Integrated battery pack safety detection device and its processing technology

Abstract

The present invention discloses an integrated battery pack safety detection device and its processing technology, wherein the detection device includes: a plurality of PCB control boards, the PCB control boards are provided with a plurality of detection slots; a detection block accommodated in the detection slots, the first side of the detection block is connected to a hard first micro-connection structure, and the first micro-connection structure is arranged with detection legs; the second side of the detection block is connected to a flexible and variable second micro-connection structure, and the back of the detection block is densely covered with detection circuits; a busbar, the busbar includes a plurality of aluminum bars; and a conductive connector, the conductive connector includes: an FPC connection body, and a conductive sheet, and a temperature sensor is provided on the conductive sheet. The present invention realizes the combination of multiple detection methods, can effectively detect the state of the battery pack in the early stage of thermal runaway, improve the accuracy and reference of the detection, and can ensure the stable connection between the aluminum bar and the PCB control board, and maintain the effectiveness of the detection device.

Description

Technical Field

[0001] The present invention relates to the technical field of battery packs, and in particular to an integrated battery pack safety detection device and a processing technology thereof. Background Art

[0002] With the rapid development of energy storage technology, batteries are increasingly used, and the requirements for battery safety and reliability are becoming higher and higher. During the use of batteries, there may be serious overcharging, battery short circuit, serious overheating, thermal runaway, impact or extrusion deformation, and puncture. These problems may cause the internal temperature and pressure of the battery to continue to rise. When it exceeds its own safety threshold, it may cause the battery to explode.

[0003] The battery safety valve is the last explosion-proof barrier of the battery itself. When the internal pressure of the battery reaches the opening threshold of the safety valve, for example, the opening threshold of the safety valve of a lithium-ion battery is usually 600~800KPa, in order to avoid the battery from exploding, the battery safety valve is opened to release gas and reduce pressure. When the battery safety valve opens, it means that the battery has a serious safety problem, so it is necessary to detect when the battery safety valve is opened to prevent the safety accident from expanding.

[0004] At present, it is usually judged whether the safety valve is in the open state by detecting the electrolyte splashed out when the safety valve is opened. Since the splashing direction of the electrolyte has a certain uncertainty and there is a certain lag in the detection after the electrolyte splashes onto the sensor, the detection effect is affected. At the same time, the detection circuit board and the battery cell are usually connected conductively with hard nickel sheets, which may become loose or deformed and damaged due to mechanical vibration during transportation or handling, causing the detection circuit board to fail due to poor contact or power failure. Summary of the invention

[0005] In order to overcome the deficiencies of the prior art, an object of the present invention is to provide an integrated battery pack safety detection device and a processing technology thereof, which have the advantages of improving the detection effect and maintaining the detection effectiveness.

[0006] The purpose of the present invention is achieved by the following technical solutions:

[0007] According to a first aspect of an embodiment of the present disclosure, there is provided an integrated battery pack safety detection device, comprising:

[0008] A plurality of PCB control boards for communicating with the BMS system, wherein the PCB control boards are provided with a plurality of detection notches corresponding to the safety valves of the respective battery cells, and the PCB control boards are fixed to the top of the battery pack and form a predetermined distance between the safety valves;

[0009] A detection block is accommodated in each of the detection slots, a first hard micro-connection structure is connected between the first side of the detection block and the PCB control board, so that the detection block is suspended in the detection slot, and detection legs are arranged on the first micro-connection structure. The detection block can bear the impact force of the opening of the safety valve to break the first micro-connection structure and the detection legs to form a first detection signal; a second side of the detection block opposite to the first side is connected to the PCB control board with a second micro-connection structure, the second micro-connection structure is flexible and deformable, and can remain connected when subjected to impact force, and the back of the detection block is densely covered with detection circuits connected to the second detection circuit, which are used to change the parallel detection resistance value of the second detection circuit when contacting the electrolyte to form a second detection signal;

[0010] A busbar, the busbar comprising a plurality of aluminum bars respectively corresponding to the positive and negative electrodes of each battery cell to achieve series connection of each single battery cell; and

[0011] A plurality of conductive connectors are respectively connected between each aluminum bar and the PCB control board, wherein the conductive connectors include: an FPC connecting body electrically connected to the PCB control board, and a conductive sheet for realizing conductive connection between the FPC connecting body and the corresponding aluminum bar, and a temperature sensor is provided on the conductive sheet to directly collect temperature information of the corresponding aluminum bar.

[0012] To implement the above technical solution, when the PCB control board is assembled on the battery pack, each detection block corresponds to the safety valve, that is, the detection block is located directly above the safety valve and forms a predetermined spacing, and is electrically connected to the bus bar through a conductive connector. Since the bus bar realizes the series connection of each battery cell, when the conductive connector forms an electrical connection between the bus bar and the PCB control board, the battery cell can be monitored;

[0013] During detection, when a battery pack fails and the safety valve opens, an upward impact force is generated and acts on the detection block. The detection block is deformed upward by the impact force, thereby causing the first micro-connection structure and the detection leg to break and generate a first detection signal. The first detection signal is the battery pack safety valve opening signal, thereby realizing the safety valve opening detection.

[0014] At the same time, when the safety valve is opened, the electrolyte will be sprayed out at the same time. When the electrolyte splashes on the back of the detection block, the detection circuit will contact the electrolyte. Since the electrolyte has good conductivity, the detection circuit will be turned on and the resistance value of the second detection circuit will be changed, thereby causing the voltage to change to form a second detection signal. The second detection signal is the battery pack leakage detection signal. Through the second detection signal, leakage detection and valve opening detection can be further realized;

[0015] The temperature sensor can directly collect the temperature information of the aluminum sheet, which can reflect the real-time temperature of the corresponding battery cell. When the temperature value exceeds the predetermined temperature threshold, it can be judged that the battery cell has thermal runaway, and an abnormal signal indicating thermal runaway of the battery pack can be generated.

[0016] Since the detection block directly bears the impact force to realize the fracture of the first micro-connection structure for valve opening detection, the detection is faster, which significantly improves the timeliness of the detection, provides a faster response for subsequent signal processing, and improves the detection effect. At the same time, through the second micro-connection structure and the detection circuit, leakage detection can be performed synchronously after the first micro-connection structure is broken, and the thermal runaway situation can be further judged in combination with the temperature detection of the temperature sensor. The combination of multiple detection methods can effectively detect the state of the battery pack in the early stage of thermal runaway, and improve the accuracy and reference of the detection;

[0017] Furthermore, by setting the conductive connector as a combination of an FPC connecting body and a conductive sheet, since the FPC connecting body has good tensile strength, when mechanical vibration is generated during transportation, the FPC connecting body can be used for buffering, thereby reducing the deformation of the conductive connection structure and effectively improving the overall tensile strength, flexibility and extensibility, and having better vibration resistance, thereby ensuring a stable connection between the aluminum sheet and the PCB control board and maintaining the effectiveness of the detection device.

