Composite battery busbar and battery using same
Through direct ultrasonic welding of the flexible circuit board and the conductive bus block, the problems of excessive weight of the existing composite battery busbar and complex production processes are solved, and weight reduction, cost reduction and connection reliability are improved.
Patent Information
- Application Number
- CN202323388177.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-13
- Publication Date
- 2025-03-18
- Estimated Expiration
- 2033-12-13
AI Technical Summary
The existing composite battery busbars are bridged with nickel chips, resulting in the overall quality of the battery module, and the production process is complicated and the cost is high.
The flexible circuit board with integrated design is directly welded to the conductive bus block, eliminating the connection of nickel sheets, and the connection is achieved through ultrasonic welding, reducing weight and production processes.
It effectively reduces the weight of the composite battery busbar, simplifies production processes, reduces costs, and improves the reliability and corrosion resistance of connections.
Smart Images
Figure CN222637574U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of battery modules, in particular to a composite battery busbar and a battery using the same. Background Art
[0002] As the demand for the range of new energy vehicles continues to grow, the cost is gradually rising. How to increase the energy efficiency of power batteries and reduce the cost of battery components has become a focus of attention.
[0003] At present, for the composite battery busbars on the market, whether it is a hot pressing solution or a blister solution, laser welding of nickel sheets is usually used as a "bridge" to connect the flexible circuit board and the conductive bus block (commonly aluminum bar), that is, one end of the nickel sheet needs to be overlapped on the flexible circuit board and welded, and the other end needs to be overlapped on the conductive bus block and welded. This connection method will not only make the overall weight of the battery module heavier, but also require two welding processes. That is, the nickel sheet solution not only needs to go through the SMT process to weld the nickel sheet and the flexible circuit board, but also needs to go through the laser welding process to weld the conductive bus block and the nickel sheet together. In order to meet greater energy needs, the size of the battery module is getting larger and larger, which will further cause the weight of the battery pack to become heavier.
[0004] Therefore, it is of practical value to study a lighter composite battery busbar. Utility Model Content
[0005] The purpose of the utility model is to provide a composite battery busbar and a battery used therein, which eliminates the nickel sheet between the flexible circuit board and the conductive bus block, and solves the problem of the heavy overall mass of the battery module in the prior art by welding the flexible circuit board and the conductive bus block through an integrated design.
[0006] In order to solve the above technical problems, in the first technical scheme of the present application, a composite battery busbar is provided, comprising a conductor assembly and an insulating plate; the conductor assembly is installed on the insulating plate; the conductor assembly comprises a plurality of flexible circuit boards and a plurality of conductive bus blocks; a plurality of pad branch arms are integrally extended outward on the side walls of the flexible circuit boards, the pad branch arms are ultrasonically welded to the conductive bus blocks, and the welding points between the pad branch arms and the conductive bus blocks are coated with anaerobic adhesive. The ultrasonic welding of the plurality of pad branch arms formed by the integral extension to the conductive bus blocks can avoid the need for nickel sheets for bridge connection as in the prior art, thereby effectively reducing the weight of the composite battery busbar.
[0007] In some embodiments of the first technical solution, a plurality of notches are provided on the side walls of the flexible circuit board, and the pad branch arms extend outward from the notches and extend out of the notches, with a gap left between the pad branch arms and the edges of the notches. Through such a setting, the movable range of the pad branch arms is increased, and stress can be released when impacted by external force, making it less likely to break.
[0008] In some embodiments of the first technical solution, the extension plane of the pad branch arm is coplanar with the plane of the flexible circuit board, that is, the extended upper plane of the pad branch arm is coplanar with the upper plane of the flexible circuit board, and the extended lower plane of the pad branch arm is coplanar with the lower plane of the flexible circuit board, which maintains the structural integrity and facilitates processing.
[0009] In some embodiments of the first technical solution, the pad branch arm is a bent arm body, which can increase the range of motion of the branch arm after bending, and can play a role in stress release when the composite battery busbar is subjected to external force.
