Aluminum-based FFC power / energy storage battery sampling assembly and method

Abstract

The invention discloses an aluminum-based FFC power / energy storage battery sampling assembly and method. The aluminum-based FFC power / energy storage battery sampling assembly comprises an aluminum conductor, and the upper surface layer and the lower surface layer of the aluminum conductor are coated with PI films to form an FFC body; a window for exposing the aluminum conductor is formed in a single surface or double surfaces of the PI film end part of the FFC body; if the window is formed in the single surface, the aluminum conductor and the crimping terminal are crimped in a one-to-one correspondence manner, and the crimping terminal is plugged into the connector in a one-to-one correspondence manner; if windows are arranged on the two sides, the aluminum conductor is welded to the PCB. The invention discloses a preparation method of an aluminum conductor in an FFC power / energy storage battery sampling assembly and a preparation method of an aluminum-based FFC body in the FFC power / energy storage battery sampling assembly, and solves the technical problems of high cost and single connection mode in the prior art by innovatively adopting a pure aluminum conductor to replace a traditional copper conductor and combining a modular windowing design.

Description

TECHNICAL FIELD

[0001] The application relates to a signal sampling assembly, in particular to an aluminum-based FFC power / energy storage battery sampling assembly and method. BACKGROUND

[0002] The existing battery sampling assembly mainly adopts pure copper conductors and is divided into two technical routes: The first one is a composite of copper conductor and PI film, which has the advantages of flexibility, foldability, high temperature resistance and strong overcurrent capacity, but the cost of copper material is high, and an additional adapter structure is needed to realize the connection with the aluminum bar; The second one is in the form of FFC, which has high production efficiency, but due to the problem of copper-aluminum heterogeneous welding, it must be connected to the aluminum bar through punching and bending of the copper foil, the connection mode is single, the process is complex and the reliability is limited. SUMMARY

[0003] In order to solve the above technical problems, the application provides an aluminum-based FFC power / energy storage battery sampling assembly and method.

[0004] In order to solve the above technical problems, the application adopts the technical scheme of: an aluminum-based FFC power / energy storage battery sampling assembly, comprising an aluminum conductor, and the upper and lower surface layers of the aluminum conductor are covered with PI film to form an FFC body; The PI film end of the FFC body is provided with a window for exposing the aluminum conductor on one side or on both sides; If the window is opened on one side, the aluminum conductor is correspondingly crimped with the crimped terminal, and the crimped terminal is correspondingly inserted into the connector; If the window is opened on both sides, the aluminum conductor is welded to the PCB.

[0005] Further, when the window for exposing the aluminum conductor is opened on one side, an aluminum bar or an adapter branch is welded to the aluminum conductor at the window of the PI film of the FFC body.

[0006] Further, when the window for exposing the aluminum conductor is opened on both sides, an aluminum bar or an adapter branch is welded to the aluminum conductor at the window of the PI film of the FFC body.

[0007] Further, the structure of the window opened on both sides is a window opened on opposite layers or a window opened on staggered layers.

[0008] A method for preparing an aluminum conductor in an FFC power / energy storage battery sampling assembly, comprising the following steps: S11, pretreating the surface of the aluminum ingot; S12, heating the pretreated aluminum ingot to 730 DEG C and keeping it molten; S13, pouring the molten aluminum into a mold to form an aluminum rod by casting; S14, refining the cast aluminum rod by heat treatment and cold working; S15, cold drawing the refined aluminum rod multiple times through multiple cold drawing dies to form an elongated straight aluminum strip; S16, feeding the aluminum strip into a wire drawing machine for further drawing to obtain an aluminum wire with a radius of 0.15 mm into a wire coil; S17, feeding the aluminum wire into a calendering device to compact and stretch the aluminum wire, so that the aluminum wire with a radius of 0.15 mm is stretched to an aluminum conductor with a width of 0.7 mm and a thickness of 0.1 mm, and the aluminum conductor is wound by a wire wheel.

[0009] Further, in step S11, first alkaline washing removes oil, then pickling removes scale, and then deionized water is used for rinsing and drying.

[0010] Further, in step S15, the end of the refined aluminum rod is pressed to a thickness of 2-3 mm by hydraulic pressure for clamping, and then the diameter is gradually reduced through 3-5 cold drawing dies, with a total elongation coefficient ≥6, to form an elongated straight aluminum strip with a radius of 2.0 mm.

