Novel integrated micro-connection structure and method applied to power and energy storage battery

Abstract

The invention discloses a novel integrated micro-connection structure and method applied to a power and energy storage battery, the novel integrated micro-connection structure comprises integrated busbars mounted on the top wall and the bottom wall of the battery, and each integrated busbar comprises an isolation plate, an aluminum bar and a flexible circuit board; the plug-in support is fixedly connected to the isolation plate, and the interface end of the flexible circuit board is installed on the plug-in support; the plug-in support is provided with a breakable micro connection point. During boxing, micro connection points are kept unbroken, the straight form of the insertion bracket is maintained, and a temporary support is provided for an interface end, so that the situation that a connector is crushed by a battery pack due to gravity falling to affect boxing assembly of a battery module is avoided; micro connection points are broken off after boxing, the plug-in bracket is bent and buckled on the side wall of the battery by utilizing a buckling structure of the plug-in bracket, and the interface is transferred from the top to the side part, so that the lateral space is fully utilized. The structure solves the two problems of assembly damage risk and insufficient top space at the same time.

Description

Technical Field

[0001] This invention relates to integrated busbar structures, and more particularly to a novel integrated micro-connection structure for use in power and energy storage batteries. Background Technology

[0002] With the development of the new energy vehicle industry, increasingly higher requirements have been placed on the energy density, space utilization and cost control of battery packs. The integrated busbar is an important component of new energy power battery modules, integrating the series and parallel connection between cells and the acquisition of signals such as voltage and temperature.

[0003] Traditional integrated busbars have two main problems during assembly: First, due to the limitations of side mounting, when the connector head is placed at the bottom of the battery pack after welding with the battery pack, it needs to be fixed by production personnel. If the fixing is unreliable, the battery pack may be damaged and scrapped. Second, due to the compact space, there is insufficient installation space in the X-axis direction. Other structural components need to be modified or the number of battery cells in the battery pack needs to be reduced to obtain space, which poses challenges to product cost and system requirements. Summary of the Invention

[0004] To address the shortcomings of the aforementioned technologies, this invention provides a novel integrated micro-connection structure applicable to power and energy storage batteries.

[0005] To solve the above technical problems, the technical solution adopted by the present invention is: a novel integrated micro-connection structure for power and energy storage batteries, comprising: an integrated busbar installed on the top and bottom walls of the power and energy storage battery, the integrated busbar including an isolation plate near the side of the power and energy storage battery, an aluminum busbar installed on the isolation plate, and a flexible circuit board connected to the aluminum busbar. A plug-in bracket is fixedly connected to the isolation plate; the common end and interface end of the flexible circuit board are mounted on the plug-in bracket; the plug-in bracket is provided with at least one breakable micro-connection point, which is configured to remain unbroken during the integration of the busbar and the battery assembly box to maintain the straight shape of the plug-in bracket and provide temporary support, and to break under external force when the plug-in bracket is bent and attached to the side wall of the battery.

[0006] Furthermore, the micro-connection point is a thin-walled connection structure integrally formed on the plug-in bracket, and its cross-sectional area is smaller than that of the main structure of the plug-in bracket.

[0007] Furthermore, there are multiple micro-connection points, which are distributed at intervals along the bending part of the plug-in bracket.

[0008] Furthermore, the maximum projected area of ​​the isolation plate is contained within the top wall of the power and energy storage battery.

[0009] Furthermore, the connector has a first state in which the microconnection point remains straight when it is not broken, and a second state in which the microconnection point is bent and attached to the side wall of the battery after it is broken.

