WO2014046116A1 - バスバーと電線との接続構造 - Google Patents

バスバーと電線との接続構造 Download PDF

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Publication number
WO2014046116A1
WO2014046116A1 PCT/JP2013/075125 JP2013075125W WO2014046116A1 WO 2014046116 A1 WO2014046116 A1 WO 2014046116A1 JP 2013075125 W JP2013075125 W JP 2013075125W WO 2014046116 A1 WO2014046116 A1 WO 2014046116A1
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WO
WIPO (PCT)
Prior art keywords
bus bar
wire
electric wire
core wire
crimp terminal
Prior art date
Application number
PCT/JP2013/075125
Other languages
English (en)
French (fr)
Inventor
吉岡　伸晃
慶吾 鈴木
Original Assignee
矢崎総業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=50341426&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2014046116(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by 矢崎総業株式会社 filed Critical 矢崎総業株式会社
Priority to CA2884369A priority Critical patent/CA2884369A1/en
Priority to EP13838872.3A priority patent/EP2899809B1/en
Publication of WO2014046116A1 publication Critical patent/WO2014046116A1/ja
Priority to US14/645,586 priority patent/US9806441B2/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/503—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the shape of the interconnectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/571—Methods or arrangements for affording protection against corrosion; Selection of materials therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/05—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations having different types of direct connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/182—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for flat conductive elements, e.g. flat cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/188—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping having an uneven wire-receiving surface to improve the contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • 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
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention relates to a connection structure between a bus bar and an electric wire, and more particularly to a connection structure between a bus bar and an electric wire used in a power supply device mounted on an electric vehicle or a hybrid vehicle.
  • a power supply device that supplies a high voltage and a high output to the electric motor is required in order to smoothly travel. It has become.
  • a power supply device having a structure in which a plurality of battery cells are connected in series is used.
  • Patent Document 1 describes such a power supply device.
  • the power supply device includes a battery module and a bus bar module.
  • a battery module a plurality of battery cells are arranged side by side by providing a positive electrode at one end of the battery cell and a negative electrode at the other end, and connecting the positive electrode of one battery cell to the negative electrode of the other battery cell among adjacent battery cells.
  • the bus bar module accommodates a plurality of bus bars that connect between adjacent battery cells of the battery module and between the battery cell and an external device.
  • Patent Document 1 discloses a structure in which a bus bar and a voltage detection terminal are electrically connected by co-fastening a bus bar and a voltage detection terminal to which a core wire of a wire terminal is caulked and connected.
  • Patent Documents 2 and 3 disclose conventional structures for connecting bus bars and electric wires such as voltage detection lines.
  • the bus bar and the electric wire are electrically connected by welding the bus bar and the core wire of the electric wire terminal. Thereby, the process of connecting a voltage detection terminal to an electric wire terminal, and the process of fastening together a voltage detection terminal to a bus bar become unnecessary.
  • connection structure of Patent Document 3 the bus bar and the electric wire are electrically connected by co-crimping the electric wire to the bus bar using a crimp terminal separate from the bus bar.
  • connection structure of Patent Document 2 since the core wire of the electric wire end is merely welded to the bus bar, when the electric wire shakes due to vibration or the like, stress acts directly on the welded portion. Therefore, there is a problem inferior in connection reliability. In order to solve this problem, it is conceivable to set a caulking portion for the covering portion of the electric wire connected to the welded portion. However, in this case, a step of welding the core wire and a step of crimping the coated portion of the electric wire are necessary, and the connection work becomes complicated.
  • the present invention provides a connection structure between a bus bar and an electric wire in which the connection operation between the bus bar and the electric wire is simple and the electrical connection performance is not impaired even if the core wire of the bus bar or the electric wire is formed of an aluminum material. With the goal.
  • a bus bar that connects between a plurality of battery cells or between a battery cell and a first external device, and a second external device that is electrically connected to the bus bar.
