Hot-pressing film integrated busbar structure for aluminum wire collection, battery module and electric vehicle

Abstract

The invention belongs to the technical field of electric automobiles, and discloses a hot-pressing film integrated busbar structure for aluminum wire collection, a battery module and an electric automobile, the hot-pressing film integrated busbar structure comprises a PET upper hot-pressing film and a PET lower hot-pressing film, an aluminum wire bar and an output aluminum bar are arranged between the PET upper hot-pressing film and the PET lower hot-pressing film, the end part of the aluminum wire bar is connected with a BMU collection board, and the BMU collection board is connected with the battery module. The aluminum wire bar comprises a main wire bar part and a plurality of branch wire bar parts, every two adjacent branch wire bar parts are located on different sides of the main wire bar part, at least one branch wire bar part is connected with an NTC temperature sensor, the other branch wire bar parts are connected with series aluminum bars, and every two adjacent series aluminum bars are arranged in a staggered mode at intervals. According to the invention, the aluminum wire collection hot-pressing film integrated busbar structure is adopted for voltage collection, no switching structure is needed, the aluminum wire bar is directly connected with the BMU collection slave board PCB, no plug-in terminal is needed, the structure is simple, the cost is low, and compared with a traditional copper wire, the mass is lighter.

Description

Technical Field

[0001] The invention relates to the technical field of electric vehicles, and in particular to a hot-pressed film integrated busbar structure for collecting aluminum wires, a battery module and an electric vehicle. Background Art

[0002] In the field of new energy power batteries, improving the integration efficiency of CCS components, reducing assembly procedures, and lowering material and process costs are the development direction of the industry. At present, the main technical solutions for CCS components can be divided into two categories: one is to use plastic brackets as structural carriers to install and fix FPC and conductive aluminum bars; the other is to hot-press FPC and conductive aluminum bars into a whole.

[0003] However, these prior art solutions have the following problems:

[0004] First, the FPC sampling structure generally adopts a nickel sheet transfer solution, which is connected to the slave PCB through the FPC tail transfer terminal, resulting in a complex structure. Secondly, the FPC itself is composed of PI insulation film, transfer nickel sheet, copper foil, etc., with a complex structure and high cost. Furthermore, since the CCS component is usually installed on the top of the battery cell, the temperature collection position is mostly on the top of the battery cell and on the conductive busbar, which affects the accuracy of the battery cell sampling.

[0005] Existing patent technologies also have some limitations. For example, a Chinese patent discloses a CCS component and battery module, which includes a signal acquisition FPC component, a plastic bracket and connectors, but the components need to be manually assembled and connected by snap-on or hot-melt fixation, resulting in low grouping efficiency and insufficient connection reliability. Another Chinese patent discloses a wiring-type collection hot-pressed film-molded wiring harness isolation plate assembly and its battery module. Although it uses a CCS component integrally molded by a wiring-type hot-pressed film, it still has the following problems: the busbar temperature is collected instead of the battery cell sampling temperature, and the error is large; the voltage collection end uses a nickel sheet adapter and a plug-in terminal to connect to the PCB slave board, and there are multiple transfers, a complex structure and high cost.

[0006] In view of the shortcomings of the existing technology, it is urgent to develop a new type of hot-pressed film integrated busbar structure to solve the above-mentioned technical problems, thereby promoting the further development of new energy power battery technology. Summary of the invention

[0007] In order to solve or partially solve the problems existing in the related art, the purpose of the present invention is to provide a hot-pressed film integrated busbar structure for aluminum wire collection, a battery module and an electric vehicle, which do not require any adapter structure, and the aluminum wire bus is directly connected to the BMU collection slave board PCB, has no plug-in terminals, has a simple structure, is low in cost, and is lighter than traditional copper wires; at the same time, since the length of the temperature collection harness can be customized, the area where the temperature sensor can be installed is expanded, and the shoulder, side and other areas of the battery cell can be selected for temperature collection, thereby improving the accuracy of temperature collection.

