FFC wire, automobile, and method for manufacturing FFC wire

Abstract

The invention discloses a flexible flat cable (FFC), an automobile and a manufacturing method of the FFC, and relates to the technical field of cables. The FFC wire comprises the insulating film, the plurality of acquisition wires and the plurality of connecting pins, and the plurality of acquisition wires are arranged between the first insulating layer and the second insulating layer of the insulating film, so that the risk of short circuit among the acquisition wires is effectively prevented, and the stability and the reliability of a circuit are ensured. The wiring end of the acquisition line is usually used for being connected with a main circuit board, and the connecting pin is used for being connected with a corresponding battery cell or a temperature sensor and used for acquiring voltage or temperature data of the battery cell. As the acquisition line extends along the second direction, and the connecting pin extends along the first direction and is integrally formed with the acquisition line, the connecting pin is not required to be perpendicular to the guide by adopting a bending mode, but is directly designed into a structure perpendicular to the guide in a production and manufacturing stage, so that when the FFC is assembled to the battery module, the production efficiency is greatly improved, and the production cost is reduced. And the assembly efficiency can be effectively improved.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to an FFC cable, an automobile, and a method for manufacturing FFC cables. Background Technology

[0002] The power battery module of an electric vehicle includes a CCS (Cruise Control System) component. The CCS component is mainly used for power transmission, signal acquisition, and battery management, playing a crucial role in the safety of the battery module and real-time monitoring of its status. The CCS component includes FFC lines, which act as the signal acquisition unit of the CCS component, responsible for transmitting key parameters such as the battery module's temperature and voltage to the battery management system. The connector pins of the FFC lines need to be bent 90° before being guided to the welding position. However, the FFC lines are flexible and difficult to bend through automated processes. Manual bending during assembly easily leads to messy connector pins, requiring significant time for sorting and alignment, resulting in low assembly efficiency. Summary of the Invention

[0003] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes an FFC line that can improve assembly efficiency.

[0004] The present invention also proposes a vehicle with the above-mentioned FFC line, and a method for manufacturing the FFC line.

[0005] According to a first aspect of the present invention, an FFC wire includes: an insulating film comprising a first insulating layer and a second insulating layer connected to each other; Multiple acquisition lines are spaced apart between the first insulating layer and the second insulating layer along a first direction. One end of the multiple acquisition lines together forms a terminal. Part of the structure of the terminal is exposed in the insulating film. The other end of the acquisition lines is a connection end and extends along a second direction, which is perpendicular to the first direction. The plurality of connecting pins are the same number as the number of the acquisition lines. The plurality of connecting pins extend along the first direction and are connected one-to-one with the connection ends of the plurality of acquisition lines. The connecting pins and the acquisition lines are configured as an integral structure, and the end of the connecting pin opposite to the connection end protrudes from the insulating film.

[0006] The FFC line according to embodiments of the present invention has at least the following beneficial effects: By placing multiple acquisition lines between the first and second insulating layers of the insulating film, the risk of short circuits between the acquisition lines is effectively prevented, ensuring the stability and reliability of the circuit. The terminals of the acquisition lines are typically used to connect to the main circuit board, while the connecting pins are used to connect to the corresponding battery cell or temperature sensor to acquire voltage or temperature data from the battery cell. Since the acquisition lines extend along the second direction, while the connecting pins extend along the first direction and are integrally formed with the acquisition lines, there is no need to bend the connecting pins to make them perpendicular to the guide. Instead, the connecting pins are designed to be perpendicular to the guide during the manufacturing stage, thus effectively improving assembly efficiency when assembling FFC lines into the battery module.

[0007] According to some embodiments of the present invention, the connecting pin includes a first connecting portion, a second connecting portion, and a fuse, wherein the first connecting portion is connected to the connecting end, the fuse is connected to the first connecting portion and located between the first connecting portion and the second connecting portion, and at least a portion of the second connecting portion protrudes from the insulating film.

[0008] According to some embodiments of the present invention, the fuse is wavy.

[0009] According to some embodiments of the present invention, the connecting leg further includes a bent section connected between the fuse and the second connecting portion, the maximum width of the bent section being less than the maximum width of the second connecting portion along the first direction, and the maximum width of the bent section being greater than the maximum width of the fuse.

[0010] According to some embodiments of the present invention, the curved section includes a first bend and a second bend connected to each other, the insulating film has a first opening in the area enclosed by the first bend, the first opening and the nearest edge of the insulating film forming a first pre-break, the insulating film has a second opening in the area enclosed by the second bend, the second opening and the nearest edge of the insulating film forming a second pre-break.

[0011] According to some embodiments of the present invention, the connecting end protrudes sequentially from the previous connecting end along the second direction, and the plurality of connecting feet are all located on the same side of the acquisition line.

[0012] According to some embodiments of the present invention, the thickness of the connecting end along the first direction is successively greater than the thickness of the previous connecting end along the first direction, and the side of the connecting end near the connecting foot along the first direction is flush with the previous connecting end.

