KR101873066B1 - Fuse apparatus and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a fuse device for a vehicle, which is applied to a battery pack mounted on an electric vehicle or a hybrid vehicle, for example, at a voltage of 450 V or higher, and a method of manufacturing the fuse device. The fuse device is coupled to a housing of a battery pack And a fuse assembly having first and second bus bars and first and second lead wires electrically connected to the battery pack, wherein the first and second lead wires are electrically connected to the first and second lead wires, Provide a configuration to be inserted and fixed in the bus bar.
By using the above-described fuse device and its manufacturing method, it is possible not only to provide a fuse for a vehicle with a high voltage of 450 V or more in a battery pack for a vehicle mounted on an electric vehicle or a hybrid vehicle, but also to minimize contact resistance.

Description

[0001] FUSE APPARATUS AND MANUFACTURING METHOD [0002]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fuse device and a method of manufacturing the same, and more particularly, to a fuse device for a vehicle applied to a vehicle battery pack mounted on an electric vehicle or a hybrid vehicle at a high voltage of, for example,

2. Description of the Related Art [0002] In general, a vehicle is equipped with various electric devices for driving the vehicle itself and for the convenience of passengers. Electric devices (hereinafter referred to as "electric fields") are electrically connected to a battery and a generator, And is operatively controlled by switch operation of the driver and electronic control of the control device.

In addition, a fuse is provided on the electric power supply lines of the electric fields, and when the electric current is excessively flowed due to an abnormality or an overload of the electric system, the heat generation is short-circuited to protect the electric fuse. For the sake of management, various fuses are integrated / I have installed.

In recent years, there has been an increasing demand for a multi-connector for distributing electric power and control signals to each electric device in the vehicle in accordance with development of electric vehicles and hybrid vehicles using high voltage and miniaturization of automobile engine room. Generally, a multi-connector used in a junction box inside an engine room is a bus bar assembly that receives power or control signals and branches to a plurality of outputs. It is connected to a bus bar to protect a device and a circuit by blocking a circuit when an over- And a fuse (Fuse).

However, since the conventional multi-connector is designed to be used at a low voltage compared with a voltage used in an electric automobile or a hybrid automobile, if it is used for a high voltage as it is, there is a risk of fire generation, There is a possibility of occurrence.

One example of the technique for solving such a problem is described in Documents 1 and 2 below.

For example, Patent Document 1 discloses a bus bar assembly comprising a main housing made of an insulating material and having an input terminal portion and an output terminal portion, a bus bar assembly installed in the main housing, forming a branch circuit between the input terminal portion and the output terminal portion, A fuse cover connected to the bus bar assembly so as to be interposed in the circuit, a fuse cover provided in a part of the main housing so as to be openable and closable for attaching and detaching the fuse, and an interlock interlocking with the opening of the fuse cover, A multi-connector for a high voltage including a switch is disclosed.

In addition, Patent Document 2 discloses a fuse-attaching apparatus that allows a fuse to be placed on a seat portion recessed on a lower surface of a main body so that the main body can be downsized as a whole.

Korean Patent Publication No. 2011-0037217 (published on April 13, 2011) Korea public utility model publication 2012-0004040 issue (2012.06.08 disclosure)

However, in the conventional technology as described above, there is not disclosed a high voltage fuse mounted on a vehicle battery pack.

In addition, in the above-described conventional fuse apparatus, the process for replacing the fuse itself is troublesome and the manufacturing process of the fuse-mounting apparatus is complicated.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a high-voltage fuse for a vehicle battery pack mounted on an electric vehicle or a hybrid vehicle, unlike a conventional fuse used in a junction box for a vehicle, And a method of manufacturing the same.

Another object of the present invention is to provide a fuse device and a method of manufacturing the same that can minimize contact resistance of a high voltage fuse for a vehicle.

In order to accomplish the above object, a fuse device according to the present invention is a fuse device coupled to a housing of a battery pack having a plurality of battery cells. The fuse device includes first and second bus bars electrically connected to the battery pack, And a fuse assembly having a fuse provided with two lead wires, wherein the first and second lead wires are inserted and fixed to the first and second bus bars.

Further, in the fuse apparatus according to the present invention, the fuse is for high voltage, the body is formed in a cylindrical shape, and the first and second wires are formed at both ends of the body.

