Integrated busbar forming die and vehicle battery integrated busbar

Abstract

The utility model relates to the technical field of vehicle battery conduction, and discloses an integrated busbar forming die. The integrated busbar forming die comprises an upper cavity die, a lower cavity die and a busbar body, the busbar body comprises an upper insulating adhesive film, an electrical connection assembly and a lower insulating adhesive film, the electrical connection assembly comprises a plurality of groups of electrodes, a busbar, an insulating sheet, a sampling terminal and a connector, one end of the sampling terminal is connected with the plurality of groups of electrodes through the busbar, and the other end of the sampling terminal is connected with the connector; the insulating sheet is arranged around the plurality of groups of electrodes and the busbar; the lower insulation adhesive film is installed in the lower cavity die, the electrical connection assembly is attached to the lower insulation adhesive film, the upper insulation adhesive film is attached to the electrical connection assembly, and the upper cavity die covers the upper insulation adhesive film. The utility model also discloses a vehicle battery integrated busbar. According to the utility model, the material cost is reduced, the production efficiency and the stability of the product quality are improved, the formation of a structure with a certain rigid support is facilitated, and the insulation property is better.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of battery conduction for vehicle, especially relates to a kind of integrated busbar forming die and battery integrated busbar for vehicle. BACKGROUND

[0002] Integrated busbar (CCS) is composed of signal acquisition components, plastic structural parts and copper-aluminum busbars, and is connected by hot pressing or riveting process. Integrated busbar is applied to new energy vehicles and energy storage battery modules to realize cell series-parallel connection, temperature and voltage acquisition, and transmit the acquired signals to battery management system (BMS).

[0003] CCS riveting process generally uses injection molded supports or plastic isolation plates. CCS hot pressing process uses PET insulation film to replace plastic isolation plates to press aluminum bars and signal acquisition components into thin sheets. This process has obvious advantages, making CCS structure lighter and thinner, and higher integration, which is beneficial to improve the space utilization and production efficiency of battery modules, so it has developed rapidly in recent years.

[0004] However, CCS hot pressing process cannot be separated from hot press and hot press mold, and the hot press mold has many shortcomings: 1) hot press mold needs to have high thermal conductivity, which makes material cost higher; 2) using hot press mold involves multiple steps such as high-temperature pressing and cooling, which leads to complicated CCS production process and low production efficiency; 3) when the cooling channel design in the mold is unreasonable, it is easy to cause uneven pressure distribution, which causes different pressures on different parts of CCS during hot pressing, thereby affecting product quality. UTILITY MODEL CONTENTS

[0005] The main purpose of the utility model is to provide an integrated busbar forming die and a battery integrated busbar for vehicle, aiming to solve at least one of the technical problems of high cost, low production efficiency and unstable product quality in producing CCS products by using hot press mold.

[0006] To achieve the above-mentioned purpose, the utility model provides an integrated busbar forming die, which comprises an upper cavity mold, a lower cavity mold and a busbar body. The busbar body comprises an upper insulation film, an electrical connection assembly and a lower insulation film. The electrical connection assembly includes a plurality of groups of electrodes, a busbar, an insulation sheet, a sampling terminal and a connector. One end of the sampling terminal is connected to the plurality of groups of electrodes through the busbar, and the other end of the sampling terminal is connected to the connector. The insulation sheet is arranged around the plurality of groups of electrodes and the busbar. The lower insulation film is installed in the lower cavity mold, the electrical connection assembly is attached to the lower insulation film, the upper insulation film is attached to the electrical connection assembly, and the upper cavity mold covers the upper insulation film.

[0007] Preferably, the upper cavity mold, the upper insulating film, the insulating sheet, the lower insulating film and the lower cavity mold are all provided with positioning holes for mounting pins.

[0008] Preferably, the electrical connection assembly is arranged between the upper and lower insulating films by cold bonding.

[0009] Preferably, the upper and lower insulating films are both acrylic films.