[0013] According to some embodiments of the present invention, the terminal includes a connected connecting segment and a narrowing segment, the narrowing segment being located at one end of the connecting segment facing the terminal, and the width of the narrowing segment gradually decreasing along the first direction in the direction of the connecting segment towards the terminal.

[0014] The automobile according to a second aspect of the present invention includes the FFC line described in the above embodiments.

[0015] The automobile according to embodiments of the present invention has at least the following beneficial effects: By employing the FFC line of the first aspect embodiment, the FFC line effectively prevents the risk of short circuits between the acquisition lines by setting multiple acquisition lines between the first and second insulating layers of the insulating film, ensuring the stability and reliability of the circuit. The terminals of the acquisition lines are typically used to connect to the main circuit board, and the connecting pins are used to connect to the corresponding battery cell or temperature sensor to acquire the voltage or temperature data of the battery cell. Since the acquisition lines extend along the second direction, while the connecting pins extend along the first direction and are integrally formed with the acquisition lines, it is not necessary to bend the connecting pins to make them perpendicular to the guide. Instead, the connecting pins are designed to be perpendicular to the guide during the manufacturing stage, thus effectively improving assembly efficiency when assembling the FFC line to the battery module.

[0016] According to a third aspect of the present invention, the FFC wire includes an insulating film, a plurality of acquisition lines, and a plurality of connecting pins. The insulating film includes a first insulating layer and a second insulating layer connected together. The first insulating layer has a first through hole and a plurality of second through holes, and the second insulating layer has a plurality of third through holes. The plurality of acquisition lines are spaced apart between the first insulating layer and the second insulating layer along a first direction. One end of the plurality of acquisition lines together constitutes a terminal, and a portion of the structure of the terminal is exposed in the insulating film. The other end of the acquisition line is a connecting end and extends along a second direction, which is perpendicular to the first direction. The plurality of connecting pins and the number of acquisition lines are the same. The plurality of connecting pins and the connecting ends of the plurality of acquisition lines are connected one-to-one, and the connecting pins and acquisition lines are configured as an integrally formed structure. The connecting pins extend along the first direction, and one end of the connecting pin opposite to the connecting end protrudes from the insulating film. The manufacturing method includes the following steps: Multiple fuses spaced apart along the second direction are sequentially punched out on a long strip of copper foil; The copper foil sheet is adhered to the base film; Multiple corresponding data acquisition lines and connecting pins are integrally cut from the copper foil sheet; Remove excess material from the copper foil sheet; The first insulating layer is heat-pressed onto one side of the acquisition line and the connecting pin. The first through hole exposes part of the structure of the terminal, and multiple second through holes expose the ends of the corresponding connecting pins. Separate the base film, the acquisition line, and the connecting pin; The second insulating layer is heat-pressed onto the other side of the acquisition line and the connecting pin, and the second insulating layer is connected to the first insulating layer, with the plurality of third through holes exposing the ends of the corresponding connecting pins; The excess portions of the first and second insulating layers are removed.

[0017] The manufacturing method according to embodiments of the present invention has at least the following beneficial effects: The FFC (Fuel Concentration Charge) line effectively prevents short circuits by placing multiple acquisition lines between the first and second insulating layers of the insulating film, ensuring circuit stability and reliability. The acquisition line terminals are typically used to connect to the main circuit board, while the connecting pins are used to connect to the corresponding battery cell or temperature sensor to collect voltage or temperature data. Because the acquisition lines extend along the second direction, while the connecting pins extend along the first direction and are integrally formed with the acquisition lines, there is no need to bend the connecting pins to make them perpendicular to the guide. Instead, the connecting pins are designed to be perpendicular to the guide during the manufacturing stage, thus significantly improving assembly efficiency when assembling the FFC line into the battery module.

[0018] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 This is a schematic diagram of the structure of an FFC line according to an embodiment of the present invention; Figure 2 yes Figure 1 Enlarged view of point A in the middle; Figure 3 This is a schematic diagram of a structure for punching out a fuse from a copper foil sheet according to an embodiment of the present invention; Figure 4 yes Figure 3 Enlarged view of point B in the middle; Figure 5 This is a schematic diagram of the bonding structure of copper foil and base film according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of a copper foil sheet punched to form a collection line and connecting pins according to an embodiment of the present invention; Figure 7 yes Figure 6 Enlarged view of point C in the middle; Figure 8 This is a schematic diagram of the structure of a copper foil sheet after punching and removing excess material according to an embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of the first insulating layer according to an embodiment of the present invention; Figure 10 This is a schematic diagram of the structure of the first insulating layer connected to the base film, the acquisition line and the connecting pin according to an embodiment of the present invention; Figure 11 This is a schematic diagram of the structure of the first insulating layer, the acquisition line, and the connecting pin after removing the bottom film according to an embodiment of the present invention; Figure 12 This is a schematic diagram of the structure of the second insulating layer according to an embodiment of the present invention; Figure 13 This is a schematic diagram of the second insulating layer being connected to the rear side of the first insulating layer according to an embodiment of the present invention; Figure 14 This is a schematic diagram of the structure of an insulating film with excess structure removed to fit the acquisition line and connector pins according to an embodiment of the present invention; Figure 15 This is a schematic diagram of the structure of the insulating film display acquisition line and the part of the connecting pin that are blocked according to an embodiment of the present invention; Figure 16 This is a flowchart of a method for manufacturing an FFC line according to an embodiment of the present invention.

