KR102415527B1 - Intelligent battery sensor and method for manufacturing the same - Google Patents

Abstract

The intelligent battery sensor according to the present invention includes a clamp member connected to one pole of a battery, a shunt resistor joined while in surface contact with at least a portion of the clamp member, and a voltage between a plurality of contact points in the shunt resistor, the plurality of A circuit board for measuring at least one of a current flowing between the contact points and a temperature at the plurality of contact points; a housing for accommodating the clamp member, the shunt resistor and the circuit board; It consists of a terminal member that is fastened to the fixed part.

Description

Intelligent battery sensor and method for manufacturing the same

The present invention relates to an intelligent battery sensor and a method for manufacturing the same.

The speed of development of various vehicle technologies that enhance driver's safety and convenience is accelerating. This development is progressing through the electronicization of parts and technologies. Accordingly, the importance of a battery serving as a main power source of various electronic devices is also increasing.

As such, as the importance of batteries in vehicles is highlighted, research and development of so-called Intelligent Battery Sensors (IBS) is increasing. IBS monitors the internal health of the battery to ensure that the various devices associated with the battery operate optimally. Therefore, IBS can be seen as a key component in diagnosing and operating various devices related to the generation, distribution and charging of energy in a vehicle.

Typically, the IBS mounted on the negative terminal of the battery operates by receiving power from the battery. Its main function is to measure the current, voltage, and temperature of a vehicle battery in real time, and predict the state of the battery based on the measured data. IBS provides these measurement results to the Electronic Control Unit (ECU), which helps various devices connected to the battery to operate properly.

Such an IBS generally includes a clamp member of a battery, a shunt resistance, a terminal member and a circuit board. At this time, the circuit board has a structure in which current, voltage, etc. are measured at both ends of the shunt resistor when the current leaked from the negative electrode of the battery sequentially flows to the clamp member, the shunt resistor, and the terminal member.

However, when clamping and bolting the post of the battery with the clamp member, the IBS may be damaged by the rotational force generated when the nut is rotated with a tool or equipment. That is, the clamp member itself may be deformed by the rotational force, and the clamp member may be separated from the housing of the IBS or the shunt resistor.

Since this problem makes it impossible to perform its function normally due to damage to the IBS itself, a method to fundamentally prevent this problem is required.

Korean Patent Publication No. 10-1890618 (Registered on August 16, 2018)

The technical problem to be achieved by the present invention is that the clamp member is deformed by the fastening force when the clamp member is bolted to the battery post and fixed by insert injection in a state in which the clamp member and the shunt resistor are bonded to each other during housing molding. or to prevent disconnection from the shunt resistor.

Another technical problem to be achieved by the present invention is to omit a complicated assembly process or a connection process by the insert injection, and to securely seat the assembly of the clamp member and the shunt resistor in the housing.

Another technical problem to be achieved by the present invention is to prevent a problem in that the shunt resistor is exposed to the outside and is oxidized and damaged by contact with air.

The technical problems of the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art from the following description.

Intelligent battery sensor according to an embodiment of the present invention for achieving the above technical problem, a clamp member connected to one pole of the battery; a shunt resistor joined while making surface contact with at least a portion of the clamp member; a circuit board for measuring at least one of a voltage between a plurality of contact points in the shunt resistor, a current flowing between the plurality of contact points, and a temperature at the plurality of contact points; a housing accommodating the clamp member, the shunt resistor, and the circuit board; and a terminal member coupled to a portion of the shunt resistor exposed to the outside of the housing.

The clamp member and the shunt resistor may be joined to each other by a brazing method.

The clamp member and the shunt resistor are received in the housing by being insert-injected together.

The circuit board includes a connection pin electrically connectable between the circuit board and the vehicle controller, and when the insert is injected, the connection pin is inserted-injected together with the clamp member and the shunt resistor.

The housing includes a through hole formed at a position where the clamp member and the shunt resistor are joined to hold the clamp member and the shunt resistor from the outside when the insert is injected.

The housing may include a body portion for protecting the clamp member, the shunt resistor, and the circuit board by surrounding and protecting the circuit board; a socket unit for accommodating the connection pin; and a housing cover that closes the body portion from the outside.

The housing cover may be coupled to the body by laser fusion.

The housing cover includes a watertight protrusion that protrudes downwardly from the housing cover toward the body, and the body includes a recess formed to correspond to the watertight protrusion.

A vent groove extending along a direction in which the watertight protrusion protrudes is formed on an inner surface of the watertight protrusion opposite the recess to prevent liquid or dust from entering the housing while preventing air between the inside and the outside of the housing is allowed to communicate.

At least one seating rib protruding inwardly so that the circuit board can be spaced apart from the lower surface of the body part is formed in the body part.

