Signal acquisition device and signal acquisition module of battery pack
By replacing traditional wire harnesses with flexible flat cables and integrated structures, the problems of large space occupation and low reliability in battery systems are solved, achieving high integration and lightweighting of battery packs, and improving the stability of signal transmission and production efficiency.
Patent Information
- Application Number
- CN202511496174.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-20
- Publication Date
- 2025-12-12
AI Technical Summary
In existing battery systems, traditional wire harness signal conversion methods result in large space occupation, are not conducive to high integration and lightweighting, and are prone to problems such as wire breakage and poor contact. They also have high production costs, low automation levels, and are difficult to meet the requirements of high energy density and intelligence.
The flexible flat cable, flexible circuit board and bracket are integrated into one structure to replace the traditional wire harness for signal transmission. The flexible flat cable has a small size, strong fatigue resistance, can adapt to complex and narrow environments, and can be directly connected to the BMS slave board to achieve rapid connection.
This design achieves a compact and lightweight internal structure for the battery pack, improving signal transmission stability and system reliability, reducing the risk of wire breakage and poor contact, simplifying the connection process, and increasing production efficiency and product consistency.
Smart Images
Figure CN121123579A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of battery pack, in particular to a signal acquisition device and a signal acquisition module of a battery pack. BACKGROUND
[0002] In the current power battery system, the acquisition of key parameters such as voltage and temperature of the battery module generally depends on the signal connection between the integrated busbar (Cells Contact System, CCS) and the battery management system (BMS). The traditional CCS structure usually integrates a sampling circuit, a flexible circuit board (FPC) or a rigid PCB, and an aluminum bar for current conduction, to realize the connection and signal acquisition of the battery cell terminal. However, the CCS module in the prior art cannot be directly connected to the BMS slave board (i.e. slave board) after completing the voltage and temperature signal acquisition, but needs to use an external adapter wire harness to lead out each signal Pin to the BMS one by one.
[0003] This signal conversion method relying on independent wire harness has many technical bottlenecks. First, the adapter wire harness is large in volume, especially when the number of signal Pins is large, the overall diameter of the wire harness increases, and the required bending radius also increases, resulting in a large amount of space occupied in the battery pack (Pack), which is not conducive to the high integration and lightweight design of the battery system; second, the wire harness is prone to material fatigue under repeated bending or long-term vibration conditions, resulting in problems such as wire breakage and poor contact, which seriously affects the reliability and service life of the system; in addition, the traditional wire harness uses manual crimping, welding and assembly processes, which have high labor involvement and low automation level in the production process, not only poor process stability and high failure rate, but also significantly increasing the manufacturing cost.
[0004] At the same time, due to the increase in the number of wire harness connection points and the complexity of the interface, it is easy to occur Pin errors, missed connections or reverse insertion during assembly, which brings great challenges to production management and quality control. With the development of battery systems towards high energy density, high safety and intelligence, the traditional wire harness conversion method has been difficult to meet the needs of efficient, reliable and low-cost industrialization. SUMMARY
[0005] The present application aims to at least solve the technical problems existing in the prior art. To this end, the present application provides a signal acquisition device and a signal acquisition module of a battery pack, which has a small volume and occupies a small space, is conducive to realizing the lightweight of the module, has strong material fatigue resistance, and can be repeatedly bent without the risk of Pin errors.
[0006] According to some embodiments of the first aspect of the present application, a signal acquisition device of a battery pack comprises a flexible flat cable, a flexible circuit board, an aluminum row and a bracket, the flexible circuit board is arranged in the middle of the bracket, the aluminum row is arranged on both sides of the bracket, the aluminum row is connected with the flexible circuit board, the end of the bracket is provided with a first connector, one end of the flexible circuit board is connected with the first connector, both ends of the flexible flat cable are respectively provided with a second connector and a third connector, the second connector is connected with the first connector, and the third connector is used for connecting with a BMS battery management system.
