JP7842257B2 - Wiring unit - Google Patents

Description

This disclosure relates to a wiring unit.

High-voltage battery packs used in electric vehicles and hybrid vehicles typically consist of multiple battery cells stacked and electrically connected in series or parallel by a wiring unit. A conventional wiring unit is the one described in Japanese Patent Publication No. 2020-527848 (see Patent Document 1 below). The battery module described in Patent Document 1 comprises a cell assembly with multiple cells stacked in the left-right direction, each cell assembly having electrode leads at its front and rear ends; a module housing configured to house the cell assembly in an internal space formed by four side walls (top, bottom, left, and right); and end frames assembled to the front and rear of the cell assembly to connect the cell assembly to an external device.

Special Publication No. 2020-527848

In the above configuration, the cell assembly has a portion where the electrode leads of adjacent battery cells are bent and overlapped so that they are electrically connected to each other. Because of this portion, there is no need to provide busbars to connect the electrode leads, and the electrode leads are electrically connected to module terminals provided on the end frame. However, due to the bending of the electrode leads and the welding of the electrode leads together, large manufacturing tolerances are likely to occur in the connection portion, especially in the front-to-back direction.

In the above configuration, when connecting the electrode leads and module terminals by laser welding or the like, the large manufacturing tolerances in the front-to-back direction of the electrode leads may prevent the module terminals from making sufficient contact with the electrode leads. When the module terminals and electrode leads are not in sufficient contact in this way, there is a possibility of poor electrical connection between the electrode leads and module terminals.

The wiring unit of this disclosure is attached to a battery stack, the battery stack is constructed by stacking a plurality of laminate-type batteries, each having electrode leads, and the battery stack has a joint portion formed by overlapping and joining the electrode leads of the laminate-type batteries. The wiring unit comprises a terminal, an electric wire connected to the terminal, and a protector that holds the terminal and the electric wire. The terminal comprises a main body, a connecting portion extending from the main body and connected to the electrode leads constituting the joint portion in a first direction, and at least one bent plate portion extending from the main body toward the laminate-type battery in the first direction. The protector has a protector body and at least one recess recessed toward the laminate-type battery in the first direction relative to the protector body and accommodating the bent plate portion. Since the bent plate portion is inserted into the recess and movable in the first direction, the connecting portion can be brought into contact with the electrode leads.

According to this disclosure, a wiring unit with excellent reliability in the electrical connection between terminals and electrode leads can be provided.

Figure 1 is a perspective view showing the front of the energy storage module according to Embodiment 1. Figure 2 is a front view of the energy storage module. Figure 3 is a magnified view of the area around the terminals in Figure 2. Figure 4 is a cross-sectional view taken along line A-A in Figure 2. Figure 5 is a cross-sectional view taken along line B-B in Figure 3. Figure 6 shows the first position of the terminal in the B-B cross-section of Figure 3. Figure 7 shows the second position of the terminal in the B-B cross-section of Figure 3. Figure 8 is a view of the B-B cross-section in Figure 3 with the terminals omitted. Figure 9 is a cross-sectional view taken along line C-C in Figure 3. Figure 10 is a cross-sectional view taken along line D-D in Figure 5. Figure 11 is a perspective view showing the area around the terminal housing in an energy storage module. Figure 12 is a diagram in which the terminals are omitted from Figure 11. Figure 13 is a perspective view of the front of the battery stack. Figure 14 is a perspective view showing the main components of a laminated battery. Figure 15 is a perspective view of a terminal connected to an electric wire. Figure 16 is a perspective view showing an example of a terminal according to Embodiment 2. Figure 17 is a perspective view showing an example of a terminal according to Embodiment 2, which is different from Figure 16. Figure 18 is a perspective view of the terminal according to Embodiment 3. Figure 19 is a perspective view of the terminal according to Embodiment 4. Figure 20 is a perspective view of the terminal according to Embodiment 5. Figure 21 is a cross-sectional view of an energy storage module, and shows the cross-section corresponding to Figure 9 of Embodiment 1. Figure 22 is a cross-sectional view of an energy storage module, and shows the cross-section corresponding to Figure 10 of Embodiment 1. Figure 23 is a front view of the front of the energy storage module according to Embodiment 6. Figure 24 is a perspective view of the terminal according to Embodiment 6. Figure 25 is a perspective view of the protector body of Embodiment 6 and (6) to (7) in other embodiments. Figure 26 is an enlarged view of region D in Figure 25. Figure 27 is a perspective view of the terminal according to Embodiment 7.

First, the embodiments of this disclosure will be listed and described.

(1) The wiring unit of this disclosure is attached to a battery stack, the battery stack is composed of a plurality of laminate-type batteries equipped with electrode leads stacked together, and includes a joint portion formed by overlapping and joining the electrode leads of the laminate-type batteries. The wiring unit comprises a terminal, an electric wire connected to the terminal, and a protector that holds the terminal and the electric wire. The terminal comprises a main body, a connecting portion extending from the main body and connected to the electrode leads constituting the joint portion in a first direction, and at least one bent plate portion extending from the main body toward the laminate-type battery in the first direction. The protector comprises a protector body and at least one recess recessed toward the laminate-type battery in the first direction relative to the protector body and accommodating the bent plate portion. Since the bent plate portion is inserted into the recess and movable in the first direction, the connecting portion can contact the electrode leads.

With this configuration, by inserting the bent plate portion into the recess and making it movable in the first direction, the connecting portion becomes movable in the first direction relative to the protector. Therefore, when the connecting portion is connected to the electrode lead constituting the joint, the connecting portion can be made to contact the electrode lead even if there is a manufacturing tolerance in the first direction of the electrode lead. This improves the reliability of the electrical connection between the connecting portion and the electrode lead.

(2) Preferably, the terminal comprises a bent portion connecting the edge of the main body portion and the edge of the bent plate portion, and a folded portion connected to the main body portion, the bent portion, and the bent plate portion, and overlapping the main body portion, the bent portion, and the bent plate portion.

This configuration allows for improved strength of the bent section through the folded-over portion.