[0010] A method for lateral space transfer and utilization for integrated busbars includes the following steps: Step 1: Provide an integrated busbar, which includes an isolation plate for mounting on the top wall of the battery and a plug-in bracket fixedly connected to the isolation plate. The plug-in bracket carries the interface end of a flexible circuit board and has at least one breakable micro-connection point. The micro-connection point maintains the plug-in bracket in a straight shape when it is not broken. Step 2: During the welding and fixing of the integrated busbar and the battery pack and the packaging process, keep the micro-connection points in an unbroken state, keep the plug-in bracket in a straight shape to occupy the vertical space at the top of the battery, and at the same time use the straight shape to provide temporary support for the interface end to prevent it from falling. Step 3: After the battery pack is packaged, apply external force to the predetermined bending part of the plug bracket to break the micro-connection point under the action of external force, thereby releasing the straight constraint on the plug bracket. Step four: Bend the broken connector bracket so that it changes from occupying the top space of the battery to being attached to the side wall of the battery. This moves the space occupied by the signal interface from the top of the battery to the side of the battery, making use of the free space on the side of the battery.

[0011] Furthermore, in step four, the connector bracket is bent at a 90° angle relative to the separator plate so that it fits against the side wall of the battery.

[0012] Furthermore, there are multiple micro-connection points, which are spaced apart along the bending part of the plug-in bracket; in the micro-connection point breaking step, multiple micro-connection points are broken in sequence by applying force to achieve controllable bending.

[0013] Furthermore, after step four, there is also a fifth step of fixing the bent plug bracket to the side wall or inner wall of the battery through the connecting structure to ensure its stable adhesion in the lateral space.

[0014] An integrated busbar assembly method based on morphological stage management includes the following steps: The plug-in bracket is rigidly connected to the isolation plate of the novel integrated micro-connection structure through at least one breakable micro-connection point, so that the plug-in bracket is in a flat first state, and the plug-in bracket carries the interface end of the flexible circuit board. Throughout the entire transportation and assembly process from the welding of the new integrated micro-connection structure to the completion of the battery assembly box, the integrity of the micro-connection point is maintained. The first state of the plug-in bracket is used to form a follow-up support for the interface end, preventing the interface end from shifting or falling under the action of gravity. After the battery pack is located behind the housing, an external force is applied to the pre-set weak point of the plug-in bracket to trigger the micro-connection point to break, so that the plug-in bracket switches from a constrained state to a free and bendable state. The connector bracket is bent to the second state, so that it is attached to the side wall of the battery, and the connector bracket is locked in the second state by an auxiliary fixing structure, thus completing the final layout of the interface from the top space to the side space.

[0015] This patent utilizes breakable micro-connection points on the plug-in bracket. During the packaging process after the integrated busbar and battery pack are welded, the micro-connection points remain unbroken, maintaining the straight shape of the plug-in bracket. This provides temporary support for the plug-in bracket and the interface end mounted on it, preventing the connector head from being damaged by gravity due to falling and stacking. It eliminates the need for manual fixation, improving production safety and consistency. After the battery pack is packaged, the micro-connection points are broken under external force, giving the plug-in bracket bending freedom. It can then be attached to the side wall of the battery, transferring the signal interface from the space-constrained top to the side. This fully utilizes the lateral space of the battery without modifying the enclosure structure or reducing the number of cells, effectively solving the problem of insufficient space in the X-axis direction and improving space utilization and system performance. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention.

[0017] Figure 2 This is a schematic diagram of the plug-in bracket.

[0018] Figure 3 This is a schematic diagram showing the transition of the micro-connection point of the plug-in bracket from the first state to the second state after being broken and bent and covered.

[0019] In the diagram: 1. Integrated busbar; 11. Isolation plate; 12. Aluminum busbar; 13. Flexible circuit board; 131. Common terminal; 132. Interface terminal; 2. Plug-in bracket; 21. Micro connection point; 3. Battery; 31. Top wall; 32. Side wall; 33. Bottom wall. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0021] Example 1 like Figures 1 to 2 As shown, the present invention provides a novel integrated micro-connection structure for power and energy storage batteries, which mainly includes two parts: an integrated busbar 1 and a plug-in bracket 2.

