Integrated busbar assembly

Abstract

The utility model discloses an integrated busbar assembly, and relates to the technical field of batteries. The integrated busbar assembly comprises an aluminum bar, and the aluminum bar is welded on the battery cell pole; the nickel sheet is welded on the aluminum bar; the first epoxy board is provided with a front loop and a back loop, and the front loop and the back loop of the first epoxy board are in conduction connection; the connector is welded on the first epoxy plate and is in conducting connection with a loop on the front surface of the first epoxy plate; and the FFC flat flexible cable is connected with the nickel sheet in a welding manner, is connected with a back loop of the first epoxy plate in a welding manner, and is further connected with the NTC thermistor in a conducting manner. According to the integrated busbar assembly provided by the utility model, as the FFC flat flexible cable can be bent and folded to adaptively change the shape, the integrated busbar assembly can be applied to CTP battery packs of various models, so that the number of types of corresponding molds is correspondingly reduced, and the manufacturing cost is reduced.

Description

Technical Field

[0001] This utility model relates to the field of battery technology, and in particular to an integrated busbar assembly. Background Technology

[0002] The battery pack CCS (Cells Contact System) is a core component in new energy vehicles and energy storage battery systems that connects battery cells and enables signal acquisition.

[0003] Currently, the signal acquisition components of battery pack CCS typically use FPC (flexible printed circuit board) to connect temperature sensors, battery cells, and BMS (battery management system) to monitor cell status, integrate cell charging and discharging functions, and transmit signal data such as voltage and temperature.

[0004] However, with the popularity of CTP battery pack solutions, the arrangement of cells in different models of CTP battery packs is different, and the placement of voltage and temperature sensors also varies. Therefore, in actual production, FPCs of different shapes and structures are produced for different models of CTP battery packs, resulting in a variety of production molds and tooling (such as film, stencil mold, die-cutting mold, etc.) for FPCs, which leads to high cost. Utility Model Content

[0005] To address the aforementioned technical deficiencies in existing technologies, this utility model provides an integrated busbar assembly that uses FFC flat flexible cables to connect the battery cells, BMS, and temperature sensors. Since the FFC flat flexible cable can be bent and folded to adapt to changing its shape, this integrated busbar assembly can be applied to various types of CTP battery packs, thereby reducing the number of corresponding mold types and lowering manufacturing costs.

[0006] The technical solution of this utility model to solve the above problems is: to provide an integrated busbar assembly, the integrated busbar assembly comprising:

[0007] The aluminum bar is welded and installed on the cell terminal.

[0008] Nickel sheets, nickel sheets welded onto aluminum bars;

[0009] The first epoxy board has a front circuit and a back circuit, and the front circuit and the back circuit of the first epoxy board are electrically connected.

[0010] The connector is soldered onto the first epoxy board and is electrically connected to the front circuit of the first epoxy board.

[0011] The FFC flat flexible cable is welded to a nickel sheet, welded to the back circuit of the first epoxy board, and also connected to an NTC thermistor.

[0012] Furthermore, the NTC thermistor is located at the QR code on the battery cell.

[0013] Furthermore, it also includes a second epoxy board, which is also provided with a back circuit. An NTC thermistor is welded to the second epoxy board and is electrically connected to the back circuit of the second epoxy board. An FFC flat flexible cable is connected to the NTC thermistor by being electrically connected to the back circuit of the second epoxy board.

[0014] Furthermore, an FR4 reinforcing plate is also bonded to the surface of the second epoxy board where the NTC thermistor is located.

[0015] Furthermore, the FR4 reinforcing plate has an opening that exposes the NTC thermistor.

[0016] Furthermore, a thermally conductive silicone pad is also bonded to the FR4 reinforcing plate, and the thermally conductive silicone pad is disposed opposite to the second epoxy plate on the two surfaces of the FR4 reinforcing plate.

[0017] Furthermore, the front circuit and the back circuit of the first epoxy board are interconnected by a fuse.

[0018] Furthermore, it also includes a vacuum forming bracket, on which multiple aluminum foils and multiple second epoxy boards are evenly arranged.

[0019] Furthermore, the vacuum forming bracket is equipped with hot riveting posts, and the aluminum bar is provided with corresponding mounting through holes for the hot riveting posts to pass through. The aluminum bar is riveted and fixed to the vacuum forming bracket by the hot riveting posts; the second epoxy board is bonded and fixed to the vacuum forming bracket.

[0020] The beneficial effects of this utility model are:

[0021] This utility model discloses an integrated busbar assembly that uses flat flexible cables to connect battery cells, BMS, and temperature sensors. Since the flat flexible cables can be bent and folded to adapt to changing shapes, this integrated busbar assembly can be applied to various types of CTP battery packs to reduce the number of corresponding mold types and lower manufacturing costs.

