An ultrasonic welding method and connector for CCS modules

Abstract

This invention belongs to the field of CCS component welding, specifically relating to an ultrasonic welding method and connector for CCS modules. The method includes the following steps: providing an ultrasonic welding system and a mobile carrier; providing a CCS module and placing the CCS module within the mobile carrier; controlling the mobile carrier to move to the ultrasonic welding system, identifying and acquiring the support position on the lower surface of the CCS module using a first camera, and identifying and acquiring the welding area on the upper surface of the CCS module using a second camera; activating the ultrasonic welding system so that the bottom mold and welding head of the ultrasonic welding system are respectively positioned opposite the support position and the welding area, and used to weld the CCS module into shape; controlling the ultrasonic welding system and / or the mobile carrier to flow into the next welding station, repeating the above steps, and sequentially welding multiple welding areas of the CCS module using the ultrasonic welding system. This invention can improve product welding quality, ensure product yield, and reduce production and processing costs.

Description

Technical Field

[0001] This invention belongs to the field of CCS component welding technology, specifically relating to an ultrasonic welding method and connector for CCS modules. Background Technology

[0002] FPC (Flexible Printed Circuit) is a highly reliable and extremely flexible printed circuit board made with polyimide or polyester film as the substrate. It features high wiring density, light weight, and thinness. FPC is an important component of the CCS (Cruise Control System) module in power batteries, which in turn is an important component of new energy power battery modules.

[0003] CCS (Computer-on-Chip) components refer to products formed by welding multiple battery cell aluminum busbars to FPC (Flexible Printed Circuit) modules in series and parallel. Traditional FPCs are formed by soldering nickel sheet structures to the FPC circuitry and then connecting them to the battery cell aluminum busbars using a laser welding process. The inventors discovered that laser welding presents at least the following technical problems:

[0004] On the one hand, laser welding can cause changes in the physical structure of FPC or aluminum busbar, damaging product performance, resulting in a higher defect rate and higher production costs. On the other hand, after laser welding, the welded part of FPC will carbonize, increasing the resistivity of the connection between FPC and aluminum busbar. This can generate high temperatures during use, leading to risks such as battery fires.

[0005] Therefore, it is necessary to improve the existing technology to overcome its shortcomings in practical applications. Summary of the Invention

[0006] Based on the aforementioned shortcomings and deficiencies in the prior art, one of the objectives of this invention is to at least solve one or more of the aforementioned problems in the prior art. In other words, one of the objectives of this invention is to provide an ultrasonic welding method and connector for CCS modules that meets one or more of the aforementioned requirements.

[0007] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0008] This invention provides an ultrasonic welding method for CCS modules, comprising the following steps:

[0009] Provide ultrasonic welding systems and mobile vehicles;

[0010] Provide a CCS module and house the CCS module within the mobile vehicle;

[0011] The mobile carrier is controlled to move to the ultrasonic welding system. The lower surface of the CCS module is identified and the support position is obtained through the first camera. The upper surface of the CCS module is identified and the welding area is obtained through the second camera.

[0012] The ultrasonic welding system is activated so that the bottom mold and welding head of the ultrasonic welding system are respectively positioned facing the support position and the welding area, and are used to weld the CCS module into shape.

[0013] Control the ultrasonic welding system and / or the mobile carrier to flow into the next welding station, repeat the above steps, and sequentially weld multiple welding areas of the CCS module through the ultrasonic welding system.

[0014] As a preferred embodiment, the CCS module includes an aluminum busbar and an FPC sheet, the aluminum busbar and the FPC sheet are attached together, the aluminum busbar is provided with a support position, and the FPC sheet is provided with a welding area.

[0015] As a preferred embodiment, the aluminum busbar is connected to a hot-pressing film, and a positioning groove is formed on the hot-pressing film. The bottom mold passes through the positioning groove and abuts against the support position.

[0016] As a preferred embodiment, the second camera sequentially acquires multiple welding areas on the FPC sheet and determines whether the welding conditions are met. If so, the ultrasonic welding system is controlled to weld the FPC sheet to the aluminum busbar; otherwise, the mobile carrier is controlled to flow into the next welding station.

