Copper bar assembly, battery pack and vehicle

Abstract

The utility model provides a copper bar assembly, a battery pack and a vehicle. The copper bar assembly comprises a copper bar, a protective layer and an insulating film, the protective layer is arranged on the outer side of the copper bar and fixed to the copper bar in a hot pressing mode, and the insulating film wraps the outer surface of the protective layer. The copper bar assembly, the battery pack and the vehicle are high in reliability and safety.

Description

Technical Field

[0001] This application relates to the field of battery pack technology, and more particularly to a copper busbar assembly, a battery pack, and a vehicle. Background Technology

[0002] In the battery packs of new energy vehicles, copper busbars are typically used for electrical power connections. The surface of these copper busbars is usually coated with an insulating layer and a fire-resistant layer to ensure their insulation, high-voltage resistance, and high-temperature resistance. Due to space constraints, the copper busbars are usually positioned above the battery cells; in extreme cases, they may be directly opposite the cell's explosion-proof valve. If a battery cell experiences thermal runaway, the electrolyte sprays out from the explosion-proof valve, creating a high-temperature, high-pressure mixture. Under this high-temperature, high-pressure impact, the insulating and fire-resistant layers of the copper busbars are unable to withstand the force of the gas, easily leading to damage and exposure of the conductors. This can result in insulation failure and potentially cause arcing, short circuits, and other phenomena, posing a significant threat to vehicle safety.

[0003] Therefore, it is necessary to provide an improved copper busbar assembly, battery pack, and vehicle to solve the above problems. Utility Model Content

[0004] This application provides a copper busbar assembly, battery pack, and vehicle that improves reliability and safety.

[0005] This application discloses a copper busbar assembly, including a copper busbar, a protective layer and an insulating film. The protective layer is disposed on the outside of the copper busbar and is hot-pressed to the copper busbar. The insulating film covers the outer surface of the protective layer.

[0006] By setting a protective layer on the outside of the copper busbar and hot-pressing it to the copper busbar, the adhesion and connection strength between the protective layer and the copper busbar are enhanced, making the connection between the protective layer and the copper busbar more stable and firm. The protective layer is resistant to high temperatures and is prevented from being blown away by high air pressure. At the same time, by covering the outer surface of the protective layer with an insulating film, the insulation performance and safety of the copper busbar assembly are further improved.

[0007] Furthermore, the protective layer is a mica tape wrapped around the outside of the copper busbar at least once or a mica coating applied to the outside of the copper busbar.

[0008] Mica tape and mica coating are environmentally friendly, high-temperature resistant, and excellent insulating materials that can reduce production costs and environmental impact while ensuring performance.

[0009] Furthermore, the insulating film includes at least one of PI film, PE film, and PET film.

[0010] By combining the insulating film and the protective layer, the copper busbar assembly can be comprehensively optimized in terms of thermal management, electrical protection, and mechanical strength, thereby improving the safety, reliability, and service life of the copper busbar assembly.

[0011] Furthermore, the copper busbar includes a main body and connecting portions located at both ends of the main body, and the protective layer covers the outer surface of the main body.

[0012] The protective layer wraps around the outer surface of the main body, protecting the main area of ​​the copper busbar. Meanwhile, the exposed connection points facilitate electrical connections.

[0013] Furthermore, the copper busbar includes a first copper busbar and a second copper busbar, and the connecting part correspondingly includes a first connecting part disposed on the first copper busbar and a second connecting part disposed on the second copper busbar, wherein the first connecting part and the second connecting part overlap and are welded to be fixed.

[0014] By overlapping and welding the first connecting part with the second connecting part, the first copper busbar and the second copper busbar are fixed together. When producing copper busbar assemblies with complex shapes, the copper busbar can be manufactured in multiple sections and then welded together, eliminating the need to design complex molds and reducing production costs.

[0015] Furthermore, a heat shrink tubing is provided at the overlap between the first connecting portion and the second connecting portion; and / or, the overlap between the first connecting portion and the second connecting portion is covered with the protective layer and the insulating film.

[0016] By providing heat shrink tubing and / or a protective layer and an insulating film at the overlap between the first and second connecting parts, the insulation, high-temperature performance, and wear resistance of the connection between the first and second copper busbars are enhanced, thereby further improving the reliability, safety, and stability of the copper busbar assembly.

[0017] Furthermore, it also includes a localized wear-resistant structure disposed on the outside of the insulating film.