[0022] The integrated busbar 1 is integrally mounted on the top wall 31 and bottom wall 33 of the power and energy storage battery 3. The integrated busbar 1 includes an isolation plate 11, aluminum bars 12, and a flexible circuit board 13. The isolation plate 11 serves as the base of the integrated busbar 1, and its lower surface near the battery 3 is attached to the top wall 31 of the battery 3. To reduce weight, increase structural strength, and facilitate heat dissipation, the isolation plate 11 has multiple hollow structures and crisscrossing reinforcing ribs. Multiple aluminum bars 12 are inserted and fixed to predetermined positions on the isolation plate 11 by injection molding or by hot riveting, snap-fitting, etc. The positions of the aluminum bars 12 correspond to the positions of the terminals on the top of the battery 3, and are used to realize series and parallel connections between multiple cells to transmit large currents. The flexible circuit board 13 is attached to the upper surface of the isolation plate 11 and is electrically connected to the signal acquisition points on the aluminum bars 12 by soldering, etc., for acquiring the voltage and temperature signals of each cell. The maximum projected area of ​​the isolation plate 11 is contained within the top wall 31 of the battery 3, ensuring that the integrated busbar 1 does not extend beyond the top of the battery.

[0023] The plug bracket 2 is fixedly connected to the isolation plate 11, specifically by welding to the bottom edge of the isolation plate 11. The common end 131 and the interface end 132 (i.e., the connector for connecting to an external battery management system) of the flexible circuit board 13 are mounted and fixed on the plug bracket 2.

[0024] like Figure 2 As shown, the core improvement of this embodiment lies in the micro-connection structure provided on the plug-in bracket 2. The plug-in bracket 2 has at least one breakable micro-connection point 21, located at the bending portion of the plug-in bracket 2. The micro-connection point 21 is an integrally formed thin-walled connection structure on the plug-in bracket 2, with a cross-sectional area smaller than that of the main structure of the plug-in bracket 2. In this embodiment, there are multiple micro-connection points 21, spaced apart along the bending portion of the plug-in bracket 2. This design allows the plug-in bracket 2 to maintain a straight shape in its initial state, facilitating integrated assembly and transport.

[0025] The advantage of this micro-connection structure design is that during the packaging process after the integrated busbar 1 and battery 3 are welded, the micro-connection point 21 remains unbroken, maintaining the straight shape of the plug-in bracket 2. This ensures that the plug-in bracket 2 maintains its initial relative position with the isolation plate 11, preventing the plug-in bracket 2 and the interface end 132 mounted on it from falling freely due to gravity, thereby preventing damage to the devices or battery pack from stacking. At this time, the plug-in bracket 2 is in the first state where the micro-connection point is unbroken.

[0026] like Figure 3As shown, when the battery pack is fully packaged and the interface 132 needs to be installed in its final position, an external force can be applied to the bending portion of the connector bracket 2, causing the micro-connection point 21 to break under the force. After the micro-connection point 21 breaks, the connector bracket 2 gains bending freedom and can be bent 90 degrees relative to the separator plate 11, allowing the connector bracket 2 to adhere to the side wall 32 of the battery 3, thus transferring the signal interface from the top to the side of the battery. At this time, the connector bracket 2 is in the second state of bending and adhering after the micro-connection point breaks. It should be noted that the bent connector bracket can be fixedly connected to the side wall 32 or the inner wall of the battery through an additional connection structure to ensure the stability and reliability of the connector bracket 2 during vehicle operation.

[0027] After the micro-connection point 21 breaks, the insertion bracket 2 bends and attaches to the side wall 32 of the battery 3. Since the insertion bracket 2 is fixedly connected to the separator 11, even if the micro-connection point 21 breaks, the insertion bracket 2 remains connected to the separator 11 and will not completely separate. This design provides temporary support during packaging, avoids potential component loss or connection reliability issues associated with a split structure, maintains the integrity of the overall structure, and facilitates easy repackaging.