[0010] In some embodiments of the first technical solution, along the outward extension direction of the pad branch arm, the pad branch arm is sequentially provided with a constant diameter section, a reduced diameter section and a welding section; the constant diameter section is curved; the reduced diameter section gradually widens along the outward extension direction of the pad branch arm; the welding section is arranged outside the notch, and the arrangement of the reduced diameter section and the welding section can enable more complete contact during welding.
[0011] In some embodiments of the first technical solution, a plurality of first mounting seats and a plurality of second mounting seats are provided on the insulating board; adjacent first mounting seats are arranged relative to each other, and the first mounting seats are used to mount the flexible circuit board; a plurality of second mounting seats are arranged around the outer sides of the plurality of first mounting seats, a plurality of second mounting seats arranged between the plurality of first mounting seats are arranged in an array, and a plurality of second mounting seats arranged at the outermost sides of the plurality of first mounting seats are arranged in an array, and the second mounting seats are used to mount the plurality of conductive bus blocks, and the regular arrangement can effectively improve the utilization efficiency of the busbar space.
[0012] In some embodiments of the first technical solution, a window through hole is provided at the bottom of the second mounting seat, and the window through hole is used for the ultrasonic welding base to abut against the conductive bus block.
[0013] In some embodiments of the first technical solution, the conductive bus block is an aluminum bar.
[0014] In some embodiments of the first technical solution, the flexible circuit board is a flexible circuit board.
[0015] In some embodiments of the first technical solution, the insulating board is a blister insulation board.
[0016] In the second technical solution of the present application, a battery is provided, which uses the composite battery busbar described in the first technical solution. Since the composite battery busbar reduces weight, the battery using the composite battery busbar can also reduce weight, which is very important for battery research and development and production.
[0017] The beneficial effects of the utility model are as follows:
[0018] 1. In the first scheme of the present application, the flexible circuit board is directly welded to the conductive bus block through the integrated extension of the pad branch arm, eliminating the nickel sheet in the traditional technology. Compared with the original "bridge" scheme using nickel sheets, this connection only uses half of the "bridge" through the integrated design. On the one hand, it increases the integrity of the composite battery busbar, and on the other hand, it reduces the weight of the composite battery busbar and saves costs.
[0019] 2. In the first solution of the present application, the welding point between the flexible circuit board and the conductive bus block is coated with anaerobic adhesive, which can effectively avoid electrochemical corrosion between the flexible circuit board and the nickel sheet and also increase the bonding strength of the welding point.
[0020] 3. In the second solution of the present application, since the weight of the composite battery busbar is reduced, the weight of the battery can be further reduced, while the production process is streamlined, effectively saving production costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order to more clearly illustrate the technical solution of the present invention, the drawings required for use in the implementation mode will be briefly introduced below. Obviously, the drawings described below are only some implementation modes of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0022] Figure 1 It is an exploded schematic diagram of the overall structure provided by the preferred embodiment of the utility model;
[0023] Figure 2 It is a structural schematic diagram of an insulating plate provided in a preferred embodiment of the utility model;
[0024] Figure 3 It is a schematic diagram of the local structure of the connection between the flexible circuit board and the conductive bus block provided by the preferred embodiment of the utility model.
[0025] The reference numerals are as follows:
[0026] 1. Conductor assembly; 10. Flexible circuit board; 100. Pad branch arm; 1000. Constant diameter section; 1001. Variable diameter section; 1002. Welding section; 101. Notch; 11. Conductive bus block;
[0027] 2. Insulation plate; 20. First mounting seat; 21. Second mounting seat. DETAILED DESCRIPTION
[0028] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.
[0029] In the prior art, for composite battery busbars on the market, whether it is a hot pressing solution or a blister solution, laser welding of nickel sheets is usually used to connect the flexible printed circuit (FPC) and the conductive busbar (commonly known as aluminum bus). In order to meet greater energy demands, the size of the battery module is getting larger and larger, which in turn leads to an increasing weight of the battery pack.
[0030] To solve the above problems, please refer to Figure 3 This solution proposes a connection method between the flexible circuit board 10 and the conductive bus block 11 without the need for a nickel sheet and an intermediate medium, that is, a connection method in which the integrated flexible circuit board 10 and the conductive bus block 11 are directly welded, which reduces the weight of the busbar and saves costs.
