Integrated busbar and connection method thereof

Abstract

The invention relates to an integrated busbar and a connection method thereof, and relates to the field of electrical connection and assembling.The integrated busbar comprises a lower insulating part, two circuit boards and a plurality of aluminum bars, the circuit boards are fixedly connected with the lower insulating part, and each circuit board comprises a plurality of flexible boards arranged in sequence; an upper plate, a first bending part, a middle plate, a second bending part and a lower plate are sequentially and integrally formed between every two adjacent flexible plates, the upper plate and the lower plate are fixedly connected with the two adjacent flexible plates respectively, and the ends, parallel to the arrangement direction of the flexible plates, of the upper plate and the middle plate are fixedly connected with the two ends of the first bending part respectively. The ends, perpendicular to the arrangement direction of the flexible boards, of the lower board and the middle board are fixedly connected with the two ends of the second bending part respectively, the multiple aluminum bars are fixedly connected to the end, close to the circuit board, of the lower insulating piece in the arrangement direction of the flexible boards, and connecting pieces are fixedly arranged between the circuit board and the aluminum bars. The method has the effects of reducing the production cost and improving the product quality.

Description

Technical Field

[0001] The present application relates to the field of electrical connection and assembly, and in particular to an integrated busbar and a connection method thereof. Background Art

[0002] The integrated busbar is a highly integrated electrical connection component for battery modules, which integrates signal acquisition components, conductive bars, insulating structural parts, etc. to realize high-voltage series and parallel connection of battery cells, temperature and voltage sampling, and data transmission functions.

[0003] Related technologies can refer to the Chinese patent announcement number CN222463343U, which discloses an integrated busbar structure of a battery connection system, including a U-shaped flexible circuit board and a mica sheet bracket, with bent nickel sheets extending from both sides of the flexible circuit board, and aluminum sheets provided on the nickel sheet side, and aluminum bar rivet holes provided on the aluminum bar sheet, and a first rivet hole of the bracket corresponding to the aluminum bar rivet hole is provided on the mica sheet bracket, a circuit board rivet hole is provided at the U-shaped bottom of the flexible circuit board, and a second rivet hole of the bracket is provided on the mica sheet bracket corresponding to the circuit board rivet hole, and rivets are installed in the aluminum bar rivet holes and the circuit board rivet holes, respectively passing through the first rivet hole of the bracket and the second rivet hole of the bracket, and the aluminum bar sheet and the flexible circuit board are riveted and fixed to the mica sheet bracket, and then the nickel sheet and the aluminum bar sheet are welded into a whole.

[0004] Regarding the aforementioned related technologies, when the integrated busbar length exceeds two meters or more, due to limitations in production equipment, it is difficult to form the long circuit board in one go. During the processing, it is often necessary to first produce multiple standard-sized flexible circuit boards, and then sequentially connect these multiple flexible circuit boards using plug-in connectors or welding to form a long circuit board structure to ensure signal transmission requirements. However, the plug-in connector and welding connection methods have high processing requirements, requiring specialized equipment and skilled operators, resulting in a complex and costly process. During transportation or folding, the plug-in connectors can easily become loose or the connection parts can be damaged, affecting product quality. Summary of the Invention

[0005] In order to reduce production costs and improve product quality, the present application provides an integrated busbar and a connection method thereof.

[0006] In a first aspect, the present application provides an integrated busbar, which adopts the following technical solution: An integrated busbar includes a lower insulating member, two circuit boards and several aluminum bars, the circuit board is fixedly connected to the lower insulating member, the circuit board includes several flexible boards arranged in sequence, and an upper plate, a first bending portion, a middle plate, a second bending portion and a lower plate are integrally formed between two adjacent flexible boards in sequence, the upper plate and the lower plate are respectively fixedly connected to the two adjacent flexible boards, one end of the upper plate and the middle plate parallel to the arrangement direction of the flexible boards are respectively fixedly connected to the two ends of the first bending portion, and one end of the lower plate and the middle plate perpendicular to the arrangement direction of the flexible boards are respectively fixedly connected to the two ends of the second bending portion, several aluminum bars are fixedly connected to one end of the lower insulating member close to the circuit board along the arrangement direction of the flexible boards, several aluminum bars are respectively located on the side of the two circuit boards away from each other, and a connecting member is fixed between the circuit board and the aluminum bar.