[0018] In some exemplary embodiments, a base plate is fixed on the top of the battery pack, and the base plate is provided with a plurality of fixing grooves adapted to the PCB control board and a plurality of positioning grooves adapted to the aluminum tabs. The PCB control board is embedded in the fixing grooves to form a predetermined spacing with the safety valve, and the fixing grooves are provided with openings corresponding to each safety valve.

[0019] To implement the above technical solution, a substrate is provided to facilitate installation and fixation of the PCB control board and the aluminum bar, and the PCB control board and the aluminum bar can be positioned so as to be conductively connected through conductive connectors, and a predetermined distance can be formed between the PCB control board and the safety valve through the limitation of the substrate, and the setting of the through port is used for the safety valve to impact the detection block when it is opened, and to limit the directional spraying of the electrolyte onto the detection block.

[0020] In some exemplary embodiments, the first micro-connection structure includes two separately arranged connecting legs, the detection circuit includes a first leg and a second leg respectively arranged on the two connecting legs, the first leg and the second leg are connected to a first detection circuit, and when the first leg and / or the second circuit is broken, the resistance value of the first detection circuit is changed to form a first detection signal.

[0021] To implement the above technical solution, when the first leg and / or the second leg is broken, the resistor connected thereto can be disconnected, thereby causing the resistance value of the entire first detection circuit to change, thereby forming a first detection signal to complete the valve opening detection.

[0022] In some exemplary embodiments, the detection circuit includes a first circuit and a second circuit, and the first circuit and the second circuit are close to each other but not in contact with each other;

[0023] The first line includes a first main line and a plurality of first branch lines connected to the first main line, the second line includes a second main line and a plurality of second branch lines connected to the second main line, the first main line basically surrounds the second line and encloses a detection area, the first branch lines are located on the inner side of the first main line, and the first branch lines and the second branch lines are arranged in sequence and alternately, the first branch lines and the second branch lines are densely distributed in the detection area, the second main line is located in the middle of the detection area, and the second branch lines are located on both sides of the second main line.

[0024] To implement the above technical solution, when a battery pack fails and causes the safety valve to open, the electrolyte will splash outward onto the detection area, and the electrolyte will change the resistance impedance between the first circuit and the second circuit, thereby changing the resistance value of the second detection circuit, and then causing the voltage to change to form a second detection signal. The second detection signal can be used as an alarm trigger signal, and leakage detection and valve opening detection can be realized; since the first main circuit surrounds the second circuit to form a detection area, and the first branch circuit and the second branch circuit are densely distributed in the detection area, when the electrolyte contacts any position in the detection area, the impedance change between the first circuit and the second circuit can be realized, thereby improving the detection efficiency and detection effect, and through the arrangement of the first branch circuit and the second branch circuit, the circuit arrangement can be made more compact, thereby realizing leakage detection as long as a small amount of electrolyte contacts the detection area, thereby improving the detection accuracy.

[0025] In some exemplary embodiments, a first terminal is formed at one end of the first main line, the second main line extends out of the first main line and forms a second terminal, the first terminal and the second terminal are connected to the second detection circuit, and when the electrolyte is contacted in the detection area, the resistance impedance between the first line and the second line changes to change the parallel detection resistance value of the second detection circuit to form a second detection signal.

[0026] In some exemplary embodiments, the first side of the FPC connecting body is provided with a connecting pad for electrically connecting to a PCB control board, and the second side is formed with a connecting ear for electrically connecting to a conductive sheet, the first end of the conductive sheet is electrically connected to the connecting ear, and the second end is electrically connected to the aluminum sheet.

[0027] To implement the above technical solution, when in use, the FPC connection body is welded to the PCB control board through the connecting pad, and the conductive sheet is welded to the bus metal bar, so that the FPC connection body and the conductive sheet are used as conductors to form a conductive connection between the PCB control board and the bus metal bar.

[0028] In some exemplary embodiments, the conductive sheet is arranged along an extension direction perpendicular to the PCB control board;

[0029] Alternatively, the connecting ear piece extends outward from the second side of the FPC connecting body, and the conductive sheet is arranged along an extending direction parallel to the PCB control board.

[0030] According to a second aspect of an embodiment of the present disclosure, a process for processing the integrated battery pack safety detection device as described in the first aspect is provided, comprising:

[0031] Taking a PCB substrate of suitable size, performing groove processing on the PCB substrate according to a predetermined process size to form a plurality of detection notches, and forming a detection block and a first micro-connection structure corresponding to each of the detection notches;

[0032] A second micro-connection structure is formed between the detection block and the PCB substrate by a pressing process;

[0033] A first detection circuit and a second detection circuit are printed on the PCB substrate, and a detection circuit is printed on each detection block to form a PCB control board, wherein a detection foot connected to the first detection circuit is arranged on the first micro-connection structure, and the second detection circuit is connected to the detection circuit through the second micro-connection structure;

[0034] Fix the preformed substrate on the top of the battery pack, and sequentially install aluminum bars into the positioning grooves on the substrate to form a busbar to connect the individual cells in series;

[0035] After the prepared PCB control board is embedded in the fixing groove on the substrate, the first side of multiple prefabricated conductive connectors are electrically connected to the preset welding points on the PCB control board, and the second side is electrically connected to each aluminum bar to form a detection device for communication with the BMS system.

[0036] In some exemplary embodiments, the method for preparing the conductive connecting member includes:

[0037] Forming conductive circuits on the FPC substrate according to a predetermined process flow;

[0038] Punching the FPC substrate to form an FPC connection body, wherein a first side of the FPC connection body is provided with a connection pad for electrical connection with a PCB control board, and a second side is formed with a connection ear piece;

[0039] The pre-processed conductive sheet and the connecting ear sheet are welded and fixed to form a conductive connection structure;

[0040] A temperature sensor is arranged in the conductive sheet to directly collect the temperature information of the aluminum sheet;

[0041] The conductive connection structure is welded to a preset welding position on the PCB control board through a connecting pad so that the conductive sheet is located outside the PCB control board for electrical connection with the aluminum sheet.

[0042] To implement the above technical solution, the FPC connecting body is used to realize the conductive connection between the PCB control board and the conductive sheet. For the convenience of processing, a number of conductive circuits corresponding to the FPC connecting body are usually formed on the FPC substrate according to the process flow of the FPC circuit board, and then a number of FPC connecting bodies are formed by punching and cutting to improve the processing efficiency; the conductive sheet can also be pre-stamped and formed, and it serves as an intermediate conductive member to realize the conductive connection between the FPC connecting body and the bus metal bar. The setting of the connecting ear piece can facilitate the welding connection with the conductive sheet to form a conductive connection structure. The setting of the connecting pad is convenient for the welding connection with the PCB control board. After the conductive connection structure is welded to the PCB control board through the connecting pad, when assembling the battery pack, the PCB control board can be assembled to the corresponding position on the battery pack, and the conductive sheet can be directly connected to the bus metal bar to realize the conductive connection between the PCB control board and the bus metal bar.