[0007] According to some embodiments of the first aspect of the present application, a signal acquisition device of a battery pack has at least the following beneficial effects: The flexible circuit board, the aluminum row and the bracket are integrated in the same structure, which improves the integration of the whole module, and the flexible flat cable is used to replace the traditional wire harness for signal transmission, which greatly reduces the volume and occupied space of the cable, is beneficial to the compactness and lightweight design of the internal layout of the battery pack, the flexible flat cable has an extremely thin cross-sectional size and a small bending radius, can adapt to complex and narrow installation environment, effectively reduces the occupation of the internal space of the battery box, is especially suitable for high-density battery systems, solves the problems of large bending radius and difficult arrangement of the traditional wire harness during multi-pin signal transmission, the flexible flat cable material itself has excellent bending resistance and vibration resistance, can withstand repeated bending and dynamic stress for a long time, avoids the problems of wire breakage or poor contact caused by material fatigue, significantly improves the stability of signal transmission and the reliability of system operation, and the FFC is respectively provided with a standardized second connector and a third connector at both ends, and the third connector can be directly connected with a BMS board to realize quick connection.
[0008] According to some embodiments of the first aspect of the present application, a signal acquisition device of a battery pack, a plurality of connection terminals are arranged in the first connector, and first and second connection parts are arranged at both ends of the connection terminals, the first connection part is connected with the flexible circuit board, and the second connection part is connected with the flexible flat cable.
[0009] According to some embodiments of the first aspect of the present application, a signal acquisition device of a battery pack, the second connection part is provided with a first connecting piece and a second connecting piece, the first connecting piece is located on the top of the second connecting piece, and the end of the first connecting piece and the end of the second connecting piece are respectively provided with a first abutting block and a second abutting block, the first abutting block is located at the front end of the second abutting block.
[0010] According to some embodiments of the first aspect of the present application, the signal acquisition device of the battery pack is characterized in that the flexible circuit board is provided with a plurality of voltage acquisition areas at the edge thereof, and a voltage acquisition nickel sheet is connected to each voltage acquisition area, and the voltage acquisition nickel sheet is connected to the aluminum row.
[0011] According to some embodiments of the first aspect of the present application, the signal acquisition device of the battery pack is characterized in that the voltage acquisition area is provided with an acquisition notch, and an acquisition end piece is arranged in the acquisition notch, the nickel sheet is connected to the acquisition end piece, the two ends of the acquisition end piece are respectively connected to the two sides of the acquisition notch, and a gap is formed between the acquisition end piece and the acquisition notch.
[0012] According to some embodiments of the first aspect of the present application, the signal acquisition device of the battery pack is characterized in that the bracket is provided with a long slot in the middle portion thereof, and a plurality of positioning slots are arranged at the edge of the bracket, the flexible circuit board is arranged in the long slot, and the aluminum row is arranged in the positioning slot.
[0013] According to some embodiments of the first aspect of the present application, the signal acquisition device of the battery pack is characterized in that an avoidance notch is arranged between the long slot and the positioning slot, and the acquisition nickel sheet is arranged in the avoidance notch.
[0014] According to some embodiments of the first aspect of the present application, the signal acquisition device of the battery pack is characterized in that a plurality of first positioning columns are arranged in the long slot, and a plurality of second positioning columns are arranged in the positioning slot, the first positioning columns are arranged in the flexible circuit board, and the second positioning columns are arranged in the aluminum row.
[0015] According to some embodiments of the first aspect of the present application, the signal acquisition device of the battery pack is characterized in that the second connector and the third connector each include a connector main body and a positioning block, the middle portion of the connector main body is provided with a slot, the end portion of the flexible flat cable is provided with a limiting hole, the middle portion of the positioning block is provided with a limiting column, the outer periphery of the connector main body is provided with a through hole, the limiting column is arranged in the through hole, the two sides of the connector main body are provided with first clamping blocks, the two sides of the positioning block are provided with second clamping blocks, and the first clamping blocks and the second clamping blocks are clamped one by one.