[0011] A method for preparing an aluminum-based FFC body in a FFC power / energy storage battery sampling assembly, comprising the following steps: S21, conductor arrangement: a plurality of aluminum conductors are sequentially threaded through a guide wheel, a precision wire arranging wheel, a pre-pressing wheel, a high-temperature melting pressing wheel, and a traction wheel; the precision wire arranging wheel is provided with grooves matched with product requirements to fix the spacing between the conductors; S22, PI film processing: the upper and lower PI films are threaded through the guide wheel and the punching tool respectively, and the punching tool punches windows or shapes in the PI films according to product requirements; the PI film cover is torn off and fixed on the winding wheel; S23, composite hot pressing: the relative positions of the upper and lower PI films and the aluminum conductors are adjusted by a shaping tool, and the positions are calibrated by a visual recognition device; the PI films and the conductors are sequentially preliminarily bonded by the pre-pressing wheel, and then heated by the high-temperature melting pressing wheel to melt the thermosetting adhesive, so as to realize complete bonding; S24, cutting and winding: the traction wheel drags the semi-finished product to a set length, and then cuts off the shaping waste; the cutting tool removes the excess waste of the semi-finished product and winds it up; S25, curing and cutting: the wound semi-finished product is fed into a high-temperature oven for heat preservation and curing; and after curing, it is cut into individual FFC body units.

[0012] Further, in step S22, if terminal piercing crimping or wire ultrasonic welding is used, the punching tool is provided with windows with a depth of 3.5 mm at the ends.

[0013] Further, if PCB ultrasonic welding is used, the punching tool is provided with windows matched with the PCB copper pads on both sides at the ends.

[0014] This invention discloses an aluminum-based FFC power / energy storage battery sampling component and method. Through innovative aluminum-based FFC design, it overcomes the aforementioned technical bottlenecks, directly replacing copper with pure aluminum conductors, reducing material costs by more than 60%. It features a unique single-sided / double-sided window structure, supporting terminal crimping and PCB soldering. Simultaneously, it utilizes a central window in the FFC body for direct soldering with the aluminum bus, eliminating branches and saving space, materials, and costs. It can also be adapted to aluminum-based FDC, with both ends of the aluminum-based FDC capable of direct laser soldering, thus further reducing costs. Leveraging the low-cost characteristics of aluminum, it achieves copper performance standards and expands connectivity capabilities across multiple scenarios, filling a gap in the industry. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the FFC sampling component of the present invention.

[0016] Figure 2 Schematic diagram of the positional relationship between the aluminum conductor and the PI film Figure 3 This is a schematic diagram of a single-window structure in Example 1.

[0017] Figure 4 This is a schematic diagram showing the connection position of the crimp terminals.

[0018] Figure 5 for Figure 1 An enlarged diagram of circle A.

[0019] Figure 6 This is a schematic diagram of the double-sided window structure in Example 2.

[0020] Figure 7 for Figure 1 An enlarged diagram of circle B.

[0021] In the diagram: 1. Aluminum conductor; 2. PI film; 3. Window; 4. Crimping terminal; 5. Connector; 6. Aluminum-based FDC; 7. Aluminum bar. Detailed Implementation

[0022] like Figure 1 The diagram shows the overall structure of the aluminum-based FFC power / energy storage battery sampling assembly, which includes an aluminum conductor and an FFC body. The aluminum conductor is sandwiched between two layers of PI film with thermosetting adhesive, and is formed by high-temperature melting and pressing to form the FFC body. A window for exposed aluminum conductor is provided on one or both sides of the PI film end of the FFC body; If a window is opened on one side, the aluminum conductor and the crimp terminal are crimped one by one, and the crimp terminal is plugged into the connector one by one. If windows are opened on both sides, aluminum conductors are soldered onto the PCB board.

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0024] Example One; Single-sided windowed connector plug-in scheme; The overall structure of the aluminum-based FFC power / energy storage battery sampling assembly, as shown in Figure 2 includes an aluminum conductor 1, which is sandwiched between two layers of PI film 2 with heat-curing glue, and is formed into an FFC body by high-temperature melting and pressing. The end of the PI film 2 is provided with a window 3 exposing the aluminum conductor.

