New energy battery aluminum sensor module
By using aluminum circuitry and polyester insulation, combined with hot pressing and die-cutting processes, the environmental pollution and cost issues associated with copper and polyimide films are resolved, achieving low-cost, environmentally friendly, and stable connection of aluminum sensor modules.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-06
- Publication Date
- 2026-03-06
AI Technical Summary
The use of copper and polyimide film in the manufacturing process of existing new energy battery sensor modules leads to environmental pollution and increased costs. Furthermore, copper and aluminum busbars cannot be directly laser welded and must be connected through a nickel sheet medium, which increases connection risks and costs.
The circuit uses aluminum material and polyester insulation layer, which are combined by hot pressing. A waveform structure is designed on the bus, and the circuit is directly welded to the bus, eliminating the nickel sheet connection and using a die-cutting process instead of an etching process.
It reduces production costs, simplifies processing techniques, reduces environmental pollution, improves connection stability and welding strength, and adapts to vibration and thermal expansion and contraction.
Smart Images
Figure CN223977938U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of battery module technology for new energy vehicles, and in particular to an aluminum sensor module for new energy batteries. Background Technology
[0002] Typically, new energy battery sensor modules consist of a flexible circuit board and nickel foil soldered together. The nickel foil is then connected to a busbar via laser welding. When the busbar is in operation, the nickel foil transmits the collected voltage signal to the flexible circuitry, thus achieving voltage acquisition. The flexible circuit board is composed of numerous copper wires, with PI (polyimide film) insulating films on top and bottom. The copper wires are formed by etching a single piece of copper foil. The chemical reagents used in the etching process can produce harmful substances such as acids, alkalis, and heavy metals, polluting the environment. Furthermore, the use of polyimide film for both the copper wires and the insulating layer increases manufacturing costs.
[0003] In addition, since copper foil and aluminum busbars are not the same material, they cannot be directly laser welded. This requires connecting the copper lines to the busbars with additional nickel sheets. The addition of nickel sheets not only increases the risk of connection points but also increases the cost of purchasing nickel sheets. Utility Model Content
[0004] Based on the shortcomings of the aforementioned background technology, the purpose of this utility model is to provide a new energy aluminum sensor module that features simple processing technology, stable connection, low production cost, and environmental friendliness.
[0005] To achieve the above objectives, this utility model provides the following technical solution:
[0006] A new energy battery aluminum sensor module includes: an upper insulating layer, a lower insulating layer, and circuitry;
[0007] The circuit is located between the upper insulating layer and the lower insulating layer, and the circuit is pressed together with the upper and lower insulating layers by hot pressing; the hot-pressed circuit and one end of the upper and lower insulating layers are connected to the connector.
[0008] Preferably, the circuit is made of aluminum.
[0009] Preferably, the upper and lower insulating layers are made of polyester as the insulating material.
[0010] Preferably, the lines are arranged on the busbar and welded together with the busbar by welding.
[0011] Preferably, the busbar includes busbar one and busbar two, and busbar one and busbar two are respectively welded to the line.
[0012] Preferably, the busbar is provided with a waveform structure.
[0013] The beneficial effects of this utility model are:
[0014] (1) This utility model provides a new energy battery aluminum sensor module. The circuit board is composed of aluminum circuits. Polyester is used as the insulating film layer on the top and bottom of the circuits. The circuits can be arranged on the busbar by welding. The overall structure is simple. The circuit uses aluminum instead of expensive copper, which not only reduces the production cost but also simplifies the processing technology. The insulation layer uses polyester instead of polyimide, which further reduces the production cost.
[0015] (2) The present invention provides a new energy battery aluminum sensor module with a waveform structure designed on the busbar to absorb vibration and thermal expansion and contraction, and to increase the welding space of the circuit. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the overall structure of an aluminum sensor module for a new energy battery according to this utility model;
[0017] Figure 2 This is an exploded view of the new energy aluminum sensor module shown.
[0018] Figure 3 This is a schematic diagram of the circuit structure in the new energy aluminum sensor module shown.
[0019] Figure 4 This is a schematic diagram of the busbar structure in the new energy aluminum sensor module shown.
[0020] Figure 5 This is a schematic diagram of the waveform structure on the bus shown.
[0021] The components in the attached diagram are labeled as follows:
[0022] 1. Upper insulation layer; 2. Lower insulation layer; 3. Circuit; 4. Busbar 1; 5. Busbar 2; 6. Waveform structure; 7. Connector; 8. Soldering area; 9. Fuse. Detailed Implementation
[0023] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the scope of protection of the present invention.
