Bus bar mounting module, bus bar assembly and battery pack tray assembly

Abstract

The invention discloses a bus bar mounting module, a bus bar assembly, a sub-tray assembly and a battery pack tray assembly. The bus bar mounting module includes: a bus bar mounting member for mounting a bus bar on a battery pack tray; and a terminal provided in an end portion of the bus bar mount for electrically connecting the bus bar. The terminal and the end portion of the bus bar mounting member form a connector adapted to mate with a mating connector, and the end portion of the bus bar mounting member forms a housing of the connector. According to the embodiment of the invention, the bus bar can be electrically connected with the flexible circuit board or the flexible flat cable through the two matched connectors, and the electric connection operation of the bus bar is simplified.

Description

Technical Field

[0001] The present invention relates to a busbar installation module, including a busbar assembly of the busbar installation module, a sub-tray assembly including the busbar assembly, and a battery pack tray assembly including the sub-tray assembly. Background Art

[0002] In the prior art, the busbars of the battery pack are usually installed on a tray. The tray usually includes a tray body and a fixing portion formed on the tray body and suitable for fixing the busbars. In the prior art, the tray is an integral injection molded part. As the number of busbars of the battery pack increases, the volume of the tray becomes larger and larger. Since the busbars need to have a higher fixing accuracy, the injection molding tolerance requirements for the tray are becoming more and more precise, the injection molding difficulty is increasing, and the cost is increasing.

[0003] In addition, in the prior art, a connection terminal is usually used to electrically connect the bus bar to the flexible circuit board or the flexible flat cable to collect the voltage of the battery cell. One end of the connection terminal is crimped to the flexible circuit board or the flexible flat cable, and the other end is welded to the bus bar, which makes the electrical connection operation of the bus bar very complicated. Summary of the invention

[0004] The purpose of the present invention is to solve at least one aspect of the above-mentioned problems and defects in the prior art.

[0005] According to one aspect of the present invention, a busbar mounting module is provided. The busbar mounting module comprises: a busbar mounting member for mounting a busbar on a battery pack tray; and a terminal, which is arranged in an end of the busbar mounting member and is used to electrically connect the busbar. The terminal and the end of the busbar mounting member constitute a connector suitable for mating with a mating connector, and the end of the busbar mounting member constitutes a housing of the connector.

[0006] According to an exemplary embodiment of the present invention, fixing columns are respectively formed at the bottom of both ends of the bus bar mounting member, and the fixing columns are used to be inserted into the cross holes on the battery pack tray to fix the bus bar mounting member to the battery pack tray.

[0007] According to another exemplary embodiment of the present invention, positioning recesses are respectively formed at the bottom of both ends of the bus bar mounting component, and the fixing column is located in the positioning recesses; the positioning recesses are used to cooperate with the positioning protrusions on the battery pack tray to position the bus bar mounting component.

[0008] According to another exemplary embodiment of the present invention, an annular groove is formed on the fixing post, and an edge portion of the cross hole on the battery pack tray is clamped in the annular groove of the fixing post, so that the fixing post is engaged with the cross hole.

[0009] According to another exemplary embodiment of the present invention, a positioning groove is formed on the top of the bus bar mounting member, and the bus bar is positioned and mounted in the positioning groove.

[0010] According to another exemplary embodiment of the present invention, the bus bar mounting module further includes: a connection member disposed in an end portion of the bus bar mounting member and electrically connecting the bus bar and the terminal.

[0011] According to another exemplary embodiment of the present invention, the bus bar mounting member is an injection molded member formed on the terminal and the connection member by an insert injection molding process, so that the bus bar mounting member, the terminal and the connection member are integrated into one piece.

[0012] According to another exemplary embodiment of the present invention, the terminal includes a substrate portion and a pin portion, and the lower end of the connecting component is riveted, welded or crimped to the substrate portion of the terminal; a socket is formed at the end of the busbar mounting member, and the pin portion of the terminal is accommodated in the socket to be electrically connected to a mating connector inserted into the socket.

[0013] According to another aspect of the present invention, a busbar assembly is provided. The busbar assembly comprises: the aforementioned busbar mounting module and a busbar. The busbar comprises: a body portion mounted on the busbar mounting member; and an elastic connecting arm connected to a side portion of the body portion, wherein the elastic connecting arm of the busbar is electrically connected to the terminal of the busbar mounting module.

[0014] According to another exemplary embodiment of the present invention, a coupling hole is formed on the end of the elastic connecting arm of the busbar, and the upper end of the connecting component of the busbar mounting module is columnar and is pressed into the coupling hole on the elastic connecting arm to be electrically connected to the elastic connecting arm.

[0015] According to another aspect of the present invention, a sub-tray assembly is provided, comprising: a sub-tray; and a plurality of the aforementioned bus bar assemblies mounted on the sub-tray.

[0016] According to an exemplary embodiment of the present invention, a positioning protrusion is formed on the sub-tray, and a cross hole is formed on the positioning protrusion; the positioning protrusion is suitable for cooperating with the positioning recess on the bus bar mounting member to position the bus bar mounting member; the cross hole is suitable for engaging with the fixing column on the bus bar mounting member to fix the bus bar mounting member.

[0017] According to another exemplary embodiment of the present invention, through holes are formed on the sub-tray to allow electrode terminals of the battery cells to pass through, so that the electrode terminals of the battery cells can pass through the through holes and be electrically connected to bus bars fixed on the sub-tray.