[0010] Preferably, the upper and lower insulating films are both provided with multiple rows of vertically arranged through hole rows, and each through hole row contains multiple through holes.

[0011] Preferably, the upper insulating film is provided with a peephole corresponding to the position of the sampling terminal.

[0012] Preferably, each group of electrodes contains a circular positive electrode connecting piece and a crescent-shaped negative electrode connecting piece, and each group of electrodes is arranged in a corresponding through hole.

[0013] Preferably, the insulating sheet includes a middle insulating sheet and edge insulating sheets provided with positioning holes, and the edge insulating sheets are provided with extensions for mounting the connectors.

[0014] In addition, the utility model also provides a kind of integrated busbar for vehicle battery, including the busbar body obtained by cold bonding of integrated busbar forming die of any one of the above;The busbar body includes upper insulating film, lower insulating film and electrical connection assembly arranged between the upper insulating film and the lower insulating film, and the electrical connection assembly contains multiple groups of electrodes, busbar, insulating sheet, sampling terminal and connector, one end of the sampling terminal is connected with the multiple groups of electrodes through the busbar, the other end of the sampling terminal is connected with the connector, and the insulating sheet is arranged around the multiple groups of electrodes and the busbar.

[0015] Preferably, the other end of the sampling terminal is connected to the connector through a wire.

[0016] Compared with the existing hot-pressing mold, the integrated busbar forming die has the following advantages:

[0017] 1) The material selection range of the upper cavity mold and the lower cavity mold of the integrated busbar forming die is wider, and the material cost is lower.

[0018] 2) The integrated busbar forming die generates integrated busbar products by cold bonding, without the need for multiple steps such as hot bonding and cooling, improving production efficiency.

[0019] 3) The integrated busbar molding die does not require the design of cooling channels, making the structure simpler and avoiding uneven pressure distribution caused by unreasonable cooling channel design, thus improving the stability of product quality.

[0020] 4) The integrated busbar forming mold, by setting an insulating sheet in the interlayer between the upper and lower insulating films, is conducive to forming a structure with a certain rigid support and better insulation. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the assembly of the integrated busbar forming mold in one embodiment of the present invention;

[0023] Figure 2 for Figure 1 Exploded view of the integrated busbar forming mold;

[0024] Figure 3 for Figure 1 A schematic diagram of the upper cavity mold of the integrated busbar forming mold;

[0025] Figure 4 for Figure 1 A schematic diagram of the lower cavity mold of the integrated busbar forming mold;

[0026] Figure 5 This is a schematic diagram of the structure of an integrated busbar for a vehicle battery according to another embodiment of the present invention;

[0027] Figure 6 For along Figure 5 Schematic diagram of the cross section of line AA in the middle;

[0028] Figure 7 for Figure 6 A magnified view of a portion of point a.

[0029] The serial numbers in the diagram are explained as follows:

[0030] 1. Upper cavity mold; 11. Recess; 2. Lower cavity mold; 21. Protrusion; 3. Upper insulating film; 4. Electrical connection assembly; 41. Electrode; 42. Busbar; 43. Insulating sheet; 44. Sampling terminal; 45. Connector; 5. Lower insulating film; 61. Through hole; 62. Viewing hole; 63. Positioning hole; 7. Pin. Detailed Implementation

[0031] For a better understanding of the above technical solutions, the exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to convey the scope of the present disclosure to those skilled in the art.

[0032] It should be understood that the specific embodiments described herein are merely intended to explain the present application and should not be used to limit the present application.

[0033] It should be understood that in the embodiments of the present application, 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" and the like indicate the orientation or positional relationship based on the coordinate system shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0034] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connection", "fixing" and the like should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0035] In the present application, unless otherwise explicitly specified and limited, the first feature is "on" or "under" the second feature. The first and second features can be in direct contact, or the first and second features can be in indirect contact through an intermediate medium. Moreover, the first feature "above", "above" and "above" the second feature can be directly above or obliquely above the second feature, or it can only mean that the horizontal height of the first feature is higher than that of the second feature. The first feature "below", "below" and "below" the second feature can be directly below or obliquely below the second feature, or it can only mean that the horizontal height of the first feature is less than that of the second feature.

