A kind of FDC's hollowing process

Abstract

The application provides a hollowing process of FDC, which uses super-long FDC products for series and parallel connection of a battery pack, reduces the difficulty of battery pack assembly, and ensures the stability and reliability of battery pack assembly. The FDC product is arranged along the length direction of the battery pack, and the FDC product is provided with a first large-diameter avoiding hole corresponding to the position of the upper convex contact point of each battery covered by the FDC product. A tongue piece is connected to the copper foil layer in the middle of the FDC product corresponding to the position of the first large-diameter avoiding hole. The tongue piece and the upper convex contact point of the corresponding battery are spaced apart. An aluminum bar is provided with a contact connecting part corresponding to the position of the large-diameter avoiding hole. The contact connecting part is pre-welded to the tongue piece. The contact connecting part covers the upper convex contact point at the corresponding position. When the battery pack is assembled, only the upper convex contact point of the battery and the contact connecting part of the aluminum bar at the corresponding position need to be welded.

Description

Technical Field

[0001] This invention relates to the technical field of ultra-long product processing, specifically a hollowing process for FDC (fiber-coated die). Background Technology

[0002] The existing battery assembly for new energy vehicles uses an FPC connection structure, which first welds the aluminum battery to the battery, and then welds the corresponding welding points of the FPC onto the aluminum battery. This assembly method is relatively complex and inconvenient to operate. In addition, the FPC is relatively soft, which makes it easy to produce weak welds when welding the aluminum battery, and the precision is not very accurate. Therefore, there is an urgent need to develop a new installation process suitable for battery assembly. Summary of the Invention

[0003] To address the aforementioned issues, this invention provides a hollowing-out process for FDC (Fuel Diode Containers), which utilizes extra-long FDC products for series and parallel connections in battery packs, reducing the difficulty of battery assembly and ensuring the stability and reliability of battery assembly.

[0004] A hollowing process for FDC (Fuel Diode) batteries is characterized in that: the FDC product is arranged along the length of the battery pack, and the FDC product has a first large-diameter clearance hole corresponding to the position of the upper protruding contact of each battery it covers. A tongue is connected to the copper foil layer in the middle of the FDC product corresponding to the position of the first large-diameter clearance hole. A gap is left between the tongue and the upper protruding contact of the corresponding battery. An aluminum bar is provided with a contact connection part corresponding to the position of the large-diameter clearance hole. The contact connection part is pre-welded to the tongue and covers the upper protruding contact at the corresponding position. When assembling the battery, it is only necessary to weld the upper protruding contact of the battery to the contact connection part of the aluminum bar at the corresponding position.

[0005] Its further features are:

[0006] The FDC product includes an upper PI hot melt adhesive layer, a copper foil layer, and a lower PI hot melt adhesive layer. The copper foil layer has a radially protruding tongue in the area corresponding to the large-diameter clearance hole. The tongue is used for welding connection with the contact connection part of the aluminum bar.

[0007] The tongue and the large-diameter clearance hole are both formed by punching.

[0008] The upper surface of the arranged battery assembly is covered with a first insulating layer. The first insulating layer has a second large-diameter clearance hole corresponding to the position of the upper protruding contact. The first insulating layer is used to insulate and isolate the aluminum bar and the non-welded part of the battery.

[0009] The aluminum bar is a number of unit aluminum bars that are arranged on both sides of the width direction of the battery module and sequentially along the length direction. Each unit aluminum bar on each side corresponds to one FDC product arrangement, so that the entire battery module can be assembled with only two FDC products.

[0010] The aluminum bar covers the upper surface of the first insulating layer and has a contact connection portion corresponding to the position of the second large-diameter clearance hole. The contact connection portion covers the corresponding upper protruding contact arrangement to ensure that the subsequent welding connection is stable and reliable.

[0011] The upper surface of the aluminum bar is covered with a second insulating layer. The second insulating layer is provided with a third large-diameter clearance hole corresponding to the position of the upper protruding contact. The second insulating layer is used to insulate and isolate the rest of the aluminum bar from the outside world.

[0012] The second and third large-diameter clearance holes located at one end of the battery assembly are designed as contour positioning holes to facilitate positioning and connection with the corresponding protruding contact at the end of the battery assembly.