[0018] By incorporating localized wear-resistant structures, copper busbar exposure or poor contact caused by friction and wear can be avoided. Furthermore, these localized wear-resistant structures can be applied to specific locations, eliminating the need for complete coverage of the copper busbar and thus preserving the compact and lightweight design of the entire copper busbar assembly.

[0019] Further, the thickness of the insulating film is 0.1-0.3 mm; and / or, the thickness of the protective layer is 0.8-2 mm.

[0020] The insulation film and protective layer are both relatively thin, so the thickness of the copper busbar assembly should not be increased as much as possible while meeting performance requirements. This is beneficial for the copper busbar assembly to meet the design requirements of lightweight and small size.

[0021] This application also discloses a battery pack including the copper busbar assembly described above.

[0022] This application also discloses a vehicle including the battery pack described above.

[0023] The copper busbar assembly, battery pack, and vehicle of this application enhance the adhesion and connection strength between the copper busbar and the protective layer by setting a protective layer on the outside of the copper busbar and hot-pressing the protective layer to the copper busbar. This makes the connection between the protective layer and the copper busbar more stable and firm, and the protective layer is resistant to high temperatures while preventing it from being blown away by high air pressure. At the same time, by covering the outer surface of the protective layer with an insulating film, the insulation performance and safety of the copper busbar assembly are further improved.

[0024] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this specification. Attached Figure Description

[0025] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this specification and, together with the description, serve to explain the principles of this specification.

[0026] Figure 1 This is a perspective view of one embodiment of the copper busbar assembly of this application.

[0027] Figure 2 yes Figure 1 The exploded diagram.

[0028] Figure 3 This is a schematic diagram of the process flow of the copper busbar assembly of this application.

[0029] Figure 4 This is a perspective view of another embodiment of the copper busbar assembly of this application.

[0030] Figure 5 yes Figure 4 The exploded diagram.

[0031] Explanation of icon numbers:

[0032] 10. Copper busbar; 101. Main body; 102. Connecting part; 11. First copper busbar; 111. First main body; 112. First connecting part; 12. Second copper busbar; 121. Second main body; 122. Second connecting part; 20. Protective layer; 21. First protective layer; 22. Second protective layer; 30. Insulating film; 31. First insulating film; 32. Second insulating film; 40. Heat shrink tubing. Detailed Implementation

[0033] The technical solutions in the embodiments (or "implementations") of this application will be clearly and completely described herein with reference to the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements.

[0034] If the embodiments of this application contain terms relating to directional indications or positional relationships (such as up, down, left, right, front, back, inside, outside, top, bottom, center, vertical, horizontal, longitudinal, transverse, length, width, counterclockwise, clockwise, axial, radial, circumferential, etc.), such terms are only used to explain the relative positional relationships and movements between components in a specific posture (as shown in the attached figures); if the specific posture changes, the directional indications or positional relationships will also change accordingly. Furthermore, the terms "first" and "second" used in the embodiments of this application are only for descriptive convenience and should not be construed as indicating or implying relative importance.

[0035] The embodiments of this application will now be described in detail.

[0036] like Figure 1 and Figure 2 As shown, this application provides a copper busbar assembly, including a copper busbar 10, a protective layer 20, and an insulating film 30. The protective layer 20 is disposed on the outside of the copper busbar 10, and the insulating film 30 covers the outside of the protective layer 20.

[0037] The protective layer 20 and the copper busbar 10 are fixed by hot pressing, which enhances the adhesion and connection strength between the protective layer and the copper busbar, making the connection between the protective layer and the copper busbar more stable and firm. The protective layer is resistant to high temperature and is prevented from being blown away by high air pressure.

[0038] The copper busbar 10 includes a main body 101 and connecting portions 102, with the connecting portions 102 located at both ends of the main body 101. The main body 101 primarily serves the function of current transmission, and a protective layer 20 covers the outside of the main body 101 to protect it. The connecting portions 102 are exposed for easy electrical connection. In this embodiment, the length of the main body 101 is much greater than the length of the connecting portion 102, and the protective layer 20 covers the entire outer surface of the main body 101, thus protecting most of the copper busbar 10 and enhancing its reliability and safety. In this application, the copper busbar 10 can be either a flexible copper busbar or a rigid copper busbar.

[0039] In this embodiment, the protective layer 20 is a mica tape wrapped around the outside of the copper busbar 10 at least one turn. Mica, as an environmentally friendly, high-temperature resistant, and excellent insulating material, is non-flammable and has a heat resistance of over 900°C. Furthermore, mica has extremely high electrical resistance and strong electrical insulation, thus providing effective safety protection for the copper busbar 10. This results in the copper busbar assembly having strong heat resistance and insulation, thereby ensuring and improving the reliability and stability of the copper busbar assembly in high-temperature environments.