(3) Preferably, the terminal includes a bent portion connecting the edge of the main body and the edge of the bent plate, the thickness direction of the bent portion continuously changes from the first direction to a direction perpendicular to the first direction as it moves from the main body toward the bent plate, and the bent portion includes a protruding portion that extends from the bent portion in the thickness direction of the bent portion.

With this configuration, the protruding portion can improve the strength of the bent section.

(4) Preferably, the bent plate portion includes a ridge portion that protrudes from the bent plate portion toward the inner wall of the recess in a direction perpendicular to the first direction and extends in the first direction, and the ridge portion and the protruding portion are formed continuously.

With this configuration, by forming the protruding portion, the contact area between the bent plate portion and the inner wall of the recess can be reduced. This allows the bent plate portion to slide more easily even when the two portions are in contact. Furthermore, because the protruding portion and the projection are formed continuously, it is easier to form both the protruding portion and the projection.

(5) Preferably, a protrusion is provided on the side wall of the recess, and the protrusion abuts against the bent plate portion.

With this configuration, the protrusions on the side walls of the recess reduce the contact surface between the recess and the bent plate. When the entire flat surface of the bent plate is in contact with the recess, sliding of the bent plate within the recess becomes even easier.

(6) Preferably, the terminal comprises a plurality of the bent plate portions.

This configuration makes it easier to control the shape of the terminals by forming multiple bent plate sections.

(7) Preferably, the protector includes a contact portion that contacts the terminal from the laminated battery side in the first direction.

With this configuration, the contact portion can restrict the terminal from moving towards the laminated battery in the first direction.

(8) Preferably, the protector includes a locking portion that engages with the terminal from the side opposite to the laminated battery side in the first direction.

With this configuration, the locking mechanism can restrict the terminal from moving in the first direction away from the laminated battery side.

(9) Preferably, the protector comprises a flexible piece extending from the protector body and capable of bending and deforming in a direction perpendicular to the first direction, the tip of the flexible piece comprising a locking portion disposed within the recess, the bent plate portion having an opening that penetrates the bent plate portion, and the rim of the opening comprising a locking receiving portion that engages with the locking portion.

With this configuration, by providing a flexible piece equipped with a locking portion, insertion into the recess of the bent plate and locking of the terminal to the protector can be performed smoothly.

(10) Preferably, the protector body is provided with a position-regulating column, the terminal has a through-hole, the position-regulating column is inserted into the through-hole, the position-regulating column includes a column body and a column head connected to the column body, and along the height direction of the column body, the projected area of the column head is larger than the projected area of the through-hole, and the projected area of the through-hole is larger than the projected area of the column body.

With this configuration, not only can the column body be passed through the through-hole on the terminal, but the terminal can also move in the height direction of the column body, and both the position-regulating column and the protector body regulate the position of the terminal against its forward and backward movement.

(11) Preferably, the terminal includes a wire connection portion extending from the main body and connected to the electric wire, the wire connection portion comprising a base and a crimping piece extending from the base, the electric wire being positioned closer to the laminate-type battery side in the first direction relative to the base and crimped by the crimping piece.

With this configuration, the wires are positioned closer to the laminated battery side in the first direction relative to the base, making it easier to reduce the protrusion of the wire connection part from the main body to the opposite side of the laminated battery in the first direction. This allows for a reduction in the dimensions of the wiring unit in the first direction.

(12) Preferably, the terminal is provided with an extended wire connection portion, the protector body is provided with a wire connection portion housing, and the wire connection portion is installed within the wire connection portion housing.

With this configuration, the combination of the wire connection section and the wire connection section housing prevents the terminal from rotating during the welding process to the electrode lead, thereby improving terminal stability and avoiding welding defects.

(13) Preferably, the connection portion is provided with an arc-shaped connection portion, several elongated holes are opened in the arc-shaped connection portion, and the arc-shaped connection portion is arranged to absorb the expansion amount of the electrode lead.

With this configuration, by installing an arc-shaped connector at the terminal connection point, the arc-shaped connector can absorb the displacement of the electrode leads that occurs during cell expansion. This avoids the risk of structural instability, detachment, and even breakage of the terminals that would otherwise be pulled and exposed when the cell undergoes expansion deformation.

[Detailed description of embodiments of this disclosure]
The embodiments of this disclosure are described below. This disclosure is not limited to these examples, but is indicated by the claims and is intended to include all modifications within the meaning and scope of the equivalents of the claims.

<Embodiment 1>
Embodiment 1 of the present disclosure will be described with reference to Figures 1 to 15. The energy storage module 10 equipped with the wiring unit 20 of this embodiment is mounted on a vehicle such as an electric vehicle or a hybrid vehicle and used as a power source for the vehicle. In the following description, for multiple identical components, only some components may be given reference numerals, and the reference numerals for other components may be omitted. Hereinafter, the direction indicated by arrow X will be described as forward, the direction indicated by arrow Y will be described as left, and the direction indicated by arrow Z will be described as upward. In this embodiment, the front-rear direction is an example of a first direction.

[Battery stack]
The energy storage module 10 comprises a battery stack 11L as shown in Figure 13 and a wiring unit 20 attached to the battery stack 11L as shown in Figure 1. As shown in Figure 1, the energy storage module 10 of this embodiment further comprises a case 15 that covers the battery stack 11L from all four sides (top, bottom, left, and right). The case 15 consists of a bottom portion 15A located on the lower side of the battery stack 11L, a top portion 15B located on the upper side of the battery stack 11L, and a pair of side portions 15C that connect the bottom portion 15A and the top portion 15B on both the left and right sides.

[Laminated batteries, electrode leads]
As shown in Figure 13, the battery stack 11L is constructed by stacking multiple laminate-type batteries 11 (18 in this embodiment) in the left-right direction. Note that Figure 13 shows only the front portion of the battery stack 11L. As shown in Figure 14, the laminate-type battery 11 is formed in a shape that is long in the front-back direction and flattened in the left-right direction. An energy storage element (not shown) is housed inside the laminate-type battery 11. A pair of electrode leads 12 are arranged on both sides of the laminate-type battery 11 in the front-back direction, protruding in opposite directions. The pair of electrode leads 12 are plate-shaped and have opposite polarities.

