JP7722541B2 - Wiring Module - Google Patents

Description

This disclosure relates to a wiring module.

High-voltage battery packs used in electric vehicles, hybrid vehicles, and the like typically consist of a large number of stacked battery cells electrically connected in series or parallel via a wiring module. A known example of such a wiring module is the conductor module described in Japanese Patent Laid-Open Publication No. 2019-32928 (Patent Document 1 below). The conductor module described in Patent Document 1 includes a wiring material and multiple bus bars. The wiring material has multiple wires that electrically connect the bus bars to the battery module monitoring unit, and fuses installed midway along the wires. Patent Document 1 cites a flexible printed circuit (FPC) as an example of the wiring material. Using an FPC as the wiring material makes it easy to install fuses on the wiring material by mounting.

Japanese Patent Application Laid-Open No. 2019-32928

In a conductor module like the one described above, if the battery cells, bus bars, etc. are changed, the wiring material must be designed and prepared separately. This makes it difficult to reduce the manufacturing costs of the wiring material.

The wiring module of the present disclosure is a wiring module attached to a plurality of energy storage elements, and includes a bus bar connected to the electrode terminals of the energy storage elements, a wiring member, a fuse unit, and a protector that holds the bus bar, the wiring member, and the fuse unit. The fuse unit includes a first terminal electrically connected to the bus bar, a second terminal electrically connected directly or indirectly to the wiring member, a resin portion covering a portion of the first terminal and a portion of the second terminal, and a chip fuse. The resin portion maintains the spacing between the first terminal and the second terminal, the first terminal includes a first connection portion exposed from the resin portion, and the second terminal includes a second connection portion exposed from the resin portion. The chip fuse includes a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion.

This disclosure makes it possible to provide a wiring module that can reduce manufacturing costs.

FIG. 1 is a plan view of the energy storage module according to the first embodiment, illustrating a state in which a cover body and a protector body are not locked together. FIG. 2 is a plan view of the energy storage module according to the first embodiment, illustrating a state in which the cover and the protector body are engaged with each other. FIG. 3 is an enlarged view of FIG. FIG. 4 is an enlarged view of FIG. FIG. 5 is a cross-sectional view taken along line AA in FIG. FIG. 6 is a cross-sectional view taken along line BB in FIG. FIG. 7 is an enlarged perspective view of the wiring module according to the first embodiment in a state in which the cover and the protector body are not engaged with each other. FIG. 8 is a plan view of the fuse unit to which electric wires are connected according to the first embodiment. FIG. 9 is a cross-sectional view taken along the line CC in FIG. FIG. 10 is a plan view of the first terminal and the second terminal according to the first embodiment. FIG. 11 is a plan view of the intermediate molded body according to the first embodiment. FIG. 12 is a plan view of the fuse unit according to the first embodiment. FIG. 13 is a perspective view of the fuse unit according to the second embodiment, illustrating a state in which the fuse unit is connected to an electric wire. FIG. 14 is a cross-sectional view of a fuse unit according to the second embodiment, and corresponds to FIG. 9 of the first embodiment. FIG. 15 is a perspective view of a fuse unit according to a third embodiment, illustrating a state in which the fuse unit is connected to an electric wire. FIG. 16 is a cross-sectional view of a fuse unit according to the third embodiment, and corresponds to FIG. 9 of the first embodiment. FIG. 17 is a cross-sectional view of a fuse unit according to the fourth embodiment, and corresponds to FIG. 9 of the first embodiment. FIG. 18 is a plan view of a fuse unit according to the fifth embodiment. FIG. 19 is a cross-sectional view taken along the line DD in FIG. FIG. 20 is a perspective view of a fuse unit according to a sixth embodiment, illustrating a state in which the fuse unit is connected to an electric wire. FIG. 21 is a plan view of a fuse unit connected to an electric wire according to a sixth embodiment. FIG. 22 is a cross-sectional view taken along the line EE in FIG. FIG. 23 is a cross-sectional view taken along the line EE in FIG. 21, showing how the third terminal is inserted into the cavity. FIG. 24 is a cross-sectional view taken along the line EE in FIG. 21, showing a state in which the third terminal is inserted into the cavity and the retainer is in the provisionally retained position. FIG. 25 is a side view of a fuse unit connected to an electric wire according to a sixth embodiment. FIG. 26 is a cross-sectional view taken along the line FF in FIG. 25, and in FIG. 26, the second terminal, the third terminal, and the electric wires are omitted. FIG. 27 is a side view of the fuse unit excluding the third terminal according to the sixth embodiment, showing a state in which the retainer is in the provisionally locked position. FIG. 28 is a cross-sectional view taken along line GG in FIG. FIG. 29 is a plan view of the first terminal, the second terminal, and the resin portion according to the sixth embodiment. 30 is a cross-sectional perspective view taken along the line HH in FIG. FIG. 31 is a cross-sectional view taken along line II of FIG. FIG. 32 is a plan view of the first terminal and the second terminal according to the sixth embodiment. FIG. 33 is a perspective view of a fuse unit according to a modified example of the first embodiment. FIG. 34 is a perspective view of a wiring module according to another embodiment, showing a state in which a fuse unit is connected to a flexible substrate.

Description of the embodiments of the present disclosure
First, embodiments of the present disclosure will be listed and described.
[1] A wiring module according to the present disclosure is a wiring module attached to a plurality of energy storage elements, and includes: a bus bar connected to an electrode terminal of the energy storage element; a wiring member; a fuse unit; and a protector that holds the bus bar, the wiring member, and the fuse unit. The fuse unit includes a first terminal electrically connected to the bus bar; a second terminal electrically connected directly or indirectly to the wiring member; a resin portion covering a portion of the first terminal and a portion of the second terminal; and a chip fuse. The resin portion maintains a gap between the first terminal and the second terminal. The first terminal includes a first connection portion exposed from the resin portion. The second terminal includes a second connection portion exposed from the resin portion. The chip fuse includes a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion.

This configuration allows chip fuses to be easily incorporated into the wiring module through implementation. Furthermore, even if the busbar or wiring components are changed, there may be no need to redesign the fuse unit, thereby reducing the manufacturing costs of the wiring module.

[2] In the above [1], it is preferable that the resin portion has a peripheral wall portion that has a portion that protrudes beyond the first connection portion and the second connection portion and is disposed around the chip fuse.

With this configuration, the peripheral wall portion can protect the chip fuse.

[3] In the above [2], it is preferable that the peripheral wall portion surrounds the first connection portion and the second connection portion.

With this configuration, the peripheral wall portion prevents foreign matter from coming into contact with the chip fuse, thereby preventing stress from occurring at the connection between the first connection portion and the first electrode, and at the connection between the second connection portion and the second electrode.

[4] In any one of [1] to [3] above, it is preferable that the fuse unit further includes a cover member that covers the fuse.

With this configuration, the cover member prevents condensation and other contaminants from adhering to the chip fuse. This prevents the first electrode and second electrode from shorting out due to condensation and other contaminants.

[5] In any one of [1] to [4] above, it is preferable that the fuse unit further includes a third terminal to which the wiring member is connected, the second terminal includes a first terminal connection portion connected to the third terminal, and the third terminal includes a second terminal connection portion connected to the first terminal connection portion by fitting.

This configuration makes it easier to connect the wiring member to the second terminal.

[6] In the above [5], it is preferable that the fuse unit further includes a retainer that is assembled to the resin portion and holds the third terminal.

With this configuration, the third terminal can be held in place relative to the resin portion, making it easier to determine the position of the third terminal relative to the resin portion.