[0013] The FDC product has one end protruding outward from the battery assembly along its length and is provided with a corresponding plug-in component, which facilitates connection with other parts of the vehicle body.

[0014] The first insulating layer is an FR4 insulating layer, and the second insulating layer is a PER insulating layer.

[0015] With this invention, two sets of FDC products are arranged on both sides of the welding area. The tongues extending from the first large-diameter clearance holes of the FDC products are welded to the contact connection parts of the aluminum bars, so that several sets of aluminum bars and two sets of FDC products form an integral product in both sides of the area. At the same time, the contact connection parts of the aluminum bars are exposed, which does not affect the welding of the aluminum bars to the battery. When assembling the battery, only the welding assembly of the battery and the aluminum bars needs to be performed, which greatly improves the production efficiency and yield and can meet the needs of modular mass production. It uses the extra-long FDC products for the series and parallel connection of the battery pack, which reduces the difficulty of battery assembly and ensures the stability and reliability of battery assembly. Attached Figure Description

[0016] Figure 1 This is a three-dimensional schematic diagram of the battery assembly connection corresponding to the process of the present invention;

[0017] Figure 2 This is a perspective view of the copper foil portion of the FDC product of the present invention;

[0018] Figure 3 This is a schematic diagram of the aluminum bar of the present invention;

[0019] Figure 4 This is a partially enlarged structural diagram of point A in the present invention;

[0020] The names corresponding to the serial numbers in the diagram are as follows:

[0021] FDC product 10, first large diameter clearance hole 11, tongue 12, plug assembly 13, battery 20, upper protruding contact 21, aluminum bar 30, contact connection part 31, first insulating layer 40, second insulating layer 50. Detailed Implementation

[0022] A hollowing process for FDC (Fuel Conversion Device): The FDC product 10 is installed along the length of the battery pack, and the FDC product 10 has a first large-diameter clearance hole 11 corresponding to the position of the upper protruding contact 21 of each battery 20 it covers. The copper foil layer in the middle of the FDC product 10 is connected to a tongue 12 corresponding to the position of the first large-diameter clearance hole. There is a gap between the tongue 12 and the upper protruding contact 21 of the corresponding battery 20. The aluminum bar 30 is provided with a contact connection portion 31 corresponding to the position of the first large-diameter clearance hole. The contact connection portion 31 is pre-welded to the tongue 12 and covers the upper protruding contact 21 at the corresponding position. When assembling the battery, it is only necessary to weld the upper protruding contact 21 of the battery 20 to the contact connection portion 31 of the aluminum bar 30 at the corresponding position.

[0023] In specific implementation, FDC product 10 includes an upper PI hot melt adhesive layer, a copper foil layer, and a lower PI hot melt adhesive layer. The copper foil layer is provided with a radially protruding tongue 12 in the area corresponding to the first large diameter clearance hole 11. The tongue 12 is used for welding connection with the contact connection part 31 of the aluminum bar 30.

[0024] The tongue 12 and the first large-diameter clearance hole 11 are both formed by punching.

[0025] The upper surface of the arranged battery assembly is covered with a first insulating layer 40, which is an FR4 insulating layer. The first insulating layer 40 is provided with a second large-diameter clearance hole corresponding to the position of the upper protruding contact 21. The first insulating layer 40 is used to insulate and isolate the non-welded parts of the aluminum bar 30 and the battery 20.

[0026] The aluminum bar 30 consists of several unit aluminum bars arranged on both sides of the width direction of the battery module and sequentially along the length direction. Each unit aluminum bar on each side corresponds to one FDC product 10, so that the entire battery module can be assembled with only two FDC products 10.

[0027] The aluminum bar 30 covers the upper surface of the first insulating layer 40 and has a contact connection portion 31 at the position corresponding to the second large diameter clearance hole. The contact connection portion 31 covers the corresponding upper protruding contact 21 to ensure that the subsequent welding connection is stable and reliable.

[0028] The upper surface of the aluminum bar 30 is covered with a second insulating layer 50, which is a PER insulating layer. The second insulating layer 50 is provided with a third large-diameter clearance hole corresponding to the position of the upper protruding contact 21. The second insulating layer 50 is used to insulate and isolate the rest of the aluminum bar 30 from the outside world.