[0040] During the hot-pressing process between the protective layer 20 and the copper busbar 10, the colloidal material within the mica tape undergoes slight melting or softening upon heating, fully utilizing its adhesive properties. This enhances the bond strength between the protective layer 20 and the copper busbar 10, preventing the protective layer 20 from being blown away by high pressure and ensuring the safety and reliability of the copper busbar assembly under high-temperature and high-pressure environments. In some cases, an adhesive layer can also be applied to one side of the mica tape to further strengthen and stabilize the connection between the mica tape and the copper busbar 10, and between different mica tapes.

[0041] The thickness of the protective layer 20 is 0.8-2mm. During the production process, the number of turns of the mica tape can be adjusted according to product requirements to control the thickness of the protective layer 20, so that the protective layer 20 can simultaneously meet the requirements of protective performance and lightweight design.

[0042] In some cases, mica can also be applied to the outside of the copper busbar 10 in other ways, such as by spraying mica powder to form a mica coating. The protective layer 20 can also be made of other materials, such as ceramic composite strips.

[0043] The insulating film 30 includes at least one of PI film (polyimide film), PE film (polyethylene film), and PET film (polyethylene terephthalate film). PI film possesses high thermal stability, electrical insulation, and chemical stability, making it suitable for the thermal stress environments that may occur in battery packs. PE film offers relatively high durability and flexibility, allowing for tight coverage of the protective layer 20 and adaptability to complex shapes of the copper busbar 10. PET film exhibits high mechanical strength and tensile strength, reducing damage caused by external impacts or vibrations. During production, the insulating film 30 can be flexibly selected or combined as needed.

[0044] The thickness of the insulating film 30 is 0.1-0.3mm. While meeting performance requirements, the thickness of the copper busbar assembly should not be increased as much as possible, which is conducive to the copper busbar assembly meeting the design requirements of lightweight and small size.

[0045] By combining the insulating film 30 with the protective layer 20, both insulation and wear resistance are improved, enabling comprehensive optimization of the copper busbar assembly in terms of thermal management, electrical protection, and mechanical strength, thereby enhancing the safety, reliability, and service life of the copper busbar assembly.

[0046] Furthermore, the copper busbar assembly of this application also includes a localized wear-resistant structure (not shown in the figure) disposed on the outer side of the insulating film 30. By providing a localized wear-resistant structure at locations requiring enhanced wear resistance within the overall package, the copper busbar 10 can be prevented from being exposed or experiencing poor contact due to friction and wear. Simultaneously, the localized wear-resistant structure can be positioned locally, without needing to completely cover the outer side of the copper busbar 10, thus not affecting the compact and lightweight design of the copper busbar assembly. The localized wear-resistant structure can be achieved by locally wrapping wear-resistant tape (such as cloth tape) or braided mesh tubing.

[0047] Please refer to the following at the same time Figure 3 When producing the copper busbar assembly, the copper busbar 10 is first formed by 3D bending or die stamping to obtain the required shape.

[0048] Then, according to the shape of the copper busbar 10, the mica tape is wound to the required thickness by hand or machine to form a protective layer 20.

[0049] Next, the copper busbar 10 covered with the protective layer 20 is placed in a dedicated hot press mold, and the hot press temperature and time are set for hot pressing. After the hot press process, the adhesive material between the mica tapes adheres to each other, thereby improving the connection strength between the protective layer 20 and the copper busbar 10. The hot press mold is customized according to the shape of the copper busbar 10, and the hot press temperature and time can be adaptively set for different thicknesses and shapes of the copper busbar 10.

[0050] Subsequently, the insulating film 30 is wrapped around the protective layer 20 by hand or machine. For locations where additional wear resistance is required, local wear-resistant structures can be added.

[0051] For copper busbars 10 with uniform cross-section and integral molding, the above-mentioned processes can be used to manufacture a copper busbar assembly. For copper busbars 10 with unequal cross-section but simple shape and structure, such as two copper busbars 10 located on the same straight line, the above-mentioned processes can be performed on both copper busbars 10 simultaneously to manufacture a copper busbar assembly. For copper busbars 10 with unequal cross-section and requiring welding, if the shape and structure of the copper busbar 10 are complex and it is difficult to hot press them with a single hot pressing mold, the protective layer 20 can be wound around multiple sections of copper busbar 10, hot pressed, and covered with an insulating film 30, and then the multiple sections of copper busbar 10 can be welded to manufacture a copper busbar assembly.