[0036] An embodiment of the present application provides a kind of integrated busbar forming die, reference Figure 1 And Figure 2The integrated busbar forming die comprises an upper cavity die 1, a lower cavity die 2 and a busbar body; the busbar body comprises an upper insulating film 3, an electrical connection assembly 4 and a lower insulating film 5, the electrical connection assembly 4 comprises a plurality of groups of electrodes 41, a busbar 42, an insulating sheet 43, a sampling terminal 44 and a connector 45, one end of the sampling terminal 44 is connected with the plurality of groups of electrodes 41 through the busbar 42, the other end of the sampling terminal 44 is connected with the connector 45, and the insulating sheet 43 is arranged around the plurality of groups of electrodes 41 and the busbar 42; the lower insulating film 5 is installed in the lower cavity die 2, the electrical connection assembly 4 is attached to the lower insulating film 5, the upper insulating film 3 is attached to the electrical connection assembly 4, and the upper cavity die 1 covers the upper insulating film 3.

[0037] It can be understood that the upper cavity die 1 and the lower cavity die 2 of the integrated busbar forming die in the embodiment adopt the same material cavity, for example, the upper cavity die 1 and the lower cavity die 2 can be selected from a polyamide cavity capable of bearing a certain pressure, an ABS plastic cavity convenient for processing and forming, an epoxy glass fiber cavity or other non-metal cavities, etc. The upper insulating film 3 and the lower insulating film 5 both adopt cold-attached insulating films, which do not need high-temperature pressing and can be tightly connected with the electrical connection assembly 4 through cold-attachment. Preferably, the thickness of the insulating sheet 43 is the same as the thickness of the busbar 42, which can make the components to be attached in the same plane, facilitating the discharge of bubbles during cold-attachment.

[0038] Preferably, the upper cavity die 1 is provided with a recess 11 on the side facing the busbar body, the shape of the recess 11 matches the shape of the combination of the electrode 41 and the busbar 42 connected therewith. Figure 3 Preferably, the lower cavity die 2 is provided with a protrusion 21 on the side facing the busbar body, the protrusion 21 is used for positioning the through hole 61 on the insulating film and the electrode 41 in the through hole 61. At this time, by arranging the recess 11 and the protrusion 21, the upper cavity die 1 and the lower cavity die 2 can be tightly pressed. Figure 4

[0039] It should be noted that the material of the electrode 41 and the busbar 42 is not limited in the embodiment and can be a metal or alloy material such as copper, aluminum, nickel, etc.

[0040] The production process of the integrated busbar forming die specifically comprises the following steps:

[0041] Step a, placing the lower insulating film 5 in the lower cavity die 2;

[0042] Step b, placing each group of electrodes 41, the busbar 42 and the insulating sheet 43 on the laid lower insulating film 5 according to the connection relationship of the electrical connection assembly 4; ​

[0043] Step c, placing the sampling terminal 44 at the connection of the busbar 42 and the insulating sheet 43, and placing the connector 45 at the outermost side of the insulating sheet 43;

[0044] Step d, covering the upper insulating adhesive film 3;

[0045] Step e, covering the upper cavity mold 1;

[0046] Step f, after the upper cavity mold 1 and the lower cavity mold 2 are pressed, the product corresponding to the busbar body, i.e. the integrated busbar for vehicle battery, is taken out.