[Joint part]
As shown in Figures 4 and 13, the battery stack 11L is provided with a junction 13 that electrically connects the four electrode leads 12 of the laminate-type batteries 11 which are arranged continuously in the left-right direction. That is, the four electrode leads 12 are bent at approximately right angles to the left or right, overlapped, and joined by laser welding to form the junction 13. The electrode leads 12 that constitute the junction 13 are connecting electrode leads 12A. Of the four connecting electrode leads 12A, the two connecting electrode leads 12A located on the right and the two connecting electrode leads 12A located on the left have opposite polarity. For example, the two connecting electrode leads 12A on the right are positive electrodes, and the two connecting electrode leads 12A on the left are negative electrodes. Therefore, in the battery stack 11L, the junction 13 connects two laminate-type batteries 11 which are connected in parallel in series. As shown in Figure 13, the battery stack 11L has four junctions 13 at its front. Although not shown in the diagram, the battery stack 11L also has four connecting parts 13 at its rear.

The formation process for the joint 13 includes bending the electrode lead 12 and laser welding, so the tolerance in the front-to-back direction of the joint 13 (and connecting electrode lead 12A) tends to be particularly large. For example, in this embodiment, the tolerance in the front-to-back direction of the joint 13 (and connecting electrode lead 12A) is approximately ± several mm, which is about five times the thickness of the electrode lead 12.

As shown in Figures 4 and 13, the battery stack 11L has an output unit 14 at the front left end. Although not shown, the battery stack 11L also has an output unit 14 at the rear right end. The output unit 14 is formed by joining two electrode leads 12 that do not constitute a joint 13. The electrode leads 12 constituting the output unit 14 are designated as output electrode leads 12B. The two output electrode leads 12B constituting one output unit 14 have the same polarity. The output unit 14 constitutes either the positive or negative electrode of the entire battery stack 11L. That is, for example, if the front output unit 14 is the overall positive electrode of the battery stack 11L, then the rear output unit 14 is the overall negative electrode of the battery stack 11L.

[Wiring Unit]
As shown in Figure 1, the wiring unit 20 of this embodiment includes a terminal 30 connected to the connecting electrode lead 12A, a busbar 40 connected to the output electrode lead 12B, an electric wire 45 connected to the terminal 30, and a protector 50 that holds the terminal 30, the busbar 40, and the electric wire 45. The configuration of the wiring unit 20, which is located on the front side of the energy storage module 10, will be described in detail below. Although not shown, the wiring unit 20 located on the rear side of the energy storage module 10 is configured similarly to the wiring unit 20 located on the front side of the energy storage module 10.

The busbar 40 has a plate-like shape and is formed by processing a conductive metal plate. As shown in Figure 2, the busbar 40 comprises a first portion 40A extending in the vertical direction and a second portion 40B connected to the upper end of the first portion 40A. The first portion 40A is flattened in the front-rear direction. The second portion 40B extends to the right from the upper end of the first portion 40A and is flattened in the vertical direction. The busbar 40 is held by the busbar holding portion 53 of the protector 50 and is connected to the output electrode lead 12B at the vertical center of the first portion 40A. A busbar-side connection portion 41 is provided at the right end of the second portion 40B.

As shown in Figure 1, the busbar-side connector 41 has a through-hole 41A through which a bolt is inserted. An external connection terminal (not shown) is superimposed on the busbar-side connector 41 and fastened to the busbar-side connector 41 with a bolt. This electrically connects the busbar-side connector 41 to the external connection terminal. The external connection terminal is used to connect an external device (not shown) to the energy storage module 10.

[Electric wire]
As shown in Figures 6 and 15, the electric wire 45 has a core wire 46 and an insulating covering member 47 that covers the core wire 46. One end of the electric wire 45 is connected to the terminal 30. As shown in Figure 1, the other end of the electric wire 45 is bundled together and connected to the connector 48. The electric wire 45 is routed into the wiring recess 50A of the protector 50 and is routed in a predetermined position.

As shown in Figure 2, the connector 48 comprises an insulating synthetic resin housing 48A and a male terminal 48B housed inside the housing 48A. The connector 48 mates with a mating connector (not shown) having a female terminal. The mating connector is connected to an external ECU (Electronic Control Unit) via wires (not shown). The ECU is a component equipped with a microcomputer, elements, etc., and has a known configuration with functions for detecting the voltage, current, temperature, etc., of each laminate-type battery 11, and controlling the charging and discharging of each laminate-type battery 11.

[Terminals]
As shown in Figure 15, the terminal 30 is made by processing a conductive metal plate. The terminal 30 comprises a main body portion 31, a connecting portion 32 extending to the right from the main body portion 31, a bent plate portion 33 extending rearward from the lower part of the main body portion 31, and a wire connecting portion 34 extending upward from the main body portion 31. As shown in Figure 3, the main body portion 31 is positioned to the left of the terminal 30 and forms a rectangle when viewed from the front. The main body portion 31 is housed in the terminal housing portion 54 such that the plate thickness direction is in the front-to-back direction.

[Connection part]
As shown in Figure 15, the connecting portion 32 has a rectangular shape that is elongated in the left-right direction and is formed flush with the main body portion 31. The connecting portion 32 protrudes further upward and downward than the main body portion 31 in the vertical direction. As shown in Figure 4, the connecting portion 32 is formed to connect by surface contact with the joint portion 13 or a part of the connecting electrode lead 12A that constitutes the joint portion 13. That is, the terminal 30 is not a member for connecting adjacent connecting electrode leads 12A, but a member for connecting a pre-connected connecting electrode lead 12A (joint portion 13) and the electric wire 45. Therefore, the vertical dimension of the connecting portion 32 may be smaller than the vertical dimension of the connecting electrode lead 12A.

[Bent plate section, curved section]
As shown in Figure 15, the bent plate portion 33 is bent approximately perpendicular to the main body portion 31 and extends to the rear. The bent plate portion 33 is positioned so that its thickness direction is vertical. The lower end of the main body portion 31 is connected to the tip of the bent plate portion 33 via the bent portion 35. The thickness direction of the bent portion 35 changes from the front-to-back direction to the up-to-down direction as it moves from the main body portion 31 towards the bent plate portion 33.

