Battery pack signal sampling wire harness

Abstract

The utility model provides a battery pack signal sampling wire harness, which comprises a first flexible circuit board, a second flexible circuit board and a right-angle crimping terminal, a plurality of first copper conductors are parallelly arranged on the first flexible circuit board at intervals, and a plurality of second copper conductors are parallelly arranged on the second flexible circuit board at intervals. The end part of the second flexible circuit board is vertically connected with the end part of the first flexible circuit board, and the first copper conductor and the second copper conductor are fixedly connected through a right-angle crimping terminal. The two FPCs are vertically spliced to form the special-shaped circuit board structure, so that the waste of copper foil materials can be effectively reduced. By using the right-angle crimping terminal, a plastic sheath and a related assembly process thereof are omitted, and the manufacturing process is simplified. Compared with a traditional plugging mode, the crimping mode is simple in process and low in cost. The connection between the copper conductors between the two flexible circuit boards is realized through the right-angle crimping terminals, so that not only can firm physical connection be provided, but also the reliability of electrical connection can be ensured.

Description

Technical Field

[0001] The utility model relates to the technical field of battery packs, in particular to a signal sampling wire harness for a battery pack. Background Art

[0002] In the technical field of battery packs, the mainstream solution for the transmission of cell sampling signals is mainly CCS (Battery Management System) plus a patch cord. However, with the increasing demand for battery power in battery packs, the number of integrated cells has also increased, resulting in a more compact electrical layout space inside the battery pack. Traditional wires and connectors occupy a large amount of space, causing design limitations.

[0003] To solve this problem, it has become a future development trend to use FPC (Flexible Printed Circuit) wire harnesses that occupy less space. FPC usually uses copper foil as the base material and is made into a wire harness through etching or die-cutting processes. Although FPC has the potential to replace traditional sampling wire harnesses in battery packs, the processing of the copper foil base material into a special-shaped structure during its production results in a large amount of waste of surplus materials, increasing costs.

[0004] Therefore, using multiple FPCs spliced together to achieve the required special-shaped structure has become a feasible solution. This method can effectively reduce the waste of copper foil, but the current splicing solutions usually adopt the methods of inserting plastic sheaths into each other or directly inserting terminals into plastic sheaths. These two solutions have the defects of high cost and large space occupation at the connection. Summary of the Utility Model

[0005] In view of this, the utility model provides a signal sampling wire harness for a battery pack to solve problems such as the compact electrical layout, large space occupation, and high cost of traditional sampling wire harnesses.

[0006] The technical solution of the utility model is realized as follows:

[0007] The utility model provides a signal sampling wire harness for a battery pack, including a first flexible printed circuit board, a second flexible printed circuit board, and a right-angle crimping terminal. A plurality of first copper conductors are arranged in parallel at intervals on the first flexible printed circuit board, and a plurality of second copper conductors are arranged in parallel at intervals on the second flexible printed circuit board. The end of the second flexible printed circuit board is vertically connected to the end of the first flexible printed circuit board, and the first copper conductors and the second copper conductors are fixedly connected through the right-angle crimping terminal.

[0008] On the basis of the above technical solution, preferably, the ends of the first flexible printed circuit board and the second flexible printed circuit board form a 45-degree bevel joint, and both ends of the right-angle crimping terminal are fixedly connected to the ends of the first copper conductors and the second copper conductors by crimping.

[0009] On the basis of the above technical solution, preferably, it also includes a third flexible circuit board connected to the first flexible circuit board or the second flexible board, and a plurality of third copper conductors are arranged in parallel and spaced apart on the third flexible circuit board, and the third copper conductor and the second copper conductor or the first copper conductor are fixedly connected by a linear crimping terminal.

[0010] On the basis of the above technical solution, preferably, it also includes a jumper type crimping terminal, which is arranged on the first flexible circuit board or the second flexible circuit board or the third flexible circuit board, and the two ends of the jumper type crimping terminal are respectively fixed to two different copper conductors on the flexible circuit board by crimping.

[0011] Further, preferably, the jumper type crimping terminal is wrapped with an insulating sleeve.

