Integrated busbar adopting flexible flat cable

Abstract

The utility model relates to an integrated busbar adopting a flexible flat cable. The integrated busbar comprises a bracket, and an FFC (Flexible Flat Cable) and a plurality of convergence pieces which are arranged on the bracket, the FFC comprises a plurality of flat copper wires and an insulating film, the flat copper wires are arranged side by side at intervals, each flat copper wire comprises a copper wire main body and a connecting copper wire which are integrated, an anti-oxidation layer is arranged outside the copper wire main body, the insulating film completely wraps the copper wire main bodies of all the flat copper wires, the connecting copper wires are pure copper, and the insulating film is made of copper. And the connecting copper wire of one flat copper wire is fixed on one confluence piece through ultrasonic welding. Compared with the prior art, the flat copper wires of the integrated busbar are directly welded with the confluence pieces in an ultrasonic manner, so that nickel sheets are saved, the material cost is reduced, the assembling process steps of the nickel sheets are also saved, and the assembling efficiency is improved; the connecting copper wire is specifically selected from pure copper, so that the problem that the welding of the connecting copper wire and the bus piece is influenced by an antioxidant material is avoided; an anti-oxidation layer does not need to be arranged on the connecting copper wire, so that the material cost can be further saved.

Description

Technical Field

[0001] This utility model belongs to the field of integrated busbar technology, specifically relating to an integrated busbar using flexible flat cables. Background Technology

[0002] Existing integrated busbars use flexible flat cables (FFC). The copper wires at the ends of the FFC data acquisition branches have nickel strips, and the data acquisition branches are connected to the busbars via these nickel strips. Due to increased cost control in the new energy industry, connecting the FFC and busbars via nickel strips not only increases material costs but also requires a nickel strip assembly process, making the process relatively complicated. Utility Model Content

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and provide an integrated busbar using flexible flat cables.

[0004] To achieve the above objectives, this utility model discloses an integrated busbar using flexible flat cables, including a bracket and an FFC cable and multiple busbar components mounted on the bracket;

[0005] The FFC cable includes multiple flat copper wires and an insulating film. The multiple flat copper wires are arranged side by side and spaced apart. Each flat copper wire includes an integral copper wire body and a connecting copper wire. The copper wire body is covered with an anti-oxidation layer. The insulating film completely covers the copper wire body of all flat copper wires. The connecting copper wire is made of pure copper. The connecting copper wire of one flat copper wire is fixed to a busbar by ultrasonic welding.

[0006] Preferably, the welding positions of the connecting copper wire and the busbar are provided with protective adhesive.

[0007] Preferably, the busbar is formed by a punching process, and the busbar is installed on the bracket along its punching direction, with connecting copper wires connected to the top surface of the busbar.

[0008] Preferably, it also includes a PCB board and a connector disposed on the PCB board. The PCB board is provided with connecting copper wires for connecting multiple flat copper wires and multiple lines for connecting copper wires, and each line is provided with a fuse.

[0009] Preferably, the connecting copper wires are fixed to the PCB board using a hot-bar soldering process.

[0010] Preferably, the copper wire body with the anti-oxidation layer is tin-plated copper wire or nickel-plated copper wire.

[0011] Preferably, the bracket is provided with a first mounting groove, and the FFC cable is fixed in the first mounting groove.

[0012] Preferably, the bracket is provided with a plurality of second mounting slots, and a busbar is installed in one of the second mounting slots;

[0013] The bracket is provided with a connecting groove that connects the first mounting groove and the second mounting groove.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0015] The flat copper wires of the FFC cable are directly ultrasonically welded to the busbars via the connecting copper wires of the flat copper wires. Compared with the existing technology where the flat copper wires are connected to the busbars via nickel strips, this saves nickel strips, reduces material costs, and also saves assembly process steps of nickel strips, thus improving assembly efficiency.

[0016] Most existing copper wires are plated with an oxide layer. During ultrasonic welding, the anti-oxidation material absorbs heat, which can affect the connection effect. In this invention, the connecting copper wire is specifically selected as pure copper, which avoids the problem of anti-oxidation material affecting the welding of the connecting copper wire and the bus.

[0017] No anti-oxidation layer is needed on the connecting copper wires, which can further save on material costs. Attached Figure Description

[0018] Figure 1 A top view of an integrated busbar using flexible flat cables, as shown in the embodiment;

[0019] Figure 2 for Figure 1 A magnified view of a portion of point A in the middle;

[0020] Figure 3 for Figure 1 Top view of the support structure;

[0021] Bracket 10; First mounting slot 11; Second mounting slot 12; Connecting slot 13;

[0022] FFC cable 20; connecting copper wire 21;

[0023] Busbar 30;

[0024] PCB board 40;

[0025] Connector 50. Detailed Implementation

[0026] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0027] An integrated busbar using flexible flat cables, see [link / reference] Figures 1-3The system includes a support 10, an FFC cable 20 mounted on the support 10, and multiple busbars 30. The FFC cable 20 includes multiple flat copper wires and an insulating film. The multiple flat copper wires are arranged side by side and spaced apart, which is the existing structure of the FFC cable 20. Each flat copper wire includes an integral copper wire body and a connecting copper wire 21. In the prior art, in order to improve the oxidation resistance of the flat copper wire and extend the service life of the product, the flat copper wire is plated with an anti-oxidation layer, such as tin plating or nickel plating, becoming tin-plated copper wire or nickel-plated copper wire. In this embodiment, an anti-oxidation layer is only provided on the outside of the copper wire body, the insulating film completely covers the copper wire body of all flat copper wires, the connecting copper wire 21 is pure copper, and the connecting copper wire 21 of one flat copper wire is fixed to a busbar 30 by ultrasonic welding.

