An integrated busbar structure based on flexible flat cable and its fabrication method

Abstract

This invention relates to the field of new energy battery technology, and in particular to an integrated busbar structure based on a flexible flat cable and its manufacturing method. The structure includes a vacuum-formed bracket, a flexible flat cable, multiple voltage acquisition harnesses, multiple aluminum busbars, and connectors. The vacuum-formed bracket has multiple grooves. The voltage acquisition harnesses include a first connecting harness and a first conductive sheet. The flexible flat cable includes an insulation layer and multiple conductors, all of which are disposed within the insulation layer. Multiple welding windows are opened at the top of the insulation layer, and conductors pass through each welding window. Gaps are formed between the left and right sides of the conductors and the inner walls of the welding windows, and solder protruding from the welding windows is pre-placed in these gaps. The first connecting harness is placed between two protruding solder pieces. This invention features a compact structure, reliable connection, and ease of automated assembly. It effectively solves problems related to space occupation, connection stability, and manufacturing consistency without sacrificing signal integrity and mechanical strength.

Description

Technical Field

[0001] This invention relates to the field of new energy battery technology, and in particular to an integrated busbar structure based on a flexible flat cable and its preparation method. Background Technology

[0002] In power battery systems, the battery management system needs to acquire key parameters such as cell voltage and temperature in real time with high precision and high reliability. Currently, the mainstream acquisition solution usually adopts an integrated busbar, whose signal acquisition components mainly include flexible printed circuit boards or wire harnesses, and are connected to the cell terminals by soldering acquisition nickel sheets to realize the extraction of electrical signals.

[0003] In existing technologies, voltage signals are typically acquired by nickel plates soldered to the battery terminals, and then the signals from each pin are extracted via an FPC or independent wiring harness, ultimately connecting to the BMS via an adapter harness. However, this approach has several significant drawbacks: First, the wiring harness used for signal conversion is relatively large, occupying considerable space within the battery pack and hindering the compact and lightweight design of the overall battery pack structure. Second, as the number of batteries connected in series and parallel increases, the required number of pins increases, leading to a larger bending radius in the adapter harness. This not only further exacerbates the space occupation problem but also increases the risk of wire fatigue and even breakage due to repeated bending, affecting long-term reliability. Third, the wiring harness assembly process is highly dependent on manual operation, resulting in low automation, poor process consistency, and high labor costs. Furthermore, if the soldering points between the wiring harness and the FPC or nickel plate rely solely on surface overlap, the contact area is small, and the bonding strength is low. Under dynamic loads, this can easily lead to incomplete soldering or desoldering, causing signal loss or even safety risks. Summary of the Invention

[0004] This invention aims to at least solve the technical problems existing in the prior art. To this end, this invention proposes an integrated busbar structure based on flexible flat cables and its manufacturing method. The structure is compact, the connection is reliable, and it is easy to automate assembly. It can effectively solve problems such as space occupation, connection stability, and manufacturing consistency without sacrificing signal integrity and mechanical strength.

[0005] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is characterized in that it includes a blister packer, a flexible flat cable, multiple voltage acquisition harnesses, multiple aluminum busbars, and connectors. The blister packer has multiple grooves, and the aluminum busbars are disposed in the grooves. The voltage acquisition harnesses include a first connecting harness and a first conductive sheet. The first conductive sheet has a first locking block and a wiring portion at both ends. The aluminum busbars have slots, and the first locking blocks engage with the slots. The flexible flat cable... The device includes an insulating layer and multiple conductors, all of which are disposed within the insulating layer. Multiple welding windows are provided on the top of the insulating layer, and each welding window contains a conductor. The width of each welding window is greater than the width of the corresponding conductor, creating gaps between the conductor and the inner wall of the welding window. Solder protruding from the welding window is pre-placed in these gaps. One end of the first connecting wire harness is connected to the connector, and the other end of the first connecting wire harness is placed between two protruding solder pieces and positioned by the protruding structure of the solder. The end of the flexible flat cable is connected to the connector.

