Integrated busbar in direct insertion connection

Abstract

The utility model discloses an integrated busbar in direct insertion connection, which comprises a flexible flat cable assembly, the flexible flat cable assembly comprises an FFC main flat cable and a plurality of FIC branch lines, the first end of the FFC main flat cable is arranged as an insertion end, and the first ends of the FIC branch lines are welded on the FFC main flat cable; the plurality of connecting bars are arranged at the tail ends of the FIC branch lines and are used for connecting single batteries; and the collector is arranged on the connecting bar, and the collector is connected with the tail end of the FIC branch line. The first end of the FFC main flat cable is provided with the plugging end, and the plugging end is used for replacing the output interface, so that the material of the output interface can be saved, in addition, the assembly process corresponding to the output interface can be omitted, the production time is saved, the assembly equipment corresponding to the output interface is saved, and the corresponding equipment cost is saved; therefore, the production cost of the integrated busbar in direct insertion connection is effectively reduced.

Description

Technical Field

[0001] This utility model relates to the field of energy storage battery technology, and in particular to an integrated busbar with direct plug-in connection. Background Technology

[0002] To improve the automated management, monitoring, and safety of new energy batteries, integrated busbars have become an essential structure. The main structure of a new energy battery consists of an integrated busbar and a battery pack. The battery pack includes multiple cells arranged in a row. The integrated busbar covers the top of the battery pack and has direct or indirect electrical connections with the positive and negative terminals of each cell. It also has direct physical contact with the cells through temperature sensors.

[0003] Integrated busbars output signals via multiple signal acquisition wires through output interfaces, while external connections also link to the output interfaces, enabling rapid assembly and signal transmission. However, the presence of output interfaces incurs material costs, assembly process costs, and equipment costs, resulting in high production costs for integrated busbars. Utility Model Content

[0004] In order to solve the technical problem of high production cost of integrated busbars in the existing technology, one of the objectives of this utility model is to provide a direct-connection integrated busbar.

[0005] One of the objectives of this utility model is achieved by the following technical solution: a direct-insertion connected integrated busbar, the integrated busbar comprising:

[0006] A flexible cabling assembly, comprising an FFC main cabling and several FIC branch cablings, wherein the first end of the FFC main cabling is configured as a plug-in end, and the first end of each FIC branch cabling is soldered to the FFC main cabling.

[0007] Several connecting bars are provided at the ends of the FIC branch lines for connecting individual battery cells;

[0008] A data collector is mounted on the connection bar and connected to the end of the FIC branch line.

[0009] Optionally, the plug end is provided with a foolproof groove, and the distance from the foolproof groove to the two sides of the plug end is different.

[0010] Optionally, at least one side of the plug-in terminal is provided with an anti-detachment groove to prevent the plug-in terminal from falling off during plugging.

[0011] Optionally, the FFC main cable includes a reinforcing sheet, two main insulation layers, and a plurality of flat main conductors disposed between the two main insulation layers;

[0012] The first end of the flat main conductor is configured as a through-hole terminal;

[0013] One of the main insulating layers has a cutout area at its first end to expose the through-hole terminal;

[0014] The reinforcing sheet is hot-pressed onto the first end of another main insulating layer to reinforce the plug-in end.

[0015] Optionally, a fuse section is provided on the FIC branch line.

[0016] Optionally, the FIC branch line includes two layers of insulation and at least one flat branch conductor disposed between the two layers of insulation;

[0017] The flat branch conductor is provided with the fuse section.

[0018] Optionally, a first welding portion is provided on the flat main guide line, and a first opening is provided on the main insulating layer for exposing the first welding portion;

[0019] The first end of the flat branch conductor is provided with a second welding part for welding with the first welding part, and the first end of the branch insulation layer is provided with a second opening for exposing the second welding part.

[0020] Optionally, the second welding part has one or more welding holes.

[0021] Optionally, the plurality of flat main lines include a main ground line and multiple main acquisition lines. The main ground line is provided with multiple first welding parts, and the main acquisition line is provided with one first welding part. The first welding parts on each of the main acquisition lines are located at different positions.