[0031] In the embodiment of the present application, a composite battery busbar is provided, please refer to 1 to Figure 3 , including a conductor component 1 and an insulating plate 2; the conductor component 1 is installed on the insulating plate 2; the conductor component 1 includes a plurality of flexible circuit boards 10 and a plurality of conductive bus blocks 11; a plurality of pad branch arms 100 are integrally extended outward on the side wall of the flexible circuit board 10, the pad branch arms 100 are ultrasonically welded to the conductive bus block 11, and the welding part between the pad branch arms 100 and the conductive bus block 11 is coated with anaerobic adhesive. After adopting this setting mode, the pad branch arms 100 are integrated with the flexible circuit board 10, and are directly welded to the conductive bus block 11 through the pad branch arms 100, avoiding the prior art. A nickel sheet is required as a "bridge" for welding connection between the flexible circuit board 10 and the conductive bus block 11, that is, the surfaces at both ends of the nickel sheet should be overlapped and abutted on the surface of the flexible circuit board 10 and the surface of the conductive bus block 11, respectively, so as to form a "bridge"-like connection. In this solution, only the flexible circuit board 10 needs to integrally extend the pad branch arm 100 to be welded to the conductive bus block 11, which is equivalent to using only half of the "bridge" in the original technology. The amount of the connection part between the flexible circuit board 10 and the conductive bus block 11 is greatly reduced, which effectively reduces the weight of the composite battery busbar and effectively reduces the production cost of the battery busbar.
[0032] Among them, the flexible circuit board 10 is as follows Figure 3The area 1002 shown is copper on one side and a protective film on the other side. The density of copper is 8.96g / cm^3. The density of nickel in the original technology is 8.908g / cm^3. When used, the thickness of the nickel sheet is generally 0.3mm, while the thickness of the pad branch arm 100 is about 0.1mm, and the area of the nickel sheet is larger than the pad branch arm 100. Considering that a composite busbar removes multiple nickel sheets, this solution can effectively reduce the weight of the connecting part, thereby reducing the weight of the entire composite battery busbar, and ultimately reducing the weight of the entire battery.
[0033] It should be understood that the use of the nickel sheet solution not only requires the SMT process to weld the nickel sheet and the flexible circuit board 10, but also requires the laser welding process to weld the aluminum bar and the conductive bus block 11 together. In the present solution, only the ultrasonic welding process is required to weld the flexible circuit board 10 and the conductive bus block 11, which saves one process and improves production efficiency.
[0034] In this embodiment, anaerobic adhesive preferably uses acrylate. After adopting this setting method, an acrylate dispensing process is performed on the welding position of the flexible circuit board 10 and the conductive bus, which can reduce electrochemical corrosion and improve connection reliability. The material of the anaerobic adhesive includes but is not limited to acrylate, and those skilled in the art can select glue that can mainly reduce electrochemical corrosion.
[0035] In some embodiments of the present application, Figure 3 As shown, the flexible circuit board 10 is mounted on the insulating board 2, and one side of the welding section of the flexible circuit board 10 is copper, that is, Figure 3 The surface at the marked welding section 1002 is copper, and the other surface of the flexible circuit board 10 is PI (polyimide). The flexible circuit board 10 includes a board body and a pad branch arm 100. The board body and the pad branch arm 100 are formed as an integral whole. The pad branch arm 100 on the flexible circuit board 10 has a copper surface that is welded to the conductive bus block 11.
[0036] Furthermore, in order to reduce the weight of the composite battery busbar, Figure 3 As shown, a plurality of notches 101 are provided on the side wall of the flexible circuit board 10, and the pad branch arm 100 extends outward from the inner wall of the notch 101 and extends out of the notch 101, leaving a gap between the pad branch arm 100 and the edge of the notch 101. After adopting this setting method, the movable range of the pad branch arm 100 is increased, and the stress can be released when impacted by external force, and it is not easy to break.
