Integrated busbar and connection method thereof

Abstract

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

Description

Technical Field

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

[0002] An integrated busbar is a highly integrated electrical connection component used in battery modules. It integrates signal acquisition components, conductive busbars, and insulating structural components into one unit, enabling high-voltage series and parallel connection of battery cells, temperature and voltage sampling, and data transmission.

[0003] Related technology can be found in Chinese Patent No. CN222463343U, which discloses an integrated busbar structure for a battery connection system. This structure includes a U-shaped flexible circuit board and a mica sheet support. Bent nickel sheets extend from both sides of the flexible circuit board, and aluminum foil sheets are provided on the nickel sheet sides. Aluminum foil rivet holes are provided on the aluminum foil sheets. A first rivet hole is provided on the mica sheet support corresponding to the aluminum foil rivet holes. A circuit board rivet hole is provided at the U-shaped bottom of the flexible circuit board, and a second rivet hole is provided on the mica sheet support corresponding to the circuit board rivet holes. Rivets are inserted into the aluminum foil rivet holes and the circuit board rivet holes, respectively passing through the first and second rivet holes of the support, to rivet and fix the aluminum foil sheets and the flexible circuit board onto the mica sheet support. Then, the nickel sheets and aluminum foil sheets are welded together as a whole.

[0004] Regarding the aforementioned technologies, when the integrated busbar length exceeds two meters, limitations in production equipment make it difficult to process long circuit boards in a single step. The process often requires first fabricating multiple standard-sized flexible circuit boards, then sequentially connecting them using plug-in connectors or soldering to form the long circuit board structure, ensuring signal transmission requirements. However, plug-in connectors and soldering methods demand sophisticated processing techniques, requiring specialized equipment and skilled operators, resulting in a complex and costly process. Furthermore, during handling or folding, plug-in connectors are prone to loosening or damage to connections, affecting product quality. Summary of the Invention

[0005] In order to reduce production costs and improve product quality, this application provides an integrated busbar and its connection method.

[0006] Firstly, this application provides an integrated busbar, employing the following technical solution: An integrated busbar includes a lower insulating component, two circuit boards, and several aluminum bars. The circuit boards are fixedly connected to the lower insulating component. Each circuit board includes several flexible plates arranged in sequence. Between two adjacent flexible plates, an upper plate, a first bending portion, a middle plate, a second bending portion, and a lower plate are integrally formed in sequence. The upper plate and the lower plate are fixedly connected to the two adjacent flexible plates, respectively. One end of the upper plate and the middle plate parallel to the arrangement direction of the flexible plates is fixedly connected to the two ends of the first bending portion, respectively. One end of the lower plate and the middle plate perpendicular to the arrangement direction of the flexible plates is fixedly connected to the two ends of the second bending portion, respectively. Several aluminum bars are fixedly connected to the lower insulating component near the circuit board along the arrangement direction of the flexible plates. The aluminum bars are located on the side of the two circuit boards that are far apart from each other. Connectors are fixed between the circuit boards and the aluminum bars.

[0007] By adopting the above technical solution, the circuit board, through its integrally formed structure of two adjacent flexible boards and the upper board, first bend, middle board, second bend, and lower board, can extend its length through two bends, reducing the production length of the circuit board. This eliminates the need for specialized equipment and skilled operators to use plug-in connectors or welding to connect multiple flexible circuit boards, thereby reducing the installation process requirements, solving the problem of inconvenient processing, lowering production costs, reducing the likelihood of loose plug-in connectors or damage to connection points during handling or folding, and improving product quality. The connector is used to achieve the electrical connection between the circuit board and the aluminum busbar.

[0008] Optionally, the connector includes a connecting piece and a limiting piece. The circuit board has a limiting groove adapted to the limiting piece at one end away from the lower insulating component. A limiting block is fixed in the limiting groove. The limiting piece has an insertion hole adapted to the limiting block. The connecting piece is fixedly connected to the limiting piece and the aluminum bar at one end near the lower insulating component and on both sides perpendicular to the flexible board arrangement direction, respectively.

