KR20140003871A - Fuse apparatus and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a vehicle fuse device and a manufacturing method thereof which are applied to a high voltage, such as 450 V or more, in a battery pack which is installed in an electric vehicle or a hybrid vehicle. The fuse device which is combined with the housing of the battery pack having multiple battery cells includes a fuse assembly which is equipped with first and second bus bars electrically connected with the battery pack and a fuse having first and second lead wires, wherein the first and second lead wires have a configuration of being inserted into the first and second bus bars. By using the fuse device and the manufacturing method thereof, the present invention not only provides a vehicle fuse for a high voltage which is 450 V or more in the battery pack for vehicles which is installed in an electric vehicle or a hybrid vehicle but also minimizes a contact resistance.

Description

Fuse apparatus and manufacturing method thereof

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fuse device and a method for manufacturing the same, and more particularly, to a fuse device for a vehicle applied to a high voltage, for example, 450V or more, and a method for manufacturing the same in a battery pack for a vehicle mounted on an electric vehicle or a hybrid vehicle.

In general, the vehicle is equipped with various electric devices for driving the vehicle itself and for the convenience of the occupants. These electric devices (hereinafter, referred to as "fields") are electrically connected to the battery and the generator to supply power for operation. Operation by the switch operation of the driver and the electronic control of the control device.

In addition, a fuse is provided on the power supply lines of the electric fields to protect them by generating a heat short circuit when an electric current flows excessively due to an abnormality or an overload of the electric system, and various fuses are integrated into the fuse box for the convenience of management. I install it.

On the other hand, in recent years, with the development of electric vehicles or hybrid vehicles using high voltage, and the miniaturization of the engine room, the demand for multi-connectors for distributing power or control signals to each electronic device inside the vehicle is also increasing. In general, the multi-connector used in the junction box inside the engine room is a bus bar assembly that receives power or control signals and branches them to a plurality of outputs. It is configured to include a fuse (Fuse).

However, since the conventional multi-connector is designed to be used at a lower voltage than the voltage used in an electric or hybrid vehicle, when used as it is, there is a risk of fire, and there is a problem of electrical interference or shielding performance between circuits. It may occur.

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

For example, Patent Document 1 below discloses 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, and forming a branch circuit between the input terminal portion and the output terminal portion, the branching. A fuse connected to the bus bar assembly so as to be interposed in a circuit, a fuse cover installed in a part of the main housing to be detachable from the fuse, and an interlock configured to block a current flowing through the fuse in conjunction with an opening of the fuse cover; A high voltage multi-connector comprising a switch is disclosed.

In addition, Patent Document 2 discloses a fuse mounting apparatus that allows the fuse to be seated in a recessed portion recessed in the lower surface of the main body so that the main body can be miniaturized as a whole.

Republic of Korea Patent Publication No. 2011-0037217 (2011.04.13 published) Republic of Korea Open Utility Model Publication No. 2012-0004040 (2012.06.08 release)

However, the above-described prior art does not disclose a high voltage fuse mounted on a vehicle battery pack.

In addition, in the conventional fuse device as described above, the process for replacing the fuse itself is cumbersome, and the manufacturing process of the fuse mounting device is complicated.

SUMMARY OF THE INVENTION An object of the present invention is to solve the problems as described above, unlike the fuse used in the junction box of a conventional vehicle, a large amount of high-voltage fuse in a battery pack for a vehicle mounted on an electric vehicle or a hybrid vehicle, etc. The present invention provides a fuse device 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, which can minimize the contact resistance of a high voltage fuse for a vehicle.

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

In the fuse device according to the present invention, the fuse is for a high voltage, the body is formed in a cylindrical shape, characterized in that the first and second wires are formed on both ends of the body.

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

In the fuse device according to the present invention, the first and second bus bars may be fixed to both ends of the fuse mounting part by a stitching method.

In the fuse device according to the present invention, the fuse mounting portion is characterized in that a plurality of support members for fixing the fuse is formed.

In addition, the fuse device according to the invention, characterized in that it further comprises a housing for housing the fuse assembly.

In the fuse device according to the present invention, the housing is provided with a locking groove, the fuse mounting portion is provided with a locking jaw, and the locking jaw is fitted into the locking groove so that the fuse assembly is mounted in the housing. It is characterized by.

In the fuse device according to the present invention, an insertion portion is provided in each of the first and second bus bars, an insertion hole is provided in the fuse mounting portion corresponding to the insertion portion, and the insertion portion is inserted into the insertion hole. Thereby the first and second bus bars are coupled to the fuse mounting portion.

