Method for manufacturing battery wiring module

Patent metadata

Field	Value
Publication number	US-10026943-B2
Application number	US-201615163770-A
Country	US
Kind code	B2
Filing date	May 25, 2016
Priority date	Dec 25, 2013
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

Provided is a method for manufacturing a battery wiring module including: a coating step of coating a first long side portion of a flat plate conductor and a plurality of linear conductors following the first long side portion by a first insulating resin portion and of coating a second long side portion of the flat plate conductor and a plurality of linear conductors following the second long side portion by a second insulating resin portion; and a cutting step of cutting the insulating resin portion so that the plurality of busbars is divided into a plurality of busbar groups and the plurality of linear conductors coated by any one of the first insulating resin portion and the second insulating resin portion and the busbar groups are separated.

First claim

What is claimed is:

1. A method for manufacturing a battery wiring module comprising steps of:
coating a first long side portion of an elongated flat plate conductor and outer peripheral portions of a plurality of linear conductors by a first insulating resin portion, the linear conductors being disposed along the first long side portion in parallel with a predetermined gap therebetween while having a predetermined gap with respect to the first long side portion;
coating a second long side portion of the flat plate conductor and outer peripheral portions of the plurality of linear conductors by a second insulating resin portion, the linear conductors being disposed along the second long side portion in parallel with a predetermined gap therebetween while having a predetermined gap with respect to the second long side portion;
separating the flat plate conductor at a predetermined gap in the longitudinal direction of the flat plate conductor;
forming a plurality of busbars electrically connecting electrode terminals provided in at least two battery cells connected to each other in the same direction among the plurality of battery cells overlapping each other in the same direction, the electrode terminals being arranged in parallel in the same direction;
cutting the insulating resin portion so that the plurality of busbars disposed in series is divided into a plurality of busbar groups and the plurality of linear conductors coated by any one insulating resin portion of the first insulating resin portion and the second insulating resin portion is separated from the busbar groups; and
connecting the plurality of linear conductors to the predetermined busbars.

2. The method for manufacturing the battery wiring module according to claim 1 , wherein
in the separating, a terminal insertion hole causing the electrode terminal to be inserted therethrough is formed in each of the busbars.

3. The method for manufacturing the battery wiring module according to claim 2 , wherein
in the connecting, a gap between the plurality of linear conductors of one end of the other insulating resin portion connecting the plurality of linear conductors and the busbar group is cut, and the linear conductors of the one end is electrically connected to the predetermined busbars of the busbar group.

4. The method for manufacturing the battery wiring module according to claim 2 , wherein
in the connecting, one end of a connection conductor is press-connected to a predetermined linear conductor of the plurality of linear conductors connected to the busbar group through the other insulating resin portion, and the other end of the connection conductor is electrically connected to the predetermined busbar of the busbar group.

5. The method for manufacturing the battery wiring module according to claim 2 , wherein
in the separating, a cathode busbar electrically connected only to a cathode terminal and an anode busbar electrically connected only to an anode terminal are formed along with the plurality of busbars in the busbar group, and a cut raised portion is formed in each of the cathode busbar and the anode busbar, and
in the connecting, the cut raised portion is electrically connected to a predetermined linear conductor of the plurality of linear conductors connected to the busbar group through the insulating resin portion.

6. The method for manufacturing the battery wiring module according to claim 2 , wherein
before the coating, the plurality of linear conductors coated by the first insulating resin portion is disposed along the first long side portion of the flat plate conductor, and the plurality of linear conductors having at least different cross-sectional shapes or physical properties is disposed along the second long side portion of the flat plate conductor.

7. The method for manufacturing the battery wiring module according to claim 2 , further comprising:
forming a connection reinforcement portion which increases a connection force of the first and second insulating resin portions with respect to the flat plate conductor in the first and second long side portions of the flat plate conductor, before the coating.

8. The method for manufacturing the battery wiring module according to claim 1 , wherein
in the connecting, a gap between the plurality of linear conductors of one end of the other insulating resin portion connecting the plurality of linear conductors and the busbar group is cut, and the linear conductors of the one end is electrically connected to the predetermined busbars of the busbar group.

9. The method for manufacturing the battery wiring module according to claim 8 , wherein
in the separating, a cathode busbar electrically connected only to a cathode terminal and an anode busbar electrically connected only to an anode terminal are formed along with the plurality of busbars in the busbar group, and a cut raised portion is formed in each of the cathode busbar and the anode busbar, and
in the connecting, the cut raised portion is electrically connected to a predetermined linear conductor of the plurality of linear conductors connected to the busbar group through the insulating resin portion.

10. The method for manufacturing the battery wiring module according to claim 8 , wherein
before the coating, the plurality of linear conductors coated by the first insulating resin portion is disposed along the first long side portion of the flat plate conductor, and the plurality of linear conductors having at least different cross-sectional shapes or physical properties is disposed along the second long side portion of the flat plate conductor.

11. The method for manufacturing the battery wiring module according to claim 8 , further comprising:
forming a connection reinforcement portion which increases a connection force of the first and second insulating resin portions with respect to the flat plate conductor in the first and second long side portions of the flat plate conductor, before the coating.

12. The method for manufacturing the battery wiring module according to claim 1 , wherein
in the connecting, one end of a connection conductor is press-connected to a predetermined linear conductor of the plurality of linear conductors connected to the busbar group through the other insulating resin portion, and the other end of the connection conductor is electrically connected to the predetermined busbar of the busbar group.

13. The method for manufacturing the battery wiring module according to claim 12 , wherein
in the separating, a cathode busbar electrically connected only to a cathode terminal and an anode busbar electrically connected only to an anode terminal are formed along with the plurality of busbars in the busbar group, and a cut raised portion is formed in each of the cathode busbar and the anode busbar, and
in the connecting, the cut raised portion is electrically connected to a predetermined linear conductor of the plurality of linear conductors connected to the busbar group through the insulating resin portion.

14. The method for manufacturing the battery wiring module according to claim 12 , wherein
before the coating, the plurality of linear conductors coated by the first insulating resin portion is disposed along the first long side portion of the flat plate conductor, and the plurality of linear conductors having at least different cross-sectional shapes or physical properties is disposed along the second long side portion of the flat plate conductor.

15. The method for manufacturing the battery wiring module according to claim 12 , further comprising:
forming a connection reinforcement porti

Assignees

• Yazaki Corp

Inventors

• Ichikawa Yoshiaki
• Mukasa Hirotaka
• Koike Hirokuni

Classifications

• H01R43/16 Primary

  for manufacturing contact members, e.g. by punching and by bending · CPC title

• H01M50/516

  by welding, soldering or brazing · CPC title

• H01M50/507

  comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules · CPC title

• H01M50/503 Primary

  characterised by the shape of the interconnectors · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title