Conducting bar and battery pack
By setting an insulating layer and a copper layer on the outer periphery of the conductor, and combining them with nickel sheets and heat sinks, the problems of insufficient current carrying capacity and poor safety of the conductor in high-capacity battery packs are solved, achieving efficient production and low-cost battery pack design.
Patent Information
- Application Number
- CN202520020292.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-03
- Publication Date
- 2026-01-23
- Estimated Expiration
- 2035-01-03
AI Technical Summary
In existing technologies, the conductive busbars of high-capacity battery packs have problems such as insufficient current carrying capacity, large space occupation, and poor safety, and high-fast-charging-rate battery products have high costs.
Design a conductive bus that uses a copper layer with an insulating layer on the outside and welded or screwed ends. Combined with nickel sheets and heat sinks, it ensures connection reliability and heat dissipation performance. Avoidance zones are set at both ends of the conductive bus to reduce temperature rise. Aluminum components and aluminum heat sinks are used to reduce costs.
It improves the current carrying capacity and safety of the busbar, reduces production costs and temperature rise, increases production efficiency, and enhances the overall performance of the battery pack.
Smart Images
Figure CN223828658U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of battery manufacturing technology, and in particular to a conductive busbar and a battery pack. Background Technology
[0002] The relevant technology indicates that current 400V or 800V power battery packs typically have a cell capacity of over 100Ah, and the solutions already in mass production have a peak fast charging rate of ≥4C. This will have a certain impact on some battery pack solutions that have high capacity requirements and contain long conductive buses.
[0003] 1. For battery packs with high capacity, if aluminum busbars are used to reduce costs, aluminum busbars have lower current carrying capacity than copper busbars, are larger in size, occupy more space, and have limited space inside the pack, which is not conducive to the application and layout of aluminum busbars. Even if they can be arranged, the safety distance between them and surrounding components will be reduced, which will increase the risk of short circuits and arcing in extreme situations such as thermal runaway or collisions.
[0004] 2. For some high-end battery products with high fast charging rates and large capacity, the cost of using long copper busbars for connection is high due to the large charging and discharging current, which reduces the product's competitiveness. Utility Model Content
[0005] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides a conductive busbar that has good current carrying capacity, small footprint, and high safety factor.
[0006] This utility model also proposes a battery pack having the above-mentioned conductive busbar.
[0007] According to the first aspect of the present invention, the conductive busbar has a first end connected to a high-voltage distribution box and a second end connected to a battery cell. The conductive busbar has a body, an insulating layer on the outer peripheral surface of the body, and a copper layer between the insulating layer and the body.
[0008] According to the present invention, the temperature rise of the conductive busbar is reduced by the processing technology of the welded or screwed joints at both ends, which solves the problem of high temperature rise at both ends of the conventional conductive busbar, which restricts the maximization of current carrying capacity. An insulating layer is set on the outermost side of the conductive busbar, and it can be pre-made into rolls according to the current carrying capacity specifications, which supports automated production and will not lead to a reduction in production efficiency when the new conductive busbar is used in actual applications.
[0009] In some embodiments, a first connection portion is formed at the first end of the conductive bus, and a clearance area is formed at the first end of the insulating layer to expose the copper layer.
[0010] In some embodiments, the first end has nickel sheets on both sides of the conductive busbar in the thickness direction.
[0011] In some embodiments, the high-voltage distribution box has a conductive mating bus and a heat sink, the conductive mating bus is located between the heat sink and the conductive bus, the first connecting portion is formed as a first connecting hole, the conductive mating bus has a second connecting hole, the conductive mating bus and the conductive bus are connected by fasteners passing through the first connecting hole and the second connecting hole, and the fasteners are threadedly connected to the heat sink.
[0012] In some embodiments, a second connection portion is formed at the second end of the conductive bus, an avoidance area is formed at the second end of the insulating layer to expose the copper layer, and an avoidance portion is formed at the second connection portion of the copper layer to expose the side surface of the body facing the battery cell.
[0013] In some embodiments, the second connection portion is welded to the battery cell, and the copper layer forms a clearance hole at the location of the second connection portion to expose the side surface of the body away from the battery cell. The second connection portion forms a welding observation hole, which penetrates the body and the weld bead extends around the welding observation hole.
[0014] In some embodiments, the high-voltage distribution box has a housing, the heat sink is disposed inside the housing, and the upper surface of the heat sink is arranged above the upper edge of the housing, and a thermal pad is provided at the bottom of the heat sink.
[0015] In some embodiments, a cold plate is provided at the bottom of the high-voltage distribution box, and the thermal pad is connected to the cold plate.