[0025] As shown in Figure 3 , a single-sided windowed rectangular window with a size of 3.5mm×48.3mm is punched at the end of the FFC, completely exposing the underlying aluminum conductor, as shown in Figure 4 The exposed aluminum conductor 2 (for convenience, the PI film is not covered) in the above window is correspondingly crimped with a crimping terminal 4, and the crimping terminal is correspondingly inserted into the connector. The crimping terminal pierces the surface of the aluminum conductor with the teeth to form a mechanical and electrical connection. As shown in Figure 5 , the crimping terminal after crimping is inserted into the connector 5 to realize quick plug-in and plug-out with external equipment.

[0026] The use of aluminum conductors instead of copper reduces costs, and the single-sided windowing combined with the piercing and crimping of the crimping terminal ensures stable contact resistance.

[0027] Example Two; The FFC body has the same aluminum conductor and PI film composite structure as in Example One.

[0028] As shown in Figure 6 , double-sided staggered windowing is used: the front window size is 6.5mm×48.7mm, and the exposed aluminum conductor is used to connect the PCB. The back window size is 5.5mm×47.7mm, and the PCB needs to be ultrasonic welded with the aluminum conductor. However, ultrasonic welding requires upper and lower clamping and conductor without film, so the PI film needs to be double-sided windowed. The front window is 1mm larger than the back window, and the front and back are staggered. After windowing, the PCB pad falls below the exposed aluminum conductor, which can be welded on the machine.

[0029] Example Three; Based on Example One or Example Two, as shown in Figure 7As shown, the application further optimizes the structure design of FFC (Flexible Flat Cable), and the specific improvements are as follows: at the non-end window 3 of the PI film 2, the aluminum-based FDC 6 is integrated by ultrasonic welding. The back of the aluminum-based FDC 6 is exposed to the aluminum conductor, and the aluminum bar 7 is directly connected by laser welding, which optimizes the traditional adapter terminal and reduces the terminal cost. The aluminum conductor and the aluminum bar are made of the same material, which ensures the high reliability of laser welding. The window size can be adjusted as needed (such as adapting to the PCB pad), which is convenient for automatic production line production. The windowed area of the middle part of the FFC is reserved to expose the aluminum conductor, and the PI film is removed to directly weld the aluminum bar or branch terminal.

[0030] When the number of battery cells is large and the product is long, the conductor spacing of a single FFC may not meet the connector PIN bit requirement. At this time, two FFCs are designed to be stacked up and down, and the aluminum bar is directly welded or branched welded through the middle window. This structure ensures that the overall width of the FFC matches the size of the connector, while optimizing the integration of signal acquisition and temperature monitoring. Through the above improvements, while ensuring the stability of signal transmission, the accuracy of temperature monitoring and the adaptability of automatic production are improved, which is suitable for different specifications of battery module application scenarios.

[0031] Embodiment four; The application also discloses a preparation method of an aluminum conductor in an FFC power / energy storage battery sampling assembly, which comprises the following steps: S11, pretreating the surface of the aluminum ingot; first, alkali washing to remove oil, then acid pickling to remove oxide skin, and then rinsing with deionized water and drying. NaOH solution is used to dissolve the oil on the surface of the aluminum ingot to remove the residual lubricant. HNO / HF mixed acid is used to remove the aluminum oxide layer to avoid impurities entering the molten aluminum liquid. Thus, the purity of the aluminum ingot is improved, the gas bubbles / inclusions during smelting are reduced, the surface activity of the aluminum ingot after pretreatment is enhanced, and the molten flowability is improved; S12, melting the pretreated aluminum ingot by heating to 730 DEG C; the melting point of aluminum is 660 DEG C, 730 DEG C ensures complete melting and moderate viscosity, constant temperature control avoids grain coarsening caused by overheating degree > 100 DEG C, which is beneficial to the optimization of melt flowability, uniform filling of the mold during casting, and reduction of the defect rate of the aluminum rod; S13, pouring the molten aluminum into a mold to form an aluminum rod by casting; S14, refining the cast aluminum rod by adopting heat treatment and cold working; S15, the refined aluminum rod is stretched into an elongated straight aluminum strip through multiple cold drawing dies; the end of the refined aluminum rod is pressed to 2-3 mm thick by hydraulic pressure for clamping, and then the diameter is gradually reduced through 3-5 cold drawing dies, the total elongation coefficient is greater than or equal to 6, and the aluminum strip with a radius of 2.0 mm is formed. Gradual deformation is adopted to avoid cracks caused by excessive instantaneous strain, and cold work hardening greatly improves the yield strength of the aluminum strip; S16, the aluminum strip is sent to a wire drawing machine for further stretching, and an aluminum wire with a radius of 0.15 mm is obtained and wound in a wire coil; thus, an ultra-fine homogeneous aluminum wire (diameter fluctuation ±0.003 mm) is obtained, which ensures that the FFC conductor spacing consistency meets the 1.3 mm precise arrangement requirement emphasized in the background technology; S17, the aluminum wire is sent to a calendering device to compact and extend the aluminum wire, so that the aluminum wire with a radius of 0.15 mm is pressed and extended to an aluminum conductor with a width of 0.7 mm and a thickness of 0.1 mm. The aluminum conductor is wound by a wire wheel. The flat conductor increases the contact area with the PI film, which is a necessary basis for the FFC power / energy storage battery sampling assembly.