[0018] According to another exemplary embodiment of the present invention, the sub-tray is an integral punched piece formed by punching a blister tape, and a row of tape holes are respectively formed on two longitudinal sides of the blister tape, and the tape holes are used to position and convey the blister tape when punching the blister tape and installing the bus bar assembly.

[0019] According to another aspect of the present invention, a battery pack tray assembly is provided, comprising: a plurality of the aforementioned sub-tray assemblies, wherein a plurality of sub-trays in the plurality of sub-tray assemblies are arranged side by side in a first direction and connected to each other to form a battery pack tray.

[0020] According to an exemplary embodiment of the present invention, the sub-pallet has a first side and a second side opposite to each other in the first direction, a row of connecting holes and a row of connecting columns are respectively formed on the first side and the second side of the sub-pallet, and the connecting columns of one sub-pallet of two adjacent sub-pallets are hot riveted into the connecting holes of the other sub-pallet, so that the multiple sub-pallets are connected to each other.

[0021] According to another exemplary embodiment of the present invention, the diameter of the connecting column is smaller than the minimum hole diameter of the connecting hole to allow the two connected sub-trays to move relative to each other in the first direction and a second direction perpendicular to the first direction, and the connecting column has a limiting flange formed by hot riveting, and the diameter of the limiting flange is larger than the minimum hole diameter of the connecting hole to prevent the connecting column from being detached from the connecting hole along its axial direction.

[0022] According to another exemplary embodiment of the present invention, the connecting hole is elliptical in shape, having a maximum aperture in the first direction and a minimum aperture in the second direction.

[0023] According to another exemplary embodiment of the present invention, the battery pack tray assembly further includes: an electrical connector, which is in the shape of a strip and extends along a first direction; and a plurality of mating connectors, which are electrically connected to the electrical connector, and the plurality of mating connectors are respectively mated with a plurality of connectors on the battery pack tray to electrically connect a plurality of bus bars on the battery pack tray to the electrical connector.

[0024] According to another exemplary embodiment of the present invention, the mating connector includes: a mating shell; and a mating terminal, which is arranged in the mating shell, one end of the mating terminal is electrically connected to the electrical connector, and the other end is matingly connected to the terminal of the connector.

[0025] According to another exemplary embodiment of the present invention, the electrical connector is a flexible circuit board, an elastic arm is formed on a side of the flexible circuit board, and one end of the mating terminal is crimped onto the elastic arm of the flexible circuit board.

[0026] According to another exemplary embodiment of the present invention, the electrical connector is a flexible flat cable, and one end of the mating terminal is crimped onto the flexible flat cable.

[0027] According to another exemplary embodiment of the present invention, an avoidance hole for avoiding the connection column on the sub-tray is formed on the electrical connector, so that the movement of the sub-tray will not be restricted by the electrical connector.

[0028] According to another exemplary embodiment of the present invention, the battery pack tray assembly includes a plurality of electrical connectors, which are arranged side by side in a second direction perpendicular to the first direction and spaced apart from each other by a predetermined distance.

[0029] In the foregoing various exemplary embodiments of the present invention, the bus bar can be electrically connected to the flexible printed circuit board or the flexible flat cable through two mating connectors, which simplifies the electrical connection operation of the bus bar.

[0030] In addition, in some of the aforementioned exemplary embodiments of the present invention, the elastic connecting arm of the busbar is electrically connected to the terminal for collecting the voltage of the battery cell. Due to the flexibility of the elastic connecting arm, the stress concentration caused by the heating of the battery cell can be absorbed.

[0031] In addition, in the aforementioned exemplary embodiments of the present invention, the sub-trays used to splice the battery pack trays are small in size and can be easily injection molded. Therefore, the present invention reduces the processing difficulty and manufacturing cost of large-sized battery pack trays. Moreover, the two connected sub-trays can move relative to each other, thereby absorbing the stress caused by the expansion of the battery core.

[0032] Other objects and advantages of the present invention will become apparent from the following description of the present invention with reference to the accompanying drawings, which will help to provide a comprehensive understanding of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 A schematic plan view showing a battery pack tray assembly according to an exemplary embodiment of the present invention;

[0034] Figure 2 An exploded schematic diagram showing a battery pack tray assembly according to an exemplary embodiment of the present invention;

[0035] Figure 3 A perspective schematic diagram showing a sub-tray assembly according to an exemplary embodiment of the present invention;

[0036] Figure 4 An exploded schematic diagram showing a sub-tray assembly according to an exemplary embodiment of the present invention;

[0037] Figure 5 A partially enlarged schematic diagram showing a sub-tray assembly according to an exemplary embodiment of the present invention;

[0038] Figure 6 A cross-sectional view showing a sub-tray assembly according to an exemplary embodiment of the present invention, wherein the bus bar mount has not yet been secured to the sub-tray;

[0039] Figure 7 A cross-sectional view showing a sub-tray assembly according to an exemplary embodiment of the present invention, wherein a bus bar mount has been secured to the sub-tray;

[0040] Figure 8 A cross-sectional view showing a bus bar mount and a bus bar according to an exemplary embodiment of the present invention;

[0041] Fig. 9 An exploded schematic diagram showing a bus bar mount and a bus bar according to an exemplary embodiment of the present invention;

[0042] Fig.10 A schematic diagram showing a blister strip made by a blister process according to an exemplary embodiment of the present invention;