[0020] Figure label: FFC line 1000; Insulating film 100; first insulating layer 110; first through hole 111; second through hole 112; second insulating layer 120; third through hole 121; first opening 130; first pre-cut 131; second opening 140; second pre-cut 141; 200; terminal 210; connector segment 211; narrowing segment 212; connector 220; upper edge 221; Connecting foot 300; First connecting part 310; Fuse 320; Bending section 330; First bending part 331; Second bending part 332; Second connecting part 340; Bottom film 400; copper foil sheet 410; first punch 411; second punch 412. Detailed Implementation

[0021] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0022] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0023] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0024] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0025] In related technologies, when FFC (Flexible Flat Cable) lines are used as signal acquisition units in battery management systems, the connector pins require manual bending and positioning. Because flexible materials lack rigid support, angular deviations and positional shifts easily occur during bending, leading to repeated adjustments in subsequent welding processes. Especially in mass production scenarios, manual operation is not only inefficient but also prone to causing misalignment of the connector pins, affecting product reliability and assembly consistency.

[0026] To solve the above problems, refer to Figure 1 and Figure 2 As shown ( Figure 1 and Figure 2 The acquisition lines 200 and connecting pins 300 are covered by the insulating film 100. To facilitate the demonstration of its structure, dashed lines are used to represent the structure where the acquisition lines 200 and connecting pins 300 are covered by the insulating film 100; at the same time, to more clearly see the arrangement of the acquisition lines 200, some acquisition lines 200 have been deleted. An embodiment of the FFC line 1000 of the present invention includes an insulating film 100, multiple acquisition lines 200, and multiple connecting pins 300. The insulating film 100 includes a first insulating layer 110 and a second insulating layer 120 interconnected. The multiple acquisition lines 200 are spaced apart between the two insulating films 100 along a first direction, which can be... Figure 1The data acquisition line 200 has an exposed terminal 210 at one end and a connecting end 220 at the other end, which is integrally formed with a connecting pin 300 arranged along the second direction. The end of the connecting pin 300 protrudes from the insulating film 100. The second direction can be... Figure 1 The left and right directions are defined in the diagram. It should be noted that, for ease of explanation, in subsequent embodiments, the first direction will be described as the up-down direction, and the second direction as the left-right direction.

[0027] The insulating film 100 refers to the insulating material layer that wraps the conductive components. It can be implemented using a polyimide film lamination structure, and a stable encapsulation structure is formed through a hot-pressing process. The acquisition line 200 refers to the conductive line that transmits electrical signals. It can be formed using a copper foil etching process and is arranged at intervals along a specific direction to maintain independent signal transmission. The connecting pin 300 refers to the conductive terminal that connects to external components. It can be formed simultaneously with the acquisition line 200 through a punching process, and its protruding end design facilitates direct soldering.

[0028] For example, the first insulating layer 110 and the second insulating layer 120 cover the main body of the acquisition line 200 through a hot-pressing process, reserving structural space in the connection end 220 area. The connecting pin 300 and the acquisition line 200 form a continuous conductive path through a punching process, and the vertically extending layout avoids cross-interference. The exposed structure of the terminal 210 is achieved through openings in the insulating film 100, ensuring reliable electrical connection. The design of the connecting pin 300 protruding from the insulating film 100 eliminates the traditional bending process, allowing for direct automated welding and positioning.

[0029] This solution utilizes an integrated molding process to make the connecting pin 300 a natural extension of the data acquisition line 200, ensuring dimensional accuracy and positional consistency, and effectively solving the technical challenge of positioning the flexible connecting pin 300. The integrated structural design eliminates manual bending processes, improving assembly efficiency while reducing operational errors. The insulating film 100 covering structure enhances the mechanical strength of the connection points, preventing poor contact caused by deformation of the flexible material. The vertically extending connecting pin 300 layout optimizes space utilization, adapting to the compact installation environment inside the battery module.

[0030] Reference Figure 2 As shown, in an embodiment of the present invention, the connecting pin 300 includes a first connecting portion 310, a second connecting portion 340, and a fuse 320. The first connecting portion 310 is connected to the connecting end 220, and the fuse 320 is connected to the first connecting portion 310 and located between the first connecting portion 310 and the second connecting portion 340. At least a portion of the second connecting portion 340 protrudes from the insulating film 100.