  • a crimp terminal for connecting the bus bar and the electric wire, and the crimp terminal has a bus bar connection portion that is crimped to the bus bar and a wire connection portion that is crimped to the wire terminal.
  • at least one of the bus bar connection portion and the wire connection portion is provided with a connection structure between the bus bar and the electric wire, characterized in that an oxide film breaking means for breaking an oxide film of the core wire of the bus bar or the wire terminal is provided.
  • the bus bar has a bus bar main body connected to the battery cell, a plate-like projection from the bus bar main body, and is crimped to the bus bar connecting portion of the crimp terminal.
  • a bus bar crimping portion, the electric wire includes the core wire and a covering portion that covers an outer periphery of the core wire, and the wire connecting portion of the crimp terminal is provided on the bus bar connecting portion side.
  • a coating crimp portion provided on the opposite side of the bus bar connecting portion, and the oxide film breaking means is a serration formed in at least one of the bus bar connecting portion and the core wire crimping portion.
  • the core wire crimping portion of the crimp terminal is formed with a plurality of protrusions that hold the core wire while preventing the serration or the axial displacement of the core wire.
  • At least one of the bus bar connection portion and the wire connection portion of the crimp terminal is provided with the oxide film breaking means for breaking the oxide film of the core wire of the bus bar or the wire terminal. Therefore, even if the core wire of the bus bar or the electric wire end is formed of an aluminum material, and the oxide film is formed on the surface of the aluminum material, the oxide film can be destroyed by crimping the crimp terminal. As a result, the contact resistance due to the oxide film does not increase, and the electrical connection performance of the core wire of the bus bar or the wire terminal can be prevented from being impaired.
  • connection with the core wire of the bus bar and the end of the electric wire and the fixing of the covering portion of the electric wire can be performed only by the step of crimping the crimp terminal to the bus bar and the electric wire. Therefore, the number of steps for connection is reduced, and the connection work is simplified.
  • the crimp terminal since the crimp terminal has the bus bar connecting portion, the core wire crimping portion, and the covering crimping portion, the connection between the bus bar and the core wire of the wire terminal, and the wire covering portion. Can be fixed simply by crimping the crimping terminal to the bus bar and the electric wire. Therefore, connection work is simplified.
  • the oxide film breaking means is serrations formed on at least one of the bus bar connection part and the core wire crimping part of the crimp terminal, the edge part of the serrations bites into the bus bar or the core wire of the electric wire terminal and destroys the oxide film. Therefore, the contact resistance due to the oxide film does not increase, and the electrical connection performance of the core wire of the bus bar or the wire terminal can be prevented from being impaired.
  • the core wire crimping portion of the crimp terminal is formed with a plurality of protrusions that hold the core wire by preventing serration or axial displacement of the core wire. Therefore, even if the core wire is formed of an aluminum material, the oxide film of the core wire can be broken, and the connection between the electric wire and the crimp terminal can be performed satisfactorily.
  • FIG. 1 is a perspective view showing a connection structure between a bus bar and an electric wire according to an embodiment of the present invention.
  • FIG. 2 is an exploded perspective view of the connection structure between the bus bar and the electric wire according to the embodiment of the present invention.
  • FIG. 3 is a perspective view of the crimp terminal according to the embodiment of the present invention.
  • connection structure 1 connects the bus bar 2 and the electric wire 3 with the crimp terminal 4.
  • the connection structure 1 is used for a power supply device mounted on an electric vehicle or a hybrid vehicle.
  • a power supply device (not shown) has a plurality of battery cells arranged side by side. Each battery cell has one end from which the positive and negative electrodes protrude. Among adjacent battery cells, a plurality of battery cells are arranged such that the positive electrode of one battery cell is connected to the negative electrode of the other battery cell.
  • the bus bar 2 connects adjacent battery cells in series, or connects between the battery cells and an external device. For this reason, the number of bus bars 2 used in the connection structure 1 is set according to the number of battery cells and the number of external devices.
  • the bus bar 2 has a bus bar main body 21 and a bus bar crimping portion 22 and is formed of a conductive metal such as an aluminum material or a copper material.
