A battery cell module with integrated busbar circuit board and a lightweight battery

Abstract

This invention provides a battery cell module and a lightweight battery with an integrated busbar circuit board. The battery cell module includes individual battery cells and a busbar circuit board. Several individual battery cells are included. The busbar circuit board is a multi-functional structure integrating a BMS control circuit, an individual battery cell voltage acquisition circuit, a temperature acquisition circuit, an equalization circuit, and a heating circuit. The busbar circuit board has tab pads or vias for soldering the tabs of each individual battery cell. The tab pads or vias are electrically connected to each other through copper busbars integrated within the busbar circuit board. After each individual battery cell is soldered to its corresponding tab pad or via, it forms a multi-cell module with the busbar circuit board. Integrating the BMS control circuit, individual battery cell voltage acquisition circuit, temperature acquisition circuit, equalization circuit, and heating circuit onto the busbar circuit board reduces complex wiring between units and the product assembly process, ensuring product reliability.

Description

Technical Field

[0001] This invention relates to the field of integrated battery module circuit structure, and in particular provides a cell module with an integrated bus circuit board and a lightweight battery. Background Technology

[0002] Currently, high-endurance, high-density battery modules are a research hotspot. The energy density performance of battery modules has always been a key indicator in the battery pack field, directly affecting the overall range. Among these, the proportion of battery modules and low-temperature charge / discharge capacity are crucial issues. Therefore, improving module integration design, reducing module weight, and improving low-temperature charge / discharge conditions are particularly important.

[0003] The existing main assembly method for battery modules involves connecting individual cells and busbars via energy storage welding, laser welding, or other methods. The busbars and BMS protection board are then connected via individual cell information acquisition wires. This connection method requires numerous wires, resulting in a complex assembly process, large size and weight, cumbersome installation, and a high susceptibility to failure. There are also designs that integrate the busbars and BMS together, such as patent document CN222980565U, which describes an integrated BMS structure including a plastic component and a BMS control board. The BMS control board is located at the center of the plastic component, and multiple busbars are located on the inner sides of the plastic component, with the multiple busbars arranged around the BMS control board. However, the existing method integrates the voltage acquisition line, temperature acquisition line, busbar and BMS into one part through low-pressure injection molding. The principle is to press the above components into plastic. The manufacturing process is not a one-piece structure, but is low-pressure injection molded together. The operation process is complicated. Before pressing, it is still a traditional wire connection method. There are problems such as damage to the circuit during the pressing process, and there is a risk of failure.

[0004] For portable power supplies used in high-altitude and cold regions, traditional methods for insulation performance mostly rely on passive solutions such as insulation cotton, which are not very effective. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an integrated lightweight battery module.

[0006] This invention provides a battery cell module with an integrated bus circuit board, including a single battery cell and a bus circuit board;

[0007] The number of individual battery cells is several, and the several individual battery cells are arranged in one or more columns along the horizontal direction;

[0008] The bus circuit board is a multi-functional structure that integrates BMS control circuit, single cell voltage acquisition circuit, temperature acquisition circuit, equalization circuit and heating circuit into one unit;

[0009] The bus circuit board has tab pads or vias for soldering the tabs of each individual battery cell. The tab pads or vias are electrically connected to each other through copper busbars integrated in the bus circuit board. After each individual battery cell is soldered to the corresponding tab pad or via, it forms a multi-cell module with the bus circuit board.

[0010] The busbar circuit board is a PCB board with two or more layers. The BMS control circuit and the individual cell voltage acquisition circuit are arranged on the top layer of the busbar circuit board, and the temperature acquisition circuit, the equalization circuit, and the heating circuit are arranged on the bottom layer of the busbar circuit board. The temperature acquisition circuit, the individual cell voltage acquisition circuit, and the equalization circuit are all connected to the corresponding tab pads or vias through copper busbars. The input terminal of the BMS control circuit is connected to the individual cell voltage acquisition circuit and the temperature acquisition circuit through copper busbars, respectively, and the output terminal is connected to the heating circuit and the equalization circuit through copper busbars, respectively.

[0011] Each individual cell voltage acquisition circuit has an on / off switch connected in series.

[0012] The temperature acquisition circuit includes one or more temperature sensors, each of which is arranged on the bottom layer of the busbar circuit board and connected to the BMS control circuit through the copper busbar inside the busbar circuit board.