[0007] By adopting the above technical solution, the circuit board is formed into an integral structure through two adjacent flexible boards and the upper board, the first bending part, the middle board, the second bending part and the lower board therebetween. The length can be extended by bending twice, thereby reducing the production length of the circuit board. No professional equipment and skilled operators are required to use plug-in connectors or welding to connect multiple flexible circuit boards, thereby reducing the installation process requirements of the circuit board, solving the problem of inconvenient processing, reducing production costs, reducing the loosening of plug-in connectors or damage to connection parts during transportation or folding, and improving product quality. The connector is used to realize the electrical connection between the circuit board and the aluminum bar.

[0008] Optionally, the connecting part includes a connecting plate and a limiting plate. A limiting groove adapted to the limiting plate is provided at one end of the circuit board away from the lower insulating part, a limiting block is fixed in the limiting groove, and a socket adapted to the limiting block is provided on the limiting plate. The connecting plate is close to one end of the lower insulating part and is fixedly connected to the limiting plate and the aluminum bar on both sides perpendicular to the arrangement direction of the flexible board.

[0009] By adopting the above technical solution, the connecting piece composed of the connecting piece and the limiting piece can realize the electrical connection between the circuit board and the aluminum bar. The limiting piece is embedded in the limiting groove of the circuit board. The limiting block is adapted to the through hole on the limiting piece to limit the installation position of the limiting piece. The connecting piece can be electrically connected to the circuit board through the limiting piece, and the connecting piece and the limiting piece are fixed together by the bulge formed by welding the limiting block.

[0010] Optionally, the aluminum bar is provided with a plurality of first positioning holes, the flexible board is provided with a plurality of second positioning holes, and the lower insulating member is provided with a plurality of third positioning holes corresponding to the first positioning holes and a plurality of fourth positioning holes corresponding to the second positioning holes.

[0011] By adopting this technical solution, the aluminum busbar has a first positioning hole and the circuit board has a second positioning hole. Together with other components, this facilitates the precise positioning and installation of the integrated busbar components, improving assembly efficiency and precision. Furthermore, the circuit board's specific structure allows for extended length, avoiding the inconvenience and damage associated with traditional connection methods. The first and second positioning holes help ensure the stable installation of this improved circuit board structure within the integrated busbar.

[0012] Optionally, the lower insulating member is provided with a plurality of positioning grooves corresponding to the aluminum bars at one end close to the circuit board, and a plurality of first positioning columns corresponding to the first positioning holes are fixed in the positioning grooves. The end of the first positioning column fixed to the positioning grooves is open and connected to the third positioning hole. The lower insulating member is provided with a plurality of second positioning columns corresponding to the second positioning holes at one end close to the circuit board, and the second positioning columns are open at one end fixed to the lower insulating member and connected to the fourth positioning hole.

[0013] By adopting the above technical solution, a positioning groove corresponding to the aluminum bar, a first positioning column corresponding to the first positioning hole in the groove, and a second positioning column corresponding to the second positioning hole are provided on the lower insulating member to achieve accurate installation and positioning of the aluminum bar and the circuit board, which facilitates the assembly of various components, improves assembly efficiency and accuracy, and ensures the structural stability and performance reliability of the integrated busbar. The third positioning hole and the fourth positioning hole are connected to the side of the lower insulating member away from the circuit board, so as to achieve accurate positioning of the integrated busbar when installed on other devices.

[0014] Optionally, a clamping block is fixedly provided on the side wall of the positioning groove, and the clamping block is chamfered at one end away from the fixed side wall of the positioning groove and at two side lines perpendicular to the depth of the positioning groove.

[0015] By adopting the above technical solution, the clamping block can limit the aluminum bar and prevent it from shifting; the chamfers provided on the clamping block facilitate the disassembly and assembly of the aluminum bar in the positioning groove.

[0016] Optionally, the lower insulating member is provided with an installation groove and several heat dissipation grooves at one end close to the circuit board. The several heat dissipation grooves are all located between the two sides of the circuit board along a direction perpendicular to the arrangement direction of the circuit board. The installation groove is used to place the upper plate, the first bending portion, the middle plate, the second bending portion and the lower plate.