[0009] By adopting the above technical solution, the connector composed of the connecting piece and the limiting piece can realize the electrical connection between the circuit board and the aluminum plate. The limiting piece is embedded in the limiting groove of the circuit board. The limiting block and the through hole on the limiting piece can restrict 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 protrusion formed by the limiting block.

[0010] Optionally, the aluminum bar has a plurality of first positioning holes, the flexible plate has a plurality of second positioning holes, and the lower insulating component has 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 the above 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 precise positioning and installation of all parts of the integrated busbar, improving assembly efficiency and accuracy. Simultaneously, the circuit board's specific structure extends its 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 overall integrated busbar.

[0012] Optionally, the lower insulating component has several positioning grooves corresponding to the aluminum bar at one end near the circuit board. Several first positioning posts corresponding to the first positioning holes are fixed in the positioning grooves. The first positioning posts are open at the end where they are fixed to the positioning grooves and communicate with the third positioning hole. The lower insulating component has several second positioning posts corresponding to the second positioning holes at one end near the circuit board. The second positioning posts are open at the end where they are fixed to the lower insulating component and communicate with the fourth positioning hole.

[0013] By adopting the above technical solution, the positioning groove corresponding to the aluminum bar and the first positioning post corresponding to the first positioning hole and the second positioning post corresponding to the second positioning hole are set on the lower insulating component, which realizes the effect of 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 component away from the circuit board, so as to realize the accurate positioning of the integrated busbar when it is installed on other devices.

[0014] Optionally, a locking block is fixed to the side wall of the positioning groove, and the end of the locking block away from the fixed side wall of the positioning groove and the two sides perpendicular to the depth of the positioning groove are chamfered.

[0015] By adopting the above technical solution, the locking block can limit the aluminum bar and prevent it from shifting; the chamfer on the locking block facilitates the installation and removal of the aluminum bar in the positioning groove.

[0016] Optionally, the lower insulating component has a mounting groove and several heat dissipation grooves at one end near the circuit board. The heat dissipation grooves are located between the two sides of the circuit board along the direction perpendicular to the circuit board's layout. The mounting groove is used to place the upper plate, the first bend, the middle plate, the second bend, and the lower plate.

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

[0018] Optionally, it also includes an upper insulating component, wherein the circuit board is located between the upper insulating component and the lower insulating component, and the upper insulating component 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 can be protected and fixed by placing it between the upper and lower insulating parts; the upper and lower insulating parts 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 the circuit board.

[0020] Secondly, this application provides a method for connecting an integrated busbar, comprising the following steps: S1, fix the position of the lower insulating component; S2 extends the length of the circuit board by bending it multiple times to meet production requirements; S3, install the bent circuit board and aluminum bar on the lower insulation component; 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 surface of the aluminum bar, thus completing the installation of the connector between the circuit board and the aluminum bar.

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

[0022] Thirdly, this application provides another method for connecting an integrated busbar, comprising the following steps: S1, fix the position of the lower insulating component; S2 extends the length of the circuit board by bending it multiple times to meet production requirements; S3, install the bent circuit board and aluminum bar on the lower insulation component; 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 surface of the aluminum bar, thus completing the installation of the connector between the circuit board and the aluminum bar. S5, cover the side of the circuit board away from the lower insulator with an upper insulator; S6 involves hot-pressing the lower and upper insulating components together to secure the circuit board and aluminum foil.

[0023] In summary, this application includes at least one of the following beneficial technical effects: 1. The circuit board, with its integrally formed structure consisting of two adjacent flexible boards, an upper board, a first bend, a middle board, a second bend, and a lower board, can extend its length through two bends, reducing the production length of the circuit board. This lowers the processing requirements of the circuit board, avoids the processing method of using plug-in connectors or welding to connect multiple flexible circuit boards, solves the problem of processing inconvenience, reduces the possibility of plug-in connectors becoming loose or connection parts being damaged during handling or folding, and improves product quality; the connector is used to realize the electrical connection between the circuit board and the aluminum bar; 2. The connector consisting of the connecting piece and the limiting piece enables the electrical connection between the circuit board and the aluminum plate. The limiting piece is embedded in the limiting groove of the circuit board. The limiting block and the through hole on the limiting piece can restrict 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 protrusion 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 parts of the integrated busbar, improving assembly efficiency and accuracy. Simultaneously, the circuit board's specific structure extends its 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 overall integrated busbar. Attached Figure Description

[0024] Figure 1 This is a top view schematic diagram of an integrated busbar structure according to Embodiment 1.