[0032] Example five; A preparation method of an aluminum-based FFC body in an FFC power / energy storage battery sampling assembly, comprising the following steps: S21, conductor arrangement: a plurality of aluminum conductors are sequentially threaded through a guide wheel, a precision wire arranging wheel, a pre-pressing wheel, a high-temperature melting pressing wheel and a traction wheel; the precision wire arranging wheel is provided with grooves matched with product requirements to fix the spacing between the conductors; S22, PI film processing: the upper and lower PI films are threaded through the guide wheel and the punching tool respectively, and the punching tool punches windows or shapes in the PI film according to product requirements; the PI film is torn off and fixed on the winding wheel; in this step, the window position and size of the punching tool are determined according to the subsequent connection method. If terminal piercing and pressure welding or wire ultrasonic welding is adopted, the punching tool is provided with a window with a depth of 3.5 mm at the end. If PCB ultrasonic welding is adopted, the punching tool is provided with a window matched with the PCB copper pad at both ends.

[0033] S23, composite hot pressing: the relative positions of the upper and lower PI films and the aluminum conductor are adjusted by a shaping tool, and the positions are calibrated by a visual recognition device; the PI film and the conductor are preliminarily bonded by the pre-pressing wheel, and then heated by the high-temperature melting pressing wheel to melt the thermosetting adhesive, so as to realize complete bonding; S24, cutting and winding: the traction wheel drags the semi-finished product to a set length, and then cuts off the shaping waste; the cutting tool removes the excess waste of the semi-finished product and winds it up; S25, curing and cutting: the wound semi-finished product is sent into a high-temperature oven for heat preservation and curing; after curing, it is cut into single FFC body units.

[0034] In summary, the application realizes low cost, high reliability and multi-functional integration of the power / energy storage battery sampling assembly by using pure aluminum conductors instead of traditional copper conductors and combining the single / double windowed modular design. The specific performance is as follows: 1) The cost is significantly reduced, the cost of aluminum conductor material is reduced by more than 60% compared with copper, and the waste is reduced through precise stroke and automatic hot pressing process; 2) The connection mode is innovated, the single windowed terminal is pierced and crimped, the double windowed staggered window supports PCB welding and aluminum bar straight welding, and the copper-aluminum heterogeneous welding problem is completely solved; 3) The function is highly integrated; a single FFC body simultaneously completes voltage sampling and temperature monitoring, and the space utilization rate is improved; 4) The process compatibility is strong, the window size is adjustable (such as 3.5mm deep matching terminal / 6.5mm wide adapting PCB pad), and supports flexible production line. The scheme has cost advantage and performance breakthrough, and perfectly meets the core needs of power battery module for lightweight, high reliability and large-scale manufacturing.

[0035] The above embodiments are not a limitation of the application, and the application is not limited to the above examples. Changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solutions of the application also belong to the protection scope of the application.

Claims

1. An aluminum-based FFC power / energy storage battery sampling assembly, characterized in that, The FFC body is formed by covering PI film on the upper and lower layers of the aluminum conductor. The PI film end of the FFC body is provided with a window exposing the aluminum conductor on one side or both sides. If the window is provided on one side, the aluminum conductor is crimped with the crimping terminal one by one, and the crimping terminal is inserted into the connector one by one. If the window is provided on both sides, the aluminum conductor is welded to the PCB.