[0031] The first connecting portion 310 refers to the conductive area in the connecting pin 300 that directly contacts the connecting end 220 of the acquisition line 200. The maximum width of the first connecting portion 310 in the left-right direction can be between 6mm and 12mm, and it is used to establish a current path between the acquisition line 200 and the fuse 320. The fuse 320 is a fusible conductor installed in the connecting pin 300, used to cut off the circuit by melting itself in the event of an overcurrent. The second connecting portion 340 refers to the extension in the connecting pin 300 used for soldering to an external circuit. The maximum width of the second connecting portion 340 in the left-right direction can be between 6mm and 12mm, and its end can extend 3mm-5mm beyond the insulating film 100, thereby providing a suitable soldering area and improving the stability of the soldering.

[0032] For example, in the copper foil stamping process, a continuous metal structure including the acquisition line 200, the first connecting portion 310, the fuse 320, and the second connecting portion 340 is cut out in one go using a die. The fuse 320 is formed into a wavy bend through the stamping process, so that it forms a conductor segment with a predetermined resistance value between the first connecting portion 310 and the second connecting portion 340. The part of the second connecting portion 340 that is not covered by the insulating film 100 is exposed and can be directly soldered to the acquisition point of the battery module.

[0033] By adopting the above technical solution, this application solves the problem of complex assembly process of fuse 320 in the prior art, and realizes the structural integration of connecting pin 300 and fuse 320. The punching process makes the connection end 220 of fuse 320 and data acquisition line 200 form a seamless connection, avoiding the problems of poor soldering or oxidation that may occur in the welding process. The structural design of directly exposed end of second connecting part 340 simplifies the welding operation process and improves the assembly efficiency of FFC line 1000 in battery module.

[0034] Reference Figure 2 As shown in the embodiment of the present invention, the fuse 320 is wavy. A wavy fuse 320 refers to a continuous broken line or curve structure formed by a bending path, which can be achieved by stamping on a metal sheet. The bending path extends the length of the conductor through which the current flows. The wavy design extends the actual effective length of the fuse 320, increasing the resistance of the conductor while maintaining a compact overall size. By adjusting the resistance, the fuse 320 can quickly melt under a specific overcurrent, improving protection accuracy. Simultaneously, the wavy structure effectively absorbs vibrations and impacts generated by the battery module through its bending design, reducing the impact of external stress on the fuse 320.

[0035] For example, the corrugated fuse 320 extends the conductor length through which current flows within a limited space via a continuously bent conductor path, thereby increasing the resistance value. When an overcurrent occurs in the circuit, the Joule heat generated by the resistance causes the fuse 320 to heat up rapidly, breaking the circuit once the melting threshold is reached. The bent structure absorbs energy through localized deformation when subjected to vibration or impact, preventing stress concentration that could lead to breakage. For example, the number of corrugated bends in the fuse 320 can be three or five, and the bending radius can be 0.5 mm or 1 mm, adjusted according to the required resistance. This invention eliminates the welding step through a one-piece corrugated structure, and simultaneously improves protection response speed by precisely controlling the resistance through path extension. The bending design also enhances resistance to mechanical shock, preventing connection failure due to vibration.

[0036] Reference Figure 2 As shown in the embodiment of the present invention, the connecting leg 300 further includes a bent section 330, which is connected between the fuse 320 and the second connecting portion 340. The maximum width of the bent section 330 is less than the maximum width of the second connecting portion 340 in the vertical direction, and the maximum width of the bent section 330 is greater than the maximum width of the fuse 320. The bent section 330 refers to a deformable structure disposed between the fuse 320 and the second connecting portion 340, which can be implemented using a U-shaped or V-shaped bending structure. Its width is between that of the fuse 320 and the second connecting portion 340, and it is used to absorb tensile stress during the thermal expansion of the battery module.

[0037] For example, the battery module heats up and expands and contracts during charging and discharging. Since the second connection part 340 is usually welded to the battery cell, it will be stretched due to thermal expansion and contraction. To address this, a bending section 330 is incorporated. When stretching occurs, the bending section 330 can extend within a certain range, preventing breakage. This effectively solves the problem of the acquisition line 200 being stretched and broken due to the thermal expansion and contraction of the battery module. The serpentine bending structure formed by the bending section 330 can adapt to deformation, ensuring the continuity of signal acquisition. This structure eliminates the need for manual adjustment of the connection pin 300 position, significantly improving assembly efficiency and product reliability.

[0038] Reference Figure 2 As shown, in an embodiment of the present invention, the bending segment 330 includes a first bending portion 331 and a second bending portion 332 connected to each other. The insulating film 100 has a first opening 130 in the area enclosed by the first bending portion 331. The first opening 130 and the edge of the nearest insulating film 100 form a first pre-break 131. The insulating film 100 has a second opening 140 in the area enclosed by the second bending portion 332. The second opening 140 and the edge of the nearest insulating film 100 form a second pre-break 141.