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

[0026] Figure 3 This is a schematic diagram of the structure of the lower insulating component, circuit board, and aluminum bar in Example 1.

[0027] Figure 4 This is a partial structural diagram of the circuit board.

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

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

[0030] Figure 7 yes Figure 3 An enlarged schematic diagram of part A in the middle.

[0031] Figure 8 This is a top view schematic diagram of an integrated busbar structure according to Embodiment 2.

[0032] Figure 9 yes Figure 8Enlarged schematic diagram of part B.

[0033] Figure 10 yes Figure 9 A cross-sectional view along the CC direction.

[0034] Explanation of reference numerals in the attached drawings: 1. Lower insulating component; 11. Third positioning hole; 12. Fourth positioning hole; 13. Positioning groove; 14. First positioning post; 15. Second positioning post; 16. Locking 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 part; 24. Middle plate; 25. Second bending part; 26. Lower plate; 27. Limiting groove; 271. Limiting block; 3. Aluminum bar; 31. First positioning hole; 4. Connecting component; 41. Connecting piece; 42. Limiting piece; 5. Upper insulating component. Detailed Implementation

[0035] The present application will be further described in detail below with reference to all the accompanying drawings. Example 1

[0036] In one aspect, embodiments of this application disclose an integrated busbar.

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

[0038] Reference Figure 3 and Figure 4 The circuit board 2 includes several flexible boards 21 arranged in sequence. Between any two adjacent flexible boards 21, 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. The upper board 22 and the lower board 26 are fixedly connected to the two adjacent flexible boards 21. One end of the upper board 22 and the middle board 24, parallel to the arrangement direction of the flexible boards 21, is fixedly connected to both ends of the first bending portion 23. One end of the lower board 26 and the middle board 24, perpendicular to the arrangement direction of the flexible boards 21, is fixedly connected to both ends of the second bending portion 25. Before bending, double-sided tape or glue is applied to parts of the lower board 26 and the upper board 22. After bending, 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, the circuit board 2 is composed of two flexible boards 21. In other embodiments, the production length of the circuit board 2 can be further reduced or the installation length of the circuit board 2 after bending can be increased by increasing the number of flexible boards 21. The circuit board 2 composed of two flexible boards 21 has a U-shaped shape before bending. For each additional flexible board 21 added to the circuit board 2, the shape of the circuit board 2 increases by one more U-shape.

[0040] Aluminum Bar 3 refers to the aluminum bracket in a battery pack that connects two battery cells. It is usually made of high-strength, highly corrosion-resistant aluminum alloy or other conductive materials. Aluminum Bar 3 connects two battery cells, ensuring the normal operation of the battery pack. Simultaneously, as a supporting structure for the cells, it maintains the spacing between them, preventing collisions and vibrations. Aluminum Bar 3 also has excellent heat dissipation properties, quickly dissipating the heat generated by the cells and preventing overheating.

[0041] Reference Figure 2 and Figure 3 The aluminum busbar 3 comprises two sheet-like structures with an arched rib in the middle, which acts as a vibration damping element. The sheet-like structures have countersunk holes and through holes. The countersunk holes are located on the lower surface of the aluminum busbar 3, facilitating the integration of the busbar with the battery module for a more stable and secure connection. The through holes are located in the middle of the countersunk holes, allowing for easy welding of the aluminum busbar 3 onto the battery module. The lower insulating component 1 has through holes corresponding to the through holes in the aluminum busbar 3 and heat dissipation holes for the battery module, reducing the weight of the lower insulating component 1 and consequently reducing the overall weight of the battery after installation. This also reduces the amount of material used in producing the lower insulating component 1, thus lowering 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 opened at the end of the circuit board 2 away from the lower insulating member 1. A limiting block 271 is fixed in the limiting groove 27. An insertion hole adapted to the limiting block 271 is opened 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 the end of the connecting piece 41 near the lower insulating member 1 and perpendicular to the arrangement direction of the flexible plate 21, respectively. The connector 4, consisting of the connecting piece 41 and the limiting piece 42, enables 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 restrict 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. The connecting piece 41 and the limiting piece 42 are fixed together by welding the protrusion formed by the limiting block 271.