[0043] In some exemplary embodiments, when the FPC connection body is formed by punching, a deformation groove is formed between the connection pad and the connection ear piece, and a micro connection piece is formed on one side of the deformation groove.

[0044] By implementing the above technical solution, the deformation groove can make a slight deformation of the FPC connection body when it is vibrated to buffer the vibration force, thereby improving the mechanical buffering performance of the FPC connection body, while the micro-connection sheet can maintain the stability of the FPC connection body structure and reduce the deformation of the FPC body.

[0045] In summary, compared with the prior art, the present invention has the following beneficial effects:

[0046] The embodiment of the present invention provides an integrated battery pack safety detection device and a processing technology thereof. When the PCB control board is assembled on the battery pack, each detection block corresponds to the safety valve, that is, the detection block is located directly above the safety valve and forms a predetermined spacing, and is electrically connected to the bus bar through a conductive connector. Since the bus bar realizes the series connection of each battery cell, when the conductive connector forms an electrical connection between the bus bar and the PCB control board, the battery cell can be monitored. During detection, when a battery pack fails and causes the safety valve to open, an upward impact force is generated and acts on the detection block. The detection block is deformed upward by the impact force, thereby causing the detection block to deform upward. The first micro-connection structure and the detection leg are broken to generate a first detection signal, which is the battery pack safety valve opening signal, thereby realizing the safety valve opening detection. At the same time, when the safety valve is opened, electrolyte will be sprayed out at the same time. When the electrolyte splashes on the back of the detection block, the detection circuit will contact the electrolyte. Since the electrolyte has good conductivity, the detection circuit will be turned on and the resistance value of the second detection circuit will be changed, thereby causing the voltage change to form a second detection signal. The second detection signal is the battery pack leakage detection signal. The leakage detection and valve opening detection can be further realized through the second detection signal. The temperature sensor can directly collect The temperature information of the aluminum bar is collected, which can reflect the real-time temperature of the battery pack. When the temperature value exceeds the preset temperature threshold, it can be determined that the battery pack has thermal runaway, and an abnormal signal indicating thermal runaway of the battery pack can be generated. Since the detection block directly bears the impact force to realize the fracture of the first micro-connection structure for valve opening detection, the detection is faster, which significantly improves the timeliness of the detection, provides a faster response for subsequent signal processing, and improves the detection effect. At the same time, through the second micro-connection structure and the detection circuit, leakage detection can be performed synchronously after the first micro-connection structure is fractured, and the thermal runaway situation can be further judged in combination with the temperature detection of the temperature sensor. , a variety of detection methods are combined with each other, which can effectively detect the early state of thermal runaway of the battery pack and improve the accuracy and reference of the detection; further, by setting the conductive connector as a combination of the FPC connection body and the conductive sheet, since the FPC connection body has good tensile strength, when mechanical vibration is generated during transportation, it can be buffered by the FPC connection body, reducing the deformation of the conductive connection structure, and effectively improving the overall tensile strength, flexibility and extensibility, and having better vibration resistance, thereby ensuring the stable connection between the aluminum sheet and the PCB control board and maintaining the effectiveness of the detection device. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 Schematic diagram of the structure of an integrated battery pack safety detection device in an embodiment of the present invention.

[0048] Figure 2It is a three-dimensional diagram of an integrated battery pack safety detection device in an embodiment of the present invention.

[0049] Figure 3 Schematic diagram of the connection structure between the PCB control board and the conductive connector in an embodiment of the present invention.

[0050] Figure 4 It is a schematic diagram of the structure of the PCB control board and the detection block in an embodiment of the present invention.

[0051] Figure 5 Schematic diagram of the structure of the first detection circuit in an embodiment of the present invention.

[0052] Figure 6 Schematic diagram of the structure of the second detection circuit in an embodiment of the present invention.

[0053] Figure 7 Schematic diagram of the structure of the conductive connecting member in an embodiment of the present invention.

[0054] Figure 8 It is a schematic structural diagram of a conductive connecting member according to another embodiment of the present invention.

[0055] Fig. 9 The figure is a schematic diagram of the connection structure between a PCB control board and a conductive connector according to another embodiment of the present invention.

[0056] The numbers and letters in the figure represent the corresponding component names:

[0057] 10. PCB control board; 11. detection notch; 20. detection block; 21. first micro-connection structure; 211. connection leg; 22. detection leg; 221. first leg; 222. second leg; 30. second micro-connection structure; 40. detection circuit; 41. first circuit; 411. first main circuit; 412. first branch circuit; 413. first terminal; 42. second circuit; 421. second main circuit; 422. second branch circuit; 423. second terminal; 50. first detection circuit; 5 1. First detection resistor; 60. Second detection circuit; 61. Second detection resistor; 70. Bus bar; 71. Aluminum bar; 80. Conductive connector; 81. FPC connection body; 811. Connection pad; 812. Connection ear; 813. Deformation groove; 814. Micro connection piece; 82. Conductive sheet; 821. Temperature sensor; 822. Accommodation groove; 823. Card-mounted spring piece; 824. Welding groove; 90. Battery pack; 91. Base plate; 92. Fixing groove; 93. Positioning groove; 94. Explosion-proof membrane. DETAILED DESCRIPTION

[0058] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0059] like Figures 1 to 9 As shown, the first aspect of an embodiment of the present invention provides an integrated battery pack safety detection device, including: a plurality of PCB control boards 10 for communicating with a BMS system, the PCB control board 10 is provided with a plurality of detection slots 11 corresponding to the safety valves of each battery cell, and the PCB control board 10 is fixed to the top of the battery pack 90 and forms a predetermined spacing with the safety valve; a detection block 20 accommodated in each detection slot 11, a bus metal bar 70, the bus metal bar 70 includes a plurality of aluminum bars 71 respectively corresponding to the positive / negative poles of each battery cell to realize the series connection of each single battery cell; and a plurality of conductive connectors 80 respectively connected between each aluminum bar 71 and the PCB control board 10.

[0060] Specifically, the BMS system refers to a battery management system, which is used to centrally control the battery pack 90. ​​This embodiment uses a PCB control board 10 as a main control board to significantly reduce costs. A BMS acquisition chip is usually provided on the PCB control board 10, and centralized data acquisition or processing is achieved through the BMS chip, which communicates with the BMS system to upload data.

[0061] Among them, a substrate 91 is fixed on the top of the battery pack 90, and the substrate 91 is made of insulating material. The substrate 91 is provided with a plurality of fixing grooves 92 adapted to the PCB control board 10 and a plurality of positioning grooves 93 adapted to the aluminum bar 71. The PCB control board 10 is embedded in the fixing groove 92 to form a predetermined spacing with the safety valve, and the fixing groove 92 is provided with a through hole corresponding to each safety valve, and an explosion-proof membrane 94 can usually be arranged above the substrate 91, and the explosion-proof membrane 94 covers the PCB control and bus metal bus 70, and a through hole corresponding to the detection slot 11 is also arranged on the explosion-proof membrane 94 for the detection block 20 to bend.