[0006] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable includes a temperature sensing harness. The temperature sensing harness includes a temperature sensor and a second conductive sheet. The two ends of the second conductive sheet are respectively provided with a second locking block and a connecting portion. The temperature sensor is disposed in the connecting portion. The temperature sensor is provided with two second connecting harnesses. The other end of the second connecting harness is placed between two protruding solder joints and positioned by the protruding structure of the solder joints.

[0007] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein the first card block and the second card block are both U-shaped, and both sides of the first card block and the second card block are provided with raised inclined surfaces, the raised inclined surfaces gradually protruding outward from the bottom to the top, and the top of the card slot near the flexible flat cable is provided with an inlet inclined surface.

[0008] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein the diameter of the first connecting wire harness is d, and the distance by which the top of the solder protrudes above the upper surface of the conductor is δ, where δ is 0.55d-0.75d, so as to achieve self-positioning of the first connecting wire harness.

[0009] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein the solder is Sn-Bi-Ag solder.

[0010] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein the Sn-Bi-Ag solder is a Sn42 / Bi57 / Ag1 eutectic alloy, and the peak welding temperature Tpeak satisfies: 180∘C≤Tpeak≤200∘C180.

[0011] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein a first connecting hole is provided on the aluminum busbar and a second connecting hole is provided in the groove, wherein the first connecting hole and the second connecting hole are correspondingly provided.

[0012] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein the first connecting harness located at one end of the flexible flat cable and the second connecting harness located at one end of the flexible flat cable are both cylindrical.

[0013] According to some embodiments of the first aspect of the present invention, an integrated busbar structure based on a flexible flat cable is provided, wherein the conductor is a flat copper conductor.

[0014] A method for preparing an integrated busbar structure according to some embodiments of the first aspect of the present invention, for preparing the integrated busbar structure of some embodiments of the first aspect, includes the following steps: S1. Fabricate the vacuum forming bracket, flexible flat cable, voltage acquisition harness, aluminum busbar, and connectors. Create welding windows on the flexible flat cable to expose the conductors. S2. Pre-place upward-protruding solder in the gaps on both sides of the welding window of the flexible flat cable; S3. Place the first connecting wire harness between the two raised solder bumps, and position it automatically by the solder bump structure; S4. Assemble the aluminum busbar and the first conductive sheet to complete the mechanical connection between the first card block and the card slot; S5. Using a Haba welding machine, hot-press welding is performed after adding solder, with the peak temperature controlled at 180–200°C, so that the solder melts and covers the first connecting wire harness and conductor; S6. Connect the end of the flexible flat cable to the connector to complete the integrated busbar assembly.

[0015] An integrated busbar structure based on a flexible flat cable and its fabrication method according to some embodiments of the present invention have at least the following beneficial effects: Using flexible flat cables instead of traditional wire harnesses reduces the space occupied by the signal lead-out layer. Simultaneously, by directly integrating positioning and welding functions within the welding window, additional intermediate components such as connecting nickel sheets and adapter terminals are eliminated, further simplifying the structure and facilitating lightweight and high-energy-density battery pack design. Pre-placed upward-protruding solder in the gaps on both sides of the welding window not only forms grooves for automatic lateral positioning of the first connecting wire harness before Habar welding, avoiding manual alignment errors, but also, after welding, the molten solder covers the wire harness, forming a robust, fully metallurgically bonded connection. This significantly increases the contact area and tensile strength, effectively resisting dynamic loads such as vibration and thermal cycling, eliminating the risk of incomplete soldering or desoldering. The 180–200°C Habar welding process window ensures sufficient wetting while remaining far below the thermal decomposition temperature of the insulation layer, effectively preventing insulation layer carbonization or warping and guaranteeing long-term electrical insulation performance. The connecting wire harness relies on the self-positioning of the solder protrusions. Habar welding is a mature hot-pressing process, and the entire process can achieve roll-to-roll or automated operation with tooling fixtures, significantly reducing reliance on manual labor, improving process consistency, and meeting the requirements of mass production.