[0047] In summary, compared with the existing hot-pressing mold, the integrated busbar forming mold of the embodiment has the following beneficial effects:

[0048] 1) The material selection range of the upper cavity mold 1 and the lower cavity mold 2 of the integrated busbar forming mold is wider, and the material cost is lower;

[0049] 2) The integrated busbar product is generated by using the integrated busbar forming mold, without the need for multiple steps such as hot bonding and cooling, thereby improving the production efficiency;

[0050] 3) The integrated busbar forming mold does not need to design a cooling flow channel, and the structure is simpler, and the problem of uneven pressure distribution caused by unreasonable cooling flow channel design can be avoided, thereby improving the stability of product quality;

[0051] 4) The integrated busbar forming mold sets the insulating sheet 43 in the interlayer of the upper insulating adhesive film 3 and the lower insulating adhesive film 5, which is conducive to forming a structure with certain rigid support and has better insulation.

[0052] In a preferred embodiment, referring to Figure 1 and Figure 2 The upper cavity mold 1, the upper insulating adhesive film 3, the insulating sheet 43, the lower insulating adhesive film 5 and the lower cavity mold 2 are all provided with positioning holes 63 for installing the pins 7.

[0053] In the embodiment, the upper cavity mold 1, the upper insulating adhesive film 3, the insulating sheet 43, the lower insulating adhesive film 5 and the lower cavity mold 2 are all provided with positioning holes 63. At this time, when producing the product by using the integrated busbar forming mold, first, the pins 7 are installed in the positioning holes 63 of the lower cavity mold 2, and then the positioning holes 63 of the lower insulating adhesive film 5, the insulating sheet 43 in the electrical connection assembly 4, the upper insulating adhesive film 3 and the upper cavity mold 1 are aligned with the positioning holes 63 of the lower cavity mold 2, and then the pins 7 are fixedly installed on the lower cavity mold 2, which can avoid the problem of position deviation in the cold bonding and pressing process, thereby improving the production quality of the product.

[0054] In a preferred embodiment, the electrical connection assembly 4 is arranged between the upper insulating adhesive film 3 and the lower insulating adhesive film 5 by cold bonding.

[0055] It can be understood that, compared with a hot-pressing mold, the integrated busbar forming mold of the embodiment adopts a cold bonding manner, cancels the steps of heat curing and cooling, improves the production efficiency of the integrated busbar, effectively avoids the problem of uneven pressure distribution caused by unreasonable design of the cooling runner in the mold, reduces the defective products, and improves the stability of product quality.

[0056] Preferably, the upper insulating adhesive film 3 and the lower insulating adhesive film 5 are both acrylic adhesive films. The acrylic adhesive film can be a dry adhesive or a 3M adhesive.

[0057] In the embodiment, the surfaces of the upper insulating adhesive film 3 and the lower insulating adhesive film 5 facing the electrical connection assembly 4 are adhesive, so that the upper insulating adhesive film 3 and the lower insulating adhesive film 5 can be connected with the electrical connection assembly 4. Further, pressure is applied to the integrated busbar forming mold at room temperature, so that the upper insulating adhesive film 3, the electrical connection assembly 4 and the lower insulating adhesive film 5 are completely bonded, forming an integrated busbar product. Compared with the PET insulating film formed by a hot-pressing mold, the acrylic adhesive film is used in the embodiment, and hot bonding is not required, so that the production efficiency is higher.

[0058] In a preferred embodiment, referring to Figure 2 , the upper insulating adhesive film 3 and the lower insulating adhesive film 5 both have a plurality of vertically arranged through hole rows; and each through hole row contains a plurality of through holes 61.

[0059] It can be understood that the through holes 61 arranged on the upper insulating adhesive film 3 and the lower insulating adhesive film 5 are coincident, and the shape of the through holes 61 can be oval or mushroom-shaped as shown in Figure 2 , and the number of rows of through hole rows and the number of through holes in each row are set according to requirements, for example, Figure 2 In the embodiment, the upper insulating adhesive film 3 and the lower insulating adhesive film 5 both have four vertically arranged through hole rows, and each through hole row contains six through holes 61. The through hole rows can provide appropriate mounting space for the electrodes 41, and ensure the electrical connection stability of the electrodes 41.

