Three-layer FDC busbar structure for signal acquisition of blade battery cell

Abstract

The utility model discloses a three -layer FDC busbar structure for blade electric core signal collection, including front CCS module and back CCS module, the front CCS module includes blister support, series connection aluminium bar, gathers nickel sheet and three -layer FDC circuit board, the blister support sets up on a plurality of blade electric core pole face, series connection aluminium bar is fixed on the blister support, is used for to the adjacent blade electric core and carries out series connection, gather nickel sheet with series connection aluminium bar fixed connection, gather nickel sheet and set up temperature sensor, three -layer FDC circuit board is located in upper middle three -layer position respectively according to from short to long, and three -layer FDC circuit board is connected with the gather nickel sheet of battery module different area respectively, the utility model discloses can realize blade electric core voltage and temperature signal collection in limited space, reduces the time cost and the volume occupation of flat cable wiring simultaneously, improves the reliability under the system severe working condition environment.

Description

Technical Field

[0001] This utility model belongs to the field of blade battery technology, specifically relating to a three-layer FDC busbar structure for signal acquisition of blade batteries. Background Technology

[0002] The statements herein provide only background information related to this invention and do not necessarily constitute prior art.

[0003] Blade cells are a specially designed type of battery. They are long and thin, resembling a blade, hence the name. The design of blade cells allows the cells to be directly inserted into the battery pack, greatly improving the volume and space utilization of the battery pack.

[0004] Battery cells typically require a Battery Management System (BMS) to monitor their voltage and temperature signals in order to provide timely feedback on any abnormal conditions. Current technologies typically use wiring harnesses to collect these signals, connecting the cells in series with aluminum plates and placing voltage and temperature sensors on these plates. The wiring harnesses from these two signal acquisition points are then connected to connectors. However, this acquisition structure has low automation; assembling a complete Wiring Harness Integrated Busbar System (CCS) acquisition module and organizing the wiring takes more than two man-hours. Furthermore, due to the small space on the terminal surfaces of blade cells, when a battery module consists of multiple blade cells, there are numerous wiring harnesses, large bending radii, and significant space requirements, making it unsuitable for the acquisition needs of battery modules containing multiple blade cells. Utility Model Content

[0005] The purpose of this invention is to provide a three-layer FDC busbar structure for acquiring signals from blade battery cells, which can acquire voltage and temperature signals from blade battery cells within a limited space, while reducing the time cost and volume of cabling and improving the reliability of the system under harsh operating conditions.

[0006] To achieve the above objectives, this utility model is implemented through the following technical solution:

[0007] In a first aspect, embodiments of this utility model provide a three-layer FDC busbar structure for acquiring signals from blade battery cells, including a front CCS module and a back CCS module. The front CCS module includes a blister bracket, a series aluminum busbar, a acquisition nickel plate, and a three-layer FDC circuit board. The blister bracket is disposed on the electrode surface of multiple blade battery cells, and the series aluminum busbar is fixed on the blister bracket for connecting adjacent blade battery cells in series. The acquisition nickel plate is fixedly connected to the series aluminum busbar, and a temperature sensor is disposed on the acquisition nickel plate. The three-layer FDC circuit board is located in the upper, middle, and lower layers from shortest to longest, and the three-layer FDC circuit board is connected to the acquisition nickel plates in different areas of the battery module.

[0008] As a further technical solution, the FDC circuit board is provided with a voltage acquisition line and a temperature acquisition line. The voltage acquisition line is connected to the acquisition nickel sheet, and the temperature acquisition line is connected to a temperature sensor.

[0009] As a further technical solution, the ends of each FDC circuit board are fixedly connected to connectors.

[0010] As a further technical solution, the length of the lower-layer FDC circuit board is three times that of the upper-layer FDC circuit board, and the length of the middle-layer FDC circuit board is twice that of the upper-layer FDC circuit board.

[0011] As a further technical solution, the nickel strip on the battery module is divided into three areas.

[0012] As a further technical solution, the serial aluminum bar is fixed to the vacuum forming bracket using a hot riveting process.

[0013] As a further technical solution, the FDC circuit board is fixed to the vacuum forming bracket using a hot riveting process.

[0014] As a further technical solution, the nickel sheet is welded to the surface of the series aluminum bar by welding.

[0015] As a further technical solution, the rear CCS module includes a rear blister bracket, a rear series aluminum bar, and a rear FDC circuit board. The rear blister bracket is disposed on the negative electrode surface of multiple blade cells, the rear series aluminum bar is fixed on the rear blister bracket, and the rear FDC circuit board is fixed on the rear blister bracket.

[0016] As a further technical solution, the FDC circuit board adopts a polyimide die-cut circuit board without etching process.

