WIRING MODULE

A wiring module is attached to an electricity storage element group including a plurality of electricity storage elements aligned. The wiring module includes: a plurality of busbars connected to electrodes of the plurality of electricity storage elements; and an insulating protector that is insulating, holds the plurality of busbars, and is attached to a case containing the electricity storage element group. The insulating protector has a positioning portion engaging with the case.

TECHNICAL FIELD

The present disclosure relates to a wiring module.

BACKGROUND ART

As an electrical-device assembly including a plurality of electricity storage elements, an electrical-device assembly described in Japanese Unexamined Patent Application Publication No. 2006-172882 is conventionally known. The electricity storage element includes a laminating-film cover. The electricity storage elements are individually contained in respective cell cases. Battery cells in which the electricity storage elements are contained in the cell cases are stacked. The plurality of electricity storage elements is positioned by the cell cases individually attached to the respective electricity storage elements.

CITATIONS LIST

Patent Literature

Patent Literature 1: Japanese Unexamined Patent Application Publication No. 2006-172882

SUMMARY OF INVENTION

Technical Problems

According to the above technique, since the electricity storage elements are individually contained in the respective cell cases, there occurs a problem that the number of components increases.

The present disclosure has been completed on the basis of the above circumstances, and an object of the present disclosure is to provide a wiring module in which the number of components is reduced.

Solutions to Problems

The present disclosure is a wiring module attached to an electricity storage element group including a plurality of electricity storage elements aligned. The wiring module includes: a plurality of busbars connected to electrodes of the plurality of electricity storage elements; and an insulating protector that is insulating, holds the plurality of busbars, and is attached to a case containing the electricity storage element group. The insulating protector has a positioning portion engaging with the case.

Effects of Invention

According to the present disclosure, the number of components of the wiring module can be reduced.

DESCRIPTION OF EMBODIMENTS

Description of Embodiments of Present Disclosure

First, aspects of the present disclosure will be listed and described.

(1) The present disclosure is a wiring module attached to an electricity storage element group including a plurality of electricity storage elements aligned. The wiring module includes: a plurality of busbars connected to electrodes of the plurality of electricity storage elements; and an insulating protector that is insulating, holds the plurality of busbars, and is attached to a case containing the electricity storage element group. The insulating protector has a positioning portion engaging with the case.

The positioning portion of the insulating protector is engaged with the case, so that the insulating protector can be positioned for the case. Thus, the plurality of electricity storage elements held by the insulating protector via the busbars can be positioned for the case. As described above, according to the present disclosure, the plurality of electricity storage elements can be positioned without using members attached to the plurality of electricity storage elements, respectively, to perform the positioning, and thus the number of components can be reduced.

(2) Preferably, the positioning portion is provided in a projection shape or a recess shape from the insulating protector, and the positioning portion recess-projection-fits to a positioning-receiving portion provided at a position on the case corresponding to the positioning portion.

The insulating protector can be positioned for the case by a simple method in which the positioning portion and the positioning-receiving portion are recess-projection-fitted to each other.

(3) Preferably, the insulating protector is provided with a side positioning portion, as the positioning portion, at a side of the insulating protector, and the case is provided with a side positioning-receiving portion, as the positioning-receiving portion, at a side wall of the case.

The side positioning portion and the side positioning-receiving portion are recess-projection-fitted to each other, so that inner walls of the side positioning-receiving portion are in contact, from above and below, with the side positioning portion. Thus, the insulating protector can be positioned with respect to an up-down direction.

(4) Preferably, the insulating protector is provided with an upper positioning portion, as the positioning portion, at an upper portion of the insulating protector, and the case is provided with an upper positioning-receiving portion, as the positioning-receiving portion, at an upper wall of the case.

The upper positioning portion and the upper positioning-receiving portion are recess-projection-fitted to each other, so that inner walls of the upper positioning-receiving portion are laterally in contact with the upper positioning portion. Thus, the insulating protector can be positioned with respect to a left-right direction.