[Opening, locking receiver]
An opening 36 is formed through the bent plate portion 33 in the vertical direction. The opening 36 is located in the left-right center of the bent plate portion 33. Of the edges of the opening 36, the rear edge is designated as a locking receiving portion 36A. As shown in Figure 7, the locking receiving portion 36A can be locked to the locking portion 65A of the flexible piece 62, which will be described later. As shown in Figure 15, the opening 36 has an expanding opening 36B that extends towards the main body portion 31. By forming the expanding opening 36B, when the terminal 30 moves in the front-rear direction relative to the protector 50, the lower end of the main body portion 31 does not interfere with the flexible piece 62 (see Figure 6).

[Wire connection section]
As shown in Figures 6 and 15, the wire connection portion 34 comprises a base portion 34A flush with the main body portion 31, and crimping pieces 34B extending from both ends of the base portion 34A in the left-right direction. The crimping piece 34B comprises a first crimping piece 34C and a second crimping piece 34D positioned vertically at a distance from the first crimping piece 34C. The first crimping piece 34C is positioned on the main body portion 31 side of the wire connection portion 34 and is crimped to the core wire 46 of the electric wire 45. The second crimping piece 34D is positioned at the upper end of the wire connection portion 34 and is crimped to the insulating covering member 47 of the electric wire 45. Note that, except for Figures 5 to 7 and 15, the wire connection portion 34 is shown in a simplified form.

As shown in Figure 6, the crimping piece 34B crimps the wire 45 at the rear of the base portion 34A. The wire connection portion 34, located at the rear of the main body portion 31, is housed within the wire connection portion housing portion 57, which will be described later. This configuration allows for a reduction in the front-to-back dimensions of the wiring unit 20.

[Protector]
As shown in Figure 1, the protector 50 is made of an insulating synthetic resin and is plate-shaped. The protector 50 includes a protector body 51 that is positioned relative to the case 15 (and battery stack 11L). As shown in Figure 2, electrode housing recesses 52 are provided in parallel in the left-right direction at the vertical center of the protector body 51. The electrode housing recesses 52 are formed to penetrate in the front-to-back direction and have a vertically elongated rectangular shape. The electrode housing recesses 52 consist of a connecting electrode housing recess 52A and an output electrode housing recess 52B. The connecting electrode housing recess 52A receives the joint portion 13 and the connecting electrode lead 12A, and the output electrode housing recess 52B receives the output electrode lead 12B and the output portion 14.

As shown in Figure 2, busbar holding portions 53 for holding the busbar 40 are provided on the upper and lower sides of the output electrode housing recess 52B. A bolt fastening portion 53A for bolting the busbar 40 is provided to the right of the upper busbar holding portion 53. A terminal housing portion 54 for housing a portion of the terminal 30 is provided diagonally to the lower left of the connecting electrode housing recess 52A.

[Contact part]
As shown in Figure 12, the terminal housing portion 54 is formed recessed to the rear of the protector body 51. The terminal housing portion 54 comprises a body housing portion 55, a recess 56, and a wire connection portion housing portion 57. The body housing portion 55 is located in the lower part of the terminal housing portion 54. The body housing portion 55 has a bottom wall portion 55A, a left wall portion 55B extending forward from the left end of the bottom wall portion 55A, and a communication hole 55C opening to the right. The communication hole 55C communicates with the connection electrode housing recess 52A. As shown in Figure 11, the body housing portion 55 houses the body portion 31 of the terminal 30. As shown in Figure 6, the front surface of the bottom wall portion 55A is a contact portion 58 that abuts against the terminal 30 from the rear. As shown in Figure 11, the portion of the main body 31 on the side of the connection portion 32 is positioned in the communication hole 55C, and the connection portion 32 is positioned inside the recess 52A for housing the connection electrode.

[recess]
As shown in Figures 8 and 12, a recess 56 is formed below the main body housing 55. The recess 56 is recessed further rearward than the main body housing 55. The recess 56 is formed by penetrating the protector 50 in the front-rear direction. As shown in Figure 10, the inner wall 59 constituting the recess 56 comprises a first inner wall 59A and a second inner wall 59B that face each other in the vertical direction, and two side walls 59C that face each other in the left-right direction. The first inner wall 59A is positioned above the second inner wall 59B (on the main body housing 55 side). The dimension between the first inner wall 59A and the second inner wall 59B is set to be the same as, or slightly larger than, the thickness of the bent plate portion 33 (dimension in the vertical direction). The dimension between the two side walls 59C is set to be the same as, or slightly larger than, the left-right dimension of the bent plate portion 33. The bent plate portion 33 is housed inside the recess 56, allowing the bent plate portion 33 to slide against the inner wall 59 of the recess 56. As the bent plate portion 33 and the inner wall 59 of the recess 56 slide against each other, the terminal 30 becomes movable in the front-rear direction relative to the protector body 51, as shown in Figures 5 to 7 and 9.

As shown in Figure 5, a guide portion 60 is formed on the front side of the lower end of the bottom wall portion 55A. The guide portion 60 is inclined downwards as it extends towards the rear. When the bent plate portion 33 is inserted into the recess 56, the guide portion 60 guides the rear end of the bent plate portion 33 so that it is led into the recess 56.

As shown in Figure 12, the wire connection housing 57 is positioned above the main body housing 55. As shown in Figure 6, the wire connection housing 57 is formed to be recessed behind the bottom wall 55A. Specifically, when the main body 31 of the terminal 30, located within the terminal housing 54, is in contact with the front surface (contact surface 58) of the bottom wall 55A, the front surface of the wire connection housing 57 is positioned so that it does not come into contact with the wire connection 34. The upper part of the wire connection housing 57 is connected to the wiring recess 50A through which the wire 45 is routed.

[Bend piece]
As shown in Figure 12, a flexure piece housing recess 61 is formed below the recess 56, recessed rearward from the protector body 51. An entry point 61A is formed in the second inner wall 59B between the recess 56 and the flexure piece housing recess 61, recessed rearward from the tip of the second inner wall 59B. The recess 56 and the flexure piece housing recess 61 are in communication through the entry point 61A. As shown in Figure 8, the flexure piece 62 extends upward from the lower inner wall of the flexure piece housing recess 61. As shown in Figure 12, by positioning a part of the flexure piece 62 inside the entry point 61A, the tip of the flexure piece 62 enters the recess 56.