[7] In any one of [1] to [6] above, it is preferable that the first terminal or the second terminal has a notch recessed from the outer edge, and the notch defines the first connection portion or the second connection portion.

With this configuration, the first connection portion or the second connection portion is defined by the notch, allowing the size of the first connection portion or the second connection portion to be appropriately adjusted, and heat dissipation from the first connection portion or the second connection portion can be controlled when mounting the chip fuse.

[8] In the above [7], it is preferable that the resin portion has a groove formed therein that is recessed toward the first and second connection portions, the inner wall of the groove is continuous with the first and second connection portions, and a portion of the groove is disposed inside the notch.

This configuration prevents molten resin from migrating through the cutouts to the outer surfaces of the first and second connection parts when forming the resin part. This prevents burrs from forming on the first and second connection parts.

[Details of the embodiment of the present disclosure]
The following describes embodiments of the present disclosure. The present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims. In the drawings, for the sake of convenience, some components may be exaggerated or simplified. Furthermore, the dimensional ratios of the components may differ between drawings. In this specification, "orthogonal" and "parallel" do not only refer to cases where the components are strictly orthogonal or parallel, but also include cases where the components are roughly orthogonal or parallel within the scope of the functions and effects of the present embodiment.

In addition, "facing" in this specification refers to surfaces or components facing each other, and includes not only cases where they are completely facing each other, but also cases where they are partially facing each other. In addition, "facing" in this specification includes both cases where there is a component separate from the two components between the two components, and cases where there is nothing between the two components.

In each drawing, three mutually perpendicular directions are shown, and these three directions are respectively designated as the first direction D1, the second direction D2, and the third direction D3. That is, the first direction D1 and the second direction D2 are mutually perpendicular, the first direction D1 and the third direction D3 are mutually perpendicular, and the second direction D2 and the third direction D3 are mutually perpendicular. By depicting arrows on both sides of the solid line indicating each direction, not only the direction of the arrow on the side with the symbol, but also the direction of the arrow on the side without the symbol, is intended to indicate the corresponding direction.

<Embodiment 1>
A first embodiment of the present disclosure will be described with reference to Figures 1 to 12. An energy storage module 1 including a wiring module 3 of this embodiment is mounted on a vehicle as a power source for driving the vehicle, such as an electric vehicle or a hybrid vehicle. In the following description, when multiple identical components are shown, only some of the components may be designated by reference numerals, and the reference numerals for the other components may be omitted.

As shown in Figures 1 and 2, the energy storage module 1 comprises a plurality of energy storage elements 2 arranged in a row, and a wiring module 3 attached to one surface (top surface) of the plurality of energy storage elements 2 in the second direction D2. The wiring module 3 is attached to both ends of the plurality of energy storage elements 2 in the first direction D1. The energy storage elements 2 have a flattened rectangular parallelepiped shape with energy storage elements housed inside. The energy storage elements 2 have two electrode terminals 2A (only some of which are shown) on both ends of their top surface in the first direction D1. One of the two electrode terminals 2A is a positive electrode, and the other is a negative electrode. The electrode terminals 2A are electrically connected to a bus bar 60.

(Wiring module 3)
As shown in Figures 3 and 4, the wiring module 3 includes a bus bar 60, a fuse unit 10 connected to the bus bar 60, an electric wire 70 (an example of a wiring member) connected to the fuse unit 10, and a protector 80 that holds the bus bar 60, the fuse unit 10, and the electric wire 70.

(Bus bar 60)
The bus bar 60 is made of a metal plate and has a rectangular shape in a plan view. The bus bar 60 is connected to the electrode terminal 2A by welding or the like. The bus bar 60 is accommodated in a bus bar accommodating portion 81 of a protector 80, which will be described later.

(Fuse unit 10)
As shown in FIGS. 7 to 9 , the fuse unit 10 includes a first terminal 20 , a second terminal 30 , a resin part 40 , and a chip fuse 50 .

(first terminal 20)
The first terminal 20 is made of a conductive metal. As shown in FIG. 10 , the first terminal 20 has a rectangular plate-shaped plate portion 21 and a through-hole 22 penetrating the plate portion 21. The through-hole 22 is disposed near an end of the plate portion 21 in the extension direction. The plate portion 21 has two recesses 21A at both ends in the width direction of the plate portion 21 (a direction perpendicular to both the extension direction and the thickness direction of the plate portion 21). The recesses 21A are recessed from the edge of the plate portion 21 in the width direction. The plate portion 21 includes a busbar connection portion 23 electrically connected to the busbar 60. The busbar connection portion 23 is connected to the busbar 60 by, for example, welding or soldering.

(Second terminal 30)
The second terminal 30 is made of a conductive metal. The metal constituting the second terminal 30 may be different from the metal constituting the first terminal 20. The second terminal 30 has a rectangular plate-shaped plate portion 31 and a through-hole 32 penetrating the plate-shaped portion 31. The through-hole 32 is disposed near an end of the plate-shaped portion 31 in the extension direction. The plate-shaped portion 31 has two recesses 31A at both ends in the width direction of the plate-shaped portion 31 (a direction perpendicular to both the extension direction and the plate thickness direction of the plate-shaped portion 31). The recesses 31A are recessed from the edge of the plate-shaped portion 31 in the width direction. The plate-shaped portion 31 has an electric wire connection portion 33 electrically connected to the electric wire 70. The electric wire connection portion 33 is connected to the electric wire 70 by, for example, soldering or the like.

(Resin part 40)
The resin portion 40 is made of an insulating synthetic resin. As shown in FIGS. 7 to 9 , the resin portion 40 is disposed between the first terminal 20 and the second terminal 30 and covers a portion of the first terminal 20 and a portion of the second terminal 30. As described below, the resin portion 40 is formed integrally with the first terminal 20 and the second terminal 30 by insert molding. As shown in FIGS. 8 and 9 , during insert molding, molten resin, which is the raw material of the resin portion 40, fills the through holes 22, 32 and the recesses 21A, 31A, thereby holding the first terminal 20 and the second terminal 30 relative to the resin portion 40. The resin portion 40 positions the first terminal 20 and the second terminal 30 so that they do not directly contact each other. The first terminal 20 and the second terminal 30 are spaced apart in the first direction D1. The first terminal 20 is arranged so that the extension direction of the plate-like portion 21 of the first terminal 20 is the first direction D1. The second terminal 30 is arranged such that the extending direction of the plate-shaped portion 31 of the second terminal 30 is the first direction D1.

(Placement surface 41)
9 , the resin portion 40 is formed to have a mounting surface 41. The mounting surface 41 is located between the first terminal 20 and the second terminal 30. The mounting surface 41 is the surface on which the chip fuse 50 is mounted. The mounting surface 41 is perpendicular to the second direction D2 (defined as the up-down direction in this specification). The second direction D2 coincides with the thickness direction of the plate-like portions 21, 31.

(First connection portion 24)
A first connection portion 24, which is a part of the outer surface of the plate-shaped portion 21, is exposed from the mounting surface 41. The first connection portion 24 is exposed from the resin portion 40 next to the mounting surface 41. The first connection portion 24 is arranged at an end of the first terminal 20 closer to the second terminal 30 in the first direction D1. The first connection portion 24 is arranged flush with the mounting surface 41. In other words, the first connection portion 24 is parallel to the mounting surface 41 and is arranged at the same position as the mounting surface 41 in the second direction D2. The first connection portion 24 is continuous with the mounting surface 41 in the first direction D1. Here, "flush" refers to a state in which two parallel surfaces are smoothly connected without any steps. In this specification, this term also includes a state that is recognized as being substantially flush, in addition to a state that is flush. A state that is recognized as being substantially flush means, for example, a state in which a slight step appears between the mounting surface 41 and the first connection portion 24 due to manufacturing tolerances, thermal expansion, etc., or a state in which the mounting surface 41 and the first connection portion 24 slightly intersect and are not strictly parallel.