[0043] Fig.11 A perspective schematic diagram showing a sub-tray according to an exemplary embodiment of the present invention;

[0044] Fig.12 A perspective schematic diagram showing two sub-trays according to an exemplary embodiment of the present invention, wherein the two sub-trays have not been connected together;

[0045] Fig.13 An enlarged cross-sectional view showing two sub-trays according to an exemplary embodiment of the present invention;

[0046] Fig.14 A perspective schematic diagram showing two sub-trays according to an exemplary embodiment of the present invention, wherein the two sub-trays have been connected together;

[0047] Fig.15A partially enlarged schematic diagram showing two sub-trays according to an exemplary embodiment of the present invention;

[0048] Fig.16 A perspective schematic diagram showing an electrical connector and a mating connector according to an exemplary embodiment of the present invention;

[0049] Fig.17 An exploded schematic diagram showing an electrical connector and a mating connector according to an exemplary embodiment of the present invention;

[0050] Fig.18 A three-dimensional schematic diagram showing the mating of a connector and a mating connector according to an exemplary embodiment of the present invention;

[0051] Fig.19 A perspective schematic diagram showing a connector and a mating connector according to an exemplary embodiment of the present invention. DETAILED DESCRIPTION

[0052] The technical solution of the present invention is further specifically described below by examples and in conjunction with the accompanying drawings. In the specification, the same or similar reference numerals indicate the same or similar components. The following description of the embodiments of the present invention with reference to the accompanying drawings is intended to explain the overall inventive concept of the present invention and should not be construed as a limitation of the present invention.

[0053] In addition, in the detailed description below, for ease of explanation, many specific details are set forth to provide a comprehensive understanding of the disclosed embodiments. However, it is apparent that one or more embodiments may be implemented without these specific details. In other cases, known structures and devices are embodied in a schematic manner to simplify the accompanying drawings.

[0054] According to an overall technical concept of the present invention, a battery pack tray is provided. The battery pack tray includes: a plurality of sub-trays arranged side by side in a first direction. The sub-tray has a first side and a second side opposite to each other in the first direction, and a row of connection holes and a row of connection columns are respectively formed on the first side and the second side of the sub-tray; the connection column of one of the two adjacent sub-trays is hot-riveted into the connection hole of the other sub-tray, so that the plurality of sub-trays are connected to each other; the diameter of the connection column is smaller than the minimum aperture of the connection hole to allow the two connected sub-trays to move relative to each other in the first direction and in a second direction perpendicular to the first direction; the connection column has a limiting flange formed by hot riveting, and the diameter of the limiting flange is larger than the minimum aperture of the connection hole to prevent the connection column from being separated from the connection hole along its axial direction.

[0055] According to another general technical concept of the present invention, there is provided a battery pack tray assembly, comprising: the aforementioned battery pack tray; a bus bar mounting member fixed to the sub-tray; and a bus bar mounted to the bus bar mounting member.

[0056] According to another general technical concept of the present invention, a busbar mounting module is provided. The busbar mounting module includes: a busbar mounting member for mounting a busbar on a battery pack tray; and a terminal, which is arranged in an end of the busbar mounting member and is used to electrically connect the busbar. The terminal and the end of the busbar mounting member constitute a connector suitable for mating with a mating connector, and the end of the busbar mounting member constitutes a housing of the connector.

[0057] According to another general technical concept of the present invention, a busbar assembly is provided. The busbar assembly comprises: the aforementioned busbar mounting module and a busbar. The busbar comprises: a body portion mounted on the busbar mounting member; and an elastic connecting arm connected to a side portion of the body portion, the elastic connecting arm of the busbar being electrically connected to the terminal of the busbar mounting module.

[0058] According to another general technical concept of the present invention, a sub-tray assembly is provided. The sub-tray assembly comprises: a sub-tray; and a plurality of the aforementioned bus bar assemblies mounted on the sub-tray.

[0059] According to another general technical concept of the present invention, a battery pack tray assembly is provided, comprising: a plurality of the aforementioned sub-tray assemblies, wherein a plurality of sub-trays in the plurality of sub-tray assemblies are arranged side by side in a first direction and connected to each other to form a battery pack tray.

[0060] Figure 1 A schematic plan view showing a battery pack tray assembly according to an exemplary embodiment of the present invention; Figure 2 An exploded schematic diagram showing a battery pack tray assembly according to an exemplary embodiment of the present invention; Figure 3 A perspective schematic diagram showing a sub-tray assembly according to an exemplary embodiment of the present invention; Fig.11 A perspective schematic diagram showing a sub-tray 10 according to an exemplary embodiment of the present invention; Fig.12 A perspective schematic diagram showing two sub-trays 10 according to an exemplary embodiment of the present invention, wherein the two sub-trays 10 have not been connected together; Fig.13 An enlarged cross-sectional view showing two sub-trays 10 according to an exemplary embodiment of the present invention; Fig.14 A perspective schematic diagram showing two sub-trays 10 according to an exemplary embodiment of the present invention, wherein the two sub-trays 10 have been connected together; Fig.15 A partially enlarged schematic diagram showing two sub-trays 10 according to an exemplary embodiment of the present invention.

[0061] like Figure 1-3 and Figure 11-15 As shown, in an exemplary embodiment of the present invention, a battery pack tray 1 is disclosed. The battery pack tray 1 includes a plurality of sub-trays 10. The plurality of sub-trays 10 are arranged side by side in a first direction X. The sub-tray 10 has a first side and a second side opposite to each other in the first direction X, and a row of connection holes 110 and a row of connection posts 120 are respectively formed on the first side and the second side of the sub-tray 10. The connection posts 120 of one of the two adjacent sub-trays 10 are hot-riveted into the connection holes 110 of the other sub-tray 10, so that the plurality of sub-trays 10 are connected to each other.