[0016] 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

[0017] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention.

[0018] Figure 2 for Figure 1 An enlarged view of part A in the image.

[0019] Figure 3 This is a schematic diagram of the structure of the thermoforming bracket according to an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the structure of the first conductive sheet according to an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the aluminum busbar structure according to an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of the structure of a flexible flat cable according to an embodiment of the present invention.

[0023] Reference numerals: 1. Vacuum forming bracket; 2. Flexible flat cable; 3. Voltage acquisition harness; 4. Aluminum busbar; 5. Connector; 6. Groove; 7. First connecting harness; 8. First conductive sheet; 9. First locking block; 10. Wiring part; 11. Slot; 12. Insulation layer; 13. Conductor; 14. Welding window; 15. Temperature sensing harness; 16. Temperature sensor; 17. Second conductive sheet; 18. Second locking block; 19. Connecting part; 20. Second connecting harness; 21. Positioning post; 22. Positioning hole; 23. Raised bevel; 24. Guide bevel; 25. First connecting hole; 26. Second connecting hole; 27. Through groove; 28. Solder. Detailed Implementation

[0024] 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.

[0025] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, left, right, front, and back, are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the module or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0026] In the description of this invention, the use of "first" and "second" is for the purpose of distinguishing technical features only, and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated or the order of the technical features indicated.

[0027] In the description of this invention, unless otherwise explicitly defined, terms such as "setting," "installing," and "connecting" 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.

[0028] like Figures 1-6 As shown, this embodiment of the invention provides an integrated busbar structure based on a flexible flat cable.

[0029] An integrated busbar structure based on a flexible flat cable includes a vacuum-formed bracket 1, a flexible flat cable 2, multiple voltage acquisition harnesses 3, multiple aluminum busbars 4, and connectors 5. The vacuum-formed bracket 1 has multiple grooves 6, and the aluminum busbars 4 are arranged one by one within each groove 6. Each voltage acquisition harness 3 includes a first connecting harness 7 and a first conductive sheet 8. The first conductive sheet 8 has a first locking block 9 and a wiring portion 10 at each end. Each aluminum busbar 4 has a slot 11, and the first locking block 9 engages with the slot 11. The flexible flat cable 2 includes an insulation layer 12 and multiple conductors 13, each conductor 13 being arranged within a... Within the insulation layer 12, a plurality of welding windows 14 are provided on the top of the insulation layer 12. Each welding window 14 has a conductor 13 passing through it. The width of the welding window 14 is greater than the width of the corresponding conductor 13, so that a gap is formed between the left and right sides of the conductor 13 and the inner wall of the welding window 14. Solder 28 protruding from the welding window is pre-placed in the gap. One end of the first connecting wire harness 7 is connected to the wiring part 10, and the other end of the first connecting wire harness 7 is placed between the two protruding solder 28 and positioned by the protruding structure of the solder 28. The end of the flexible flat cable 2 is connected to the connector 5.

[0030] This embodiment describes an integrated busbar structure based on a flexible flat cable. The aluminum busbar 4 has two slots 11, located on its left and right sides respectively. Specifically, the slots 11 on both sides of the aluminum busbar 4 facilitate dual-sided wiring or redundant design, enhancing the reliability of signal acquisition and assembly flexibility.

[0031] This embodiment describes an integrated busbar structure based on a flexible flat cable, including a temperature sensing harness 15. The temperature sensing harness 15 includes a temperature sensor 16 and a second conductive sheet 17. The two ends of the second conductive sheet 17 are respectively provided with a second locking block 18 and a connecting portion 19. The temperature sensor 16 is disposed within the connecting portion 19. The temperature sensor 16 has two second connecting harnesses 20. The other end of the second connecting harness 20 is welded to the conductor 13 through the welding window 14. The other end of the second connecting harness 20 is placed between two protruding solder 28s and positioned by the protruding structure of the solder 28s. Specifically, the temperature acquisition function is integrated into the same flexible flat cable 2 system, realizing a unified transmission path for voltage and temperature signals, eliminating the need for additional temperature sensing harnesses, further simplifying the structure, saving space, and improving the BMS's comprehensive monitoring capability of the battery cell status.