As shown in Figure 8, the flexible piece 62 comprises a plurality of plate portions 63 that are elongated in the front-rear direction and flattened in the vertical direction, and a connecting portion 64 that connects two adjacent plate portions 63. In this embodiment, the plurality of plate portions 63 are composed of a tip-side plate portion 63A positioned on the tip side (upper side) of the flexible piece 62 and a base-side plate portion 63B positioned on the base-side (lower side) of the flexible piece 62. The tip-side plate portion 63A and the base-side plate portion 63B are arranged to overlap with a gap in the vertical direction. The tip of the tip-side plate portion 63A and the tip of the base-side plate portion 63B are smoothly connected without any steps by an arch-shaped connecting portion 64. The rear end of the base-side plate portion 63B is connected to the lower inner wall of the flexible piece housing recess 61. The flexible piece 62 is capable of bending and deforming in the vertical direction.

[Locking part]
The front side plate portion 63A is provided with a locking projection 65 that protrudes upward from the upper surface of the front side plate portion 63A. The locking projection 65 is located at the rear end of the front side plate portion 63A. The rear end surface of the locking projection 65 is a locking portion 65A. An inclined portion 65B is located on the front part of the locking projection 65. The inclined portion 65B is inclined upward as it extends towards the rear. The locking portion 65A and the inclined portion 65B are arranged to connect in the front-rear direction. The locking projection 65 is located in the front space within the recess 56.

When inserting the bent plate portion 33 into the recess 56, the flexible piece 62 gradually bends downward as the rear end of the bent plate portion 33 is moved backward while contacting the inclined portion 65B of the locking projection 65. When the rear end surface (locking portion 65A) of the locking projection 65 is positioned within the opening 36 of the bent plate portion 33, the flexible piece 62 returns from its elastically deformed state to its natural state, and the locking portion 65A and the locking receiving portion 36A face each other in the front-rear direction and become lockable (see Figure 7). In this way, by providing the inclined portion 65B, the insertion of the bent plate portion 33 into the recess 56 and the locking of the bent plate portion 33 and the locking portion 65A can be smoothly performed.

[Movement of the terminals in the forward and backward direction relative to the protector]
The configuration of the protector 50 housing the terminal 30 and the configuration of the terminal 30 are as described above, and next, the movement of the terminal 30 in the front-rear direction relative to the protector 50 will be described. As described above, the tolerance in the front-rear direction of the joint 13 (and connecting electrode lead 12A) tends to be large, so the connecting portion 32 of the terminal 30 can also move in the front-rear direction to match the position of the joint 13 in the front-rear direction. Therefore, it is possible to ensure that the terminal 30 and the connecting electrode lead 12A are in contact, thereby improving the reliability of the electrical connection between the terminal 30 and the connecting electrode lead 12A using laser welding.

In this embodiment, since the bent plate portion 33 of the terminal 30 is positioned within the recess 56 of the terminal housing portion 54, the terminal 30 becomes movable in the front-rear direction relative to the protector 50. The terminal 30 is movable in the front-rear direction between a first position (see Figure 6) and a second position (see Figure 7) relative to the protector body 51. Here, the first position is the rearmost position to which the terminal 30 can move, and the second position is the frontmost position to which the terminal 30 can move. As shown in Figure 6, when the terminal 30 is positioned in the first position, the rear surface of the body portion 31 abuts against the contact portion 58. This restricts the rearward movement of the terminal 30. As shown in Figure 7, when the terminal 30 is positioned in the second position, the locking receiving portion 36A of the terminal 30 and the locking portion 65A of the flexible piece 62 are locked together. This restricts the forward movement of the terminal 30.

The length in the front-to-back direction between the first and second positions is set to be equal to or greater than twice the tolerance of the connecting electrode lead 12A in the front-to-back direction. The intermediate position between the first and second positions is the average position of the connecting electrode lead 12A in the front-to-back direction. By setting the first and second positions in this way, after the protector body 51 of the wiring unit 20 is fixed to the battery stack 11L, the terminal 30 becomes able to follow the connecting electrode lead 12A. Specifically, when performing laser welding between the terminal 30 and the connecting electrode lead 12A, the connection portion 32 of the terminal 30 is pressed against the connecting electrode lead 12A using a jig or the like. At this time, the terminal 30 and the connecting electrode lead 12A move together in the front-to-back direction. This ensures that the connection portion 32 and the connecting electrode lead 12A are in close contact, resulting in good laser welding between the connection portion 32 and the connecting electrode lead 12A.

[Effects of Embodiment 1]
According to Embodiment 1, the following actions and effects occurred. The wiring unit 20 according to Embodiment 1 is attached to a battery stack 11L, which is constructed by stacking a plurality of laminate-type batteries 11 equipped with electrode leads 12, and has a joint portion 13 formed by overlapping and joining the electrode leads 12 of the laminate-type batteries 11, the wiring unit 20 comprises a terminal 30, an electric wire 45 connected to the terminal 30, and a protector 50 that holds the terminal 30 and the electric wire 45, the terminal 30 comprises a main body portion 31 and an electrode lead 12 extending from the main body portion 31 that constitutes the joint portion 13 and The protector 50 comprises a connecting portion 32 connected opposite to each other in one direction (front-rear direction), and at least one bent plate portion 33 extending from the main body portion 31 toward the laminated battery 11 side (rear side) in a first direction. The protector 50 has a protector body 51 and at least one recess 56 recessed toward the laminated battery 11 side in a first direction relative to the protector body 51 to accommodate the bent plate portion 33. The bent plate portion 33 can be inserted into the recess 56 and moved in the first direction, thereby allowing the connecting portion 32 to contact the electrode lead 12.

With this configuration, by inserting the bent plate portion 33 into the recess 56 and making it movable in the first direction, the connecting portion 32 becomes movable in the first direction relative to the protector 50. Therefore, when the connecting portion 32 is connected to the electrode lead 12 constituting the joint portion 13, the connecting portion 32 can be made to contact the electrode lead 12 even if the electrode lead 12 has a manufacturing tolerance in the first direction. This improves the reliability of the electrical connection between the connecting portion 32 and the electrode lead 12.