[0008] To achieve the above-mentioned purpose, the present invention provides a hot-pressed film integrated busbar structure for aluminum wire collection, comprising a PET upper hot-pressed film and a PET lower hot-pressed film, an aluminum wire bus and an output aluminum bar are arranged between the PET upper hot-pressed film and the PET lower hot-pressed film, the end of the aluminum wire bus is connected to a BMU collection board, the aluminum wire bus comprises a main wire bus part and a plurality of branch wire bus parts, two adjacent branch wire bus parts are located on different sides of the main wire bus part, at least one branch wire bus part is connected to an NTC temperature sensor, and the remaining branch wire bus parts are connected to series aluminum bars, and two adjacent series aluminum bars are arranged at intervals and staggered.

[0009] In some embodiments of the present invention, the output aluminum bar is Z-shaped.

[0010] In some embodiments of the present invention, the series-connected aluminum bars are in the shape of a "X".

[0011] In some embodiments of the present invention, two adjacent aluminum bars connected in series are connected to a single battery cell to form a Z-shaped structure.

[0012] In some embodiments of the present invention, each series aluminum bar connects two adjacent single battery cells.

[0013] In some embodiments of the present invention, one end of a single cell located at an end is connected to an output aluminum bar, and the output aluminum bars located at both ends are located on different sides of the aluminum wire bus.

[0014] In some embodiments of the present invention, a BMU acquisition board is provided with an acquisition board pad.

[0015] In some embodiments of the present invention, the main line row portion and the branch line row portion are arranged perpendicular to each other.

[0016] The present invention also provides a battery module, which includes the hot-pressed film integrated busbar structure collected by the aluminum wire in the above embodiment.

[0017] The present invention also discloses an electric vehicle, which comprises the battery module in the above embodiment.

[0018] The beneficial effects of the present invention are as follows: the present invention provides a hot-pressed film integrated busbar structure, battery module and electric vehicle for aluminum wire collection, which have significant advantages in many aspects. First of all, the structure does not require any adapter components, and the aluminum wire bus can be directly connected to the BMU collection board PCB, eliminating the plug-in terminals, greatly simplifying the overall structure, and thus reducing production costs. It is particularly worth mentioning that the present invention innovatively uses aluminum wire as the conductive substrate instead of copper wire or copper foil used in traditional wiring harnesses and FPCs. This change not only further reduces costs, but also significantly reduces the overall weight, which has a positive impact on the range and overall performance of electric vehicles.

[0019] Another important feature of the present invention is that the high temperature resistant aluminum wire is directly welded to the aluminum busbar, which completely eliminates the need for a nickel sheet transfer structure for voltage sampling. At the same time, the output end of the aluminum wire is directly connected to the BMU slave board pad, eliminating the transfer structure such as the plug-in terminal. These innovations greatly simplify the sampling path and reduce redundant parts, which not only reduces material costs, but also improves the reliability of the overall structure.

[0020] The design of the present invention allows for customization of the length of the temperature acquisition harness, significantly expanding the installation area of ​​the temperature sensor. The flexibility of the aluminum wire itself allows the NTC temperature sensor to be flexibly installed in multiple locations such as the shoulder, side, and back of the battery cell, rather than being limited to the top of the battery cell. This flexibility greatly improves the accuracy and comprehensiveness of temperature acquisition, which is of great significance for the precise control of the battery management system and the extension of battery life.

[0021] In addition, the structural design of the present invention is ingenious, using a Z-shaped output aluminum bar and a "J"-shaped series aluminum bar, and by staggering the adjacent series aluminum bars, an efficient and compact connection method is formed. This design not only optimizes space utilization, but also improves the stability and reliability of the overall structure. In particular, the design of each series aluminum bar connecting two adjacent single cells, and the connection method of the end single cells and the output aluminum bar further simplify the overall structure and improve assembly efficiency.

[0022] The present invention effectively solves multiple problems existing in the prior art through innovative structural design and material selection. It not only simplifies the production process and significantly reduces costs, but also improves the accuracy and flexibility of temperature acquisition, optimizes space utilization, and improves overall performance. These improvements are of great significance for improving the performance, reliability and cost-effectiveness of battery modules and promoting the development of electric vehicle technology. These advantages of the present invention will bring innovative progress to the field of new energy power batteries and provide strong support for the sustainable development of the electric vehicle industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0024] Figure 1 It is a schematic diagram of the assembly of the hot-pressed film integrated busbar structure of the aluminum wire collection of the present invention;

[0025] Figure 2 Schematic diagram of the hot-pressed film integrated busbar structure of the aluminum wire collection of the present invention;

[0026] Figure 3 It is an exploded view of the hot-pressed film integrated busbar structure collected by the aluminum wire of the present invention. DETAILED DESCRIPTION

[0027] The technical solution of the present invention (including the preferred technical solution) is further described in detail below by means of the accompanying drawings and by listing some optional 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.