[0039] The first bend 331 refers to a section of the connecting leg 300 with a specific bending shape, which can be achieved using a U-shaped bending structure, and its bending direction is complementary to that of the second bend 332. The second bend 332 refers to an extended bending section connected to the first bend 331, which can be achieved using a reverse bending path. The first opening 130 refers to a hole structure located in the area of ​​the insulating film 100 corresponding to the first bend 331, which can be formed by a punching process, and a weak area of ​​a predetermined width is retained between its edge and the boundary of the insulating film 100. The second opening 140 adopts a symmetrical design with the first opening 130, forming a hole with the same structure at the corresponding position of the second bend 332. The first pre-break 131 refers to a weak connection area between the edge of the first opening 130 and the boundary of the insulating film 100, which can be formed by controlling the opening spacing to create a fracture guide line with mechanical strength lower than other areas. The second pre-break 141 forms a fracture trigger point in the second bend 332 using the same principle.

[0040] For example, when the battery module expands and contracts due to charging and discharging, the acquisition line 200 is subjected to tensile stress. At this time, the first bend 331 and the second bend 332 of the bent section 330 undergo elastic deformation through a serpentine bending structure. The first pre-break 131 formed by the first opening 130 and the edge of the insulating film 100 at the first bend 331, and the second pre-break 141 formed by the second opening 140 and the edge of the second bend 332, will preferentially break when the tensile stress exceeds the threshold. After the breakage, the bent section 330 releases the stress, allowing the acquisition line 200 to achieve length compensation while maintaining electrical connection, and preventing stress transmission to the fuse 320 or the main structure of the connecting pin 300. In this process, the breakage sequence of the two pre-breaks can be controlled according to the difference in the opening positions. For example, the second pre-break 141 can be designed to break earlier than the first pre-break 131, thereby releasing tensile forces in different directions in stages.

[0041] This solution employs a double pre-break structure at the bend 330, maintaining the connection before fracture to facilitate the welding and installation of the FFC line 1000 without causing significant bending deformation of the connecting pin 300. After welding, when the battery module's thermal expansion and contraction during operation stretches the connecting pin 300, the tensile stress is preferentially released in the pre-designed weak area. This protects critical electrical connections and prevents overall structural failure through a phased fracture mechanism. The controllable fracture characteristics at the pre-break effectively disperse mechanical stress, extending product lifespan and avoiding the risk of poor welding or short circuits caused by deformation of the insulating film 100.

[0042] Reference Figure 1As shown, in this embodiment of the invention, the connecting ends 220 protrude sequentially from the previous connecting end 220 in the left-right direction, and multiple connecting feet 300 are all located on the same side of the acquisition line 200. The connecting ends 220 protruding sequentially in the left-right direction means that adjacent connecting ends 220 form a stepped arrangement in the left-right direction, which can be achieved by cutting the acquisition line 200 into connecting ends 220 of different lengths using a punching process. This arrangement eliminates the need for the connecting feet 300 to cross or misalign during bending, facilitating processing in a unified direction. The connecting feet 300 being located on the same side of the acquisition line 200 means that all connecting feet 300 are concentrated in a single-sided area along the vertical direction of the acquisition line 200, which can be achieved by maintaining the connecting feet 300 on the same side as the acquisition line 200 during the cutting of the copper foil sheet 410. This layout eliminates the chaotic distribution of the connecting feet 300, forming an orderly arrangement structure.

[0043] For example, the connecting ends 220 of the acquisition line 200 protrude in an increasing manner in the left-right direction, forming a stepped distribution. Each connecting leg 300 is fixed to the end of the connecting end 220 at the corresponding step position, and all connecting legs 300 extend in the vertical direction and remain on the same side. In the bending process, the connecting legs 300 can be clamped by a uniform fixture and bent to a predetermined angle without the need to adjust their positions individually. Thus, the bending operation of the connecting legs 300 can be completed continuously in automated equipment, avoiding the arrangement disorder caused by manual intervention.

[0044] By adopting the above technical solution, this application solves the problem of low efficiency in the bending process of the 1000 connecting pin 300 of the FFC line. The directional arrangement structure of the connecting pin 300 makes automated bending possible, significantly shortens the assembly time, and avoids the positional deviation of the connecting pin 300 caused by manual operation, thereby improving product consistency and reliability.

[0045] Reference Figure 1 As shown, in the embodiment of the present invention, the thickness of the connecting end 220 along the vertical direction is successively greater than the thickness of the previous connecting end 220 along the vertical direction, and the side of the connecting end 220 near the connecting foot 300 along the vertical direction is flush with the previous connecting end 220, that is, the upper edge 221 of the connecting end 220 is flush with the upper edge 221 of the previous connecting end 220.

[0046] The phrase "the thickness of each connecting end 220 increases sequentially in the vertical direction" means that among multiple connecting ends 220 arranged vertically, the thickness of each connecting end 220 increases sequentially in the vertical direction. This can be achieved by using a punching process to process the copper foil into a stepped thickness. By gradually increasing the thickness, the connecting ends 220 form a continuous copper layer support structure inside the insulating film 100. The phrase "the side of the connecting end 220 near the connecting foot 300 is flush with the previous connecting end 220" means that the sides of two adjacent connecting ends 220 near the connecting foot 300 are on the same plane in the vertical direction. The edges of the stepped thickness structure can be aligned by adjusting the cutting path of the punching die. This design ensures that the connecting ends 220 remain flat during the thermoforming process.