[0022] Optionally, the width of the fuse section is smaller than that of the non-fuse section.

[0023] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0024] In this invention, the first end of the FFC main cable is provided with a plug-in end, which replaces the output interface. This firstly saves the material of the output interface. In addition, it can eliminate the assembly process corresponding to the output interface, saving production time and the assembly equipment corresponding to the output interface, thus saving the corresponding equipment cost. This effectively reduces the production cost of the direct-plug integrated busbar. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the integrated busbar structure of this utility model;

[0026] Figure 2This is a top view of the integrated busbar of this utility model;

[0027] Figure 3 for Figure 1 A magnified view of a local area A in the middle;

[0028] Figure 4 This is a schematic diagram of the side structure of the plug-in end of the FFC main busbar in the integrated busbar of this utility model;

[0029] Figure 5 This is a schematic diagram showing the connection state between the FIC branch line and the temperature acquisition device in the integrated busbar of this utility model;

[0030] Figure 6 This is another structural schematic diagram of the temperature acquisition device in the integrated busbar of this utility model;

[0031] Figure 7 This is a schematic diagram of the connecting row in the integrated busbar of this utility model.

[0032] Explanation of reference numerals in the attached diagram:

[0033] 1. Flexible ribbon cable assembly; 11. FFC main ribbon cable; 11a. Plug-in terminal; 11b. Anti-fooling groove; 11c. Anti-detachment groove; 111. Reinforcing sheet; 112. Main insulation layer; 113. Flat main conductor; 12. FIC branch line; 121. Sub-insulation layer; 122. Flat branch conductor; 1221. Fuse section; 1222. Second welding part; 1223. Welding hole;

[0034] 2. Connecting strip; 21. Snap-fit ​​hole;

[0035] 3. Data acquisition unit; 31. Temperature data acquisition unit; 311. Data acquisition motherboard; 312. Thermistor chip; 313. Nickel sheet; 3131. Bending part; 3132. Protrusion; 32. Voltage data acquisition unit;

[0036] 4. Pallet. Detailed Implementation

[0037] The following will refer to the appendices in the embodiments of this application. Figure 1 To be continued Figure 7 The technical solutions in the embodiments of this application are clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0038] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0039] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0040] like Figure 1-3 The diagram shows a plug-in integrated busbar, which includes a flexible cabling assembly 1, several connecting bars 2, and several data collectors 3.

[0041] Specifically, the flexible cable assembly 1 includes an FFC (Flexible Flat Cable) main cable 11 and several FIC (Fuse Inside Cable) branch cables 12. The first end of the FFC main cable 11 is configured as a plug-in terminal 11a, and the first end of each FIC branch cable 12 is soldered to the FFC main cable 11. A connector 2 is located at the end of each FIC branch cable 12 for connecting individual battery cells. A data collector 3 is located on the connector 2 and is connected to the end of each FIC branch cable 12.

[0042] In this embodiment, a plug-in terminal 11a is provided at the first end of the FFC main bus 11. The plug-in terminal 11a replaces the output interface. First, it can save the material of the output interface. In addition, the assembly process corresponding to the output interface can be omitted, saving production time. It also saves the assembly equipment corresponding to the output interface, saving the corresponding equipment cost, thereby effectively reducing the production cost of the direct plug-in integrated bus.

[0043] In some embodiments of the plug-in terminal 11a, such as Figure 3As shown, the plug-in terminal 11a is provided with a foolproof groove 11b, and the distance from the foolproof groove 11b to the two sides of the plug-in terminal 11a is not the same. Specifically, the foolproof groove 11b itself may be positioned off-center, not in the middle of the first end of the FFC main cable 11, thus making the distance from the foolproof groove 11b to the two sides of the plug-in terminal 11a different. Alternatively, the foolproof groove 11b may be located in the middle of the first end of the FFC main cable 11, but notches of different widths are machined on both sides of the plug-in terminal 11a, causing the distance from the foolproof groove 11b to the two sides of the plug-in terminal 11a to change differently, forming different distances. In this embodiment, the foolproof groove 11b is provided on the plug-in terminal 11a, and the distance from the foolproof groove 11b to the two sides of the plug-in terminal 11a is different, so that the plug-in terminal 11a cannot be inserted into an external interface when reversed.