[0022] In addition, this invention further enhances the safety of the entire integrated busbar assembly by setting a fuse structure between the front circuit and the back circuit of the first epoxy board. Attached Figure Description

[0023] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. In these drawings, similar reference numerals are used to denote similar elements. The drawings described below are some embodiments of the present invention, but not all embodiments. Other drawings will be readily available to those skilled in the art based on these drawings without any inventive effort.

[0024] Figure 1 This is an overall structural diagram of the integrated busbar assembly in this embodiment;

[0025] Figure 2 for Figure 1 Enlarged view of the local structural domain at position A in the image;

[0026] Figure 3 for Figure 1 Enlarged view of the local structure at position B in the image;

[0027] Figure 4 This is a schematic diagram of the assembly principle of the second epoxy board, NTC thermistor, FR4 reinforcing plate and thermally conductive silicone pad in this embodiment;

[0028] 1-Aluminum bar, 2-Nickel sheet, 3-First epoxy board, 4-Connector, 5-FFC flat flexible cable, 6-NTC thermistor, 7-Second epoxy board, 8-FR4 reinforcing plate, 9-Opening, 10-Thermal conductive silicone pad, 11-Blister bracket, 12-Thermal riveting post. Detailed Implementation

[0029] The directional terms such as up, down, left, right, front, back, front, back, top, and bottom mentioned or possibly used in this specification are defined relative to the construction shown in the accompanying drawings. The terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively. These are relative concepts and may therefore vary depending on their location and usage. Therefore, these or other directional terms should not be interpreted as restrictive.

[0030] Please see Figures 1 to 4An integrated busbar assembly according to a specific embodiment of this utility model includes an aluminum bar 1, a nickel sheet 2, a first epoxy board 3, a connector 4, an NTC thermistor 6, and an FFC flat flexible cable 5. The flat flexible cable has one external terminal and multiple internal terminals. One external terminal is electrically connected to the connector 4 through the epoxy board. A portion of the internal terminals are electrically connected to the multiple aluminum bars 1 through the nickel sheet 2. The multiple aluminum bars 1 are electrically connected to the terminals of multiple battery cells one by one. Another portion of the internal terminals are electrically connected to the multiple NTC thermistors 6. The multiple NTC thermistors 6 are positioned above the QR code of the battery cell where the temperature change is most significant, according to the specific size and model of the battery module.

[0031] Thus, when the integrated busbar assembly is electrically connected to the battery BMS system at connector 4, the battery BMS system can obtain the corresponding data signals and control the charging and discharging of each cell.

[0032] It should be emphasized that in this embodiment, the FFC flat flexible cable 5 is a cable structure. Within a reasonable range, technicians can bend its inner terminals, outer terminals, and body in various directions, so it can be transformed into different shapes to adapt to the usage requirements of batteries of different sizes. This allows the corresponding module tooling used to manufacture the FFC flat flexible cable 5 to be simplified to a few types, thereby reducing the manufacturing and procurement costs of the integrated busbar assembly.

[0033] In addition, such as Figure 1 As shown, in this embodiment, the aluminum bar 1 has two structural forms: a longitudinally placed long strip plate and a transversely placed wide strip plate. Both structural forms of the aluminum bar 1 are connected to the corresponding battery cell terminals by welding. A nickel sheet 2 is welded to the upper surface of each aluminum bar 1. An FFC flat flexible cable 5 is connected to the nickel sheets 2 on multiple transversely equidistant aluminum bars 1 by welding through multiple internal terminals, so as to conduct electricity with multiple aluminum bars 1 at the same time.

[0034] Furthermore, the first epoxy board 3 has a front circuit on its upper end face and a back circuit on its lower end face. The first epoxy board 3 has a fuse structure inside, and the front circuit and the back circuit of the first epoxy board 3 are electrically connected to each other through the fuse structure. The connector 4 is welded to the upper end face of the first epoxy board 3 and is electrically connected to the front circuit of the first epoxy board 3. One external terminal of the FFC flat flexible cable 5 extends to the lower end face of the first epoxy board 3 to connect with the back circuit, thereby electrically connecting the aluminum bar 1 and the connector 4, and the NTC thermistor 6 and the connector 4.

[0035] Further, please refer to Figure 1In this embodiment, multiple aluminum batteries 1 are installed on the same blister bracket 11. The specific shape and size of the blister bracket 11 correspond to the shape of the upper surface of the corresponding battery, so that technicians can align and install multiple aluminum batteries 1 with the terminals of multiple battery cells one by one by fixing and installing the blister bracket 11.