[0017] By adopting the above technical solution, the mounting groove can place the upper plate, the first bending portion, the middle plate, the second bending portion and the lower plate, making the layout of the circuit board more reasonable and compact; the heat dissipation groove is located between the two sides of the circuit board perpendicular to the arrangement direction of the circuit board, which helps to improve the heat dissipation performance of the circuit board.

[0018] Optionally, an upper insulating member is further included, the circuit board is located between the upper insulating member and the lower insulating member, and the upper insulating member is also provided with a plurality of third positioning holes corresponding to the first positioning holes and a plurality of fourth positioning holes corresponding to the second positioning holes.

[0019] By adopting the above technical solution, the circuit board is placed between the upper insulating member and the lower insulating member, which can protect and fix the circuit board; the upper insulating member and the lower insulating member are provided with a third positioning hole corresponding to the first positioning hole and a fourth positioning hole corresponding to the second positioning hole, which helps to accurately install and position.

[0020] In a second aspect, the present application provides a method for connecting an integrated busbar, comprising the following steps: S1, fix the position of the lower insulation; S2, extending the length of the circuit board by bending it multiple times to meet production requirements; S3, installing the bent circuit board and aluminum bar on the lower insulating member; S4, the limiting piece is embedded in the limiting groove on the circuit board, and the end of the connecting piece away from the limiting piece is placed on the upper end surface of the aluminum bar, completing the installation of the connecting piece between the circuit board and the aluminum bar.

[0021] Optionally, in S3, the aluminum bar is placed between the bottom wall of the positioning groove and the block, the first positioning column is inserted into the first positioning hole on the aluminum bar, the block limits the aluminum bar, and the second positioning column on the lower insulating part is inserted into the second positioning hole on the circuit board.

[0022] In a third aspect, the present application provides another method for connecting an integrated busbar, comprising the following steps: S1, fix the position of the lower insulation; S2, extending the length of the circuit board by bending it multiple times to meet production requirements; S3, installing the bent circuit board and aluminum bar on the lower insulating member; S4: The limiting piece is embedded in the limiting groove on the circuit board, and the end of the connecting piece away from the limiting piece is placed on the upper end surface of the aluminum bar, completing the installation of the connecting piece between the circuit board and the aluminum bar; S5, covering the upper insulating member on the side of the circuit board away from the lower insulating member; S6, hot pressing the lower insulating member and the upper insulating member to fix the circuit board and the aluminum bar.

[0023] In summary, this application includes at least one of the following beneficial technical effects: 1. The circuit board is formed as a single piece by two adjacent flexible boards and the upper board, the first bend, the middle board, the second bend, and the lower board therebetween. The length of the circuit board can be extended by bending twice, which reduces the production length of the circuit board, thereby reducing the processing requirements of the circuit board and avoiding the use of plug-in connectors or welding to connect multiple flexible circuit boards. This solves the problem of inconvenience in processing, reduces the loosening of plug-in connectors or damage to connection parts during transportation or folding, and improves product quality. The connector is used to achieve electrical connection between the circuit board and the aluminum bar. 2. The connector composed of the connecting piece and the limiting piece can realize the electrical connection between the circuit board and the aluminum bar. The limiting piece is embedded in the limiting groove of the circuit board. The limiting block is adapted to the through hole on the limiting piece to limit the installation position of the limiting piece. The connecting piece can be electrically connected to the circuit board through the limiting piece. The connecting piece and the limiting piece are fixed together by welding the convex bulge formed by the limiting block. 3. The aluminum busbar has a first positioning hole, and the circuit board has a second positioning hole. Together with other components, this facilitates precise positioning and installation of all components in the integrated busbar, improving assembly efficiency and precision. Furthermore, the circuit board's specific structure allows for extended length, avoiding the inconvenience and damage associated with traditional connection methods. The first and second positioning holes help ensure stable installation of this improved circuit board structure within the integrated busbar. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of the top view of the integrated busbar in Example 1.

[0025] Figure 2 yes Figure 1 Schematic diagram of the explosion structure.