(5) Preferably, the case includes: a containing portion having an opening portion that opens forward or rearward; and a lid attached to the containing portion to close the opening portion, and the insulating protector is held between the lid and the containing portion.

The insulating protector is held between the containing portion and the lid, so that the insulating protector is positioned with respect to a front-rear direction.

Details of Embodiments of Present Disclosure

Hereinafter, embodiments of the present disclosure will be described. It is intended that the present disclosure is not limited to these examples, but is indicated by the claims, and includes all modifications within the meaning equivalent to the claims and the scope of the claims.

First Embodiment

A first embodiment in which a wiring module10according to the present disclosure is applied to an electricity storage module11will be described with reference toFIGS.1to11. The electricity storage module11is mounted on a vehicle (not illustrated), such as an electric car or a hybrid car, to be used as a driving source. The electricity storage module11according to the present embodiment includes a case13, a plurality of electricity storage elements12contained in the case13, and the wiring module10attached to the plurality of electricity storage elements12. The wiring module10includes a plurality of busbars26connected to lead terminals24(an example of electrodes) of the plurality of electricity storage elements12, and a front insulating protector14(an example of an insulating protector) holding the plurality of busbars26and attached to the case13. In the following description, a direction indicated by an arrow line Z is an upward direction, a direction indicated by an arrow line Y is a forward direction, and a direction indicated by an arrow line X is a leftward direction. For a plurality of the same members, only some of the members may be denoted by a reference sign, and the reference sign of the other members may be omitted. An up-down direction, a left-right direction, and a front-rear direction are orthogonal to each other.

As illustrated inFIG.1, the electricity storage module11has a substantially rectangular-parallelepiped shape elongated in the front-rear direction. As illustrated inFIG.2, the electricity storage module11includes an electricity storage element group15contained in the case13and including the plurality of electricity storage elements12aligning in the left-right direction. The case13includes a containing portion13A that is metallic, a front lid21(an example of a lid) attached to a front end portion of the containing portion13A, and a rear lid22(an example of the lid) attached to a rear end portion of the containing portion13A. The containing portion13A as a whole has a rectangular-tube shape having opening portions20that open forward and rearward, respectively. As a metal of which the containing portion13A is made, any metal, such as aluminum, an aluminum alloy, or stainless steel, can be appropriately selected.

The containing portion13A has a bottom wall16, a left wall17extending upward from a left edge of the bottom wall16, a right wall18extending upward from a right edge of the bottom wall16, and an upper wall19coupling an upper end edge of the left wall17and an upper end edge of the right wall18. The bottom wall16, the left wall17, the right wall18, and the upper wall19have a rectangular shape elongated in the front-rear direction. The upper wall19is welded to the upper end edge of the left wall17and the upper end edge of the right wall18by a publicly known method, such as laser welding, electric resistance welding, or arc welding. The bottom wall16, the left wall17, and the right wall18may be connected by welding. Alternatively, the bottom wall16, the left wall17, and the right wall18may be formed by bending a single metal plate. Alternatively, a long metal member having a U-shaped cross section may be formed by extrusion, and cut into a predetermined length.

As illustrated inFIG.1, the front lid21(an example of the lid) is attached to the front end portion of the containing portion13A. The front lid21closes the front opening portion20of the containing portion13A. The rear lid22is attached to the rear end portion of the containing portion13A. The rear lid22closes the rear opening portion20of the containing portion13A.

As illustrated inFIG.2, the electricity storage element12includes an electricity generation element (not illustrated) contained in a laminating-film cover23. An edge portion of a laminating film constituting the laminating-film cover23is thermally welded. The lead terminals24protrude forward and rearward from a front end portion and a rear end portion of the laminating-film cover23, respectively. The front lead terminal24and the rear lead terminal24have different polarities. One of the front lead terminal24and the rear lead terminal24is a positive electrode terminal, and the other is a negative electrode terminal.

The electricity storage element12as a whole is formed in a plate shape elongated in the front-rear direction. The plurality of (eight in the present embodiment) electricity storage elements12is aligned in the left-right direction to form the one electricity storage element group15. In the electricity storage element group15, the electricity storage elements12are aligned such that the lead terminals24adjacent to each other in the left-right direction have different polarities.

