Busbar module

A busbar module includes a case to be attached to a battery assembly, a busbar supported by the case and to be connected to an electrode of single cells of the battery assembly and electric wires to be routed in the case. The case is provided with electric wire routing grooves to accommodate the electric wires, the electric wire routing grooves intersecting with one another. A part of the plurality of electric wires bends at a connection portion of the plurality of electric wire routing grooves. The connection portion is provided with a guide taper provided inside a bent portion of the part of the plurality of electric wires and a wire locking portion to lock the at least a part of the electric wires at a side of the bent portion of the at least the part of the electric wires.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to Japanese Patent Application No. 2020-006204 filed on Jan. 17, 2020, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a busbar module.

BACKGROUND

A power supply device mounted on various vehicles, such as an electric automobile that travels using an electric motor and a hybrid automobile that travels using an engine and an electric motor in combination, is provided with a busbar module an upper portion of a battery assembly including a plurality of single cells. The busbar module includes a plurality of busbars electrically connected to electrodes of the plurality of single cells. These busbars are accommodated and held in a resin case attached to the upper portion of the battery assembly (see, for example, JP2012-164591A). The case of the busbar module includes an electric wire routing groove for accommodating and routing an electric wire such as a voltage detection line connected to an electrode of a single cell to detect a voltage of the single cell and a temperature detection line connected to a thermistor to measure a temperature of a single cell.

However, in a case where a plurality of electric wire routing groove portions that intersect with each other and are connected to each other, an electric wire may be bent and routed at a connection portion of the electric wire routing groove portions, in such a case, at the connection portion of the electric wire routing groove portions, the electric wire may protrude from the electric wire routing groove portion and ride on a corner portion of the electric wire routing groove portion.

SUMMARY

Illustrative aspects of the present invention provide a busbar module configured to allow routing of an electric wire smoothly to an electric wire routing groove portion of a case without problems such as a protrusion.

According to an illustrative aspect of the present invention, a busbar module includes a case configured to be attached to a battery assembly including a plurality of single cells, a busbar supported by the case and configured to be electrically connected to an electrode of each of the plurality of single cells of the battery assembly and a plurality of electric wires configured to be routed in the case. The case is provided with a plurality of electric wire routing grooves configured to accommodate and route the plurality of electric wires, the plurality of electric wire routing grooves intersecting with and being connected to one another. At least a part of the plurality of electric wires are configured to be bent at a connection portion of the plurality of electric wire routing grooves at which the plurality of electric wire routing grooves are connected to one another. The connection portion is provided with a guide taper provided inside a bent portion of the at least a part of the plurality of electric wires, the guide taper being configured to guide the at least a part of the plurality of electric wires and a wire locking portion configured to lock the at least a part of the plurality of electric wires at a side of the bent portion of the at least a part of the plurality of electric wires.

DESCRIPTION OF EMBODIMENTS

Hereinafter, embodiments of the present invention will be described with reference to the drawings.FIG. 1is a perspective view of a busbar module10and a battery assembly1according to an embodiment of the present invention.

As shown inFIG. 1, a power supply device2includes the busbar module10according to the embodiment attached to an upper portion of the battery assembly1. The power supply device2is mounted on and used in various vehicles such as an electric automobile that travels using an electric motor, and a hybrid automobile that travels using an engine and an electric motor in combination, and supplies power to the electric motor.

The battery assembly1includes a plurality of single cells3arranged in a row along one direction. Each of the single cells3is formed in a rectangular parallelepiped shape, and includes a pair of electrodes5protruding from one end side and the other end side of an upper surface of the single cell3. One of the pair of electrodes5is a positive electrode and the other one is a negative electrode.

In the battery assembly1, the plurality of (four in this example) singe cells3are provided adjacent to each other and form one set of the single cells3, and the electrodes5are aligned thereon. The busbar module10connects sets of the single cells3in series by busbars50to be described later.

FIG. 2is an exploded perspective view of the busbar module10according to the embodiment. As shown inFIG. 2, the busbar module10includes a case20, the busbars50, and a wire harness60including a plurality of electric wires61.

The case20is formed of, for example, an electrically insulating synthetic resin, and includes a plurality of busbar accommodating portions21.

