Battery pack assembly

Abstract

The utility model relates to a battery pack assembly, which belongs to the field of automobile batteries and comprises a lower box body, an upper cover assembly and a battery cell, a plurality of battery cells are respectively arranged in the lower box body to form a battery pack; the upper cover assembly comprises an upper cover, an FPC wire harness and a contact structure. A plurality of branch wire harnesses of the FPC wire harness are respectively welded on the contact structures; a quick connector, an uncovering detection sensor and a BMS (Battery Management System) are respectively arranged at one end in the lower box body; one part of the quick connector is connected with the BMS; the plurality of FPC wire harnesses are respectively connected with the other part of the quick connector through patch cords; the cover opening detection sensor transmits a cover opening signal or a cover closing signal to the BMS; the upper cover assembly is arranged on the lower box body, and the contact structure is pressed on the series aluminum row to form the whole battery pack assembly; and the BMS is connected with the battery pack according to the cover opening signal and disconnected with the battery pack according to the cover closing signal. According to the utility model, industrial automatic production can be adopted, the production efficiency is high, the cost is low, and the safety is high.

Description

Technical Field

[0001] The utility model relates to the field of automobile batteries, in particular to a battery pack assembly. Background Art

[0002] In the battery pack of new energy vehicles, for safety reasons, the voltage and temperature of each battery cell need to be monitored and summarized in the BMS (Battery Management System). The BMS makes corresponding measures based on the actual data to avoid problems such as battery pack cell voltage imbalance and thermal runaway. The traditional solution is to connect and transmit signals through a wiring harness. The wiring harness is separated from the upper cover. After the wiring harness is welded on site, the upper cover is installed to seal the entire battery pack. There are the following problems:

[0003] 1. The traditional wiring harness connection solution requires welding the wiring harness connector to the aluminum busbar at the production site. However, due to the high line speed flexibility, the consistency of the welding position of the parts is poor, and the production efficiency is low. The differences generated during welding are difficult to trace and identify, and welding automation is difficult to achieve. Manual assembly is the only option, resulting in high costs for large-scale industrial production.

[0004] 2. Traditional wiring harness connection solutions cannot control the risks brought by excessive current, and are not as safe as FPC / FDC (Flexible Printed Circuit, Flexible Printed Circuit Board / Flexible Die-Cut Cable, Flexible Circuit Board) and other flexible wire speed solutions. Utility Model Content

[0005] In order to solve the above problems existing in the prior art, the utility model provides a battery pack assembly, which can realize automated production and improve the overall safety of the battery pack assembly.

[0006] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0007] A battery pack assembly, comprising a lower box body, an upper cover assembly and a battery cell;

[0008] A plurality of the battery cells are respectively installed in the lower box to form a battery pack; the battery cells in each row are grouped in pairs, and the upper ends of the two battery cells in each group are connected in series by welding a series aluminum bar;

[0009] The upper cover assembly includes an upper cover, an FPC harness and a contact structure; a plurality of the FPC harnesses are respectively fixed in the upper cover; a plurality of the contact structures on both sides of the FPC harness are respectively installed in the upper cover, and the position of the contact structure matches the position of the series aluminum bar; a plurality of branch harnesses of the FPC harness are respectively welded on the contact structure;

[0010] A quick connector, a cover opening detection sensor and a BMS are respectively installed at one end of the lower box; the quick connector is composed of two parts connected by a one-touch plug-in structure, one part of which is connected to the BMS; a plurality of FPC harnesses are respectively connected to the other part of the quick connector through adapter cables; the cover opening detection sensor is connected to the BMS, and is used to detect the cover opening signal and the cover closing signal of the lower box and the upper cover assembly, and transmit the cover opening signal or the cover closing signal to the BMS;

[0011] After the two parts of the quick connector are connected, the upper cover assembly is installed on the lower box body, and the contact structure is pressed onto the series aluminum bar to form the entire battery pack assembly; the BMS is connected to the battery pack according to the cover opening signal, and disconnected from the battery pack according to the cover closing signal.

[0012] Furthermore, the contact structure is an elastic contact connection structure.

[0013] Furthermore, the contact structure consists of a compression spring and a contact; the compression spring is sleeved on the contact, and the contact is assembled or riveted inside the upper cover; when the upper cover assembly is installed on the lower box body, one end of the compression spring is supported on the inner side of the upper cover, and the other end presses the contact onto the series aluminum bar through elastic force.

[0014] Furthermore, the contact is a T-shaped structure composed of a flat plate and a columnar structure, the flat plate is installed in the upper cover through the columnar structure; the compression spring is sleeved on the columnar structure; and the branch harness of the FPC harness is welded and connected to the inner side of the flat plate.