[0012] On the basis of the above technical solution, preferably, both the right-angle crimping terminal and the straight crimping terminal include metal terminals.

[0013] Further, preferably, the right-angle crimping terminal, the straight crimping terminal and the jumper crimping terminal all include metal sheets, and crimping contacts are respectively provided on both end surfaces of the metal sheets.

[0014] On the basis of the above technical solution, preferably, a reinforcing plate made of epoxy resin is provided on the back of the connection between the first flexible circuit board, the second flexible circuit board and the third flexible circuit board, and the reinforcing plate is fixedly connected to the flexible circuit board by heat riveting.

[0015] On the basis of the above technical solution, preferably, sealant is coated at the crimping points between the right-angle crimping terminal, the straight crimping terminal and the jumper crimping terminal and the copper conductor.

[0016] Compared with the prior art, the utility model has the following beneficial effects:

[0017] (1) By vertically splicing two FPCs to form a heterogeneous circuit board structure, the waste of copper foil materials can be effectively reduced. By using right-angle crimping terminals, the plastic sheath and its related assembly process are eliminated, simplifying the manufacturing process. Compared with the traditional plug-in method, the crimping method is simple and low-cost. The right-angle crimping terminals are used to connect the copper conductors between the two flexible circuit boards, which not only provides a firm physical connection, but also ensures the reliability of the electrical connection.

[0018] (2) The 45-degree bevel joint can enable the flexible printed circuit board to better adapt to the internal space layout of the battery pack. This connection method can achieve more flexible and compact wiring within a limited space, effectively utilize the space, and reduce interference. By optimizing the joint angle and crimping process, the material utilization is more efficient, reducing material waste caused by irregular structures, thereby further reducing production costs. The 45-degree joint angle helps to optimize the conductor path, reduce bends and path irregularities in signal transmission, and further improve electrical performance.

[0019] (3) By introducing a third flexible printed circuit board, the use of a single large-sized copper foil can be avoided, thus reducing material waste. The shorter printed circuit board is easier to use standard-sized copper foil materials, reducing material costs. At the same time, the shorter flexible printed circuit board has lower manufacturing difficulty, simpler production processes, and is easier to achieve automated production. (4) By setting up cross-connect type crimp terminals, signal cross-connection can be directly achieved on the flexible printed circuit board, reducing the length of the signal transmission path, reducing signal attenuation and interference, and improving signal transmission quality. The cross-connect type crimp terminals can reduce unnecessary wire winding and jumpers, improving the neatness and reliability of the circuit.

[0020] (5) Using metal crimp terminals as the connection medium between flexible printed circuit boards, compared with the traditional soldering (brazing) scheme, the terminal crimping is more secure, with better mechanical strength; it is not easy to produce loose connections, and the electrical performance is better; compared with the traditional soldering (brazing) scheme, the melting point of the metal terminal (usually copper) is higher than that of tin, and the heat resistance performance is better than that of tin, and it can be applied to high-temperature environments at the same time. Description of the Drawings

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0022] Figure 1 It is a front three-dimensional structural schematic diagram of the signal acquisition wire harness of the battery pack disclosed by the present invention;

[0023] Figure 2 It is a three-dimensional structural schematic diagram of three types of crimp terminals disclosed by the present invention;

[0024] Figure 3 It is a back three-dimensional structural schematic diagram of the signal acquisition wire harness of the battery pack disclosed by the present invention; Reference numerals:

[0025] 1. First flexible printed circuit board; 2. Second flexible printed circuit board; 3. Right-angle crimp terminal; 11. First copper conductor; 21. Second copper conductor; 4. Third flexible printed circuit board; 41. Third copper conductor; 5. Straight crimp terminal; 6. Cross-connecting crimp terminal; 61. Insulating sleeve; 31. Metal sheet; 32. Pressing contact point; 7. Reinforcing plate. Detailed implementation mode

[0026] Next, in combination with the implementation mode of the present invention, the technical solutions in the implementation mode of the present invention will be clearly and completely described. Obviously, the described implementation mode is only a part of the implementation modes of the present invention, rather than all the implementation modes. Based on the implementation modes in the present invention, all other implementation modes obtained by those of ordinary skill in the art without creative efforts belong to the protection scope of the present invention.