The busbar accommodating portions21are arranged in two rows along an arrangement direction of the plurality of single cells3, along which the plurality of single cells3are arranged. The busbar accommodating portion21is formed in a frame shape, and the busbars50are to be accommodated in the busbar accommodating portion21.

A first electric wire routing groove portion31A and a second electric wire routing groove portion31B, which are a part of electric wire routing grooves, are provided between the two rows of busbar accommodating portions21. The first electric wire routing groove portion31A and the second electric wire routing groove portion31B extend along the rows of the busbar accommodating portions21in a longitudinal direction of the case20, respectively. In addition, a first electric wire passing portion33A, a second electric wire passing portion33B, and a third electric wire passing portion33C, which are also a part of electric wire routing grooves, are provided between the first electric wire routing groove portion31A and the second electric wire routing groove portion31B, as the electric wire routing groove portion.

The first electric wire passing portion33A is provided in a vicinity of one end20A (first end20A) of the case20. The second electric wire passing portion33B is provided in a middle of the case20in a longitudinal direction, and the third electric wire passing portion33C is provided in a vicinity of the other end20B (second end20B) of the case20. In other words, when a direction from the other end20B (second end20B) toward the one end20A (first end20A) is defined as a first direction and another direction oriented from the one end20A toward the other end20B, which is opposite to the first direction, is defined as a second direction, the first electric wire passing portion33A is provided furthest in the first direction, the second electric wire passing portion33B is in the middle and the third electric wire passing portion33C is furthest in the second direction. As shown inFIG. 1, a cover25is attached to the case20from above. By attaching the cover25to the case20, the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C are covered with the cover25.

The case20includes an electric wire take-out portion35. The electric wire take-out portion35is provided between the first electric wire passing portion33A and the second electric wire passing portion33B in the first electric wire routing groove portion31A. An electric wire holding cover36can be attached to the electric wire take-out portion35from above.

As shown inFIG. 2, the plurality of electric wires61of the wire harness60are electric wires for voltage detection with connection terminals62connected to end portions, and electric wires for temperature measurement with thermistors63connected to end portions. The connection terminals62are fastened to the electrodes5of the single cells3together with the respective busbars50, and are electrically connected to the busbars50. In addition, the thermistor63comes into contact with a specific single cell3of the battery assembly1to measure a temperature of the single cell3. Each electric wire61of the wire harness60is connected either to a control circuit board (not shown) including a voltage monitoring circuit and a temperature monitoring circuit.

The electric wires61of the wire harness60according to the present embodiment are divided into an electric wire group61A drawn into from one end20A side of the case20and an electric wire group61B drawn into from the other end20B side of the case20with respect to the electric wire take-out portion35. A part of the electric wire group61A drawn into the electric wire take-out portion35from the one end20A side of the case20in the first electric wire routing groove portion31A, which is accommodated and routed in the second electric wire routing groove portion31B, is drawn closer into the other end20B side of the case20than the electric wire take-out portion35. Further, the electric wire group61A is passed through the second electric wire routing groove portion31B and the first electric wire passing portion33A, drawn into the first electric wire routing groove portion31A from the one end20A side of the case20, and guided to the electric wire take-out portion35.

The electric wire group61B drawn into the electric wire take-out portion35from the other end20B side of the case20in the first electric wire routing groove portion31A is drawn closer into the other end20B side of the case20than the electric wire take-out portion35. In addition, a part of the electric wire group61B accommodated and routed in the second electric wire routing groove portion31B is passed through the second electric wire passing portion33B and the third electric wire passing portion33C provided closer to the other end side of the case20than the electric wire take-out portion35(i.e., the second electric wire passing portion33B and the third electric wire passing portion33C is provided further in the second direction than the electric wire take-out portion35), and then is drawn into the first electric wire routing groove portion31A. The electric wire group61B is collected by the first electric wire routing groove portion31A and guided to the electric wire take-out portion35.

That is, the electric wires61of the wire harness60are accommodated and routed in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C. The electric wires61are drawn out to an outside from the electric wire take-out portion35provided in the first electric wire routing groove portion31A.

FIG. 3is a plan view and a partial enlarged view of the busbar module10according to the embodiment.FIG. 4is a perspective view and a partial enlarged view of the busbar module10according to the embodiment.

The case20of the busbar module10is divided at a substantially middle portion in the longitudinal direction. Thus, the case20is composed of two divided cases22,23which are divided in the longitudinal direction. These divided cases22,23have a first coupling portion41and a second coupling portion45, and are coupled to each other to form the case20.

