Circular flexible flat cable and integrated busbar

Abstract

The utility model discloses a kind of circular flexible flat cable and integrated female row, wherein the circular flexible flat cable includes two layers of insulating layer and several circular conductors, several The circular conductors are arranged in two layers The insulating layer is spaced and side by side, two The insulating layer hot-press bonding and covering The circular conductor. Two layers of insulating layer and several circular conductors are hot-pressed into circular flexible flat cable, circular conductor compared with flat conductor, with higher strength, when carrying out data interface docking, aluminum bar welding, with existing docking, welding technology equipment better adaptability, with good convenience;At the same time, after circular conductor is stripped insulating layer and exposed, subsequent processing reinforcement is not needed, can be directly used for docking or welding, required processing technology is less, with lower production assembly cost.

Description

Technical Field

[0001] This utility model relates to the field of new energy cable technology, and in particular to a circular flexible flat cable and an integrated busbar. Background Technology

[0002] In the fields of new energy vehicle power batteries and new energy storage (such as industrial and commercial energy storage, home portable energy storage, substation and big data center energy storage), cables are important components of battery packs. Cables are often used for batch connections and signal transmission for functions such as voltage and temperature acquisition. For cabling, to increase the integration of energy storage batteries, existing technologies mainly use FPC (Flexible Printed Circuit) and FFC (Flexible Flat Cable) as connecting harnesses for integrated busbars.

[0003] In these ribbon cables, the metal terminals at the ends are mostly flat, making them prone to bending, warping, and detachment. Therefore, most of them require reinforcement at the ends. Existing flat ribbon cables already have high production costs, and additional reinforcement is needed on top of that, resulting in high production costs. Utility Model Content

[0004] In order to solve the technical problem of high production cost of wiring in integrated busbars in the prior art, one of the objectives of this utility model is to provide a circular flexible flat cable.

[0005] One of the objectives of this utility model is achieved through the following technical solution:

[0006] A circular flexible flat cable includes two insulating layers and a plurality of circular conductors. The plurality of circular conductors are arranged side by side at intervals between the two insulating layers. The two insulating layers are heat-pressed together and cover the circular conductors.

[0007] Optionally, the cross-section of the insulating layer includes a plurality of hot-press bonding portions for hot-press bonding and a plurality of covering portions for covering and protecting the circular wire. The covering portions are arc-shaped and are disposed between two adjacent hot-press bonding portions.

[0008] Optionally, the circular conductor is a single wire core with a circular cross-section.

[0009] Optionally, the circular conductor is a stranded conductor, which is composed of several conductor cores twisted together.

[0010] Optionally, the number of wire cores is 3n, where n is a natural number greater than zero.

[0011] Optionally, the insulating layer is a PET film or a PI film.

[0012] Optionally, an adhesive layer is provided on the inner side of the insulating layer.

[0013] Optionally, the thickness of the adhesive layer is greater than the thickness of the insulating layer.

[0014] Optionally, the adhesive layer has a thickness of 90 to 50 micrometers, and the insulating layer has a thickness of 15 to 45 micrometers.

[0015] One of the objectives of this utility model is to provide an integrated busbar, which is achieved by the following technical solution:

[0016] An integrated busbar includes a data interface and a circular flexible flat cable. The circular flexible flat cable has a first metal terminal at its first end, which is an exposed circular conductor. The circular flexible flat cable is divided into several branches for data acquisition at its second end. Each branch includes at least one branch circular conductor. The end of each branch is provided with a second metal terminal, which is an exposed branch circular conductor.

[0017] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0018] Two layers of insulation and several round conductors are hot-pressed into a round flexible flat cable. Compared with flat conductors, round conductors have higher strength and are more compatible with existing docking and welding technologies and equipment when performing data interface docking and aluminum bar welding, which is convenient. At the same time, after the round conductors are stripped of the insulation layer and exposed, no further processing or reinforcement is required. They can be used directly for docking or welding, requiring fewer processing steps and resulting in lower production and assembly costs. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the circular flexible flat cable of this utility model;

[0020] Figure 2 This is a side view of the circular flexible flat cable of this utility model.

[0021] Figure 3 This is a side view of another embodiment of the circular flexible flat cable of this utility model.

[0022] Explanation of reference numerals in the attached diagram:

[0023] 1. Insulating layer; 11. Hot-pressed bonding part; 12. Covering part;

[0024] 2. Circular wire;

[0025] 3. Adhesive layer. Detailed Implementation

[0026] The following will refer to the appendices in the embodiments of this application. Figure 1 To be continued Figure 3 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.