[0013] The equalization circuit consists of multiple equalization resistors arranged in the middle area of ​​two rows of tab pads or vias on the bottom layer of the busbar circuit board. The number of equalization resistors is an integer multiple of the number of cells in the battery module. The equalization resistors are connected to each individual battery cell through copper busbars, tab pads or vias.

[0014] The heating circuit is arranged in the outer area of ​​each tab pad or via on the bottom layer of the bus circuit board.

[0015] The gap between the busbar circuit board and the battery cell assembly after welding is filled with thermally conductive adhesive, which is thermally conductive silicone or thermally conductive polyurethane adhesive.

[0016] The bus circuit board integrates a Type-C port and a DC bidirectional charging / discharging port.

[0017] The present invention also provides a lightweight battery, comprising a housing and a cell module as described in any one of claims 1-5, wherein the cell module is assembled inside the housing;

[0018] The battery casing is made of carbon fiber, and the top of the casing has a window to accommodate a Type-C and DC charging / discharging port.

[0019] It also includes solar panels;

[0020] The housing has multiple sets of magnetic contact groups and solar panel control switches on one side; each set of magnetic contact groups consists of a pair of positive and negative contacts, which are connected to the BMS control circuit on the busbar circuit board and the battery cell module to form an electrical circuit. The solar panel control switch is connected to the BMS control circuit on the busbar circuit board to form a control circuit.

[0021] The solar panel has an opening for a solar panel control switch and a second set of magnetic contacts corresponding to the first set of magnetic contacts. After the solar panel is attracted by the corresponding first set of magnetic contacts and the second set of magnetic contacts, a charging and discharging circuit is formed.

[0022] The solar panel is a multi-page foldable structure composed of multiple rectangular planes that integrate heating functions. After folding, the solar panel has the same dimensions as the shell structure and can be completely wrapped around the shell.

[0023] The overlapping edges of the folded solar panel have corresponding Velcro straps for easy securing after wrapping.

[0024] The solar panel has a four-layer structure from the inside out, consisting of a solar crystal panel, a buffer membrane, a heating film, and a nylon cloth.

[0025] The solar panel can charge the battery body after it is unfolded; when the solar panel control switch is turned on, the solar panel can provide supplemental heating to the human body, the battery body or other objects.

[0026] Compared with existing technologies, this invention integrates the BMS control circuit, individual cell voltage acquisition circuit, temperature acquisition circuit, equalization circuit, and heating circuit onto a busbar circuit board to form a multi-functional structure. This integration of the cell, busbar, and control circuit reduces complex wiring between units, simplifies product assembly, ensures product reliability, saves significant transfer space, and increases the energy density of the battery module. Simultaneously, utilizing the heat generated by the equalization resistor during charging equalization, it provides a heating source for the battery. Furthermore, the integrated heating circuit on the busbar circuit board allows for on-demand battery heating, ensuring low-temperature performance. Additionally, the battery casing features an integrated heating solar panel that magnetically attaches to the outer wall of the electromagnetic module and can be wrapped around the battery module. Unfolding and activating the heating switch allows for supplemental heating of the human body, the module itself, or other objects. The panel can also be attached to clothing or other surfaces via Velcro, and can be unfolded to charge the battery module. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the battery cell module provided in an embodiment of the present invention;

[0028] Figure 2 This is a schematic diagram of the battery module with the top cover removed, provided in an embodiment of the present invention.

[0029] Figure 3 This is a schematic diagram of the top surface layout of the bus circuit board provided in an embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram of the busbar circuit board and the top copper layer of the PCB provided in an embodiment of the present invention;

[0031] Figure 5 This is a schematic diagram of the bus circuit board and the copper-plated circuit in the middle layer of the PCB provided in an embodiment of the present invention;

[0032] Figure 6 This is a schematic diagram of the bottom layout of the busbar circuit board provided in an embodiment of the present invention;

[0033] Figure 7 This is a schematic cross-sectional view of a solar panel provided in an embodiment of the present invention;

[0034] Figure 8 This is a schematic diagram illustrating the relationship between the solar panel and the battery module provided in an embodiment of the present invention;

[0035] Figure 9 This is a schematic diagram of the outer surface structure of a solar panel provided in an embodiment of the present invention;

[0036] Figure 10 This is a schematic diagram of a battery module provided in an embodiment of the present invention;

[0037] Figure 11 This is a block diagram illustrating the control principle of the battery of the present invention;