As shown inFIGS. 3 and 4, at connection portions where the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C intersect with and are connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B, a part of the electric wires61is bent and routed.

Next, a structure at the positions where the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C are connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B will be described.

A plurality of guide tapers (tapered corners)37are formed at positions where the first electric wire passing portion33A is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. These guide tapers37are provided at corner portions inside bent portions of the electric wires61which are bent and routed at the positions where the first electric wire passing portion33A is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. These guide tapers37are formed at an angle of approximately 45° with respect to the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the first electric wire passing portion33A. The guide tapers37are formed by removing corners at which the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the first electric wire passing portion33A intersect with one another. As a result, the bent portions of the electric wires61routed at the positions where the first electric wire passing portion33A is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B are gently bent and routed along the guide tapers37.

Similarly, the guide tapers37are formed at the corner portions inside the bends of the electric wires61which are bent and routed at positions where the second electric wire passing portion33B is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. These guide tapers37are formed at an angle of approximately 45° with respect to the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the second electric wire passing portion33B. As a result, the bent portions of the electric wires61routed at the positions where the second electric wire passing portion33B is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B are gently bent and routed along the guide tapers37.

In addition, the guide tapers37are formed at the corner portions inside the bends of the electric wires61which are bent and routed at positions where the third electric wire passing portion33C is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. These guide tapers37are formed at an angle of approximately 45° with respect to the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the third electric wire passing portion33C. As a result, the bent portions of the electric wires61routed at the positions where the third electric wire passing portion33C is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B are gently bent and routed along the guide tapers37.

A single electric wire locking portion38is, or a plurality of electric wire locking portions38(a first wire locking portion and a second wire locking portion) are provided at positions where the first electric wire passing portion33A is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. Each of these electric wire locking portions38has a pair of locking pieces39. The electric wires61are accommodated in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the first electric wire passing portion33A by pushing the electric wires61from above into the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the first electric wire passing portion33A such that the electric wires61pass between the locking pieces39. At least a side of the bent portions or both sides of the bent portions of the electric wires61accommodated in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the first electric wire passing portion33A is or are locked and retained by the locking pieces39of a single wire locking portion38or the plurality of wire locking portions38(first and second wire locking portions38).

Similarly, the single or the plurality of electric wire locking portions38(the first wire locking portion and the second wire locking portion) are provided at the positions where the second electric wire passing portion33B is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. Thus, a side or both sides of each of the bent portions of the electric wires61accommodated in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the second electric wire passing portion33B is or are locked and retained by the locking pieces39of the single wire locking portion38or the electric wire locking portions38.

The single or the plurality of electric wire locking portions38(the first wire locking portion and the second wire locking portion) are also provided at the positions where the third electric wire passing portion33C is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. Thus, a side or both sides of each of the bent portions of the electric wires61accommodated in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, and the third electric wire passing portion33C are locked and retained by the locking pieces39of the single wire locking portion38or the electric wire locking portions38.

Here, busbar modules100,110according to reference examples will be described.FIG. 5is a plan view of a part of the busbar module100according to a reference example. As shown inFIG. 5, in the busbar module100according to the reference example, a case101includes parallel electric wire routing groove portions102, and an electric wire passing portion103connecting the electric wire routing groove portions102. The electric wire passing portion103is provided with an electric wire locking portion105having a pair of locking pieces106. In the case101, the electric wires61is accommodated and routed in the electric wire routing groove portions102and the electric wire passing portion103, and the electric wires61are locked by the electric wire locking portion105provided in the electric wire passing portion103.

FIG. 6is a plan view of a part of the busbar module110according to another reference example. As shown inFIG. 6, in the busbar module110according to the another reference example, a case111includes parallel electric wire routing groove portions112, and an electric wire passing portion113connecting the electric wire routing groove portions112. In the case111, the electric wires61are accommodated and routed in the electric wire routing groove portions112and the electric wire passing portion113. The electric wire passing portion113also serves as an electric wire lead-out mouth, and the electric wires61routed in the electric wire routing groove portions112are guided to an end portion of the wire passing portion113via branch portions S connecting the electric wire routing groove portions112and the electric wire passing portion113and drawn out to an outside.