[0047] For example, multiple connectors 220 form a stepped thickness distribution in the vertical direction, with the edge of each connector 220 near the connector pin 300 aligned with the previous connector 220. During hot-press bonding of the insulating film 100, the continuous copper layer support structure can evenly distribute thermal stress, preventing the insulating film 100 from shrinking or warping due to local lack of support. Therefore, the contact surface between the acquisition line 200 and external devices remains stable during the welding process, avoiding welding misalignment due to local collapse. During battery module assembly, the flat acquisition line 200 reduces the risk of friction with the top cover.

[0048] This solution, through a stepped thickness design, ensures that the insulating film 100 is consistently supported by the copper layer during processing, eliminating surface unevenness caused by material shrinkage and resolving welding defects and assembly safety hazards in the FFC line 1000 caused by deformation of the insulating film 100. During hot pressing and baking processes, the copper layer support structure effectively inhibits the shrinkage of the insulating film 100, ensuring the flatness of the acquisition line 200. During internal assembly in the battery module, the flat acquisition line 200 avoids friction with the cover plate, improving long-term reliability.

[0049] Reference Figure 1 As shown in the embodiment of the present invention, the terminal 210 includes a connecting section 211 and a narrowing section 212. The narrowing section 212 is located at the end of the connecting section 211 facing the connection terminal 220. Along the direction from the connecting section 211 to the connection terminal 220, the width of the narrowing section 212 gradually decreases in the vertical direction. The connecting section 211 refers to a wide conductive area used to connect external terminals. Its width remains constant in the vertical direction, and the design of its width must meet the electrical safety clearance requirements for terminal insertion. The narrowing section 212 refers to the transition area connecting the wire body and the terminal 210. By linearly reducing the conductor width to form a spatial compression structure, the lateral dimension of the wire body is reduced while maintaining conductivity.

[0050] For example, the combined structure of the connecting segment 211 and the narrowing segment 212 achieves functional zoning through differentiated width design. The connecting segment 211 maintains a relatively large width to meet the safety spacing requirements when the connector terminals are plugged in, while the narrowing segment 212 adapts to the narrow space inside the battery module through a gradual width change. During the manufacturing process, the copper foil material is punched and formed into a conductor structure with a gradually changing width. The first insulating layer 110 and the second insulating layer 120 are wrapped along the contour of the narrowing segment 212 during hot pressing to ensure the bonding accuracy between the insulating film 100 and the conductor.

[0051] Through the above technical solution, this application resolves the contradiction between the limited internal space of the battery module and the electrical safety clearance requirements. The narrow section 212 structure allows the cable body to adapt to narrow installation spaces, while the connection section 211 maintains sufficient width to ensure reliable terminal connection. The combined effect of these two aspects improves space utilization while avoiding the risk of deformation of the insulating film 100 due to insufficient local support, and ensures the flatness of the acquisition line 200 during the hot pressing process and its long-term stability.

[0052] An embodiment of the present invention includes an FFC line 1000, which includes an insulating film 100, a plurality of acquisition lines 200, and a plurality of connecting pins 300. The insulating film 100 includes a first insulating layer 110 and a second insulating layer 120 connected together. The plurality of acquisition lines 200 are spaced apart in the vertical direction between the first insulating layer 110 and the second insulating layer 120. One end of the plurality of acquisition lines 200 together forms a terminal 210, and part of the structure of the terminal 210 is exposed in the insulating film 100. The other end of the acquisition lines 200 is a connecting end 220 and extends in the left-right direction, which is perpendicular to the vertical direction. The plurality of connecting pins 300 are the same number as the acquisition lines 200. The plurality of connecting pins 300 extend in the vertical direction and are connected one-to-one with the connecting ends 220 of the plurality of acquisition lines 200. The connecting pins 300 and the acquisition lines 200 are configured as an integrally formed structure, and the end of the connecting pin 300 opposite to the connecting end 220 protrudes from the insulating film 100.

[0053] Through the above technical solution, this application solves the problem of low assembly efficiency caused by the difficulty in positioning the flexible wire connector 300, and realizes efficient and automated production of the power battery module signal acquisition unit. The integrated design of the connector 300 and the acquisition line 200 avoids pin misalignment during the welding process and improves the signal transmission reliability of the battery management system. The double-layer composite structure of the insulating film 100 effectively suppresses the deformation of the acquisition line 200 during the hot pressing process, ensuring the flatness requirements of the FFC line 1000 in the environment of limited internal space of the battery module.