[0043] During the assembly of the integrated busbar, a tooling fixture needs to be fixed on the workbench. Several insertion rods are fixed on the upper surface of the tooling fixture to fix the lower insulation component 1. Then, the circuit board 2 and aluminum busbar 3 are installed on the lower insulation component 1. At the same time, when the integrated busbar is installed onto the battery module, the battery module is also equipped with positioning rods for positioning the lower insulation component 1.

[0044] Reference Figure 3 The aluminum busbar 3 has several first positioning holes 31, and the flexible board 21 has several second positioning holes 211. Together with other components, this facilitates precise positioning and installation of all components of the integrated busbar, improving assembly efficiency and accuracy. Simultaneously, the circuit board 2 employs a specific structure that extends its length, avoiding the inconvenience and damage associated with traditional connection methods. The first positioning holes 31 and second positioning holes 211 help ensure the stable installation of this improved circuit board 2 structure within the overall integrated busbar.

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

[0046] Reference Figure 1 and Figure 2 The circuit board 2 is located between the upper insulating component 5 and the lower insulating component 1. Both the upper insulating component 5 and the lower insulating component 1 have several third positioning holes 11 corresponding to the first positioning hole 31 and several fourth positioning holes 12 corresponding to the second positioning hole 211. The insertion rods are inserted into the third positioning holes 11 and the fourth positioning holes 12 respectively to fix the position of the lower insulating component 1, which helps to accurately install and position it. At the same time, when the integrated busbar is installed on the battery module, the positioning rods are inserted into the third positioning holes 11 and the fourth positioning holes 12 respectively. The insertion rods and positioning rods pass through the lower insulating component 1, the circuit board 2, the aluminum busbar 3, and the upper insulating component 5 in sequence.

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

[0048] The implementation principle of the integrated busbar in this application embodiment is as follows: The circuit board 2 is integrally formed by two adjacent flexible boards 21 and the upper board 22, the first bending part 23, the middle board 24, the second bending part 25 and the lower board 26 between them. The length can be extended by two bends, which reduces the production length of the circuit board 2. It eliminates the need for special equipment and skilled operators 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 occurrence of loose plug-in connectors or damage to connection parts during handling or folding, and improving product quality; the connector 4 is used to realize the electrical connection between the circuit board 2 and the aluminum busbar 3.

[0049] On the other hand, embodiments of this application disclose a method for connecting an integrated busbar, comprising the following steps: S1, fix the lower insulating part 1 on the tooling fixture, and insert the rod through the third positioning hole 11 and the fourth positioning hole 12 on the lower insulating part 1; S2, the circuit board 2 is bent into a long strip multiple times to extend its length and meet production requirements; S3, place the aluminum bar 3 and the circuit board 2 on the lower insulating component 1, align the first positioning hole 31 with the third positioning hole 11 of the lower insulating component 1, align the second positioning hole 211 with the fourth positioning hole 12 of the lower insulating component 1, and insert the rod through the first positioning hole 31 and the second positioning hole 211. 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 surface of the aluminum bar 3, thus completing the installation of the connecting piece 4 between the circuit board 2 and the aluminum bar 3. S5, the upper insulating component 5 is covered on the side of the circuit board 2 away from the lower insulating component 1. The third positioning hole 11 and the fourth positioning hole 12 of the upper insulating component 5 are sleeved on the outside of the plug rod. The upper insulating component 5 covers the aluminum bar 3 and the circuit board 2. S5. Place the tooling fixture together on the hot pressing equipment, and hot press the lower insulating part 1 and the upper insulating part 5 together to fix the circuit board 2 and the aluminum busbar 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 component 1 and the connection method of the integrated busbar.