In the former reference example, when the electric wires61are bent and routed at connection portions between the electric wire routing groove portions102and the electric wire passing portion103, the electric wires61may get on corner portions inside bents at the connection portions between the electric wire routing groove portions102and the electric wire passing portion103. Then, when a cover is attached to an upper portion of the electric wire routing groove portions102and the electric wire passing portion103, at this corner portion (see, for example, B portion inFIG. 5), the electric wires61may be caught/bitten, and reliability of voltage detection or temperature measurement may be lowered.

Further, in the latter reference example, a routing direction of the electric wires61may be wrong at the branch portions S during a routing work of routing the electric wires61to the connection portions between the electric wire routing groove portions112and the electric wire passing portion113, which may cause erroneous routing.

Meanwhile, according to the bushbar module10according to the embodiment, the guide tapers37formed inside the bends of the electric wires61which are bent and routed to guide the electric wires61are provided at connection points where the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C intersect with and are connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. As a result, when the electric wires61are routed at the connection portions, the electric wires61can be smoothly bent along the guide tapers37without difficulty to be accommodated in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C. Moreover, when performing the routing work, a routing direction of the electric wires61can be easily grasped by using the guide tapers37as marks, and erroneous routing can be prevented. When the electric wires61are accommodated in the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C, both sides of each of the bent portions of the electric wires61are locked by the electric wire locking portions38, so that the accommodated electric wires61can be reliably prevented from falling off from the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C.

As a result, the workability of routing the electric wires61to the first electric wire routing groove portion31A, the second electric wire routing groove portion31B, the first electric wire passing portion33A, the second electric wire passing portion33B, and the third electric wire passing portion33C can be improved, and occurrence of a routing failure in which the electric wires protrude can be prevented.

Moreover, by attaching the cover25to the case20, it is possible to further prevent the electric wires61from falling off. In addition, since protrusion of the electric wires61is prevented, biting of the electric wires61can be prevented by attaching the cover25. As a result, damage caused by being the electric wires61bitten such as an electric wire for voltage detection and an electric wire for temperature measurement can be prevented, and the busbar module10having high reliability can be obtained.

FIG. 7is a perspective view of the electric wire take-out portion35provided in the case20.FIGS. 8A and 8Bare diagrams showing the electric wire take-out portion35, whereFIG. 8Ais a plan view andFIG. 8Bis a cross-sectional view taken along a line A-A inFIG. 8A.

As shown inFIGS. 7, 8A, and 8B, the electric wire holding cover36is attached to the electric wire take-out portion35. As a result, an upper portion of the electric wire take-out portion35is covered by the electric wire holding cover36. When the electric wire holding cover36is attached to the electric wire take-out portion35, the electric wire lead-out mouth34that opens toward the other end20B side of the case20is formed in the electric wire take-out portion35. The electric wire holding cover36includes the guide portion32that gradually inclines upward toward the electric wire lead-out mouth34when the electric wire holding cover36is attached to the take-out portion35.

The electric wire group61A is drawn into the electric wire take-out portion35of the first electric wire routing groove portion31A from one end20A side of the case20, and the electric wire group61B is drawn into the electric wire take-out portion35of the first electric wire routing groove portion31A from the other end20B side of the case20. In the electric wire take-out portion35, the electric wire group61B from the other end20B side of the case20is folded back, and the electric wire group61A from the one end20A side of the case20is overlapped with a folded portion of the folded electric wire group61B. Further, these electric wire groups61A,61B are collectively drawn out from the electric wire lead-out mouth34formed by attaching the electric wire holding cover36to the electric wire take-out portion35(seeFIG. 8B).

It is conceivable that all the electric wires61routed in the second electric wire routing groove portion31B closer to the other end20B side of the case20than the electric wire take-out portion35are routed so as to be guided to the first electric wire routing groove portion31A through the second electric wire passing portion33B and the third electric wire passing portion33C, which are closer to the other end20B of the case20than the electric wire take-out portion35. However, in this case, in the first electric wire routing groove portion31A, the number of electric wires61drawn into the electric wire take-out portion35from the other end20B side of the case20increases. That is, the number of electric wires61that are folded back and drawn out from the electric wire lead-out mouth34toward the other end20B side of the case20increases in the electric wire take-out portion35. Then, in the electric wire take-out portion35, the electric wires61that are vertically overlapped with one another become bulky.