[0054] Reference Figure 1 and Figure 2As shown in the embodiment of the present invention, the manufacturing method of the FFC line 1000 includes an insulating film 100, a plurality of acquisition lines 200, and a plurality of connecting pins 300. The insulating film 100 includes a first insulating layer 110 and a second insulating layer 120 connected to each other. The first insulating layer 110 is provided with a first through hole 111 and a plurality of second through holes 112, and the second insulating layer 120 is provided with a plurality of third through holes 121. The plurality of acquisition lines 200 are spaced apart in the vertical direction between the first insulating layer 110 and the second insulating layer 120, and one end of the plurality of acquisition lines 200 together constitutes a connector. Terminal 210, part of the structure of terminal 210 is exposed on insulating film 100. The other end of acquisition line 200 is connection terminal 220 and extends in the left and right direction, which is perpendicular to the up and down direction. The number of multiple connection pins 300 and acquisition lines 200 is the same. The multiple connection pins 300 and the connection terminals 220 of multiple acquisition lines 200 are connected one-to-one. The connection pins 300 and acquisition lines 200 are configured as an integral structure. The connection pins 300 extend in the up and down direction, and the end of the connection pin 300 away from the connection terminal 220 protrudes from insulating film 100.

[0055] Reference Figure 16 As shown, the manufacturing method includes the following steps: Step S1601: Multiple fuses 320, spaced apart in the left-right direction, are sequentially punched out from a long strip of copper foil 410. For example... Figure 3 and Figure 4 As shown, a continuous precision punching press is used to punch out the first punch 411 and the second punch 412 at corresponding positions on the copper foil sheet 410 using a high-precision hardware punching die. A fuse 320 is formed between the first punch 411 and the second punch 412.

[0056] Step S1602: Adhere the copper foil sheet 410 onto the base film 400. For example... Figure 5 As shown, the base film 400 and the copper foil sheet 410 can be pasted together using a rotary die-cutting machine. The base film 400 is adhesive and can be a PET film coated with pressure-sensitive adhesive, or a high-temperature resistant PET film with silicone added. The base film 400 is used to support the copper foil sheet 410, facilitating the subsequent peeling off of excess material from the copper foil sheet 410, and also facilitating the pasting of the first insulating layer 110.

[0057] Step S1603: Multiple corresponding acquisition lines 200 and connecting pins 300 are integrally cut from the copper foil sheet 410. For example... Figure 6 and Figure 7 As shown, multiple corresponding connecting acquisition lines 200 and connecting feet 300 are cut out in one piece by a circular cutter and a circular cutter mold. The outlines of the acquisition lines 200 and connecting feet 300 are simultaneously formed on the copper foil sheet 410 by a punching process to ensure that the two are formed as one piece.

[0058] Step S1604: Remove excess material from the copper foil 410. (Refer to...) Figure 8 As shown, removing excess material from the copper foil sheet 410 refers to removing the copper foil material from the portion not containing the acquisition lines 200 and connecting pins 300 from the base film 400. This can be done mechanically using a rotary knife and a stripping blade, or by air blowing to improve material utilization. Since the acquisition lines 200 and connecting pins 300 are adhered to the base film 400 at this point, removing the excess material will fix the positions of adjacent acquisition lines 200 and connecting pins 300 without causing confusion.

[0059] Step S1605: The first insulating layer 110 is heat-pressed onto one side of the acquisition line 200 and the connecting pin 300. The first through hole 111 exposes part of the structure of the terminal 210, and multiple second through holes 112 expose the ends of the corresponding connecting pins 300. (Refer to...) Figure 9 and Figure 10 As shown, hot-pressing the first insulating layer 110 onto one side of the acquisition line 200 and the connecting foot 300 means using a circular knife machine, a circular knife mold, and a hot press roller to heat and pressurize the insulating layer to bond it to the copper foil structure. Polyimide film can be used as the insulating layer to provide electrical insulation and mechanical protection.

[0060] Step S1606: Separate the base film 400, the acquisition line 200, and the connecting pin 300. (Refer to...) Figure 11 As shown, since the base film 400 serves as a temporary fixation for the acquisition line 200 and the connecting pin 300, after the first insulating layer 110 is attached, the position between adjacent acquisition lines 200 can be restricted by the first insulating layer 110, so the base film 400 can be removed.

[0061] Step S1607: The second insulating layer 120 is hot-pressed onto the other side of the acquisition line 200 and the connecting pin 300, and the second insulating layer 120 is connected to the first insulating layer 110, exposing the ends of the corresponding connecting pins 300 through multiple third through holes 121. (Refer to...) Figure 12 and Figure 13 As shown, hot-pressing the second insulating layer 120 to the other side means that after the first insulating layer 110 is attached, the same process is used to cover the other side with an insulating layer. A double-sided hot-pressing process can be used to fuse the insulating layers on both sides at the edge area to form a closed structure.

[0062] Step S1608: Remove the excess portions of the first insulating layer 110 and the second insulating layer 120. (Refer to...) Figure 14 and Figure 15 As shown, the excess portions of the first insulation layer 110 and the second insulation layer 120 can be cut into shapes that fit the acquisition line 200 and the connecting pin 300 using a circular cutter, so that the structure of the FFC line 1000 is more compact.