[0062] like Figure 1-3 and Figure 11-15 As shown, in the illustrated embodiment, the diameter of the connecting post 120 is smaller than the minimum aperture of the connecting hole 110, so as to allow the two connected sub-trays 10 to move relative to each other in a first direction X and a second direction Y perpendicular to the first direction X. The connecting post 120 has a limiting flange 120a formed by heat riveting, and the diameter of the limiting flange 120a is larger than the minimum aperture of the connecting hole 110, so as to prevent the connecting post 120 from being separated from the connecting hole 110 along its axial direction.

[0063] like Figure 1-3 and Figure 11-15 As shown, in the illustrated embodiment, the connecting hole 110 is elliptical, having a maximum aperture in the first direction X and a minimum aperture in the second direction Y.

[0064] like Figure 1-3 and Figure 11-15 As shown, in the illustrated embodiment, a positioning protrusion 11 is formed on the sub-tray 10, and a cross hole 12 is formed on the positioning protrusion 11. The positioning protrusion 11 is suitable for cooperating with the positioning recess 31 on the busbar mounting member 3 to position the busbar mounting member 3. The cross hole 12 is suitable for engaging with the fixing column 32 on the busbar mounting member 3 to fix the busbar mounting member 3.

[0065] like Figure 1-3 and Figure 11-15 As shown, in the illustrated embodiment, a through hole 101 is formed on the sub-tray 10 to allow the electrode terminal of the battery cell (not shown) to pass through, so that the electrode terminal of the battery cell can pass through the through hole 101 and be electrically connected to the bus bar 2 fixed on the sub-tray 10.

[0066] Fig.10 A schematic diagram showing a blister tape 10 ′ manufactured by a blister process according to an exemplary embodiment of the present invention.

[0067] like Figure 1-3 and Figure 10-15 As shown, in the illustrated embodiment, when manufacturing the sub-tray 10, the blister process is first used to manufacture the sub-tray 10. Fig.10 The blister tape 10' is then punched and cut to form Fig.11 The sub-tray 10 shown. In this way, the processing difficulty and manufacturing cost of the large-sized battery pack tray 1 can be reduced. In the illustrated embodiment, the sub-tray 10 is an integrated punched piece formed by punching the blister tape 10', and a row of strip holes 130 are respectively formed on the two longitudinal sides of the blister tape 10'. The strip holes 130 are used to position and convey the blister tape 10' when punching the blister tape 10' and installing the bus bar assembly on the sub-tray 10. In this way, the punching process of the blister tape 10' and the installation operation of the bus bar assembly can be fully automated, thereby improving production efficiency.

[0068] Figure 4 An exploded schematic diagram showing a sub-tray assembly according to an exemplary embodiment of the present invention; Figure 5 A partially enlarged schematic diagram showing a sub-tray assembly according to an exemplary embodiment of the present invention; Figure 6 A cross-sectional view showing a sub-tray assembly according to an exemplary embodiment of the present invention, wherein the bus bar mounting member 3 has not yet been fixed to the sub-tray 10; Figure 7 A cross-sectional view showing a sub-tray assembly according to an exemplary embodiment of the present invention, wherein the bus bar mount 3 has been fixed to the sub-tray 10; Figure 8 A cross-sectional view showing a bus bar mounting member 3 and a bus bar 2 according to an exemplary embodiment of the present invention; Fig. 9 An exploded schematic diagram of a bus bar mount 3 and a bus bar 2 according to an exemplary embodiment of the present invention is shown.

[0069] like Figures 1 to 15 As shown, in another exemplary embodiment of the present invention, a battery pack tray assembly is also disclosed. The battery pack tray assembly includes: a battery pack tray 1, a bus bar 2 and a bus bar mounting member 3. The bus bar mounting member 3 is fixed to the sub-tray 10. The bus bar 2 is mounted on the bus bar mounting member 3.

[0070] like Figures 1 to 15 As shown, in the illustrated embodiment, positioning recesses 31 are formed at the bottom of both ends of the busbar mounting member 3, and the positioning protrusions 11 on the sub-tray 10 are embedded in the positioning recesses 31. Fixing columns 32 are formed at both ends of the busbar mounting member 3, and the fixing columns 32 are located in the positioning recesses 31 and inserted into the cross holes 12 on the sub-tray 10.

[0071] like Figures 1 to 15As shown, in the illustrated embodiment, an annular groove 32 a is formed on the fixing post 32 , and the edge of the cross hole 12 on the sub-tray 10 is clamped in the annular groove 32 a of the fixing post 32 , so that the fixing post 32 and the cross hole 12 are engaged together.

[0072] like Figures 1 to 15 As shown, in the illustrated embodiment, a positioning groove 301 is formed on the top of the bus bar mounting member 3 , and the bus bar 2 is positioned and mounted in the positioning groove 301 .

[0073] like Figures 1 to 15 As shown, in the illustrated embodiment, the battery pack tray assembly further includes a terminal 40, which is disposed in the end 30 of the bus bar mounting member 3 and is electrically connected to the bus bar 2. The terminal 40 and the end 30 of the bus bar mounting member 3 constitute a connector 4 suitable for mating with a mating connector 6, and the end 30 of the bus bar mounting member 3 constitutes a housing of the connector 4.