As illustrated inFIG.3, the front insulating protector14that closes, from the front, the opening portion20is attached to the front end portion of the containing portion13A. The front insulating protector14is formed by injection-molding an insulating synthetic resin material. As illustrated inFIG.4, the front insulating protector14as a whole is formed in a plate shape that is rectangular when viewed in the front-rear direction. As illustrated inFIG.5, in the front insulating protector14, a plurality of (eight in the present embodiment) slits25extending in the up-down direction is formed at intervals in the left-right direction. The lead terminals24of the electricity storage elements12are inserted in the slits25from the rear to the front.

As illustrated inFIG.4, on the front insulating protector14, the plurality of busbars26made of a metal plate is attached to positions near the slits25. An upper end portion of the busbar26is held between a holding portion27formed on the front insulating protector14and having a groove shape. A protrusion28protruding rearward is formed at a lower end portion of the busbar26. The protrusion28is inserted, from the front, in a fixing hole29provided with the front insulating protector14.

Among the busbars26, the busbars26located at the left end portion and the right end portion are output busbars26A electrically connected to an external circuit. Formed at an upper end portion of the output busbar26A is an output terminal portion30to which an external busbar33constituting the external circuit is connected. Formed through the output terminal portion30is a through hole31that is through in the up-down direction. A bolt32is inserted in the through hole31, and the bolt32is screwed in a nut (not illustrated), so that the output busbar26A and the external busbar33are electrically connected (seeFIG.6).

As illustrated inFIG.4, the output busbar26A has a connection portion34having a plate shape elongated in the up-down direction. As illustrated inFIG.5, in a region in front of the front insulating protector14, the lead terminals24inserted, from the rear, through the slits25are electrically connected to the connection portions34. The connection portions34and the lead terminals24are connected by a publicly known technique, such as welding, soldering, or brazing. In the present embodiment, the connection portions34and the lead terminals24are connected by laser welding.

Among the five busbars26, the three busbars26different from the output busbar26A are connection busbars26B. The connection busbars26B are formed in a plate shape elongated in the up-down direction. As illustrated inFIG.5, in a region in front of the front insulating protector14, the lead terminals24inserted, from the rear, through the slits25are electrically connected to the connection busbars26B. The connection busbars26B and the lead terminals24are connected by a publicly known technique, such as welding, soldering, or brazing. In the present embodiment, the connection busbars26B and the lead terminals24are connected by laser welding.

As illustrated inFIG.7, on a left end portion of the front insulating protector14, formed at a position close to the upper end portion is a left positioning portion35(an example of a positioning portion and an example of a side positioning portion) protruding leftward and forward in a projection shape. The left positioning portion35has a rectangular shape extending in the front-rear direction when viewed from the left.

As illustrated inFIG.3, on a front end portion of the left wall17of the containing portion13A, formed at a position corresponding to the left positioning portion35is a left positioning-receiving portion36(an example of a positioning-receiving portion and an example of a side positioning-receiving portion) that dips, in a recess shape, rearward from an opening edge of the opening portion20. The left positioning portion35is fitted, from the front, in the left positioning-receiving portion36. In other words, the up-down-direction span dimension of the left positioning-receiving portion36is set equal to or slightly larger than the up-down-direction height dimension of the left positioning portion35(seeFIG.8).

As illustrated inFIG.7, on a right end portion of the front insulating protector14, formed at a position close to the upper end portion is a right positioning portion37(an example of the positioning portion and an example of the side positioning portion) protruding rightward and forward in a projection shape. The right positioning portion37has a rectangular shape extending in the front-rear direction when viewed from the right.

As illustrated inFIG.3, on a front end portion of the right wall18of the containing portion13A, formed at a position corresponding to the right positioning portion37is a right positioning-receiving portion38(an example of the positioning-receiving portion and an example of the side positioning-receiving portion) that dips, in a recess shape, rearward from an opening edge of the opening portion20. The right positioning portion37is fitted, from the front, in the right positioning-receiving portion38. Although not illustrated in detail, the up-down-direction span dimension of the right positioning-receiving portion38is set equal to or slightly larger than the up-down-direction height dimension of the right positioning portion37.