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

[0052] Reference Figure 8 and Figure 9The lower insulating component 1 has several positioning slots 13 for mounting aluminum bars 3 at one end near the circuit board 2. A locking block 16 is fixed to the side wall of each positioning slot 13. The locking block 16 has two chamfered edges 161 on its side end away from the fixed side wall of the positioning slot 13 and perpendicular to the depth of the positioning slot 13. The locking block 16 limits the movement of the aluminum bar 3 within the positioning slot 13, and the chamfered edges 161 facilitate the installation and removal of the aluminum bar 3 within the positioning slot 13. The aluminum bar 3 has several first positioning holes 31, and several first positioning posts 14 corresponding to the first positioning holes 31 are fixed in the positioning slots 13. The flexible board 21 has several second positioning holes 211, and several second positioning posts 15 corresponding to the second positioning holes 211 are fixed to the end of the lower insulating component 1 near the circuit board 2.

[0053] Reference Figure 10 The first positioning post 14 is fixed to the positioning groove 13 at one end, which 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 insulating component 1 near the circuit board 2. The end of each second positioning post 15 fixed to the lower insulating component 1 is open and communicates with the fourth positioning hole 12. Insert rods are inserted into the third positioning hole 11 and the fourth positioning hole 12 respectively to fix the position of the lower insulating component 1. Simultaneously, when the integrated busbar is installed onto the battery module, the positioning rods are inserted into the third positioning hole 11 and the fourth positioning hole 12 respectively.

[0054] Reference Figure 8 The lower insulating component 1 has a mounting groove 17 and several heat dissipation grooves 18 at one end near the circuit board 2. The heat dissipation grooves 18 are located between the two sides of the circuit board 2 along a direction perpendicular to its arrangement. The mounting groove 17 is used to accommodate the upper plate 22, the first bend 23, the middle plate 24, the second bend 25, and the lower plate 26. The size and shape of the mounting groove 17 are designed according to the bending structure of the circuit board 2, and can accommodate the upper plate 22, the first bend 23, the middle plate 24, the second bend 25, and the lower plate 26, preventing the lower insulating component 1 from protruding outwards. The heat dissipation grooves 18 can improve the heat dissipation performance of the circuit board 2, preventing the circuit board 2 from being affected by overheating.

[0055] On the other hand, this embodiment discloses a method for connecting an integrated busbar, including the following steps: S1, fix the lower insulating part 1 on the tooling fixture, and insert the rod into the third positioning hole 11 and the fourth positioning hole 12; S2, the circuit board 2 is bent into a long strip multiple times to extend its length and meet production requirements; S3, during the installation of aluminum bar 3 onto lower insulating component 1, aluminum bar 3 is pressed. The two sheet-like structures are squeezed towards the middle under the action of the chamfer 161 of the locking block 16. After the arched rib is bent, aluminum bar 3 is placed between the bottom wall of positioning groove 13 and locking block 16. The first positioning post 14 is inserted into the first positioning hole 31 on aluminum bar 3. The locking block 16 plays a limiting role for aluminum bar 3. The second positioning post 15 on lower insulating component 1 is inserted into the second positioning hole 211 on circuit board 2. The first positioning hole 31 is aligned with the third positioning hole 11 of lower insulating component 1. Circuit board 2 is installed on lower insulating component 1. The second positioning hole 211 is aligned with the fourth positioning hole 12 of lower insulating component 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 surface of the aluminum bar 3, thus completing the installation of the connecting piece 4 between the circuit board 2 and the aluminum bar 3.