[0027] 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.

[0028] 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.

[0029] like Figure 1 , Figure 2 The present invention provides a circular flexible flat cable, comprising two insulating layers 1 and a plurality of circular conductors 2. The plurality of circular conductors 2 are arranged side by side at intervals between the two insulating layers 1. The two insulating layers 1 are hot-pressed together and cover the circular conductors 2. In this embodiment, the two insulating layers 1 and the plurality of circular conductors 2 are hot-pressed into a circular flexible flat cable. Compared with flat conductors, the circular conductors 2 have higher strength and better compatibility with existing docking and welding technologies and equipment when performing data interface docking and aluminum foil welding, thus providing good convenience. At the same time, after the circular conductors 2 are exposed by peeling off the insulating layer 1, no further processing or reinforcement is required, and they can be directly used for docking or welding, requiring fewer processing steps and resulting in lower production and assembly costs.

[0030] In addition, since the circular conductors in the circular flexible flat cable are in a circular shape, they also have high strength. The circular flexible flat cable can be directly terminald and pinned. The circular flexible flat cable in this embodiment is simple to use and easy to assemble.

[0031] Furthermore, for FPCs and FFCs, due to the flat shape of their internal conductors, after branching, the flat conductors on the branch can only bend vertically, not laterally, and cannot skip adjacent flat conductors for connection or soldering. Similarly, branch lines can only bend, not skip adjacent branch lines for connection or soldering; that is, branch lines and flat conductors cannot skip pins. However, in this embodiment, after branching from the circular flexible flat cable, the circular conductor 2 on the branch can bend vertically, horizontally, and laterally, meaning the circular conductor on the branch can bend vertically, horizontally, and laterally, and can skip adjacent circular conductors for connection or soldering. Similarly, branch lines can also bend vertically, horizontally, and laterally, and can skip adjacent branch lines for connection or soldering, achieving pin-skipping connection and soldering between branch lines and circular conductors, resulting in better assembly convenience.

[0032] In some embodiments of insulating layer 1, such as Figure 2 As shown, the cross-section of the insulating layer 1 includes several hot-press bonding portions 11 for hot-press bonding and several covering portions 12 for covering and protecting the circular wire 2. The covering portions 12 are arc-shaped and are disposed between two adjacent hot-press bonding portions 11.

[0033] For circular conductor 2, specifically includes a conductor whose cross-section is circular. For example, circular conductor 2 is a single conductor with a circular cross-section.

[0034] This also includes multiple wire cores that are twisted together to form a circle or near-circular shape. For example, circular conductor 2 is a stranded conductor, which is composed of several wire cores twisted together. When using stranded conductors, because they use multiple smaller diameter wire cores, they are easier to bend and easier to lay. In addition, the internal stress generated by bending is less, the internal damage caused by bending is less, and they have a longer service life.

[0035] For stranded conductors, the number of cores is 3n, where n is a natural number greater than zero.

[0036] The aforementioned insulating layer 1 is a PET (polyethylene terephthalate) film or a PI (polyimide) film.

[0037] In addition, such as Figure 3 As shown, an adhesive layer 3 is provided on the inner side of the insulating layer 1. By providing the adhesive layer 3, the bonding strength is improved. Specifically, after providing the adhesive layer 3, hot-pressing fusion can be achieved, thereby improving the bonding strength.

[0038] Furthermore, the thickness of the adhesive layer 3 is greater than the thickness of the insulation layer 1. Compared to the thickness of the flat wire, the thickness of the round wire 2 is greater. Therefore, in order to more completely cover the round wire 2, the thickness of the adhesive layer 3 is increased in this embodiment. During hot pressing, under the pressure of the round wire 2, the adhesive layer 3 can move to both sides to avoid the round wire 2, providing space for covering the round wire 2, reducing the protrusion of the covering part 12, increasing the flatness of the insulation layer 1, and reducing the overall thickness after hot pressing, thereby achieving or approaching the flatness and thickness of the insulation layer 1 when hot pressing the flat wire.

[0039] Meanwhile, since the circular wire 2 has a large thickness, it is easy for the heat-pressed bonding part 11 to be difficult to fully adhere or insufficiently heat-pressed during hot pressing. In this embodiment, the thickness of the adhesive layer 3 is increased and the thickness of the insulation layer 1 is reduced. The adhesive layer 3 generates sufficient movement and avoidance during hot pressing, so that the heat-pressed bonding part 11 can be effectively heat-pressed and can be stably and firmly bonded together.