[0074] like Figures 1 to 15 As shown, in the illustrated embodiment, the battery pack tray assembly further includes a connecting component 41 , which is disposed in the end portion 30 of the bus bar mount 3 and electrically connects the bus bar 2 and the terminal 40 .

[0075] like Figures 1 to 15 As shown, in the illustrated embodiment, the busbar mounting member 3 is an injection molded member formed on the terminal 40 and the connecting member 41 by an insert injection molding process, so that the busbar mounting member 3, the terminal 40 and the connecting member 41 become an integral member.

[0076] like Figures 1 to 15 As shown, in the illustrated embodiment, the busbar 2 includes: a body portion 20 and an elastic connecting arm 21. The body portion 20 is mounted on the busbar mounting member 3. The elastic connecting arm 21 is connected to the side of the body portion 20. The connecting component 41 electrically connects the elastic connecting arm 21 of the busbar 2 and the terminal 40.

[0077] like Figures 1 to 15 As shown, in the illustrated embodiment, the busbar 2 is an integrated stamping part. The elastic connecting arm 21 of the busbar 2 is electrically connected to the terminal 40 for collecting the voltage of the battery cell. In the illustrated embodiment, due to the flexibility of the elastic connecting arm, the stress concentration caused by the heating of the battery cell can be absorbed.

[0078] like Figures 1 to 15 As shown, in the illustrated embodiment, a coupling hole 21 a is formed on the end of the elastic connecting arm 21 of the busbar 2, and the upper end 41 a of the connecting component 41 is columnar and is pressed into the coupling hole 21 a on the elastic connecting arm 21 to be electrically connected to the elastic connecting arm 21.

[0079] like Figures 1 to 15As shown, in the illustrated embodiment, the terminal 40 includes a substrate portion 40a and a pin portion 40b, and the lower end of the connecting member 41 is riveted, welded or crimped to the substrate portion 40a of the terminal 40. An insertion hole 302 is formed at the end 30 of the busbar mounting member 3, and the pin portion 40b of the terminal 40 is accommodated in the insertion hole 302 to be electrically connected to the mating connector 6 inserted into the insertion hole 302.

[0080] Fig.16 A perspective schematic diagram showing an electrical connector 5 and a mating connector 6 according to an exemplary embodiment of the present invention; Fig.17 An exploded schematic diagram showing an electrical connector 5 and a mating connector 6 according to an exemplary embodiment of the present invention; Fig.18 A three-dimensional schematic diagram showing the mating of a connector 4 and a mating connector 6 according to an exemplary embodiment of the present invention; Fig.19 A schematic perspective view showing a connector 4 and a mating connector 6 according to an exemplary embodiment of the present invention.

[0081] like Figures 1 to 19 As shown, in the illustrated embodiment, the battery pack tray assembly further includes an electrical connector 5 and a plurality of mating connectors 6. The electrical connector 5 is strip-shaped and extends along a first direction X. The plurality of mating connectors 6 are electrically connected to the electrical connector 5. The plurality of mating connectors 6 are mated with the plurality of connectors 4 on the battery pack tray 1, respectively, to electrically connect the plurality of bus bars 2 on the battery pack tray 1 to the electrical connector 5.

[0082] like Figures 1 to 19 As shown, in the illustrated embodiment, the mating connector 6 comprises: a mating housing 61 and a mating terminal 60, and the mating terminal 60 is arranged in the mating housing 61. One end 60a of the mating terminal 60 is electrically connected to the electrical connector 5, and the other end 60b is matingly connected to the terminal 40 of the connector 4.

[0083] like Figures 1 to 19 As shown, in the illustrated embodiment, the electrical connector 5 is a flexible circuit board, a resilient arm 51 is formed on the side of the flexible circuit board, and one end 60a of the mating terminal 60 is crimped onto the resilient arm 51 of the flexible circuit board.

[0084] However, the present invention is not limited to the illustrated embodiment. For example, in another exemplary embodiment of the present invention, the electrical connector 5 may also be a flexible flat cable, and one end 60a of the mating terminal 60 is crimped onto the flexible flat cable.

[0085] like Figures 1 to 19 As shown, in the illustrated embodiment, an avoidance hole 501 for avoiding the connection column 120 on the sub-tray 10 is formed on the electrical connector 5 , so that the movement of the sub-tray 10 will not be restricted by the electrical connector 5 .

[0086] like Figures 1 to 19 As shown, in the illustrated embodiment, the battery pack tray assembly includes a plurality of electrical connectors 5, which are arranged side by side in a second direction Y perpendicular to the first direction X and are spaced apart from each other by a predetermined distance.

[0087] like Figures 1 to 19 As shown, in another exemplary embodiment of the present invention, a busbar mounting module is also disclosed. The busbar mounting module includes: a busbar mounting member 3 and a terminal 40. The busbar mounting member 3 is used to mount the busbar 2 on the battery pack tray 1. The terminal 40 is arranged in the end 30 of the busbar mounting member 3 for electrically connecting the busbar 2. The terminal 40 and the end 30 of the busbar mounting member 3 constitute a connector 4 suitable for mating with a mating connector 6, and the end 30 of the busbar mounting member 3 constitutes a housing of the connector 4.