[0015] Furthermore, the quick connector is connected to a power switch provided in the BMS via a wiring harness.

[0016] Furthermore, the upper cover is an integral injection-molded part.

[0017] Furthermore, a fuse is installed on the FPC harness.

[0018] Furthermore, the plurality of battery cells are respectively assembled on the lower box body in a matrix arrangement, and the series-connected aluminum rows at the upper ends of two adjacent rows of battery cells are alternately arranged.

[0019] Furthermore, the upper cover has a limiting structure for installing the FPC wiring harness and an assembly socket for installing the contact structure; the position of the limiting structure matches the position between two adjacent rows of battery cells, and the FPC wiring harness is laid in the limiting structure; the position of the assembly socket matches the position of the series aluminum row, and the contact structure is installed in the assembly socket.

[0020] Furthermore, the FPC harness is fixed in the limiting structure by heat riveting.

[0021] Beneficial effects of the utility model:

[0022] The utility model has a simple structure, combines the battery pack with an integrally-injected upper cover and a flexible circuit of FPC / FDC, can be produced by industrial automation, has high production efficiency, few production bottlenecks, low production costs, and the produced battery pack assembly has high overall safety.

[0023] The utility model connects the FPC wiring harness with the series aluminum bar through an elastic contact structure, so that the FPC wiring harness and the series aluminum bar can be connected without welding, which can avoid welding again at the assembly site and greatly improve production efficiency.

[0024] The utility model centrally connects the FPC wiring harness to one end of the quick connector by means of terminal integration, realizes one-touch plug-in connection of the flexible circuit, and greatly improves the splitting efficiency.

[0025] The utility model can avoid false contact caused by contact deviation when the upper cover is not assembled in place by using the cover opening detection sensor. When the cover opening detection sensor detects that the upper cover is opened, the BMS can control the connection between the BMS and the battery pack according to the contact disconnection signal to achieve the purpose of protection. In addition, the flexible circuit of FPC / FDC can be blown when the current is overloaded by locally setting a fuse to avoid the risk of thermal runaway.

[0026] The flexible circuit of the FPC / FDC of the utility model has good overall shape and size consistency, which is convenient for automated welding and riveting using automated equipment to improve production efficiency, reduce production costs, and facilitate traceability and identification when problems occur. In addition, the upper cover assembly is a modular integrated structure, and the upper cover is a standardized one-piece injection molded part, which can be installed with FPC harnesses of consistent size, which is easy to realize automated separate production and facilitate the improvement of production capacity. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a schematic diagram of the battery pack assembly structure of the utility model;

[0028] Figure 2 This is a schematic diagram of the upper cover assembly of the utility model;

[0029] Figure 3 It is a schematic diagram of the contact structure in the utility model.

[0030] Among them: 1-lower box, 2-upper cover assembly, 3-battery cell, 4-series aluminum bar, 5-adapter, 6-quick connector, 7-opening detection sensor, 8-upper cover, 9-FPC wiring harness, 10-contact structure, 11-compression spring, 12-contact, 13-BMS. DETAILED DESCRIPTION

[0031] In order to enable those skilled in the art to better understand the technical solution of the present application, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0032] The terms such as up, down, left, right, front and back in this application document are based on the positional relationships shown in the drawings. If the drawings are different, the corresponding positional relationships may also change accordingly, so they cannot be understood as limiting the scope of protection.

[0033] In the present utility model, the terms "install", "connected", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, an integral connection, a mechanical connection, an electrical connection or mutual communication, a direct connection, an indirect connection through an intermediate medium, the internal connection of two components, or the interaction relationship between two components. For ordinary technicians in this field, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances.

[0034] This embodiment describes a battery pack assembly, which combines the structural features of the battery pack integral injection molded upper cover and the FPC / FDC flexible circuit solution to achieve a one-touch plug-and-unplug connection of the FPC / FDC flexible circuit. This embodiment is described using the FPC flexible circuit as an example.

[0035] like Figure 1 As shown, the battery pack assembly is mainly composed of a lower box body 1, an upper cover assembly 2 and a battery cell 3.

[0036] A plurality of battery cells 3 are respectively assembled on the lower box body 1 in a matrix arrangement to form a battery pack. The battery cells 3 in each row are grouped in pairs, and a series aluminum bar 4 is welded on the upper ends of two battery cells 3 in each group to connect the two battery cells 3 in series, and the series aluminum bars 4 on the upper ends of two adjacent rows of battery cells 3 are arranged alternately.