[0024] Example:
[0025] This embodiment introduces an aluminum sensor module for new energy batteries.
[0026] refer to Figure 1 , 2 As shown, Figure 1 This is a schematic diagram of the overall structure of an aluminum sensor module for a new energy battery according to this utility model. Figure 2 This is an exploded view of the new energy aluminum sensor module shown. A new energy battery aluminum sensor module includes: an upper insulating layer 1, a lower insulating layer 2, and circuitry 3.
[0027] The line 3 is located between the upper insulating layer 1 and the lower insulating layer 2. The line 3, the upper insulating layer 1, and the lower insulating layer 2 are pressed together by hot pressing. The hot-pressed line 3 and one end of the upper insulating layer 1 and the lower insulating layer 2 are connected to the connector 7.
[0028] In this embodiment, the circuit 3 is made of aluminum, replacing the expensive copper material used in existing products. Aluminum can be processed into aluminum wires to form a circuit board through die-cutting, which greatly reduces production costs.
[0029] In this embodiment, the upper insulating layer 2 and the lower insulating layer 3 are made of polyester as the insulating film layer. Polyester has excellent electrical insulation properties, high mechanical strength, good thermal stability and chemical stability, and is widely used in capacitors, motors, transformers, cables and other fields, making it an ideal insulating material. Moreover, using polyester for the insulating layer is less expensive than using polyimide in the prior art. The upper and lower insulating layers can be completed by a die-cutting process, which is both efficient and environmentally friendly compared to the etching process used in the prior art.
[0030] Furthermore, the lines are arranged on a busbar, which includes busbar 4 and busbar 5. Busbar 4 and busbar 5 are welded to the lines 3 by welding.
[0031] In this invention, aluminum is used instead of expensive copper for the circuit, which not only reduces production costs but also simplifies the processing. Because both the circuit material and the busbar are made of aluminum, the circuit can be directly welded to the busbar using laser welding, compared to the existing technology which requires nickel sheets as a medium to weld the copper circuit to the busbar. Furthermore, to ensure welding strength, the newly designed circuit has a significantly increased welding area. Figure 3 As shown, Figure 3 This is a schematic diagram of the circuit structure in the new energy aluminum sensor module shown. The welding area 8 on line 3 provides sufficient welding area to achieve a stable connection between the line and the busbar. A fuse 9 is designed to be connected at one end of the welding area 8. This fuse is designed to protect the line safety during the voltage acquisition process.
[0032] To increase the welding space for the circuit, in this embodiment, the welding area of the busbar is separately lengthened and a waveform structure 6 is designed to absorb vibration and thermal expansion and contraction. For example... Figure 4 ,5 As shown, Figure 4 This is a schematic diagram of the busbar structure in the new energy aluminum sensor module shown. Figure 5 The diagram shows the waveform structure on the busbar. This structural design provides more space compared to traditional new energy battery sensor modules, which are typically arranged in the narrow space of two busbars. This allows the wiring to be located on top of the busbar and directly rest on the aluminum busbar, facilitating soldering.
[0033] Compared with existing technologies, the aluminum sensor module for new energy batteries formed by the above-mentioned technology has a simpler overall processing technology, a more stable connection between the circuit board and the busbar, and a significant reduction in production costs.
[0034] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the description and drawings of this utility model, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.
Claims
1. A new energy battery aluminum sensor module, characterized in that, The utility model relates to a kind of circuit board, including: Upper insulating layer (1), lower insulating layer (2), line (3); The line (3) is located between the upper insulating layer (1) and the lower insulating layer (2), and the line (3) is pressed together with the upper insulating layer (1) and the lower insulating layer (2) by hot pressing mode;One end of the line (3) and the upper insulating layer (1) and the lower insulating layer (2) after hot pressing is connected with connector (7).
2. The new energy battery aluminum sensor module according to claim 1, characterized in that: The line (3) is made of aluminum material.
3. The new energy battery aluminum sensor module according to claim 1, characterized in that: The upper insulating layer (1) and the lower insulating layer (2) use polyester as insulating material.
4. The new energy battery aluminum sensor module according to claim 1, characterized in that: The line (3) is arranged on bus bar, and the line (3) is welded with bus bar by welding mode.
5. The new energy battery aluminum sensor module according to claim 4, characterized in that: The bus bar includes bus bar one (4), bus bar two (5), and the bus bar one (4) and the bus bar two (5) are welded with line (3) respectively.
6. The new energy battery aluminum sensor module according to claim 4, characterized in that: Wave structure (6) is provided on the bus bar.