Integrated busbar with battery swelling detection function

Abstract

The utility model discloses a kind of integrated busbar with battery expansion function detection, the integrated busbar includes: first insulating layer, flexible circuit component, circuit connection part, second insulating layer, expansion detection piece and output port;First insulating layer is set on the negative electrode of battery monomer;Flexible circuit component is set below first insulating layer, for electrical connection and signal transmission;Circuit connection part is set below flexible circuit component and is connected to battery pole column;Second insulating layer is set below flexible circuit component, and first insulating layer covers flexible circuit component and circuit connection part jointly;Expansion detection piece is fixed in the negative electrode position of first insulating layer corresponding battery monomer;When first insulating layer deformation, expansion detection piece exports the electrical signal caused by resistance to flexible circuit component;Output port is electrically connected with flexible circuit component.By the above setting, the sensitivity of integrated busbar to battery expansion detection is higher, simple structure, higher safety.

Description

Technical Field

[0001] This utility model relates to the field of battery energy technology, and in particular to an integrated busbar with a battery expansion detection function. Background Technology

[0002] With the rapid development of new energy vehicles and energy storage systems, the requirements for the safety and reliability of lithium batteries are increasing. However, lithium batteries are prone to expansion under conditions such as overcharging, over-discharging, and overheating, leading to a decline in battery performance, such as reduced capacity and voltage fluctuations, and may even cause safety accidents such as short circuits, thermal runaway, and even fires and explosions.

[0003] Currently, monitoring lithium battery expansion is mainly achieved by placing pressure sensors between battery packs, but this method has significant shortcomings. On the one hand, the mechanical interactions between adjacent cells during expansion are complex, making it difficult to accurately pinpoint the specific cell that is expanding. On the other hand, this method involves a complex assembly process, increasing manufacturing costs and maintenance difficulty, which is not conducive to large-scale applications and the high reliability requirements of systems. Utility Model Content

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide an integrated busbar with battery expansion detection capabilities. This integrated busbar offers high accuracy in battery deformation detection, a simple structure, and high safety.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An integrated busbar with battery expansion detection function includes: a first insulating layer, a flexible circuit assembly, a circuit connection portion, a second insulating layer, an expansion detection element, and an output port. The first insulating layer, flexible circuit assembly, circuit connection portion, and second insulating layer are arranged sequentially, with the first insulating layer at the top. The flexible circuit assembly is disposed below the first insulating layer and is used for electrical connection and signal transmission. The circuit connection portion is disposed below the flexible circuit assembly and connected to the battery terminal for electrical conduction. The second insulating layer is disposed below the circuit connection portion and does not cover the contact between the circuit connection portion and the battery terminal, and together with the first insulating layer, covers the flexible circuit assembly and the circuit connection portion. The expansion detection element is fixed to the negative terminal position of the corresponding battery cell on the first insulating layer and is electrically connected to the flexible circuit assembly. When the first insulating layer deforms, the expansion detection element outputs an electrical signal caused by resistance to the flexible circuit assembly. The output port is electrically connected to the flexible circuit assembly and is used to receive the electrical signal emitted by the expansion detection element and output battery expansion status information.

[0007] Furthermore, the expansion detection element is made of a composite material of carbon nanotubes and thermoplastic elastomer foam.

[0008] Furthermore, when the expansion detection device detects battery expansion, it sends an expansion alarm signal to an external control unit via a flexible circuit assembly.

[0009] Furthermore, the flexible circuit assembly includes a flexible printed circuit board, which is electrically connected to the expansion detection element via an electrical signal filtering circuit and to the output port for transmitting and stabilizing expansion status signals.

[0010] The circuit connection part is made of aluminum sheet and is welded to the battery terminal; several nickel sheets are provided on both sides of the flexible circuit assembly corresponding to the circuit connection part, and the nickel sheets are electrically connected to the circuit connection part.

[0011] Furthermore, the expansion detection element and the flexible circuit assembly are connected to the ground via a series resistor R, and an RC filter circuit composed of a capacitor C is connected to the external battery management system through the output port.

[0012] Furthermore, the flexible circuit assembly is connected to an external battery management system via an output port, which includes an independent signal transmission channel for outputting expansion status signals and battery voltage and temperature information, respectively.

[0013] Furthermore, the integrated busbar also includes a temperature measuring element and a safety valve detection element, which are electrically connected to the flexible circuit assembly, and the temperature measuring element is electrically connected to the circuit connection part.

[0014] Furthermore, the safety valve detection component includes a safety valve detection sensor, a first safety valve detection acquisition line, and a second safety valve detection acquisition line. Both the first and second safety valve detection acquisition lines are mounted on the safety valve detection component and are separate from each other. The safety valve detection component is electrically connected to the flexible circuit assembly. The first and second safety valve detection acquisition lines are arranged in a fan-shaped pattern on the corresponding area of ​​the safety valve portion of the battery cell, and are also arranged in a pattern of mutual intersection but not connection. They are connected to the flexible circuit assembly respectively through an S-shaped winding connection path.