In the fuse assembly according to the present invention, the fuse assembly may further include a fuse mounting portion to which the first and second bus bars are coupled.

Further, in the fuse apparatus according to the present invention, the first and second bus bars are fixed to both ends of the fuse mounting unit by a stitching method.

Further, in the fuse apparatus according to the present invention, the fuse mounting portion is formed with a plurality of support members for fixing the fuse.

The fuse device according to the present invention may further include a housing for housing the fuse assembly.

Further, in the fuse device according to the present invention, the housing is provided with a latching groove, the latching jaw is provided on the fuse mounting portion, and the latching jaw is fitted into the latching groove, so that the fuse assembly is mounted .

Further, in the fuse apparatus according to the present invention, the first and second bus bars are each provided with an insertion portion, the fuse mounting portion is provided with an insertion hole corresponding to the insertion portion, and the insertion portion is inserted into the insertion hole The first and second bus bars are coupled to the fuse mounting portion.

Further, in the fuse apparatus according to the present invention, the first and second bus bars are each provided with an upright terminal, and the first and second lead wires are resistance-welded to the upright terminal via the support member do.

According to another aspect of the present invention, there is provided a fuse device, wherein a connection part for contacting an external connection member connected to the battery packs is formed at one side of the first and second bus bars.

In order to accomplish the object of the present invention, there is provided a method of manufacturing a fuse device, which is coupled to a housing of a battery pack having a plurality of battery cells, the method comprising the steps of: (a) (B) attaching the first and second bus bars to the fuse mounting portion, (c) mounting the fuse on the fuse mounting portion, (d) inserting the fuse assembly formed in the step (c) And mounting it on the housing.

In the method of manufacturing a fuse device according to the present invention, in the step (c), each lead wire of the fuse is bonded to the first and second bus bars by resistance welding.

Further, in the method of manufacturing a fuse device according to the present invention, the steps (b) to (d) are performed by an automated process.

Further, in the method of manufacturing a fuse device according to the present invention, the steps (a) to (c) may be performed on lead frames each having a plurality of first and second bus bars, And the fuse assembly is provided by cutting correspondingly.

As described above, according to the fuse apparatus and the method of manufacturing the same according to the present invention, it is possible to provide a fuse for a vehicular battery pack mounted on an electric vehicle or a hybrid vehicle, Can be obtained.

Further, according to the fuse apparatus and the manufacturing method thereof according to the present invention, it is possible to obtain an effect that the manufacture of the fuse apparatus can be easily realized in a large amount.

Further, according to the fuse apparatus and the method for manufacturing the same according to the present invention, it is also possible to easily realize the replacement of the fuse apparatus.

1 is an exploded perspective view illustrating a configuration of a fuse device according to the present invention,
Fig. 2 is an exploded perspective view of the bus bar and the fuse mounting portion shown in Fig. 1,
Fig. 3 is a perspective view showing the back surface of the fuse mounting portion for explaining the coupling relation between the bus bar and the fuse mounting portion shown in Fig. 2,
FIG. 4 is a side view showing a state where the bus bar shown in FIG. 2 is coupled to the fuse mounting portion;
FIG. 5 is a perspective view showing a coupling relation between a fuse mounting portion and a housing in the fuse device according to the present invention, FIG.
FIG. 6 is a perspective view showing a coupling relationship between a bus bar and a connector of a fuse device according to the present invention,
7 is a perspective view showing a state in which the fuse device according to the present invention is mounted on a vehicle battery pack,
8 is a partially cutaway perspective view for explaining a coupling relationship between a bus and a wiring,
9 is a process diagram for explaining a manufacturing process of the fuse device according to the present invention,
10 is a perspective view showing a step of providing a lead frame,
11 is a perspective view showing the step of mounting the fuse mounting portion shown in Fig. 1,
Fig. 12 is a perspective view showing the step of mounting the fuse shown in Fig. 1; Fig.

These and other objects and novel features of the present invention will become more apparent from the description of the present specification and the accompanying drawings.

Hereinafter, the configuration and manufacturing process of the fuse device according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 5. FIG.

FIG. 2 is a perspective view of the bus bar and the fuse mounting unit shown in FIG. 1, and FIG. 3 is a perspective view showing a connection relationship between the bus bar and the fuse mounting unit shown in FIG. FIG. 4 is a side view showing a state where the bus bar shown in FIG. 2 is coupled to the fuse mounting portion, and FIG. 5 is a side view showing the fuse mounting portion and the housing of the vehicle fuse device according to the present invention. FIG.