[0017] As a preferred option, it also includes:

[0018] A high-speed chain conveyor is provided, on which the moving carrier is mounted to position the CCS module; by controlling the movement of the high-speed chain conveyor, the ultrasonic welding system sequentially welds multiple welding areas on the CCS module.

[0019] As a preferred embodiment, the ultrasonic welding system further includes:

[0020] A first drive module and a second drive module are provided. The first drive module drives the bottom mold to rise so that the bottom mold abuts against the support position of the aluminum strip. The second drive module drives the welding head to fall so that the welding head abuts against the welding area of ​​the FPC sheet.

[0021] As a preferred embodiment, the ultrasonic welding system has a welding pressure of 500N~1000N, an amplitude of 35μm~55μm, and a welding power of 500W~1000W.

[0022] As a preferred embodiment, the residual area after welding of the CCS module is greater than 30%.

[0023] The present invention also provides a CCS module connector, which is manufactured by the ultrasonic welding method described in any of the above schemes.

[0024] As a preferred embodiment, the CCS module connector includes:

[0025] FPC sheet, wherein the upper surface of the FPC sheet has a welding area;

[0026] An aluminum busbar, the lower surface of which has a support position, and the upper surface of which is in contact with the lower surface of the FPC sheet;

[0027] The area of ​​the welding region is 30-60 square millimeters, and the upper surface of the aluminum busbar is welded to the lower surface of the FPC sheet.

[0028] Compared with the prior art, the beneficial effects of this invention are:

[0029] This invention provides an ultrasonic welding method for CCS modules. Through the non-fusion welding process of ultrasonic welding, the welding quality of products can be improved, the product yield can be guaranteed, and the production and processing costs can be reduced.

[0030] This invention provides an ultrasonic welding method for CCS modules. Ultrasonic welding does not damage the product structure, ensuring product performance and yield, and has low manufacturing costs. After welding, the FPC will not carbonize, resulting in lower resistivity at the connection between the FPC and the aluminum busbar, thus reducing battery heat generation. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained from these drawings without creative effort.

[0032] Figure 1 This is a schematic flowchart of an ultrasonic welding method for CCS modules according to an embodiment of the present invention;

[0033] Figure 2 This is a partial half-section schematic diagram of the CCS module according to an embodiment of the present invention;

[0034] Figure 3 This is a partial half-section schematic diagram of the upper surface of the FPC sheet according to an embodiment of the present invention;

[0035] Figure 4 This is a partial half-sectional schematic diagram of the lower surface of the aluminum busbar according to an embodiment of the present invention;

[0036] Figure 5 This is a side view of an embodiment of the present invention for ultrasonic welding of a CCS module;

[0037] Figure 6 yes Figure 5 A schematic diagram of the welding of CCS modules;

[0038] Figure 7 This is a schematic diagram of the state of the CCS module after welding according to an embodiment of the present invention;

[0039] Figure 8 This is a schematic diagram of the peeled-off state of the CCS module according to an embodiment of the present invention;

[0040] 1 FPC sheet, 10 welding area, 20 support position, 21 aluminum busbar, 22 hot press film, 221 positioning groove, 31 bottom mold, 32 welding head, 33 first drive module, 34 second drive module, 41 first camera, 42 second camera, 5 moving vehicle, 6 speed chain line, S peeling residue. Detailed Implementation

[0041] To more clearly illustrate the embodiments of the present invention, specific implementation methods will be described below with reference to the accompanying drawings. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings and other implementation methods can be obtained based on these drawings without any creative effort.

[0042] In the description of the embodiments of the present invention, the terms "first," "second," etc., are used only for distinguishing in the description and have no special meaning. They are only for the convenience of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0043] In order to improve the welding quality of CCS module products, ensure product yield, and reduce production and processing costs, such as Figure 1 A schematic flowchart of an ultrasonic welding method for CCS modules according to one embodiment is shown.

[0044] It is understood that specific terms are used in this invention to describe particular embodiments, such as "one embodiment," "one or more embodiments," and / or "some embodiments," which refer to a particular feature, structure, or characteristic related to at least one embodiment of the invention. Therefore, it should be emphasized and noted that "one embodiment," "one or more embodiments," and / or "some embodiments" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment.