[0044] More specifically, the anti-misfit groove 11b is a groove structure that starts from the end face of the plug end 11a, extends along the length of the FFC main cable 11, and penetrates both main insulation layers 112 vertically.

[0045] In addition, to ensure the stability of the connection, such as Figure 3 As shown, at least one side of the plug-in terminal 11a is provided with an anti-detachment groove 11c to prevent the plug-in terminal 11a from falling off during plugging. When the plug-in terminal 11a is plugged into an external interface, the anti-detachment groove 11c can cooperate with the protrusion in the external interface to lock the plug-in terminal 11a, prevent the plug-in terminal 11a from loosening, and effectively improve the stability of the plugging.

[0046] Furthermore, such as Figure 3 , Figure 4 As shown, the FFC main cable 11 includes a reinforcing sheet 111, two main insulating layers 112, and several flat main conductors 113 disposed between the two main insulating layers 112. The first end of each flat main conductor 113 is configured as a through-hole terminal, which is a structure for inserting into an external interface and is a terminal for electrical connection with the external interface. One of the main insulating layers 112 has a cutout area at its first end to expose the through-hole terminal. The reinforcing sheet 111 is hot-pressed onto the first end of the other main insulating layer 112 to reinforce the plug-in end 11a. Hot-pressing the reinforcing sheet 111 onto the first end of the other main insulating layer 112 increases the through-hole terminal's ability to maintain its shape and increases its strength. This reinforces the plug-in end 11a, preventing or reducing bending deformation during assembly and use, and improving ease of use and service life.

[0047] In some embodiments of the FIC branch line 12, such as Figure 5As shown, the FIC branch line 12 is provided with a fuse section 1221. Specifically, the FIC branch line 12 includes two layers of insulation 121 and at least one flat branch conductor 122 disposed between the two layers of insulation 121. One of the flat branch conductors 122 is provided with a fuse section 1221. In this way, the FIC branch line 12 will melt when the current is too large, which can limit the conduction of large current, improve the safety of the integrated busbar, and avoid excessive heat generation and ignition.

[0048] Furthermore, such as Figure 5 As shown, the flat main conductor 113 has a first welding portion, and the main insulation layer 112 has a first opening for exposing the first welding portion. The first end of the flat branch conductor 122 has a second welding portion 1222 for welding with the first welding portion, and the first end of the branch insulation layer 121 has a second opening for exposing the second welding portion 1222. The first opening is formed on the main insulation layer 112, and the second opening is formed at the first end of the branch insulation layer 121, thereby exposing the second opening to facilitate direct contact between the second welding portion 1222 and the first welding portion, and to facilitate welding equipment to weld the second welding portion 1222 onto the first welding portion.

[0049] Furthermore, the second welding part 1222 is provided with a welding hole 1223 or several welding holes 1223. When welding the second welding part 1222 to the first welding part, welding can be performed through the welding hole 1223. For example, when performing ultrasonic or laser welding, the side wall of the welding hole 1223 can be directly heated to achieve welding at the welding hole 1223, forming a good avoidance effect.

[0050] In addition, the flat main conductors 113 include a main ground line and multiple main acquisition lines. The main ground line has multiple first solder joints, and each main acquisition line has one first solder joint, with the first solder joints on each main acquisition line located at different positions. When soldering the FIC branch line 12 to the FFC main cable 11, if each FIC branch line 12 has a ground line, it can be soldered simultaneously to the first solder joints at different positions. Thus, a single main ground line connects multiple branch ground lines simultaneously, reducing the number of main ground lines required for the FFC main cable 11 to only one, significantly reducing the number of flat main conductors 113 in the FFC main cable 11 and reducing the width of the FFC main cable 11.