[0017] The beneficial effects of the above-described embodiments of this utility model are as follows:

[0018] This invention integrates a voltage / temperature signal acquisition system for at least 30 battery cells within the confined space of the blade battery cell's electrode surface using a three-layer stepped FDC circuit board partitioning architecture. This reduces the time and volume costs of cabling and wiring, and the three-layer FDC design improves the system's reliability under harsh operating conditions. The three-layer connector design allows the acquisition circuit board to acquire signals from at least thirty battery cell modules within the narrow space of the battery cell electrode surface, reducing the volume occupied by the battery cell electrode surface, facilitating installation, and saving space.

[0019] This invention utilizes a flexible die-cut circuit board (FDC). FDC eliminates the etching process, making it more environmentally friendly and reducing manufacturing time and costs. It is compatible with various master-slave BMS systems. The temperature adaptability of FDC (-40℃-150℃) is superior to traditional wiring harnesses (-30-85℃). Traditional wiring harnesses are prone to aging and significantly reduced lifespan at high temperatures, and become brittle at low temperatures, resulting in large resistance changes and signal acquisition delays or anomalies. FDC circuit boards exhibit high reliability under harsh operating conditions (vibration, high humidity, low temperature). Furthermore, compared to FPC circuit boards (flexible circuit boards), it has lower manufacturing costs, eliminates the etching process, avoids adverse environmental impacts, and has a shorter processing cycle. Attached Figure Description

[0020] The accompanying drawings, which form part of this specification, are used to provide a further understanding of this utility model. The illustrative embodiments of this utility model and their descriptions are used to explain this utility model and do not constitute an improper limitation of this utility model.

[0021] Figure 1 This is a front view of the blade battery module of this utility model;

[0022] Figure 2 This is a schematic diagram of the back connection of the blade battery module of this utility model;

[0023] Figure 3 This is a schematic diagram of the front-side CCS module of this utility model;

[0024] Figure 4 This is a schematic diagram of the structure of the rear CCS module of this utility model;

[0025] Figure 5 This is an exploded view of the front CCS module of this utility model;

[0026] Figure 6 This is an exploded view of the rear CCS module of this utility model.

[0027] The diagram is for illustrative purposes only.

[0028] Among them, 1. Front CCS module; 101. Upper FDC circuit board; 102. Middle FDC circuit board; 103. Lower FDC circuit board; 104. Series aluminum bar; 105. Nickel strip acquisition; 106. Connector; 107. Vacuum forming bracket; 2. Rear CCS module; 201. Rear vacuum forming bracket; 202. Rear series aluminum bar; 203. Rear FDC circuit board. Detailed Implementation

[0029] It should be noted that the following detailed description is exemplary and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0030] Explanation of relevant terms:

[0031] CCS: Integrated busbar system, used for connecting and managing battery cells.

[0032] FDC: Flexible Die-Cut Circuit Board, a type of flexible circuit board made by die-cutting polyimide (most) circuit boards.

[0033] BMS: Battery Management System, mainly used to monitor the status of various signals (voltage, temperature) of the battery and provide timely feedback on various abnormal states.

[0034] Example 1

[0035] In a typical embodiment of this utility model, such as Figures 1-6 As shown, a three-layer FDC busbar structure for acquiring signals from blade battery cells is provided, including a front CCS module 1 and a back CCS module 2. The front CCS module 1 includes a blister bracket 107, a series aluminum bar 104, a acquisition nickel plate 105, and a three-layer FDC circuit board. The blister bracket 107 is disposed on the electrode surface of multiple blade battery cells, and the series aluminum bar 104 is fixed on the blister bracket 107 for connecting adjacent blade battery cells in series. The acquisition nickel plate 105 is fixedly connected to the series aluminum bar 104, and a temperature sensor is disposed on the acquisition nickel plate 105. The three-layer FDC circuit board is located in the upper, middle, and lower layers from shortest to longest, and the three-layer FDC circuit board is connected to the acquisition nickel plate 105 in different areas of the battery module.

[0036] The above structure is suitable for blade battery modules. The three-layer stepped FDC circuit board allows for signal routing of multiple blade batteries within a limited space, significantly reducing space requirements. The partitioned acquisition strategy shortens the signal acquisition path and avoids interlayer wiring crossings, solving the problems of large space occupation and resonance loosening associated with traditional wiring harnesses.

[0037] In this embodiment, the FDC circuit board is a polyimide die-cut circuit board without etching process. The FDC circuit board is equipped with voltage acquisition lines and temperature acquisition lines. The voltage acquisition line is connected to the acquisition nickel sheet 105, and the temperature acquisition line is connected to a temperature sensor. The temperature adaptability of FDC (-40℃-150℃) is higher than that of traditional wire harnesses (-30-85℃). Traditional wire harnesses are prone to aging and have a significantly reduced lifespan at high temperatures, and become brittle at low temperatures, resulting in large changes in wire harness resistance, leading to signal acquisition delays or anomalies. The FDC circuit board has high reliability under harsh operating conditions (vibration, high humidity, low temperature). Furthermore, compared to FPC circuit boards (flexible circuit boards), the manufacturing cost is lower, there is no etching process during manufacturing so it does not have an adverse impact on the environment, and the processing cycle is shorter.