[0038] In the diagram: 1-Single battery cell, 2-Busbar circuit board, 21-On / off switch element, 22-Type-C, DC bidirectional charging / discharging port, 23-Electrical tab pad or via, 24-BMS control circuit, 25-Single battery cell voltage acquisition circuit, 26-Communication circuit, 27-Copper busbar, 28-Heating circuit, 29-Temperature acquisition circuit, 30-Equalization circuit, 3-Thermal conductive adhesive, 4-Battery casing, 5-Solar panel, 51-Solar crystal panel, 52-Buffer diaphragm, 53-Heating film, 54-Nylon cloth, 55-Magnetic contact group one, 56-Solar panel control switch, 57-Hook and loop fastener, 6-Battery module. Detailed Implementation

[0039] The embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. The following detailed description of the embodiments and the accompanying drawings are used to illustrate the principles of the present invention by way of example, but should not be used to limit the scope of the present invention. That is, the present invention is not limited to the described preferred embodiments, and the scope of the present invention is defined by the claims.

[0040] In the description of this invention, it should be noted that, unless otherwise stated, "a plurality of" means two or more; the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance; those skilled in the art can understand the specific meaning of the above terms in this invention as appropriate.

[0041] like Figure 1-6 and Figure 11 As shown, the present invention provides a battery module with an integrated busbar circuit board, the battery module including a single battery cell 1 and a busbar circuit board 2;

[0042] The bus circuit board 2 is a multi-functional structure that integrates BMS control circuit 24, single cell voltage acquisition circuit 25, temperature acquisition circuit 29, equalization circuit 30, heating circuit 28, Type-C port and DC charging / discharging bidirectional port into one unit.

[0043] The number of individual battery cells 1 is several. These individual battery cells 1 are arranged in one or more columns along the horizontal direction.

[0044] The busbar circuit board 2 has tab pads or vias 23 for soldering the tabs of each individual battery cell 1. The solder points of the individual battery cells are electrically connected by copper busbars 27 to form a multi-cell module. The busbar circuit board 2 is a two-layer or multi-layer PCB board, and the copper busbars 27 are located within the multi-layer PCB board of the busbar circuit board 2. The busbar circuit board 2 can also serve as a fixing board for the battery module formed by the individual battery cells 1, ensuring its internal mechanical strength. The BMS control circuit 24 and the individual battery cell voltage acquisition circuit 25 are evenly and reasonably arranged on the top layer of the busbar circuit board 2, excluding the solder points and the copper busbar area. The temperature acquisition circuit 29, the equalization circuit 30, and the heating circuit 28 are evenly and reasonably arranged on the bottom layer of the busbar circuit board 2, excluding the core solder points and the copper busbar area.

[0045] Each individual cell voltage acquisition circuit 25 on the busbar circuit board 2 has an on / off switch 21. The individual cell 1 is soldered onto the busbar circuit board 2 in the following order: first, the high-frequency series is soldered, then the low-frequency series is soldered, and finally the on / off switch is closed. The on / off switch 21 is a DIP switch or a jumper cap. The on / off state of the on / off switch 21 allows the BMS control circuit 24 to be maintained under power-off conditions.

[0046] The temperature sensors of the temperature acquisition circuit 29 are arranged on the outer periphery and inner area of ​​the bottom layer of the bus circuit board, and there are one or more of them. The input end of the temperature sensor is connected to the corresponding tab pad or via 23 through the copper bus bar, and the output end is connected to the BMS control circuit 24 through the copper bus bar inside the bus circuit board 2.

[0047] The balancing resistors of the balancing circuit 30 are arranged in the middle area of ​​the tab soldering points of the individual cell 1 on the bottom layer of the busbar circuit board 2, and their number is an integer multiple of the number of battery modules in series 6. The number of balancing resistors is an integer multiple of the number of battery modules in series; the balancing resistors are connected to each individual cell through copper busbars, tab solder pads, or vias 23; the heating circuit 28 is arranged in the outer area of ​​each tab soldering point on the bottom layer of the busbar circuit board 2. The balancing circuit is used to actively activate the balancing function under low-temperature charging conditions, and heats the battery module while calibrating battery consistency, ensuring low-temperature charging safety; the heating circuit is used to actively activate the heating function when the battery module temperature is below -20℃ to ensure that the battery module can be charged and discharged stably; under charging conditions, the balancing circuit and the heating circuit can be activated simultaneously to ensure that the battery module heats up quickly, and in extremely cold conditions, the battery module is heated to a rechargeable temperature before charging is activated.

[0048] After the busbar circuit board 2 is soldered to the individual battery cell 1, the gap is filled with thermally conductive adhesive 3. The thermally conductive adhesive 3 can be either thermally conductive silicone or thermally conductive polyurethane adhesive.