In Embodiment 1, the protector 50 includes a contact portion 58 that contacts the terminal 30 from the laminated battery 11 side in the first direction.

With this configuration, the contact portion 58 can restrict the terminal 30 from moving toward the laminated battery 11 in the first direction.

In Embodiment 1, the protector 50 includes a locking portion 65A that engages with the terminal 30 from the opposite side (front side) of the laminated battery 11 in the first direction.

With this configuration, the locking portion 65A can restrict the terminal 30 from moving to the opposite side of the laminated battery 11 in the first direction.

In Embodiment 1, the protector 50 includes a flexible piece 62 extending from the protector body 51 and capable of bending and deforming in a direction perpendicular to the first direction (vertical direction). The tip of the flexible piece 62 is provided with a locking portion 65A located within the recess 56. The bent plate portion 33 has an opening 36 that penetrates the bent plate portion 33, and the edge of the opening 36 is provided with a locking receiving portion 36A that engages with the locking portion 65A.

With this configuration, by installing the flexible piece 62 equipped with the locking portion 65A, the insertion of the bent plate portion 33 into the recess 56 and the locking of the terminal 30 to the protector 50 can be performed smoothly.

In Embodiment 1, the terminal 30 includes a wire connection portion 34 extending from the main body portion 31 and connected to the electric wire 45. The wire connection portion 34 comprises a base portion 34A and a crimping piece 34B extending from the base portion 34A. The electric wire 45 is positioned further toward the laminate-type battery 11 in the first direction than the base portion 34A and is crimped to the crimping piece 34B.

With this configuration, since the electric wire 45 is positioned further toward the laminated battery 11 in the first direction than the base portion 34A, it is easier to reduce the dimension of the electric wire connection portion 34 protruding from the main body portion 31 toward the opposite side of the laminated battery 11 in the first direction. This allows for a reduction in the dimensions of the wiring unit 20 in the first direction.

<Embodiment 2>
Embodiment 2 of the present disclosure will be described with reference to Figures 16 and 17. Components identical to those in Embodiment 1 are denoted by the same reference numerals as in Embodiment 1, and their descriptions may be omitted. Also, the same effects as in Embodiment 1 will not be described. The terminal 130 according to Embodiment 2 includes two bent plate portions 33. By increasing the number of bent plate portions 33 compared to Embodiment 1, the shape of the terminal 130 moving relative to the protector 50 is made more stable.

The two bent plate portions 33 are arranged extending in the same direction as the main body portion 31 of the terminal 130, that is, in the front-to-back direction in which the terminal 130 can move. For example, as shown in Figure 16, the two bent plate portions 33 may be arranged below and to the left of the main body portion 31. Alternatively, as shown in Figure 17, the two bent plate portions 33 may be arranged below and above the main body portion 31 so as to face each other. Although not shown, the protector 50 has recesses 56 at positions corresponding to the two bent plate portions 33. That is, the protector 50 has two recesses 56 formed for each terminal 130.

[Effects of Embodiment 2]
According to Embodiment 2, the following actions and effects occurred. In Embodiment 2, the terminal 130 is provided with a plurality (two) of bent plate portions 33.

With this configuration, the shape of the terminal 130 can be easily controlled by forming multiple bent plate portions 33.

<Embodiment 3>
Embodiment 3 of the present disclosure will be described with reference to Figure 18. Components identical to those in Embodiment 1 are denoted by the same reference numerals as in Embodiment 1, and their descriptions may be omitted. Also, the same effects and advantages as in Embodiment 1 will not be described. The terminal 230 according to Embodiment 3 is provided with a folded portion 237 at its left end. The folded portion 237 is folded over so as to overlap the left end of the main body portion 31, the left end of the bent portion 35, and the left end of the bent plate portion 33.

[Effects of Embodiment 3]
According to Embodiment 3, the following actions and effects occurred. In Embodiment 3, the terminal 230 includes a bent portion 35 that connects the edge of the main body portion 31 and the edge of the bent plate portion 33, and a folded portion 237 that is connected to the main body portion 31, the bent portion 35 and the bent plate portion 33 and overlaps the main body portion 31, the bent portion 35 and the bent plate portion 33.

With this configuration, the folded portion 237 can improve the strength of the bent portion 35.

<Embodiment 4>
Embodiment 4 of this disclosure will be described with reference to Figure 19. Structures identical to those in Embodiment 1 are denoted by the same reference numerals as in Embodiment 1, and their descriptions may be omitted. Similarly, the same effects and functions as in Embodiment 1 will not be described. The terminal 330 according to Embodiment 4 is provided with a projection 337 at its left end. The projection 337 includes at least a portion that protrudes from the outer curved surface of the bent portion 35 in the thickness direction of the bent portion 35. The projection 337 of Embodiment 4 further includes a portion that protrudes forward from the front surface of the main body portion 31 and a portion that protrudes downward from the lower surface of the bent plate portion 33. The projection 337 of Embodiment 4 is formed by hammering.

[Effects of Embodiment 4]
According to Embodiment 4, the following actions and effects occurred. In Embodiment 4, the terminal 330 is provided with a bent portion 35 that connects the edge of the main body portion 31 and the edge of the bent plate portion 33. The thickness direction of the bent portion 35 continuously changes from a first direction (front-to-back direction) to a direction perpendicular to the first direction (up-down direction) as it moves from the main body portion 31 toward the bent plate portion 33, and the bent portion 35 is provided with a protruding portion 337 that protrudes from the bent portion 35 in the thickness direction of the bent portion 35.

With this configuration, the protrusion 337 can improve the strength of the bent portion 35.

<Embodiment 5>
Embodiment 5 of the present disclosure will be described with reference to Figures 20 to 22. Components identical to those in Embodiment 1 are denoted by the same reference numerals as in Embodiment 1, and their descriptions may be omitted. Also, the same effects as in Embodiment 1 will be omitted from the description. As shown in Figure 20, the terminal 430 according to Embodiment 5 includes a protruding portion 437 that protrudes from the bent portion 35, similar to the protruding portion 337 of Embodiment 4, and a ridged portion 438 that is formed on the bent plate portion 33 in continuity with the protruding portion 437.

