Mounting structure for current sensor

• US 7,755,346 B2
• Filed: 07/25/2006
• Issued: 07/13/2010
• Est. Priority Date: 08/01/2005
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Tanizawa, Yukihiko
• Primary Examiner(s): Abrams; Neil
• Application Number:
  US11/491,985
• Publication Number:
  US 20070025065A1
• Time in Patent Office: 1,449 Days
• Field of Search: 439/754, 324/117.R, 324/117.H
• US Class Current: 324/117.00H
• CPC Class Codes: G01R 15/207 Constructional details independent of the type of device used
• CPC Class Codes: G01R 31/364 Battery terminal connectors with integrated measuring arrangements
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• CPC Class Codes: H01F 38/30 Constructions
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• CPC Class Codes: H01R 11/287 Intermediate parts between battery post and cable end piece
• CPC Class Codes: H01R 13/6683 with built-in sensor
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A mounting structure for a current sensor is provided. The current sensor is arranged between a negative terminal of a battery and a grounding unit. The mounting structure includes a battery grounding cable which has one end connected with the negative terminal of the battery, and a fixing unit which is electrically conductive to electrically connect other end of the battery grounding cable with the grounding unit. The fixing unit and the battery grounding cable constructs a current path which connects the negative terminal with the grounding unit. The current sensor is fixed by the fixing unit to the grounding unit, and disposed to detect current flowing through the fixing unit.

Claims

1. A mounting structure for a current sensor which is arranged between a negative terminal of a battery and a grounding unit, the current sensor having a magnetism-electricity converting element, the mounting structure comprising:

a battery grounding cable which has one end connected with the negative terminal of the battery;

a fixing unit which is electrically conductive to electrically connect other end of the battery grounding cable with the grounding unit,

the fixing unit and the battery grounding cable constructing a current path which connects the negative terminal with the grounding unit,

the current sensor is fixed by the fixing unit to the grounding unit, and disposed to detect current flowing through the fixing unit; and

an electrical insulating member which is non-magnetic, wherein

the current sensor includes a substantially C-shaped flux concentration core having a circumferential gap, in which the magnetism-electricity converting element is arranged,

the fixing unit fixes the current sensor with respect to the grounding unit, in such a manner that the fixing unit is inserted through the flux concentration core with the electrical insulating member interposed therebetween,

the electrical insulating member is a case for housing the magnetism-electricity converting element and the flux concentration core,

the case has an insertion hole which is through the case and positioned corresponding to the flux concentration core,

the fixing unit fixes the current sensor to the grounding unit in such a manner that the fixing unit is inserted through the flux concentration core and the insertion hole of the case,

the case is made of a resin, and

the case has at least one rib which is made of the resin and arranged between a first portion of the case at a side of the grounding unit and a second portion of the case at a side of the flux concentration core, to partially connect the first portion of the case and the second portion of the case.

2. The mounting structure according to claim 1, wherein the current sensor is fixedly mounted at the fixing unit by one of a press-fitting of the fixing unit into the current sensor and an engaging of the fixing unit with the current sensor.

3. The mounting structure according to claim 1, wherein the fixing unit is constructed to clamp the current sensor between the fixing unit and the grounding unit.

4. The mounting structure according to claim 3, wherein:

the grounding unit has a through hole;

the fixing unit s a fastening unit, which protrudes from the through hole to be fastened to the grounding unit so that the fastening unit is electrically connected with the grounding unit; and

the current sensor is clamped between an end portion of the fastening unit and the grounding unit.

5. The mounting structure according to claim 4, wherein

the fastening unit is swaged to be fastened to the grounding unit and clamp the current sensor between the fastening unit and the grounding unit.

6. The mounting structure according to claim 3, wherein:

the grounding unit has a through hole;

the fixing unit is an engagement unit, which protrudes from the through hole to be engaged with the grounding unit so that the engagement unit is electrically connected with the grounding unit; and

the current sensor is clamped between one end portion of the engagement unit and the grounding unit.

7. The mounting structure according to claim 1, wherein the insertion hole of the case is positioned at a substantial center of the current sensor.

8. The mounting structure according to claim 1, wherein the insertion hole of the case is arranged at a substantial center of mass position of the current sensor.

9. The mounting structure according to claim 1, further comprising

a reinforcement member which is constructed of a non-magnetic material and integrated with an surface of the insertion hole of the case,

wherein the case is made of a resin.

10. The mounting structure according to claim 1, wherein the fixing unit is constructed of a non-magnetic material.

11. The mounting structure according to claim 2, wherein the current sensor has an insertion hole, into which the fixing unit is press-fitted.

12. The mounting structure according to claim 3, further comprising

an electrical insulating member which is non-magnetic and clamped between the fixing unit and the grounding unit, wherein:

the magnetism-electricity converting element is housed in the electrical insulating member; and

the fixing unit fixes the current sensor with respect to the grounding unit, in such a manner that the fixing unit is arranged at one side of the electrical insulating member.

13. The mounting structure according to claim 4, wherein:

the fastening unit includes a nut and a bolt, which has a head portion and a shaft portion extending from the head portion;

the shaft portion is inserted through the through hole of the grounding unit to be fastened to the grounding unit by the nut, which is arranged at an opposite side of the grounding unit to the head portion of the bolt; and

the current sensor is clamped between the head portion of the bolt and the grounding unit.

14. The mounting structure according to claim 6, wherein

the engagement unit includes:

an engagement portion which couples with the grounding unit;

a head portion which clamps the current sensor between the head portion and the grounding unit; and

a pole portion which connects the engagement portion with the head portion,

the engagement portion and the head portion being respectively positioned at two opposite sides of the grounding unit.

15. The mounting structure according to claim 9, wherein the reinforcement member has an extension portion which extends along a surface of the grounding unit and contacts the surface.

16. The mounting structure according to claim 9, wherein the non-magnetic material of the reinforcement member has a larger stiffness than the resin of which the case is made.

17. The mounting structure according to claim 1, wherein the grounding unit is arranged at a vehicle, where the current sensor is fixed via the fixing unit.