According to the busbar module10according to the present embodiment, the electric wire group61A routed closer to the other end20B side of the case20than the electric wire take-out portion35in the second electric wire routing groove portion31B is passed through the first electric wire passing portion33A on the one end20A side of the case20, then guided to the first electric wire routing groove portion31A and drawn out from the electric wire take-out portion35. As a result, in the electric wire take-out portion35, the number of electric wires61in the electric wires group61B drawn from the other end20B side of the case20can be reduced. That is, in the electric wire take-out portion35, the number of electric wires61in the electric wire groups61B, after drawn into from the other end20B side of the case20, folded back toward the other end20B side of the case20and drawn out from the other end20B side of the case20can be reduced. Therefore, it is possible to prevent bulkiness of the electric wires61in the electric wire take-out portion35, and to reduce the height of the electric wires61.

Since, in the case20, only the first electric wire passing portion33A is closer to the one end20A side than the electric wire take-out portion35among three electric wire passing portions (i.e., only the first electric wire passing portion33A is provided further in the first direction than the electric wire take-out portion35), a routing route of the electric wire group61A is limited. Therefore, when a routing work of the wire harness60to the case20is performed, the electric wire groups61A,61B can be smoothly routed while preventing erroneous routing of the electric wire group61A.

In addition, according to the busbar module10according to the present embodiment, the electric wire holding cover36that holds the electric wires61and forms the electric wire lead-out mouth34which opens toward the other end20B side of the case20and from which the electric wires61are drawn out is attached to the electric wire take-out portion35. Therefore, by attaching the electric wire holding cover36to the electric wire take-out portion35, a plurality of electric wires61can be held by the electric wire take-out portion35, and the electric wires61can be smoothly led out from the electric wire lead-out mouth34.

In addition, the electric wire holding cover36includes the guide portion32that guides the electric wire group61A drawn into the electric wire take-out portion35from the one end20A side of the case20to the electric wire lead-out mouth34. Accordingly, by attaching the electric wire holding cover36to the electric wire take-out portion35, the electric wire group61A that is accommodated in the first electric wire routing groove portion31A and is drawn into the electric wire take-out portion35from the one end20A side of the case20can be guided to the electric wire lead-out mouth34by the guide portion32, and can be smoothly led out from the electric wire lead-out mouth34.

Next, a busbar module10A according to another embodiment of the present invention will be described. The same components as those in the embodiment are denoted by the same reference numerals, and description thereof is omitted.FIG. 9is a plan view and a partial enlarged view of the busbar module10A according to the another embodiment of the present invention.FIG. 10is a perspective view and a partial enlarged view of the busbar module10A according to the another embodiment.

As shown inFIGS. 9 and 10, in the busbar module10A according to the another embodiment, two guide ribs40are provided at positions where the first electric wire passing portion33A is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. One guide rib40is provided at a corner portion between the first electric wire routing groove portion31A and the first electric wire passing portion33A. The guide taper37is formed at the corner portion where the guide rib40is provided, and the guide rib40protrudes from the guide taper37. The other guide rib40protrudes from a wall surface opposite to the first electric wire passing portion33A at the connection portion between the second electric wire routing groove portion31B and the first electric wire passing portion33A. A routing direction of the electric wires61is regulated by the guide ribs40at the positions where the first electric wire passing portion33A is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B that are provided with the guide rib40. As a result, the electric wires61are guided by the guide ribs40to a predetermined routing route.

Similarly, the two guide ribs40are provided at positions where the second electric wire passing portion33B is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. One guide rib40is provided at a corner portion between the first electric wire routing groove portion31A and the second electric wire passing portion33B. The guide taper37is formed at the corner portion where the guide rib40is provided, and the guide rib40protrudes from the guide taper37. The other guide rib40protrudes from a wall surface opposite to the second electric wire passing portion33B at the connection portion between the second electric wire routing groove portion31B and the second electric wire passing portion33B. Even at positions where the second electric wire passing portion33B is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B that are provided with the guide rib40, the routing direction of the electric wires61is regulated by the guide ribs40, and the electric wires61are guided to the predetermined routing route.