The protrusion 437 in Embodiment 5 has a smaller left-right dimension compared to the protrusion 337 in Embodiment 4. Furthermore, the terminal 430 in Embodiment 5 has two protrusions 437 arranged in the left-right direction. These two protrusions 437 are formed at the left and right ends of the bent portion 35. Each protrusion 437 includes at least a portion that projects from the outer curved surface of the bent portion 35 in the thickness direction of the bent portion 35. The protrusion 437 in Embodiment 5 further includes a portion that projects forward from the front surface of the main body portion 31.

In Embodiment 5, two protrusions 438 are formed at the left and right ends of the bent plate portion 33. The protrusions 438 are elongated in the front-rear direction and project downward from the lower surface of the bent plate portion 33. The tip of the protrusion 438 and the lower end of the projection 437 are continuous. The projection 437 and protrusion 438 in Embodiment 5 are formed by reinforcement processing. Similar to the projection 337 in Embodiment 4, the projection 437 and protrusion 438 contribute to improving the strength of the bent portion 35.

As shown in Figures 21 and 22, in the energy storage module 410 (wiring unit 420) of Embodiment 5, the protruding portion 438 is housed within the recess 56 of the protector 50. The protruding portion 438 is positioned to face and slide against the second inner wall 59B of the protector 50. In Embodiment 1, the entire lower surface of the bent plate portion 33 makes surface contact with the second inner wall 59B; however, in Embodiment 5, the lower part of the protruding portion 438 on the bent plate portion 33 makes surface contact with the second inner wall 59B, sliding in a manner similar to so-called line contact. As a result, compared to Embodiment 1, the frictional resistance related to the sliding contact between the terminal 430 and the inner wall 59 of the recess 56 is reduced in Embodiment 5, and the terminal 430 becomes easier to move in the front-rear direction relative to the protector body 51.

[Effects of Embodiment 5]
According to Embodiment 5, the following actions and effects occurred. In Embodiment 5, the bent plate portion 33 is provided with a protruding portion 438 that extends in the first direction and protrudes from the bent plate portion 33 toward the inner wall 59 (second inner wall 59B) of the recess 56 in a direction perpendicular to the first direction (downward), and the protruding portion 438 and the projection portion 437 are formed continuously.

With this configuration, by forming the protruding portion 438, the area where the bent plate portion 33 and the inner wall 59 of the recess 56 come into contact with each other can be reduced. Therefore, even when the bent plate portion 33 and the inner wall 59 of the recess 56 come into contact, the bent plate portion 33 slides easily. Furthermore, because the protruding portion 438 and the projection portion 437 are formed continuously, it is easier to form the protruding portion 438 and the projection portion 437.

<Embodiment 6>
Embodiment 6 will be described with reference to Figures 23 to 26. Components identical to those in Embodiment 1 are denoted by the same reference numerals as in Embodiment 1, and their descriptions may be omitted. Also, the same effects as in Embodiment 1 will be omitted from the description. As shown in Figures 24 and 26, a wire connection portion 34 extends from the terminal 30, and a wire connection portion housing portion 57 is provided in the protector body 50, with the wire connection portion 34 installed within the wire connection portion housing portion 57.

[Effects of Embodiment 6]
With this configuration, the combination installation of the wire connection section 34 and the wire connection section housing section 57 prevents the terminal 30 from rotating during the welding process to the electrode lead 12, thereby improving the stability of the terminal 30 and avoiding welding defects.

<Embodiment 7>
Embodiment 7 will be described with reference to Figure 27. Components identical to those in Embodiment 1 are denoted by the same reference numerals as in Embodiment 1, and their descriptions may be omitted. Also, the same effects as in Embodiment 1 will be omitted from the description. The connection portion 32 is provided with an arc-shaped connection portion 32A, which is arranged to absorb the displacement of the electrode lead 12. Furthermore, several elongated holes are opened in the arc-shaped connection portion 32A so that it forms a comb-like shape, and in this way, when displacement occurs in the electrode lead 12, the arc-shaped connection portion 32A deforms, contributing to absorbing the displacement of the electrode lead 12.

[Effects of Embodiment 7]
With this configuration, when the laminated battery 11 undergoes expansion deformation, the electrode lead 12 also undergoes a certain degree of displacement along with the cell by connecting the electrode lead 12 to the end of the laminated battery 11. However, in this embodiment, by installing an arc-shaped connection part 32A on the connection part 32 of the terminal 30, the arc-shaped connection part 32A can absorb the amount of displacement of the electrode lead 12. This prevents the terminal 30 from being pulled when displacement occurs in the electrode lead 12, thus avoiding the risk of structural instability, detachment, and ultimately breakage of the terminal 30.

<Other Embodiments>
(1) In the above embodiment, the joint 13 is formed by joining four electrode leads 12, but is not limited thereto. The joint may be formed by joining multiple electrode leads. (2) In Embodiment 1, the terminal 30 is configured to have an opening 36, and the edge of the opening 36 is provided with a locking receiving portion 36A, but is not limited thereto. For example, the terminal may be configured not to have an opening, and may be provided with a locking receiving portion that protrudes from the bent plate portion. (3) In the above embodiment, the protector 50 is provided with a flexible piece 62, and the flexible piece 62 is provided with a locking portion 65A, but is not limited thereto. The protector may be locked to the terminal from the front by a member different from the flexible piece. (4) In Embodiment 1, the wire connection portion 34 extends upward from the main body portion 31, but may extend downward from the main body portion 31 as shown in Figures 23 and 24. (5) In Embodiment 1, the bent plate portion 33 is located at the lower end of the main body portion 31, but as shown in Figures 23 and 24, it may be located above the main body portion 31. (6) As another alternative to Embodiment 5, as shown in Figures 25 and 26, in this embodiment, a protrusion 56A is provided on the side wall of the recess 56, and the protrusion 56A abuts against the flat bent plate portion 33, reducing the contact area between the recess 56 and the bent plate portion 33, making it easier for the bent plate portion 33 to move within the recess 56. (7) As another alternative to the locking portion 65A in Embodiment 1, as shown in Figures 25 and 26, in this embodiment, a position regulating column 66 is provided on the protector body 50, a through hole 37 is opened in the terminal 30, and the position regulating column 66 is inserted into the through hole 37. Specifically, the position-regulating column 66 includes a column body 66A and a column head 66B connected to the column body 66A. Along the height direction of the column body 66A, the projected area of the column head 66B is larger than the projected area of the through-hole 37, and the projected area of the through-hole 37 is larger than the projected area of the column body 66A. In this way, not only can the column body 66A be passed through the through-hole 37 on the terminal 30, but the terminal 30 can also move in the height direction of the column body 66A, and the column head 66B and the protector body together regulate the position of the terminal 30 in the forward and backward movement direction.