[0036] It should be noted that in this embodiment, the blister bracket 11 is provided with a number of hot riveting posts 12. Each aluminum bar 1 is provided with a corresponding mounting through hole for the hot riveting post 12 to pass through. Technicians can make the hot riveting post 12 pass through the mounting through hole and use a hot soldering iron to contact the upper part of the hot riveting post 12 so that the upper part of the hot riveting post 12 is deformed by heat, thereby fixing and limiting the aluminum bar 1, so as to rivet and fix the aluminum bar 1 to the blister bracket 11.

[0037] Further, please refer to Figure 1 , Figure 3 In this embodiment, multiple second epoxy boards 7 are also bonded and fixed to the lower end face of the blister bracket 11, and each of the multiple second epoxy boards 7 corresponds one-to-one with the QR code position of the battery cell at the location of the most significant temperature change within the battery. Furthermore, a back circuit is provided at the lower end face of each second epoxy board 7, and an NTC thermistor 6 is welded onto the back circuit of each second epoxy board 7, so that each thermistor faces the corresponding battery cell QR code.

[0038] Furthermore, to prevent damage to the NTC thermistor 6 from external impacts or vibrations, and to ensure its detection sensitivity, please refer to [link to relevant documentation]. Figure 4 In this embodiment, an FR4 reinforcing plate 8 is further bonded and fixed to the lower end face of the second epoxy board 7. The FR4 reinforcing plate 8 has an opening 9, which is circular and the size of the opening 9 is consistent with the shape and size of the NTC thermistor 6, so as to expose the NTC thermistor 6. This allows the NTC thermistor 6 to be protected while also enabling it to directly detect the cell temperature.

[0039] In addition, in order to further reduce the impact of the FR4 reinforcing plate 8 on the detection sensitivity of the NTC thermistor 6 and to further isolate and protect the NTC thermistor 6, a thermally conductive silicone pad 10 is also covered and bonded to the lower end surface of the FR4 reinforcing plate 8. The thermally conductive silicone pad 10 has excellent thermal conductivity, which makes it easier for the NTC thermistor 6 to detect changes in cell temperature more quickly; and the thermally conductive silicone pad 10 can also cover and block the opening 9 to isolate and protect the NTC thermistor 6.

[0040] Anything not mentioned above applies to existing technologies.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. An integrated busbar assembly, characterized in that, The integrated busbar assembly includes: Aluminum bar (1), wherein the aluminum bar (1) is welded onto the battery cell terminal post; Nickel sheet (2), said nickel sheet (2) is welded onto aluminum bar (1); The first epoxy board (3) is provided with a front circuit and a back circuit, and the front circuit and the back circuit of the first epoxy board (3) are connected in a conductive manner. Connector (4), the connector (4) is welded to the first epoxy board (3) and is connected to the front circuit of the first epoxy board (3); The FFC flat flexible cable (5) is welded to the nickel sheet (2), welded to the back circuit of the first epoxy board (3), and connected to the NTC thermistor (6).

2. The integrated busbar assembly as described in claim 1, characterized in that, The NTC thermistor (6) is located at the QR code on the battery cell.

3. The integrated busbar assembly as described in claim 1, characterized in that, It also includes a second epoxy board (7), on which a back circuit is also provided. The NTC thermistor (6) is welded on the second epoxy board (7). The NTC thermistor (6) is electrically connected to the back circuit of the second epoxy board (7). The FFC flat flexible cable (5) is electrically connected to the NTC thermistor (6) through the back circuit of the second epoxy board (7).

4. The integrated busbar assembly as described in claim 3, characterized in that, The surface of the second epoxy board (7) where the NTC thermistor (6) is provided is also bonded with an FR4 reinforcing plate (8).

5. The integrated busbar assembly as described in claim 4, characterized in that, The FR4 reinforcing plate (8) has an opening (9) that exposes the NTC thermistor (6).

6. The integrated busbar assembly as described in claim 4, characterized in that, A thermally conductive silicone pad (10) is also bonded to the FR4 reinforcing plate (8). The thermally conductive silicone pad (10) and the second epoxy plate (7) are disposed opposite to each other on the two surfaces of the FR4 reinforcing plate (8).

7. The integrated busbar assembly as described in claim 1, characterized in that, The front circuit and the back circuit of the first epoxy board (3) are connected to each other by a fuse.

8. The integrated busbar assembly as described in claim 3, characterized in that, It also includes a blister bracket (11), on which a plurality of aluminum bars (1) and a plurality of second epoxy boards (7) are evenly arranged.

9. The integrated busbar assembly as described in claim 8, characterized in that, The thermoforming bracket (11) is provided with a hot riveting post (12), and the aluminum bar (1) is provided with a corresponding mounting through hole for the hot riveting post (12) to pass through. The aluminum bar (1) is riveted and fixed to the thermoforming bracket (11) through the hot riveting post (12); the second epoxy board (7) is bonded and fixed to the thermoforming bracket (11).

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