[0016] According to some embodiments of the second aspect of the present application, the signal acquisition module of the battery pack includes a plurality of signal acquisition devices according to some embodiments of the first aspect of the present application, and the plurality of signal acquisition devices are arranged in an array.
[0017] According to some embodiments of the second aspect of the present application, the signal acquisition module of the battery pack has the same beneficial effects as the signal acquisition device of the battery pack according to some embodiments of the first aspect of the present application, and details are not repeated here.
[0018] Additional aspects and advantages of the present application will be in part apparent and in part pointed out below in the description of embodiments of the present application. BRIEF DESCRIPTION OF DRAWINGS
[0019] The above and / or additional aspects and advantages of the present application will become apparent and be readily appreciated from the following description of embodiments, given by way of example, and with reference to the following drawings. Figure 1 Structure diagram of an embodiment of the first aspect of the present application.
[0020] Figure 2 Structure diagram of an embodiment of the first aspect of the present application. Figure 1 Enlarged view of part A in FIG. 1.
[0021] Figure 3 Structure diagram of a support of an embodiment of the first aspect of the present application.
[0022] Figure 4 Structure exploded view of a flexible flat cable, a second connector and a third connector of an embodiment of the first aspect of the present application.
[0023] Figure 5 Sectional view of a first connector of an embodiment of the first aspect of the present application.
[0024] Figure 6 Structure diagram of an embodiment of the second aspect of the present application.
[0025] Reference signs: 1, flexible flat cable; 2, flexible circuit board; 3, aluminum bar; 4, support; 5, first connector; 6, second connector; 7, third connector; 8, connecting terminal; 9, first connecting part; 10, second connecting part; 11, first connecting sheet; 12, second connecting sheet; 13, first abutting block; 14, second abutting block; 15, conductive connecting part; 16, voltage collection area; 17, voltage collection nickel sheet; 18, NTC nickel sheet; 19, collection notch; 20, collection end sheet; 21, long slot; 22, positioning slot; 23, avoidance notch; 24, first positioning column; 25, second positioning column; 26, connector main body; 27, positioning block; 28, insertion slot; 29, limiting hole; 30, limiting column; 31, through hole; 32, first clamping block; 33, second clamping block. DETAILED DESCRIPTION
[0026] Embodiments of the present application are described below in detail, examples of which are shown in the drawings, wherein the same or similar reference signs represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary and are only used to explain the present application, and cannot be understood as a limitation of the present application.
[0027] In the description of the present application, it should be understood that the orientation description, such as the orientation or position relationship indicated by up, down, left, right, front, back and the like, is based on the orientation or position relationship shown in the drawings, and is only for the purpose of facilitating the description of the present application and simplifying the description, and does not indicate or imply that the modules or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation of the present application.
[0028] In the description of the present application, if the first, second, etc. are described, they are only used for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated or the order of technical features indicated.
[0029] In the description of the present application, unless otherwise explicitly limited, the words such as arrangement, installation, connection and the like should be broadly understood, and the person skilled in the art can reasonably determine the specific meaning of the above words in the present application in combination with the specific content of the technical scheme.
[0030] As shown in Figures 1-5 The first aspect of the present application provides a signal acquisition device of a battery pack.
[0031] A signal acquisition device of a battery pack, comprising a flexible flat cable 1, a flexible circuit board 2, an aluminum bar 3 and a support 4, the flexible circuit board 2 is arranged in the middle of the support 4, the aluminum bar 3 is arranged on both sides of the support 4, the aluminum bar 3 is connected with the flexible circuit board 2, the end of the support 4 is provided with a first connector 5, the flexible circuit board 2 is connected with one end of the first connector 5, both ends of the flexible flat cable 1 are respectively provided with a second connector 6 and a third connector 7, the second connector 6 is connected with the first connector 5, and the third connector 7 is used for connecting with a BMS battery management system.