[0063] Compared to existing technologies, the traditional FFC line 1000 requires the fuse 320 and the data acquisition line 200 to be processed separately and then welded, and the connecting pin 300 needs to be manually bent and positioned, resulting in complex processes and low precision. This method uses integrated punching and double-sided hot pressing processes to form the fuse 320, data acquisition line 200, and connecting pin 300 into a single structure, eliminating the need for bending or secondary welding. At the same time, the through-hole design of the insulation layer ensures that the end of the connecting pin 300 is precisely exposed, allowing for direct automated assembly.

[0064] Through the above technical solution, this application solves the problem of low bending efficiency caused by the flexible structure of the FFC line 1000 connector 300. The integrally molded acquisition line 200 and connector 300 avoid separate welding and reduce assembly steps; the double-sided hot pressing process of the insulation layer ensures a flat structure and avoids local deformation; the end of the connector 300 is precisely exposed through a through hole, which can be directly aligned and connected to the external circuit, improving the efficiency of automated assembly.

[0065] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. An FFC line, characterized in that, include: An insulating film, comprising a first insulating layer and a second insulating layer connected together; Multiple acquisition lines are spaced apart between the first insulating layer and the second insulating layer along a first direction. One end of the multiple acquisition lines together forms a terminal. Part of the structure of the terminal is exposed in the insulating film. The other end of the acquisition lines is a connection end and extends along a second direction, which is perpendicular to the first direction. The plurality of connecting pins are the same number as the number of the acquisition lines. The plurality of connecting pins extend along the first direction and are connected one-to-one with the connection ends of the plurality of acquisition lines. The connecting pins and the acquisition lines are configured as an integral structure, and the end of the connecting pin opposite to the connection end protrudes from the insulating film.

2. The FFC line according to claim 1, characterized in that: The connecting pin includes a first connecting portion, a second connecting portion, and a fuse. The first connecting portion is connected to the connecting end, and the fuse is connected to the first connecting portion and located between the first connecting portion and the second connecting portion. At least a portion of the second connecting portion protrudes from the insulating film.

3. The FFC line according to claim 2, characterized in that: The fuse is wavy.

4. The FFC line according to claim 2, characterized in that: The connecting leg further includes a bent section, which is connected between the fuse and the second connecting part. The maximum width of the bent section is less than the maximum width of the second connecting part along the first direction, and the maximum width of the bent section is greater than the maximum width of the fuse.

5. The FFC line according to claim 4, characterized in that: The curved section includes a first bend and a second bend connected to each other. The insulating film has a first opening in the area enclosed by the first bend, and the first opening and the nearest edge of the insulating film form a first pre-break. The insulating film has a second opening in the area enclosed by the second bend, and the second opening and the nearest edge of the insulating film form a second pre-break.

6. The FFC line according to claim 1, characterized in that: The connecting ends protrude sequentially from the previous connecting end along the second direction, and the multiple connecting pins are all located on the same side of the acquisition line.

7. The FFC line according to claim 1, characterized in that: The thickness of the connecting end along the first direction is successively greater than the thickness of the previous connecting end along the first direction, and the side of the connecting end near the connecting foot along the first direction is flush with the previous connecting end.

8. The FFC line according to claim 1, characterized in that: The terminal includes a connected connecting segment and a narrowing segment. The narrowing segment is located at the end of the connecting segment facing the terminal. Along the direction of the connecting segment towards the terminal, the width of the narrowing segment gradually decreases in the first direction.

9. An automobile, characterized in that, Includes the FFC line according to any one of claims 1 to 8.

10. A method for manufacturing FFC wire, characterized in that: The FFC line includes an insulating film, multiple acquisition lines, and multiple connector pins. The insulating film includes a first insulating layer and a second insulating layer connected together. The first insulating layer has a first through hole and multiple second through holes, and the second insulating layer has multiple third through holes. The multiple acquisition lines are spaced apart between the first insulating layer and the second insulating layer along a first direction. One end of the multiple acquisition lines together forms a terminal, and part of the structure of the terminal is exposed in the insulating film. The other end of the acquisition line is a connector and extends along a second direction, which is perpendicular to the first direction. The number of connector pins is the same as the number of acquisition lines. The multiple connector pins and the connector ends of the multiple acquisition lines are connected one-to-one, and the connector pins and acquisition lines are configured as an integral structure. The connector pins extend along the first direction, and the end of the connector pin opposite to the connector end protrudes from the insulating film. The manufacturing method includes the following steps: Multiple fuses spaced apart along the second direction are sequentially punched out on a long strip of copper foil; The copper foil sheet is adhered to the base film; Multiple corresponding data acquisition lines and connecting pins are integrally cut from the copper foil sheet; Remove excess material from the copper foil sheet; The first insulating layer is heat-pressed onto one side of the acquisition line and the connecting pin. The first through hole exposes part of the structure of the terminal, and multiple second through holes expose the ends of the corresponding connecting pins. Separate the base film, the acquisition line, and the connecting pin; The second insulating layer is heat-pressed onto the other side of the acquisition line and the connecting pin, and the second insulating layer is connected to the first insulating layer, with the plurality of third through holes exposing the ends of the corresponding connecting pins; The excess portions of the first and second insulating layers are removed.

Images