1 and 2, a fuse unit according to the present invention includes a first bus bar 11, a second bus bar 12, and a third bus bar 14. The fuse unit is coupled to a housing of a battery pack having a plurality of battery cells. ), A fuse mounting portion (20), a fuse (30) having first and second lead wires (31, 32), and a housing (40).

The first and second bus bars 11 and 12 are formed by stamping and the first and second bus bars 11 and 12 are respectively bent at 90 degrees to provide upright terminals 13, The upstanding terminal (13) is provided with a substantially U-shaped groove.

The first and second bus bars 11 and 12 are composed of insertion portions 111 and 121 and connection portions 112 and 122. The insertion portions 111 and 121 are provided with fuse mounting portions 20 on both sides, A plurality of grooved toothed portions 14 for engaging with the grooves 14 are provided. The connection portion 112 of the first bus bar 11 is provided to protrude as one side for electrical connection outside the fuse device for a vehicle and the connection portion 122 of the first bus bar 12 is protruded to a substantially ' . The first bus bar 11 and the second bus bar 12 are fixed to both ends of the fuse mounting portion 20 by a stitching method.

In addition, the structure of the first and second bus bars 11 and 12 is not limited to the structure shown in Fig. 2, but may be modified depending on the use.

The fuse mounting portion 20 is formed by injection molding. As shown in FIG. 2, the fuse mounting portion 20 is provided with a plurality of support members for supporting the inserted fuse. As the support member, first and second support plates 21 and 22 are provided upright on both sides in the width direction of the fuse mounting portion 20, and the inserted fuses 21 and 22 are inserted into the first and second support plates 21 and 22, A protrusion 23 for supporting each of them is formed. The support protrusions 23 are inclined downward in order to facilitate the insertion of the fuse, and the ends thereof are made parallel to the fuse mounting portion 20 in order to fix the inserted fuse.

A pair of support plates 24 are provided on both sides of the fuse mounting portion 20 in the longitudinal direction to support the wires 31 and 32 of the inserted fuse 30, A substantially V-shaped groove corresponding to the position of the U-shaped groove formed in the upright terminal 13 is provided.

A plurality of inner protrusions 25 are provided in the width direction of the lower portion of the fuse mounting portion 20 and a locking protrusion 26 is provided in a portion of the inner protrusion 25 formed on both sides. An insertion hole 27 is provided outside the pair of support plates 24 at a depth corresponding to the length of the insertion portions 111 and 121 to insert the first and second bus bars 11 and 12, respectively. A configuration corresponding to the toothed portion 14 of the first and second bus bars 11 and 12 is provided inside the insertion hole 27 so that the first and second bus bars 11 and 12 are inserted Can be prevented.

2, a retaining projection 28 for further fixing the inserted fuse 30 is provided inside the pair of support plates 24 as shown in Fig.

The first and second bus bars 11 and 12 and the fuse mounting portion 20 are connected to each other by a serrated portion 14 provided on each of the first and second bus bars 11 and 12, Respectively, into the insertion holes 27 of the first and second insertion portions 26a and 26b.

Then, a fuse 30 having first and second lead wires 31 and 32 is mounted on the fuse mounting portion 20.

The fuse 30 is inserted by inserting the fuse body between the first support plate 21 and the second support plate 22 and connecting the first and second lead wires 31 and 32 to the U- Shaped grooves of the holding plate 24, as shown in Fig. Thereafter, resistance welding is performed to the upright terminal 13 and the first and second lead wires 31 and 32 provided on the first and second bus bars 11 and 12 so as to minimize the contact resistance. In the present invention, the upright terminal 13 and the first and second lead wires 31 and 32 are described as resistance welding. However, the present invention is not limited to this, and normal electrical welding can be applied.

By mounting the fuse 30 in this way, a fuse assembly as shown in Fig. 1 is completed. The completed fuse assembly is mounted in the housing 40 as shown in Figs.

On the other hand, the fuse 30 applied to the present invention is used for electrical and electronic circuit protection as an output of a battery pack for a vehicle mounted on an electric vehicle or a hybrid vehicle, for example, a fuse for 500 VAC and 400 VDC, The cap is made of nickel plating, and the first and second lead wires 31 and 32 are made of tin-plated copper.