The circuit board further includes a plurality of connection pins electrically connecting the plurality of contact points of the shunt resistor, and one end of the plurality of connection pins is in contact with the plurality of contact points of the shunt resistor and is connected to the plurality of connection pins. The other end is fixed to the circuit board.

The plurality of contact points may be three or more points.

One end of the plurality of connection pins is welded or press-fit-coupled to a plurality of contact points of the shunt resistor, and the other end of the plurality of connection pins is press-fit-coupled to the circuit board.

The exposed portion of the shunt resistor and the terminal member are fastened by bolt-nut coupling.

The bolt used in the bolt-nut coupling includes a bolt head and a screw coupled to the nut, and is connected to the screw so that the bolt can be fixed while press-fitting the shunt resistor during the bolt-nut coupling. It further includes at least one protrusion protruding in the radial direction on the inner surface side of the bolt head.

The shunt resistor includes a bolt fastening hole to which the bolt is fastened, and at least one seating groove is formed around the bolt fastening hole in the shunt resistor to correspond to the at least one protrusion.

The terminal member extends to the chassis of the vehicle and is connected to a cable serving as a grounding line, and a fixing member for fixing the cable to the chassis of the vehicle is formed at the extended end of the cable.

The terminal member includes a stopper protruding or bent from the terminal member to engage the exposed portion of the shunt resistor to prevent relative rotation between the shunt resistor and the terminal member during the bolt-nut coupling.

The fixing member includes a stopper protruding or bent from the fixing member so that the fixing member does not rotate when it is coupled to a chassis of the vehicle by a fastener.

The shunt resistor may include an extension formed extending from one edge of the shunt resistor to prevent the shunt resistor from being separated from the housing after the insert injection.

According to an embodiment of the present invention for achieving the above technical problem, there is provided a manufacturing method for manufacturing an intelligent battery sensor, comprising: bonding the clamp member to the shunt resistor while in surface contact with the shunt resistor; insert-injecting the joined clamp member and the shunt resistor to generate the housing; connecting a plurality of contact points in the shunt resistor and the circuit board by a plurality of connection pins; and fastening the exposed portion of the shunt resistor to the terminal member.

The bonding may include bonding the clamp member and the shunt resistor to each other by a brazing method.

The generating of the housing may include insert-injecting a connection pin electrically connectable between the circuit board and the vehicle controller together with the clamp member and the shunt resistor during the insert-injection.

The connecting by the plurality of connecting pins may include welding or press-fit coupling one end of the plurality of connecting pins to a plurality of contact points of the shunt resistor; and press-fit coupling the other ends of the plurality of connection pins to the circuit board.

The manufacturing method further includes the step of closing the housing by laser welding a housing cover of the housing in a state in which the clamp member, the shunt resistor, and the circuit board are accommodated in the housing.

The fastening includes fastening the exposed portion of the shunt resistor and the terminal member by bolt-nut coupling.

According to the intelligent battery sensor according to the present invention, it is possible to minimize the deviation of the clamp member from the shunt resistance within the deformation of the clamp member due to the clamping force of the clamp member, thus improving the durability and stability of the intelligent battery sensor.

According to the intelligent battery sensor according to the present invention, since insert injection is performed in a state in which the clamp member and a part of the shunt resistor are joined, there is no need to insert a separate insulating material in the spaced part between the two.

In addition, according to the intelligent battery sensor according to the present invention, since the connection pins of the circuit board as well as the clamp member and the shunt resistor can be inserted and injected together, the connection pins are firmly seated in the housing and the intelligent battery sensor is manufactured at the same time. The process can be further simplified.

1A is a perspective view illustrating an intelligent battery sensor according to an embodiment of the present invention.
FIG. 1B is a perspective view showing a part except for a cable and a fixing member; FIG.
FIG. 1C is a perspective view with the housing removed from FIG. 2B to show the internal structure.
2A is a perspective view illustrating a cable connected to a terminal member and a fixing member;
FIG. 2B is an exploded perspective view of FIG. 2A ;
2C is a view showing a form of fixing a fixing member connected to a cable to a chassis of a vehicle;
3A is a perspective view of the intelligent battery sensor as shown in FIG. 1C when the housing is removed and viewed from another angle.
3B is a perspective view illustrating a circuit board.
3C is a view showing an embodiment in which connection pins and a shunt resistor are coupled by press fit.
4A is a perspective view of the housing as viewed in a direction in which a connection pin is shown.
4B is a plan view illustrating the body part after the housing cover is removed from the housing.
Figure 4c is a plan view additionally showing the connection pin and the connection pin in Figure 4b.
4D is a plan view further illustrating the circuit board in FIG. 4C .
Figure 4e is a perspective view of the inside of the body portion cut off in Figure 4d.
4F is a plan view illustrating a state in which the body portion is closed with a housing cover in FIG. 4D .
5A is a perspective view illustrating a shape in which the housing cover closes the body.
5B is a perspective view of the housing cover as viewed from the inner side.
Figure 5c is a partial perspective view showing an enlarged shape of the watertight protrusion in the housing cover.
6A is a perspective view showing a through hole through which a junction end of a shunt resistor can be accessed from the outside of the body of the housing.
6B is a perspective view illustrating a through hole through which a step portion of the clamp member can be accessed from the outside of the body portion of the housing.
7A is a front view showing a state in which the exposed part of the shunt resistor and the terminal member are fastened by bolt-nut coupling.
Figure 7b is a front view showing only the bolts in Figure 7a.
7C is a plan view illustrating a shunt resistor provided with a seating groove around a bolt fastening hole.
8 is a plan view illustrating a shape of a shunt resistor and a housing according to another embodiment of the present invention.