[0032] It is understood that the conductor 13 is a flat copper conductor.

[0033] This embodiment describes an integrated busbar structure based on flexible flat cables. Each groove 6 is equipped with a positioning post 21, and each aluminum busbar 4 has a positioning hole 22. The positioning posts 21 pass through the positioning holes 22. Specifically, the cooperation between the positioning posts 21 and the positioning holes 22 ensures the precise installation position of the aluminum busbar 4 in the vacuum forming bracket 1, preventing assembly misalignment or loosening, improving the consistency of the overall structure and assembly efficiency, and facilitating automated production.

[0034] This embodiment describes an integrated busbar structure based on a flexible flat cable. Both the first locking block 9 and the second locking block 18 are U-shaped. Both sides of the first locking block 9 and the second locking block 18 are provided with raised inclined surfaces 23, which gradually protrude outwards from the bottom to the top. The top of the slot 11 near the flexible flat cable 2 is provided with an inlet inclined surface 24. Specifically, the U-shaped locking blocks, in conjunction with the raised inclined surfaces 23 and the inlet inclined surface 24 of the slot 11, form a self-guiding and self-locking locking structure. This facilitates quick insertion and ensures a secure connection, effectively preventing contact loosening caused by vibration or thermal expansion and contraction, and improving the long-term reliability of the electrical connection.

[0035] In this embodiment, an integrated busbar structure based on a flexible flat cable is described, wherein the first connecting harness 7 and the second connecting harness 20 located at one end of the flexible flat cable are both cylindrical.

[0036] This embodiment describes an integrated busbar structure based on a flexible flat cable. The diameters of the first connecting wire harness 7 and the second connecting wire harness 20 are denoted as 'd'. The distance 'δ' is the top of the solder 28 above the upper surface of the conductor, where 'δ' is between 0.55d and 0.75d, to achieve self-positioning of the first connecting wire harness. Specifically, by limiting the ratio range of the solder protrusion height 'δ' to the diameter 'd' of the connecting wire harness, the center of gravity of the circular wire harness is ensured to be stable and not to roll or shift after placement, achieving high-precision self-positioning and providing consistent initial alignment conditions for subsequent Habar welding.

[0037] This embodiment describes an integrated busbar structure based on a flexible flat cable. The solder used is Sn-Bi-Ag solder, specifically a Sn42 / Bi57 / Ag1 eutectic alloy. The peak welding temperature Tpeak satisfies the following condition: 180°C ≤ Tpeak ≤ 200°C ≤ 180°C. Specifically, the Sn42 / Bi57 / Ag1 eutectic alloy is selected, and the peak welding temperature is controlled within the 180–200°C range. This ensures complete melting and flow of the solder to form a circumferential structure while staying away from the thermal decomposition threshold of the PI film, thus balancing welding quality and material safety.

[0038] It is understandable that the insulating polyimide (PI) film, using Sn-Bi-Ag solder, has a melting point of only 138°C. Combined with the Habar soldering process window of 180–200°C, it ensures sufficient wetting while being far below the thermal decomposition temperature of the polyimide (PI) film (approximately 250°C).

[0039] The pre-set volume of the Sn-Bi-Ag solder is calculated according to the formula. Calculate, where, For the width of the welded window, The width of the copper conductor. For the length of the welded window, For the thickness of the copper conductor, This is the fill factor, with a value range of 1.05–1.15. Specifically, 1.1 is supplied precisely through dispensing or micro-punching.

[0040] The integrated busbar structure based on flexible flat cables described in this embodiment has a U-shaped wiring portion 10 and a cylindrical connecting portion 19. Specifically, the U-shaped wiring portion 10 facilitates stable crimping or welding with the first connecting wire harness 7, while the cylindrical connecting portion 19 can tightly wrap and fix the temperature sensor 16, improving mechanical strength and electrical contact stability, while also adapting to different sensor packaging forms and enhancing versatility.