[0060] In a preferred embodiment, referring to Figure 2 , the upper insulating adhesive film 3 is provided with a peephole 62 corresponding to the position of the sampling terminal 44.

[0061] It can be understood that the upper insulating film 3 is also provided with a plurality of peep holes 62 corresponding to the number of sampling terminals 44, and the peep holes 62 are arranged above the first connecting end of the sampling terminal 44 (i.e. the end of the sampling terminal 44 connected to the bus bar 42), and the peep holes 62 are preferably circular. In this embodiment, the peep holes 62 are arranged on the upper insulating film 3 to expose the sampling terminals 44, which facilitates laser welding of the sampling terminals 44 and visual capture during laser welding.

[0062] In a preferred embodiment, each group of the electrodes 41 includes a circular positive connecting piece and a crescent-shaped negative connecting piece, and each group of the electrodes 41 is arranged in a corresponding through hole 61.

[0063] It can be understood that each group of electrodes 41 includes a positive connecting piece and a negative connecting piece arranged opposite to each other in the through hole 61. For each group of electrodes 41 in the same row, the positive connecting piece of the previous group of electrodes 41 is electrically connected to the negative connecting piece of the subsequent group of electrodes 41 through the bus bar 42, and for each group of electrodes 41 in the same row, the positive connecting piece or the negative connecting piece is electrically connected through the multi-segment bent bus bar 42. Through this arrangement, the electrical connection stability of the product can be improved.

[0064] In a preferred embodiment, the insulating sheet 43 includes an intermediate insulating sheet and an edge insulating sheet having a positioning hole 63, and the edge insulating sheet is provided with an extension for mounting the connector 45.

[0065] More specifically, the insulating sheet 43 includes a plurality of intermediate insulating sheets and two edge insulating sheets, which are a left edge insulating sheet and a right edge insulating sheet, respectively. The intermediate insulating sheets are separated by the electrodes 41 and the bus bars 42 connected thereto, i.e. the intermediate insulating sheets are arranged outside the through holes 61 and the area surrounded by the bus bars 42.

[0066] At this time, the inner side of the right edge insulating sheet is provided with a sampling terminal 44 corresponding to the middle position of each bus bar 42, and the outer side of the right edge insulating sheet is provided with an extension, and the connector 45 is arranged on the extension. Through the connector 45, the collected signals can be transmitted to the battery management system.

[0067] Further, the insulating sheet 43 can be made of different materials according to requirements, such as insulating paper, Mylar paper, epoxy glass fiber plate and PEF (polyethylene) sheet, and the insulating sheet 43 can be further treated on the surface to improve the removal of bubbles during cold bonding and avoid bonding bubbles, such as frosted matte treatment on the surface of the insulating sheet 43.

[0068] Further, the electrical connection assembly 4 corresponding to the position of the edge insulation sheet on the right side is also provided with a wire row for connecting the sampling terminal 44 and the connector 45. It should be noted that in the embodiment, the sampling terminal 44 and the wire row are not limited to be arranged above the insulation sheet 43, as long as they are ensured to be below the upper insulation film 3, at least to be sandwiched by the upper insulation film 3 and the lower insulation film 5, so as to avoid the sampling terminal 44 and the wire row being exposed, and improve the electrical safety.

[0069] It can be understood that, in the embodiment, the insulation sheet 43 is arranged in the interlayer of the upper insulation film 3 and the lower insulation film 5, so as to form an integrated busbar structure with certain rigid support, and the integrated busbar product has better insulation.

[0070] In addition, the utility model discloses another embodiment further provides a vehicle battery integrated busbar, referring to Figures 5 to 7 The vehicle battery integrated busbar includes the busbar body obtained by cold pasting and pressing of the integrated busbar forming die of any one of the above-mentioned embodiments, and the busbar body includes the upper insulation film 3, the lower insulation film 5 and the electrical connection assembly 4 arranged between the upper insulation film 3 and the lower insulation film 5, the electrical connection assembly 4 includes a plurality of groups of electrodes 41, a busbar 42, an insulation sheet 43, a sampling terminal 44 and a connector 45, one end of the sampling terminal 44 is connected with the plurality of groups of electrodes 41 through the busbar 42, the other end of the sampling terminal 44 is connected with the connector 45, and the insulation sheet 43 is arranged around the plurality of groups of electrodes 41 and the busbar 42.