[0032] The application improves the integration of the whole module by integrating the flexible circuit board 2, the aluminum row 3 and the support 4 in the same structure; meanwhile, the flexible flat cable 1 is used to replace the traditional wire harness for signal transmission, which greatly reduces the cable volume and the occupied space, is beneficial to the compactness and lightweight design of the internal layout of the battery pack, and has the advantages that the flexible flat cable 1 has an extremely thin cross-sectional size and a small bending radius, can adapt to a complex and narrow installation environment, effectively reduces the occupation of the internal space of the battery box, is especially suitable for a high-density battery system, solves the problem that the traditional wire harness has a large bending radius and is difficult to arrange when a plurality of pins are used for signal transmission, the material of the flexible flat cable 1 has excellent bending resistance and vibration resistance, can withstand repeated bending and dynamic stress for a long time, avoids the problems of disconnection and poor contact caused by material fatigue, and significantly improves the stability of signal transmission and the reliability of system operation; the flexible flat cable 1 is respectively provided with a standardized second connector 6 and a third connector 7 at two ends, and the third connector 7 can be directly connected to a BMS board to realize quick connection.
[0033] The signal acquisition device of the battery pack has the advantages that the first connector 5 is provided with a plurality of connection terminals 8, the two ends of the connection terminal 8 are respectively provided with a first connecting part 9 and a second connecting part 10, the first connecting part 9 is connected with the flexible circuit board 2, and the second connecting part 10 is connected with the flexible flat cable 1. Specifically, the stable electrical connection between the flexible circuit board 2 and the flexible flat cable 1 is realized by arranging the connection terminal 8 with the double connecting parts in the first connector 5, and the reliability of signal transmission is improved; meanwhile, the integrated terminal structure simplifies the connection process, reduces the contact resistance, and avoids the problem of signal interruption caused by loose connection.
[0034] The signal acquisition device of the battery pack has the advantages that the second connecting part 10 is provided with a first connecting sheet 11 and a second connecting sheet 12, the first connecting sheet 11 is located at the top of the second connecting sheet 12, the end of the first connecting sheet 11 and the end of the second connecting sheet 12 are respectively provided with a first abutting block 13 and a second abutting block 14, and the first abutting block 13 is located at the front end of the second abutting block 14. Specifically, the abutting block structure is arranged in an upper-lower stacking and front-rear staggered mode, the contact area and the pressure connection stability between the connection terminal 8 and the flexible flat cable 1 are enhanced, and double contact protection is formed; the first abutting block 13 at the front end is first contacted with foreign matters, and the second abutting block 14 at the rear end can be stably connected with the flexible flat cable 1; and the first connecting sheet 11 and the second connecting sheet 12 are independent of each other, when the first abutting block 13 is contacted with foreign matters, the second abutting block 14 is not connected, the mechanical strength and the electrical reliability of connection are improved.
[0035] The signal acquisition device of the battery pack described in this embodiment, both ends of the flexible flat cable 1 are provided with conductive connection parts 15, and the conductors of the flexible flat cable 1 protrude to the conductive connection parts 15. Specifically, the design of the conductors protruding to the conductive connection parts 15 facilitates precise alignment and firm crimping with the connector terminals, and is also conducive to positioning and assembly in automated production, thereby improving manufacturing efficiency and product consistency.
[0036] The signal acquisition device of the battery pack described in this embodiment, a plurality of voltage acquisition areas 16 are arranged at the edges of the flexible circuit board 2, voltage acquisition nickel sheets 17 are connected to the voltage acquisition areas 16, and the voltage acquisition nickel sheets 17 are connected with the aluminum bars 3. Specifically, by arranging the special voltage acquisition areas 16 on the flexible circuit board 2 and connecting the voltage acquisition nickel sheets 17 with the aluminum bars 3 to be conductive, the accurate acquisition of the voltage of each battery cell is realized; the voltage acquisition nickel sheets 17 have good conductivity and corrosion resistance, ensuring the stability and accuracy of voltage signal acquisition during long-term use and improving the monitoring accuracy of the battery management system.