[0028] Therefore, this invention forms an integrated busbar assembly method based on morphological stage management, comprising the following steps: The plug-in bracket is rigidly connected to the isolation plate of the novel integrated micro-connection structure through at least one breakable micro-connection point, so that the plug-in bracket is in a flat first state, and the plug-in bracket carries the interface end of the flexible circuit board. Throughout the entire transportation and assembly process from the welding of the new integrated micro-connection structure to the completion of the battery assembly box, the integrity of the micro-connection point is maintained. The first state of the plug-in bracket is used to form a follow-up support for the interface end, preventing the interface end from shifting or falling under the action of gravity. After the battery pack is located behind the housing, an external force is applied to the pre-set weak point of the plug-in bracket to trigger the micro-connection point to break, so that the plug-in bracket switches from a constrained state to a free and bendable state. The connector bracket is bent to the second state, so that it is attached to the side wall of the battery, and the connector bracket is locked in the second state by an auxiliary fixing structure, thus completing the final layout of the interface from the top space to the side space.

[0029] Example 2 This embodiment is basically the same as Embodiment 1, except that the location and number of micro-connection points are different to adapt to different production and assembly needs.

[0030] In this embodiment, five micro-connection points are located at both ends and the middle of the bent portion of the connector bracket. The cross-sectional area of ​​the micro-connection point in the middle is slightly larger than that of the micro-connection points at both ends to provide stronger support. This design ensures temporary support while also facilitating the sequential breakage of the micro-connection points when bending is required, achieving a more controllable bending process. Furthermore, this distribution ensures that even if some micro-connection points break accidentally during use, the remaining micro-connection points can maintain the straight shape of the connector bracket, improving structural reliability.

[0031] Therefore, this embodiment provides a method for lateral space transfer and utilization for integrated busbars, including the following steps: Step 1: Provide an integrated busbar 1, which includes an isolation plate 11 for mounting on the top wall 31 of the battery 3 and a plug-in bracket 2 fixedly connected to the isolation plate 11. The plug-in bracket 2 carries the interface end 132 of the flexible circuit board 13, and the plug-in bracket 2 is provided with five breakable micro-connection points 21 distributed at intervals along the bending part. The cross-sectional area of ​​the micro-connection point in the middle position is larger than that of the micro-connection points at both ends. When the micro-connection points are not broken, they together maintain the plug-in bracket 2 in a straight shape. Step 2: During the welding and fixing of the integrated busbar 1 and the battery pack 3 and the packaging process, all micro-connection points 21 are kept in an unbroken state, so that the plug-in bracket 2 is kept in a straight shape to occupy the vertical space at the top of the battery 3. At the same time, the straight shape is used to provide temporary support for the interface end 132 to prevent it from falling. Step 3: After the battery pack 3 is packed, an external force is applied to the predetermined bending part of the plug-in bracket 2, so that multiple micro-connection points 21 break in sequence under the action of the external force. The micro-connection points with weaker strength at both ends break first, followed by the micro-connection points with stronger strength in the middle, thereby gradually releasing the straightness constraint on the plug-in bracket 2. Step 4: Bend the broken plug bracket 2 so that it bends 90° relative to the isolation plate 11, changing it from occupying the top space of the battery 3 to being attached to the side wall 32 of the battery 3. This transfers the space occupied by the signal interface from the top of the battery 3 to the side of the battery 3, making use of the free space on the side of the battery. Step 5: Fix the bent plug bracket 2 to the side wall 32 of the battery 3 or the inner wall of the battery box through a connecting structure (such as a buckle, adhesive or bolt) to ensure stable adhesion under operating conditions such as vehicle operation and avoid vibration causing the interface to loosen.

[0032] The above embodiments are not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present invention are also within the protection scope of the present invention.

Claims

1. A novel integrated micro-connection structure for use in power and energy storage batteries, characterized in that, include: An integrated busbar is installed on the top and bottom walls of the power and energy storage battery. The integrated busbar includes an isolation plate near the side of the power and energy storage battery, an aluminum busbar installed on the isolation plate, and a flexible circuit board connected to the aluminum busbar. A plug-in bracket is fixedly connected to an isolation plate; the common end and interface end of the flexible circuit board are mounted on the plug-in bracket; characterized in that: the plug-in bracket is provided with at least one breakable micro-connection point, the micro-connection point is configured to remain unbroken during the integration of the busbar and the battery assembly box to maintain the straight shape of the plug-in bracket and provide temporary support, and to break under external force when the plug-in bracket is bent and attached to the side wall of the battery.