In the fuse device according to the present invention, the first and second bus bars are provided with upright terminals, respectively, and the first and second lead wires are resistance-welded to the upright terminals via the support member. do.

In addition, in the fuse device according to the present invention, one side of the first and second bus bar is characterized in that the connection portion in contact with the external connection member connected to the battery pack is formed.

In addition, the manufacturing method of the fuse device according to the present invention to achieve the diffuser object is a method of manufacturing a fuse device coupled to the housing of the battery pack containing a plurality of battery cells, (a) the first and second bus bar and fuse Providing a mounting portion, (b) coupling the first and second bus bars to a fuse mounting portion, (c) mounting a fuse on the fuse mounting portion, and (d) replacing the fuse assembly formed in step (c). And mounting to the housing.

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

In the method of manufacturing a fuse device according to the present invention, the steps (b) to (d) may be performed by an automated process.

In the method of manufacturing a fuse device according to the present invention, the steps (a) to (c) are performed on a lead frame having a plurality of first and second bus bars, respectively, and the lead frame is mounted to each fuse mounting portion. The fuse assembly is provided by correspondingly cutting.

As described above, the fuse device and the method of manufacturing the same according to the present invention not only provide a fuse for a high voltage vehicle of 450V or more in a vehicle battery pack mounted on an electric vehicle or a hybrid vehicle, but also minimize the contact resistance of the fuse. The effect can be obtained.

Moreover, according to the fuse apparatus and its manufacturing method which concern on this invention, the effect that manufacture of a fuse apparatus can be implemented easily in large quantities is acquired.

Further, according to the fuse device and the manufacturing method thereof according to the present invention, the effect that replacement of the fuse device can be easily realized is also obtained.

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 unit of FIG. 1; FIG.
3 is a perspective view illustrating the rear surface of the fuse mounting unit to explain a coupling relationship between the bus bar and the fuse mounting unit illustrated in FIG. 2;
4 is a side view illustrating a state in which the bus bar illustrated in FIG. 2 is coupled to a fuse mounting unit;
5 is a perspective view illustrating a coupling relationship between a fuse mounting unit and a housing in a fuse device according to the present invention;
6 is a perspective view showing a coupling relationship between a bus bar and a connector of the 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 the vehicle battery pack 100,
8 is a partial cutaway perspective view illustrating a coupling relationship between a bus bar and a wire;
9 is a process chart for explaining a manufacturing process of the fuse device according to the present invention;
10 is a perspective view showing a step of preparing a lead frame;
11 is a perspective view illustrating a step of mounting the fuse mounting unit shown in FIG. 1;
12 is a perspective view showing the step of mounting the fuse shown in 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.

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

The fuse device according to the present invention is a fuse device coupled to a housing of a battery pack in which a plurality of battery cells are embedded, and as shown in FIGS. 1 and 2, the first bus bar 11 and the second bus bar 12. ), A fuse mounting unit 20, a fuse 30 having first and second lead wires 31 and 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 90 degrees to provide upright terminals 13. The upright terminal 13 is provided with a substantially U-shaped groove.

In addition, the first and second bus bars 11 and 12 may include insertion parts 111 and 121 and connecting parts 112 and 122. The insertion parts 111 and 121 may have fuse mounting parts 20 at both sides thereof, as shown in FIG. 2. A tooth portion 14 having a plurality of grooves formed therein for engagement with is provided. The connection part 112 of the first bus bar 11 is provided to protrude to one side as a part for electrical connection outside the vehicle fuse device, and the connection part 122 of the first bus bar 12 protrudes to approximately 'A'. It is prepared. The first bus bar 11 and the second bus bar 12 are respectively fixed to both ends of the fuse mounting unit 20 by a stitching method.

In addition, the structure of the 1st and 2nd bus bars 11 and 12 is not limited to the structure shown in FIG. 2, It can be modified according to a use.

The fuse mounting portion 20 is molded by injection, and as shown in Figure 2, the fuse mounting portion 20 is provided with a plurality of support members for supporting the inserted fuse. As the supporting member, the first and second supporting plates 21 and 22 are provided upright on both sides of the fuse mounting portion 20 in the width direction, and the fuse inserted into the first and second supporting plates 21 and 22. In order to prevent the separation of the support protrusions 23 are formed respectively. The supporting projection 23 is inclined downward to easily insert the fuse, and its end portion is made of a surface parallel to the fuse mounting portion 20 to fix the inserted fuse.