[0051] Preferably, the main ground line is located in the middle of the multiple main acquisition lines.

[0052] For fuse section 1221, the width of fuse section 1221 is smaller than that of non-fuse section 1221.

[0053] In some embodiments of collector 3, such as Figure 2 As shown, the data acquisition unit 3 includes a temperature data acquisition unit 31 and a voltage data acquisition unit 32.

[0054] In some embodiments of the voltage acquisition device 32, the voltage acquisition device 32 is specifically a nickel sheet 313 terminal, and more specifically a Z-shaped structure, that is, when the nickel sheet 313 terminal is not bent and soldered, the whole is approximately Z-shaped.

[0055] In some embodiments of the temperature acquisition device 31, such as Figure 2 , Figure 5 , Figure 7 As shown, connector 2 has a snap-fit ​​hole 21. Temperature acquisition unit 31 includes a main board 311, a thermistor chip 312, and a nickel plate 313. The main board 311 is mounted on connector 2 and has three connection terminals, including a positive terminal, a negative terminal, and a ground terminal. The branch cable connected to temperature acquisition unit 31 has three second conductors, which extend simultaneously towards temperature acquisition unit 31 and are respectively connected to the positive terminal, the negative terminal, and the ground terminal.

[0056] Thermistor chip 312 is mounted on the acquisition motherboard 311 and abuts against the connection bar 2. In this way, thermistor chip 312 senses the temperature on the connection bar 2 and generates an electrical signal.

[0057] One end of the nickel sheet 313 is connected to the acquisition motherboard 311, and the other end of the nickel sheet 313 has a bent portion 3131 that fits into the snap-fit ​​hole 21. Specifically, the nickel sheet 313 can be a structure that fixes the acquisition motherboard 311 to the connecting strip 2. Alternatively, the acquisition motherboard 311 can be fixed to the connecting strip 2 with adhesive. In addition to its own temperature and voltage acquisition functions, the nickel sheet 313 also has an auxiliary fixing structure. Specifically, it is a positioning structure before the acquisition motherboard 311 is fixed to the connecting strip 2, and an auxiliary reinforcement structure after the acquisition motherboard 311 is fixed to the connecting strip 2.

[0058] The data acquisition motherboard 311 is fixed to the connector 2 with thermally conductive adhesive. The thermally conductive adhesive secures the data acquisition motherboard 311 to the connector 2. The bottom of the thermistor chip 312 passes through the data acquisition motherboard 311, and the thermally conductive adhesive adheres the bottom of the thermistor chip 312 to the connector 2. The thermally conductive adhesive serves both to fix the data acquisition motherboard 311 and to transfer heat from the connector 2 to the thermistor chip 312.

[0059] Furthermore, such as Figure 5 , Figure 6 As shown, a protrusion 3132 is provided on the side of the bent portion 3131. By providing the protrusion 3132, the pressure between the bent portion 3131 and the snap-fit ​​hole 21 is increased, thereby enhancing the snap-fit ​​strength between the bent portion 3131 and the snap-fit ​​hole 21.

[0060] For connector 2, connector 2 includes multiple series-connected busbars and two output electrodes. The series-connected busbars are either aluminum or copper, and the output electrodes are either aluminum or copper sheets.

[0061] Specifically, the connection row 2 is arranged in two columns, with the two output electrodes located at both ends of one column of connection row 2, or at the ends of both columns of connection row 2 respectively.

[0062] The arrangement of nickel sheet 313 includes horizontal placement and vertical placement, such as... Figure 5 In the vertical arrangement of the nickel sheet 313 shown, the branch lines, the acquisition motherboard 311, and the nickel sheet 313 are arranged in a straight line. For example... Figure 6 As shown, in the horizontal arrangement of the nickel sheet 313, the acquisition motherboard 311 and the nickel sheet 313 are perpendicular to each other.