(Second connection portion 34)
The second connection portion 34, which is a part of the outer surface of the plate-shaped portion 31, is exposed from the mounting surface 41. The second connection portion 34 is exposed from the resin portion 40 next to the mounting surface 41. The second connection portion 34 is arranged at an end of the second terminal 30 closer to the first terminal 20 in the first direction D1. The second connection portion 34 is arranged flush with the mounting surface 41.

(Peripheral wall portion 42)
As shown in FIG. 7 , the resin part 40 has a peripheral wall part 42 that protrudes beyond the first connection part 24 and the second connection part 34. The peripheral wall part 42 protrudes, for example, in a direction perpendicular to the first connection part 24 and the second connection part 34. The peripheral wall part 42 extends, for example, from the mounting surface 41 to one side (upward) in the second direction D2. The peripheral wall part 42 is arranged to surround the chip fuse 50 in a direction perpendicular to the second direction D2. The peripheral wall part 42 is arranged so as not to come into contact with the chip fuse 50. As shown in FIG. 9 , the height of the peripheral wall part 42 from the mounting surface 41 (the dimension in the second direction D2) is greater than the height of the chip fuse 50.

(Chip fuse 50)
As shown in FIG. 7 , the chip fuse 50 includes a first electrode 51 and a second electrode 52. When the chip fuse 50 melts due to a large current flowing through it, the first electrode 51 and the second electrode 52 are electrically insulated from each other. The chip fuse 50 is placed on a mounting surface 41. The first electrode 51 is disposed on the first connecting portion 24, and the second electrode 52 is disposed on the second connecting portion 34. The first electrode 51 and the first connecting portion 24 are connected by soldering. The second electrode 52 and the second connecting portion 34 are connected by soldering. That is, the chip fuse 50 is mounted on an intermediate molded body 43 (see FIG. 11 ) that includes the first terminal 20, the second terminal 30, and the resin portion 40. Therefore, the chip fuse 50 can be easily incorporated into the fuse unit 10 through a mounting process (see FIG. 12 ).

The fuse unit 10 constitutes a component for mounting the chip fuse 50 without using a flexible printed circuit (FPC). That is, the first terminal 20, second terminal 30, and resin part 40 form the first connection part 24 and second connection part 34 on which the chip fuse 50 can be mounted. This makes it easy to reduce the manufacturing cost of the fuse unit 10.

(Electric wire 70)
As shown in FIG. 3 , the electric wires 70 connected to the fuse unit 10 are housed together in an electric wire housing portion 82 of a protector 80 (described later). The electric wires 70 are arranged inside the electric wire housing portion 82, extending in a third direction D3. The electric wires 70 are connected to a connector 71 at the end opposite the fuse unit 10. The connector 71 is configured to be connected to an external ECU (Electronic Control Unit) or the like. The ECU is equipped with a microcomputer, elements, and the like, and has a well-known configuration that has functions for detecting the voltage, current, temperature, etc. of each storage element 2 and for controlling the charge and discharge of each storage element 2. The electric wires 70 function as voltage detection lines.

The wiring module 3 of this embodiment includes an electric wire 70 instead of an FPC as the voltage detection line. Therefore, the wiring module 3 can be manufactured at a lower cost than a wiring module that uses an FPC as the voltage detection line.

(Protector 80)
The protector 80 is made of insulating synthetic resin. As shown in Figures 3 and 4, the protector 80 includes a protector body 80A and a lid 80B that covers the protector body 80A from above. The lid 80B is integrally formed with the protector body 80A via a hinge portion 80C. The hinge portion 80C is configured to be elastically deformable. As shown in Figure 6, by elastically deforming the hinge portion 80C, the lid 80B can be assembled by stacking it on top of the protector body 80A.

The protector body 80A is tray-shaped. As shown in FIG. 3, the protector body 80A includes a busbar accommodating section 81 that accommodates the busbar 60, an electric wire accommodating section 82 that accommodates multiple electric wires 70, and an intermediate wiring section 83 that is arranged between the busbar accommodating section 81 and the electric wire accommodating section 82. The busbar accommodating sections 81 are frame-shaped and are arranged side by side in the third direction D3.

The wire accommodating section 82 is groove-shaped and extends in the third direction D3. The wire accommodating section 82 includes a bottom wall 82A, a first side wall 82B rising upward from one end of the bottom wall 82A in the first direction D1, and a second side wall 82C rising upward from the other end of the bottom wall 82A in the first direction D1. The first side wall 82B is located closer to the intermediate routing section 83 than the second side wall 82C. A notch 82D is formed in the first side wall 82B. The wire 70 can be received from the intermediate routing section 83 into the wire accommodating section 82 through this notch 82D. The second side wall 82C is connected to the lid 80B via a hinge 80C.

The intermediate wiring section 83 accommodates the fuse unit 10 and the wire 70 connected to the fuse unit 10. As shown in Figures 5 and 6, the intermediate wiring section 83 has a bottom surface 83A and a protrusion receiving portion 83B recessed downward from the bottom surface 83A.

As shown in Figures 3 and 4, the lid 80B is configured to be able to close the wire housing section 82 and part of the intermediate routing section 83 of the protector body 80A from above. As shown in Figure 3, the lid 80B has a plate-shaped section 84 and a protrusion 85 that protrudes from the plate-shaped section 84. Although not shown, a locking structure is provided between the lid 80B and the protector body 80A, and this locking structure allows the lid 80B to maintain a state in which it closes the protector body 80A.

As shown in Figures 5 and 6, the protrusion 85 is, for example, block-shaped. When the cover 80B closes the protector body 80A, the protrusion 85 is arranged opposite the protrusion receiving portion 83B in the vertical direction, and the electric wire 70 is arranged between the protrusion 85 and the protrusion receiving portion 83B. The distance between the protrusion 85 and the protrusion receiving portion 83B is approximately the same as the diameter of the electric wire 70. As a result, when the cover 80B is assembled to the protector body 80A, the electric wire 70 is clamped between the protrusion 85 and the protrusion receiving portion 83B. Therefore, the electric wire 70 can be fixed to the protector 80 by the protrusion 85 and the protrusion receiving portion 83B (an example of a fixing portion).

Since the wiring module 3 of this embodiment is used in a vehicle, it is expected that vibrations will be applied to the electric wires 70. Furthermore, the electric wires 70 are connected to the connector 71, and it is expected that tensile stress will be applied to the electric wires 70 when this connector 71 is connected to an external ECU or the like. As described above, in this embodiment, the electric wires 70 are fixed to the protector 80 by the protrusion 85 and the protrusion receiving portion 83B. Therefore, even if vibrations or tensile stresses are applied to the electric wires 70, the vibrations and tensile stresses are less likely to be transmitted to the connection between the electric wires 70 and the fuse unit 10. Therefore, damage to the connection between the electric wires 70 and the fuse unit 10 can be suppressed.

(Method for manufacturing the fuse unit 10 and the wiring module 3)
The above is the configuration of the fuse unit 10 and the wiring module 3. Below, we will explain one example of a method for manufacturing the fuse unit 10 and the wiring module 3. First, a metal plate is pressed to form the first terminal 20 and the second terminal 30 (terminal forming process, see FIG. 10 ).