  • the bus bar 2 is formed of an aluminum material. Since the bus bar 2 is made of an aluminum material, an oxide film is formed on the surface of the bus bar 2 over time. However, the oxide film on the bus bar crimping portion 22 is broken by the oxide film breaking means 5 formed on the crimp terminal 4.
  • the bus bar body 21 is formed in a flat plate shape such as a rectangle and is connected to a battery cell or an external device.
  • the bus bar main body 21 is formed with two through holes 23 through which the positive and negative electrodes of the battery cell or the terminal of the external device passes.
  • the bus bar crimping portion 22 has a plate shape from the end of the bus bar main body 21 and protrudes outward.
  • the crimp terminal 4 is crimped to the bus bar crimping portion 22. By this crimping, the bus bar crimping portion 22 is connected to the crimping terminal 4.
  • a covered electric wire including a core wire 31 and a covering portion 32 that covers the outer periphery of the core wire 31 is used.
  • the core wire 31 is formed to have a predetermined thickness by twisting a plurality of strands made of a copper material.
  • the covering portion 32 is made of an insulating resin.
  • the electric wire 3 is connected to the bus bar 2 via the crimp terminal 4 in a state where the covering portion 32 is peeled off and the core wire 31 is exposed.
  • the crimp terminal 4 electrically connects the bus bar 2 and the electric wire 3 by crimping the bus bar 2 and the electric wire 3 to the crimp terminal 4.
  • the crimp terminal 4 includes a bus bar connection portion 41 and a wire connection portion 42.
  • the crimp terminal 4 is formed of a conductive metal such as stainless steel or spring steel.
  • the bus bar connection part 41 of the crimp terminal 4 is crimped to the bus bar crimp part 22 of the bus bar 2. Thereby, the crimp terminal 4 and the bus bar 2 are electrically connected.
  • the wire connecting portion 42 is formed so as to be connected to the bus bar connecting portion 41 through the connecting portion 45, and the wire connecting portion 42 includes the core wire crimping portion 43 and the covering crimping portion 44. Have.
  • the core wire crimping portion 43 is located in a portion where the wire connecting portion 42 is adjacent to the connecting portion 45 (on the bus bar connecting portion 41 side).
  • the core wire crimping portion 43 is crimped to the core wire 31 of the stripped electric wire 3.
  • the covering caulking portion 44 is provided on the side opposite to the portion where the wire connecting portion 42 is adjacent to the continuous portion 45.
  • the covering crimping portion 44 is crimped to the covering portion 32 of the electric wire 3.
  • the crimp terminal 4 is fixed to the electric wire 3 by crimping the covering crimping portion 44.
  • the crimp terminal 4 is formed with oxide film breaking means 5.
  • the oxide film breaking means 5 is provided on the pressure bonding surface 41 a on the upper surface of the bus bar connecting portion 41.
  • the oxide film breaking means 5 is formed by serrations 51 on the crimping surface 41 a of the bus bar connecting portion 41.
  • the serration 51 is formed by punching a plurality of small rectangular grooves in the crimping surface 41a of the bus bar connecting portion 41. The plurality of rectangular grooves are arranged in a lattice pattern on the pressure-bonding surface 41 a of the bus bar connecting portion 41.
  • a plurality of protrusions 53 are formed on the core wire crimping portion 43 of the crimp terminal 4.
  • the plurality of protrusions 53 are formed along a direction substantially orthogonal to the axial direction of the core wire 31 of the electric wire 3.
  • connection structure 1 of the present embodiment Next, assembly of the connection structure 1 of the present embodiment will be described.
  • the bus bar crimping portion 22 of the bus bar 2 is installed on the bus bar connecting portion 41 of the crimping terminal 4, and the exposed core wire 31 is peeled off the wire 3 on the core wire crimping portion 43 of the crimping terminal 4.
  • the covering portion 32 of the electric wire 3 is placed on the covering and crimping portion 44 of the crimp terminal 4.