[0028] In this embodiment, the integrated busbar of the FFC cable 20 is directly ultrasonically welded to the integrated busbar of the busbar of the busbar 30 via the connecting copper wire 21 of the flat copper wire. Compared with the prior art where the flat copper wire is connected to the busbar 30 via nickel strips, this saves nickel strips, reduces material costs, and also saves assembly process steps of nickel strips, improving assembly efficiency. Most existing copper wires are plated with an oxide layer. During ultrasonic welding, the anti-oxidation material absorbs heat during welding, which can affect the connection effect. In this invention, the connecting copper wire 21 is specifically selected as pure copper, which avoids the problem of anti-oxidation material affecting the welding of the connecting copper wire 21 and the busbar 30. The flat copper wire only has an anti-oxidation layer on the main body of the copper wire; the connecting copper wire 21 does not need an anti-oxidation layer, which further saves material costs.

[0029] In this embodiment, a protective adhesive is provided at the welding position connecting the copper wire 21 and the busbar 30. The protective adhesive at the welding position can not only improve the oxidation resistance of the welding position, but also increase the pull-out force and peel force between the copper wire 21 and the busbar 30.

[0030] In this embodiment, the busbar 30 is formed by a punching process. The busbar 30 is mounted on the bracket 10 along its punching direction. The connecting copper wire 21 is connected to the top surface of the busbar 30. In this way, the burrs generated during the punching process of the busbar 30 are all directed towards the bracket 10 and not towards the FFC cable 20. This can avoid the problem of burrs rubbing against the branches of the FFC cable 20, damaging the insulating film, and causing the insulation resistance to fail to meet the requirements.

[0031] In this embodiment, the integrated busbar also includes a PCB board 40 and a connector 50 disposed on the PCB board 40. The PCB board 40 is provided with connecting copper wires 21 for connecting multiple flat copper wires and multiple lines (not shown in the figure) for connecting the copper wires 21. Specifically, the connecting copper wires 21 are fixed to the PCB board 40 by hot-bar soldering, and the connector 50 is fixed to the PCB board 40 by SMT process. In this way, the connector 50 and the BMS can be connected by a single plug. Each line is provided with a fuse, so that when the current is too large or an overload occurs, the fuse will blow, which ensures safe use.

[0032] In this embodiment, the bracket 10 is provided with a first mounting groove 11, and the FFC cable 20 is fixed in the first mounting groove 11.

[0033] In this embodiment, the bracket 10 is provided with a plurality of second mounting slots 12, and a busbar 30 is installed in a second mounting slot 12. Specifically, in this embodiment, the busbar 30 is fixed to the bracket 10 by a first hot riveting post in the second mounting slot 12.

[0034] The bracket 10 is provided with a connecting groove 13 that connects the first mounting groove 11 and the second mounting groove 12. By setting the connecting groove 13, the connecting copper wire 21 can be directly bent into the second mounting groove 12 and connected to the busbar 30, avoiding the problem that the two are not connected and the FFC branch needs to be bent multiple times to connect the connecting copper wire 21 to the busbar 30, which is a complicated processing step.

[0035] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating this utility model, and are not intended to limit the implementation of this utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. An integrated busbar using flexible flat cables, characterized in that: Includes a bracket and an FFC cable mounted on the bracket, as well as multiple busbars; The FFC cable includes multiple flat copper wires and an insulating film. The multiple flat copper wires are arranged side by side and spaced apart. Each flat copper wire includes an integral copper wire body and a connecting copper wire. The copper wire body is covered with an anti-oxidation layer. The insulating film completely covers the copper wire body of all flat copper wires. The connecting copper wire is made of pure copper. The connecting copper wire of one flat copper wire is fixed to a busbar by ultrasonic welding.

2. The integrated busbar using flexible flat cables according to claim 1, characterized in that: Protective adhesive is provided at the welding positions of the connecting copper wire and the busbar.

3. The integrated busbar using flexible flat cables according to claim 1, characterized in that: The busbar is formed by a punching process and is mounted on a bracket along its punching direction. A connecting copper wire is connected to the top surface of the busbar.

4. The integrated busbar using flexible flat cables according to claim 1, characterized in that: It also includes a PCB board and a connector on the PCB board. The PCB board has connecting copper wires for connecting multiple flat copper wires and multiple lines for connecting copper wires. Each line has a fuse.

5. The integrated busbar using flexible flat cables according to claim 4, characterized in that: The connecting copper wires are fixed to the PCB board using a hot-bar soldering process.

6. The integrated busbar using flexible flat cables according to claim 1, characterized in that: The copper wire with an anti-oxidation layer is either tin-plated or nickel-plated.

7. The integrated busbar using flexible flat cables according to claim 1, characterized in that: The bracket is provided with a first mounting slot, and the FFC cable is fixed in the first mounting slot.

8. The integrated busbar using flexible flat cables according to claim 7, characterized in that: The bracket is provided with multiple second mounting slots, and a busbar is installed in one of the second mounting slots; The bracket is provided with a connecting groove that connects the first mounting groove and the second mounting groove.

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