In a state where the front insulating protector14is assembled with the containing portion13A, a rear end portion of the left positioning portion35is in contact with, from the front, a rear wall of the left positioning-receiving portion36(seeFIGS.8and9). A rear end portion of the right positioning portion37is in contact with, from the front, a rear wall of the right positioning-receiving portion38(seeFIG.9). Thus, the front insulating protector14is held in a state where the front insulating protector14is positioned for the case13with respect to the rear.

As illustrated inFIG.6, in a state where the front lid21is attached to the front end portion of the containing portion13A, the front lid21is in contact with, from the front, the left positioning portion35and the right positioning portion37of the front insulating protector14. Thus, the front insulating protector14is held between the containing portion13A and the front lid21. As a result, the front insulating protector14is held in a state where the front insulating protector14is positioned for the case13with respect to the front.

As illustrated inFIG.4, on an upper end portion of the front insulating protector14, formed at a position close to the left end portion is an upper positioning portion39(an example of the positioning portion) protruding upward in a projection shape. The upper positioning portion39is formed in a rectangular shape extending in the up-down direction when viewed from the front.

As illustrated inFIG.3, on a front end portion of the upper wall19of the containing portion13A, formed at a position corresponding to the upper positioning portion39is an upper positioning-receiving portion40(an example of the positioning-receiving portion) that dips, in a recess shape, rearward from an opening edge of the opening portion20. The upper positioning portion39is fitted, from the front, in the upper positioning-receiving portion40. In other words, the left-right-direction span dimension of the upper positioning-receiving portion40is set equal to or slightly larger than the left-right-direction width dimension of the upper positioning portion39(seeFIG.6).

As illustrated inFIG.2, a rear insulating protector41that closes, from the rear, the opening portion20is attached to a rear end portion of the containing portion13A. The rear insulating protector41is formed by injection-molding an insulating synthetic resin material. The rear insulating protector41as a whole is formed in a plate shape that is rectangular when viewed in the front-rear direction. In the rear insulating protector41, a plurality of (eight in the present embodiment) slits25extending in the up-down direction is formed at intervals in the left-right direction. The lead terminals24of the electricity storage elements12are inserted in the slits25from the front to the rear.

On the rear insulating protector41, a plurality of connection busbars26B made of a metal plate is attached to positions near the slits25. In a region behind the rear insulating protector41, the lead terminals24inserted, from the front, through the slits25are electrically connected to the connection busbars26B. The connection busbars26B and the lead terminals24are connected by a publicly known technique, such as welding, soldering, or brazing. In the present embodiment, the connection busbars26B and the lead terminals24are connected by laser welding.

[Manufacturing Method of Present Embodiment]

Subsequently, an example of a method for manufacturing the electricity storage module11according to the present embodiment will be described. Methods for manufacturing the electricity storage module11are not limited to the following description.

A front insulating protector14and a rear insulating protector41are formed by injection-molding a synthetic resin material. Output busbars26A and connection busbars26B are assembled with the front insulating protector14. Connection busbars26B are assembled with the rear insulating protector41(seeFIG.4).

A bottom wall16, a left wall17, and a right wall18cut into predetermined shapes are welded by laser. Thus, a metal member having the bottom wall16, the left wall17, and the right wall18, and having a groove shape that opens upward is formed (seeFIG.10).

As illustrated inFIG.10, an electricity storage element group15including eight electricity storage elements12aligned in the left-right direction is contained, from above, in the metal member having the groove shape.

As illustrated inFIG.10, the front insulating protector14is assembled, from the front, with the metal member having the groove shape. At this time, lead terminals24are inserted, from the rear, into slits25of the front insulating protector14. A left positioning portion35of the front insulating protector14recess-projection-fits in a left positioning-receiving portion36of a case13, and a right positioning portion37of the front insulating protector14recess-projection-fits in a right positioning-receiving portion38of the case13. Thus, the front insulating protector14is positioned for the left side wall and the right side wall with respect to the up-down direction.