[0062] The substrate 91 is provided to facilitate installation and fixation of the PCB control board 10 and the aluminum bar 71, and to position the PCB control board 10 and the aluminum bar 71 so as to be conductively connected through the conductive connector 80. The limitation of the substrate 91 can form a predetermined distance between the PCB control board 10 and the safety valve. The opening is provided to allow the safety valve to impact the detection block 20 when it is opened, and to limit the directional spraying of the electrolyte onto the detection block 20.

[0063] A hard first micro-connection structure 21 is connected between the first side of the detection block 20 and the PCB control board 10 so that the detection block 20 is suspended in the detection slot 11. Detection legs 22 are arranged on the first micro-connection structure 21. The detection block 20 can withstand the impact force of the opening of the safety valve to break the first micro-connection structure 21 and the detection legs 22 to form a first detection signal; the second side of the detection block 20 opposite to the first side is connected to the PCB control board 10 with a second micro-connection structure 30. The second micro-connection structure 30 is flexible and deformable and can remain connected when subjected to impact force. The back of the detection block 20 is densely covered with detection circuits 40 connected to the second detection circuit 60, which are used to change the parallel detection resistance value of the second detection circuit 60 when contacting the electrolyte to form a second detection signal.

[0064] Specifically, the detection block 20 is in an elliptical, oval, square, hexagonal or other shape, and the detection slot 11 as a whole is also in an elliptical, oval, square, hexagonal or other shape corresponding to the detection block 20. Preferably, the detection block 20 and the detection slot 11 are both set to be elliptical, the outer edge of the detection block 20 is 1-3mm away from the edge of the detection slot 11, the area of ​​the detection block 20 is 1.1-1.3 times the switch area of ​​the safety valve, and in a normal state, the distance between the detection block 20 and the safety valve is 1-3mm; preferably, the outer edge of the detection block 20 is 2mm away from the edge of the detection slot 11, the area of ​​the detection block 20 is 1.2 times the switch area of ​​the safety valve, and in a normal state, the distance between the detection block 20 and the safety valve is 2mm.

[0065] The first micro-connection structure 21 includes two separately arranged connecting legs 211, the width of the connecting legs 211 is 1-2 mm, preferably set to 1.6 mm, and the detection leg 22 includes a first leg 221 and a second leg 222 respectively arranged on the two connecting legs 211, the first leg 221 and the second leg 222 are connected to the first detection circuit 50, and when the first leg 221 and / or the second leg 222 are broken, the resistance value of the first detection circuit 50 is changed to form a first detection signal.

[0066] It can be understood that the first detection circuit 50 is printed on the PCB control board 10 and the detection block 20. The first detection circuit 50 includes a first detection resistor 51. The first leg 221 and the second leg 222 are connected in parallel with the first detection resistor 51. When the first leg 221 and / or the second leg 222 are broken, the first detection resistor 51 can be disconnected, so that the resistance value of the entire first detection circuit 50 changes, thereby forming a first detection signal to complete the valve opening detection.

[0067] The thickness of the PCB control board 10 is 1.4-1.8 mm. Preferably, the thickness of the PCB control board 10 is set to 1.6 mm. Since the connecting leg 211 is directly formed in the PCB control board 10, the thickness of the PCB control board 10 is the same as the thickness of the connecting leg 211. By setting a suitable board thickness, the connecting leg 211 has a suitable load-bearing performance, so that the detection block 20 can break after being subjected to a suitable impact force to achieve valve opening detection.

[0068] The second micro-connection structure 30 adopts a pressed plate process to achieve a soft connection between the detection block 20 and the PCB control board 10, and the thickness of the second micro-connection structure 30 is 0.2-0.5mm. Preferably, the thickness of the second micro-connection structure 30 is set to 0.3mm, which can ensure that the second micro-connection structure 30 can be freely bent within a range of at least 90° without breaking, so that leakage detection can still be achieved after the first micro-connection structure 21 is broken, thereby achieving a dual-mode detection effect.

[0069] The detection circuit 40 includes a first circuit 41 and a second circuit 42, and the first circuit 41 and the second circuit 42 are close to each other but do not touch each other; the first circuit 41 includes a first main circuit 411 and a plurality of first branch circuits 412 connected to the first main circuit 411, and the second circuit 42 includes a second main circuit 421 and a plurality of second branch circuits 422 connected to the second main circuit 421, the first main circuit 411 basically surrounds the second circuit 42 and encloses to form a detection area, the first branch circuit 412 is located on the inner side of the first main circuit 411, and each first branch circuit 412 and each second branch circuit 422 are arranged in sequence and alternately, the first branch circuit 412 and the second branch circuit 422 are densely distributed in the detection area, the second main circuit 421 is located in the middle of the detection area, and the second branch circuit 422 is located on both sides of the second main circuit 421.

[0070] Among them, a first terminal 413 is formed at one end of the first main line 411, and the second main line 421 extends from the first main line 411 and forms a second terminal 423. The first terminal 413 and the second terminal 423 are connected to the second detection circuit 60. When the electrolyte is contacted in the detection area, the resistance impedance between the first line 41 and the second line 42 changes to change the parallel detection resistance value of the second detection circuit 60 to form a second detection signal.

[0071] When a failure occurs in the battery pack 90 and the safety valve opens, the electrolyte will splash outward onto the detection area. The electrolyte will change the resistance impedance between the first circuit 41 and the second circuit 42, thereby changing the parallel detection resistance value of the second detection circuit 60, and then causing the voltage to change to form a second detection signal. The second detection signal can be used as an alarm trigger signal to realize leakage detection and valve opening detection. Since the first main circuit 411 surrounds the second circuit 42 to form a detection area, and the first branch circuit 412 and the second branch circuit 422 are densely distributed in the detection area, when the electrolyte contacts any position in the detection area, the impedance change between the first circuit 41 and the second circuit 42 can be realized, thereby improving the detection efficiency and detection effect. Through the arrangement of the first branch circuit 412 and the second branch circuit 422, the circuit arrangement can be made more compact, thereby realizing leakage detection as long as a small amount of electrolyte contacts the detection area, thereby improving the detection accuracy.

[0072] The second main line 421 is linear and located at the central axis of the first main line 411. Specifically, the second main line 421 can be straight or wavy. In this embodiment, the second main line 421 is set to be straight, and multiple second branch lines 422 are symmetrically arranged on both sides of the second main line 421. One end of the second branch line 422 is connected to the second main line 421, and the other end extends to the vicinity of the first main line 411.