Advantages and features of the present invention and methods of achieving them will become apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in a variety of different forms, and only these embodiments allow the disclosure of the present invention to be complete, and common knowledge in the technical field to which the present invention belongs It is provided to fully inform the possessor of the scope of the invention, and the present invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout.

Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used with the meaning commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, terms defined in a commonly used dictionary are not to be interpreted ideally or excessively unless clearly defined in particular.

The terminology used herein is for the purpose of describing the embodiments and is not intended to limit the present invention. In this specification, the singular also includes the plural unless otherwise specified in the phrase. As used herein, “comprises” and/or “comprising” does not exclude the presence or addition of one or more other components in addition to the stated components.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1A is a perspective view showing the intelligent battery sensor 100 according to an embodiment of the present invention, FIG. 1B is a perspective view showing a part except for the cable 55 and the fixing member 54, and FIG. 1C is It is a perspective view with the housing 40 removed in FIG. 1B to show the internal structure.

1A to 1C , the intelligent battery sensor 100 includes a clamp member 10 , a shunt resistor 20 , a circuit board 30 , and the components 10 , 20 , and 30 . The housing 40 and the shunt resistor 20 may be configured to include a fastening member, for example, a terminal member 50 fastened by a bolt 60 . The terminal member 50 may be electrically connected to the chassis of the vehicle through the cable 55 and the fixing member 54 .

One end of the clamp member 10 is connected to one pole of a vehicle battery (not shown). For example, the clamp member 10 is connected to the negative electrode of the battery, and serves to fix the intelligent battery sensor 100 . The clamp member 10 may include a flange 13 extending from the clamp member 10 , and a step portion 15 for bonding with the shunt resistor 20 is formed at the distal end of the flange 13 . do. Accordingly, the flange 13 and the step 15 are approximately parallel but not on the same plane. Accordingly, when the step portion 15 is joined to the shunt resistor 20 , the flange 13 may be spaced apart from the shunt resistor 20 without contacting it.

The shunt resistor 20 , particularly the joint end 25 of the shunt resistor 20 , is joined to each other while in surface contact with the clamp member 10 , in particular the stepped part 15 . Specifically, the clamp member 10 and the shunt resistor 20 may be joined to each other by a brazing method. Such brazing refers to a method of joining the clamp member 10 and the shunt resistor 20 using a base material to be joined, that is, a filler metal having a lower melting point than the clamp member 10 and the shunt resistor 20 .

The circuit board 30 may measure the current, voltage, or temperature of the shunt resistor 20 . Specifically, the circuit board 3 may measure at least one of a voltage generated between a plurality of contact points in the shunt resistor 20 , a current flowing between the plurality of contact points, or a temperature at the plurality of contact points. To this end, an integrated circuit (IC) may be surface mounted (SMT) on the circuit board 30 .

The housing 40 accommodates the clamp member 10 , the shunt resistor 20 , and the circuit board 30 . Preferably, the clamp member 10 and the shunt resistor 20 may be accommodated in the housing 40 by being insert-injected together. For example, the housing 40 may be molded by injecting a melt of a synthetic resin material into a certain mold. At this time, the clamp member 10 and the shunt resistor 20 bonded thereto are inserted together therein. It can be injection molded and this is called insert injection. Since the housing 40 may be heated to an arbitrary temperature or higher for the soldering operation of the circuit board 30 later, it is preferable to be made of a material having excellent heat resistance. (PPS) resin may be used, and any synthetic resin material capable of injection molding and reflow operation may be used.