[0037] Furthermore, in order to improve the space utilization of the composite battery busbar, Figure 3As shown, the extended plane of the pad branch arm 100 is coplanar with the plane of the flexible circuit board 10, that is, the extended upper plane of the pad branch arm 100 is coplanar with the upper plane of the flexible circuit board 10, and the extended lower plane of the pad branch arm 100 is coplanar with the lower plane of the flexible circuit board 10. The thickness of the pad branch arm 100 and the flexible circuit board 10 are kept consistent within the error range. After adopting this setting, the flexible circuit board 10 and the pad branch arm 100 are kept on the same plane, maintaining integrity and facilitating processing.
[0038] For the above-mentioned pad branch arm 100, as Figure 3 As shown, the pad branch arm 100 is a bent arm body. After adopting this arrangement, the activity range of the branch arm is increased, and the stress can be released when the composite battery busbar is subjected to external force.
[0039] Specifically, Figure 3 As shown, the pad branch arm 100 includes an integrated constant diameter section 1000, a reduced diameter section 1001 and a welding section 1002; along the outward extension direction of the pad branch arm 100, the constant diameter section 1000, the reduced diameter section 1001 and the welding section 1002 are arranged in sequence, and the surfaces of the constant diameter section 1000, the reduced diameter section 1001 and the welding section 1002 are smoothly transitioned and connected, that is, the constant diameter section 1000 is integrated with the flexible circuit board 10, and the two ends of the reduced diameter section 1001 are respectively connected to the constant diameter section 1000. 0 and the welding section 1002 are integrally connected, the constant diameter section 1000 is curved; the reduced diameter section 1001 gradually widens along the outward extension direction of the pad branch arm 100; the welding section 1002 is arranged outside the notch 101. After adopting this arrangement, on the one hand, the curved constant diameter section 1000 can reduce welding deformation, and on the other hand, the arrangement of the reduced diameter section 1001 makes the welding section 1002 widen synchronously, which can make it more fully contact with the conductive shunt block during welding, thereby improving the tightness of welding.
[0040] In some embodiments of the present application, Figure 3 As shown, the conductive bus block 11 is installed on the insulating plate 2, and the conductive bus block 11 is preferably made of aluminum bar.
[0041] In some embodiments of the present application, Figure 2 As shown, the insulating plate 2 is provided with a plurality of regularly arranged first mounting seats 20 and a plurality of second mounting seats 21, wherein the shape of the first mounting seat 20 matches the shape of the flexible circuit board 10, and the first mounting seat 20 is used to mount the flexible circuit board 10, and the shape of the second mounting seat 21 matches the shape of the conductive return block, and the second mounting seat 21 is used to mount a plurality of conductive bus blocks 11. After adopting this setting method, the regularly arranged method can increase the installation amount of the flexible circuit board 10 and the conductive bus block 11, and improve the utilization efficiency of the composite battery busbar installation space.
[0042] For the first mounting seat 20, if Figure 2 As shown, a plurality of first mounting seats 20 are arranged in parallel along the length direction of the insulating plate 2, and a plurality of support bars are provided at intervals on the first mounting seats 20 to support the installation of the flexible circuit board 10, wherein the number of the first mounting seats 20 is selected according to the needs of technical personnel in the field. In this example, the number of the first mounting seats 20 is preferably two.
[0043] For the second mounting base 21, if Figure 2 As shown, multiple second mounting seats 21 are arranged around the outer sides of the multiple first mounting seats 20, multiple second mounting seats 21 arranged between the multiple first mounting seats 20 are arranged in an array, and multiple second mounting seats 21 arranged at the outermost sides of the multiple first mounting seats 20 are arranged in an array, that is, multiple second mounting seats 21 are arranged around each first mounting seat 20 to maximize the number of connections between the flexible circuit board 10 and the conductive bus block 11.
[0044] Among them, a window through hole is also provided at the bottom of the second mounting base 21, and the window through hole is used to facilitate ultrasonic welding, that is, the welding base passes through the window through hole and abuts against the conductive bus block 11, and the welding head of the ultrasonic welding machine abuts against the pad branch arm 1002. Under the action of ultrasonic waves, the pad branch arm 100 and the conductive bus block 11 are welded together to achieve electrical transmission.