Next, the resin part 40 is insert-molded using a portion of the first terminal 20 and a portion of the second terminal 30 as inserts (resin part formation process). The first terminal 20 and the second terminal 30 are placed in a mold, and the mold is filled with molten resin, which is the raw material for the resin part 40. During this process, the first terminal 20 and the second terminal 30 are positioned so that they do not come into direct contact. The first terminal 20 and the second terminal 30 are appropriately positioned within the mold so that the first connection part 24 and the second connection part 34 adjacent to the mounting surface 41 are exposed from the resin part 40 and are flush with the mounting surface 41. Once the resin has hardened, the mold is removed, and an intermediate molded body 43 is obtained (see Figure 11).

The chip fuse 50 is placed on the mounting surface 41 of the intermediate molded body 43, and the first electrode 51 is mounted to the first connection portion 24, and the second electrode 52 is mounted to the second connection portion 34 (mounting process, see Figure 12). This completes the manufacturing of the fuse unit 10.

The busbar 60 is formed by pressing a metal plate. The protector 80 is provided by injection molding an insulating synthetic resin.

Multiple electric wires 70 are connected to the connector 71. Each electric wire 70 is cut to a predetermined length, exposing the core wire at its end. The electric wire connection portion 33 of the second terminal 30 of the fuse unit 10 is connected to the core wire of the electric wire 70 by soldering.

The busbar 60 is housed in the busbar housing portion 81 of the protector 80. Multiple electric wires 70 are housed together in the electric wire housing portion 82. The fuse unit 10 and a portion of the electric wires 70 are arranged in the intermediate routing portion 83. The busbar 60 and the busbar connection portion 23 of the first terminal 20 of the fuse unit 10 are connected by welding.

With the wire 70 placed inside the protrusion receiving portion 83B of the intermediate wiring section 83, the protector body 80A is closed by the lid 80B. This clamps the wire 70 between the protrusion receiving portion 83B and the protrusion 85. This completes the manufacturing of the wiring module 3.

(Effects of the First Embodiment)
(1-1) The wiring module 3 of the first embodiment is a wiring module 3 attached to a plurality of energy storage elements 2, and includes a bus bar 60 connected to the electrode terminals 2A of the energy storage elements 2, a wiring member (electric wire 70), a fuse unit 10, and a protector 80 that holds the bus bar 60, the wiring member, and the fuse unit 10. The fuse unit 10 includes a first terminal 20 electrically connected to the bus bar 60 and a second terminal 20 electrically connected directly or indirectly to the wiring member. the first terminal 20 has a first connection portion 24 exposed from the resin portion 40; the second terminal 30 has a second connection portion 34 exposed from the resin portion 40; and the chip fuse 50 has a first electrode 51 mounted on the first connection portion 24 and a second electrode 52 mounted on the second connection portion 34.

This configuration allows the chip fuse 50 to be easily incorporated into the wiring module 3 through implementation. Furthermore, even if the bus bar 60 or wiring member is changed, there may be no need to redesign the fuse unit 10, thereby reducing the manufacturing cost of the wiring module 3.

(1-2) In embodiment 1, the resin portion 40 has a peripheral wall portion 42 that has a portion that protrudes beyond the first connection portion 24 and the second connection portion 34 and is disposed around the chip fuse 50.

With this configuration, the peripheral wall portion 42 can protect the chip fuse 50.

(1-3) In embodiment 1, the peripheral wall portion 42 surrounds the first connection portion 24 and the second connection portion 34.

With this configuration, the peripheral wall 42 prevents foreign matter from coming into contact with the chip fuse 50, thereby preventing stress from occurring in the connection between the first connection portion 24 and the first electrode 51, and in the connection between the second connection portion 34 and the second electrode 52.

<Embodiment 2>
A second embodiment of the present disclosure will be described with reference to Figures 13 and 14. The fuse unit 110 according to the second embodiment has the same configuration as the first embodiment except that it further includes a lid portion 144 (an example of a cover member). Therefore, a description of the same components and effects as those of the first embodiment will be omitted.

(Lid part 144)
The lid portion 144 is made of insulating synthetic resin, insulating tape, or the like. As shown in Fig. 14, the lid portion 144 is attached to the upper end surface of the peripheral wall portion 42 and closes the opening 42A defined by the peripheral wall portion 42. The lid portion 144 and the chip fuse 50 are disposed with a space between them. The fuse unit 110 of the second embodiment can be manufactured by attaching the lid portion 144 to the fuse unit 10 of the first embodiment.

According to the configuration of embodiment 2, the lid portion 144 can prevent water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 melts, electrical continuity between the first connection portion 24 and the second connection portion 34 through water droplets can be prevented.

<Embodiment 3>
A third embodiment of the present disclosure will be described with reference to Figures 15 and 16. A fuse unit 210 according to the third embodiment has the same configuration as that of the first embodiment, except that it further includes a sealing portion 245 (an example of a cover member). Therefore, a description of the same components and effects as those of the first embodiment will be omitted.

(Sealing portion 245)
The sealing portion 245 is made of a curable insulating resin. The sealing portion 245 may be made of a resin different from the synthetic resin that makes up the resin portion 40. The sealing portion 245 may be transparent. The sealing portion 245 of embodiment 3 is, for example, a potting agent. As shown in FIG. 16 , the sealing portion 245 is arranged so as to fill the space within the opening 42A of the peripheral wall portion 42. The sealing portion 245 is in close contact with the outer surface of the chip fuse 50, the first connecting portion 24, the second connecting portion 34, and the mounting surface 41. The sealing portion 245 is formed by filling the opening 42A with uncured liquid insulating resin after the mounting process and curing the insulating resin. A bottomed recess is formed inside the peripheral wall 42 by the inner circumferential surface of the peripheral wall 42, a surface of the resin part 40 between the first terminal 20 and the second terminal 30 that is exposed inside the peripheral wall 42, the surface of the first terminal 20 that is exposed inside the peripheral wall 42, and the surface of the second terminal 30 that is exposed inside the peripheral wall 42. Therefore, by arranging the molten sealing part 245 in this recess, the chip fuse 50, the connection part between the first connection part 24 and the first electrode 51, and the connection part between the second connection part 34 and the second electrode 52 can be easily covered by the sealing part 245.

(Through hole 246)
Furthermore, a through hole 246 may be formed in the resin part 40. This through hole 246 penetrates through the mounting surface 41 and the lower surface of the resin part 40. The through hole 246 exposes a part of the outer surface of the chip fuse 50 that is different from the first electrode 51 and the second electrode 52 to the outside. In other words, the entire outer surface of the chip fuse 50 is not covered by the sealing part 245 and the resin part 40. The first electrode 51 and the second electrode 52 are not exposed to the outside through the through hole 246. The through hole 246 may be formed, for example, during the resin part formation process or after the resin part formation process.

According to the configuration of embodiment 3, the sealing portion 245 can prevent water droplets from entering the opening 42A of the peripheral wall portion 42. Therefore, after the chip fuse 50 melts, electrical continuity between the first connection portion 24 and the second connection portion 34 through water droplets can be prevented.

<Fourth Embodiment>
A fourth embodiment of the present disclosure will be described with reference to Fig. 17. A fuse unit 310 according to the fourth embodiment is configured substantially similarly to the third embodiment except for the configuration of a sealing portion 345 (an example of a cover member), and therefore, descriptions of the same components and effects as those of the first and third embodiments will be omitted.

(Sealing portion 345)
The sealing portion 345 in the fourth embodiment is, for example, a moisture-proof coating agent. The sealing portion 345 is in close contact with the outer surface of the chip fuse 50, the first connecting portion 24, the second connecting portion 34, and the mounting surface 41 within the opening 42A of the peripheral wall portion 42. The sealing portion 345 does not have to fill the entire space within the opening 42A.