However, in order to maintain the flow of current flowing from the clamp member 10 to the shunt resistor 20 , the clamp member 10 and the shunt resistor 20 may be in contact with only a part of the clamp member 10 and insulated in the remaining area. In addition, in this way, by reducing the contact area between the shunt resistor 20 and the clamp member 10, the amount of brazing welding used in the joining process is reduced, and the material cost and the time required for the process can be reduced. As shown in FIG. 1C , only the stepped portion 15 of the clamp member 10 is in contact with the shunt resistor 20 and the flange 13 is spaced parallel to the shunt resistor 20 . When the insert injection is performed in this state, the material of the insulating housing 40 is filled in the spaced gap between the clamp member 10 and the shunt resistor 20 and the terminal member 30 . There is no need to insert a separate insulating material.

In addition, the circuit board 30 has a connection pin 31 for electrically connecting the circuit board 30 and a vehicle controller (not shown) such as an ECU (Electronic Control Unit). At the time of insert injection, the connection pin 31 may be inserted-injected together with the clamp member 10 and the shunt resistor 20, through which the connection pin 31 is attached to the housing 40 without a separate process. can be made to be anchored against the

The vehicle controller is connected to the circuit board 30 through a connection pin 31, so that a generator based on a signal measured and output from the circuit board 30, that is, a signal for current, voltage, and temperature measurement values of the vehicle battery. It is possible to control the operation of other devices (not shown), such as. In particular, when the capacity of the vehicle battery is insufficient according to the current, voltage, and temperature of the vehicle battery measured by the vehicle battery sensor of the present invention, the vehicle controller operates the generator to charge the vehicle battery power, and when the charging capacity is filled, the generator control to prevent discharging and overcharging of the vehicle battery by stopping the vehicle.

The terminal member 50 may be coupled to a portion 22 of the shunt resistor 20 exposed to the outside of the housing 40 through a coupling member. In this case, the exposed portion 22 of the shunt resistor 20 and the terminal member 50 may be securely fastened by bolt-nut coupling.

At this time, the terminal member 50 is protruded or bent from the terminal member 50 to prevent relative rotation between the shunt resistor 20 and the terminal member 50 when the bolt-nut is coupled. and a stopper 51 that engages the exposed portion 22 of the shunt resistor 20 .

2A is a perspective view showing the cable 55 and the fixing member 54 connected to the terminal member 50, and FIG. 2B is an exploded perspective view of FIG. 2A.

Referring to FIGS. 2A and 2B , the cable 55 is composed of a copper wire and a sheath (insulation material), is a conductor that transmits electrical signals, and the fixing member 54 is connected to the cable 55 and is connected to the chassis (Fig. It is assembled with 5) of 2c. Both ends of the cable 55 are respectively connected to the fastening part 501 of the terminal member 50 and the fastening part 541 of the fixing member 54, respectively, so that from the terminal member 50 to the fixing member 54 as a whole, the electrical is connected to Accordingly, the terminal member 50 , the cable 55 , and the fixing member 54 may be connected to the chassis 5 of the vehicle while serving as a grounding wire. Therefore, when viewed as a whole, the current flowing out from the negative post of the battery sequentially passes through the clamp member 10 , the shunt resistor 20 , the terminal member 50 , the cable 55 , and the fixing member 54 to the chassis 5 of the vehicle. ), that is, it flows into the ground.

FIG. 2C is a view showing a form of fixing the fixing member 54 connected to the cable 55 to the chassis 5 of the vehicle. The bolt fastening hole 56 of the fixing member 54 is coupled to the screw hole 6 formed in the chassis 5 of the vehicle by a fastener (not shown). In this coupling process, a stopper 52 is protruded or bent so that the fixing member 54 does not rotate. To this end, the stopper 52 may be fitted into the groove 8 formed on one side of the chassis 5 of the vehicle.

3A is a perspective view of the intelligent battery sensor 100 as shown in FIG. 1C with the housing 40 removed and viewed from another angle. Referring to FIG. 3A , the shunt resistor 20 bonded to the stepped portion 15 of the clamp member 10 is electrically connected to the circuit board 30 and the plurality of connection pins 32a, 32b, and 32c at a plurality of contact points. is connected to Specifically, one end of the plurality of connection pins 32a, 32b, and 32c is in contact with the plurality of contact points of the shunt resistor 20 and the other ends of the plurality of connection pins 32a, 32b, and 32c are connected to the circuit board 30 ) is fixed to The number of the plurality of contact points and the connecting pins is the same as each other, and the number is two or more. For example, two contact points may be used for the purpose of measuring a current or voltage flowing across them, and the other contact point may be used for the purpose of grounding.

In the present invention, the number of the contact points is exemplified as three, but it is not necessarily limited thereto, and the number may be selected as two, three, or more according to the intention of the designer.