10,410 Energy storage module 11 Laminated battery 11L Battery stack 12 Electrode lead 12A Connecting electrode lead 12B Output electrode lead 13 Joint 14 Output section 15 Case 15A Bottom 15B Top 15C Side 20,420 Wiring unit 30,130,230,330,430 Terminal 31 Main body 32 Connection section 32A Arc-shaped connection section 33 Bent plate section 34 Wire connection section 34A Base 34B Crimping piece 34C First crimping piece 34D Second crimping piece 35 Bent section 36 Opening 37 Through hole 36A Locking receiver 36B Expanded opening 40 Bus bar 40A First section 40B Second section 41 Busbar side connection part 41A Through hole 45 Electric wire 46 Core wire 47 Insulating sheathing member 48 Connector 48A Case 48B Male terminal 50 Protector 50A Wiring recess 51 Protector body 52 Electrode housing recess 52A Connection electrode housing recess 52B Output electrode housing recess 53 Busbar holding part 53A Bolt fastening part 54 Terminal housing part 55 Body housing part 55A Bottom wall part 55B Left wall part 55C Communication hole 56 Recess 56A Protrusion 57 Electric wire connection housing part 58 Contact part 59 Inner wall 59A First inner wall 59B Second inner wall 59C Side wall 60 Guide part 61 Flexible piece housing recess 61A Inlet 62 Flexible piece 63 Plate part 63A Distal side plate part 63B Proximal side plate part 64 Connecting part 65 Locking projection 65A Locking part 65B Inclined part 66 Position regulating column 66A Column body 66B Pillar head 237 Folded part 337, 437 Projection part 438 Projection part

Claims (13)

A wiring unit is attached to a battery stack, the battery stack is composed of multiple laminate-type batteries having electrode leads, and the laminate-type batteries have a joint portion where the electrode leads of the laminate-type batteries are overlapped and joined together.
Terminals and
The wire connected to the aforementioned terminal,
A protector that holds the terminal and the electric wire,
The terminal comprises a main body, a connecting portion extending from the main body and connected to the electrode lead constituting the joint in a first direction, and at least one bent plate portion extending from the main body toward the laminated battery in the first direction.
The wiring unit is characterized in that the protector comprises a protector body and at least one recess that is recessed toward the laminated battery side in the first direction relative to the protector body and accommodates the bent plate portion, and the bent plate portion is inserted into the recess and becomes movable in the first direction so that the connection portion can contact the electrode lead. The wiring unit according to claim 1, characterized in that the terminal comprises a bent portion that connects the edge of the main body portion and the edge of the bent plate portion, and a folded portion that connects to the main body portion, the bent portion and the bent plate portion and is superimposed on the main body portion, the bent portion and the bent plate portion. The wiring unit according to claim 1, wherein the terminal has a bent portion that connects the edge of the main body portion and the edge of the bent plate portion, the thickness direction of the bent portion changes continuously from the first direction to a direction perpendicular to the first direction as it moves from the main body portion toward the bent plate portion, and the bent portion has a protruding portion that protrudes from the bent portion in the thickness direction of the bent portion. The wiring unit according to claim 3, wherein the bent plate portion has a projection that protrudes from the bent plate portion to the inner wall of the recess in a direction perpendicular to the first direction and extends in the first direction, and the projection is formed continuously with the projection. The wiring unit according to claim 1, characterized in that a protrusion is provided on the side wall of the recess, and the protrusion is capable of contacting the bent plate portion. The wiring unit according to any one of claims 1 to 4, characterized in that the terminal comprises a plurality of the bent plate portions. The wiring unit according to any one of claims 1 to 4, characterized in that the protector has a contact portion that contacts the terminal from the laminated battery side in the first direction. The wiring unit according to any one of claims 1 to 4, characterized in that the protector has a locking portion that locks onto the terminal from the opposite side of the laminated battery in the first direction. The wiring unit according to claim 8, wherein the protector comprises a flexible piece extending from the protector body and capable of bending and deforming in a direction perpendicular to the first direction, the tip of the flexible piece comprises a locking portion disposed in the recess, the bent plate portion has an opening formed through the bent plate portion, and the rim of the opening comprises a locking receiving portion that engages with the locking portion. The protector body is provided with a position-regulating post, the terminal has a through hole, and the position-regulating post is inserted into the through hole.
The wiring unit according to claim 1, wherein the position-regulating column includes a column body and a column head connected to the column body, and along the height direction of the column body, the projected area of the column head is larger than the projected area of the through-hole, and the projected area of the through-hole is larger than the projected area of the column body. The wiring unit according to any one of claims 1 to 4, wherein the terminal is provided with a wire connection portion that extends from the main body and is connected to the electric wire, the wire connection portion comprises a base portion and a crimping piece extending from the base portion, and the electric wire is positioned further toward the laminated battery in the first direction from the base portion and is crimped by the crimping piece. The wiring unit according to claim 1, characterized in that a wire connection portion extends from the terminal, a wire connection portion housing portion is provided in the protector body, and the wire connection portion is installed within the wire connection portion housing portion. The wiring unit according to claim 1, characterized in that the connection portion is provided with an arc-shaped connection portion, several holes are opened in the arc-shaped connection portion, and the arc-shaped connection portion is arranged to absorb the amount of displacement of the electrode lead.