[0016] In some embodiments, the thickness of the insulating layer is 0.5 mm to 1 mm, and / or the thickness of the body is less than 2 mm, and / or the body is formed of an aluminum component.
[0017] The battery pack according to the second aspect of the present invention includes the conductive busbar according to the first aspect of the present invention.
[0018] According to the present invention, by setting the conductive busbar of the first aspect, the overall performance of the battery pack is improved, the battery pack production and assembly are facilitated, the production efficiency is improved, and the production cost is reduced.
[0019] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description
[0020] Figure 1This is a schematic diagram of a conductive busbar according to an embodiment of the present utility model;
[0021] Figure 2 yes Figure 1 A partially enlarged schematic diagram of the first connection hole of the conductive bus shown;
[0022] Figure 3 yes Figure 2 A cross-sectional schematic diagram of the first connecting hole shown in the figure;
[0023] Figure 4 yes Figure 1 A schematic diagram of the conductive busbar from another angle;
[0024] Figure 5 yes Figure 4 A partially enlarged schematic diagram of the second connection portion of the conductive bus shown;
[0025] Figure 6 yes Figure 5 A cross-sectional schematic diagram of the second connection portion shown in the figure;
[0026] Figure 7 yes Figure 1 A schematic diagram of the conductive busbar at another angle shown;
[0027] Figure 8 yes Figure 1 The diagram shows the connection between the busbar and the battery cell.
[0028] Figure 9 yes Figure 8 The diagram shows the connection between the conductor bar and the high-voltage distribution box.
[0029] Figure 10 yes Figure 8 The diagram shows the assembly of the conductor bus, battery cell, and high-voltage distribution box.
[0030] Figure 11 yes Figure 9 The diagram shows the connection between the conductive busbar, the conductive mating busbar, and the heat sink.
[0031] Figure 12 yes Figure 11 A partially enlarged schematic diagram of the conductive busbar, conductive mating busbar, and heat sink in the diagram;
[0032] Figure 13 yes Figure 9 A schematic diagram of the high-voltage distribution box shown;
[0033] Figure 14 yes Figure 13 A schematic diagram of the high-voltage distribution box from another angle;
[0034] Figure 15 yes Figure 13 The diagram shows a high-voltage distribution box, excluding the conductive busbar;
[0035] Figure 16 yes Figure 1 The diagram shows the connection between the conductive busbar and the heat sink.
[0036] Figure 17 yes Figure 13 A schematic diagram of the high-voltage distribution box from another angle;
[0037] Figure 18 yes Figure 17 The cross-sectional view at point AA shown in the figure;
[0038] Figure 19 yes Figure 8 The diagram shows the assembly of the conductor bar and the high-voltage distribution box from another angle.
[0039] Figure 20 yes Figure 19 The cross-sectional view at BB shown in the figure.
[0040] Figure label:
[0041] 100. Conductive busbar; 1. Body; 2. Copper layer; 3. Insulating layer; 301. Clearance hole; 4. First connection hole; 5. Second connection part; 501. Welding observation hole; 502. Weld bead; 6. Nickel sheet; 20. Battery cell; 30. High voltage distribution box; 31. Heat sink; 32. Conductive busbar; 321. Second connection hole; 33. Housing; 40. Fastener; 41. Thermal pad; 50. Cold plate. Detailed Implementation
[0042] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.
[0043] The following is for reference. Figures 1-20 The conductive busbar 100 according to a first aspect embodiment of the present invention is described.
[0044] like Figures 1-20As shown, according to the first aspect of the present invention, a conductive busbar 100 has a first end connected to a high-voltage distribution box 30 and a second end connected to a battery cell 20. The conductive busbar 100 has a body 1, an insulating layer 3 on the outer periphery of the body 1, and a copper layer 2 between the insulating layer 3 and the body 1. It is understood that the high-voltage distribution box 30 is a key component in electric vehicles used for distributing and managing high-voltage power. The first end of the conductive busbar 100 is connected to the high-voltage distribution box 30, and the second end of the conductive busbar 100 is directly connected to the battery cell 20 in the battery pack. The copper layer 2 on the outer side of the conductive busbar 100 body 1 enhances conductivity, reduces resistance, and reduces power loss during transmission. The insulating layer 3 covers the outer periphery of the conductive busbar 100 body 1, providing insulation protection and preventing short circuits and arcing. The material of the insulating layer 3 typically has good electrical insulation properties and high-temperature resistance.