[0052] like Figure 4 and Figure 5 The copper busbar 10 includes a first copper busbar 11 and a second copper busbar 12. The main body 101 correspondingly includes a first main body 111 disposed on the first copper busbar 11 and a second main body 121 disposed on the second copper busbar 12. The connecting part 102 correspondingly includes a first connecting part 112 disposed on the first copper busbar 11 and a second connecting part 122 disposed on the second copper busbar 12. The first connecting part 112 and the second connecting part 122 overlap and are welded together for fixation.

[0053] During the production process, the first copper busbar 11 and the second copper busbar 12 undergo the aforementioned processes respectively. The first copper busbar 11 is covered with a first protective layer 21 and a first insulating film 31, while the second copper busbar 12 is covered with a second protective layer 22 and a second insulating film 32. Then, the first connecting part 112 and the second connecting part 122 are welded together. In this way, when manufacturing complex-shaped copper busbar assemblies, the copper busbar 10 can be divided into multiple sections for manufacturing and then welded together, eliminating the need for complex molds and reducing production costs.

[0054] After welding, since the overlap between the first connecting part 112 and the second connecting part 122 is still exposed, a heat shrink tubing 40 can be fitted over the overlap to enhance the insulation, high-temperature resistance, and wear resistance of the connection between the first copper busbar 11 and the second copper busbar 12. In some cases, such as Figure 5 As shown, the protective layer 20 and the insulating film 30 can also be wrapped again at the overlap of the first connecting part 112 and the second connecting part 122.

[0055] Figure 4 and Figure 5 The first copper busbar 11 and the second copper busbar 12 are shown to be arranged perpendicularly. In the design, the first copper busbar 11 and the second copper busbar 12 can also be inclined or located on the same straight line. This application does not limit the positional relationship between different copper busbars 10. The number of copper busbars 10 that need to be welded and fixed is also not limited.

[0056] This application also provides a battery pack including the copper busbar assembly described above.

[0057] This application also provides a vehicle including the battery pack described above.

[0058] The copper busbar assembly, battery pack, and vehicle of this application enhance the adhesion and connection strength between the protective layer 20 and the copper busbar 10 by providing a protective layer 20 on the outside of the copper busbar 10 and hot-pressing the protective layer 20 to the copper busbar 10. This makes the connection between the protective layer 20 and the copper busbar 10 more stable and secure, and the protective layer 20 is resistant to high temperatures while preventing it from being blown away by high air pressure. At the same time, by covering the outer surface of the protective layer 20 with an insulating film 30, the insulation performance and safety of the copper busbar assembly are further improved.

[0059] It should be noted that the technical solutions or features described in the above embodiments can be combined or supplemented with each other without conflict. The scope of protection of this application is not limited to the precise structures described in the above embodiments and shown in the accompanying drawings; all modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A copper busbar assembly, characterized in that, The assembly includes a copper busbar, a protective layer, and an insulating film. The protective layer is disposed on the outside of the copper busbar and is hot-pressed to the copper busbar. The insulating film covers the outer surface of the protective layer. The copper busbar assembly also includes a local wear-resistant structure disposed on the outside of the insulating film.

2. The copper busbar assembly according to claim 1, characterized in that, The protective layer is a mica tape wrapped around the outside of the copper busbar at least once or a mica coating applied to the outside of the copper busbar.

3. The copper busbar assembly according to claim 1, characterized in that, The insulating film includes at least one of PI film, PE film, and PET film.

4. The copper busbar assembly according to claim 1, characterized in that, The copper busbar includes a main body and connecting portions located at both ends of the main body, and the protective layer covers the outer surface of the main body.

5. The copper busbar assembly according to claim 4, characterized in that, The copper busbar includes a first copper busbar and a second copper busbar. The connecting part includes a first connecting part disposed on the first copper busbar and a second connecting part disposed on the second copper busbar. The first connecting part and the second connecting part overlap and are welded together.

6. The copper busbar assembly according to claim 5, characterized in that, A heat shrink tubing is fitted over the overlap between the first connecting part and the second connecting part; and / or, the overlap between the first connecting part and the second connecting part is covered with the protective layer and the insulating film.

7. The copper busbar assembly according to claim 1, characterized in that, The thickness of the insulating film is 0.1-0.3 mm; and / or the thickness of the protective layer is 0.8-2 mm.

8. A battery pack, characterized in that, Includes the copper busbar assembly as described in any one of claims 1-7.

9. A vehicle, characterized in that, Includes the battery pack as described in claim 8.

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