<Embodiment 5>
A fifth embodiment of the present disclosure will be described with reference to Figures 18 and 19. A fuse unit 410 according to the fifth embodiment is configured substantially similarly to the first embodiment except for the absence of the peripheral wall portion 42 and the configuration of the plate-shaped portions 421 and 431. Therefore, a description of the same components and effects as those of the first embodiment will be omitted.

The fuse unit 410 includes a first terminal 420, a second terminal 430, a resin part 440, and a chip fuse 50. As shown in FIG. 19 , the resin part 440 does not have a peripheral wall part 42. The upper surface of the resin part 440 serves as the mounting surface 41.

The plate-shaped portion 421 of the first terminal 420 includes a first plate portion 421A, a second plate portion 421B, and a third plate portion 421C. The second plate portion 421B and the third plate portion 421C are formed narrower than the first plate portion 421A (see Figure 18). The first plate portion 421A is a plate-shaped member that is continuous with the busbar connection portion 23 in the first direction D1. The second plate portion 421B extends upward from the end of the first plate portion 421A opposite the busbar connection portion 23 in the first direction D1. The third plate portion 421C extends in the first direction D1 from the upper end of the second plate portion 421B. The third plate portion 421C and the first plate portion 421A extend on opposite sides of the second plate portion 421B in the first direction D1. The upper surface of the third plate portion 421C serves as the first connection portion 24.

The plate portion 431 of the second terminal 430 includes a first plate portion 431A, a second plate portion 431B, and a third plate portion 431C. The second plate portion 431B and the third plate portion 431C are formed narrower than the first plate portion 431A (see Figure 18). The first plate portion 431A is a portion that is continuous with the wire connection portion 33 in the first direction D1. The second plate portion 431B extends upward from the end of the first plate portion 431A opposite the wire connection portion 33 in the first direction D1. The third plate portion 431C extends in the first direction D1 from the upper end of the second plate portion 431B. The third plate portion 431C and the first plate portion 431A extend on opposite sides of the second plate portion 431B in the first direction D1. The upper surface of the third plate portion 431C serves as the second connection portion 34.

<Embodiment 6>
A sixth embodiment of the present disclosure will be described with reference to Figures 20 to 32. Unlike the first to fifth embodiments, the fuse unit 610 according to the sixth embodiment further includes a third terminal 680, and the second terminal 630 and the electric wire 70 are connected via the third terminal 680. Hereinafter, descriptions of the same components, functions, and effects as those of the first embodiment may be omitted.

As shown in Figures 20 and 21, the fuse unit 610 includes a first terminal 620, a second terminal 630, a resin part 640, and a chip fuse 50. Furthermore, as shown in Figure 22, the fuse unit 610 includes a third terminal 680 disposed inside the resin part 640. The third terminal 680 is connected to the electric wire 70.

(First terminal 620, notch 625)
32 , the first terminal 620 has a plate-like portion 21, a through hole 22, two recesses 21A, a bus bar connection portion 23, and a first connection portion 24, similar to the first terminal 20 of the first embodiment. The first terminal 620 also has a notch 625, which is a configuration different from the first terminal 20 of the first embodiment. The notch 625 is formed as a pair by recessing from an outer edge portion on one side in the extension direction of the first terminal 620. The first connection portion 24 is defined by the notch 625. In other words, the first connection portion 24 and the notch 625 are adjacent to each other in the width direction of the first terminal 620. The notch 625 appropriately sets the area of the first connection portion 24 in a plan view.

If the notch 625 were not provided, there is a possibility that the heat transfer to the first terminal 620 would be large when connecting the first electrode 51 of the chip fuse 50 and the first connection portion 24 by soldering. However, in this embodiment, by appropriately adjusting the size of the first connection portion 24 using the notch 625, it is possible to appropriately control the heat transfer to the first terminal 620.

(Second terminal 630, tab portion 633)
Similar to the second terminal 30 of the first embodiment, the second terminal 630 includes a plate-shaped portion 31, a through hole 32, two recesses 31A, and a second connection portion 34. The plate-shaped portion 31 has two recesses 31A at both ends in the width direction of the second terminal 30 (a direction perpendicular to both the extension direction of the second terminal 30 and the thickness direction of the plate-shaped portion 31). The recesses 31A are recessed from the edge of the second terminal 30 in the width direction. The second terminal 630 also includes a tab portion 633 (an example of a first terminal connection portion). The tab portion 633 is formed continuous with the plate-shaped portion 31 in the extension direction of the second terminal 630. The tab portion 633 is rod-shaped and extends from the edge of the plate-shaped portion 31 in the extension direction of the second terminal 630.

(Notch 635)
The second terminal 630 has a notch 635, similar to the first terminal 620. The notch 635 is formed as a pair by being recessed from the outer edge of the second terminal 630 on the side opposite the tab portion 633 in the extension direction. The second connection portion 34 is defined by the notch 635. In other words, the second connection portion 34 and the notch 635 are adjacent to each other in the width direction of the second terminal 630. The notch 635 appropriately sets the area of the second connection portion 34 in a plan view. By appropriately adjusting the size of the second connection portion 34 using the notch 635, heat conduction to the second terminal 630 can be appropriately controlled.

(Third terminal 680)
The third terminal 680 is made of a conductive metal. The metal constituting the third terminal 680 may be different from the metal constituting the first terminal 620 and the metal constituting the second terminal 630. As shown in Fig. 23 , the third terminal 680 includes a connecting tube portion 681 (an example of a second terminal connecting portion) connected to the second terminal 630, and a barrel portion 682. The barrel portion 682 is formed continuous with the connecting tube portion 681 in the extension direction of the third terminal 680. The barrel portion 682 includes a core wire crimping portion 682A that is crimped to the core wire of the electric wire 70, and an insulating coating crimping portion 682B that is crimped to the insulating coating of the electric wire 70.

(Connecting tube portion 681)
The connecting tube portion 681 includes a tube wall portion 683 having, for example, a rectangular tube shape and a resilient contact piece 684 formed inside the tube wall portion 683. The tube wall portion 683 is open in the first direction D1. The resilient contact piece 684 extends from the inner surface of the tube wall portion 683 and is resiliently deformable in a direction perpendicular to the first direction D1. The connecting tube portion 681 also has a locking hole 683A formed through the tube wall portion 683. As shown in FIGS. 22 to 24 , the tab portion 633 of the second terminal 630 is inserted into the tube wall portion 683, and the resilient contact piece 684 contacts the tab portion 633, thereby electrically connecting the third terminal 680 and the second terminal 630. That is, the connecting tube portion 681 and the tab portion 633 are electrically connected by fitting. Therefore, the second terminal 630 and the electric wire 70 are electrically connected via the third terminal 680.

In this embodiment, the second terminal 630 is not directly connected to the electric wire 70, but is indirectly connected to the electric wire 70 via the third terminal 680. Therefore, when electrically connecting the fuse unit 610 and the electric wire 70, for example, it is possible to prevent damage to the connection portion between the chip fuse 50 and the second terminal 630 due to stress, etc. This makes it easier to ensure the reliability of the electrical connection between the fuse unit 610 and the electric wire 70.

(Resin part 640)
As shown in FIG. 29 , the resin portion 640 covers a portion of the first terminal 620 and a portion of the second terminal 630. As in the first embodiment, the resin portion 640 is integrally formed with the first terminal 620 and the second terminal 630 by insert molding. The first terminal 620 and the second terminal 630 are each fixed to the resin portion 640. The resin portion 640 has an intermediate portion 641 disposed between the first terminal 620 and the second terminal 630 in the first direction D1. The resin portion 640 maintains the distance between the first terminal 620 and the second terminal 630. The resin portion 640 exposes the first connection portion 24, which is a portion of the outer surface of the plate-shaped portion 21, and the second connection portion 34, which is a portion of the outer surface of the plate-shaped portion 31. The first connection portion 24 and the second connection portion 34 are disposed at a predetermined distance in the first direction D1 by the resin portion 640. Furthermore, the resin portion 640 exposes the bus bar connection portion 23 to the outside.