In addition, the fuse mounting portion 20 is provided with a pair of support plates 24 upright on both sides in the longitudinal direction to support the wires 31 and 32 of the inserted fuse 30, each support plate 24 An approximately V-shaped groove is provided in correspondence with the position of the U-shaped groove formed in the upright terminal 13.

A plurality of guide protrusions 25 are provided in the lower portion of the fuse mounting portion 20 in the width direction, and a locking jaw 26 is provided in a portion of the guide protrusions 25 formed at both sides thereof. In addition, an insertion hole 27 is provided outside the pair of supporting plates 24 to a depth corresponding to the length of the insertion portions 111 and 121 to insert the first and second bus bars 11.12, respectively. Inside the insertion hole 27, a configuration corresponding to the toothed portions 14 of the first and second bus bars 11 and 12 is provided, and the first and second bus bars 11 and 12 are removed after insertion. Can be prevented.

In addition, as shown in FIG. 2, a holding protrusion 28 for further fixing the inserted fuse 30 is provided inside the pair of support plates 24.

Coupling of the first and second bus bars 11 and 12 and the fuse mounting unit 20 includes a tooth 14 provided at each of the first and second bus bars 11 and 12. Each of the insertion holes 27 is easily realized by simple insertion.

After that, the fuse 30 having the first and second lead wires 31 and 32 is mounted to the fuse 30.

Mounting of the fuse 30 inserts the fuse body between the first support plate 21 and the second support plate 22, and connects the first and second lead wires 31 and 32 to the U-shape of the upright terminal 13, respectively. Is inserted into the groove of the groove and the V-shaped groove of the holding plate 24. Thereafter, resistance welding is performed on the upright terminals 13 and the first and second lead wires 31 and 32 provided on the first and second bus bars 11 and 12, respectively, to minimize the contact resistance. In the present invention, the upright terminal 13 and the first and second lead wires 31 and 32 have been described as resistance welding. However, the present invention is not limited thereto, and ordinary electrical welding can be applied.

By mounting the fuse 30 as described above, a fuse assembly as shown in FIG. 1 is completed. The completed fuse assembly is mounted in a housing 40 as shown in FIGS. 1 and 5.

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

As shown in FIGS. 1 and 5, the housing 40 includes a first inserting portion 41 into which the first bus bar 11 is inserted and a connection portion 112 of the first bus bar 11 outside the housing. The first guide jaw 42 and the plurality of second guide jaw 43 and the second bus bar 12 to guide the plurality of guide protrusions 25 when the fuse mounting portion 20 is inserted into After the second insertion part 44 to be inserted and the fuse assembly are mounted in the housing 40, a locking groove 45 formed to engage and secure the locking jaw 26 is provided to prevent the fuse assembly from being separated. . In addition, the outside of the first insertion part 41 functions as a locking protrusion fixed to the housing of the battery pack when the vehicle fuse device according to the present invention is mounted on the vehicle battery pack 100.

That is, in the vehicle fuse device according to the present invention, as shown in FIGS. 1 and 5, the fuse assembly may be disposed on the first insertion part 41, the first and second guide jaws 42 and 43 provided in the housing 40. It fits together and it is completed by engaging the latching jaw 26 with the locking groove 45. FIG.

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

The vehicle fuse device formed as described above is mounted to, for example, a battery pack as shown in FIGS. 6 and 7.

FIG. 6 is a perspective view illustrating a coupling relationship between a bus bar and a connector of a vehicle fuse device according to the present invention, FIG. 7 is a perspective view illustrating a state in which the vehicle fuse device according to the present invention is mounted on a vehicle battery pack 100, and FIG. 8. Is a partially cutaway perspective view illustrating the coupling relationship between the bus bars and the wiring.

As shown in FIG. 6, in the vehicle fuse device according to the present invention, the first bus bar 11 is fitted to the connection terminal 51 of the connector 50 provided in the vehicle battery pack 100. 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 wire guide 46 for guiding the insertion of the wire 60, and the wire 60 is inserted through the wire guide 46 to connect with the second bus bar 12. do. The connection of the second bus bar 12 and the wiring 60 is realized by a conventional electrical connection method.

Next, a manufacturing process of the vehicle fuse device according to the first embodiment of the present invention will be described with reference to FIG. 9.

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

First, as shown in FIG. 2, first and second bus bars 11 and 12 and a 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 provided by bending 90 degrees, and the fuse mounting portion 20 is molded by injection.

Next, as shown in FIG. 3, the first and second bus bars 11 and 12 are coupled to the fuse mounting unit 20 (S20). As shown in FIG. 3, the coupling between the first and second bus bars 11 and 12 and the fuse mounting unit 20 may include insertion holes provided outside the pair of supporting plates 24 of the fuse mounting unit 20. 27 is easily realized by inserting the insertion portions 111 and 121 of the first and second bus bars 11 and 12.