  • the bus bar connecting portion 41 is crimped to the bus bar crimping portion 22 by crimping the bus bar connecting portion 41, the core wire crimping portion 43 and the covering crimping portion 44, and the core wire crimping portion 43 is crimped to the core wire 31 of the electric wire 3. Is done.
  • the bus bar 2 and the electric wire 3 are electrically connected via the crimp terminal 4.
  • the electric wire 3 is held by the crimping terminal 4 by the crimping of the covering crimping portion 44 to the covering portion 32 of the electric wire 3.
  • connection between the bus bar 2 and the core wire 31 of the electric wire 3 and the fixing of the covering portion 32 of the electric wire 3 can be performed only by the step of crimping the crimp terminal 4 to the bus bar 2 and the electric wire 3. Therefore, the number of steps for connection is reduced, and the connection work is simplified.
  • the oxide film breaking means 5 made of serrations 51 is provided on the bus bar connecting portion 41 of the crimp terminal 4. Therefore, even if the bus bar 2 is made of an aluminum material, the oxide film of the bus bar 2 is destroyed when the crimp terminal 4 is crimped to the bus bar 2. As a result, it is possible to make a connection without impairing the electrical connection performance.
  • the core wire 31 can be prevented from shifting in the axial direction. Therefore, the crimp terminal 4 can reliably hold the core wire 31.
  • the bus bar 2 is formed of an aluminum material
  • the crimp terminal 4 is provided by providing the oxide film breaking means 5 including the serrations 51 with respect to the core wire crimp portion 43 of the crimp terminal 4.
  • the oxide film of the core wire 31 can be broken. That is, by providing the oxide wire breaking means 5 in the core wire crimping portion 43, even if the oxide wire is formed on the core wire 31, the oxide wire on the core wire 31 can be broken by crimping the crimp terminal 4 to the electric wire 3. Therefore, it is possible to prevent the electrical connection performance between the electric wire 3 and the crimp terminal 4 from being impaired.
