A maintenance-friendly fuse structure with post-fuse rewelding and battery pack

Abstract

A kind of easy maintenance fuse structure and battery pack of repeated welding after fusing, wherein easy maintenance fuse structure of repeated welding after fusing includes: printed wiring board 1, a plurality of etching fuse 2 arranged in the printed wiring board 1, a plurality of solder pad 3 arranged on the printed wiring board 1 and with one end of the etching fuse 2 is connected, metal sheet 4 is connected on the printed wiring board 1 and with the other end of the etching fuse 2 is connected;Wherein, the upper layer of the printed wiring board 1 is welding area, the lower layer is hard or soft insulating material.The beneficial effects of the utility model lie in that: 1, easy maintenance, low maintenance cost;2, etching fuse is set in printed wiring board, height is reduced, so that product structure becomes compact;3, metal sheet and battery pack aluminum bar connection compatibility is high, impedance is small;4, high mechanical strength, long service life;5, low production cost.

Description

Technical Field

[0001] This application relates to the field of electronic technology, specifically to a fuse structure and battery pack that can be repeatedly soldered after melting and is easy to maintain. Background Technology

[0002] With the rapid development of new energy vehicles, power batteries are essential components, and their safety remains a critical issue. Currently, integrated busbars (Cells Contact System, CCS) use flexible printed circuit boards (FPCs) to collect and transmit electrical signals such as voltage, current, and temperature, integrating fuses onto the FPC. This is because fuse functionality can be easily implemented on FPCs; however, FPCs are relatively expensive.

[0003] When using lower-cost flexible flat cables (FFC) or wire harnesses to collect and transmit electrical signals, fuses cannot be integrated, and the entire CCS lacks fuse functionality. This results in less effective thermal management of the battery pack, and the circuit cannot be promptly cut off by a fuse in case of abnormal current.

[0004] Regarding the etched fuse solution, the applicant discovered during application that if it blows, the entire printed circuit board (PCB) needs to be replaced, and the metal sheets and connecting wires need to be re-soldered, resulting in high maintenance costs and low efficiency.

[0005] Therefore, there is an urgent need to develop a fuse structure and battery pack that are easy to maintain, have low maintenance costs, and can be repeatedly welded after melting. Utility Model Content

[0006] This application aims to solve the aforementioned technical problems.

[0007] Therefore, the first objective of this application is to propose a fuse structure that can be repeatedly welded after melting, is easy to maintain, and has low maintenance costs.

[0008] The second objective of this application is to propose a battery pack.

[0009] To achieve the above objectives, this application discloses a fuse structure that can be repeatedly soldered and is easy to maintain after melting. The structure includes a printed circuit board 1, a plurality of etched fuses 2 disposed on the printed circuit board 1, a plurality of solder pads 3 disposed on the printed circuit board 1 and connected to one end of the etched fuses 2, and a metal sheet 4 connected to the printed circuit board 1 and connected to the other end of the etched fuses 2. The upper layer of the printed circuit board 1 is a soldering area, and the lower layer is a rigid or flexible insulating material.

[0010] In addition, the fuse structure that can be repeatedly welded and is easy to maintain after melting according to the above-mentioned technical solution of this application may also have the following additional technical features:

[0011] Optionally, the printed circuit board 1 and the metal sheet 4 are connected by surface mount, soldering, or laser welding processes.

[0012] Optionally, a through-hole 5 is provided at the connection between the metal sheet 4 and the printed circuit board 1.

[0013] Optionally, the metal sheet 4 has a flat shape.

[0014] Optionally, the metal sheet 4 is bent at a right angle into a stepped shape, with the upper step connected to the upper layer of the printed circuit board 1 and connected to the etched fuse 2; the lower step is flush with the bottom of the printed circuit board 1.

[0015] To achieve the above objectives, a second aspect of this application provides a battery pack including a fuse structure that is easy to maintain and can be repeatedly welded after melting, as provided in the first aspect of this application.

[0016] The beneficial effects of this application are: 1. Easy to maintain and low maintenance cost; 2. The fuse is etched in the printed circuit board, which reduces the height and makes the product structure more compact; 3. The metal sheet and the battery pack aluminum bar have high compatibility and low impedance; 4. High mechanical strength and long service life; 5. Low production cost. Attached Figure Description

[0017] Figure 1 This is a perspective view of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to an embodiment of this application.

[0018] Figure 2 This is a design drawing of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to an embodiment of this application. Figure 2 (a) is the front view. Figure 2 (b) is a bottom view. Figure 2 (a) is a three-dimensional image;

[0019] Figure 3 This is a perspective view of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to another embodiment of this application;

[0020] Figure 4 This is a design drawing of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to another embodiment of this application. Figure 4 (a) is the front view. Figure 4 (b) is a bottom view. Figure 4 (a) is a 3D diagram.