[0028] like Figure 1-3 As shown, the present invention provides an innovative hot-pressed film integrated busbar structure for aluminum wire collection, which not only simplifies the production process, but also significantly improves the performance and reliability of the battery module. The specific implementation of the present invention will be described in detail below.

[0029] The core components of the present invention include an upper PET hot-pressed film 5 and a lower PET hot-pressed film 9, between which an aluminum wire row 7 and an output aluminum bar 8 are arranged. The end of the aluminum wire row 7 is connected to the BMU acquisition board 2 to form a complete electrical circuit. The entire structural design is ingenious, which not only ensures the reliability of the electrical connection, but also realizes the compactness of the structure.

[0030] The aluminum wire row 7 is a key component of the present invention, which includes a main wire row section 71 and multiple branch wire row sections 72. This design allows efficient transmission of current and signals, while facilitating the connection of temperature sensors and single cells. The main wire row section 71 and the branch wire row section 72 are arranged perpendicular to each other. This orthogonal layout not only optimizes space utilization, but also reduces electromagnetic interference. Two adjacent branch wire row sections 72 are located on different sides of the main wire row section 71. This staggered arrangement further increases the flexibility of wiring and space utilization.

[0031] In terms of temperature monitoring, at least one branch line section 72 is connected to an NTC temperature sensor 4. This design allows accurate temperature monitoring at different positions of the battery module, improving the accuracy and comprehensiveness of temperature acquisition. The remaining branch line sections 72 are connected to series aluminum bars 6. These series aluminum bars 6 are designed in a "J" shape, and two adjacent series aluminum bars 6 are arranged at intervals and staggered. This arrangement not only saves space, but also improves the stability of the structure.

[0032] The output aluminum bar 8 adopts a Z-shaped design, which increases the flexibility of the structure and helps to adapt to the space limitations and thermal expansion inside the battery module. One end of the single battery cell 3 at the end is connected to the output aluminum bar 8, while the output aluminum bars 8 at both ends are located on different sides of the aluminum wire row 7. This design achieves efficient transmission and uniform distribution of current.

[0033] In terms of the connection of the single cells, each series aluminum bar 6 connects two adjacent single cells 3. This connection method not only simplifies the structure, but also improves the assembly efficiency. More importantly, two adjacent series aluminum bars 6 and one single cell 3 form a Z-shaped structure, which increases the flexibility of the structure and helps to relieve thermal and mechanical stress.

[0034] The BMU acquisition board 2 is provided with an acquisition board pad 21. This design allows the acquisition aluminum wire output end to be directly connected to the BMU slave board pad, eliminating the traditional transfer structure such as the plug-in terminal, simplifying the sampling path, and reducing the material cost.

[0035] The manufacturing process of the aluminum wire collection hot pressing film integrated busbar assembly of the present invention includes the following steps: First, the high temperature resistant aluminum wire busbar 7 is welded with the series aluminum bar 6, the output aluminum bar 8, and the NTC temperature sensor 4 to form a sampling busbar. This step ensures a reliable electrical connection between the components. Then, the collection aluminum wire 7 and the overcurrent aluminum bar are wrapped by PET hot pressing film technology to form a CCS integrated collection assembly. This step not only protects the internal components, but also enhances the stability of the overall structure.

[0036] After the battery cells 3 are stacked into groups, the CCS assembly 1 containing the aluminum wire row is installed on the upper part of the battery cells. At the same time, the NTC temperature sampling sensor 4 is fixed to the side of the battery. This flexible arrangement allows temperature sampling at multiple locations such as the shoulder, side, and back of the battery cell, greatly improving the accuracy of temperature monitoring. Next, the battery cell pole is welded to the overcurrent aluminum bar to ensure efficient transmission of current. Finally, the output end of the acquisition aluminum wire is directly connected to the pad 21 on the BMU acquisition board, eliminating the transfer structure such as the plug-in terminal, further reducing the production cost.