[0037] The quick connector 6, the cover opening detection sensor 7 and the BMS13 are respectively installed at one end of the lower box body 1. The quick connector 6 consists of a male head and a female head, and the male head and the female head can be quickly connected and separated through a one-button plug-in structure. The installation direction of the male head and the female head does not affect its one-button plug-in. The following takes the female head of the quick connector 6 installed at one end of the inner side of the lower box body 1 as an example to illustrate the use of the quick connector 6 in this embodiment. The female head is connected to the power switch set in the BMS13 through a wiring harness. Under the control of the BMS13, the power switch can be closed and disconnected, thereby controlling the battery pack to supply power to the outside. The cover opening detection sensor 7 is connected to the BMS13 signal, which is used to detect the cover opening signal and cover closing signal of the upper cover assembly 2 and the lower box body 1, and transmit the cover opening signal or cover closing signal to the BMS13.

[0038] like Figure 2 As shown, the upper cover assembly 2 is mainly composed of an upper cover 8 , an FPC wiring harness 9 and a contact structure 10 .

[0039] The upper cover 8 is an integrally molded part, and has an opening at its bottom, the size of which matches the size of the battery pack. The inner side of the top of the upper cover 8 has a limit structure for installing the FPC harness 9 and an assembly card seat for installing the contact structure 10, and multiple assembly cards are alternately arranged on both sides of the limit structure. After the battery pack assembly structure is set, the upper cover 8 can be automatically injection molded as a standardized injection molded part, with high production efficiency.

[0040] Preferably, the position of the limiting structure matches the position between two adjacent rows of battery cells 3, and the limiting structure can be a long slot, along which the FPC harness 9 is laid. A plurality of FPC harnesses 9 are fixed in the limiting structure by hot riveting.

[0041] The position of the assembly card seat matches the position of the series aluminum bar 4. The assembly card seat can be a column hole or a groove structure, etc., for assembling or riveting the contact structure 10, and the inner diameter of the assembly card seat matches the size of the connection part of the contact structure 10.

[0042] The contact structure 10 of this embodiment is an elastic contact connection structure. Figure 3 As shown, the contact structure 10 is composed of a compression spring 11 and a contact 12. The contact 12 is a T-shaped structure composed of a flat plate and a columnar structure. The columnar structure is installed in the middle of one side of the flat plate. The flat plate is used to contact the series aluminum bar 4. The columnar structure is a connecting part, which is used to be assembled or riveted in the assembly socket of the upper cover 8.

[0043] When assembling the multiple contact structures 10, firstly, the compression spring 11 is sleeved on the columnar structure of the contact 12, and then the columnar structure is assembled or riveted into the assembly base, so that the flat plate of the contact 12 is placed at the outer end of the assembly base opening.

[0044] The FPC harness 9 is composed of branch harnesses according to the number of series aluminum bars 4 to be connected, and the ends of the branch harnesses are separated according to the designed positions of the series aluminum bars 4, and the ends of the branch harnesses are welded one by one on the inner side of the plate of the contact 12 (i.e., the side close to the columnar structure).

[0045] The harness connector of the FPC harness 9 is connected to one end of the adapter wire 5, and the other ends of the multiple adapter wires 5 are respectively connected to the male connectors of the quick connector 6, thereby integrating one end of the multiple FPC harnesses 9. When the male connector and the female connector of the quick connector 6 are connected with one click, the quick connector 6, the FPC harness 9, the contact structure 10 and the BMS 13 together form an FPC flexible circuit.

[0046] The upper cover assembly 2 is buckled on the lower box body 1 through the upper cover 8 and assembled and connected by bolts to form the entire battery pack assembly.

[0047] In the battery pack assembly, the compression spring 11 is compressed, one end of the compression spring 11 is supported on the inner side of the upper cover 8, and the other end presses the contact 12 on the series aluminum bar 4 through elastic force, so that the FPC harness 9 is connected to the series aluminum bar 4, and the FPC harness 9 and the series aluminum bar 4 can be connected without welding. At the same time, the cover opening detection sensor 7 contacts the upper cover 8, and the cover opening detection sensor 7 detects that the upper cover assembly 2 and the lower box 1 have been assembled in place, and transmits the cover closing signal to BMS13. BMS13 determines that the upper cover assembly 2 and the lower box 1 have been assembled in place according to the cover closing signal, closes the power supply switch, connects the battery pack with BMS13, and supplies power to the outside. When the cover opening detection sensor 7 detects that the upper cover 8 is opened, BMS13 disconnects the power supply switch according to the cover opening signal, that is, disconnects the connection with the battery pack, and stops the battery pack from supplying power, thereby achieving the purpose of protection.

[0048] In this embodiment, a fuse is also installed on the FPC harness 9, which can be blown when the current is overloaded, cutting off the FPC harness 9 to avoid the risk of thermal runaway.