[0045] In some embodiments, an ultrasonic welding method for CCS modules is provided, comprising the following steps:

[0046] S10. Provide an ultrasonic welding system and a mobile carrier, the mobile carrier being located on the production line and capable of moving relative to the ultrasonic welding system to move the workpiece to be welded.

[0047] An ultrasonic welding system includes an ultrasonic generator, an ultrasonic triplet, and a bottom mold. The ultrasonic generator is connected to the ultrasonic triplet, the bottom mold is used to support the workpiece to be welded, and the ultrasonic triplet is used to weld the workpiece into shape.

[0048] Specifically, the ultrasonic triple unit includes a transducer, an amplitude modulator, and a welding head. The transducer is connected to the amplitude modulator, and the amplitude modulator is connected to the welding head. The low-frequency AC power is converted into high-frequency power by the ultrasonic generator. The transducer converts the high-frequency power into mechanical motion. The mechanical motion then changes the amplitude through the amplitude modulator and is transmitted to the welding head. The welding head transmits the received vibration energy to the surface of the workpiece to be welded. Under pressure, the surfaces of the workpieces to be welded rub against each other to generate heat and form fusion between molecular layers, thereby achieving ultrasonic welding.

[0049] S20. Provide a CCS module and house the CCS module within the mobile vehicle.

[0050] Figure 2 A partial half-sectional schematic diagram of one embodiment of the CCS module is shown. It should be noted that these and subsequent figures are merely illustrative and are not drawn to scale, and should not be construed as limiting the scope of protection of this invention. Furthermore, variations in different embodiments can be appropriately combined.

[0051] like Figure 2 As shown, the CCS module includes an aluminum busbar 21 and an FPC sheet 1. The aluminum busbar 21 and the FPC sheet 1 are attached together. The aluminum busbar 21 is provided with a support position, and the FPC sheet 1 is provided with a welding area.

[0052] Specifically, the aluminum busbar 21 is connected to the hot-press film 22, and a positioning groove 221 is formed on the hot-press film 22. The bottom mold passes through the positioning groove 221 and abuts against the support position. The aluminum busbar 21 is 400μm thick, and the hot-press film 22 is made of PET with a thickness of 150μm. The hot-press film 22 supports and positions the aluminum busbar 21 and the FPC sheet 1 to ensure stability during welding and avoid misalignment during welding.

[0053] Furthermore, the FPC sheet 1 includes a protective film 11 for connecting lines, an adhesive surface 12, and a line surface 13 arranged sequentially from top to bottom. The thickness of the protective film 11 is 25 μm, the thickness of the adhesive surface 12 is 35 μm, and the thickness of the line surface 13 is 35 μm. Among them, the line surface 13 is made of copper.

[0054] S30. Control the mobile carrier to move to the ultrasonic welding system, identify the lower surface of the CCS module and obtain the support position through the first camera, and identify the upper surface of the CCS module and obtain the welding area through the second camera.

[0055] Figure 3 A partial half-section schematic diagram of the upper surface of an FPC sheet under one embodiment is shown. Figure 4 A partial half-section schematic diagram of the lower surface of the aluminum busbar in one embodiment is shown. Figure 5 A side view is shown during ultrasonic welding of a CCS module according to one embodiment.

[0056] Specifically, the ultrasonic welding system is equipped with a first camera 41 and a second camera 42. The first camera 41 is used to capture the support position of the aluminum busbar 21, and the second camera 42 is used to capture the welding area of ​​the FPC sheet 1. The second camera 42 sequentially captures multiple welding areas 10 on the FPC sheet 1 and determines whether they meet the welding conditions. If they do, the ultrasonic welding system is controlled to weld the FPC sheet 1 and the aluminum busbar 21; otherwise, the moving carrier 5 is controlled to flow into the next welding station.

[0057] It should be noted that the welding areas 10 of the FPC sheet 1 correspond one-to-one with the support positions 20 of the aluminum busbar 21. Since there are multiple welding areas 10 on the same FPC sheet 1, there are also multiple support positions 20 on the corresponding aluminum busbar 21. That is, there are multiple welding stations on the FPC sheet 1 and the aluminum busbar 21 to be welded.