[0027] As Figure 1 shown, in combination with Figures 2-3 , the present invention discloses a signal sampling wire harness for a battery pack, including a first flexible printed circuit board 1, a second flexible printed circuit board 2 and a right-angle crimp terminal 3.

[0028] A plurality of first copper conductors 11 are arranged in parallel at intervals on the first flexible printed circuit board 1, and a plurality of second copper conductors 21 are arranged in parallel at intervals on the second flexible printed circuit board 2. In this embodiment, both the first copper conductor 11 and the second copper conductor 21 are realized by an etching process, and these copper conductors are the wires on the flexible printed circuit board.

[0029] The end of the second flexible printed circuit board 2 is vertically connected to the end of the first flexible printed circuit board 1, and the first copper conductor 11 and the second copper conductor 21 are fixedly connected through a right-angle crimp terminal 3.

[0030] The processing of the special-shaped structure of the traditional FPC will cause a large amount of material waste. By vertically splicing two FPCs to form a special-shaped circuit board structure, the waste of copper foil materials can be effectively reduced. By using the right-angle crimp terminal 3 for connection, it is possible to avoid methods such as inserting plastic sheaths or directly inserting terminals into plastic sheaths, improve the material utilization rate, and reduce the production cost.

[0031] By using the right-angle crimp terminal 3, the plastic sheath and its related assembly processes are omitted, thus simplifying the manufacturing process. Compared with the traditional plug-in method, the crimping method has a relatively simple process and low cost. By using the right-angle crimp terminal 3 to realize the connection between the copper conductors of two flexible printed circuit boards, it can not only provide a firm physical connection, but also ensure the reliability of the electrical connection. The design of the crimp terminal can ensure good contact between the copper conductors, reduce the resistance, and improve the stability and efficiency of signal transmission.

[0032] As some preferred embodiments, the end of the first flexible circuit board 1 and the end of the second flexible circuit board 2 form a 45-degree bevel joint, and the two ends of the right-angle crimping terminal 3 are respectively fixed to the end of the first copper conductor 11 and the end of the second copper conductor 21 by crimping.

[0033] The 45-degree bevel joint allows the flexible circuit board to better adapt to the spatial layout inside the battery pack. This connection method can achieve more flexible and compact wiring in a limited space, effectively utilize space, and reduce interference. By optimizing the joint angle and crimping process, material utilization is more efficient, reducing material waste caused by special-shaped structures, thereby further reducing production costs. The 45-degree joint angle helps to optimize the conductor path, reduce bends and path irregularities in signal transmission, and further improve electrical performance.

[0034] Since the flexible circuit boards that need to be arranged in the battery pack are relatively long, for example, the first flexible circuit board 1 or the second flexible circuit board 2 needs to be relatively long, if a single large-size copper foil is directly used for processing, on the one hand, it will cause waste of materials, and on the other hand, the large-size copper foil may need to be customized, which is costly.

[0035] Therefore, when a longer flexible circuit board needs to be arranged, a third flexible circuit board 4 can also be set up. The third flexible circuit board 4 is used to connect with the first flexible circuit board 1 or the second flexible board. A plurality of third copper conductors 41 are arranged in parallel and at intervals on the third flexible circuit board 4. The third copper conductor 41 and the second copper conductor 21 or the first copper conductor 11 are fixedly connected by a linear crimping terminal 5.

[0036] By introducing the third flexible circuit board 4, the use of a single large-sized copper foil can be avoided, thereby reducing material waste. Shorter circuit boards are more likely to use copper foil materials of standard sizes, reducing material costs. By using shorter flexible circuit boards to connect to each other, standard-sized copper foil materials can be used to reduce production costs. Shorter flexible circuit boards are less difficult to manufacture, the production process is simpler, and automated production is easy to achieve, reducing manufacturing costs. Shorter flexible circuit boards are easier to install and arrange, especially inside battery packs with limited space, which improves the convenience and flexibility of installation.