  • the oxide film breaking means 5 including the serrations 51 with respect to the bus bar connecting portion 41 and the core wire crimping portion 43 of the crimp terminal 4 When the crimp terminal 4 is crimped to the bus bar 2 and the electric wire 3, the oxide film on the bus bar 2 and the core wire 31 can be broken.
  • the serration 51 is formed by arranging a plurality of rectangular grooves in a lattice shape, but may be formed by arranging a plurality of horizontally long grooves in one direction.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

接続構造（１）は、バスバー（２）と電線（３）とを圧着端子（４）によって接続する。圧着端子（４）は、バスバー（２）に圧着されるバスバー接続部（４１）と、電線（３）の端末に圧着される電線接続部（４２）とを有する。バスバー接続部（４１）と電線接続部（４２）の少なくとも一方に、バスバー（２）又は電線（３）の端末の芯線（３１）の酸化被膜を破壊する酸化被膜破壊手段（５）が設けられる。

Description

バスバーと電線との接続構造
　本発明は、バスバーと電線との接続構造に関し、特に電気自動車やハイブリッド自動車に搭載される電源装置に用いられる、バスバーと電線との接続構造に関する。
　電動モータを用いて走行する電気自動車や、電動モータとエンジンとを併用して走行するハイブリッド自動車において、円滑な走行を行うために、電動モータに高電圧且つ高出力を供給する電源装置が必要となっている。この電源装置として、複数の電池セルを直列に接続した構造を有する電源装置が用いられている。
　特許文献１には、このような電源装置が記載されている。この電源装置は、電池モジュール及びバスバーモジュールを備えている。電池モジュールにおいて、電池セルの一端に正極及び他端に負極を設け、隣り合う電池セルのうち、一方の電池セルの正極を他方の電池セルの負極に接続した状態で、複数の電池セルが横並びに配置される。バスバーモジュールは、電池モジュールの隣り合う電池セルの間及び電池セルと外部機器との間を接続する複数のバスバーを収容する。
　隣り合う電池セルのうち、一方の電池セルの正極及び他方の電池セルの負極がバスバーを貫通するように、複数の電池セルは直列に接続されている。電線（電圧検出線）の端末をバスバーに接続することにより、各電池セルの電位又は電池モジュールの電圧が測定される。特許文献１は、バスバーと、電線端末の芯線が加締め接続された電圧検出端子とを共締めすることにより、バスバーと電圧検出端子とを電気的に接続した構造を開示している。
　特許文献２及び３は、バスバーと電圧検出線等の電線とを接続する従来の構造を開示している。
　特許文献２の接続構造では、バスバーと電線端末の芯線とを溶着することにより、バスバーと電線とを電気的に接続している。これにより、電線端末に電圧検出端子を接続する工程及び電圧検出端子をバスバーに共締めする工程が不要となる。
　特許文献３の接続構造では、バスバーとは別体の圧着端子を用いてバスバーに電線を共圧着することにより、バスバーと電線とを電気的に接続している。
特開２００３－４５４０９号公報 特開２０１１－４０３３２号公報 特開２０１２－５９６５８号公報
　特許文献２の接続構造では、電線端末の芯線をバスバーに溶着しているだけなので、振動等による電線の振れが生じると、溶着部分に直接に応力が作用する。そのため、接続の信頼性に劣る問題がある。この問題を解決するため、溶着部分に連接する電線の被覆部に対する加締め部を設定することが考えられる。しかしながら、この場合には、芯線を溶着する工程及び電線の被覆部に対する加締めの工程が必要となり、接続作業が複雑となる。