The two guide ribs40are also provided at positions where the third electric wire passing portion33C is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B. One guide rib40is provided at a corner portion between the first electric wire routing groove portion31A and the third electric wire passing portion33C. The guide taper37is formed at the corner portion where the guide rib40is provided, and the guide rib40protrudes from the guide taper37. The other guide rib40protrudes from a wall surface opposite to the third electric wire passing portion33C at the connection portion between the second electric wire routing groove portion31B and the third electric wire passing portion33C. Even at positions where the third electric wire passing portion33C is connected to the first electric wire routing groove portion31A and the second electric wire routing groove portion31B that are provided with the guide rib40, the routing direction of the electric wires61is regulated by the guide ribs40, and the electric wires61are guided to the predetermined routing route.

As described above, in the busbar module10A according to the another embodiment, the routing direction of the electric wires61is regulated by the guide ribs40, and the electric wires61are guided to the predetermined routing route. Further, by visually checking the guide ribs40, an operator can recognize that attention is required for the routing route of the electric wires61. As a result, the workability of routing the electric wires61can be further improved, and the erroneous routing can be prevented.

While the present invention has been described with reference to certain exemplary embodiments thereof, the scope of the present invention is not limited to the exemplary embodiments described above, and it will be understood by those skilled in the art that various changes and modifications may be made therein without departing from the scope of the present invention as defined by the appended claims.

According to an aspect of the embodiments described above, a busbar module (10,10A) includes a case (20) configured to be attached to a battery assembly (1) including a plurality of single cells (3), a bushbar (50) supported by the case (20) and configured to be electrically connected to an electrode (5) of each of the plurality of single cells (3) of the battery assembly (1) and a plurality of electric wires (61) configured to be routed in the case (20). The case (20) is provided with a plurality of electric wire routing grooves (first and second electric wire routing groove portions31A,31B, first to third electric wire passing portions33A to33C) configured to accommodate and route the plurality of electric wires (61), the plurality of electric wire routing grooves (first and second electric wire routing groove portions31A,31B, first to third electric wire passing portions33A to33C) intersecting with and being connected to one another. At least a part of the plurality of electric wires (61) is configured to be bent at a connection portion of the plurality of electric wire routing grooves (first and second electric wire routing groove portions31A,31B, first to third electric wire passing portions33A to33C) at which the plurality of electric wire routing grooves (first and second electric wire routing groove portions31A,31B, first to third electric wire passing portions33A to33C) are connected to one another. The connection portion is provided with a guide taper (37) provided inside a bent portion of the at least a part of the plurality of electric wires (61), the guide taper being configured to guide the at least a part of the plurality of electric wires (61) and a wire locking portion (38) configured to lock the at least a part of the plurality of electric wires (61) at a side of the bent portion of the at least a part of the plurality of electric wires (61).

The wire locking portion (38) may include a first wire locking portion (38) and a second wire locking portion (38) configured to lock the at least a part of the plurality of electric wires (61) at both sides of the bent portion of the at least a part of the plurality of electric wires (61), respectively.

According to the busbar module having the above configuration, the connection portion of the electric wire routing groove portions is provided with the guide taper formed inside the bend of the electric wires which are bent and routed to guide the electric wires. As a result, when the electric wires are routed to the connection portion of the electric wire routing groove portions, the electric wires can be bent smoothly along the guide taper without difficulty and accommodated in the electric wire routing groove portions. Moreover, when performing a routing work, a routing direction of the electric wires can be easily grasped by using the guide taper as a mark, and erroneous routing can be prevented. Further, when the electric wires are accommodated in the electric wire routing groove portions, the both end positions of the bent portion of the electric wires which are bent and routed are locked by the electric wire locking portion, respectively, so that the accommodated electric wires can be reliably prevented from coming out from the electric wire routing groove portions. As a result, it is possible to improve workability of routing the electric wires to the electric wire routing groove portions, and it is possible to prevent occurrence of a routing failure in which the electric wires protrude from the electric wire routing groove portions at the connection portion of the electric wire routing groove portions.

The busbar module (10,10A) may further include a cover (25) configured to be attached to the case (20). The cover (25) may be configured to cover the electric wire routing grooves (first and second electric wire routing groove portions31A,31B, first to third electric wire passing portions33A to33C).