[0026] Figure 3 It is a structural diagram of the lower insulating member, circuit board and aluminum bar in Example 1.

[0027] Figure 4 It is a schematic diagram of the local structure of the circuit board.

[0028] Figure 5 It is a schematic diagram of the structure when the two flexible plates are not bent.

[0029] Figure 6 It is a schematic diagram of the structure of the three flexible plates when they are not bent.

[0030] Figure 7 yes Figure 3 Enlarged schematic diagram of part A.

[0031] Figure 8 This is a schematic diagram of the top view of the integrated busbar in Example 2.

[0032] Figure 9 yes Figure 8Schematic diagram of the enlarged portion B.

[0033] Figure 10 yes Figure 9 Schematic cross-section in the CC direction.

[0034] Explanation of the accompanying drawings: 1. Lower insulating member; 11. Third positioning hole; 12. Fourth positioning hole; 13. Positioning groove; 14. First positioning column; 15. Second positioning column; 16. Block; 161. Chamfer; 17. Mounting groove; 18. Heat dissipation groove; 2. Circuit board; 21. Flexible board; 211. Second positioning hole; 22. Upper plate; 23. First bending portion; 24. Middle plate; 25. Second bending portion; 26. Lower plate; 27. Limiting groove; 271. Limiting block; 3. Aluminum bar; 31. First positioning hole; 4. Connecting member; 41. Connecting plate; 42. Limiting plate; 5. Upper insulating member. DETAILED DESCRIPTION

[0035] The present application is further described in detail below in conjunction with all the accompanying drawings. Example 1

[0036] In a first aspect, an embodiment of the present application discloses an integrated busbar.

[0037] Reference Figure 1 and Figure 2 An integrated busbar includes a lower insulator 1, two circuit boards 2, and several aluminum bars 3. The two circuit boards 2 are located on either side of the lower insulator 1 along its length, and are fixedly connected to the lower insulator 1. The aluminum bars 3 are fixedly connected to the end of the lower insulator 1 near the circuit boards 2 along the arrangement direction of the flexible board 21. The aluminum bars 3 are located on the side of the two circuit boards 2 that is away from each other, that is, the side of the circuit boards 2 that is close to the side of the lower insulator 1.

[0038] Reference Figure 3 and Figure 4 The circuit board 2 includes several sequentially arranged flexible boards 21. An upper board 22, a first bend 23, a middle board 24, a second bend 25, and a lower board 26 are integrally formed between two adjacent flexible boards 21. The upper board 22 and the lower board 26 are each fixedly connected to the two adjacent flexible boards 21. The ends of the upper board 22 and the middle board 24, which are parallel to the arrangement direction of the flexible boards 21, are fixedly connected to the ends of the first bend 23. The ends of the lower board 26 and the middle board 24, which are perpendicular to the arrangement direction of the flexible boards 21, are fixedly connected to the ends of the second bend 25. Before the circuit board 2 is bent, double-sided tape or glue is partially applied to the lower board 26 and the upper board 22. After the circuit board 2 is bent, the upper board 22 and the middle board 24, and the lower board 26 and the middle board 24, are bonded together using double-sided tape or glue.

[0039] Reference Figure 5 and Figure 6 In this embodiment, circuit board 2 is composed of two flexible boards 21. In other embodiments, the number of flexible boards 21 can be increased to further reduce the production length of circuit board 2 or increase the installation length of circuit board 2 after bending. Circuit board 2, composed of two flexible boards 21, has a U-shape before bending. Each additional flexible board 21 adds another U-shape to the shape of circuit board 2.

[0040] Aluminum bar 3 refers to the aluminum bracket that connects two battery cells in a battery pack. It is typically made of a high-strength, corrosion-resistant aluminum alloy or other conductive material. Aluminum bar 3 connects the two cells to ensure proper function of the battery pack. It also serves as a support structure for the cells, maintaining spacing between them and preventing collisions and vibrations. Aluminum bar 3 also has excellent heat dissipation properties, quickly dissipating heat generated by the cells to prevent overheating.