2. The novel integrated micro-connection structure for power and energy storage batteries according to claim 1, characterized in that: The micro-connection point is a thin-walled connection structure integrally formed on the plug-in bracket, and its cross-sectional area is smaller than that of the main structure of the plug-in bracket.

3. The novel integrated micro-connection structure for power and energy storage batteries according to claim 1, characterized in that: The number of micro-connection points is multiple, and they are distributed at intervals along the bending part of the plug-in bracket.

4. The novel integrated micro-connection structure for power and energy storage batteries according to claim 1, characterized in that: The maximum projected area of ​​the isolation plate is contained within the top wall of the power and energy storage battery.

5. The novel integrated micro-connection structure for power and energy storage batteries according to claim 1, characterized in that: The connector bracket has a first state in which it remains straight when the micro-connection point is not broken, and a second state in which it is bent and attached to the side wall of the battery after the micro-connection point is broken.

6. A method for lateral space transfer and utilization of integrated busbars, characterized in that, Includes the following steps: Step 1: Provide an integrated busbar, which includes an isolation plate for mounting on the top wall of the battery and a plug-in bracket fixedly connected to the isolation plate. The plug-in bracket carries the interface end of a flexible circuit board and has at least one breakable micro-connection point. The micro-connection point maintains the plug-in bracket in a straight shape when it is not broken. Step 2: During the welding and fixing of the integrated busbar and the battery pack and the packaging process, keep the micro connection point in an unbroken state, keep the plug bracket in a straight shape to occupy the vertical space at the top of the battery, and use the straight shape to provide temporary support for the interface end to prevent it from falling. Step 3: After the battery pack is packaged, apply external force to the predetermined bending part of the plug-in bracket to break the micro-connection point under the action of external force, thereby releasing the straightness constraint on the plug-in bracket. Step four: Bend the broken connector bracket so that it changes from occupying the top space of the battery to being attached to the side wall of the battery. This moves the space occupied by the signal interface from the top of the battery to the side of the battery, making use of the free space on the side of the battery.

7. The method for lateral space transfer and utilization for integrated busbars according to claim 6, characterized in that: In step four, the insertion bracket is bent at 90° relative to the separator plate so that it fits against the side wall of the battery.

8. The method for lateral space transfer and utilization for integrated busbars according to claim 7, characterized in that: The micro-connection points are multiple and are distributed at intervals along the bending part of the plug-in bracket; in the micro-connection point breaking step, multiple micro-connection points are broken sequentially by applying force to achieve controllable bending.

9. The method for lateral space transfer and utilization for integrated busbars according to claim 8, characterized in that: Following step four, step five further includes fixing the bent plug bracket to the battery sidewall or battery inner wall via a connecting structure to ensure stable adhesion in the lateral space.

10. An integrated busbar assembly method based on morphological staged management, characterized in that, Includes the following steps: The plug-in bracket is rigidly connected to the isolation plate of the novel integrated micro-connection structure through at least one breakable micro-connection point, so that the plug-in bracket is in a flat first state, and the plug-in bracket carries the interface end of the flexible circuit board. Throughout the entire transportation and assembly process from the welding of the novel integrated micro-connection structure to the completion of the battery assembly box, the integrity of the micro-connection point is maintained. The first state of the plug-in bracket forms a follow-up support for the interface end, preventing the interface end from shifting or falling under the action of gravity. After the battery pack is located behind the housing, an external force is applied to the pre-set weak point of the plug-in bracket to trigger the micro-connection point to break, so that the plug-in bracket switches from a constrained state to a free and bendable state. The connector bracket is bent to the second state, so that it is attached to the side wall of the battery, and the connector bracket is locked in the second state by an auxiliary fixing structure, thus completing the final layout of the interface from the top space to the side space.

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