[0088] like Figures 1 to 19 As shown, in the illustrated embodiment, fixing columns 32 are respectively formed at the bottom of both ends of the bus bar mounting member 3, and the fixing columns 32 are used to be inserted into the cross holes 12 on the battery pack tray 1 to fix the bus bar mounting member 3 to the battery pack tray 1.

[0089] like Figures 1 to 19 As shown, in the illustrated embodiment, positioning recesses 31 are respectively formed at the bottom of both ends of the busbar mounting member 3, and the fixing column 32 is located in the positioning recesses 31. The positioning recesses 31 are used to cooperate with the positioning protrusions 11 on the battery pack tray 1 to position the busbar mounting member 3.

[0090] like Figures 1 to 19 As shown, in the illustrated embodiment, an annular groove 32 a is formed on the fixing column 32 , and the edge of the cross hole 12 on the battery pack tray 1 is clamped in the annular groove 32 a of the fixing column 32 , so that the fixing column 32 is engaged with the cross hole 12 .

[0091] like Figures 1 to 19 As shown, in the illustrated embodiment, a positioning groove 301 is formed on the top of the bus bar mounting member 3 , and the bus bar 2 is positioned and mounted in the positioning groove 301 .

[0092] like Figures 1 to 19 As shown, in the illustrated embodiment, the busbar mounting module further includes a connection component 41 , which is disposed in the end portion 30 of the busbar mounting member 3 and electrically connects the busbar 2 and the terminal 40 .

[0093] like Figures 1 to 19 As shown, in the illustrated embodiment, the busbar mounting member 3 is an injection molded member formed on the terminal 40 and the connecting member 41 by an insert injection molding process, so that the busbar mounting member 3, the terminal 40 and the connecting member 41 become an integral member.

[0094] like Figures 1 to 19 As shown, in the illustrated embodiment, the terminal 40 includes a substrate portion 40a and a pin portion 40b, and the lower end of the connecting member 41 is riveted, welded or crimped to the substrate portion 40a of the terminal 40. An insertion hole 302 is formed at the end 30 of the busbar mounting member 3, and the pin portion 40b of the terminal 40 is accommodated in the insertion hole 302 to be electrically connected to the mating connector 6 inserted into the insertion hole 302.

[0095] like Figures 1 to 19 As shown, in another exemplary embodiment of the present invention, a busbar assembly is also disclosed. The busbar assembly includes: the aforementioned busbar mounting module and a busbar 2. The busbar 2 includes: a body portion 20 and an elastic connecting arm 21. The body portion 20 of the busbar 2 is mounted on the busbar mounting member 3. The elastic connecting arm 21 is connected to the side of the body portion 20. The elastic connecting arm 21 of the busbar 2 is electrically connected to the terminal 40 of the busbar mounting module.

[0096] like Figures 1 to 19 As shown, in the illustrated embodiment, a coupling hole 21a is formed at the end of the elastic connecting arm 21 of the busbar 2, and the upper end 41a of the connecting component 41 of the busbar mounting module is columnar and is pressed into the coupling hole 21a on the elastic connecting arm 21 to be electrically connected to the elastic connecting arm 21.

[0097] like Figures 1 to 19 As shown, in another exemplary embodiment of the present invention, a sub-tray assembly is also disclosed. The sub-tray assembly comprises: a sub-tray 10 and a plurality of the aforementioned bus bar assemblies. The plurality of bus bar assemblies are mounted on the sub-tray 10 .

[0098] like Figures 1 to 19 As shown, in the illustrated embodiment, a positioning protrusion 11 is formed on the sub-tray 10, and a cross hole 12 is formed on the positioning protrusion 11. The positioning protrusion 11 is suitable for cooperating with the positioning recess 31 on the busbar mounting member 3 to position the busbar mounting member 3. The cross hole 12 is suitable for engaging with the fixing column 32 on the busbar mounting member 3 to fix the busbar mounting member 3.

[0099] like Figures 1 to 19 As shown, in the illustrated embodiment, a through hole 101 is formed on the sub-tray 10 to allow the electrode terminal of the battery cell to pass through, so that the electrode terminal of the battery cell can pass through the through hole 101 and be electrically connected to the bus bar 2 fixed on the sub-tray 10.

[0100] like Figures 1 to 19As shown, in another exemplary embodiment of the present invention, a battery pack tray assembly is also disclosed. The battery pack tray assembly includes a plurality of the aforementioned sub-tray assemblies, wherein a plurality of sub-trays 10 in the plurality of sub-tray assemblies are arranged side by side in a first direction X and connected to each other to form a battery pack tray 1.

[0101] like Figures 1 to 19 As shown, in the illustrated embodiment, the sub-tray 10 has a first side and a second side opposite to each other in a first direction X, and a row of connection holes 110 and a row of connection posts 120 are respectively formed on the first side and the second side of the sub-tray 10. The connection posts 120 of one of the two adjacent sub-trays 10 are hot-riveted to the connection holes 110 of the other sub-tray 10, so that the plurality of sub-trays 10 are connected to each other.

[0102] like Figures 1 to 19 As shown, in the illustrated embodiment, the diameter of the connecting post 120 is smaller than the minimum aperture of the connecting hole 110, so as to allow the two connected sub-trays 10 to move relative to each other in a first direction X and a second direction Y perpendicular to the first direction X. The connecting post 120 has a limiting flange 120a formed by heat riveting, and the diameter of the limiting flange 120a is larger than the minimum aperture of the connecting hole 110, so as to prevent the connecting post 120 from being separated from the connecting hole 110 along its axial direction.