[0021] Figure label:

[0022] 1-Printed circuit board, 2-Etched fuse, 3-Solder pad, 4-Metal sheet, 5-Through-tin hole. Detailed Implementation

[0023] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or parts / elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0024] The following describes, with reference to the accompanying drawings, an embodiment of the present application of a fuse structure that can be repeatedly welded and is easy to maintain after melting.

[0025] Figure 1 This is a perspective view of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to an embodiment of this application. Figure 2 This is a design drawing of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to an embodiment of this application. Figure 2 (a) is the front view. Figure 2 (b) is a bottom view. Figure 2 (a) is a 3D diagram. For example... Figure 1-2 As shown: This fuse structure, which can be repeatedly soldered and is easy to maintain after melting, includes a printed circuit board 1, multiple etched fuses 2 disposed on the printed circuit board 1, multiple solder pads 3 disposed on the printed circuit board 1 and connected to one end of the etched fuses 2, and a metal sheet 4 connected to the printed circuit board 1 and connected to the other end of the etched fuses 2; wherein, the upper layer of the printed circuit board 1 is a soldering area, and the lower layer is a rigid or flexible insulating material.

[0026] According to one embodiment of this application, the metal sheet 4 has a flat shape. Example 1:

[0027] Metal sheet 4 is made of metal, such as nickel, steel, aluminum, or copper, and can be used to weld battery pack aluminum bars and other materials. This material selection improves the welding compatibility between metal sheet 4 and battery pack aluminum bars, reduces interface impedance, and enhances current transmission stability. Circuit board 1 is a printed circuit board. The upper layer is the solder pad, i.e., the soldering area, where FFC or wire harness components can be soldered. The lower layer can be a rigid printed circuit board insulating material to ensure insulation from the aluminum bars or other metal structures in the battery pack below. It can be placed directly or attached to the aluminum bars or other components using double-sided adhesive. The rigid printed circuit board insulating material provides mechanical support, preventing connection failures caused by deformation of flexible materials, while also maintaining insulation between the printed circuit board and the aluminum bars or other components below. Alternatively, depending on the battery pack design requirements, such as providing a buffer function, the lower layer of the printed circuit board can be a soft material. Solder pad 3 is made of bare copper or tin-plated material, and can be used to solder FFC or wire harness components, providing convenient and reliable soldering connections. Fuse 2 is a fine line etched using FPC technology. It functions as a fuse according to different current fusing requirements. When the current is abnormal, it can melt here. In addition, since etched fuse 2 is entirely on the PCB, unlike traditional fuses which have raised parts, the overall height of the product is reduced.

[0028] This application's solution addresses the issue of needing to replace the entire PCB once a fuse blows. It involves installing two etched fuses 2 on the printed circuit board 1, with corresponding solder pads 3 connected to each etched fuse 2. In use, components such as FFCs or wire harnesses are soldered onto one pad, with the other as a spare. When the etched fuse 2 in this circuit blows, maintenance personnel can simply remove the FFC or wire harness and solder it to the other pad to activate the spare circuit, eliminating the need to replace the entire PCB and significantly improving product maintenance convenience.

[0029] In this embodiment, the metal sheet 4 has a flat shape, a simple structure, and low production cost. The portion of the metal sheet 4 protruding from the printed circuit board 1 can be suspended below or have an insulating pad layer provided.

[0030] The fuse structure described in this application, which allows for repeated soldering and easy maintenance after blowing, can accommodate multiple fuse circuits and pads. When the main circuit blows, the wires can be directly soldered to a spare pad to activate the spare fuse. This design avoids the need to replace the entire PCB assembly, reducing maintenance time and costs. The ability to reuse the same PCB assembly after multiple blows significantly extends the product's lifespan. The fuse structure can be directly fixed to components such as aluminum alloy bars, achieving a bracketless CCS structure and simplifying the assembly process.

[0031] According to one embodiment of this application, the printed circuit board 1 and the metal sheet 4 are connected by surface mount technology (SMT), soldering, or laser welding.

[0032] Specifically, the metal sheet 4 can be connected to the printed circuit board 1 using SMT (Surface Mount Technology), which can effectively reduce the product size and save production costs. Laser welding can also be used, due to its small heat-affected zone, concentrated and rapid heating, and low thermal stress. Traditional soldering can also be used.

[0033] According to one embodiment of this application, a through-hole 5 is provided at the connection between the metal sheet 4 and the printed circuit board 1.

[0034] Specifically, when the metal sheet is welded to the aluminum bar, the hole facilitates solder penetration, ensuring reliable welding; and it also allows gases generated during welding to escape, ensuring a reliable weld connection.

