形成され、
上記円筒状電極端子と上記終端用接続導体の円筒部とは、溶接によって接続されている電源装置。An assembled battery configured by combining a plurality of cells each having a cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side;
An inter-battery connection conductor for connecting in series the cells constituting the assembled battery;
A terminating connection conductor for connecting the cell at the end of the assembled battery and a cable connected to the external output terminal ;
The terminating connection conductor has a cylindrical portion connected to the cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side of the unit cell on one end side, and a flat plate portion on the other end side. A tube-like portion into which the cable is inserted is formed along one side of the flat plate-like portion ,
The power supply device in which the cylindrical electrode terminal and the cylindrical portion of the terminal connection conductor are connected by welding . 上記終端用接続導体は、上記チューブ状部の外側から少なくとも１個の圧着部材でかしめられることにより上記ケーブルと接続されている請求項３に記載の電源装置。The terminating connection conductors, power supply device according to claim 3 that is connected with the cable by caulking at least one crimping member from the outside of the tubular portion. 正極側及び／又は負極側に円筒状電極端子が取り付けられた単電池又はこの単電池が複数組み合わされた組電池を備えてなる電源装置に引き出し導線を接続する方法において、
上記単電池の正極側及び／又は負極側に取り付けられた円筒状電極端子と引き出し導線とを溶接電極によって上記円筒状電極端子の内側と外側から挟み込んで加圧することにより上記単電池の円筒状電極端子に引き出し導線を接続する引き出し導線の接続方法。In a method of connecting a lead conductor to a power supply device comprising a single cell having a cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side or a combination battery in which a plurality of such single cells are combined,
The cylindrical electrode of the unit cell is formed by sandwiching and pressing a cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side of the unit cell and a lead wire from the inside and outside of the cylindrical electrode terminal by a welding electrode. connection of the extraction wire to connect the lead wires to the terminals. 正極側及び／又は負極側に円筒状電極端子が取り付けられた単電池又はこの単電池が複数組み合わされた組電池を備えてなる電源装置に引き出し導線を接続する方法において、
上記単電池の正極側及び／又は負極側に取り付けられた円筒状電極端子と一端側に引き出し導線が接続された棒状の圧着端子の他端側とを溶接電極によって上記円筒状電極端子の内側と外側から挟み込んで加圧することにより上記単電池の円筒状電極端子に引き出し導線を接続する引き出し導線の接続方法。In a method of connecting a lead conductor to a power supply device comprising a single cell having a cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side or a combination battery in which a plurality of such single cells are combined,
The cylindrical electrode terminal attached to the positive electrode side and / or the negative electrode side of the unit cell and the other end side of the rod-shaped crimp terminal having a lead wire connected to one end side are welded to the inside of the cylindrical electrode terminal. connection of the extraction wire to connect the lead wires to a cylindrical electrode terminals of the unit cells by pressurizing sandwich from the outside. 上記引き出し導線は、上記組電池を構成する各単電池の電圧を検出する電圧検出線である請求項５又は請求項６に記載の引き出し導線の接続方法。The drawer conductor connection method of the extraction conductor according to claim 5 or claim 6 Ru voltage detecting lines der to detect the voltage of each cell constituting the battery pack.
JP24639998A 1998-08-31 1998-08-31 Power supply device and method of connecting lead wires Expired - Lifetime JP4379931B2 (en)

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