[0037] The signal sampling harness of this embodiment also includes a jumper-type crimping terminal 6, which can be arranged on the first flexible circuit board 1, the second flexible circuit board 2 or the third flexible circuit board 4. The two ends of the jumper-type crimping terminal 6 are respectively fixed to two different copper conductors on the flexible circuit board by crimping.

[0038] The bridging type crimp terminal 6 provides a flexible electrical connection method, which can achieve bridging connections between different copper conductors as needed, adapt to the requirements of complex circuit designs, allow multi-level electrical connections to be realized on a single flexible printed circuit board, optimize the space layout of the printed circuit board, and improve the flexibility and efficiency of circuit design.

[0039] By setting the bridging type crimp terminal 6, signal bridging can be directly achieved on the flexible printed circuit board, reducing the length of the signal transmission path, reducing signal attenuation and interference, and improving signal transmission quality. The bridging type crimp terminal 6 can reduce unnecessary wire winding and jumpers, improving the neatness and reliability of the circuit.

[0040] Preferably, the bridging type crimp terminal 6 is wrapped with an insulating sleeve 61, which can prevent the bridging type crimp terminal 6 from contacting and short-circuiting with other copper conductors, effectively reducing the electrical interference between the bridging type crimp terminals 6, and improving the transmission quality and stability of the signal sampling wire harness.

[0041] In this embodiment, the right-angle type crimp terminal 3 is used to achieve electrical connections in the vertical direction in the battery pack signal sampling wire harness. The straight type crimp terminal 5 is used to achieve straight electrical connections in the same plane in the battery pack signal sampling wire harness. The bridging type crimp terminal 6 is used to achieve electrical connections across different copper conductors.

[0042] The right-angle type crimp terminal 3, the straight type crimp terminal 5, and the bridging type crimp terminal 6 are all metal terminals. Since the terminals are all made of metal materials, they have excellent electrical conductivity, ensuring stable and low-loss transmission of electrical signals in the sampling wire harness. The high mechanical strength of the metal terminals ensures reliability during the crimping process and in use, and they are not easily deformed or broken due to mechanical stress.

[0043] The high electrical conductivity and mechanical strength of the metal terminals ensure the reliability of each connection point in the battery pack signal sampling wire harness, avoiding poor connections caused by factors such as temperature changes and vibrations. The high electrical conductivity of the metal terminals ensures low signal loss during the transmission of the battery pack signal sampling wire harness, maintaining the stability of the circuit and the integrity of the signal.

[0044] In this embodiment, the right-angle type crimp terminal 3, the straight type crimp terminal 5, and the bridging type crimp terminal 6 all include a metal sheet 31. The metal sheet 31 is made of a metal material with high electrical conductivity and high mechanical strength, such as copper or copper alloy. Pressing contact points 32 are respectively arranged on the two end surfaces of the metal sheet 31 for reliable mechanical connection with the connection ends of the copper conductors in the flexible printed circuit board, ensuring a stable and low-resistance electrical connection between the copper conductors between the flexible circuits, and at the same time improving the mechanical strength of the connection points.

[0045] Using a crimp terminal as the connection medium between flexible printed circuit boards, compared with the traditional soldering (brazing) solution, the terminal crimping is more reliable and has better mechanical strength; it is not easy to produce loose connections and has better electrical performance; compared with the traditional soldering (brazing) solution, the metal terminal (usually made of copper) has a higher melting point than tin and better temperature resistance, and can be applied to high-temperature environments at the same time.

[0046] As some preferred embodiments, a reinforcing plate 7 made of epoxy resin is provided on the back of the connection of the first flexible printed circuit board 1, the second flexible printed circuit board 2 and the third flexible printed circuit board 4, and the reinforcing plate 7 is fixedly connected to the flexible printed circuit board by a thermal riveting method.

[0047] The reinforcing plate 7 made of epoxy resin increases the mechanical strength of the connection of the flexible printed circuit board and prevents breakage or damage caused by mechanical stresses such as bending and stretching. The reinforcing plate 7 is fixed at the connection of the flexible printed circuit board by a thermal riveting method, ensuring the stability of the connection and avoiding unstable electrical connection caused by mechanical vibration or impact.