[0035] Figure 3 This is a perspective view of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to another embodiment of this application; Figure 4 This is a design drawing of a fuse structure that is easy to maintain and can be repeatedly welded after melting, according to another embodiment of this application. Figure 4 (a) is the front view. Figure 4 (b) is a bottom view. Figure 4 (a) is a 3D diagram, such as Figure 3-4 As shown: the metal sheet 4 is bent at a right angle into a stepped shape, the upper step is connected to the upper layer of the printed circuit board 1 and to the etched fuse 2; the lower step is flush with the bottom of the printed circuit board 1. Example 2:

[0036] Firstly, the flush-mounted step design with the PCB allows for direct mounting to the battery pack aluminum frame or module housing, avoiding the extra space required by traditional vertical soldering. This enables a bracket-free CCS structure, eliminating the bracket components for fixing metal plates in traditional CCS, reducing the number of parts and assembly complexity. This results in better product space adaptability. This design can save 5-8mm of vertical space for the product.

[0037] Secondly, it boasts excellent mechanical stability: the metal sheet forms a physically interlocked structure through right-angle bending, resulting in a relatively stable structure. Regarding impact resistance, the lower step, flush with the bottom of the PCB, creates an "L"-shaped support between the metal sheet and the PCB, resisting high-frequency vibrations during battery pack operation (such as the bumpy conditions of new energy vehicles) and preventing fatigue fracture of solder joints (compared to an unbent cantilever structure). In terms of welding strength, the connection point between the upper step and the upper layer of the PCB is directly welded to the etched fuse, while the contact surface between the lower step and the aluminum busbar is fixed through laser welding or riveting, forming a double anchoring point and reducing the risk of single-point failure. Furthermore, the lower step of the metal sheet is flush with the bottom of the PCB, achieving a large-area contact with the aluminum busbar. The aluminum busbar is generally a flat structure, connecting to the metal sheet on one side and supporting the printed circuit board on the other, eliminating the need for additional components or an uneven structure. Vibration test results show that this fuse structure, which is re-welded and easy to maintain after melting, has approximately three times the lifespan.

[0038] Finally, the metal sheet can be formed in one step through stamping, simplifying the processing. Furthermore, the pre-formed stepped structure of the metal sheet allows for direct positioning during SMT soldering, avoiding precision errors caused by on-site bending. This reduces the overall FFC production cost by approximately 15% to 20%.

[0039] Based on the above embodiments, this invention also proposes a battery pack, including: a fuse structure that can be repeatedly welded and is easy to maintain after melting, as described in the above embodiments.

[0040] According to a battery pack disclosed in this application, the reusable and easily maintainable fuse structure can accommodate multiple fuse circuits and pads. When the main circuit blows, the wires can be directly soldered to the spare pads to activate the spare fuse. This design avoids the need to replace the entire PCB assembly, reducing maintenance time and costs. The ability to reuse the same PCB assembly after multiple blows significantly extends the product's lifespan. The fuse structure can be directly fixed to components such as aluminum batteries, achieving a bracketless CCS structure and simplifying the assembly process.

[0041] The above embodiments are preferred implementations of this application. In addition, this application can be implemented in other ways. Any obvious substitutions without departing from the concept of this application are within the protection scope of this application.

Claims

1. A fuse structure that can be repeatedly welded and is easy to maintain after melting, characterized in that, include: Printed circuit board (1), multiple etched fuses (2) disposed on the printed circuit board (1), multiple pads (3) disposed on the printed circuit board (1) and connected to one end of the etched fuses (2), and metal sheet (4) connected on the printed circuit board (1) and connected to the other end of the etched fuses (2). The upper layer of the printed circuit board (1) is a soldering area, and the lower layer is a rigid or soft insulating material.

2. The fuse structure that is easy to maintain and can be repeatedly welded after melting, as described in claim 1, is characterized in that: The printed circuit board (1) and the metal sheet (4) are connected by surface mount, soldering, or laser welding processes.

3. The fuse structure that is easy to maintain and can be repeatedly welded after melting, as described in claim 1, is characterized in that: The metal sheet (4) is provided with a through-hole (5) at the connection between it and the printed circuit board (1).

4. The fuse structure that is easy to maintain and can be repeatedly welded after melting, as described in claim 1, is characterized in that: The metal sheet (4) has a flat shape.

5. The fuse structure that is easy to maintain and can be repeatedly welded after melting, as described in claim 1, is characterized in that: The metal sheet (4) is bent at a right angle into a stepped shape. The upper step is connected to the upper layer of the printed circuit board (1) and to the etched fuse (2); the lower step is flush with the bottom of the printed circuit board (1).

6. A battery pack, characterized in that: This includes a fuse structure that is easy to maintain and can be repeatedly welded after melting, as described in any one of claims 1-5.

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