[0037] In this embodiment, the voltage acquisition areas 16 are connected with voltage acquisition nickel sheets 17 or NTC nickel sheets 18, and the NTC nickel sheets 18 can simultaneously acquire temperature data.
[0038] The signal acquisition device of the battery pack described in this embodiment, the voltage acquisition area 16 is provided with an acquisition notch 19, the acquisition notch 19 is provided with an acquisition end piece 20, the voltage acquisition nickel sheet 17 is connected with the acquisition end piece 20, the two ends of the acquisition end piece 20 are respectively connected with the two sides of the acquisition notch 19, and the acquisition end piece 20 has a gap with the acquisition notch 19. Specifically, the acquisition end piece 20 is fixed at the sidewall of the acquisition notch 19 by two ends and is designed to be suspended in the middle to form an elastic structure, and the gap is reserved to produce a slight deformation during assembly to compensate for the size tolerance, ensure the uniformity of the contact pressure of the voltage acquisition nickel sheet 17 and the aluminum bar 3, improve the connection reliability, and at the same time relieve the influence of thermal stress and prevent cracking.
[0039] The signal acquisition device of the battery pack described in this embodiment, the middle part of the bracket 4 is provided with a long slot 21, and the edges of the bracket 4 are provided with a plurality of positioning grooves 22, the flexible circuit board 2 is arranged in the long slot 21, and the aluminum bar 3 is arranged in the positioning groove 22. Specifically, the long slot 21 and the positioning groove 22 are used to fix the flexible circuit board 2 and the aluminum bar 3 respectively, to realize the precise positioning and isolated installation of each functional component, avoid mutual interference, and improve the assembly accuracy and structural stability; at the same time, it is convenient for automated assembly, reduces the manual error, and improves the production efficiency.
[0040] The signal acquisition device of the battery pack, the long slot 21 and the positioning slot 22 are provided with an avoiding gap 23, the voltage acquisition nickel sheet 17 and the NTC nickel sheet 18 are located in the avoiding gap 23. Specifically, the avoiding gap 23 provides sufficient installation and deformation space for the voltage acquisition nickel sheet 17 and the NTC nickel sheet 18, avoids the voltage acquisition nickel sheet 17 and the NTC nickel sheet 18 from being extruded and deformed or damaged in the assembly process, ensures good contact between the voltage acquisition nickel sheet 17 and the aluminum row 3, and helps to improve the compactness and safety of the overall structure.
[0041] The signal acquisition device of the battery pack, the long slot 21 and the positioning slot 22 are provided with an avoiding gap 23, the voltage acquisition nickel sheet 17 and the NTC nickel sheet 18 are located in the avoiding gap 23. Specifically, the avoiding gap 23 provides sufficient installation and deformation space for the voltage acquisition nickel sheet 17 and the NTC nickel sheet 18, avoids the voltage acquisition nickel sheet 17 and the NTC nickel sheet 18 from being extruded and deformed or damaged in the assembly process, ensures good contact between the voltage acquisition nickel sheet 17 and the aluminum row 3, and helps to improve the compactness and safety of the overall structure.
[0042] The signal acquisition device of the battery pack, the second connector 6 and the third connector 7 each include a connector main body 26 and a positioning block 27, the middle part of the connector main body 26 is provided with a slot 28, the end of the flexible flat cable 1 is provided with a limiting hole 29, the middle part of the positioning block 27 is provided with a limiting column 30, the outer periphery of the connector main body 26 is provided with a through hole 31, the limiting column 30 is arranged in the through hole 31, the two sides of the connector main body 26 are provided with a first clamping block 32, the two sides of the positioning block 27 are each provided with a second clamping block 33, and the first clamping block 32 and the second clamping block 33 are clamped one by one. Specifically, the positioning block 27 with the limiting column 30 and the clamping block structure is matched with the connector main body 26, precise positioning and locking of the flexible flat cable 1 are realized through the limiting hole 29, the clamping structure is firm and reliable, assembly can be completed without additional fasteners, the connector assembly efficiency and the anti-vibration capability are improved, the connection is effectively prevented from falling off, and the signal transmission continuity is ensured.