In the front insulating protector14, the lead terminals24and the output busbars26A are brought into contact with each other, and the lead terminals24and the connection busbars26B are brought into contact with each other using jigs (not illustrated). In this state, the lead terminals24and the output busbars26A are welded by laser, and the lead terminals24and the connection busbars26B are welded by laser.

As illustrated inFIG.10, the rear insulating protector41is assembled, from the rear, with the metal member having the groove shape. At this time, lead terminals24are inserted, from the front, into slits25of the rear insulating protector41.

In the rear insulating protector41, the lead terminals24and the connection busbars26B are brought into contact with each other using jigs (not illustrated). In this state, the lead terminals24and the connection busbars26B are welded by laser.

As illustrated inFIG.11, an upper wall19is placed, from above, on an upper end edge of the left wall17and an upper end edge of the right wall18. At this time, an upper positioning portion39of the front insulating protector14recess-projection-fits in an upper positioning-receiving portion40of the upper wall19. Thus, the upper wall19and the front insulating protector14are positioned with respect to the left-right direction.

The upper wall19and the upper end edge of the left wall17are welded by laser, and the upper wall19and the upper end edge of the right wall18are welded by laser. Thus, a containing portion13A is formed.

A front lid21is assembled with a front end portion of the containing portion13A. A rear lid22is also assembled with a rear end portion of the containing portion13A.

The front lid21is welded by laser to a front end portion of the bottom wall16, a front end portion of the left wall17, a front end portion of the right wall18, and a front end portion of the upper wall19. Thus, the front insulating protector14is held and positioned for the case13with respect to the front-rear direction. The rear lid22is welded by laser to a rear end portion of the bottom wall16, a rear end portion of the left wall17, a rear end portion of the right wall18, and a rear end portion of the upper wall19. Thus, an electricity storage module11is completed.

As illustrated inFIG.6, external busbars33are connected to the output busbars26A as follows. End portions of the external busbars33are laid on output terminal portions30of the output busbars26A. Bolts32are inserted, from above, into through holes31and screwed in nuts.

At this time, if in the output busbar26A at a left end portion of the front insulating protector14, the bolt32is rotated in a direction indicated by an arrow line A (clockwise direction), the left positioning portion35of the front insulating protector14receives a force in a direction in which the left positioning portion35is pulled forward out from the left positioning-receiving portion36. Since the front lid21is in contact, from the front, with the left positioning portion35, the front insulating protector14is prevented from moving forward.

Further, if in the output busbar26A at a right end portion of the front insulating protector14, the bolt32is rotated in a direction indicated by an arrow line B (clockwise direction), the right positioning portion37of the front insulating protector14receives a force in a direction in which the right positioning portion37is pushed into the right positioning-receiving portion38. Since the right positioning portion37is in contact, from the front, with a rear wall of the right positioning-receiving portion38, the front insulating protector14is prevented from moving rearward.

Operations and Effects of Embodiment

Next, operations and effects of the present embodiment will be described. The wiring module10according to the present embodiment is attached to the electricity storage element group15including the plurality of electricity storage elements12aligned. The wiring module10according to the present embodiment includes the plurality of busbars26connected to the lead terminals24of the plurality of electricity storage elements12, and the front insulating protector14that is insulating, holds the plurality of busbars26, and is attached to the case13containing the electricity storage element group15. The front insulating protector14has the left positioning portion35, the right positioning portion37, and the upper positioning portion39engaging with the case13.

The left positioning portion35, the right positioning portion37, and the upper positioning portion39provided for the insulating protector are engaged with the case13, so that the front insulating protector14can be positioned for the case13. Thus, the plurality of electricity storage elements12held by the front insulating protector14can be positioned for the case13. As described above, according to the present embodiment, the plurality of electricity storage elements12can be positioned without using members attached to the plurality of electricity storage elements12, respectively, to perform the positioning, and thus the number of components can be reduced.