As shown in Figure 30, one end face (upper) of the intermediate portion 641 in the second direction D2 is defined as the reference surface 641A. The reference surface 641A is flush with the first connecting portion 24 (outer surface of the plate-shaped portion 21) and the second connecting portion 34 (outer surface of the plate-shaped portion 31). The reference surface 641A is perpendicular to the second direction D2 (up-down direction). The second direction D2 coincides with the thickness direction of the plate-shaped portions 21 and 31.

As shown in FIG. 22 , the resin portion 640 may have a through hole 246, similar to embodiment 3. The through hole 246 penetrates the intermediate portion 641 in the second direction D2.

As shown in Figures 30 and 31 , the resin part 640 includes a peripheral wall part 42, similar to embodiment 1. The peripheral wall part 42 extends from the reference surface 641A to one side (upward) in the second direction D2. That is, the peripheral wall part 42 has a portion that protrudes upward beyond the first connection part 24 and the second connection part 34. The peripheral wall part 42 is disposed around the chip fuse 50. Furthermore, the peripheral wall part 42 surrounds the first connection part 24 and the second connection part 34 in a direction perpendicular to the second direction D2.

(Groove 641B)
The intermediate portion 641 has a groove 641B recessed from the reference surface 641A toward the other side (downward) in the second direction D2. The groove 641B is recessed downward relative to the first connection portion 24 and the second connection portion 34. As shown in FIG. 30 , the groove 641B is composed of a bottom surface BS that is substantially parallel to the reference surface 641A, a first inner surface S1 connecting the bottom surface BS to the first connection portion 24, a second inner surface S2 connecting the bottom surface BS to the second connection portion 34, and a third inner surface S3 connecting the bottom surface BS to the reference surface 641A. The groove 641B is adjacent to each of the first connection portion 24 and the second connection portion 34 when viewed from a direction perpendicular to the first connection portion 24 and the second connection portion 34 (the second direction D2). As shown in FIG. 22 , the bottom surface BS faces the chip fuse 50 in the second direction D2. A gap is provided between the bottom surface BS and the chip fuse 50. As shown in FIGS. 30 and 31, a portion of the groove 641B is disposed inside the notches 625 and 635.

As shown in FIG. 31 , by providing a groove 641B in the resin part 640, a portion of the side surface of the first terminal 620 continuing from the outer edge of the first connection part 24 (hereinafter referred to as the first side surface part SP1) may be exposed from the resin part 640. The first connection part 24 may be connected to the first inner surface S1 via the first side surface part SP1. Similarly, by providing a groove 641B in the resin part 640, a portion of the side surface of the second terminal 630 continuing from the outer edge of the second connection part 34 (hereinafter referred to as the second side surface part) may be exposed from the resin part 640. The second connection part 34 may be connected to the second inner surface S2 via the second side surface part.

The first connection portion 24 may be directly connected to the inner surface of the groove 641. The second connection portion 34 may be directly connected to the inner surface of the groove 641.

If groove 641B were not provided, molten resin could migrate to the outer surfaces (top surfaces) of the first and second connection portions 24 and 34 when forming the resin portion 640 by insert molding, resulting in the formation of burrs on the first and second connection portions 24 and 34. In such cases, the burrs could cause poor electrical connection between the first connection portion 24 and the first electrode 51 or between the second connection portion 34 and the second electrode 52. However, in this embodiment, groove 641B is provided in the intermediate portion 641. Therefore, when forming the resin portion 640, molten resin is more likely to migrate into groove 641B than onto the top surfaces of the first and second connection portions 24 and 34. Therefore, the formation of burrs on the first and second connection portions 24 and 34 can be suppressed.

As shown in Figures 22 and 29, the resin portion 640 includes a housing portion 643 formed continuously with the intermediate portion 641 and the peripheral wall portion 42. The housing portion 643 extends from the intermediate portion 641 on the opposite side from the first terminal 620. The housing portion 643 has a cavity 644 in which the third terminal 680 is housed. The cavity 644 extends in the first direction D1 and opens to one side in the first direction D1 (the right side in the figure). The tab portion 633 of the second terminal 630 and a portion of the plate-shaped portion 31, which is the base end of the tab portion 633, are arranged at the end of the cavity 644 on the other side in the first direction D1 (the left side in the figure).

As shown in FIG. 29, the housing portion 643 includes a bottom wall 643A (see FIG. 22), a pair of side walls 643B, and a ceiling wall 643C. As shown in FIG. 26, the pair of side walls 643B extend from both ends of the bottom wall 643A in the third direction D3 to one side (upward) in the second direction D2. As shown in FIG. 22, the ceiling wall 643C faces the bottom wall 643A in the second direction D2. As shown in FIG. 29, the ceiling wall 643C connects one end (upper end) of the pair of side walls 643B in the second direction D2. The cavity 644 is an internal space defined by the bottom wall 643A, the pair of side walls 643B, and the ceiling wall 643C.

As shown in FIG. 22, a first communication hole 643C1 is provided in a portion of the ceiling wall 643C closer to the middle portion 641. The first communication hole 643C1 penetrates the ceiling wall 643C in the second direction D2 and communicates with the cavity 644. A second communication hole 643A1 is provided in the end of the bottom wall 643A closer to the middle portion 641. The second communication hole 643A1 penetrates the bottom wall 643A in the second direction D2 and communicates with the cavity 644.

As shown in FIG. 29, a mounting recess 645 for mounting a retainer 690 (described below) is formed in approximately two-thirds of the area on the other side (left side in the figure) of the housing portion 643 in the first direction D1. The mounting recess 645 has a first mounting recess 645A recessed from the outer surface of the ceiling wall 643C, and a second mounting recess 645B recessed from the outer surfaces of the pair of side walls 643B. The end of the first mounting recess 645A closer to the intermediate portion 641 extends to the peripheral wall portion 42. As shown in FIG. 22, the first mounting recess 645A is in communication with the first communication hole 643C1.

As shown in FIG. 29, the second mounting recess 645B is connected to the first mounting recess 645A. The housing portion 643 includes a shaft portion 646, a temporary locking portion 647, and a full locking portion 648 that protrude from the inner wall of the second mounting recess 645B in the third direction D3. The shaft portion 646 is generally cylindrical. The shaft portion 646 is located on a portion of the inner wall of the second mounting recess 645B closer to the middle portion 641 in the first direction D1. The temporary locking portion 647 and the full locking portion 648 are located on an end of the inner wall of the second mounting recess 645B opposite the middle portion 641 in the first direction D1. The temporary locking portion 647 and the full locking portion 648 are located close to each other. The temporary locking portion 647 is located on one side (the right side in the figure) of the full locking portion 648 in the first direction D1. Also, as shown in FIG. 26, the temporary locking portion 647 is arranged on one side (above) of the full locking portion 648 in the second direction D2.