[0037] The present invention has a number of technical advantages. First, aluminum wire is innovatively used as the conductive substrate, replacing the traditional copper wire or copper foil. This change not only reduces the cost, but also significantly reduces the overall weight, which has a positive significance for improving the endurance of electric vehicles. Secondly, through direct welding and hot pressing wrapping technology, the present invention eliminates the nickel sheet transfer structure and the plug-in terminal, greatly simplifies the overall structure, improves reliability, and reduces production costs.

[0038] In terms of temperature monitoring, the flexible nature of aluminum wire allows NTC temperature sensors to be flexibly installed in multiple locations of the battery cell, greatly improving the accuracy and comprehensiveness of temperature acquisition. This is essential for precise control of the battery management system and extending battery life. The design of Z-shaped output aluminum bar, I-shaped series aluminum bar, and staggered arrangement not only optimizes space utilization, but also improves the stability and reliability of the overall structure. In addition, the design of each series aluminum bar connecting two adjacent single cells, as well as the connection method between the end single cells and the output aluminum bar, simplifies the overall structure and improves assembly efficiency.

[0039] The aluminum wire collection hot pressing film integrated busbar structure of the present invention is not only suitable for battery modules, but can also be widely used in various types of electric vehicles. Its lightweight, high efficiency and high reliability characteristics make it an important innovation to promote the development of new energy vehicle technology. By adopting this advanced CCS component, electric vehicle manufacturers can produce products with better performance, lower cost and longer endurance. This will not only help improve the market competitiveness of electric vehicles, but will also make important contributions to solving energy and environmental problems.

[0040] The aluminum wire collection hot-pressed film integrated busbar structure provided by the present invention represents an important technological breakthrough in the field of battery management systems. Through innovative material selection, ingenious structural design and optimized manufacturing process, the present invention successfully solves multiple technical challenges faced by traditional CCS components. It not only simplifies the production process and significantly reduces costs, but also improves the accuracy and flexibility of temperature collection, optimizes space utilization, and improves overall performance. These improvements are of great significance for improving the performance, reliability and cost-effectiveness of battery modules, as well as promoting the development of electric vehicle technology. With the rapid development of the new energy vehicle industry, the present invention is expected to play a key role in the design and manufacture of electric vehicles in the future, and make important contributions to the realization of a cleaner and more efficient transportation system.

[0041] Those skilled in the art will readily appreciate that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A hot-pressed film integrated busbar structure for aluminum wire collection, characterized in that: The invention comprises a PET upper hot-pressed film (5) and a PET lower hot-pressed film (9), wherein an aluminum wire row (7) and an output aluminum bar (8) are arranged between the PET upper hot-pressed film (5) and the PET lower hot-pressed film (9), wherein the end of the aluminum wire row (7) is connected to a BMU acquisition board (2), wherein the aluminum wire row (7) comprises a main wire row portion (71) and a plurality of branch wire row portions (72), wherein two adjacent branch wire row portions (72) are located on different sides of the main wire row portion (71), wherein at least one branch wire row portion (72) is connected to an NTC temperature sensor (4), and the remaining branch wire row portions (72) are connected to series aluminum bars (6), wherein two adjacent series aluminum bars (6) are arranged in an interval and staggered manner.

2. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 1 is characterized in that: The output aluminum bar (8) is Z-shaped.

3. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 1, characterized in that: The series-connected aluminum bars (6) are in the shape of a cross.

4. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 1, characterized in that: Two adjacent aluminum bars (6) connected in series form a Z-shaped structure with a single battery cell (3).

5. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 1, characterized in that: Each series aluminum bar (6) connects two adjacent single battery cells (3).

6. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 1, characterized in that: One end of the single cell (3) located at the end is connected to the output aluminum bar (8), and the output aluminum bars (8) located at both ends are located on different sides of the aluminum wire row (7).

7. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 6, characterized in that: The BMU acquisition board (2) is provided with an acquisition board welding pad (21).

8. The hot-pressed film integrated busbar structure for aluminum wire collection according to claim 1, characterized in that: The main line row part (71) and the branch line row part (72) are arranged perpendicular to each other.

9. A battery module, characterized in that: The battery module comprises a hot-pressed film integrated busbar structure collected by aluminum wire according to any one of claims 1 to 8.

10. An electric vehicle, characterized in that: The electric vehicle comprises the battery module according to claim 9.

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