[0041] Reference Figure 2 and Figure 3 The aluminum bar 3 comprises two sheet-like structures, each with an arched rib in the middle, which acts as a vibration buffer. The sheet-like structure is provided with countersunk holes and through holes. The countersunk holes are provided on the lower surface of the aluminum bar 3. The provision of the countersunk holes facilitates the coordinated installation of the integrated busbar and the battery module, making the connection more stable and secure. The through hole is located in the middle of the countersunk holes, and the provision of the through hole facilitates the welding of the aluminum bar 3 to the battery module. The lower insulating member 1 is provided with through holes corresponding to the through holes of the aluminum bar 3 and heat dissipation holes for dissipating heat from the battery module, thereby reducing the weight of the lower insulating member 1 and, in turn, the overall weight of the battery after installation, reducing the materials used in the production of the lower insulating member 1, and reducing production costs.

[0042] Reference Figure 3 and Figure 7 A connector 4 is fixed between the circuit board 2 and the aluminum bar 3. The connector 4 includes a connecting piece 41 and a limiting piece 42. A limiting groove 27 adapted to the limiting piece 42 is defined at the end of the circuit board 2 away from the lower insulating piece 1. A limiting block 271 is fixed within the limiting groove 27. The limiting piece 42 is provided with a socket adapted to the limiting block 271. The connecting piece 41 is fixedly connected to the limiting piece 42 and the aluminum bar 3 on both sides of the connecting piece 41, which is close to the end of the lower insulating piece 1 and perpendicular to the arrangement direction of the flexible board 21. The connector 4 composed of the connecting piece 41 and the limiting piece 42 can realize the electrical connection between the circuit board 2 and the aluminum bar 3. The limiting piece 42 is embedded in the limiting groove 27 of the circuit board 2. The limiting block 271 is adapted to the through hole on the limiting piece 42 to limit the installation position of the limiting piece 42. The connecting piece 41 can be electrically connected to the circuit board 2 through the limiting piece 42, and the connecting piece 41 and the limiting piece 42 are fixed together by welding the convex bump formed by the limiting block 271.

[0043] During the integrated busbar assembly process, a jig is fixed to the workbench. Several pins are fixed to the upper end of the jig to secure the lower insulator 1. The circuit board 2 and aluminum bar 3 are then installed on the lower insulator 1. The battery module is also equipped with positioning pins to position the lower insulator 1 when the integrated busbar is installed on the battery module.

[0044] Reference Figure 3 Aluminum bar 3 is provided with several first positioning holes 31, while flexible board 21 is provided with several second positioning holes 211. These holes, in conjunction with other components, facilitate the precise positioning and installation of the components of the integrated busbar, improving assembly efficiency and precision. Furthermore, the circuit board 2 utilizes a specific structure to extend its length, avoiding the inconvenience and fragility of traditional connection methods. The first and second positioning holes 31, 211 help ensure the stable installation of this improved circuit board 2 structure within the integrated busbar.

[0045] Reference Figure 1 , this embodiment also includes an upper insulating member 5, and both the upper insulating member 5 and the lower insulating member 1 are hot-pressed films.

[0046] Reference Figure 1 and Figure 2 The circuit board 2 is located between the upper insulator 5 and the lower insulator 1. Both the upper insulator 5 and the lower insulator 1 are provided with a plurality of third positioning holes 11 corresponding to the first positioning holes 31 and a plurality of fourth positioning holes 12 corresponding to the second positioning holes 211. Insertion rods are inserted into the third and fourth positioning holes 11, 12, respectively, to secure the position of the lower insulator 1, facilitating accurate installation and positioning. When the integrated busbar is mounted on the battery module, the positioning rods are inserted into the third and fourth positioning holes 11, 12, respectively. The insertion rods and positioning rods pass through the lower insulator 1, the circuit board 2, the aluminum bar 3, and the upper insulator 5, in sequence.

[0047] Reference Figure 2 The upper insulating member 5 is provided with through holes corresponding to the connecting piece 41, the limiting piece 42, the arched rib and the countersunk hole of the aluminum bar 3. The upper insulating member 5 is also provided with several heat dissipation holes at the same position of the lower insulating member 1 for heat dissipation of the battery.