　特許文献３の接続構造では、圧着端子を用いてバスバーに電線を共圧着するため、電線の振れが直接影響することが少ない。しかしながら、バスバー又は電線の芯線がアルミ材によって形成される場合には、これらの表面に酸化被膜が形成される。この酸化被膜により、バスバーと電線との圧着面での接触抵抗が増加して、発熱等の原因となる問題がある。
　本発明は、バスバーと電線との接続作業が簡単であり、バスバー又は電線の芯線がアルミ材によって形成されていても、電気的接続性能が損なうことのないバスバーと電線の接続構造を提供することを目的とする。
　本発明の第１の態様によれば、複数の電池セル間、又は電池セルと第１外部機器との間を接続するバスバーと、前記バスバーに電気的に接続される、第２外部機器に接続された電線と、前記バスバーと前記電線とを接続する圧着端子と、を備え、前記圧着端子は、前記バスバーに圧着されるバスバー接続部と、前記電線端末に圧着される電線接続部とを有し、前記バスバー接続部及び前記電線接続部の少なくとも一方に、前記バスバー又は前記電線端末の芯線の酸化被膜を破壊する酸化被膜破壊手段を設けたことを特徴とするバスバーと電線との接続構造を提供する。
　本発明の第２の態様によれば、前記バスバーは、前記電池セルに接続されるバスバー本体と、前記バスバー本体から板状に突設されて、前記圧着端子の前記バスバー接続部に圧着されるバスバー圧着部とを有し、前記電線は、前記芯線と、前記芯線の外周を被覆する被覆部とを有し、前記圧着端子の前記電線接続部は、バスバー接続部側に設けられた芯線圧着部と、前記バスバー接続部と反対側に設けられた被覆加締め部とを有し、前記酸化被膜破壊手段は、前記バスバー接続部及び前記芯線圧着部の少なくとも一方に形成されたセレーションである。
　本発明の第３の態様によれば、前記圧着端子の前記芯線圧着部には、前記セレーション、又は前記芯線の軸方向へのずれを阻止して芯線を保持する複数の突状が形成されている。
　本発明の第１の態様によれば、圧着端子のバスバー接続部及び電線接続部の少なくとも一方に、バスバー又は電線端末の芯線の酸化被膜を破壊する酸化被膜破壊手段を設けている。それゆえ、バスバー又は電線端末の芯線がアルミ材によって形成され、アルミ材の表面に酸化被膜が形成されていても、圧着端子を圧着することにより酸化被膜を破壊することができる。結果として、酸化被膜に起因した接触抵抗が増加することがなく、バスバー又は電線端末の芯線の電気的接続性能が損なわれることを防止できる。
　圧着端子をバスバー及び電線に圧着する工程だけで、バスバー及び電線端末の芯線との接続、及び電線の被覆部の固定を行うことができる。それゆえ、接続のための工程が少なくなり、接続作業が簡単となる。
　本発明の第２の態様によれば、圧着端子は、バスバー接続部、芯線圧着部、及び被覆加締め部を有しているため、バスバー及び電線端末の芯線との接続、及び電線の被覆部の固定を、圧着端子をバスバー及び電線に圧着するだけで行うことができる。それゆえ、接続作業が簡単となる。
　酸化被膜破壊手段を圧着端子のバスバー接続部及び芯線圧着部の少なくとも一方に形成されたセレーションであるため、セレーションのエッジ部がバスバー又は電線端末の芯線に食い込んで酸化被膜を破壊する。それゆえ、酸化被膜に起因した接触抵抗が増加することがなく、バスバー又は電線端末の芯線の電気的接続性能が損なわれることを防止できる。
　本発明の第３の態様によれば、圧着端子の芯線圧着部には、セレーション、又は芯線の軸方向へのずれを阻止して芯線を保持する複数の突状が形成されている。それゆえ、芯線がアルミ材によって形成されていても、芯線の酸化被膜を破壊することができ、かつ、電線と圧着端子との接続を良好に行うことができる。
図１は、本発明の実施形態に係るバスバーと電線との接続構造を示す斜視図である。 図２は、本発明の実施形態に係るバスバーと電線との接続構造の分解斜視図である。 図３は、本発明の実施形態に係る圧着端子の斜視図である。
　以下、図１乃至３を参照して、本発明の実施形態を詳細に説明する。
　接続構造１は、バスバー２と電線３とを圧着端子４によって接続する。接続構造１は、電気自動車やハイブリッド自動車に搭載される電源装置に用いられる。
　電源装置（図示略）は、横並びに配置された複数の電池セルを有している。各電池セルは、正極及び負極が突出する一端を有する。隣り合う電池セルのうち、一方の電池セルの正極が他方の電池セルの負極に接続されるように、複数の電池セルが配置される。バスバー２は、隣り合う電池セルを直列に接続し、又は、電池セルと外部機器との間を接続する。このため、接続構造１に使用されるバスバー２の数は、電池セルの数及び外部機器の数に応じて設定される。