[0063] In some embodiments of integrated busbars, such as Figure 1 As shown, the integrated busbar also includes a tray 4, which has multiple first openings corresponding to the electrodes of the battery cells. A series busbar is fixed on the tray 4, and the electrodes of two adjacent battery cells are welded to both ends of the series busbar.

[0064] Specifically, tray 4 is flat, which gives it a minimalist structure, reducing its production cost and thus the overall cost of the integrated busbar.

[0065] For the series busbar placed on the tray 4, both ends of the series busbar are provided with welding holes 1223 and connection holes. The series busbar is welded to the electrode of the battery cell at the welding holes 1223, and the series busbar is fixedly connected to the tray 4 at the connection holes.

[0066] Of course, to improve assembly convenience, tray 4 is equipped with two rows of positioning slots. The two rows of connecting bars 2 are placed in the two rows of positioning slots respectively. Through the positioning slots, the series bars and output electrodes can be accurately positioned during assembly, thus speeding up production efficiency.

[0067] When assembling the tandem row, adhesive can be applied by dispensing glue into the connecting holes to bond the tandem row into the positioning groove. Alternatively, positioning posts can be installed on tray 4, with the upper end of the positioning post protruding from the tandem row, and the tandem row can be fixed into the positioning groove by heat fusion of the positioning post.

[0068] The above embodiments are merely preferred embodiments of this utility model and should not be construed as limiting the scope of protection of this utility model. Any non-substantial changes and substitutions made by those skilled in the art based on this utility model shall fall within the scope of protection claimed by this utility model.

Claims

1. An integrated busbar with direct-plug connection, characterized in that, The integrated busbar includes: A flexible cabling assembly, comprising an FFC main cabling and several FIC branch cablings, wherein the first end of the FFC main cabling is configured as a plug-in end, and the first end of each FIC branch cabling is soldered to the FFC main cabling. Several connecting bars are provided at the ends of the FIC branch lines for connecting individual battery cells; A data collector is mounted on the connection bar and connected to the end of the FIC branch line.

2. The integrated busbar with direct-plug connection as described in claim 1, characterized in that, The plug end is provided with a foolproof groove, and the distance from the foolproof groove to the two sides of the plug end is not the same.

3. The integrated busbar with direct-plug connection as described in claim 1 or 2, characterized in that, At least one side of the plug terminal is provided with an anti-detachment groove to prevent the plug terminal from falling off during plugging.

4. The integrated busbar with direct-plug connection as described in claim 1, characterized in that, The FFC main cable includes a reinforcing sheet, two main insulation layers, and several flat main conductors disposed between the two main insulation layers; The first end of the flat main conductor is configured as a through-hole terminal; One of the main insulating layers has a cutout area at its first end to expose the through-hole terminal; The reinforcing sheet is hot-pressed onto the first end of another main insulating layer to reinforce the plug-in end.

5. The integrated busbar with direct-plug connection as described in claim 4, characterized in that, The FIC branch line is equipped with a fuse section.

6. The integrated busbar with direct-plug connection as described in claim 5, characterized in that, The FIC branch line includes two layers of insulation and at least one flat branch conductor disposed between the two layers of insulation; The flat branch conductor is provided with the fuse section.

7. The integrated busbar with direct-plug connection as described in claim 6, characterized in that, A first welding portion is provided on the flat main guide line, and a first opening is provided on the main insulating layer to expose the first welding portion; The first end of the flat branch conductor is provided with a second welding part for welding with the first welding part, and the first end of the branch insulation layer is provided with a second opening for exposing the second welding part.

8. The integrated busbar with direct-plug connection as described in claim 7, characterized in that, The second welding part has one or more welding holes.

9. The integrated busbar with direct-plug connection as described in claim 7 or 8, characterized in that, The aforementioned flat main lines include a main ground line and multiple main acquisition lines. The main ground line is provided with multiple first welding parts, and the main acquisition line is provided with one first welding part. The first welding parts on each of the main acquisition lines are located at different positions.

10. The integrated busbar with direct-plug connection as described in claim 6, characterized in that, The width of the fuse section is smaller than that of the non-fuse section.

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