1 and 5, the housing 40 includes a first insertion portion 41 into which the first bus bar 11 is inserted and a connection portion 112 of the first bus bar 11 from the outside of the housing A plurality of second guide tabs 43 for guiding a plurality of inner protrusions 25 when the fuse mounting part 20 is inserted, a second bus bar 12 for guiding a plurality of inner protrusions 25, A second inserting portion 44 to be inserted into the housing 40 and a latching groove 45 formed to fix the latching jaw 26 to prevent the fuse assembly from being detached after the fuse assembly is mounted on the housing 40 . The outside of the first insertion portion 41 functions as a locking protrusion that is fixed to the housing of the battery pack when the fuse device for a vehicle according to the present invention is mounted on the battery pack 100 for a vehicle.

That is, as shown in FIGS. 1 and 5, the fuse assembly for a vehicle according to the present invention includes a first insertion portion 41, first and second guide tines 42 and 43 provided in the housing 40, And engaging the engaging jaws 26 with the engaging grooves 45, as shown in Fig.

The fuse mounting portion 20 and the housing 40 are made of an insulating material such as plastic or synthetic resin for insulation from the first and second bus bars 11 and 12 and the connector and the like.

The vehicle fuse apparatus formed as described above is mounted on a battery pack as shown in Figs. 6 and 7, for example.

7 is a perspective view showing a state where the fuse device for a vehicle according to the present invention is mounted on a vehicle battery pack 100. Fig. 8 is a perspective view showing a fuse device for a vehicle according to the present invention, Is a partially cutaway perspective view for explaining the connection relationship between the bus bar and the wiring.

6, the first bus bar 11 is fitted to the connection terminal 51 of the connector 50 provided in the battery pack 100 for a vehicle, The two bus bars 12 are coupled to the wiring 60, for example, as shown in Fig. That is, the housing 40 is provided with a wiring guide portion 46 for guiding the insertion of the wiring 60, and the wiring 60 is inserted through the wiring guide portion 46 and connected to the second bus bar 12 do. The connection between the second bus bar 12 and the wiring 60 is realized by a normal electrical connection method.

Next, a manufacturing process of the fuse device for a vehicle according to the first embodiment of the present invention will be described with reference to FIG.

9 is a process diagram for explaining the manufacturing process of the fuse device for a vehicle according to the present invention.

First, as shown in FIG. 2, the first and second bus bars 11 and 12 and the fuse mounting unit 20 are respectively provided (S10). As described above, the first and second bus bars 11 and 12 are formed by stamping, the upright terminal 13 is bent by 90 degrees, and the fuse mounting portion 20 is formed by injection molding.

Next, as shown in FIG. 3, the first and second bus bars 11 and 12 are coupled to the fuse mounting portion 20 (S20). As shown in FIG. 3, the first and second bus bars 11 and 12 and the fuse mounting portion 20 are coupled to each other through an insertion hole (not shown) provided outside the pair of support plates 24 of the fuse mounting portion 20 27 by inserting the insertion portions 111, 121 of the first and second bus bars 11, 12.

Then, the fuse 30 having the first and second lead wires 31 and 32 is mounted on the fuse mounting portion 20 (S30). The step S30 includes a step of performing resistance welding to the upright terminal 13 and the first and second lead wires 31 and 32 provided on the first and second bus bars 11 and 12, respectively.

Next, the fuse assembly formed in step S30 is mounted on the housing 40 as shown in FIGS. 1 and 5, thereby completing the vehicle fuse apparatus as shown in FIG. 6 (S40).

In the present invention, steps S20 to S40 are executed by an automated process.

Next, a second embodiment of the present invention will be described with reference to Figs. 10 to 12. Fig.

FIG. 10 is a perspective view showing a step of providing a lead frame, FIG. 11 is a perspective view showing a step of mounting the fuse mounting portion shown in FIG. 1, and FIG. 12 is a perspective view showing a step of mounting the fuse shown in FIG. 1 .

First, as shown in FIG. 10, a lead frame 10 having first and second bus bars 11 and 12 is provided (S10). The lead frame 10 can be easily realized by a typical lead frame forming process and the upright terminals 13 are formed on the first and second bus bars 11.12 by the die process and the pressing process. The upstanding terminal (13) is provided with a substantially U-shaped groove.