　バスバー２は、バスバー本体２１及びバスバー圧着部２２を有しており、アルミ材、銅材等の導電性金属によって形成される。本実施形態において、バスバー２はアルミ材によって形成されている。バスバー２はアルミ材からなるため、経時的にバスバー２の表面に酸化被膜が形成される。しかしながら、バスバー圧着部２２の酸化被膜は、圧着端子４に形成された酸化被膜破壊手段５によって破壊される。
　バスバー本体２１は矩形等の平板状に形成されており、電池セル又は外部機器に接続される。この接続を行うために、バスバー本体２１には電池セルの正極及び負極、又は外部機器の端子が貫通する２つの貫通孔２３が形成されている。バスバー圧着部２２は、バスバー本体２１の端部から板状となって外方に突設されている。バスバー圧着部２２には圧着端子４が圧着される。この圧着により、バスバー圧着部２２は圧着端子４に接続される。
　電線３には、芯線３１と、芯線３１の外周を被覆する被覆部３２とからなる被覆電線が用いられる。芯線３１は、銅材からなる複数の素線を撚ることにより所定の太さとなるように形成されている。被覆部３２は、絶縁性樹脂によって形成されている。電線３は、被覆部３２を皮剥きして芯線３１を露出させた状態で、圧着端子４を介してバスバー２に接続される。
　圧着端子４は、バスバー２及び電線３を圧着端子４に圧着することにより、バスバー２及び電線３を電気的に接続する。圧着端子４は、バスバー接続部４１及び電線接続部４２を有する。圧着端子４はステンレス、ばね鋼等の導電性金属によって形成される。
　圧着端子４のバスバー接続部４１は、バスバー２のバスバー圧着部２２に圧着される。これより、圧着端子４とバスバー２とが電気的に接続される。
　図３に示すように、電線接続部４２は、連設部４５を介してバスバー接続部４１と連接するように形成されており、電線接続部４２は芯線圧着部４３及び被覆加締め部４４を有する。
　芯線圧着部４３は、電線接続部４２が連設部４５に隣接する部分（バスバー接続部４１側）に位置している。芯線圧着部４３は、皮剥きされた電線３の芯線３１に圧着される。これにより、圧着端子４と電線３とが電気的に接続される。被覆加締め部４４は、電線接続部４２が連設部４５に隣接する部分と反対側に設けられている。被覆加締め部４４は、電線３の被覆部３２に加締められる。被覆加締め部４４を加締めることにより、圧着端子４が電線３に固定される。
　圧着端子４には、図２及び図３に示すように、酸化被膜破壊手段５が形成されている。本実施形態において、酸化被膜破壊手段５は、バスバー接続部４１の上面の圧着面４１ａに設けられる。酸化被膜破壊手段５は、バスバー接続部４１の圧着面４１ａのセレーション５１によって形成されている。セレーション５１は、バスバー接続部４１の圧着面４１ａに対して、複数の小さな矩形溝を穿つことにより形成されている。複数の矩形溝は、バスバー接続部４１の圧着面４１ａ上で格子状に配列されている。圧着端子４をバスバー圧着部２２に圧着する時に、バスバー圧着部２２の表面の酸化被膜は、セレーション５１で破壊される。
　図２及び図３に示すように、圧着端子４の芯線圧着部４３には複数の突状５３が形成されている。複数の突状５３は、電線３の芯線３１の軸方向と略直交する方向に沿って形成されている。複数の突状５３を芯線圧着部４３に形成することにより、芯線圧着部４３に圧着された芯線３１の軸方向のずれを阻止して、芯線３１を保持することができる。
　次に、本実施形態の接続構造１の組み付けを説明する。
　図２に示すように、バスバー２のバスバー圧着部２２を圧着端子４のバスバー接続部４１上に設置し、電線３を皮剥きして露出した芯線３１を圧着端子４の芯線圧着部４３上に設置し、電線３の被覆部３２を圧着端子４の被覆加締め部４４上に設置する。この状態で、バスバー接続部４１、芯線圧着部４３及び被覆加締め部４４を加締めることにより、バスバー接続部４１はバスバー圧着部２２に圧着され、芯線圧着部４３は電線３の芯線３１に圧着される。これにより、バスバー２と電線３とが圧着端子４を介して電気的に接続される。加えて、被覆加締め部４４が電線３の被覆部３２に圧着されることにより、電線３が圧着端子４に保持される。