[0045] According to the embodiment of the present invention, the conductive busbar 100 reduces the temperature rise by processing the welded or screwed joints at both ends, thus solving the problem of high temperature rise at both ends of the conventional conductive busbar 100, which restricts the maximization of current carrying capacity. An insulating layer is provided on the outermost side of the conductive busbar 100, and it can be pre-made into rolls according to the current carrying capacity specifications, supporting automated production and preventing the problem of reduced production efficiency when the new conductive busbar 100 is used in actual applications.
[0046] In other embodiments, the second end of the conductive bus 100 is connected to an adapter.
[0047] In some embodiments of this utility model, such as Figures 1-4 As shown, a first connecting portion is formed at the first end of the conductive bus 100, and a clearance area is formed at the first end of the insulating layer 3 to expose the copper layer 2. It can be understood that the first connecting portion at the first end of the conductive bus 100 is used to connect to the high-voltage distribution box 30. At the first end, the insulating layer 3 forms a clearance area, exposing the copper layer 2. This allows for direct contact and connection with the high-voltage distribution box 30, maximizing the conductivity of the connection point, reducing contact resistance, improving the reliability and stability of the connection, and reducing complex wiring steps, thus improving production efficiency.
[0048] In some embodiments of this utility model, such as Figure 2 As shown, nickel sheets 6 are provided on both sides of the first end of the conductive busbar 100 in the thickness direction. Nickel has good corrosion resistance and oxidation resistance, which can effectively prevent the performance of the conductive busbar 100 from deteriorating due to oxidation or other corrosion during long-term use. The protective effect of the nickel sheets 6 can extend the service life of the conductive busbar 100, reduce the frequency of maintenance and replacement, and improve the overall reliability of the battery pack.
[0049] In some embodiments of this utility model, such as Figures 9-20 As shown, the high-voltage distribution box 30 has a conductive mating bus 32 and a heat sink 31. The conductive mating bus 32 is located between the heat sink 31 and the conductive bus 100. A first connecting portion is formed as a first connecting hole 4, and a second connecting hole 321 is formed on the conductive mating bus 32. The conductive mating bus 32 and the conductive bus 100 are connected by a fastener 40 passing through the first connecting hole 4 and the second connecting hole 321. The fastener 40 is threadedly connected to the heat sink 31. Here, the heat sink 31 is preferably made of aluminum. Aluminum has good thermal conductivity and can effectively conduct heat away from the high-voltage distribution box 30, ensuring that the temperature of the battery pack is controlled within a safe range. This not only improves the reliability and conductivity of the connection but also enhances the heat dissipation performance, ensuring the safety and stability of the battery pack.
[0050] In some embodiments of this utility model, such as Figure 1 , Figure 5 , Figure 6 As shown, a second connecting portion 5 is formed at the second end of the conductive bus 100. An insulating layer 3 has a clearance area formed at the second end to expose the copper layer 2. The copper layer 2 also has a clearance area at the second connecting portion 5 to expose the surface of the body 1 facing the battery cell 20. It can be understood that the second connecting portion 5 at the second end of the conductive bus 100 is used to connect to the battery cell 20. At the second end, the insulating layer 3 forms a clearance area, exposing the copper layer 2. The copper layer 2 has a clearance area at the second connecting portion 5, exposing the surface of the body 1 facing the battery cell 20. Thus, by forming a clearance area at the second end to expose the copper layer 2, it can directly contact and connect with the battery cell 20. This ensures maximized conductivity at the connection point, reduces contact resistance, and improves the reliability and stability of the connection. The clearance area of the copper layer 2, exposing the surface of the body 1 facing the battery cell 20, further reduces contact resistance and ensures efficient power transmission.
[0051] In some embodiments of this utility model, such as Figure 5 and Figure 6 As shown, the second connecting portion 5 is welded to the battery cell 20. A clearance hole 301 is formed in the copper layer 2 at the location of the second connecting portion 5 to expose the surface of the body 1 facing away from the battery cell 20. A welding observation hole 501 is formed in the second connecting portion 5, penetrating the body 1, and a weld bead 502 extends around the welding observation hole 501. Thus, by forming the clearance hole 301 in the second connecting portion 5, the surface of the body 1 facing away from the battery cell 20 is exposed, improving the reliability and conductivity of the weld. Furthermore, the welding observation hole 501 penetrating the body 1 allows for convenient inspection of the weld quality, ensuring the continuity and integrity of the weld bead 502. The weld bead 502 extending around the welding observation hole 501 further improves the mechanical strength and conductivity of the weld.