[0029] The second and third large-diameter clearance holes located at one end of the battery assembly are set as contour positioning holes to facilitate positioning and connection with the corresponding protruding contact 21 at the end of the battery assembly.

[0030] The FDC product 10 has one end protruding outward from the battery pack along its length and is provided with a corresponding plug-in component 13. The plug-in component 13 facilitates connection with other parts of the vehicle body.

[0031] Its working principle is as follows: Two sets of FDC products are arranged on both sides of the welding area. The tongues protruding from the first large diameter clearance hole of the FDC product are welded to the contact connection part of the aluminum bar, so that several sets of aluminum bars and two sets of FDC products form an integral product in both sides. At the same time, the contact connection part of the aluminum bar is exposed, which does not affect the welding of the aluminum bar to the battery. When assembling the battery, only the battery and aluminum bar need to be welded together, which greatly improves the production efficiency and yield and can meet the needs of modular mass production. It uses the extra-long FDC product for the series and parallel connection of the battery pack, which reduces the difficulty of battery assembly and ensures the stability and reliability of battery assembly.

[0032] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0033] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A hollowing process for FDC (Flat Diode), characterized in that: The FDC product is installed along the length of the battery assembly, and a first large-diameter clearance hole is provided for the upper protruding contact position of each battery covered by the FDC product. A tongue is connected to the copper foil layer in the middle of the FDC product at the position of the first large-diameter clearance hole. A gap is left between the tongue and the upper protruding contact of the corresponding battery. A contact connection part is provided for the aluminum bar at the position of the large-diameter clearance hole. The front part of the contact connection part is pre-welded to the tongue in the first large-diameter clearance hole, and the rear part of the contact connection part covers the upper protruding contact at the corresponding position of the other first large-diameter clearance hole adjacent to the first large-diameter clearance hole. When assembling the battery, it is only necessary to weld the upper protruding contact of the battery to the contact connection part of the aluminum bar at the corresponding position. The aluminum bar consists of several unit aluminum bars arranged on both sides of the width direction of the battery module and sequentially along the length direction. Each unit aluminum bar on each side corresponds to one FDC product arrangement, so that the entire battery module can be assembled with only two FDC products.

2. The FDC hollowing process as described in claim 1, characterized in that: The FDC product includes an upper PI hot melt adhesive layer, a copper foil layer, and a lower PI hot melt adhesive layer. The copper foil layer has a radially convex tongue in the area corresponding to the large-diameter clearance hole. The tongue is used for welding connection with the contact connection part of the aluminum bar.

3. The FDC hollowing process as described in claim 2, characterized in that: The tongue and the large-diameter clearance hole are both formed by punching.

4. The FDC hollowing process as described in claim 2, characterized in that: The upper surface of the arranged battery assembly is covered with a first insulating layer. The first insulating layer has a second large-diameter clearance hole corresponding to the position of the upper protruding contact. The first insulating layer is used to insulate and isolate the aluminum bar and the non-welded part of the battery.

5. The FDC hollowing process as described in claim 1, characterized in that: The aluminum bar covers the upper surface of the first insulating layer and has a contact connection portion at the position corresponding to the second large-diameter clearance hole. The contact connection portion covers the corresponding upper protruding contact arrangement.

6. The FDC hollowing process as described in claim 5, characterized in that: The upper surface of the aluminum bar is covered with a second insulating layer. The second insulating layer has a third large-diameter clearance hole corresponding to the position of the upper protruding contact. The second insulating layer is used to insulate and isolate the rest of the aluminum bar from the outside world.

7. The FDC hollowing process as described in claim 6, characterized in that: The second and third large-diameter clearance holes located at one end of the battery assembly are designed as contour positioning holes.

8. The FDC hollowing process as described in claim 1, characterized in that: One end of the FDC product protrudes outward from the battery assembly along its length and is provided with a corresponding plug-in component, which facilitates connection with other parts of the vehicle body.

9. The FDC hollowing process as described in claim 6, characterized in that: The first insulating layer is an FR4 insulating layer, and the second insulating layer is a PER insulating layer.

Images