Specifically, one end of the plurality of connection pins 32a, 32b, and 32c may be welded by solder at a plurality of contact points of the shunt resistor 20, and of the plurality of connection pins 32a, 32b, and 32c The other end may be press-fit coupled to the circuit board 30 .

Referring to FIG. 3B , the circuit board 30 includes a plurality of connection pins 31 for electrically connecting to a vehicle controller (not shown) and a plurality of contact points of the shunt resistor 20 . of the connecting pins 32a, 32b, and 32c. At this time, since the connection pin 31 is fixed to the housing 40 by insert injection as described above, the other end may be coupled to the circuit board 30 by press-fitting. In addition, one end, that is, the bent end of the connecting pins 32a, 32b, 32c, is connected to the shunt resistor 20 by welding, while the opposite end may be connected to the circuit board 30 by press fit. . However, in addition to the press fit as described above, snap-fit or other coupling methods are not excluded.

In addition, in FIGS. 3A and 3B, the bent ends of the connection pins 32a, 32b, and 32c have been described as being connected to the shunt resistor 20 by welding, but the present invention is not limited thereto. Like the coupling, as shown in FIG. 3C , it may be coupled to the shunt resistor 20 by press-fitting. In this case, while there is an advantage in that the welding process is omitted, a process of machining a coupling groove in the shunt resistor 20 for press-fit coupling will be further required.

4A is a perspective view of the housing 40 as viewed in the direction in which the connection pin 31 is seen. The housing 40 can be divided into several sections, for example, a body portion 42 , a socket portion 43 and a housing cover 44 . The body portion 42 is an accommodation space that surrounds and protects the clamp member 10 , the shunt resistor 20 , and the circuit board 30 . One side of the body portion 42 may be open, and may be closed by the housing cover 44 after accommodating other components. In this case, the housing cover 44 may be coupled to the body 42 by laser welding. In addition, the socket part 43 accommodates the connection pins 31 which are input/output terminals of the circuit board 30 and has a structure into which an external connector can be inserted.

4B is a plan view illustrating the body portion 42 with the housing cover 44 removed from the housing 40 . The body portion 42 may be divided into a portion formed by insert injection and a space for accommodating the remaining circuit board 30 . A partition wall 423 may be formed between the portion formed by the insert injection and the accommodation space, and one or more windows are provided in the partition wall 423 for electrical connection between the circuit board 30 and the shunt resistor 20 . ) (424, 425) are formed. It has a structure that allows communication between the accommodation space and the shunt resistor 20 through these windows 424 and 425 . In addition, a plurality of seating ribs 422 protruding inwardly so that the circuit board 30 can be spaced apart from the lower surface of the body portion 42 are formed on the partition wall 423 of the body portion 42 .

FIG. 4C is a plan view additionally illustrating the connection pins 32a, 32b, and 32c and the connection pin 31 in FIG. 4B. Referring to FIG. 4C , the connecting pin 31 is integrally coupled to the body 42 of the housing 40 by insert injection, and the connecting pins 32a, 32b, and 32c are welded to the shunt resistor 20 by welding. is connected by

FIG. 4D is a plan view additionally showing the circuit board 30 in FIG. 4C , and FIG. 4E is a perspective view of the body part 42 in FIG. 4D , as viewed from the inside. Referring to FIGS. 4D and 4E , the end portions of the connection pins 32a , 32b , 32c and the connection pin 31 shown in FIG. 4C are coupled to the circuit board 30 by press-fitting. At this time, since the circuit board 30 is seated while being in contact with the plurality of seating ribs 422 , they are spaced apart so as not to come into direct contact with the partition wall 423 of the body portion 42 . Therefore, it is possible to prevent interference between the barrier rib 423 such as electronic components, wires, etc. mounted on the surface of the circuit board 30 , and when the circuit board 30 is seated on the body portion 42 , the connection pins 32a and 32b , 32c) and the end of the connection pin 31 can be press-fit coupled to the circuit board 30 at an appropriate position, so that the electrical connection can be ensured. In addition, it is possible to prevent the connection pins 32a, 32b, 32c or the connection pins 31 from being damaged while the circuit board 30 is seated on the body portion 42 .

FIG. 4f is a plan view illustrating a state in which the body portion 42 is closed with the housing cover 44 in FIG. 4d . In FIG. 4D , after the circuit board 30 is installed, the body part 42 is in a closed state by coupling the housing cover 44 to the body part 42 . Such bonding can be achieved, for example, by laser fusion.

5A is a perspective view illustrating a shape in which the housing cover 44 closes the body portion 42 , FIG. 5B is a perspective view of the housing cover 44 as viewed from the inner side, and FIG. 5C is a watertight protrusion in the housing cover 44 . It is a partial perspective view showing an enlarged shape of (441).