[0041] This embodiment describes an integrated busbar structure based on a flexible flat cable. The aluminum busbar 4 has a first connecting hole 25, and the groove 6 has a second connecting hole 26. The first connecting hole 25 and the second connecting hole 26 are correspondingly arranged. Specifically, through the alignment design of the first connecting hole 25 and the second connecting hole 26, the aluminum busbar 4 can be connected to the battery module.

[0042] This embodiment describes an integrated busbar structure based on flexible flat cables. The vacuum-formed bracket 1 has a through-slot 27 in its center, and the flexible flat cable 2 is disposed within this through-slot 27. Grooves 6 are located on both sides of the through-slot 27. Specifically, the through-slot 27 provides a dedicated routing channel for the flexible flat cable 2, while the grooves 6 of the aluminum busbars 4 are arranged on both sides, achieving a compact layout with routing in the middle and sampling on both sides, optimizing space utilization and improving overall integration.

[0043] Understandably, since the conductors 13 within the flexible flat cable 2 are limited, more aluminum busbars 4 can be connected by setting up two or more flexible flat cables 2.

[0044] This invention also provides a method for preparing an integrated busbar structure. A method for preparing an integrated busbar structure, comprising the following steps: S1. Prepare a thermoforming bracket 1, a flexible flat cable 2, a voltage acquisition harness 3, a temperature acquisition harness 15, an aluminum busbar 4, and a connector. Make a welding window 14 on the flexible flat cable 2 to expose the conductor 13. S2. An upwardly protruding solder 28 is pre-placed in the gap on both sides of the welding window 14 of the flexible flat cable; S3. Place the first connecting wire harness 7 and the second connecting wire harness 20 between the two raised solder 28, and automatically position them by the raised structure of the solder 28. S4. Assemble the aluminum busbar 4 and the first conductive sheet 8 to complete the mechanical connection between the first locking block 9 and the slot 11, and between the second locking block 18 and the slot 11; S5. Using a Haba welding equipment, hot-press welding is performed after adding solder 28, with the peak temperature controlled at 180–200°C, so that the solder 28 melts and covers the first connecting wire harness 7 and conductor 13. S6. Connect the flexible flat cable 2 end to connector 5, apply adhesive to the welding position, and complete the integrated busbar assembly.

[0045] This invention uses a flexible flat cable 2 to replace the traditional wire harness, reducing the space occupied by the signal lead-out layer. Simultaneously, by directly integrating positioning and welding functions within the welding window 14, it eliminates the need for additional connecting nickel sheets, adapter terminals, and other intermediate components, further simplifying the structure and facilitating lightweight and high-energy-density battery pack design. The upward-protruding solder 28 pre-placed in the gaps on both sides of the welding window 14 not only forms grooves before the Happening process to automatically laterally position the first connecting wire harness 7, avoiding manual alignment errors, but also, after welding, the solder 28 melts and covers the wire harness, forming a robust, fully metallurgically bonded connection, significantly improving… The contact area and tensile strength effectively resist dynamic loads such as vibration and thermal cycling, eliminating the risk of incomplete soldering and desoldering. The 180–200°C Habar welding process window ensures sufficient wetting while being far below the thermal decomposition temperature of the insulation layer 12, effectively preventing carbonization or warping of the insulation layer and ensuring long-term electrical insulation performance. The first connecting wire harness 7 and the second connecting wire harness 20 rely on the self-positioning of the solder 28 protrusion. Habar welding is a mature hot pressing process, and the entire process can realize roll-to-roll or tooling fixture automatic operation, greatly reducing manual dependence, improving process consistency, and meeting the requirements of mass production.