The first and second bus bars 11 and 12 are provided on both sides with serrations 14 having a plurality of grooves for molding with the fuse mounting unit 20 described later.

Although FIG. 10 shows a structure in which three first and second bus bars 11 and 12 are provided, the present invention is not limited thereto, and a plurality of first and second bus bars 11 and 12 may be provided.

Next, as shown in FIG. 11, the fuse mounting portion 20 is mounted on the first and second bus bars 11 and 12.

Since the fuse mounting portion 20 is the same as the fuse mounting portion 20 except for the portion of the insertion hole 27 described in the first embodiment, repetitive description thereof will be omitted. That is, in the second embodiment, the coupling of the first and second bus bars 11 and 12 and the fuse mounting portion 20 is realized by insert molding. The first and second bus bars 11 and 12 are formed by molding the toothed portion 14 of each of the first and second bus bars 11 and 12 to be inserted into the fuse mounting portion 20, The fuse mounting portion 20 is mounted.

12, a fuse 30 having first and second lead wires 31 and 32 is mounted on the fuse mounting portion 20 and the first and second bus bars 11 and 12 are mounted, Resistance welding is performed on the upright terminal 13 and the first and second lead wires 31 and 32 provided on the first and second lead wires 12 and 12, respectively.

The fuse assembly is completed by mounting the fuse 30 in this way. The finished fuse assembly is cut in the lead frame 10 to form a single piece. That is, the fuse assembly is provided by cutting the lead frame 10 corresponding to each fuse mounting portion.

Next, by mounting the fuse assembly to the housing 40 as shown in Figs. 1 and 5, a vehicle fuse apparatus as in the first embodiment is completed.

Although the present invention has been described in detail with reference to the above embodiments, it is needless to say that the present invention is not limited to the above-described embodiments, and various modifications may be made without departing from the spirit of the present invention.

By using the fuse device for a vehicle and the method of manufacturing the same according to the present invention, it is possible to provide a fuse device for a vehicle which is applied to 450V or more.

11: 1st bus bar
12: Second bus bar
20: Fuse mounting part
30: Fuse
40: Housing
50: Connector

Claims (14)

A fuse device coupled to a housing of a battery pack having a plurality of battery cells,
First and second bus bars electrically connected to the battery pack and each having an upright terminal;
A fuse having first and second lead wires; And
A fuse mounting portion in which the first and second bus bars are coupled and a plurality of support members for fixing the fuse are formed;
The fuse assembly comprising:
Wherein the first and second lead wires are resistance-welded to the upright terminal via the support member and inserted and fixed to the first and second bus bars. The method according to claim 1,
Wherein the fuse is for high voltage, the body is formed in a cylindrical shape, and the first and second wires are formed at both ends of the body. delete The method according to claim 1,
Wherein the first and second bus bars are fixed to both ends of the fuse mounting portion by a stitching method. delete The method according to claim 1,
Further comprising a housing for receiving the fuse assembly. The method according to claim 6,
Wherein the housing is provided with a latching groove, the latching jaw is provided on the fuse mounting portion, and the latching jaw is fitted into the latching groove, thereby mounting the fuse assembly on the housing. The method according to claim 1,
Wherein each of the first and second bus bars is provided with an insertion portion,
Wherein the fuse mounting portion is provided with an insertion hole corresponding to the insertion portion,
And the first and second bus bars are coupled to the fuse mounting portion by inserting the insertion portion into the insertion hole. delete 9. The method of claim 8,
Wherein a connection part is formed at one side of the first and second bus bars to contact an external connection member connected to the battery packs. A manufacturing method of a fuse device coupled to a housing of a battery pack having a plurality of battery cells,
(a) providing first and second bus bars and a fuse mount,
(b) coupling the first and second bus bars to the fuse mount,
(c) attaching a fuse to the fuse mounting portion and bonding the first and second lead wires of the fuse to the first and second bus bars, respectively, by resistance welding to form a fuse assembly,
(d) mounting the fuse assembly formed in step (c) to the housing. delete 12. The method of claim 11,
Wherein the steps (b) to (d) are performed by an automated process. 12. The method of claim 11,
The steps (a) to (c) are performed on a lead frame having a plurality of first and second bus bars, respectively, wherein the fuse assembly is provided by cutting the lead frame corresponding to each fuse mount Wherein the fuse assembly is mounted on the fuse assembly.

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