5A to 5C , the housing cover 44 includes a watertight protrusion 441 protruding downward from the housing cover 44 toward the body 42 . Correspondingly, a recess 421 formed to correspond to the watertight protrusion 441 is formed in the body portion 42 .

A vent groove 442 extending in a direction in which the watertight protrusion 441 protrudes is formed on an inner surface of the watertight protrusion 441 facing the recess 421 . Through this configuration, when the housing cover 44 is coupled to the body portion 42 by laser fusion, the inside of the housing 40 is prevented from entering the liquid or dust from the outside. and air communication between the outside and the outside is allowed. This is to prevent thermal expansion and damage of the housing 40 by forming a channel through which the heated and expanded air in the housing 40 can flow out of the housing 40 .

6A is a perspective view showing a through hole 41a through which the junction end 25 of the shunt resistor 20 can be accessed from the outside of the body portion 42 of the housing 40, and FIG. 6B is a perspective view of the housing 40 It is a perspective view showing a through hole 41b that can access the stepped portion 15 of the clamp member 10 from the outside of the body portion 42 .

As described above, forming the through-holes 41a and 41b on both sides of the body 42 of the housing 40 at the positions where the clamp member 10 and the shunt resistor 20 are joined is mutually beneficial during insert injection. A space is allowed to firmly grip the clamp member 10 and the shunt resistor 20 that are joined from the outside. If the assembly of the clamp member 10 and the shunt resistor 20 moves during insert injection, a defect may occur, so that the assembly is accurately held in place.

7A is a front view showing a state in which the exposed portion 22 of the shunt resistor 20 and the terminal member (not shown in FIG. 7A) are fastened by a bolt 60-nut 65 coupling, and FIG. 7B is It is a front view showing only the bolt 60 in FIG. 7A. 7A and 7B , the bolt 60 used for coupling the bolt-nut includes a bolt head 61 and a screw 62 coupled to the nut 65 .

In addition, the bolt 60 is the inner surface of the bolt head 61 connected to the screw 62 so that the bolt 60 can be fixed while the shunt resistor 20 is press-fitted during the bolt-nut coupling. It may further include at least one protrusion 63 protruding in the radial direction to the side. These protrusions 63 may be formed to protrude in a radial direction at every predetermined angle, that is, radially. Since the protrusion 63 can plastically deform the shunt resistor 20 made of a relatively soft material due to the fastening force when the bolt 60 is fastened with the nut 65, the bolt 60 and the nut 65 can be plastically deformed. ) can prevent unintentional loosening after fastening.

Alternatively, as shown in FIG. 7C , at least one seating groove 24 may be additionally provided around the bolt fastening hole 23 formed in the shunt resistor 20 . The seating groove 24 may be formed in a shape and number corresponding to the at least one protrusion 63 . When the shunt resistor 20 and the terminal member 50 are fastened with the bolt 60 through the fastening device, the protrusion 63 of the bolt 60 press-fits the shunt resistor 20 . At this time, the bolt 60 and the shunt resistor 20 are not fastened at the correct positions, and their positions are slightly misaligned or the press-fitting is not performed properly, so a defect may occur. According to the combination of the protrusion 63 of the bolt 60 and the seating groove 24 of the shunt resistor 20, the advantage of fundamentally eliminating such defects is provided.

8 is a plan view illustrating the shapes of the shunt resistor 20 and the housing 40 according to another embodiment of the present invention. After the shunt resistor 20 is securely mounted in the housing 40 by insert injection, the shunt resistor 20 should not be separated from the housing 40 . However, due to the structure in which a part of the shunt resistor 26 is exposed to the outside of the housing 40 for fastening with the terminal member 50, if there is some defect in the insert injection, the shunt resistor 26 will remain in the housing even after the insert injection. The problem of escaping from (40) may arise.

In consideration of this, the shunt resistor 20 is formed extending from one edge 27 to prevent the shunt resistor 20 from being separated from the housing 40 after the insert injection. may include more. Since this extended part 26 is protruded and seated inside the housing 40 after insert injection, even if the shunt resistor 20 is pulled to the right of FIG. 8 , the shunt resistor 20 is It is not separated from the housing (40).

The structure and function of the intelligent battery sensor 100 according to embodiments of the present invention have been described in detail above. Hereinafter, an embodiment of a manufacturing method for manufacturing such an intelligent battery sensor 100 will be described. The manufacturing method for manufacturing the intelligent battery sensor 100 according to an embodiment of the present invention may largely include a bonding step, a housing creation step, a pin connection step, and a terminal fastening step.

In the bonding step, the clamp member 10 is bonded while making surface contact with the shunt resistor 20 . In this case, the bonding between the clamp member 10 and the shunt resistor 20 may be made by a brazing method.