[0058] Before welding, the lower surface 102 of the FPC sheet 1 is brought into contact with the upper surface 211 of the aluminum busbar 21, that is, the two are put together. At the same time, the FPC sheet 1 and the aluminum busbar 21 are installed in the positioning groove 221 of the hot press film 22 so that the two can be welded together by ultrasonic waves.

[0059] It should be noted that, in this description, "up" and "down" are used for convenience only and do not imply any specific, fixed direction. In fact, they are used to reflect the relative position and / or orientation between different parts of an object.

[0060] In one or more embodiments, the ultrasonic welding method further includes:

[0061] like Figure 5 As shown, a first drive module 33 and a second drive module 34 are provided. The first drive module 33 drives the bottom mold 31 to rise so that the bottom mold 31 abuts against the support position 20 of the aluminum strip 21. The second drive module 34 drives the welding head 32 to fall so that the welding head 32 abuts against the welding area 10 of the FPC sheet 1.

[0062] First, after the first camera 41 acquires the support position 20 on the lower surface of the CCS module, the first drive module 33 drives the bottom mold 31 to rise and abut against the support position 20. Then, the second camera 42 acquires the welding area 10 on the upper surface of the CCS module, and the second drive module 34 drives the welding head 32 to descend and abut against the welding area 10. The second camera 42 captures the welding area of ​​the FPC sheet. When welding conditions are not met, the system sends a signal to stop welding and proceeds to the next welding station. The second camera enables defect detection of the FPC sheet to avoid welding defects that could affect the yield of the CCS module.

[0063] S40. Start the ultrasonic welding system so that the bottom mold and welding head of the ultrasonic welding system are positioned directly opposite the support position and the welding area, respectively, and are used to weld the CCS module into shape.

[0064] Figure 6 This diagram illustrates the welding of the welding head and the bottom mold to the CCS module according to one embodiment. Figure 7 A schematic diagram of the state of a CCS module after welding is shown in one embodiment.

[0065] The first and second drive modules drive the bottom mold and welding head to abut against the upper and lower surfaces of the CCS module, respectively. The ultrasonic generator is activated and emits ultrasonic waves. The ultrasonic vibration is transmitted to the surface of the welding head through the transducer and amplitude modulator. The FPC sheet 1 and aluminum busbar 1 on a welding station are welded together by ultrasonic welding and connected through the welding area 10.

[0066] When welding FPC sheet 1 and aluminum busbar 21, the ultrasonic welding system requires a welding pressure of 500N~1000N. In one embodiment, the welding pressure can be set to 500N, 800N, or 1000N, which can be set according to actual needs.

[0067] Furthermore, the amplitude during welding is 35μm~55μm. In one embodiment, the amplitude can reach 35μm, 45μm, or 55μm, and can be set according to actual needs.

[0068] Furthermore, the welding power is 500W~1000W. In one embodiment, the power can be set to 500W, 800W, or 1000W, which can be set according to actual needs.

[0069] Furthermore, based on this, the welding frequency is 20KHz and the welding time is 0.7s~1s.

[0070] S50. Control the ultrasonic welding system and / or the mobile carrier to flow into the next welding station, repeat the above steps, and weld multiple welding areas of the CCS module in sequence through the ultrasonic welding system.

[0071] like Figure 5 As shown, in one or more embodiments of the ultrasonic welding method for CCS modules, the ultrasonic welding method further includes providing a double-speed chain 6, on which a movable carrier 5 is mounted, the two being kept relatively fixed, and the CCS module A is positioned by the movable carrier 5.

[0072] On one hand, the movement of the double-speed chain conveyor 6 can be controlled to move the CCS module A on the mobile carrier 5 relative to the ultrasonic welding system, so that the ultrasonic welding system can sequentially weld multiple welding areas on the CCS module A. On the other hand, the movement of the ultrasonic welding system can also be controlled to sequentially weld multiple welding areas of the CCS module A on the mobile carrier 5.

[0073] Figure 8 A schematic diagram of the peeling state of a CCS module under one embodiment is shown. The welded FPC sheet and aluminum busbar are subjected to a tensile test to peel them off. The tensile force of the peeling test is 5N~15N, and the peeled residual area is greater than 30%. Figure 8 As shown, the ratio of the residual area S to the welded area 10 is greater than 30%, which can meet the needs of practical applications.