[0048] The implementation principle of an integrated busbar in an embodiment of the present application is as follows: the circuit board 2 is formed as a whole through two adjacent flexible boards 21 and the upper board 22, the first bending portion 23, the middle board 24, the second bending portion 25 and the lower board 26 therebetween. The length can be extended by bending twice, thereby reducing the production length of the circuit board 2. No professional equipment and skilled operators are required to use plug-in connectors or welding to connect multiple flexible circuit boards 2, thereby reducing the installation process requirements of the circuit board 2, solving the problem of inconvenient processing, reducing production costs, reducing the loosening of plug-in connectors or damage to connection parts during transportation or folding, and improving product quality; the connector 4 is used to realize the electrical connection between the circuit board 2 and the aluminum bar 3.

[0049] On the other hand, an embodiment of the present application discloses a method for connecting an integrated busbar, comprising the following steps: S1, fix the lower insulating member 1 on the fixture, and insert the rod through the third positioning hole 11 and the fourth positioning hole 12 on the lower insulating member 1; S2, bending the circuit board 2 into a long strip multiple times to extend the length of the circuit board 2 to meet production requirements; S3, place the aluminum bar 3 and the circuit board 2 on the lower insulating member 1, align the first positioning hole 31 with the third positioning hole 11 of the lower insulating member 1, align the second positioning hole 211 with the fourth positioning hole 12 of the lower insulating member 1, and insert the rod through the first positioning hole 31 and the second positioning hole 211; S4, the limiting piece 42 is inserted into the limiting groove 27 on the circuit board 2, and the end of the connecting piece 41 away from the limiting piece 42 is placed on the upper end surface of the aluminum bar 3, completing the installation of the connecting piece 4 between the circuit board 2 and the aluminum bar 3; S5, cover the upper insulating member 5 on the side of the circuit board 2 away from the lower insulating member 1, and sleeve the third positioning hole 11 and the fourth positioning hole 12 of the upper insulating member 5 on the outside of the insertion rod. The upper insulating member 5 covers the aluminum bar 3 and the circuit board 2; S5, placing the jig together on the hot pressing equipment, hot pressing the lower insulating part 1 and the upper insulating part 5 to composite them, so as to fix the circuit board 2 and the aluminum bar 3 to form an integrated busbar. Example 2

[0050] The difference between this embodiment and embodiment 1 lies in the structure of the lower insulating member 1 and the connection method of the integrated busbar.

[0051] First aspect In this embodiment, the lower insulating member 1 is a plastic template made by a vacuum forming device, and is used to support and install the circuit board 2 and the aluminum bar 3.

[0052] Reference Figure 8 and Figure 9The lower insulating member 1 is provided with a plurality of positioning slots 13 for mounting the aluminum bar 3 at one end thereof, which is close to the circuit board 2. A clamping block 16 is fixed to the side wall of the positioning slot 13. The clamping block 16 is provided with a chamfer 161 on two sides of the end thereof, which is away from the fixed side wall of the positioning slot 13 and perpendicular to the depth of the positioning slot 13. The clamping block 16 can limit the aluminum bar 3 and prevent it from shaking in the positioning slot 13. The chamfer 161 provided on the clamping block 16 facilitates the assembly and disassembly of the aluminum bar 3 in the positioning slot 13. The aluminum bar 3 is provided with a plurality of first positioning holes 31, and the positioning slot 13 is provided with a plurality of first positioning posts 14 corresponding to the first positioning holes 31. The flexible board 21 is provided with a plurality of second positioning holes 211, and the lower insulating member 1 is provided with a plurality of second positioning posts 15 corresponding to the second positioning holes 211, which are fixed to the end thereof, which is close to the circuit board 2.

[0053] Reference Figure 10 The end of the first positioning post 14 fixed to the positioning groove 13 is open and communicates with the third positioning hole 11. Several second positioning posts 15 corresponding to the second positioning holes 211 are fixed to the end of the lower insulator 1 near the circuit board 2. The end of the second positioning post 15 fixed to the lower insulator 1 is open and communicates with the fourth positioning hole 12. Insertion rods are inserted into the third and fourth positioning holes 11 and 12, respectively, to fix the position of the lower insulator 1. When the integrated busbar is installed on the battery module, the positioning rods are inserted into the third and fourth positioning holes 11 and 12, respectively.