In the housing creation step, the housing 40 is created through insert injection of the joined clamp member 10 and the shunt resistor 20 . In this housing creation step, the connection pin 31 that electrically connects the circuit board 30 and the vehicle controller together with the clamp member 10 and the shunt resistor 20 may be insert-injected. .

In the pin connection step, a plurality of contact points in the shunt resistor 20 and the circuit board are connected by a plurality of connection pins 32a, 32b, and 32c. Specifically, the pin connection step includes welding or press-fit coupling one end of the plurality of connection pins 32a, 32b, and 32c to a plurality of contact points of the shunt resistor 20, and the plurality of connection pins 32a , 32b, 32c) may include the step of press-fit coupling the other end to the circuit board (30).

In addition, in the terminal fastening step, the portion 22 of the shunt resistor 20 exposed to the outside of the housing and the terminal member 50 are fastened by a fastener. Specifically, the fastening method may be a bolt-nut combination.

Additionally, in a state in which the clamp member 10 , the shunt resistor 20 , and the circuit board 30 are accommodated in the housing 40 , the housing cover 44 of the housing 40 is laser fused to the By closing the housing, the manufacturing process of the intelligent battery sensor 100 can be finished.

Although the embodiments of the present invention have been described above with reference to the accompanying drawings, those of ordinary skill in the art to which the present invention pertains can realize that the present invention can be embodied in other specific forms without changing its technical spirit or essential features. you will be able to understand Therefore, it should be understood that the embodiments described above are illustrative in all respects and not restrictive.

10: clamp member 13: flange
15: step part 20: shunt resistor
21a, 21b, 21c: plurality of contact points 22: exposed portion
23, 53, 56: bolt fastening hole 24: seating groove
25: abutment end 26: extension
30: circuit board 31: connection pin
32a, 32b, 32c: Connection pin 40: Housing
41: through hole 42: body part
421: recess 422: seating rib
423: bulkhead 424, 425: window
43: socket part 44: housing cover
441: watertight projection 442: vent groove
50: terminal member 51, 52: stopper
54: fixing member 55: cable
60: bolt 61: bolt head
62: screw 63: protrusion
65: nut 100: intelligent battery sensor

Claims (26)