[0045] In some embodiments of the present application, the insulating board 2 is preferably a blister insulation board, which has excellent physical and mechanical properties, especially excellent impact resistance, high tensile strength, bending strength and compressive strength; small creep and dimensional stability; good heat resistance and low temperature resistance, stable mechanical properties, dimensional stability, electrical properties and flame retardancy in a wide temperature range, and can be used for a long time at -60 to 120°C; no obvious melting point, molten state at 220-230°C; due to the high rigidity of the molecular chain, the resin melt has high viscosity; low water absorption, small shrinkage, high dimensional accuracy, good dimensional stability, and low film permeability; it is a self-extinguishing material; stable to light, but not resistant to ultraviolet light, and has good weather resistance; oil-resistant and acid-resistant, and the rest of the panels that can achieve heat insulation and insulation can be selected by technical personnel in this field.
[0046] It should be understood that the installation of the conductive bus block 11 and the flexible circuit board 10 and the insulating board 2 is all completed by heat riveting.
[0047] From the above, it can be seen that the structure and principle of a composite battery busbar of the present application, and a battery using the above-mentioned composite battery busbar will be introduced below, which at least includes a shell, a battery pack and a composite battery busbar, the battery pack is arranged in the shell, the composite battery busbar is connected to the shell, and the conductive bus block (aluminum bar) of the composite battery busbar is connected to the electrode of the battery pack. After adopting this setting method, since the weight of the composite battery busbar is reduced, the weight of the overall battery will also be reduced, effectively reducing the production cost.
[0048] The above is a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several improvements and modifications without departing from the principle of the present invention. These improvements and modifications are also considered to be within the protection scope of the present invention.
Claims
1. A composite battery busbar, characterized in that: including a conductor assembly and an insulating plate; The conductor assembly is mounted on the insulating plate; The conductor assembly includes a plurality of flexible circuit boards and a plurality of conductive bus blocks; A plurality of pad branch arms are integrally extended outward from the side wall of the flexible circuit board, the pad branch arms are ultrasonically welded to the conductive bus block, and the welding points between the pad branch arms and the conductive bus block are coated with anaerobic adhesive.
2. The composite battery busbar according to claim 1, characterized in that: A plurality of notches are arranged on the side wall of the flexible circuit board, and the pad branch arms extend outward from the notches and extend out of the notches, with a gap being left between the pad branch arms and the edge of the notches.
3. The composite battery busbar according to claim 1, characterized in that: The extension plane of the pad branch arm is coplanar with the plane of the flexible circuit board.
4. The composite battery busbar according to claim 2, characterized in that: The pad branch arm is a bent arm body.
5. The composite battery busbar according to claim 4, characterized in that: Along the outward extension direction of the pad branch arm, the pad branch arm is provided with a constant diameter section, a reduced diameter section and a welding section in sequence; The constant diameter section is curved; The diameter-changing section gradually widens in the direction in which the pad branch arm extends outward; The welding section is arranged outside the notch.
6. The composite battery busbar according to claim 1, characterized in that: The insulating plate is provided with a plurality of first mounting seats and a plurality of second mounting seats; The adjacent first mounting seats are arranged opposite to each other, and the first mounting seats are used to mount the flexible circuit board; A plurality of the second mounting seats are arranged around the outer sides of the plurality of the first mounting seats, a plurality of the second mounting seats arranged between the plurality of the first mounting seats are arranged in an array, and a plurality of the second mounting seats arranged at the outermost sides of the plurality of the first mounting seats are arranged in an array, and the second mounting seats are used to mount the plurality of the conductive bus blocks.
7. The composite battery busbar according to claim 6, characterized in that: A window through hole is provided at the bottom of the second mounting seat.
8. The composite battery busbar according to claim 1, characterized in that: The conductive bus block is an aluminum bar.
9. The composite battery busbar according to claim 1, characterized in that: The insulating plate is a blister insulation plate.
10. A battery, characterized in that: A composite battery busbar as described in any one of claims 1 to 9 is applied.