[0048] In specific implementation, a reinforcing plate 7 made of epoxy resin is provided on the back of the connection of the flexible printed circuit board. The reinforcing plate 7 and the flexible printed circuit board are heated to a certain temperature by a thermal riveting device, and then pressure is applied to firmly fix them together to ensure the mechanical strength and electrical stability of the connection.

[0049] As some preferred embodiments, a sealing glue is coated on the crimping parts of the right-angle crimp terminal 3, the straight-line crimp terminal 5 and the cross-connection crimp terminal 6 with the copper conductor. After the crimping is completed, the sealing glue is used to coat the crimping part. The coating of the sealing glue ensures that the crimping part is not affected by environmental factors and improves the long-term stability and reliability of the connection. The sealing glue can isolate oxygen and other corrosive substances in the air, preventing the oxidation and corrosion of the copper conductor and the terminal. After curing, the sealing glue forms a protective layer, increasing the mechanical strength of the crimping part and preventing loosening or breakage caused by external forces.

[0050] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A battery pack signal sampling wire harness, characterized in that: The invention comprises a first flexible circuit board (1), a second flexible circuit board (2) and a right-angle crimping terminal (3); a plurality of first copper conductors (11) are arranged in parallel and at intervals on the first flexible circuit board (1); a plurality of second copper conductors (21) are arranged in parallel and at intervals on the second flexible circuit board (2); an end of the second flexible circuit board (2) is vertically connected to an end of the first flexible circuit board (1); and the first copper conductor (11) and the second copper conductor (21) are fixedly connected via the right-angle crimping terminal (3).

2. The battery pack signal sampling wire harness according to claim 1, wherein: The end of the first flexible circuit board (1) and the end of the second flexible circuit board (2) are joined at a 45-degree angle, and the two ends of the right-angle crimping terminal (3) are respectively fixed to the end of the first copper conductor (11) and the end of the second copper conductor (21) by crimping.

3. The battery pack signal sampling wire harness according to claim 2, characterized in that: The invention also comprises a third flexible circuit board (4) connected to the first flexible circuit board (1) or the second flexible circuit board, wherein a plurality of third copper conductors (41) are arranged in parallel and at intervals on the third flexible circuit board (4), and the third copper conductor (41) is fixedly connected to the second copper conductor (21) or the first copper conductor (11) via a linear crimping terminal (5).

4. The battery pack signal sampling wire harness according to claim 3, characterized in that: It also includes a jumper-type crimping terminal (6), which is arranged on the first flexible circuit board (1) or the second flexible circuit board (2) or the third flexible circuit board (4), and the two ends of the jumper-type crimping terminal (6) are respectively fixed to two different copper conductors on the flexible circuit board by crimping.

5. The signal sampling wire harness of the battery pack according to claim 4, characterized in that: The jumper type crimping terminal (6) is wrapped with an insulating sleeve (61).

6. The signal sampling wire harness of the battery pack according to claim 4, wherein: The right-angle crimping terminal (3), the straight-line crimping terminal (5) and the jumper crimping terminal (6) are all metal terminals.

7. The signal sampling wire harness of the battery pack according to claim 6, wherein: The right-angle crimping terminal (3), the straight-line crimping terminal (5) and the jumper crimping terminal (6) all comprise a metal sheet (31), and crimping contacts (32) are respectively arranged on the surfaces of both ends of the metal sheet (31).

8. The signal sampling wire harness for a battery pack according to claim 3, wherein: A reinforcing plate (7) made of epoxy resin is provided on the back of the connection between the first flexible circuit board (1), the second flexible circuit board (2) and the third flexible circuit board (4); the reinforcing plate (7) and the flexible circuit board are fixedly connected by heat riveting.

9. The battery pack signal sampling wire harness according to claim 4, characterized in that: Sealant is applied at the crimping points between the right-angle crimping terminal (3), the straight crimping terminal (5) and the jumper crimping terminal (6) and the copper conductor.

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