[0103] like Figures 1 to 19 As shown, in the illustrated embodiment, the connecting hole 110 is elliptical, having a maximum aperture in the first direction X and a minimum aperture in the second direction Y.

[0104] like Figures 1 to 19 As shown, in the illustrated embodiment, the battery pack tray assembly further includes: an electrical connector 5 and a plurality of mating connectors 6. The electrical connector 5 is strip-shaped and extends along the first direction X. The plurality of mating connectors 6 are electrically connected to the electrical connector 5. The plurality of mating connectors 6 are respectively mated with the plurality of connectors 4 on the battery pack tray 1 to electrically connect the plurality of bus bars 2 on the battery pack tray 1 to the electrical connector 5.

[0105] like Figures 1 to 19 As shown, in the illustrated embodiment, the mating connector 6 comprises: a mating housing 61 and a mating terminal 60, and the mating terminal 60 is arranged in the mating housing 61. One end 60a of the mating terminal 60 is electrically connected to the electrical connector 5, and the other end 60b is matingly connected to the terminal 40 of the connector 4.

[0106] like Figures 1 to 19 As shown, in the illustrated embodiment, the electrical connector 5 is a flexible circuit board, a resilient arm 51 is formed on the side of the flexible circuit board, and one end 60a of the mating terminal 60 is crimped onto the resilient arm 51 of the flexible circuit board.

[0107] However, the present invention is not limited to the illustrated embodiment. For example, in another exemplary embodiment of the present invention, the electrical connector 5 may be a flexible flat cable, and one end 60 a of the mating terminal 60 is crimped onto the flexible flat cable.

[0108] like Figures 1 to 19 As shown, in the illustrated embodiment, an avoidance hole 501 for avoiding the connection column 120 on the sub-tray 10 is formed on the electrical connector 5 , so that the movement of the sub-tray 10 will not be restricted by the electrical connector 5 .

[0109] like Figures 1 to 19 As shown, in the illustrated embodiment, the battery pack tray assembly includes a plurality of electrical connectors 5, which are arranged side by side in a second direction Y perpendicular to the first direction X and are spaced apart from each other by a predetermined distance.

[0110] Those skilled in the art will appreciate that the embodiments described above are exemplary and may be improved upon by those skilled in the art. The structures described in the various embodiments may be freely combined without causing any conflicts in structure or principle, and these changes should fall within the scope of protection of the present invention.

[0111] Although the present invention has been described in conjunction with the accompanying drawings, the embodiments disclosed in the accompanying drawings are intended to exemplify the preferred implementations of the present invention and should not be construed as limiting the present invention.

[0112] Although some embodiments of the general inventive concept have been shown and described, it will be appreciated by those skilled in the art that changes may be made to these embodiments without departing from the principles and spirit of the general inventive concept, the scope of which is defined in the claims and their equivalents.

[0113] It should be noted that the word "comprising" does not exclude other elements or steps, and the word "a" or "an" does not exclude a plurality. In addition, any element reference signs in the claims shall not be construed as limiting the scope of the present invention.

Claims

1. A busbar mounting module, characterized in that: include: A busbar mounting member (3) for mounting the busbar (2) on the battery pack tray (1); and a terminal (40) disposed in the end portion (30) of the busbar mounting member (3) for electrically connecting the busbar (2), The terminal (40) and the end (30) of the busbar mounting member (3) constitute a connector (4) suitable for mating with a mating connector (6), and the end (30) of the busbar mounting member (3) constitutes a housing of the connector (4).

2. The busbar mounting module according to claim 1, characterized in that: Fixing columns (32) are respectively formed at the bottom of both ends of the busbar mounting member (3), and the fixing columns (32) are used to be inserted into the cross holes (12) on the battery pack tray (1) to fix the busbar mounting member (3) to the battery pack tray (1).

3. The busbar mounting module according to claim 2, characterized in that: Positioning recesses (31) are respectively formed at the bottom of both ends of the busbar mounting member (3), and the fixing column (32) is located in the positioning recess (31); The positioning recess (31) is used to cooperate with the positioning protrusion (11) on the battery pack tray (1) to position the busbar mounting member (3).

4. The busbar mounting module according to claim 2, characterized in that: An annular groove (32a) is formed on the fixing column (32), and the edge of the cross hole (12) on the battery pack tray (1) is clamped in the annular groove (32a) of the fixing column (32), so that the fixing column (32) and the cross hole (12) are engaged together.

5. The busbar mounting module according to claim 1, characterized in that: A positioning groove (301) is formed on the top of the busbar mounting member (3), and the busbar (2) is positioned and mounted in the positioning groove (301).

6. The busbar mounting module according to claim 1, characterized in that: Also includes: A connecting component (41) is provided in the end portion (30) of the busbar mounting member (3) and electrically connects the busbar (2) and the terminal (40).

7. The busbar mounting module according to claim 6, characterized in that: The busbar mounting member (3) is an injection molded member formed on the terminal (40) and the connecting member (41) by an embedded injection molding process, so that the busbar mounting member (3), the terminal (40) and the connecting member (41) form an integrated member.

8. The busbar mounting module according to claim 6, characterized in that: The terminal (40) comprises a substrate portion (40a) and a pin portion (40b), and the lower end of the connecting component (41) is riveted, welded or crimped onto the substrate portion (40a) of the terminal (40); An insertion hole (302) is formed at the end (30) of the busbar mounting member (3), and the pin portion (40b) of the terminal (40) is received in the insertion hole (302) to be electrically connected to a mating connector (6) inserted into the insertion hole (302).