(Retainer 690)
As shown in FIGS. 20 to 22 , the fuse unit 610 of this embodiment includes a retainer 690 that is assembled to the resin portion 640. The retainer 690 is made of insulating synthetic resin. The retainer 690 is configured to be assembled to the resin portion 640 at a temporary locking position (see FIG. 27 ) and a full locking position (see FIG. 25 ). As shown in FIG. 26 , the retainer 690 has a generally gate-like shape when viewed from the first direction D1. As shown in FIG. 20 , the retainer 690 includes a main body 691, a pair of locking pieces 692, and a pair of side walls 693. The pair of locking pieces 692 and the pair of side walls 693 extend from both ends of the main body 691 in the third direction D3. The locking pieces 692 are disposed on one side (the right side in the figure) of the side walls 693 in the first direction D1. As shown in FIG. 26 , the main body 691 is configured to be accommodated in the first mounting recess 645A. The pair of lock pieces 692 and the pair of side walls 693 are adapted to be housed in the second mounting recess 645B.

As shown in FIG. 22, the retainer 690 includes a lance 694 and a retaining portion 695. The lance 694 extends from the main body portion 691 to the other side in the first direction D1 (to the left in the figure) and to the other side in the second direction D2 (downward). The lance 694 is elastically deformable with respect to the main body portion 691. The retaining portion 695 protrudes from the main body portion 691 to the other side in the second direction D2 (downward). The retaining portion 695 is generally block-shaped.

As shown in Figures 23 and 24, when the retainer 690 is in the temporary locking position, the retaining portion 695 does not enter the cavity 644, and only the tip of the lance 694 enters the cavity 644 through the first communicating hole 643C1. When the retainer 690 is in the temporary locking position, the third terminal 680 is allowed to be inserted through the opening on one side (the right side in the figure) of the cavity 644 in the first direction D1. This is because the retaining portion 695 is not positioned to interfere with the third terminal 680, and the lance 694 can elastically deform even when it interferes with the third terminal 680.

As shown in FIG. 22 , when the retainer 690 is in the full locking position, the lance 694 and the retaining portion 695 are positioned within the cavity 644 via the first communicating hole 643C1. When the third terminal 680 is positioned in the correct position within the cavity 644, the lance 694 engages with the inner wall of the locking hole 683A of the third terminal 680. The retaining portion 695 engages with the end of the connecting tube portion 681 on one side (the right side in the figure) in the first direction D1. This allows the third terminal 680 to be held within the cavity 644. In other words, the third terminal 680 can be held relative to the resin portion 640. Note that the third terminal 680 is restricted from moving from its correct position within the cavity 644 to the other side (the left side in the figure) in the first direction D1 by abutting against the edge (see FIG. 29 ) of the plate portion 31 of the second terminal 630 positioned within the cavity 644. Whether the third terminal 680 is in the correct position within the cavity 644 or is partially inserted can be confirmed by the second communication hole 643A1.

As shown in Figures 25 and 27, the retainer 690 has an insertion hole 693A that penetrates the side wall 693 in the third direction D3. The shaft 646 is inserted into the insertion hole 693A. The retainer 690 is rotatable around the shaft 646, and can move between a temporary locking position and a full locking position.

28, the retainer 690 has a locking protrusion 692A that protrudes from the tip of the locking piece 692 toward the inner wall of the second mounting recess 645B. The locking protrusion 692A is disposed between the temporary locking portion 647 and the full locking portion 648, thereby holding the retainer 690 in the temporary locking position. As shown in FIG. 26, the locking protrusion 692A is disposed on the other side (downward) of the full locking portion 648 in the second direction D2, thereby holding the retainer 690 in the full locking position. In particular, when the retainer 690 is in the full locking position, the locking protrusion 692A engages with the full locking portion 648, thereby preventing the retainer 690 from rotating counterclockwise in FIG. 25 from the full locking position. Furthermore, the engagement between the main body 691 and the inner wall of the first mounting recess 645A prevents the retainer 690 from rotating clockwise in FIG. 25 from the full engagement position.

(Method of manufacturing fuse unit 610)
The above is the configuration of the fuse unit 610. An example of a manufacturing method for the fuse unit 610 will now be described. First, as in the example of a manufacturing method for the fuse unit 10 of embodiment 1, the resin part 640 is integrally molded with the first terminal 620 and the second terminal 630 by insert molding (see FIG. 29 ). Then, the first electrode 51 and the second electrode 52 of the chip fuse 50 are mounted on the first connecting part 24 and the second connecting part 34, respectively.

Next, the retainer 690 is attached to the resin part 640 and placed in the temporary locking position. That is, the shaft part 646 is inserted into the insertion hole 693A, and the locking protrusion 692A is placed in the gap between the temporary locking part 647 and the full locking part 648.

With the retainer 690 in the provisional locking position, the third terminal 680, which has been previously formed from a metal plate and connected to the wire 70, is inserted (see Figure 23). During insertion of the third terminal 680, the lance 694 interferes with the connecting tube portion 681 and elastically deforms. When the third terminal 680 is inserted into the correct position within the cavity 644, the lance 694 elastically returns to its original position and enters the locking hole 683A (see Figure 24).

Once the third terminal 680 is properly positioned within the cavity 644, the retainer 690 is moved to the full-locking position. When the retainer 690 is rotated clockwise in FIG. 27 from the partial-locking position, the locking piece 692 elastically deforms, causing the locking protrusion 692A to move over the full-locking portion 648. When the locking protrusion 692A moves toward the other side (downward) in the second direction D2 relative to the full-locking portion 648, the locking piece 692 elastically returns, and the retainer 690 reaches the full-locking position (see FIG. 26). During this time, the lance 694 penetrates the depth of the locking hole 683A, allowing the lance 694 to engage with the inner wall of the locking hole 683A (see FIG. 22). The retaining portion 695 is positioned on one side (the right side in the figure) of the connecting tube portion 681 in the first direction D1, allowing it to engage with the connecting tube portion 681. This holds the third terminal 680 in the cavity 644. This completes the manufacturing of the fuse unit 610.

(Effects of the Sixth Embodiment)
(6-1) The fuse unit 610 according to the sixth embodiment further includes a third terminal 680 to which a wiring member (electric wire 70) is connected, the second terminal 630 includes a first terminal connection portion (tab portion 633) connected to the third terminal 680, and the third terminal 680 includes a second terminal connection portion (connection tube portion 681) connected to the first terminal connection portion by fitting.

This configuration makes it easier to connect the wiring member to the second terminal 630.

(6-2) The fuse unit 610 according to the sixth embodiment further includes a retainer 690 that is assembled to the resin part 640 and holds the third terminal 680.

With this configuration, the third terminal 680 can be held relative to the resin part 640, making it easier to determine the position of the third terminal 680 relative to the resin part 640.

(6-3) In embodiment 6, the first terminal 620 or the second terminal 630 has a notch 625, 635 recessed from the outer edge, and the notch 625, 635 defines the first connection portion 24 or the second connection portion 34.

With this configuration, the first connection portion 24 or the second connection portion 34 is defined by the notches 625, 635, allowing the size of the first connection portion 24 or the second connection portion 34 to be appropriately adjusted, and heat dissipation from the first connection portion 24 or the second connection portion 34 can be controlled when mounting the chip fuse 50.

(6-4) In embodiment 6, a groove 641B recessed toward the first connecting portion 24 and the second connecting portion 34 is formed in the resin portion 640, and the inner surfaces (first inner surface S1 and second inner surface S2) constituting the groove 641B are continuous with the first connecting portion 24 and the second connecting portion 34, with a portion of the groove 641B located inside the notches 625, 635.

This configuration prevents molten resin from migrating through the notches 625, 635 to the outer surfaces of the first and second connecting portions 24, 34 when forming the resin portion 640. This prevents burrs from forming on the first and second connecting portions 24, 34.

(Other embodiments)
The above-described first to sixth embodiments can be modified as follows: The above-described first to sixth embodiments and the following modifications can be combined with each other to the extent that no technical contradiction occurs.