[0049] like Figure 11 Temperature acquisition circuit 29, single cell voltage acquisition circuit 25 and equalization circuit 30 are all connected to the corresponding tab pads or vias 23 via copper busbars. The input terminal of BMS control circuit 24 is connected to single cell voltage acquisition circuit 25 and temperature acquisition circuit 29 via copper busbars, and the output terminal is connected to heating circuit 28 and equalization circuit 30 via copper busbars.

[0050] like Figure 2 and Figure 10 The present invention also provides a lightweight battery, including the cell module and the housing 4 described above. The cell module is assembled in the battery housing 4 to form a battery module 6. The battery housing 4 is made of carbon fiber, and the top of the battery housing 4 has a clearance port for a bidirectional DC charging and discharging port 22 such as Type-C or DC.

[0051] like Figure 8 and Figure 9 In another technical solution, the battery module 6 is covered by a solar panel 5. The side of the housing 4 has a magnetic contact group 1 55 and a solar panel control switch 56. The magnetic contact group 1 consists of positive and negative contacts. The positive and negative contacts and the wires of the solar panel control switch 56 are connected to the BMS, or they can be set on the top of the battery module. Similar to the Type-C method, the switching element is directly soldered to the busbar circuit board 2 and arranged through the opening at the top of the module housing. The solar panel 5 has a magnetic contact group 2 corresponding to the magnetic contact group 1. After the solar panel 5 is attracted by the corresponding magnetic contact group 1 and magnetic contact group 2, a charging and discharging circuit is formed.

[0052] Furthermore, the solar panel 5 is a multi-page foldable structure with integrated heating function. The solar panel 5 is a combination of multiple rectangular planes, each of which is similar in size to the surface of the shell 4. The shell has 6 surfaces, and the solar panel also has 6 surfaces. The size of the solar panel is exactly the same as the 6 surfaces of the shell, so that it can be completely and tightly wrapped around the shell. The solar panel 5 is attached to the outer wall of the battery module 6 through magnetic contact group 2. After folding, it is consistent with the structural size of the shell and can be wrapped around the outside of the battery module 6.

[0053] The solar panel can have more than 6 faces. The overlapping edges of the solar panel after folding it 5 times have corresponding Velcro straps for easy wrapping and securing. The Velcro straps are attached to the outer surfaces of adjacent solar panels.

[0054] like Figure 7 , Figure 8 The solar panel 5 has a four-layer structure from the inside out, namely, solar crystal panel 51, buffer membrane 52, heating film 53, and nylon cloth 54. The buffer membrane 52 ensures the heat preservation and impact resistance of the solar crystal panel 51 and the battery module 6. The nylon cloth 54 is a waterproof, wear-resistant, and impact-resistant nylon material. The output cables of the solar crystal panels 51 on multiple surfaces of the solar panel 5 are connected in series and then connected to the magnetic contact group two via wires.

[0055] When the solar panel 5 is unfolded, it can charge the battery module 6. When the solar panel 5 is unfolded and the solar panel control switch 56 is turned on, it can provide supplemental heating to the human body, the battery module 6 itself, or other objects. It can be attached to clothing and other object surfaces via Velcro 57. This invention is intended for use as a portable power source in high-altitude, cold regions. In high-altitude areas with low temperatures and high solar intensity, the battery module 6 can be charged using the solar panel or via the aforementioned Type-C, DC, or other bidirectional charging / discharging ports.

[0056] Solar panel 5 can charge the battery module through sunlight. The six sides of solar panel 5 encase the battery module, providing waterproofing and shock resistance, and when the heating function is activated, it heats the periphery of the battery module. When the solar panel is attached to the human body surface, the heating function provides a heat source.

[0057] Example

[0058] Reference Figure 1 It is a 7-in-1 parallel battery module. The weight of a single cell is 120g, the total weight of the 7 series is 840g, the weight of the bus circuit board 5 is 16.4g, the weight of the carbon fiber shell 7 is 74.6g, the weight of other components is 35.4g, and the total weight of the battery module is 966.4g. The actual assembly rate is 87%. The assembly rate will be higher if there are more single cells.