Thereafter, the fuse 30 having the first and second lead wires 31 and 32 is mounted on the fuse mounting unit 20 (S30). The step S30 also includes a step of performing resistance welding on the upright terminals 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 vehicle fuse device as shown in FIG. 6 is completed by mounting the fuse assembly formed in the step S30 to the housing 40 as shown in FIGS. 1 and 5 (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.

10 is a perspective view illustrating a step of preparing a lead frame, FIG. 11 is a perspective view illustrating a step of mounting the fuse mounting unit illustrated in FIG. 1, and FIG. 12 is a perspective view illustrating a step of mounting the fuse illustrated in FIG. 1. .

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

In addition, the teeth 14 having a plurality of grooves are formed on both sides of the first and second bus bars 11 and 12 for molding with the fuse mounting part 20 to be described later.

In addition, although FIG. 10 illustrates a structure in which three first and second bus bars 11 and 12 are provided, the structure is not limited thereto, and a plurality of bus bars 11 and 12 may be provided.

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

Since the fuse mounting portion 20 is the same except for the portion of the insertion hole 27 described in the first embodiment, the repeated description thereof will be omitted. That is, in the second embodiment, the combination of the first and second bus bars 11 and 12 and the fuse mounting unit 20 is realized by insert molding. That is, the teeth 14 formed in each of the first and second bus bars 11 and 12 are molded so as to be inserted into the fuse mounting part 20, thereby forming the first and second bus bars 11 and 12. The fuse mounting portion 20 is mounted.

12, the fuse 30 having the first and second lead wires 31 and 32 is mounted on the fuse mounting part 20, and the first and second bus bars 11, Resistance welding is performed to the upright terminals 13 and the first and second lead wires 31 and 32 respectively provided in 12).

In this way, the fuse assembly is completed by mounting the fuse 30. The completed 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, the vehicle fuse device 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 vehicle fuse device and the manufacturing method thereof according to the present invention, a vehicle fuse device applied to 450V or more can be provided.

11: first bus bar
12: second bus bar
20: fuse mounting portion
30: fuse
40: Housing
50: connector

Claims (14)

A fuse device in which a plurality of battery cells are coupled to a housing of an embedded battery pack,
A fuse assembly having fuses provided with first and second bus bars and first and second lead wires electrically connected to the battery pack,
And the first and second lead wires are inserted into and fixed to the first and second bus bars. The method of claim 1,
The fuse is for high voltage, the body is formed in a cylindrical shape, the fuse device, characterized in that the first and second wires are formed on both ends of the body. The method of claim 1,
And the fuse assembly further comprises a fuse mount to which the first and second bus bars are coupled. The method of claim 3,
And the first and second bus bars are fixed to the both ends of the fuse mounting part by a stitching method. The method of claim 3,
A fuse device, characterized in that the fuse mounting portion is formed with a plurality of support members for fixing the fuse. The method of claim 3,
And a housing for receiving the fuse assembly. The method according to claim 6,
A fuse groove is provided in the housing, a fuse jaw is provided in the fuse mounting portion, and the fuse assembly is mounted to the housing by fitting the catch jaw into the catch groove. 5. The method of claim 4,
Inserts are provided in the first and second bus bars, respectively.
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. The method of claim 5,
Upright terminals are provided in the first and second bus bars, respectively.
And the first and second lead wires are resistance welded to the upright terminal via the support member. 10. The method according to claim 8 or 9,
One side of the first and second bus bar, the fuse device, characterized in that the contact portion is formed in contact with the external connection member connected to the battery pack. A manufacturing method of a fuse device coupled to a housing of a battery pack having a plurality of battery cells embedded therein,
(a) providing first and second bus bars and fuse mounts,
(b) coupling the first and second bus bars to a fuse compartment;
(c) mounting a fuse to the fuse mounting unit;
(d) mounting the fuse assembly formed in the step (c) to the housing. 12. The method of claim 11,
And in the step (c), each lead wire of the fuse is joined to the first and second bus bars by resistance welding. 12. The method of claim 11,
The method of manufacturing a fuse device, characterized in that the steps (b) to (d) is performed by an automated process. 12. The method of claim 11,
Steps (a) to (c) are each executed on a lead frame having a plurality of first and second bus bars, and the fuse assembly is prepared by cutting the lead frame corresponding to each fuse insert. Method for manufacturing a fuse device characterized in that.

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