[0073] In other embodiments, the second main line 421 can also be set to be an elongated round shape, and the central axis of the second main line 421 is consistent with the central axis of the first main line 411, and multiple second branch lines 422 are symmetrically arranged on both sides of the second main line 421, one end of the second branch line 422 is connected to the second main line 421, and the other end extends to the vicinity of the first main line 411. When the second main line 421 is set to be an elongated round shape, it is easier to etch and form.

[0074] The second detection circuit 60 includes a second detection resistor 61, which is connected in parallel with the second detection resistor 61 through the second micro-connection structure 30 to change the resistance value of the second detection circuit 60 when the detection area contacts the electrolyte to form a second detection signal. When the detection area contacts the electrolyte, the impedance between the first circuit 41 and the second circuit 42 can be changed. At the same time, the changed resistance value is made more obvious through the parallel second detection resistor 61, thereby realizing leakage detection and improving detection accuracy.

[0075] At the same time, in some embodiments, the first detection resistor 51 and the second detection resistor 61 can be connected to a number of precision adjustment resistors to further adjust the detection accuracy. It can be understood that the first detection circuit 50 and the second detection circuit 60 are connected to the BMS acquisition chip to upload to the BMS system when the detection signal is formed.

[0076] The conductive connector 80 includes: an FPC connecting body 81 electrically connected to the PCB control board 10, and a conductive sheet 82 for realizing conductive connection between the FPC connecting body 81 and the corresponding aluminum bar 71. A temperature sensor 821 is provided on the conductive sheet 82 to directly collect temperature information of the corresponding aluminum bar 71.

[0077] Specifically, a connecting pad 811 for electrically connecting to the PCB control board 10 is provided on the first side of the FPC connecting body 81, and a connecting ear 812 for electrically connecting to the conductive sheet 82 is formed on the second side. The first end of the conductive sheet 82 is electrically connected to the connecting ear 812, and the second end is electrically connected to the aluminum sheet 71. When in use, the FPC connecting body 81 is welded to the PCB control board 10 through the connecting pad 811, and the conductive sheet 82 is welded to the bus metal bar 70, so that the FPC connecting body 81 and the conductive sheet 82 are used as conductors to form a conductive connection between the PCB control board 10 and the bus metal bar 70.

[0078] The FPC connection body 81 is pre-cut from an FPC substrate, and its base is usually polyimide. The connection pad 811 is a fixed welding area on the FPC connection body 81, which can be welded and fixed to the conductive solder joint on the PCB control board 10 by soldering or other methods. A welding area is also provided on the connection ear 812 for welding and fixing with the conductive sheet 82. The size of the connection ear 812 needs to be sufficient to form a weld with the conductive sheet 82.

[0079] At the same time, a deformation groove 813 is opened in the FPC connection body 81 between the connection pad 811 and the connection ear piece 812, and a micro connection piece 814 is formed on one side of the deformation groove 813. The deformation groove 813 is long and is located near the middle of the FPC connection body 81, so that the FPC connection body 81 can disperse the vibration force when subjected to mechanical vibration, and the micro connection piece 814 is naturally formed after the deformation groove 813 is opened; the deformation groove 813 can further improve the mechanical buffering performance of the FPC connection body 81, and the micro connection piece 814 can maintain the stability of the structure of the FPC connection body 81 and reduce the deformation of the FPC connection body 81.

[0080] The aluminum bar 71 is used to connect adjacent single-cell batteries in series. It can usually be connected to the battery cell by aluminum wire welding. The conductive sheet 82 is made of hard nickel sheet to have a better conductive effect. The conductive sheet 82 can be welded and fixed to the bus metal bar 70 by laser welding.

[0081] In this embodiment, the connecting ear 812 extends outward from the second side of the FPC connecting body 81, and the conductive sheet 82 is arranged along an extension direction parallel to the PCB control board 10. It can be understood that in this embodiment, the connecting ear 812 needs to extend above the aluminum bar 71 so that when the conductive sheet 82 is welded to the connecting ear 812, it is also located above the aluminum bar 71 so that the two can be welded and connected.

[0082] In another embodiment, Figure 8 and Fig. 9 As shown, the conductive sheet 82 is arranged along an extension direction perpendicular to the PCB control board 10. In this embodiment, the connecting ear 812 does not need to extend outward, but extends outward from the second end of the conductive sheet 82 to the top of the aluminum bar 71 to facilitate the welding connection between the two. The advantage of this method is that since the FPC connection body 81 is arranged with a conductive circuit, when the connecting ear 812 extends outward to the aluminum bar 71, it will inevitably overlap with the aluminum bar 71, and there is a certain risk of leakage. When this embodiment is adopted, the FPC connection body 81 will not overlap with the aluminum bar 71, thereby eliminating the risk of leakage.

[0083] The temperature sensor 821 is set on the conductive sheet 82, and is used to collect the temperature information transmitted by the corresponding aluminum bar sheet 71. The conductive sheet 82 also has a good thermal conductivity. Therefore, when the temperature sensor 821 is in contact with the conductive sheet 82, the temperature of the bus metal bus 70 can be basically obtained. By setting the temperature sensor 821 on the conductive sheet 82, the collected temperature signal can be made more accurate, so as to facilitate thermal runaway monitoring of the battery pack 90.

[0084] Furthermore, a receiving groove 822 is provided on the conductive sheet 82 for receiving the temperature sensor 821, and clamping spring pieces 823 are symmetrically provided on both sides of the receiving groove 822. The clamping spring pieces 823 are used to clamp and fix the temperature sensor 821. The clamping spring pieces 823 can be formed by bending the portion of the conductive sheet 82 in the receiving groove 822 upward to facilitate the connection and fixation of the temperature sensor 821, and a welding groove 824 is also provided on the conductive sheet 82 on one side of the receiving groove 822 to facilitate the welding and fixation of the conductive sheet 82 and the connecting ear piece 812.

[0085] When the PCB control board 10 is assembled on the battery pack 90, each detection block 20 corresponds to the safety valve, that is, the detection block 20 is located directly above the safety valve and forms a predetermined interval, and is electrically connected to the bus bar 70 through the conductive connector 80. Since the bus bar 70 realizes the series connection of each battery cell, when the conductive connector 80 forms an electrical connection between the bus bar 70 and the PCB control board 10, the battery cell can be monitored;

[0086] During detection, when the battery pack 90 fails and the safety valve is opened, an upward impact force is generated and acts on the detection block 20. The detection block 20 is deformed upward by the impact force, thereby causing the first micro-connection structure 21 and the detection leg 22 to break and generate a first detection signal. The first detection signal is the safety valve opening signal of the battery pack 90, thereby realizing the safety valve opening detection.