[0059] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A battery cell module with an integrated busbar circuit board, characterized in that: Includes individual battery cells (1) and busbar circuit boards (2); The single battery cell (1) is a plurality of cells, and the plurality of single battery cells (1) are arranged in one or more columns along the horizontal direction; The bus circuit board is a multi-functional structure that integrates BMS control circuit (24), single cell voltage acquisition circuit (25), temperature acquisition circuit (29), equalization circuit (30), and heating circuit (28) into one unit. The bus circuit board has tab pads or vias (23) for soldering the tabs of each individual battery cell. The tab pads or vias (23) are electrically connected to each other through copper busbars integrated in the bus circuit board (2). After each individual battery cell (1) is soldered to the corresponding tab pad or via (23), it forms a multi-cell module with the bus circuit board (2).

2. A battery cell module with an integrated busbar circuit board according to claim 1, characterized in that: The busbar circuit board (2) is a PCB board with two or more layers; the BMS control circuit (24) and the individual cell voltage acquisition circuit (25) are arranged on the top layer of the busbar circuit board (2), and the temperature acquisition circuit (29), the equalization circuit (30), and the heating circuit (28) are arranged on the bottom layer of the busbar circuit board (2). The temperature acquisition circuit (29), the individual cell voltage acquisition circuit (25), and the equalization circuit (30) are all connected to the corresponding tab pads or vias (23) through copper busbars. The input terminal of the BMS control circuit (24) is connected to the individual cell voltage acquisition circuit (25) and the temperature acquisition circuit (29) through copper busbars, and the output terminal is connected to the heating circuit (28) and the equalization circuit (30) through copper busbars.

3. A battery cell module with an integrated busbar circuit board according to claim 2, characterized in that: Each individual cell voltage acquisition circuit (25) is equipped with an on / off switch connected in series.

4. A battery cell module with an integrated busbar circuit board according to claim 1 or 3, characterized in that: The temperature acquisition circuit (29) includes one or more temperature sensors. Each temperature sensor is arranged on the bottom layer of the busbar circuit board (2) and connected to the BMS control circuit (24) through the copper busbar inside the busbar circuit board (2). The equalization circuit (30) consists of multiple equalization resistors arranged in the middle area of ​​the two rows of tab pads or vias (23) on the bottom layer of the bus circuit board (2). The number of equalization resistors is an integer multiple of the number of battery cell modules. The equalizing resistor is connected to each individual cell via a copper busbar, tab pad, or via (23); The heating circuit (28) is arranged in the outer area of ​​each tab pad or via (23) on the bottom layer of the bus circuit board (2).

5. A battery cell module with an integrated busbar circuit board according to claim 1, characterized in that: The gap between the bus circuit board (2) and the battery cell assembly after welding is filled with thermally conductive adhesive, which is thermally conductive silicone or thermally conductive polyurethane adhesive. The bus circuit board (2) integrates a Type-C port and a DC bidirectional charging / discharging port.

6. A lightweight battery, characterized in that: The battery module includes housing 4 and any one of claims 1-5, wherein the battery module is assembled inside housing (4); The battery casing is made of carbon fiber, and the top of the casing has a window to accommodate a Type-C and DC charging / discharging port.

7. A lightweight battery according to claim 6, characterized in that: It also includes solar panels (5); The housing (4) has multiple sets of magnetic contact group 1 (55) and solar panel control switch (56) on one side; each set of magnetic contact group 1 consists of a pair of positive and negative contacts, the positive and negative contacts are connected to the BMS control circuit (24) on the busbar circuit board (2) and the battery cell module to form an electrical circuit, and the solar panel control switch (56) is connected to the BMS control circuit (24) on the busbar circuit board (2) to form a control circuit; The solar panel (5) has an opening for a solar panel control switch (56) and a magnetic contact group two corresponding to the magnetic contact group one. After the solar panel (5) is attracted by the corresponding magnetic contact group one and magnetic contact group two, a charging and discharging circuit is formed.

8. A lightweight battery according to claim 6, characterized in that: The solar panel (5) is a multi-page foldable structure composed of multiple rectangular planes and integrating heating function. After folding, the solar panel (5) has the same size as the shell structure and can be completely wrapped around the shell.

9. A lightweight battery according to claim 7 or 8, characterized in that: The overlapping edge of the folded solar panel (5) has corresponding Velcro, which makes it easy to fix after wrapping.

10. A lightweight battery according to claim 9, characterized in that: The solar panel (5) has a four-layer structure from the inside out, namely, a solar crystal panel (51), a buffer membrane (52), a heating film (53), and a nylon cloth (54); The solar panel (5) can charge the battery body after it is unfolded; when the solar panel control switch (56) is turned on, the solar panel (5) can provide supplementary heating to the human body, the battery body or other objects.

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