[0052] It is understandable that, since the contact resistance at the bolted connection is usually greater than the resistance of the busbar 100 itself, the temperature at the bolted connections at both ends of the busbar 100 is usually higher than that at the middle position. Therefore, the upper limit of the temperature at both ends directly determines the maximum allowable current carrying capacity of the busbar 100. However, according to the "Code for Construction and Acceptance of Busbar Installation Engineering" (GB 50149-2010), the DC resistance of the busbar connection weld joint should not be greater than 1.05 times the DC resistance of the raw materials with the same specifications and dimensions. The resistance at the welded connection is relatively small, basically close to the conductivity of the busbar 100 itself. Therefore, the use of welding connection can improve the current carrying capacity of the busbar 100.
[0053] In some embodiments of this utility model, the high-voltage distribution box 30 has a housing 33, a heat sink 31 is disposed inside the housing 33, and the upper surface of the heat sink 31 is arranged higher than the upper edge of the housing 33. A thermally conductive pad 41 is provided at the bottom of the heat sink 31. It can be understood that a part of the heat sink 31 is exposed outside the housing 33, which increases the contact area with the outside air, improves the effect of natural convection heat dissipation, and facilitates connection and assembly. Here, the heat sink 31 is an aluminum block.
[0054] Reference Figure 20 As shown, the bottom of the high-voltage distribution box 30 is provided with a cold plate 50, and the heat sink 31 is connected to the cold plate 50 through the heat-conducting pad 41 to exchange heat with the cold plate 30, thereby improving the heat dissipation efficiency and heat dissipation effect.
[0055] In some embodiments of this utility model, the thickness of the nickel sheet 6 is 0.1 mm.
[0056] In some embodiments of this utility model, the thickness of the insulating layer 3 is 0.5mm-1mm. For example, the thickness of the insulating layer 3 can be 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1.0mm, etc.
[0057] Optionally, the insulating layer 3 is made of PA12 material.
[0058] Furthermore, the thickness of the body 1 is less than 2 mm, and the body 1 is formed of aluminum.
[0059] A battery pack according to a second aspect of the present invention includes a conductive busbar 100 according to the first aspect of the present invention described above.
[0060] According to the battery pack of the present invention, by setting the conductive busbar 100 of the first aspect embodiment above, the overall performance of the battery pack is improved, the battery pack production and assembly are facilitated, the production efficiency is improved, and the production cost is reduced.
[0061] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0062] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.
[0063] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0064] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.
[0065] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.
Claims
1. A conductive bus, characterized in that, The first end of the conductive busbar is connected to a high-voltage distribution box, and the second end of the conductive busbar is connected to a battery cell. The conductive busbar has a body, and an insulating layer is provided on the outer peripheral surface of the body. A copper layer is provided between the insulating layer and the body.
2. The conductive bus according to claim 1, characterized in that, The first end of the conductive busbar has a first connection portion, and the insulating layer has a clearance area at the first end to expose the copper layer.
3. The conductive bus according to claim 2, characterized in that, The first end has nickel sheets on both sides of the conductive busbar in the thickness direction.
4. The conductive bus according to claim 2, characterized in that, The high-voltage distribution box has a conductive mating bus and a heat sink. The conductive mating bus is located between the heat sink and the conductive bus. The first connecting part is formed as a first connecting hole. The conductive mating bus has a second connecting hole. The conductive mating bus and the conductive bus are connected by fasteners passing through the first connecting hole and the second connecting hole. The fasteners are threadedly connected to the heat sink.
5. The conductive bus according to claim 1, characterized in that, The second end of the conductive busbar has a second connection portion, and the insulating layer has a clearance area at the second end to expose the copper layer. The copper layer has a clearance portion at the second connection portion to expose the side surface of the body facing the battery cell.
6. The conductive bus according to claim 5, characterized in that, The second connection portion is welded to the battery cell. A clearance hole is formed in the copper layer at the location of the second connection portion to expose the side surface of the body facing away from the battery cell. A welding observation hole is formed in the second connection portion. The welding observation hole penetrates the body and the weld bead extends around the welding observation hole.
7. The conductive bus according to claim 4, characterized in that, The high-voltage distribution box has a housing, the heat sink is disposed inside the housing, and the upper surface of the heat sink is arranged above the upper edge of the housing, and a thermal pad is provided at the bottom of the heat sink.
8. The conductive bus according to claim 7, characterized in that, The bottom of the high-voltage distribution box is equipped with a cold plate, and the heat-conducting pad is connected to the cold plate.
9. The conductive bus according to any one of claims 1-8, characterized in that, The thickness of the insulating layer is 0.5mm-1mm, and / or the thickness of the body is less than 2mm, and / or the body is formed of an aluminum part.
10. A battery pack, characterized in that, The conductive busbar includes any one of claims 1-9.