2. The aluminum-based FFC power / energy cell sampling assembly of claim 1, wherein, When the window exposing the aluminum conductor is provided on one side, an aluminum bar or a branch is welded to the aluminum conductor at the window of the PI film of the FFC body.

3. The aluminum-based FFC power / energy cell sampling assembly of claim 1, wherein, When the window exposing the aluminum conductor is provided on both sides, an aluminum bar or a branch is welded to the aluminum conductor at the window of the PI film of the FFC body.

4. The aluminum-based FFC power / energy cell sampling assembly of claim 3, wherein, The structure of the window provided on both sides is a window provided on the opposite layers or a window provided on staggered layers.

5. A method for preparing an aluminum conductor in a FFC power / energy storage battery sampling assembly, characterized by, The method comprises the following steps: S11, pretreating the surface of the aluminum ingot; S12, heating the pretreated aluminum ingot to 730 ℃ and keeping it molten; S13, pouring the molten aluminum into a mold to form an aluminum rod by casting; S14, refining the cast aluminum rod by heat treatment and cold working; S15, cold-drawing the refined aluminum rod into an elongated straight aluminum strip through multiple cold-drawing dies; S16, feeding the aluminum strip into a wire drawing machine for further drawing to obtain an aluminum wire with a radius of 0.15 mm into a wire coil; S17, feeding the aluminum wire into a calendering device to compact and stretch the aluminum wire, so that the aluminum wire with a radius of 0.15 mm is stretched to an aluminum conductor with a width of 0.7 mm and a thickness of 0.1 mm, and the aluminum conductor is wound by a wire wheel.

6. The method for preparing aluminum conductors in the FFC power / energy storage battery sampling assembly according to claim 5, characterized in that, In the step S11, the oil is removed by alkaline washing, then the scale is removed by pickling, and then the workpiece is rinsed with deionized water and dried.

7. The method for preparing aluminum conductors in the FFC power / energy storage battery sampling assembly according to claim 5, characterized in that, In the step S15, the end of the refined aluminum rod is pressed to a thickness of 2-3 mm by hydraulic pressure for clamping, and then the diameter is gradually reduced through 3-5 cold-drawing dies, the total elongation coefficient is ≥6, and an elongated straight aluminum strip with a radius of 2.0 mm is formed.

8. A method for preparing an aluminum-based FFC body in an FFC power / energy storage battery sampling assembly, characterized in that, The method comprises the following steps: S21, conductor arrangement: a plurality of aluminum conductors are sequentially threaded through a guide wheel, a precision wire arranging wheel, a pre-pressing wheel, a high-temperature melting and pressing wheel, and a traction wheel; the precision wire arranging wheel is provided with grooves matched with product requirements to fix the spacing between the conductors; S22, PI film processing: the upper and lower PI films are threaded through the guide wheel and a punching tool, the punching tool punches windows or shapes the PI film according to product requirements; the PI film is torn off and fixed on a winding wheel; S23, composite hot pressing: the relative positions of the upper and lower PI films and the aluminum conductors are adjusted by a shaping tool, and the positions are calibrated by a visual recognition device; the PI film and the conductors are preliminarily bonded by the pre-pressing wheel, and then heated by the high-temperature melting and pressing wheel to melt the thermosetting glue, so that complete bonding is achieved; S24, cutting and winding: the semi-finished product is pulled to a set length by the traction wheel, and the shaping waste is cut off; the excess waste of the semi-finished product is removed by a cutting tool and wound; S25, curing and cutting: the wound semi-finished product is sent into a high-temperature oven for curing; after curing, it is cut into individual FFC body units.

9. The method of claim 8, wherein the aluminum-based FFC body is prepared by the steps of: providing a FFC body; and coating the FFC body with a coating of a material selected from the group consisting of aluminum, aluminum alloys, and combinations thereof. In the step S22, if terminal piercing and crimping or wire ultrasonic welding is used, the punching tool is provided with a window with a depth of 3.5 mm at the end.

10. The method for preparing the aluminum-based FFC body in the FFC power / energy storage battery sampling assembly according to claim 9, characterized in that, If the PCB ultrasonic welding, punching tool in the end of the double-sided opening with the PCB copper pad matching window.

Images