[0087] At the same time, when the safety valve is opened, the electrolyte will be sprayed out at the same time. When the electrolyte splashes on the back of the detection block 20, the detection circuit 40 will contact the electrolyte. Since the electrolyte has good conductivity, the detection circuit 40 will be turned on and change the resistance value of the second detection circuit 60, thereby causing a voltage change to form a second detection signal. The second detection signal is a leakage detection signal of the battery pack 90. ​​Through the second detection signal, leakage detection and valve opening detection can be further realized;

[0088] The temperature information of the aluminum sheet 71 can be directly collected by the temperature sensor 821, thereby reflecting the real-time temperature of the corresponding collected battery cell. When the temperature value exceeds the predetermined temperature threshold, it can be determined that the battery cell has thermal runaway, and an abnormal signal indicating thermal runaway of the battery pack 90 can be generated.

[0089] Since the detection block 20 directly bears the impact force to realize the fracture of the first micro-connection structure 21 for valve opening detection, the detection is faster, which significantly improves the timeliness of the detection, provides a faster response for subsequent signal processing, and improves the detection effect. At the same time, through the second micro-connection structure 30 and the detection circuit 40, after the first micro-connection structure 21 is fractured, leakage detection can be performed synchronously, and the thermal runaway situation can be further judged in combination with the temperature detection of the temperature sensor 821. The combination of multiple detection methods can effectively detect the state of the battery pack 90 in the early stage of thermal runaway, and improve the accuracy and reference of the detection;

[0090] Furthermore, by configuring the conductive connector 80 as a combination of an FPC connecting body 81 and a conductive sheet 82, since the FPC connecting body 81 has good tensile strength, when mechanical vibration is generated during transportation, the FPC connecting body 81 can be used for buffering, thereby reducing deformation of the conductive connection structure and effectively improving the overall tensile strength, flexibility and extensibility, and having better vibration resistance, thereby ensuring a stable connection between the aluminum sheet 71 and the PCB control board 10 and maintaining the effectiveness of the detection device.

[0091] A second aspect of an embodiment of the present invention provides a process for manufacturing the integrated battery pack safety detection device according to the first aspect, comprising:

[0092] S100, take a PCB substrate of suitable size, perform groove processing on the PCB substrate according to a predetermined process size to form a plurality of detection notches 11, and form a detection block 20 and a first micro-connection structure 21 corresponding to each detection notch 11, wherein the first micro-connection structure 21 includes two spaced-apart connecting legs 211, the connecting legs 211 are located on one side of the detection block 20 so that the detection block 20 is suspended in the detection notch 11, the outer edge of the detection block 20 is 1-3 mm away from the edge of the detection notch 11, the area of ​​the detection block 20 is 1.1-1.3 times the switch area of ​​the safety valve, and the width of the connecting legs 211 is 1-2 mm.

[0093] S200, forming a second micro-connection structure 30 between the detection block 20 and the PCB substrate by a lamination process, wherein the lamination process can be to add a soft connection structure between the PCB substrate and the detection block 20 by lamination, and the soft connection structure has conductivity. Preferably, the thickness of the second micro-connection structure 30 is 0.2-0.5 mm to form a soft connection with the PCB substrate, and the upper surface of the second micro-connection structure 30 is substantially flush with the surface of the PCB substrate.

[0094] S300, printing a first detection circuit 50 and a second detection circuit 60 on a PCB substrate, and printing a detection circuit 40 on each detection block 20 to form a PCB control board 10, wherein a detection foot 22 connected to the first detection circuit 50 is arranged on the first micro-connection structure 21, and the second detection circuit 60 is connected to the detection circuit 40 via the second micro-connection structure 30.

[0095] Among them, the detection circuit 40 includes a first circuit 41 and a second circuit 42, the first circuit 41 and the second circuit 42 are close to each other but not in contact with each other; the first circuit 41 includes a first main circuit 411 and a plurality of first branch circuits 412 connected to the first main circuit 411, the second circuit 42 includes a second main circuit 421 and a plurality of second branch circuits 422 connected to the second main circuit 421, the first main circuit 411 basically surrounds the second circuit 42 and encloses to form a detection area, the first branch circuit 412 is located on the inner side of the first main circuit 411, and each first branch circuit 412 and each second branch circuit 422 are arranged in sequence and alternately, the first branch circuit 412 and the second branch circuit 422 are densely distributed in the detection area, the second main circuit 421 is located in the middle of the detection area, and the second branch circuit 422 is located on both sides of the second main circuit 421, and the spacing between the first branch circuit 412 and the second branch circuit 422 is 0.2-0.6mm, preferably set to 0.5mm.

[0096] S400, fix the preformed substrate 91 on the top of the battery pack 90, and sequentially install the aluminum bar pieces 71 into the positioning grooves 93 on the substrate 91 to form a bus metal bus 70 to connect each single battery cell in series; wherein, the substrate 91 can be integrally formed from an insulating material by vacuum forming, injection molding, or the like, and after the molding is completed, a fixing groove 92 that matches the PCB control board 10 and a positioning groove 93 that matches the aluminum bar piece 71 are formed on the substrate 91, and a positioning pin is also configured on the substrate 91, and a plurality of positioning holes that match the positioning pins are provided on the PCB control board 10 and the aluminum bar piece 71. During installation, the positioning pins are inserted into the positioning holes to achieve positioning and fixation of the aluminum bar piece 71 and the PCB control board 10, and after the aluminum bar piece 71 is positioned and installed, it can be connected to the battery cell by aluminum wire welding.

[0097] S500, after the prepared PCB control board 10 is embedded in the fixing groove 92 on the substrate 91, the first sides of multiple prefabricated conductive connectors 80 are electrically connected to the preset welding positions on the PCB control board 10, and the second sides are electrically connected to the aluminum bars 71 to form a detection device for communication connection with the BMS system. The conductive connectors 80 can be pre-soldered on the PCB control board 10, or they can be installed on the substrate 91 and then welded to the PCB control board 10.

[0098] The preparation method of the conductive connecting member 80 includes:

[0099] S501, forming a conductive circuit on the FPC substrate according to a predetermined process flow, the specific process flow can adopt the existing FPC circuit board processing process, at least one area corresponding to the conductive connection structure is formed on the FPC substrate, and the conductive circuit is arranged in the area.

[0100] S502 , punching the FPC substrate to form an FPC connection body 81 , wherein a first side of the FPC connection body 81 is provided with a connection pad 811 for electrical connection with the PCB control board 10 , and a second side extends outward to form a connection ear piece 812 .

[0101] It can be understood that the conductive circuit is located on the FPC connecting body 81, so that the FPC connecting body 81 can perform conductive connection. The connecting pad 811 is a welding area reserved on the FPC connecting body 81, which can be reserved and formed when the conductive circuit is formed. The connecting ear 812 is a portion protruding outward from the FPC connecting body 81. A welding area is also provided on the connecting ear 812 for welding and fixing with the conductive connecting piece. The size of the connecting ear 812 needs to be sufficient to form a weld with the conductive connecting piece.