- The shapes and relative arrangement of the first terminal, second terminal, and resin portion are not limited to those described in embodiments 1 to 6 above, and may be modified as appropriate within the scope of achieving the objectives of this disclosure.

- In the first embodiment described above, the second terminal 30 includes a plate-shaped wire connection portion 33 that is connected to the wire 70 by soldering, but the wire connection portion may also be, for example, a wire crimping portion that is crimped onto the wire.

- In the above-described first embodiment, the end faces of the first terminal 20 and the second terminal 30 in the third direction D3 were substantially flush with the end face of the resin part 40 in the third direction D3 (see FIG. 7), but the end faces of the first terminal and the second terminal in the third direction D3 do not have to be substantially flush with the end face of the resin part in the third direction D3. For example, as a modification of the first embodiment, as shown in FIG. 33, a configuration may be adopted in which the resin part 40 covers the end faces of the first terminal 20 and the second terminal 30 in the third direction D3.

In the first embodiment described above, the electric wire 70 is fixed to the protector 80 by the protrusion 85 and the protrusion receiving portion 83B. However, for example, the protrusion receiving portion may not be provided, and the electric wire may be fixed by the protrusion and the bottom surface of the intermediate routing portion. The shape of the fixing portion may also be different from that described above. It is preferable that the fixing portion includes a first member that contacts the electric wire from one side in a direction perpendicular to the extension direction of the electric wire, and a second member that contacts the electric wire from the other side in the direction perpendicular to the extension direction of the electric wire and clamps the electric wire between the first member and the second member. The first member and the second member may be formed integrally or separately. For example, the first member may be the bottom surface of the intermediate routing portion, and the second member may be a locking claw that extends elastically from the bottom surface.

- In the first embodiment described above, the protector body 80A and the lid body 80B are connected by the hinge portion 80C, but the protector body and the lid body may be formed separately.

- In the first embodiment described above, the wiring member is an electric wire 70, but the wiring member does not have to be an electric wire. For example, as shown in FIG. 34, the wiring module 703 may include a flexible substrate 770 (an example of a wiring member) as the wiring member. Here, the flexible substrate 770 is, for example, a flexible printed circuit board or a flexible flat cable. The flexible substrate 770 and the second terminal 30 may be connected by, for example, soldering. Note that the bus bar and protector are omitted from FIG. 34. The protector has a fixing portion that fixes the flexible substrate 770.

- In the first embodiment described above, the mounting surface 41 of the resin part 40 was flush with the first connection portion 24 of the first terminal 20 and the second connection portion 34 of the second terminal 30, but the mounting surface may be formed with a step relative to the first connection portion and the second connection portion.

- In the first embodiment described above, the resin part 40 had a mounting surface 41 on which the chip fuse 50 was placed, but the resin part does not have to have a mounting surface. In other words, the resin part does not have to have a surface that contacts the chip fuse, as long as the first electrode and second electrode of the chip fuse are connected to the first connection portion of the first terminal and the second connection portion of the second terminal, respectively.

- In the sixth embodiment described above, the fuse unit 610 includes a retainer 690 that is attached to the resin portion 640, but the fuse unit does not need to include a retainer. If a retainer is not provided, the housing portion may be provided with a retaining portion for holding the third terminal within the cavity.

- In the sixth embodiment described above, the tab portion 633 is exemplified as the first terminal connection portion, and the tubular connection portion 681 is exemplified as the second terminal connection portion. However, for example, the first terminal connection portion may be the tubular connection portion, and the second terminal connection portion may be the tab portion.

The shape of the retainer 690 in the sixth embodiment is an example, and the shape of the retainer may be changed as desired as long as it functions to secure the third terminal to the resin portion. For example, in the sixth embodiment, the retainer 690 is held at a temporary locking position and a full locking position relative to the resin portion 640, but it is also possible to set only the full locking position and omit the temporary locking position. Furthermore, the retainer may move linearly rather than rotate relative to the resin portion.

1: Energy storage module 2: Energy storage element 2A: Electrode terminal 3: Wiring module 10: Fuse unit 20: First terminal 21: Plate-shaped portion 21A: Recess 22: Through hole 23: Bus bar connection portion 24: First connection portion 30: Second terminal 31: Plate-shaped portion 31A: Recess 32: Through hole 33: Electric wire connection portion 34: Second connection portion 40: Resin portion 41: Mounting surface 42: Peripheral wall portion 42A: Opening 43: Intermediate molded body 50: Chip fuse 51: First electrode 52: Second electrode 60: Bus bar 70: Electric wire (wiring member)
71: Connector 80: Protector 80A: Protector body 80B: Lid 80C: Hinge portion 81: Bus bar accommodating portion 82: Electric wire accommodating portion 82A: Bottom wall 82B: First side wall 82C: Second side wall 82D: Notch portion 83: Intermediate wiring portion 83A: Bottom surface 83B: Protrusion receiving portion (fixing portion)
84: Plate-shaped portion 85: Protruding portion (fixing portion)
110: Fuse unit 144: Lid portion (cover member)
210: Fuse unit 245: Sealing portion (cover member)
246: Through hole 310: Fuse unit 345: Sealing portion (cover member)
410: Fuse unit 420: First terminal 421: Plate portion 421A: First plate portion 421B: Second plate portion 421C: Third plate portion 430: Second terminal 431: Plate portion 431A: First plate portion 431B: Second plate portion 431C: Third plate portion 440: Resin portion 610: Fuse unit 620: First terminal 625: Notch 630: Second terminal 633: Tab portion (first terminal connection portion)
635: Notch 640: Resin portion 641: Middle portion 641A: Reference surface 641B: Groove 643: Housing portion 643A: Bottom wall 643A1: Second communication hole 643B: Side wall 643C: Ceiling wall 643C1: First communication hole 644: Cavity 645: Mounting recess 645A: First mounting recess 645B: Second mounting recess 646: Shaft portion 647: Provisional locking portion 648: Full locking portion 680: Third terminal 681: Connection tube portion (second terminal connection portion)
682: Barrel portion 682A: Core wire crimping portion 682B: Insulation coating crimping portion 683: Cylinder wall portion 683A: Locking hole 684: Elastic contact piece 690: Retainer 691: Main body portion 692: Locking piece 692A: Locking protrusion 693: Side wall 693A: Insertion hole 694: Lance 695: Retaining portion 703: Wiring module 770: Flexible substrate (wiring member)
BS: Bottom surface S1: First inner surface S2: Second inner surface S3: Third inner surface SP1: First side surface D1: First direction D2: Second direction D3: Third direction

Claims (2)

A wiring module attached to a plurality of energy storage elements,
a bus bar connected to an electrode terminal of the energy storage element;
A wiring member;
A fuse unit;
a protector that holds the bus bar, the wiring member, and the fuse unit,
the fuse unit includes a first terminal electrically connected to the bus bar, a second terminal electrically connected directly or indirectly to the wiring member, a resin portion covering a portion of the first terminal and a portion of the second terminal, and a chip fuse;
the resin portion maintains a distance between the first terminal and the second terminal;
the first terminal includes a first connection portion exposed from the resin portion,
the second terminal includes a second connection portion exposed from the resin portion,
the chip fuse includes a first electrode mounted on the first connection portion and a second electrode mounted on the second connection portion;
the first terminal or the second terminal has a notch recessed from an outer edge portion,
The wiring module, wherein the cutout defines the first connection portion or the second connection portion. a groove recessed relative to the first connecting portion and the second connecting portion is formed in the resin portion;
an inner wall of the groove is continuous with the first connecting portion and the second connecting portion;
The wiring module according to claim 1 , wherein a portion of the groove is disposed inside the notch.