[0049] In addition, the upper cover assembly 2 of the present embodiment, the standardized production of the upper cover 8, and the assembly of the FPC harness 9 and the contact structure 10 can all be completed in other workshops or places through the production and assembly of automated equipment, which is highly efficient and convenient for tracing and identifying problems. This can avoid the production capacity constraints caused by the concentration of materials in one location and also reduce production costs.

[0050] Although the principle of the present invention is described in detail above in conjunction with the preferred embodiments of the present invention, those skilled in the art should understand that the above embodiments are merely explanations of the exemplary implementation of the present invention, and are not intended to limit the scope of the present invention. The details in the embodiments do not constitute limitations on the scope of the present invention. Without departing from the spirit and scope of the present invention, any obvious changes such as equivalent transformations and simple replacements based on the technical solution of the present invention fall within the scope of protection of the present invention.

Claims

1. A battery pack assembly, characterized in that: The battery pack assembly comprises a lower box body (1), an upper cover assembly (2) and a battery cell (3); A plurality of the battery cells (3) are respectively installed in the lower box (1) to form a battery pack; the battery cells (3) in each row of the battery cells (3) are grouped in pairs, and the upper ends of the two battery cells (3) in each group are connected in series by welding a series aluminum bar (4); The upper cover assembly (2) comprises an upper cover (8), an FPC wiring harness (9) and a contact structure (10); a plurality of the FPC wiring harnesses (9) are respectively fixed in the upper cover (8); a plurality of the contact structures (10) are respectively installed in the upper cover (8) on both sides of the FPC wiring harness (9), and the positions of the contact structures (10) match the positions of the series-connected aluminum bars (4); a plurality of branch wiring harnesses of the FPC wiring harness (9) are respectively welded on the contact structures (10); A quick connector (6), a cover opening detection sensor (7) and a BMS (13) are respectively installed at one end of the lower box (1); the quick connector (6) is composed of two parts connected by a one-touch plug-in structure, one part of which is connected to the BMS (13); a plurality of FPC harnesses (9) are respectively connected to the other part of the quick connector (6) through adapter cables (5); the cover opening detection sensor (7) is connected to the BMS (13) and is used to detect the cover opening signal and the cover closing signal of the lower box (1) and the upper cover assembly (2), and transmit the cover opening signal or the cover closing signal to the BMS (13); After the two parts of the quick connector (6) are connected, the upper cover assembly (2) is installed on the lower box (1), and the contact structure (10) is pressed onto the series aluminum bar (4) to form the entire battery pack assembly; the BMS (13) is connected to the battery pack according to the cover opening signal, and is disconnected from the battery pack according to the cover closing signal.

2. The battery pack assembly according to claim 1, characterized in that: The contact structure (10) is an elastic contact connection structure.

3. The battery pack assembly according to claim 2, characterized in that: The contact structure (10) is composed of a compression spring (11) and a contact (12); the compression spring (11) is sleeved on the contact (12), and the contact (12) is assembled or riveted inside the upper cover (8); when the upper cover assembly (2) is installed on the lower box body (1), one end of the compression spring (11) is supported on the inner side of the upper cover (8), and the other end presses the contact (12) onto the series aluminum bar (4) through elastic force.

4. The battery pack assembly according to claim 3, characterized in that: The contact (12) is a T-shaped structure composed of a flat plate and a columnar structure; the flat plate is installed in the upper cover (8) through the columnar structure; the compression spring (11) is sleeved on the columnar structure; and the branch wire harness of the FPC wire harness (9) is welded and connected to the inner side of the flat plate.

5. The battery pack assembly according to claim 1, characterized in that: The quick connector (6) is connected to a power supply switch arranged in the BMS (13) via a wiring harness.

6. The battery pack assembly according to claim 1, characterized in that: The upper cover (8) is an integral injection-molded part.

7. The battery pack assembly according to claim 1, characterized in that: A fuse is installed on the FPC harness (9).

8. The battery pack assembly according to claim 1, characterized in that: The plurality of battery cells (3) are respectively assembled on the lower box body (1) in a matrix arrangement, and the series-connected aluminum rows (4) at the upper ends of two adjacent rows of battery cells (3) are arranged alternately.

9. The battery pack assembly according to claim 1, characterized in that: The upper cover (8) has a limiting structure for installing the FPC wiring harness (9) and an assembly card seat for installing the contact structure (10); the position of the limiting structure matches the position between two adjacent rows of the battery cells (3), and the FPC wiring harness (9) is laid in the limiting structure; the position of the assembly card seat matches the position of the series-connected aluminum row (4), and the contact structure (10) is installed in the assembly card seat.

10. The battery pack assembly according to claim 9, characterized in that: The FPC harness (9) is fixed in the limiting structure by heat riveting.

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