[0102] At the same time, when the FPC connection body 81 is formed by punching, a deformation groove 813 is formed between the connection pad 811 and the connection ear piece 812, and a micro connection piece 814 is formed on one side of the deformation groove 813. The deformation groove 813 is in the shape of an elongated strip and is located near the middle of the FPC connection body 81, so that the FPC connection body 81 can disperse the vibration force when subjected to mechanical vibration, and the micro connection piece 814 is naturally formed after the deformation groove 813 is opened; the deformation groove 813 can make the FPC connection body 81 slightly deformed when subjected to vibration to buffer the vibration force, thereby improving the mechanical buffering performance of the FPC connection body 81, and the micro connection piece 814 can maintain the stability of the structure of the FPC connection body 81 and reduce the deformation of the FPC body.

[0103] S503, the pre-processed conductive sheet 82 and the connecting ear sheet 812 are welded and fixed to form a conductive connection structure, wherein the conductive sheet 82 is in a strip shape as a whole, and can be pre-stamped according to the design size, and the conductive sheet 82 and the connecting ear sheet 812 can be welded and connected by soldering, laser welding, etc. The conductive sheet 82 is preferably made of a hard nickel sheet to have a better conductive effect. At the same time, a welding groove 824 is also stamped and formed on one side of the accommodating groove 822 on the conductive sheet 82 to facilitate the welding connection between the conductive sheet 82 and the FPC connecting body 81.

[0104] S504. A temperature sensor 821 is set in the conductive sheet 82 for directly collecting the temperature information of the aluminum sheet 71. A receiving groove 822 is also stamped on the conductive sheet 82. The temperature sensor 821 is placed in the receiving groove 822, and the temperature sensor 821 is welded to the FPC connecting body 81 for directly collecting the temperature information transmitted by the corresponding bus metal bus 70. It can be understood that the detection end of the temperature sensor 821 can contact the bus metal bus 70 or the conductive sheet 82 to collect the corresponding temperature information, and the conductive end of the temperature sensor 821 is welded to the FPC connecting body 81 for conductive connection, so as to transmit the collected temperature information to the PCB control board 10, so as to realize temperature monitoring of the battery pack 90.

[0105] S505. The conductive connection structure is welded to a preset connection position of the PCB control board 10 through the connecting pad 811 so that the conductive sheet 82 is located on the outside of the PCB control board 10 for electrical connection with the bus metal bar 70. Specifically, the connecting pad 811 can be welded and fixed to the conductive solder point on the PCB control board 10 by soldering or the like, and the conductive sheet 82 can be welded and fixed to the bus metal bar 70 by laser welding.

[0106] In one embodiment, the connecting ear piece 812 extends outward from the second side of the FPC connecting body 81, and the conductive sheet 82 is arranged along the extension direction parallel to the PCB control board 10. It can be understood that the state after welding is completed is as follows: Figure 3 As shown, in this embodiment, the connecting ear piece 812 needs to extend above the aluminum bar piece 71 so that when the conductive sheet 82 and the connecting ear piece 812 are welded together, they are also located above the aluminum bar piece 71 so that the two can be welded together.

[0107] In another embodiment, the conductive sheet 82 is arranged along an extension direction perpendicular to the PCB control board 10. In this embodiment, the connecting ear piece 812 does not need to extend outward, but extends outward from the second end of the conductive sheet 82 to the top of the aluminum bar piece 71 to facilitate the welding connection between the two. In this embodiment, a portion of the PCB control board 10 corresponding to the conductive connection structure is usually provided with a avoidance groove, which can accommodate a part of the structure of the FPC connection body 81, so that the FPC connection body 81 will not extend above the aluminum bar piece 71. The state after welding is completed is as shown in FIG. Fig. 9 As shown; the advantage of this method is that: since the conductive circuit is arranged on the FPC connection body 81, when the connecting ear 812 extends outward to the aluminum bar 71, it will inevitably overlap with the aluminum bar 71, and there is a certain risk of leakage. When this embodiment is adopted, the FPC connection body 81 will not overlap with the aluminum bar 71, thereby eliminating the risk of leakage.

[0108] The FPC connection body 81 is used to realize the conductive connection between the PCB control board 10 and the conductive sheet 82. For the convenience of processing, a number of conductive circuits corresponding to the FPC connection body 81 are usually formed on the FPC substrate according to the process flow of the FPC circuit board, and then a punching process is performed to form a number of FPC connection bodies 81 to improve the processing efficiency; the conductive sheet 82 can also be pre-stamped and formed, and it serves as an intermediate conductive member to realize the conductive connection between the FPC connection body 81 and the bus metal bar 70. The setting of the connecting ear piece 812 can facilitate welding connection with the conductive sheet 82 to form a conductive connection structure. The setting of the connecting pad 811 facilitates welding connection with the PCB control board 10. After the conductive connection structure is welded to the PCB control board 10 through the connecting pad 811, when assembling the battery pack 90, the PCB control board 10 can be assembled to the corresponding position on the battery pack 90, and the conductive sheet 82 can be directly connected to the bus metal bar 70 to realize the conductive connection between the PCB control board 10 and the bus metal bar 70.

[0109] Through the above-mentioned process, the installation and electrical connection of the battery cells, the bus metal bus 70, the PCB control board 10 and the conductive connector 80 are realized, and the efficient processing and forming of the PCB control board 10 and the conductive connection are realized. By configuring the first micro-connection structure 21 and the first detection circuit 50, the second micro-connection structure 30 and the second detection circuit 60, and the temperature sensor 821, a variety of detection methods are combined with each other, which can effectively detect the state of the battery pack 90 in the early stage of thermal runaway, thereby improving the accuracy and reference of the detection.

[0110] In order to verify the specific detection functions of different detection block size structures, the following comparative experiments are provided for illustration:

[0111] Comparative Experiment 1

[0112] The probability of breaking of the connecting leg was tested by setting different size ratios of the detection block and the safety valve. Specifically, the size ratios of the detection block and the safety valve were set to 0.8:1, 1:1, and 1.2:1, respectively. Then, the detection block and the safety valve were set accordingly, and the valve opening test was performed to determine the probability of breaking of different detection blocks. The specific test results are as follows:

[0113]

[0114] According to the test results, when the size ratio of the detection block to the safety valve is greater than 1.2, it can be guaranteed that the detection block will be triggered to open 100%.

[0115] Comparative Experiment 2

[0116] Different PCB control board thicknesses were set to test the breaking force of the connecting legs. Specifically, PCB control boards with thicknesses of 0.8mm, 1.0mm, 1.5mm, and 2.0mm were set respectively. Then the detection block and the safety valve were set accordingly, and the valve opening test was performed to determine the breaking force of different detection blocks. The specific test results are as follows:

[0117]

[0118] According to the test results, when the thickness of the PCB control board is 1.6mm, it can ensure that the connecting legs are effectively broken under the action of a 20N breaking force, and at the same time it will not cause the detection block to trigger a short circuit too easily. In actual applications, since the second micro-connection structure can also form a connecting force, a thinner PCB control board can also be set, so that the connecting legs will not be easily broken during transportation.