[0054] Reference Figure 8 The end of the lower insulating member 1 near the circuit board 2 is provided with a mounting slot 17 and several heat dissipation slots 18. These slots 18 are located between two sides of the circuit board 2, perpendicular to the direction in which the circuit boards 2 are arranged. Mounting slot 17 is used to accommodate the upper plate 22, first bend 23, middle plate 24, second bend 25, and lower plate 26. The size and shape of mounting slot 17 are designed based on the bending structure of the circuit board 2 to accommodate the upper plate 22, first bend 23, middle plate 24, second bend 25, and lower plate 26, while preventing the lower insulating member 1 from protruding outward. The heat dissipation slots 18 improve the heat dissipation performance of the circuit board 2 and prevent the circuit board 2 from overheating and affecting its performance.

[0055] On the other hand, this embodiment discloses a method for connecting an integrated busbar, comprising the following steps: S1, fix the lower insulating member 1 on the fixture, and insert the insertion rod into the third positioning hole 11 and the fourth positioning hole 12; S2, bending the circuit board 2 into a long strip multiple times to extend the length of the circuit board 2 to meet production requirements; S3. During the installation of the aluminum bar 3 onto the lower insulating member 1, the aluminum bar 3 is pressed. The two sheet-like structures are squeezed toward the center by the chamfer 161 of the clamping block 16. After the arched rib is bent, the aluminum bar 3 is placed between the bottom wall of the positioning groove 13 and the clamping block 16. The first positioning post 14 is inserted into the first positioning hole 31 on the aluminum bar 3. The clamping block 16 limits the aluminum bar 3. The second positioning post 15 on the lower insulating member 1 is inserted into the second positioning hole 211 on the circuit board 2. The first positioning hole 31 is aligned with the third positioning hole 11 of the lower insulating member 1. The circuit board 2 is installed on the lower insulating member 1, and the second positioning hole 211 is aligned with the fourth positioning hole 12 of the lower insulating member 1. S4, the limiting piece 42 is embedded in the limiting groove 27 on the circuit board 2, and the end of the connecting piece 41 away from the limiting piece 42 is placed on the upper end surface of the aluminum bar 3, completing the installation of the connecting piece 4 between the circuit board 2 and the aluminum bar 3.

Claims

1. An integrated busbar, characterized by: The invention comprises a lower insulating member (1), two circuit boards (2) and a plurality of aluminum bars (3), wherein the circuit board (2) is fixedly connected to the lower insulating member (1), the circuit board (2) comprises a plurality of flexible boards (21) arranged in sequence, an upper board (22), a first bending portion (23), a middle board (24), a second bending portion (25) and a lower board (26) are integrally formed between two adjacent flexible boards (21), the upper board (22) and the lower board (26) are respectively fixedly connected to the two adjacent flexible boards (21), and the upper board (22) and the middle board (24) are parallel to each other. One end in the arrangement direction of the flexible board (21) is fixedly connected to the two ends of the first bending portion (23), and one end of the lower board (26) and the middle board (24) perpendicular to the arrangement direction of the flexible board (21) is fixedly connected to the two ends of the second bending portion (25). A plurality of aluminum bars (3) are fixedly connected to one end of the lower insulating member (1) close to the circuit board (2) along the arrangement direction of the flexible board (21). The plurality of aluminum bars (3) are respectively located on the side of the two circuit boards (2) away from each other, and a connecting member (4) is fixedly provided between the circuit board (2) and the aluminum bar (3).

2. The integrated busbar according to claim 1, characterized in that: The connecting member (4) includes a connecting piece (41) and a limiting piece (42). A limiting groove (27) adapted to the limiting piece (42) is provided at one end of the circuit board (2) away from the lower insulating member (1). A limiting block (271) is fixedly provided in the limiting groove (27). A jack adapted to the limiting block (271) is provided on the limiting piece (42). The connecting piece (41) is fixedly connected to the limiting piece (42) and the aluminum bar (3) on both sides of one end close to the lower insulating member (1) and perpendicular to the arrangement direction of the flexible board (21).