9. A busbar assembly, characterized in that: include: The busbar mounting module according to any one of claims 1 to 8; and Busbar (2), comprising: A main body (20) mounted on the busbar mounting member (3); and An elastic connecting arm (21) is connected to the side of the main body (20). The elastic connecting arm (21) of the busbar (2) is electrically connected to the terminal (40) of the busbar mounting module.

10. The bus bar assembly according to claim 9, characterized in that: A coupling hole (21a) is formed at the end of the elastic connecting arm (21) of the busbar (2), and the upper end (41a) of the connecting component (41) of the busbar mounting module is columnar and is pressed into the coupling hole (21a) on the elastic connecting arm (21) to be electrically connected to the elastic connecting arm (21).

11. A sub-tray assembly, characterized in that: include: a sub-tray (10); and A plurality of bus bar assemblies are mounted on the sub-tray (10), The busbar assembly is the busbar assembly according to claim 9 or 10.

12. The sub-tray assembly according to claim 11, characterized in that: A positioning protrusion (11) is formed on the sub-tray (10), and a cross hole (12) is formed on the positioning protrusion (11); The positioning protrusion (11) is suitable for cooperating with the positioning recess (31) on the busbar mounting member (3) to position the busbar mounting member (3); The cross hole (12) is suitable for engaging with a fixing column (32) on the busbar mounting member (3) to fix the busbar mounting member (3).

13. The sub-tray assembly according to claim 11, characterized in that: A through hole (101) is formed on the sub-tray (10) to allow the electrode terminal of the battery cell to pass through, so that the electrode terminal of the battery cell can pass through the through hole (101) and be electrically connected to the bus bar (2) fixed on the sub-tray (10).

14. The sub-tray assembly according to claim 11, characterized in that: The sub-tray (10) is an integrated punched piece formed by punching a blister tape (10'), and a row of tape holes (130) are respectively formed on two longitudinal sides of the blister tape (10'), and the tape holes (130) are used to position and convey the blister tape (10') when punching the blister tape (10') and installing the busbar assembly.

15. A battery pack tray assembly, characterized in that: include: A plurality of sub-tray assemblies as claimed in any one of claims 11 to 14, A plurality of sub-trays (10) in the plurality of sub-tray assemblies are arranged side by side in a first direction (X) and connected to each other to form a battery pack tray (1).

16. The battery pack tray assembly according to claim 15, characterized in that: The sub-tray (10) has a first side and a second side opposite to each other in the first direction (X), and a row of connection holes (110) and a row of connection posts (120) are respectively formed on the first side and the second side of the sub-tray (10). The connection column (120) of one sub-tray (10) of two adjacent sub-trays (10) is heat-riveted into the connection hole (110) of the other sub-tray (10), so that the plurality of sub-trays (10) are connected to each other.

17. The battery pack tray assembly according to claim 16, characterized in that: The diameter of the connecting column (120) is smaller than the minimum hole diameter of the connecting hole (110) so as to allow the two connected sub-trays (10) to move relative to each other in the first direction (X) and a second direction (Y) perpendicular to the first direction (X). The connecting column (120) has a limiting flange (120a) formed by heat riveting, and the diameter of the limiting flange (120a) is larger than the minimum hole diameter of the connecting hole (110) to prevent the connecting column (120) from being separated from the connecting hole (110) along its axial direction.

18. The battery pack tray assembly according to claim 17, characterized in that: The connecting hole (110) is elliptical in shape, and has a maximum aperture in the first direction (X) and a minimum aperture in the second direction (Y).

19. The battery pack tray assembly according to claim 15, characterized in that: Also includes: An electrical connector (5) in the shape of a strip and extending along a first direction (X); and A plurality of mating connectors (6) electrically connected to the electrical connector (5), The plurality of mating connectors (6) are respectively mated with the plurality of connectors (4) on the battery pack tray (1) to electrically connect the plurality of bus bars (2) on the battery pack tray (1) to the electrical connector (5).

20. The battery pack tray assembly according to claim 19, characterized in that: The mating connector (6) comprises: A mating housing (61); and The mating terminal (60) is arranged in the mating housing (61), One end (60a) of the mating terminal (60) is electrically connected to the electrical connector (5), and the other end (60b) is matingly connected to the terminal (40) of the connector (4).

21. The battery pack tray assembly according to claim 20, characterized in that: The electrical connector (5) is a flexible circuit board, a resilient arm (51) is formed on the side of the flexible circuit board, and one end (60a) of the mating terminal (60) is crimped onto the resilient arm (51) of the flexible circuit board.

22. The battery pack tray assembly according to claim 20, characterized in that: The electrical connector (5) is a flexible flat cable, and one end (60a) of the mating terminal (60) is crimped onto the flexible flat cable.

23. The battery pack tray assembly according to claim 19, characterized in that: An avoidance hole (501) for avoiding the connection column (120) on the sub-tray (10) is formed on the electrical connector (5), so that the movement of the sub-tray (10) will not be restricted by the electrical connector (5).

24. The battery pack tray assembly according to claim 19, characterized in that: The battery pack tray assembly comprises a plurality of electrical connectors (5), which are arranged side by side in a second direction (Y) perpendicular to the first direction (X) and are spaced apart from each other by a predetermined distance.

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