[0119] Comparative Experiment 3

[0120] The leakage detection accuracy was tested by setting different spacings between the first branch line and the second branch line. Specifically, spacings of 1mm, 0.8mm, 0.5mm, and 0.2mm were set respectively. Then the detection block and the safety valve were set correspondingly, and the valve opening test was performed to determine the leakage detection accuracy of different detection blocks. The specific test results are as follows:

[0121]

[0122] According to the test results, when the distance between the first branch line and the second branch line is in the range of 0.5mm±0.1mm, high-precision leakage detection can be guaranteed, and the high humidity misjudgment rate is also within a reasonable range.

[0123] The above embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present invention, which are equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of them belong to the protection scope of the present invention.

Claims

1. An integrated battery pack safety detection device, characterized in that: include: A plurality of PCB control boards for communicating with the BMS system, wherein the PCB control boards are provided with a plurality of detection notches corresponding to the safety valves of the respective battery cells, and the PCB control boards are fixed to the top of the battery pack and form a predetermined distance between the safety valves; A detection block is accommodated in each of the detection slots, a first hard micro-connection structure is connected between the first side of the detection block and the PCB control board, so that the detection block is suspended in the detection slot, and detection legs are arranged on the first micro-connection structure. The detection block can bear the impact force of the opening of the safety valve to break the first micro-connection structure and the detection legs to form a first detection signal; a second side of the detection block opposite to the first side is connected to the PCB control board with a second micro-connection structure, the second micro-connection structure is flexible and deformable, and can remain connected when subjected to impact force, and the back of the detection block is densely covered with detection circuits connected to the second detection circuit, which are used to change the parallel detection resistance value of the second detection circuit when contacting the electrolyte to form a second detection signal; A busbar, the busbar comprising a plurality of aluminum bars respectively corresponding to the positive / negative electrodes of each battery cell to achieve series connection of each single battery cell; as well as, A plurality of conductive connectors are respectively connected between each aluminum bar and the PCB control board, wherein the conductive connectors include: an FPC connecting body electrically connected to the PCB control board, and a conductive sheet for realizing conductive connection between the FPC connecting body and the corresponding aluminum bar, and a temperature sensor is provided on the conductive sheet to directly collect temperature information of the corresponding aluminum bar.

2. The integrated battery pack safety detection device according to claim 1, characterized in that: A base plate is fixed on the top of the battery pack, and the base plate is provided with a plurality of fixing grooves adapted to the PCB control board and a plurality of positioning grooves adapted to the aluminum bar. The PCB control board is embedded in the fixing groove to form a predetermined spacing with the safety valve, and the fixing groove is provided with a through opening corresponding to each safety valve.

3. The integrated battery pack safety detection device according to claim 1 or 2, characterized in that: The first micro-connection structure includes two separately arranged connecting legs, and the detection circuit includes a first leg and a second leg respectively arranged on the two connecting legs. The first leg and the second leg are connected to a first detection circuit. When the first leg and / or the second circuit is broken, the resistance value of the first detection circuit is changed to form a first detection signal.

4. The integrated battery pack safety detection device according to claim 1 or 2, characterized in that: The detection circuit includes a first circuit and a second circuit, wherein the first circuit and the second circuit are close to each other but do not contact each other; The first line includes a first main line and a plurality of first branch lines connected to the first main line, the second line includes a second main line and a plurality of second branch lines connected to the second main line, the first main line basically surrounds the second line and encloses a detection area, the first branch lines are located on the inner side of the first main line, and the first branch lines and the second branch lines are arranged in sequence and alternately, the first branch lines and the second branch lines are densely distributed in the detection area, the second main line is located in the middle of the detection area, and the second branch lines are located on both sides of the second main line.

5. The integrated battery pack safety detection device according to claim 4, characterized in that: A first terminal is formed at one end of the first main line, and the second main line extends out of the first main line and forms a second terminal. The first terminal and the second terminal are connected to the second detection circuit. When the electrolyte is contacted in the detection area, the resistance impedance between the first line and the second line changes to change the parallel detection resistance value of the second detection circuit to form a second detection signal.

6. The integrated battery pack safety detection device according to claim 1, characterized in that: The first side of the FPC connecting body is provided with a connecting pad for electrically connecting to the PCB control board, and the second side is formed with a connecting ear for electrically connecting to the conductive sheet. The first end of the conductive sheet is electrically connected to the connecting ear, and the second end is electrically connected to the aluminum sheet.

7. The integrated battery pack safety detection device according to claim 6, characterized in that: The conductive sheet is arranged along an extension direction perpendicular to the PCB control board; Alternatively, the connecting ear piece extends outward from the second side of the FPC connecting body, and the conductive sheet is arranged along an extending direction parallel to the PCB control board.

8. A process for manufacturing an integrated battery pack safety detection device as claimed in any one of claims 1 to 7, characterized in that: include: Taking a PCB substrate of suitable size, performing groove processing on the PCB substrate according to a predetermined process size to form a plurality of detection notches, and forming a detection block and a first micro-connection structure corresponding to each of the detection notches; A second micro-connection structure is formed between the detection block and the PCB substrate by a pressing process; A first detection circuit and a second detection circuit are printed on the PCB substrate, and a detection circuit is printed on each detection block to form a PCB control board, wherein a detection foot connected to the first detection circuit is arranged on the first micro-connection structure, and the second detection circuit is connected to the detection circuit through the second micro-connection structure; Fix the preformed substrate on the top of the battery pack, and sequentially install aluminum bars into the positioning grooves on the substrate to form a busbar to connect the individual cells in series; After the prepared PCB control board is embedded in the fixing groove on the substrate, the first side of multiple prefabricated conductive connectors are electrically connected to the preset welding points on the PCB control board, and the second side is electrically connected to each aluminum bar to form a detection device for communication with the BMS system.

9. The process according to claim 8, characterized in that The method for preparing the conductive connecting member comprises: Forming conductive circuits on the FPC substrate according to a predetermined process flow; Punching the FPC substrate to form an FPC connection body, wherein a first side of the FPC connection body is provided with a connection pad for electrical connection with a PCB control board, and a second side is formed with a connection ear piece; The pre-processed conductive sheet and the connecting ear sheet are welded and fixed to form a conductive connection structure; A temperature sensor is arranged in the conductive sheet to directly collect the temperature information of the aluminum sheet; The conductive connection structure is welded to a preset welding position on the PCB control board through a connecting pad so that the conductive sheet is located outside the PCB control board for electrical connection with the aluminum sheet.

10. The process according to claim 9, characterized in that When the FPC connection body is formed by punching, a deformation groove is formed between the connection pad and the connection ear piece, and a micro connection piece is formed on one side of the deformation groove.

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