　圧着端子４をバスバー２に圧着する過程において、バスバー接続部４１にセレーション５１が形成されていることにより、セレーション５１を形成する複数の矩形溝のエッジ部が、バスバー２のバスバー圧着部２２に食い込む。この食い込みにより、バスバー圧着部２２に酸化被膜が形成されていても、酸化被膜が破壊される。それゆえ、バスバー圧着部２２の導体がバスバー接続部４１と直接に接触して、バスバー２と圧着端子４とが良好に電気的に接続される。結果として、酸化被膜に起因した接触抵抗の増加がなく、発熱を防止することができる。
　加えて、芯線圧着部４３に形成された複数の突状５３が、電線３の芯線３１に食い込むため、芯線３１の軸方向へのずれが阻止される。従って、電線３と圧着端子４とが良好に接続される。
　本実施形態によれば、圧着端子４をバスバー２及び電線３に圧着する工程だけで、バスバー２と電線３の芯線３１との接続、及び電線３の被覆部３２の固定を行うことができる。それゆえ、接続のための工程が少なくなり、接続作業が簡単となる。
　圧着端子４のバスバー接続部４１に、セレーション５１からなる酸化被膜破壊手段５が設けられている。それゆえ、バスバー２がアルミ材によって形成されていても、圧着端子４をバスバー２に圧着する時に、バスバー２の酸化被膜が破壊される。結果として、電気的接続性能を損なうことのない接続を行うことができる。
　圧着端子４の芯線圧着部４３に複数の突状５３が形成されているため、芯線３１の軸方向へのずれを阻止することができる。それゆえ、圧着端子４は芯線３１を確実に保持することができる。
　本実施形態では、バスバー２がアルミ材により形成されている場合を説明した。これに対して、電線３の芯線３１がアルミ材により形成されている場合には、圧着端子４の芯線圧着部４３に対してセレーション５１からなる酸化被膜破壊手段５を設けることにより、圧着端子４を電線３に圧着する時に、芯線３１の酸化被膜を破壊することができる。すなわち、芯線圧着部４３に酸化被膜破壊手段５を設けることにより、芯線３１に酸化被膜が形成されていても、圧着端子４を電線３に圧着することにより、芯線３１の酸化被膜を破壊できる。それゆえ、電線３と圧着端子４との電気的接続性能を損なうことを防止できる。
　バスバー２及び電線３の芯線３１がアルミ材によって形成されている場合には、圧着端子４のバスバー接続部４１及び芯線圧着部４３に対してセレーション５１からなる酸化被膜破壊手段５を設けることにより、圧着端子４をバスバー２及び電線３に圧着する時に、バスバー２及び芯線３１の酸化被膜を破壊することができる。
　セレーション５１は、複数の矩形溝を格子状に配置することで形成されているが、複数の横長の溝を一方向に並べて配置することで形成しても良い。
１　接続構造
２　バスバー
３　電線
４　圧着端子
５　酸化被膜破壊手段
２１　バスバー本体
２２　バスバー圧着部
３１　芯線
３２　被覆部
４１　バスバー接続部
４２　電線接続部
４３　芯線圧着部
４４　被覆加締め部
５１　セレーション
５３　突状

Claims (3)

  1. 　複数の電池セル間、又は電池セルと第１外部機器との間を接続するバスバーと、
     前記バスバーに電気的に接続される、第２外部機器に接続された電線と、
    　前記バスバーと前記電線とを接続する圧着端子と、
     を備え、
    　前記圧着端子は、前記バスバーに圧着されるバスバー接続部と、前記電線端末に圧着される電線接続部とを有し、
    　前記バスバー接続部及び前記電線接続部の少なくとも一方に、前記バスバー又は前記電線端末の芯線の酸化被膜を破壊する酸化被膜破壊手段を設けたことを特徴とするバスバーと電線との接続構造。
  2. 　前記バスバーは、前記電池セルに接続されるバスバー本体と、前記バスバー本体から板状に突設されて、前記圧着端子の前記バスバー接続部に圧着されるバスバー圧着部とを有し、
    　前記電線は、前記芯線と、前記芯線の外周を被覆する被覆部とを有し、
    　前記圧着端子の前記電線接続部は、バスバー接続部側に設けられた芯線圧着部と、前記バスバー接続部と反対側に設けられた被覆加締め部とを有し、
    　前記酸化被膜破壊手段は、前記バスバー接続部及び前記芯線圧着部の少なくとも一方に形成されたセレーションであることを特徴とする請求項１に記載のバスバーと電線との接続構造。
  3. 　前記圧着端子の前記芯線圧着部には、前記セレーション、又は前記芯線の軸方向へのずれを阻止して芯線を保持する複数の突状が形成されていることを特徴とする請求項２に記載のバスバーと電線との接続構造。
PCT/JP2013/075125 2012-09-19 2013-09-18 バスバーと電線との接続構造 WO2014046116A1 (ja)

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