[0040] Specifically, the adhesive layer 3 has a thickness of 90 to 50 micrometers, and the insulating layer 1 has a thickness of 15 to 45 micrometers. In one preferred embodiment, the adhesive layer 3 has a thickness of 75 micrometers, and the insulating layer 1 has a thickness of 25 micrometers. Compared to conventional flat circuits, this embodiment reduces the thickness of the insulating layer 1 and increases the thickness of the adhesive layer 3. During hot pressing, the circular conductor 2 squeezes the adhesive layer 3, causing the 75-micrometer adhesive layer 3 to move and make way during hot pressing, providing space for covering the circular conductor 2, reducing the protrusion of the covering portion 12, increasing the flatness of the insulating layer 1, reducing the overall thickness after hot pressing, and improving the bonding effect.

[0041] This utility model also provides an integrated busbar, which includes a data interface and the aforementioned circular flexible flat cable. The first end of the circular flexible flat cable is provided with a first metal terminal, which is an exposed circular conductor 2, specifically the circular conductor 2 exposed after the insulation layer 1 is peeled off. The second end of the circular flexible flat cable is divided into several branches for data acquisition using a branching process. Each branch includes two branch insulation layers 1 and at least one branch circular conductor, located between the two branch insulation layers 1. The branch insulation layer 1 is formed by dividing the aforementioned insulation layer 1 using a branching process, and the branch circular conductor is formed by dividing the aforementioned circular conductor 2 using a branching process. The end of each branch is provided with a second metal terminal, which is the exposed branch circular conductor.

[0042] In this embodiment, the integrated busbar adopts a circular flexible flat cable. The structure is formed by hot pressing two insulation layers 1 and several circular conductors 2. Compared with flat conductors, the circular conductors 2 have higher strength and better compatibility with existing docking and welding technologies and equipment when performing data interface docking and aluminum busbar welding, which has good convenience. At the same time, after the circular conductors 2 are exposed by peeling off the insulation layer 1, no further processing and reinforcement are required, and they can be used directly for docking or welding, requiring fewer processing steps and effectively reducing the production and assembly cost of the integrated busbar.

[0043] 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. A circular flexible flat cable, characterized in that, The circular flexible flat cable includes two insulation layers and several circular conductors. The several circular conductors are arranged side by side at intervals between the two insulation layers. The two insulation layers are hot-pressed together and cover the circular conductors. The circular conductors are stranded conductors, which are made of several wire cores twisted together. The end of the circular flexible flat cable is divided into several branches by a branching process. Each branch includes two layers of branch insulation and at least one circular conductor. The circular conductor is located between the two layers of branch insulation, and the end of the branch is provided with a metal terminal.

2. The circular flexible flat cable as described in claim 1, characterized in that, The cross-section of the insulating layer includes several hot-press bonding portions for hot-press bonding and several covering portions for covering and protecting the circular wire. The covering portions are arc-shaped and are disposed between two adjacent hot-press bonding portions.

3. The circular flexible flat cable as described in claim 1, characterized in that, The circular conductor is a single wire core with a circular cross-section.

4. The circular flexible flat cable as described in claim 1, characterized in that, The number of wire cores is 3n, where n is a natural number greater than zero.

5. The circular flexible flat cable as described in claim 1, characterized in that, The insulating layer is a PET film or a PI film.

6. The circular flexible flat cable as described in claim 1 or 5, characterized in that, An adhesive layer is provided on the inner side of the insulating layer.

7. The circular flexible flat cable as described in claim 6, characterized in that, The thickness of the adhesive layer is greater than the thickness of the insulating layer.

8. The circular flexible flat cable as described in claim 7, characterized in that, The adhesive layer has a thickness of 90 to 50 micrometers, and the insulating layer has a thickness of 15 to 45 micrometers.

9. An integrated busbar, characterized in that, The integrated busbar includes a data interface and a circular flexible flat cable as described in any one of claims 1 to 8. The first end of the circular flexible flat cable is provided with a first metal terminal, which is an exposed circular conductor. The second end of the circular flexible flat cable is divided into several branches for data acquisition. Each branch includes at least one branch circular conductor. The end of each branch is provided with a second metal terminal, which is an exposed branch circular conductor.

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