Structure and method of mounting current sensor to battery cable

Abstract

A structure of mounting a current sensor to a battery cable includes a battery cable, a thermal fusion bonding tape wound around an outer circumference of the battery cable, and a current sensor. The current sensor includes a housing including a current detecting part configured to detect a current flowing through the battery cable, and a holder configured to hold and compress a thermal fusion bonding tape mounting portion in cooperation with the housing to deform a cross-sectional shape of the thermal fusion bonding tape mounting portion into an elliptical shape. The thermal fusion bonding tape mounting portion is a portion where the thermal fusion bonding tape is wound around the battery cable. Upon a compression between the housing and the holder being released, the elliptical shape of the cross-sectional shape of the thermal fusion bonding tape mounting portion is maintained.

What is claimed is: 
     
         1 . A structure of mounting a current sensor to a battery cable, the structure comprising:
 a battery cable;   a thermal fusion bonding tape wound around an outer circumference of the battery cable; and   a current sensor comprising
 a housing including a current detecting part configured to detect a current flowing through the battery cable, and 
 a holder configured to hold and compress a thermal fusion bonding tape mounting portion in cooperation with the housing to deform a cross-sectional shape of the thermal fusion bonding tape mounting portion into an elliptical shape, the thermal fusion bonding tape mounting portion being a portion where the thermal fusion bonding tape is wound around the battery cable, 
   wherein upon a compression between the housing and the holder being released, the elliptical shape of the cross-sectional shape of the thermal fusion bonding tape mounting portion, is maintained.   
     
     
         2 . The structure of mounting a current sensor to a battery cable according to  claim 1 ,
 wherein the housing comprises
 a housing body including the current detecting part, and 
 a cover disposed separated from the current detecting part and mounted to the housing body to cover the current detecting part, and 
   wherein the thermal fusion bonding tape mounting portion is held between the holder and the cover.   
     
     
         3 . The structure of mounting a current sensor to a battery cable according to  claim 2 , further comprising a soft filler filled between the current detecting part and the cover. 
     
     
         4 . A method of mounting a current sensor to a battery cable, the method comprising:
 mounting a thermal fusion bonding tape to an outer circumference of a battery cable;   sandwiching and compressing a thermal fusion bonding tape mounting portion between a housing and a holder of a current sensor, and fixing the thermal fusion bonding tape mounting portion to the housing, the thermal fusion bonding tape mounting portion being a portion where the thermal fusion bonding tape is mounted to the battery cable;   heating and softening the thermal fusion bonding tape after the fixing of the thermal fusion bonding tape mounting portion to the housing; and   curing the thermal fusion bonding tape after the softening of the thermal fusion bonding tape.   
     
     
         5 . A structure of mounting a current sensor to a battery cable produced by:
 mounting a thermal fusion bonding tape to an outer circumference of a battery cable;   sandwiching and compressing a thermal fusion bonding tape mounting portion between a housing and a holder of a current sensor, and fixing the thermal fusion bonding tape mounting portion to the housing, the thermal fusion bonding tape mounting portion being a portion where the thermal fusion bonding tape is mounted to the battery cable;   heating and softening the thermal fusion bonding tape after the fixing of the thermal fusion bonding tape mounting portion to the housing; and   curing the thermal fusion bonding tape after the softening of the thermal fusion bonding tape.   
     
     
         6 . The structure of mounting a current sensor to a battery cable according to  claim 5 ,
 wherein the housing comprises
 a housing body including a current detecting part configured to detect a current flowing through the battery cable, and 
 a cover disposed separated from the current detecting part and mounted to the housing body to cover the current detecting part, and 
   wherein the thermal fusion bonding tape mounting portion is held between the holder and the cover.   
     
     
         7 . The structure of mounting a current sensor to a battery cable according to  claim 6 , further comprising a soft filler filled between the current detecting part and the cover.