3. The integrated busbar according to claim 2, characterized in that: The aluminum bar (3) is provided with a plurality of first positioning holes (31), the flexible plate (21) is provided with a plurality of second positioning holes (211), and the lower insulating member (1) is provided with a plurality of third positioning holes (11) corresponding to the first positioning holes (31) and a plurality of fourth positioning holes (12) corresponding to the second positioning holes (211).

4. The integrated busbar according to claim 3, characterized in that: The lower insulating member (1) is provided with a plurality of positioning grooves (13) corresponding to the aluminum bars (3) at one end thereof close to the circuit board (2), and a plurality of first positioning posts (14) corresponding to the first positioning holes (31) are fixed in the positioning grooves (13). The first positioning posts (14) are opened at one end fixed to the positioning grooves (13) and are communicated with the third positioning holes (11). The lower insulating member (1) is provided with a plurality of second positioning posts (15) corresponding to the second positioning holes (211) at one end thereof close to the circuit board (2), and the second positioning posts (15) are opened at one end fixed to the lower insulating member (1) and are communicated with the fourth positioning holes (12).

5. The integrated busbar according to claim 4, characterized in that: A clamping block (16) is fixedly provided on the side wall of the positioning groove (13), and chamfers (161) are provided on two side lines of the clamping block (16) that are away from one end of the fixed positioning groove (13) side wall and perpendicular to the depth of the positioning groove (13).

6. The integrated busbar according to claim 5, characterized in that: The lower insulating member (1) is provided with a mounting groove (17) and a plurality of heat dissipation grooves (18) at one end thereof close to the circuit board (2). The plurality of heat dissipation grooves (18) are all located between two sides of the circuit board (2) along a direction perpendicular to the arrangement direction of the circuit board (2). The mounting groove (17) is used to place the upper plate (22), the first bending portion (23), the middle plate (24), the second bending portion (25) and the lower plate (26).

7. The integrated busbar according to claim 3, characterized in that: It also includes an upper insulating member (5), the circuit board (2) is located between the upper insulating member (5) and the lower insulating member (1), and the upper insulating member (5) is also provided with a plurality of third positioning holes (11) corresponding to the first positioning holes (31) and a plurality of fourth positioning holes (12) corresponding to the second positioning holes (211).

8. A method for connecting an integrated busbar, applied to an integrated busbar according to any one of claims 3 to 6, characterized in that: The steps include: S1, fixes the position of the lower insulating member (1); S2, extending the length of the circuit board (2) by bending the circuit board (2) multiple times to meet production requirements; S3, installing the bent circuit board (2) and aluminum bar (3) on the lower insulating member (1); S4, the limiting piece (42) is embedded in the limiting groove (27) on the circuit board (2), and the end of the connecting piece (41) away from the limiting piece (42) is placed on the upper end surface of the aluminum bar (3), completing the installation of the connecting piece (4) between the circuit board (2) and the aluminum bar (3).

9. The method for connecting an integrated busbar according to claim 8, characterized in that: In the S3, the aluminum bar (3) is placed between the bottom wall of the positioning groove (13) and the clamping block (16), the first positioning column (14) is inserted into the first positioning hole (31) on the aluminum bar (3), the clamping block (16) serves to limit the aluminum bar (3), and the second positioning column (15) on the lower insulating member (1) is inserted into the second positioning hole (211) on the circuit board (2).

10. A method for connecting an integrated busbar, applied to the integrated busbar according to claim 7, characterized in that: The steps include: S1, fixes the position of the lower insulating member (1); S2, extending the length of the circuit board (2) by bending the circuit board (2) multiple times to meet production requirements; S3, installing the bent circuit board (2) and aluminum bar (3) on the lower insulating member (1); S4, the limiting piece (42) is embedded in the limiting groove (27) on the circuit board (2), and the end of the connecting piece (41) away from the limiting piece (42) is placed on the upper end surface of the aluminum bar (3), completing the installation of the connecting piece (4) between the circuit board (2) and the aluminum bar (3); S5, covering the upper insulating member (5) on the side of the circuit board (2) away from the lower insulating member (1); S6, hot pressing the lower insulating member (1) and the upper insulating member (5) to fix the circuit board (2) and the aluminum bar (3).

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