[0038] Furthermore, the end of each FDC circuit board is fixedly connected to connector 106. The ground end of each FDC circuit board is independently connected to connector 106 to output signals, achieving physical isolation of the three layers of signals.

[0039] In this embodiment, the lower FDC circuit board 103 is three times the length of the upper FDC circuit board 101, and the middle FDC circuit board 102 is twice the length of the upper FDC circuit board 101. Furthermore, the acquisition nickel plate 105 on the battery module is divided into three equal areas. Taking a cell module containing 30 blade cells as an example, the upper FDC circuit board 101 acquires data from cells 1-10, the middle FDC circuit board 102 acquires data from cells 1-20 (covering cells 11-20), and the lower FDC circuit board 103 acquires data from cells 1-30 (covering cells 21-30), eliminating winding redundancy. There is no electrical overlap between adjacent FDC circuit boards, reducing the short-circuit risk to zero.

[0040] In this embodiment, the serial aluminum bar 104 is fixed to the blister bracket 107 using a hot riveting process, and the FDC circuit board is fixed to the blister bracket 107 using a hot riveting process. Both the serial aluminum bar 104 and the FDC circuit board are fixed to the blister bracket 107 using a hot riveting process, forming a "metal-plastic" composite anchoring structure to improve the overall strength. The nickel plate 105 is welded to the surface of the serial aluminum bar 104 by welding, solving the problem of tearing of traditional FPC pads.

[0041] In this embodiment, the rear-side CCS module 2 includes a rear-side vacuum forming bracket 201, a rear-side series aluminum bus 202, and a rear-side FDC circuit board 203. The rear-side vacuum forming bracket 201 is disposed on the negative electrode surface of multiple blade cells, the rear-side series aluminum bus 202 is fixed on the rear-side vacuum forming bracket 201, and the rear-side FDC circuit board 203 is fixed on the rear-side vacuum forming bracket 201. The rear-side series aluminum bus 202 and the rear-side FDC circuit board 203 of the rear-side CCS module 2 are used to realize the series connection between adjacent blade cells.

[0042] The three-layer connector design of the FDC circuit board in this embodiment reduces the time cost and volume of cabling and wiring, and the three-layer FDC design can improve the reliability of the system under harsh operating conditions. The three-layer connector design allows the acquisition circuit board to acquire signals from the thirty-cell module in the narrow space of the cell terminal surface, reducing the volume occupied by the cell terminal surface, which is convenient for installation and saves space. The use of flexible die-cut circuit board (FDC) is environmentally friendly and has low manufacturing time and cost, as FDC has no etching process. It can be adapted to various master-slave BMS.

[0043] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A three-layer FDC busbar structure for signal acquisition of blade battery cells, characterized in that, The device includes a front-side CCS module and a rear-side CCS module. The front-side CCS module includes a blister pack, a series aluminum busbar, a nickel sensor, and a three-layer FDC circuit board. The blister pack is mounted on the electrode surfaces of multiple blade cells, and the series aluminum busbar is fixed to the blister pack for connecting adjacent blade cells in series. The nickel sensor is fixedly connected to the series aluminum busbar and has a temperature sensor mounted on it. The three-layer FDC circuit board is located in the upper, middle, and lower layers from shortest to longest, and is connected to the nickel sensor in different areas of the battery module.

2. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The FDC circuit board is equipped with a voltage acquisition line and a temperature acquisition line. The voltage acquisition line is connected to the acquisition nickel sheet, and the temperature acquisition line is connected to the temperature sensor.

3. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 2, characterized in that, Each layer of the FDC circuit board is fixedly connected to a connector at its end.

4. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The length of the lower-layer FDC circuit board is three times that of the upper-layer FDC circuit board, and the length of the middle-layer FDC circuit board is twice that of the upper-layer FDC circuit board.

5. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The nickel strip on the battery module is divided into three areas.

6. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The serial aluminum bar is fixed to the vacuum forming bracket using a hot riveting process.

7. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The FDC circuit board is fixed to the vacuum forming bracket using a hot riveting process.

8. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The nickel sheet is welded to the surface of the series aluminum bar using a welding method.

9. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The rear-side CCS module includes a rear-side blister bracket, a rear-side series aluminum bus, and a rear-side FDC circuit board. The rear-side blister bracket is disposed on the negative electrode surface of multiple blade cells, the rear-side series aluminum bus is fixed on the rear-side blister bracket, and the rear-side FDC circuit board is fixed on the rear-side blister bracket.

10. The three-layer FDC busbar structure for blade battery cell signal acquisition as described in claim 1, characterized in that, The FDC circuit board is a polyimide die-cut circuit board without etching process.

Images