[0043] As shown in Figure 6 The second aspect embodiment of the present application provides a signal acquisition module of a battery pack, which comprises a plurality of signal acquisition devices of the first aspect embodiment, and the plurality of signal acquisition devices are arranged in an array.
[0044] Although the embodiments of the present application have been shown and described, those skilled in the art can understand that various changes, modifications, replacements and variations can be made to the embodiments without departing from the principles and purposes of the present application, and the scope of the present application is defined by the claims and their equivalents.
Claims
1. A signal acquisition device for a battery pack, characterized in that: The device includes a flexible flat cable, a flexible circuit board, aluminum busbars, and a support frame. The flexible circuit board is located in the middle of the support frame, and the aluminum busbars are located on both sides of the support frame. The aluminum busbars are connected to the flexible circuit board. A first connector is provided at one end of the support frame, and the flexible circuit board is connected to one end of the first connector. A second connector and a third connector are respectively provided at both ends of the flexible flat cable. The second connector is connected to the first connector, and the third connector is used to connect to the BMS battery management system.
2. The signal acquisition device for a battery pack according to claim 1, characterized in that: The first connector is provided with a plurality of connection terminals, and each connection terminal is provided with a first connection part and a second connection part at both ends. The first connection part is connected to the flexible circuit board, and the second connection part is connected to the flexible flat cable.
3. The signal acquisition device for a battery pack according to claim 1, characterized in that: The second connecting part is provided with a first connecting piece and a second connecting piece. The first connecting piece is located at the top of the second connecting piece. The ends of the first connecting piece and the ends of the second connecting piece are respectively provided with a first abutting block and a second abutting block. The first abutting block is located at the front end of the second abutting block.
4. The signal acquisition device for a battery pack according to claim 1, characterized in that: Multiple voltage acquisition areas are provided along the edge of the flexible circuit board, and voltage acquisition nickel plates are connected to the voltage acquisition areas. The voltage acquisition nickel plates are connected to the aluminum busbar.
5. The signal acquisition device for a battery pack according to claim 4, characterized in that: The voltage acquisition area is provided with an acquisition notch, and an acquisition terminal piece is provided in the acquisition notch. The nickel sheet is connected to the acquisition terminal piece, and the two ends of the acquisition terminal piece are respectively connected to the two sides of the acquisition notch. There is a gap between the acquisition terminal piece and the acquisition notch.
6. The signal acquisition device for a battery pack according to claim 4, characterized in that: The bracket has a long groove in the middle and multiple positioning grooves along its edge. The flexible circuit board is disposed in the long groove and the aluminum busbar is disposed in the positioning groove.
7. The signal acquisition device for a battery pack according to claim 6, characterized in that: An avoidance notch is provided between the elongated groove and the positioning groove, and the nickel sheet to be collected is located in the avoidance notch.
8. The signal acquisition device for a battery pack according to claim 6, characterized in that: The elongated groove is provided with a plurality of first positioning posts, and each positioning groove is provided with a plurality of second positioning posts. The first positioning posts pass through the flexible circuit board, and the second positioning posts pass through the aluminum busbar.
9. The signal acquisition device for a battery pack according to claim 1, characterized in that: Both the second connector and the third connector include a connector body and a positioning block. The connector body has a slot in the middle, and the end of the flexible flat cable has a limiting hole. The positioning block has a limiting post in the middle, and the outer periphery of the connector body has a through hole through which the limiting post passes. The connector body has a first locking block on both sides, and the positioning block has a second locking block on both sides. The first locking block and the second locking block engage one by one.
10. A signal acquisition module for a battery pack, characterized in that: It includes multiple signal acquisition devices as described in any one of claims 1-9, wherein the multiple signal acquisition devices are arranged in an array.