According to the busbar module having the above configuration, when the cover is attached in the case, the electric wire routing groove portions are closed by the cover. Therefore, the electric wires routed in the electric wire routing groove portions can be further prevented from coming off. In addition, since protrusion of the electric wires at the connection portion of the electric wire routing groove portions is prevented, biting of the electric wires can be prevented by assembling the cover. As a result, damage caused by biting an electric wire such as an electric wire for voltage detection and an electric wire for temperature measurement can be prevented, and the busbar module having high reliability can be obtained.

The connection portion may be provided with a guide rib (40) configured to regulate a routing direction of the at least a part of the plurality of electric wires (61) and to guide the at least a part of the plurality of electric wires (61) to a predetermined routing route.

According to the busbar module having the above configuration, when the electric wires are routed in the case, the routing direction of the electric wires is regulated by the guide rib, and the electric wires are guided to the predetermined routing route. Further, by visually checking the guide rib, an operator can recognize that attention is required for the routing route of the electric wires. As a result, the workability of routing the electric wires can be further increased, and the erroneous routing can be prevented.

The plurality of electric wire routing grooves may include a first electric wire routing groove portion (31A) and a second electric wire routing groove portion (31B) provided in parallel with each other and extending from a first end (20A) to a second end (20B) of the case (20) in a longitudinal direction, and a plurality of electric wire passing portions (first to third electric wire passing portions33A to33C) each connecting the first electric wire routing groove portion (31A) and the second electric wire routing groove portion (31B) with each other. The first electric wire routing groove portion (31A) may be provided with an electric wire take-out portion (35) in a middle of the case (20) in the longitudinal direction, the electric wire take-out portion (35) being configured such that the plurality of electric wires (61) are drawn out from the electric wire take-out portion (35) in a second direction oriented from the first end (20A) toward the second end (20B) of the case (20), an opposite direction to the second direction being a first direction oriented from the second end (20B) toward the first end (20A). At least a part (electric wire group61A) of the plurality of electric wires (61) accommodated in the second electric wire routing groove portion (31B) may pass through one (first electric wire passing portion33A) of the plurality of electric wire passing portions (first to third electric wire passing portions33A to33C), the one (first electric wire passing portion33A) being provided further in the first direction than the electric wire take-out portion (35), extend in the first electric wire routing groove portion (31A) in the second direction and further extend out of the electric wire take-out portion (35) in the second direction.

According to the busbar module having the above configuration, at least a part of the electric wires routed in the second electric wire routing groove portion on the other end side of the case with respect to the electric wire take-out portion is passed through the electric wire passing portion on the one end side of the case, then guided to the first electric wire routing groove portion, and drawn out from the electric wire take-out portion. As a result, in the electric wire take-out portion, the number of electric wires drawn into from the other end side of the case can be reduced. In other words, in the electric wire take-out portion, the number of electric wires folded back to and drawn out from the other end side of the case after drawn into from the other end side of the case can be reduced. Therefore, it is possible to prevent bulkiness of the electric wires in the electric wire take-out portion, and to reduce height.

The busbar module (10,10A) may further include an electric wire holding cover (36) configured to be attached to the electric wire take-out portion (35). The electric wire holding cover (36) may be configured to, when the electric wire holding cover (36) is attached to the electric wire take-out portion (35), hold the at least a part (electric wire group61A) of the plurality electric wires (61) and to form an electric wire lead-out mouth (34) opening toward the second end (20B) of the case (20), the electric wire lead-out mouth (34) being configured such that the at least a part (electric wire group61A) of the plurality of electric wires (61) is drawn out from the electric wire lead-out mouth (34).

According to the bushbar module having the above configuration, by attaching the electric wire holding cover to the electric wire take-out portion, the plurality of electric wires can be held by the electric wire take-out portion, and these electric wires can be smoothly led out from the electric wire lead-out mouth.

The electric wire holding cover (36) may include a guide portion (32) configured to guide the at least a part (electric wire group61A) of the plurality of electric wires (electric wire group61A) drawn into the electric wire take-out portion (35) from a side of the first end (20A) of the case (20) toward the electric wire lead-out mouth (34).

According to the busbar module having the above configuration, by attaching the electric wire holding cover to the electric wire take-out portion, the electric wires accommodated in the first electric wire routing groove portion and drawn into the electric wire take-out portion from the one end side of the case can be guided to the electric wire lead-out mouth by the guide portion, and can be smoothly led out from the electric wire lead-out mouth.