The left positioning portion35, the right positioning portion37, and the upper positioning portion39are provided in a projection shape from the insulating protector. Provided at positions on the case13corresponding to the left positioning portion35, the right positioning portion37, and the upper positioning portion39, respectively, are the left positioning-receiving portion36, the right positioning portion37, and the upper positioning-receiving portion40in a recess shape. The left positioning portion35recess-projection-fits in the left positioning-receiving portion36. The right positioning portion37recess-projection-fits in the right positioning-receiving portion38. The upper positioning portion39recess-projection-fits in the upper positioning-receiving portion40.

The insulating protector can be positioned for the case13by a simple method in which the left positioning portion35is recess-projection-fitted in the left positioning-receiving portion36, the right positioning portion37is recess-projection-fitted in the right positioning-receiving portion38, and the upper positioning portion39is recess-projection-fitted in the upper positioning-receiving portion40.

The left positioning portion35is provided at a left end portion of the insulating protector. The left positioning portion35is provided at the left wall17of the case13. The right positioning portion37is provided at a right end portion of the insulating protector. The right positioning-receiving portion38is provided at the right wall18of the case13.

The left positioning portion35is recess-projection-fitted in the left positioning-receiving portion36, and the right positioning portion37is recess-projection-fitted in the right positioning-receiving portion38, so that inner walls of the left positioning-receiving portion36and the right positioning-receiving portion38are in contact, from above and below, with the left positioning portion35and the right positioning portion37. Thus, the insulating protector can be positioned with respect to an up-down direction.

The upper positioning portion39is provided at an upper portion of the insulating protector. The upper positioning-receiving portion40is provided at the upper wall19of the case13.

The upper positioning portion39is recess-projection-fitted in an upper positioning recess, so that inner walls of the upper positioning recess are laterally in contact with the upper positioning portion39. Thus, the insulating protector can be positioned with respect to the up-down direction.

The case13includes the containing portion13A having the opening portions20that open forward and rearward, and the front lid21attached to a front end portion of the containing portion13A to close the opening portion20. The front insulating protector14is held between the front lid21and the containing portion13A.

The front insulating protector14is held between the containing portion13A and the front lid21, so that the front insulating protector14is positioned with respect to the front-rear direction.

Other Embodiments

(1) In the first embodiment, as an insulating protector having positioning portions, as the front insulating protector14attached to a front end portion of the containing portion13A, the rear insulating protector41attached to a rear end portion of the containing portion13A may have positioning portions. In this case, the rear insulating protector41may be held between the rear lid22and the containing portion13A.

(2) In the first embodiment, the left positioning portion35is provided at a left end portion of the front insulating protector14, and the right positioning portion37is provided at the right end portion; however, the front insulating protector14does not necessarily have such a configuration. Only the left positioning portion35may be provided for the front insulating protector14, or only the right positioning portion37may be provided for the front insulating protector14.

(3) In the first embodiment, the positioning portions are formed in a projection shape, and the positioning-receiving portions are formed in a recess shape; however, the positioning portions and the positioning-receiving portions do not necessarily have such a configuration. Positioning portions may be formed in a recess shape, and positioning-receiving portions may be formed in a projection shape.

(4) In the first embodiment, the front lid21is assembled with a front end portion of the containing portion13A; however, the front lid21may be omitted.

(5) In the first embodiment, the number of the electricity storage elements12constituting the electricity storage element group15is eight; however, the number may be two to seven, or nine or more.

(6) In a state where the front lid21is attached to a front end portion of the containing portion13A, the front lid21may be in contact, from the front, with the upper positioning portion39.

(7) The electricity storage element12according to the first embodiment includes the laminating-film cover23; however, the electricity storage element12does not necessarily have such a configuration. The electricity storage element12may include any cover having any shape, such as a cylindrical shape or a rectangular-tube shape. As a material of which the cover is made, any material, such as a metal or a synthetic resin, can be selected.

REFERENCE SIGNS LIST