[0071] Preferably, the other end of the sampling terminal 44 is connected to the connector 45 through a wire. The wire can be a FPC flexible wire or a FFC wire.

[0072] Preferably, the upper insulation film 3 and the lower insulation film 5 each have a plurality of vertical through hole rows, each group of the electrodes 41 includes a circular positive electrode connecting sheet and a crescent negative electrode connecting sheet, each group of the electrodes 41 is arranged in one of the through holes 61, the insulation sheet 43 includes a middle insulation sheet and an edge insulation sheet with a positioning hole 63, and the edge insulation sheet is provided with an extension for mounting the connector 45.

[0073] It can be understood that, in the embodiment, the vehicle battery integrated busbar is obtained by cold pasting and pressing of the integrated busbar forming die, so as to have higher production efficiency and better quality stability, and the insulation sheet 43 arranged in the interlayer of the upper insulation film 3 and the lower insulation film 5 is beneficial to form a structure with certain rigid support and has better insulation.

[0074] The above are only preferred embodiments of the present application, and do not limit the patent range of the present application, and any equivalent structure or equivalent process transformation made by using the content of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection range of the present application.

Claims

1. An integrated busbar forming die, characterized by, The application relates to an integrated busbar forming die and a busbar body formed by the integrated busbar forming die. The upper cavity die (1), the upper insulating film (3), the insulating sheet (43), the lower insulating film (5) and the lower cavity die (2) are provided with positioning holes (63) for mounting pins (7).

2. The integrated busbar forming die of claim 1, wherein, The electrical connection assembly (4) is arranged between the upper insulating film (3) and the lower insulating film (5) by cold bonding and pressing.

3. The integrated busbar forming die of claim 1, wherein, The upper insulating film (3) and the lower insulating film (5) are both acrylic films.

4. The integrated busbar forming die of claim 3, wherein, The upper insulating film (3) and the lower insulating film (5) are both provided with a plurality of vertically-arranged through hole rows; each through hole row comprises a plurality of through holes (61).

5. The integrated busbar forming die of claim 1, wherein, The upper insulating film (3) is provided with a peep hole (62) corresponding to the position of the sampling terminal (44).

6. The integrated busbar forming die of claim 5, wherein, Each group of the electrodes (41) comprises a circular positive electrode connecting sheet and a crescent-shaped negative electrode connecting sheet, and each group of the electrodes (41) is arranged in a corresponding through hole (61).

7. The integrated busbar forming die of claim 5, wherein, The insulating sheet (43) comprises a middle insulating sheet and an edge insulating sheet provided with positioning holes (63), and the edge insulating sheet is provided with an extension part for mounting the connector (45).

8. The integrated busbar forming die of claim 1, wherein, The application relates to a busbar body formed by cold bonding and pressing of an integrated busbar forming die; the busbar body comprises an upper insulating film (3), a lower insulating film (5) and an electrical connection assembly (4) arranged between the upper insulating film (3) and the lower insulating film (5); the electrical connection assembly (4) comprises a plurality of groups of electrodes (41), a busbar (42), an insulating sheet (43), a sampling terminal (44) and a connector (45); one end of the sampling terminal (44) is connected to the plurality of groups of electrodes (41) through the busbar (42), and the other end of the sampling terminal (44) is connected to the connector (45); the insulating sheet (43) is arranged around the plurality of groups of electrodes (41) and the busbar (42).

9. A battery integrated busbar for vehicles, characterized by, The other end of the sampling terminal (44) is connected to the connector (45) through a wire.

10. The battery-integrated busbar for vehicles according to claim 9, wherein ​

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