[0074] In some embodiments, a CCS module connector is also provided, which is manufactured using the ultrasonic welding method described above, such as... Figure 7 As shown, the CCS module connector includes:

[0075] FPC sheet 1, the upper surface 101 of FPC sheet 1 has a welding area;

[0076] Aluminum busbar 21, the lower surface 212 of aluminum busbar 21 has a support position, and the upper surface 211 of aluminum busbar 21 is attached to the lower surface 102 of FPC sheet 1.

[0077] The area of ​​the welding area 10 is 30-60 square millimeters, and the upper surface 211 of the aluminum busbar 21 is welded to the lower surface 102 of the FPC sheet 1.

[0078] Ultrasonic welding of FPC sheets and aluminum busbars can improve product welding quality, ensure product yield, and reduce production and processing costs. Ultrasonic welding does not damage the product structure, ensuring product performance and yield, and has low manufacturing costs. After welding, the FPC will not carbonize, resulting in lower resistivity at the connection between the FPC and the aluminum busbar, thus reducing battery heat generation.

[0079] The above description is merely a detailed explanation of preferred embodiments and principles of the present invention. For those skilled in the art, there may be changes in specific implementation methods based on the ideas provided by the present invention, and these changes should also be considered within the scope of protection of the present invention.

Claims

1. An ultrasonic welding method for CCS modules, characterized in that, Includes the following steps: Provide ultrasonic welding systems and mobile vehicles; A CCS module is provided and housed within the mobile carrier; the CCS module includes an aluminum busbar and an FPC sheet, the aluminum busbar and the FPC sheet are bonded together, the aluminum busbar is provided with a support position, and the FPC sheet is provided with a welding area; the aluminum busbar is connected to a hot-pressing film, the hot-pressing film has a positioning groove, and the bottom mold passes through the positioning groove and abuts against the support position; The mobile carrier is controlled to move to the ultrasonic welding system. A first camera identifies the lower surface of the CCS module and obtains the support position, while a second camera identifies the upper surface of the CCS module and obtains the welding area. The second camera sequentially obtains multiple welding areas on the FPC sheet and determines whether they meet the welding conditions. If so, the ultrasonic welding system is controlled to weld the FPC sheet to the aluminum busbar. If not, the mobile carrier is controlled to flow into the next welding station. The ultrasonic welding system is activated so that the bottom mold and welding head of the ultrasonic welding system are respectively positioned facing the support position and the welding area, and are used to weld the CCS module into shape. Control the ultrasonic welding system and / or the mobile carrier to flow into the next welding station, repeat the above steps, and sequentially weld multiple welding areas of the CCS module through the ultrasonic welding system.

2. The ultrasonic welding method for CCS modules according to claim 1, characterized in that, Also includes: A high-speed chain conveyor is provided, on which the moving carrier is mounted to position the CCS module; by controlling the movement of the high-speed chain conveyor, the ultrasonic welding system sequentially welds multiple welding areas on the CCS module.

3. The ultrasonic welding method for CCS modules according to claim 1, characterized in that, The ultrasonic welding system also includes: A first drive module and a second drive module are provided. The first drive module drives the bottom mold to rise so that the bottom mold abuts against the support position of the aluminum strip. The second drive module drives the welding head to fall so that the welding head abuts against the welding area of ​​the FPC sheet.

4. The ultrasonic welding method for CCS modules according to claim 1, characterized in that, The ultrasonic welding system has a welding pressure of 500N~1000N, an amplitude of 35μm~55μm, and a welding power of 500W~1000W.

5. The ultrasonic welding method for CCS modules according to claim 1, characterized in that, The residual area after welding of the CCS module is greater than 30%.

6. A CCS module connector, characterized in that, It is manufactured by ultrasonic welding as described in any one of claims 1 to 5.

7. A CCS module connector according to claim 6, characterized in that, include: FPC sheet, wherein the upper surface of the FPC sheet has a welding area; An aluminum busbar, the lower surface of which has a support position, and the upper surface of which is in contact with the lower surface of the FPC sheet; The area of ​​the welding region is 30-60 square millimeters, and the upper surface of the aluminum busbar is welded to the lower surface of the FPC sheet.

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