Claims

1. An integrated busbar, characterized in that: The device includes a lower insulating component (1), two circuit boards (2), and several aluminum bars (3). The circuit boards (2) are fixedly connected to the lower insulating component (1). The circuit boards (2) include several flexible plates (21) arranged in sequence. Between two adjacent flexible plates (21), an upper plate (22), a first bending part (23), a middle plate (24), a second bending part (25), and a lower plate (26) are integrally formed in sequence. The upper plate (22) and the lower plate (26) are fixedly connected to the two adjacent flexible plates (21), respectively. The upper plate (22) and the middle plate (24) are flat. One end of the flexible plate (21) is fixedly connected to both ends of the first bending part (23) in the direction of the arrangement. The ends of the lower plate (26) and the middle plate (24) perpendicular to the direction of the arrangement of the flexible plate (21) are fixedly connected to both ends of the second bending part (25). Several aluminum bars (3) are fixedly connected to the end of the lower insulating member (1) near the circuit board (2) in the direction of the arrangement of the flexible plate (21). Several aluminum bars (3) are located on the side of the two circuit boards (2) that are far away from each other. A connecting member (4) is fixed between the circuit board (2) and the aluminum bars (3).

2. The integrated busbar according to claim 1, characterized in that: The connector (4) includes a connecting piece (41) and a limiting piece (42). The circuit board (2) has a limiting groove (27) adapted to the limiting piece (42) at one end away from the lower insulating member (1). A limiting block (271) is fixed in the limiting groove (27). The limiting piece (42) has an insertion hole 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) near the lower insulating member (1) and perpendicular to the arrangement direction of the flexible plate (21).

3. The integrated busbar according to claim 2, characterized in that: The aluminum bar (3) has several first positioning holes (31), the flexible plate (21) has several second positioning holes (211), and the lower insulating member (1) has several third positioning holes (11) corresponding to the first positioning holes (31) and several 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 component (1) has several positioning grooves (13) that correspond one-to-one with the aluminum bar (3) at one end of the circuit board (2). Several first positioning posts (14) corresponding to the first positioning hole (31) are fixed in the positioning grooves (13). The first positioning post (14) is open at one end of the positioning groove (13) and communicates with the third positioning hole (11). The lower insulating component (1) has several second positioning posts (15) corresponding to the second positioning hole (211) at one end of the circuit board (2). The second positioning post (15) is open at one end of the lower insulating component (1) and communicates with the fourth positioning hole (12).

5. The integrated busbar according to claim 4, characterized in that: The side wall of the positioning groove (13) is fixed with a locking block (16), and the two sides of the locking block (16) away from the fixed side wall of the positioning groove (13) and perpendicular to the depth of the positioning groove (13) are chamfered (161).

6. The integrated busbar according to claim 5, characterized in that: The lower insulating component (1) has an installation groove (17) and several heat dissipation grooves (18) at one end near the circuit board (2). The several heat dissipation grooves (18) are located between the two sides of the circuit board (2) along the direction perpendicular to the circuit board (2). The installation groove (17) is used to place the upper plate (22), the first bend (23), the middle plate (24), the second bend (25), and the lower plate (26).

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

8. A method for connecting an integrated busbar, applied to an integrated busbar as described in any one of claims 3-6, characterized in that, Includes the following steps: S1, fix the position of the lower insulating component (1); S2, the circuit board (2) is extended in length by bending it multiple times to meet production requirements; S3, install the bent circuit board (2) and aluminum bar (3) on the lower insulation component (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 surface of the aluminum bar (3) to complete the installation of the connector (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 S3, the aluminum bar (3) is placed between the bottom wall of the positioning groove (13) and the locking block (16), the first positioning post (14) is inserted into the first positioning hole (31) on the aluminum bar (3), the locking block (16) plays a limiting role on the aluminum bar (3), and the second positioning post (15) on the lower insulating component (1) is inserted into the second positioning hole (211) on the circuit board (2).

10. A method for connecting an integrated busbar, applied to an integrated busbar as described in claim 7, characterized in that, Includes the following steps: S1, fix the position of the lower insulating component (1); S2, the circuit board (2) is extended in length by bending it multiple times to meet production requirements; S3, install the bent circuit board (2) and aluminum bar (3) on the lower insulation component (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 surface of the aluminum bar (3) to complete the installation of the connector (4) between the circuit board (2) and the aluminum bar (3). S5, cover the side of the circuit board (2) away from the lower insulator (1) with the upper insulator (5); S6, the lower insulating part (1) and the upper insulating part (5) are hot-pressed together to fix the circuit board (2) and the aluminum bar (3).

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