a clamp member connected to one pole of the battery;
a shunt resistor joined while making surface contact with at least a portion of the clamp member;
a circuit board for measuring at least one of a voltage between a plurality of contact points in the shunt resistor, a current flowing between the plurality of contact points, and a temperature at the plurality of contact points;
a housing accommodating the clamp member, the shunt resistor, and the circuit board; and
a terminal member coupled to a portion of the shunt resistor exposed to the outside of the housing;
the clamp member and the shunt resistor are accommodated in the housing by being insert-injected together;
The housing is
a body part surrounding and protecting the clamp member, the shunt resistor, and the circuit board; and
and a housing cover that closes the body part from the outside;
The housing cover includes a watertight protrusion protruding downward from the housing cover toward the body,
The body portion includes a recess formed to correspond to the watertight projection,
A vent groove extending along a direction in which the watertight protrusion protrudes is formed on an inner surface of the watertight protrusion opposite the recess,
A channel through which the air heated and expanded in the housing can be discharged to the outside of the housing is formed by the vent groove to prevent liquid or dust from flowing into the housing while preventing air between the inside and the outside of the housing The intelligent battery sensor, characterized in that it is allowed to communicate. According to claim 1,
The clamp member and the shunt resistor are joined to each other by a brazing method, an intelligent battery sensor. According to claim 1,
The circuit board includes a connection pin electrically connectable between the circuit board and the vehicle controller,
When the insert is injected, the connection pin is injected together with the clamp member and the shunt resistor, an intelligent battery sensor. According to claim 1,
The housing includes a through hole formed at a position where the clamp member and the shunt resistor are joined to hold the clamp member and the shunt resistor from the outside when the insert is injected. 4. The method of claim 3,
The housing further comprises a socket for accommodating the connection pin, intelligent battery sensor. According to claim 1,
The housing cover is coupled or bonded by fusion with the body, an intelligent battery sensor. delete delete According to claim 1, wherein the body portion
At least one seating rib protruding inwardly so that the circuit board can be spaced apart from the lower surface of the body is formed, the intelligent battery sensor. 4. The method of claim 3,
The circuit board further includes a plurality of connection pins electrically connecting the plurality of contact points of the shunt resistor;
One end of the plurality of connection pins is in contact with the plurality of contact points of the shunt resistor and the other end of the plurality of connection pins is fixed to the circuit board. 11. The method of claim 10,
wherein the plurality of contact points are three or more points. 11. The method of claim 10,
One end of the plurality of connection pins is welded to the plurality of contact points of the shunt resistor, and the other end of the plurality of connection pins is press-fit coupled to the circuit board, intelligent battery sensor. a clamp member connected to one pole of the battery;
a shunt resistor joined while making surface contact with at least a portion of the clamp member;
a circuit board for measuring at least one of a voltage between a plurality of contact points in the shunt resistor, a current flowing between the plurality of contact points, and a temperature at the plurality of contact points;
a housing accommodating the clamp member, the shunt resistor, and the circuit board; and
a terminal member coupled to a portion of the shunt resistor exposed to the outside of the housing;
the clamp member and the shunt resistor are accommodated in the housing by being insert-injected together;
The exposed portion of the shunt resistor and the terminal member are fastened by bolt-nut coupling,
The bolt used in the bolt-nut coupling includes a bolt head and a screw coupled to the nut,
The bolt-nut further comprises at least one protrusion protruding toward the shunt resistor from the inner surface side of the bolt head connected to the screw so that the bolt can be fixed while press-fitting the shunt resistor when the bolt-nut is coupled. battery sensor. delete 14. The method of claim 13,
The shunt resistor includes a bolt fastening hole to which the bolt is fastened,
In the shunt resistor, at least one seating groove is formed around the bolt fastening hole to correspond to the at least one protrusion. 14. The method of claim 13,
the terminal member includes a stopper that protrudes or bends from the terminal member to engage the exposed portion of the shunt resistor to prevent relative rotation between the shunt resistor and the terminal member during bolt-nut engagement battery sensor. According to claim 1,
The terminal member is connected to a cable that extends to one side of the vehicle and serves as a grounding wire,
A fixing member for fixing the cable to one side of the vehicle is formed at the extended end of the cable, the intelligent battery sensor. 18. The method of claim 17,
The fixing member includes a stopper protruding or bent from the fixing member so that the fixing member does not rotate when engaged with one side of the vehicle by a fastener. The method of claim 1, wherein the shunt resistor is
and an extension part formed to extend from one edge of the shunt resistor to prevent the shunt resistor from being separated from the housing after the insert injection. As a manufacturing method for manufacturing the intelligent battery sensor according to claim 1,
bonding the clamp member while surface-contacting the shunt resistor;
insert-injecting the joined clamp member and the shunt resistor to generate the housing;
connecting a plurality of contact points in the shunt resistor and the circuit board by a plurality of connection pins; and
fastening the exposed portion of the shunt resistor and the terminal member;
The housing is
a body part surrounding and protecting the clamp member, the shunt resistor, and the circuit board; and
and a housing cover that closes the body part from the outside;
The housing cover includes a watertight protrusion protruding downward from the housing cover toward the body,
The body portion includes a recess formed to correspond to the watertight projection,
A vent groove extending along a direction in which the watertight protrusion protrudes is formed on an inner surface of the watertight protrusion opposite the recess,
A channel through which the air heated and expanded in the housing can be discharged to the outside of the housing is formed by the vent groove to prevent liquid or dust from flowing into the housing while preventing air between the inside and the outside of the housing It is allowed to communicate, the manufacturing method. The method of claim 20, wherein the bonding step
and bonding the clamp member and the shunt resistor to each other by a brazing method. 21. The method of claim 20, wherein creating the housing comprises:
and insert-injecting a connection pin electrically connectable between the circuit board and the vehicle controller together with the clamp member and the shunt resistor during the insert-injection. The method of claim 20, wherein the connecting by the plurality of connecting pins comprises:
welding one end of the plurality of connection pins to a plurality of contact points of the shunt resistor; and
and press-fit coupling the other ends of the plurality of connection pins to the circuit board. 21. The method of claim 20,
The method of claim 1, further comprising: coupling or bonding a housing cover to the housing by laser welding while the clamp member, the shunt resistor, and the circuit board are accommodated in the housing. The method of claim 20, wherein the fastening step
and fastening the exposed portion of the shunt resistor and the terminal member by bolt-nut coupling. As a manufacturing method for manufacturing the intelligent battery sensor according to claim 13,
bonding the clamp member while surface-contacting the shunt resistor;
insert-injecting the joined clamp member and the shunt resistor to generate the housing;
connecting a plurality of contact points in the shunt resistor and the circuit board by a plurality of connection pins; and
fastening the exposed portion of the shunt resistor and the terminal member;
The exposed portion of the shunt resistor and the terminal member are fastened by bolt-nut coupling,
The bolt used in the bolt-nut coupling includes a bolt head and a screw coupled to the nut,
Manufacturing, further comprising: at least one protrusion protruding toward the shunt resistor from an inner surface side of the bolt head connected to the screw so that the bolt can be fixed while press-fitting the shunt resistor when the bolt-nut is coupled Way.

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