[0046] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An integrated busbar structure based on flexible flat cables, characterized in that: The device includes a vacuum-formed bracket, a flexible flat cable, multiple voltage acquisition harnesses, multiple aluminum busbars, and a connector. The vacuum-formed bracket has multiple grooves, and the aluminum busbars are arranged in the grooves. The voltage acquisition harnesses include a first connecting harness and a first conductive sheet. The two ends of the first conductive sheet are respectively provided with a first locking block and a wiring portion. The aluminum busbars are provided with slots, and the first locking blocks engage with the slots. The flexible flat cable includes an insulation layer and multiple conductors, all of which are disposed within the insulation layer. The top of the insulation layer has multiple welding windows, and the conductors pass through each welding window. The width of each welding window is greater than the width of the corresponding conductor, so that gaps are formed between the left and right sides of the conductor and the inner wall of the welding window. Solder protruding from the welding window is pre-placed in the gaps. One end of the first connecting harness is connected to the wiring portion, and the other end of the first connecting harness is placed between two protruding solder pieces and positioned by the protruding structure of the solder pieces. The end of the flexible flat cable is connected to the connector.

2. The integrated busbar structure based on flexible flat cable according to claim 1, characterized in that: The device includes a temperature sensing harness, which includes a temperature sensor and a second conductive sheet. The two ends of the second conductive sheet are respectively provided with a second locking block and a connecting part. The temperature sensor is disposed in the connecting part. The temperature sensor is provided with two second connecting harnesses. The other end of the second connecting harness is placed between two protruding solder and positioned by the protruding structure of the solder.

3. The integrated busbar structure based on flexible flat cable according to claim 2, characterized in that: Both the first and second card blocks are U-shaped, and both sides of the first and second card blocks are provided with raised inclined surfaces. The raised inclined surfaces gradually protrude outward from the bottom to the top, and the top of the card slot near the flexible flat cable is provided with an inlet inclined surface.

4. The integrated busbar structure based on flexible flat cable according to claim 1, characterized in that: The solder is Sn-Bi-Ag solder.

5. An integrated busbar structure based on a flexible flat cable according to claim 4, characterized in that: The Sn-Bi-Ag solder is a Sn42 / Bi57 / Ag1 eutectic alloy, and the peak welding temperature Tpeak satisfies: 180∘C≤Tpeak≤200∘C180.

6. The integrated busbar structure based on flexible flat cable according to claim 1, characterized in that: The aluminum busbar is provided with a first connecting hole, and the groove is provided with a second connecting hole, with the first connecting hole and the second connecting hole being provided in correspondence.

7. An integrated busbar structure based on a flexible flat cable according to claim 2, characterized in that: Both the first connecting harness located at one end of the flexible flat cable and the second connecting harness located at one end of the flexible flat cable are cylindrical.

8. An integrated busbar structure based on a flexible flat cable according to claim 7, characterized in that: Let the diameter of the first connecting wire harness be d, and the distance between the top of the solder and the upper surface of the conductor be δ, where δ is 0.55d-0.75d, so as to achieve self-positioning of the first connecting wire harness.

9. An integrated busbar structure based on a flexible flat cable according to claim 1, characterized in that: The conductor is a flat copper conductor.

10. A method for preparing an integrated busbar structure, used to prepare the integrated busbar structure according to any one of claims 1-9, characterized in that, Includes the following steps: S1. Fabricate the vacuum forming bracket, flexible flat cable, voltage acquisition harness, aluminum busbar, and connectors. Create welding windows on the flexible flat cable to expose the conductors. S2. Pre-place upward-protruding solder in the gaps on both sides of the welding window of the flexible flat cable; S3. Place the first connecting wire harness between the two raised solder bumps, and position it automatically by the solder bump structure; S4. Assemble the aluminum busbar and the first conductive sheet to complete the mechanical connection between the first card block and the card slot; S5. Using a Haba welding machine, hot-press welding is performed after adding solder, with the peak temperature controlled at 180–200°C, so that the solder melts and covers the first connecting wire harness and conductor; S6. Connect the end of the flexible flat cable to the connector to complete the integrated busbar assembly.

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