[0015] The aforementioned integrated busbar with battery expansion detection function integrates an expansion detection device above the negative electrode of the battery cell and uses flexible circuit components to achieve electrical connection and signal transmission. When the battery expands and causes the first insulation layer to deform, the expansion detection device can output an electrical signal in time, which is transmitted to the battery management system through the flexible circuit components, thereby realizing real-time monitoring and early warning of the battery expansion state, and effectively improving the safety and reliability of the battery system. Attached Figure Description

[0016] Figure 1 This is an exploded view of the integrated busbar provided by this utility model;

[0017] Figure 2This is a structural schematic diagram of the integrated busbar provided by this utility model;

[0018] Figure 3 This is based on the circuit connection diagram of the expansion detection device provided by this utility model;

[0019] Figure 4 This is a structural schematic diagram of the safety valve detection component provided by this utility model. Detailed Implementation

[0020] The technical solutions in the embodiments of this utility model will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0021] like Figure 1 and Figure 2 As shown, this application provides an integrated busbar with a battery expansion detection function. The integrated busbar includes: a first insulating layer 1, a flexible circuit assembly 2, a circuit connection portion 3, a second insulating layer 4, an expansion detection element 5, and an output port 6. The first insulating layer 1, flexible circuit assembly 2, circuit connection portion 3, and second insulating layer 4 are arranged in sequence, with the first insulating layer 1 at the top. The flexible circuit assembly 2 is located below the first insulating layer 1 and is used for electrical connection and signal transmission. The circuit connection portion 3 is located below the flexible circuit assembly 2 and connected to the battery terminal for electrical conduction. The second insulating layer 4 is located below the circuit connection portion 5. Below the connection portion 3, without covering the contact between the circuit connection portion 3 and the battery terminal, the flexible circuit assembly 2 and the circuit connection portion 3 are covered together with the first insulating layer 1; the expansion detection element 5 is fixed at the negative terminal position of the battery cell corresponding to the first insulating layer 1 and is electrically connected to the flexible circuit assembly 2; when the first insulating layer 1 deforms, the expansion detection element 5 outputs an electrical signal caused by resistance to the flexible circuit assembly 2; the output port 6 is electrically connected to the flexible circuit assembly 2 and is used to receive the electrical signal emitted by the expansion detection element 5 and other information of the battery collected by the flexible circuit assembly 2 (such as voltage, temperature, safety valve collection, etc.), and output the expansion status information of the battery.

[0022] By directly aligning the expansion detection element 5 with the negative terminal of a single battery cell, the system can effectively distinguish and locate the individual cells that have expanded, avoiding misjudgments caused by complex mechanical interference between adjacent cells and improving the accuracy and reliability of expansion detection. Simultaneously, the integrated structural design integrates the expansion detection function with the busbar circuit, eliminating the need for a separate, complex pressure sensor and its associated support. This reduces the number of components, lowers manufacturing and assembly costs, and shortens the production cycle. Furthermore, the integrated design of the expansion detection element 5 and the flexible circuit assembly 2 simplifies electrical connections and detection signal output, facilitating standardized production and modular maintenance, meeting the needs of large-scale applications, and reducing maintenance difficulty and system failure rate.

[0023] More specifically, the expansion detection element 5 is made of a composite material of carbon nanotubes and thermoplastic elastomer foam. Carbon nanotubes possess excellent electrical conductivity and mechanical strength. When combined with thermoplastic elastomer foam, the composite material exhibits significant resistance changes under stress and deformation, thereby improving detection sensitivity. The carbon nanotubes can be replaced with other nanomaterials with excellent electrical conductivity, such as graphene or carbon black, to optimize the sensor's electrical performance and cost structure, depending on the specific application requirements.

[0024] Furthermore, when the expansion detection device 5 detects battery expansion, it sends an expansion alarm signal to the external control unit via the flexible circuit assembly 2. This setup enables early warning of abnormal battery expansion, facilitating timely and effective intervention to prevent safety accidents caused by expansion. Simultaneously, this warning mechanism boasts advantages such as fast response speed and stable signal transmission, significantly enhancing the safety and reliability of the battery system.

[0025] Furthermore, the flexible circuit assembly 2 includes a flexible printed circuit board, which is electrically connected to the expansion detection element 5 via an electrical signal filtering circuit and to the output port 6 for transmitting and stabilizing expansion status signals.

[0026] like Figure 2 As shown, the circuit connection part 3 is an aluminum sheet, which is welded to the battery terminal. Several nickel sheets 21 are provided on both sides of the flexible circuit assembly 2 corresponding to the circuit connection part 3, and the nickel sheets 21 are electrically connected to the circuit connection part 3. The excellent weldability and corrosion resistance of nickel ensure the stability and durability of the circuit connection. This composite structure of the circuit connection part 3 improves the conductivity and mechanical strength of the connection interface, while reducing contact resistance and energy loss.

[0027] like Figure 3As shown, the expansion detection element 5 and the flexible circuit assembly 2 are connected in series with a resistor R1 and grounded, and are connected to an external battery management system through an RC filter circuit composed of a capacitor C1 via the output port 6. This configuration avoids false alarms or signal distortion caused by environmental electromagnetic interference, improving the accuracy of expansion monitoring and the reliability of system response.

[0028] Furthermore, the flexible circuit assembly 22 is connected to an external battery management system through the output port 6. The output port 6 includes an independent signal transmission channel for outputting expansion state signals, battery voltage and temperature information, and safety valve detection and acquisition information, thereby ensuring that various types of data do not interfere with each other, improving the accuracy of monitoring data and the real-time performance of system response, and further providing strong technical support for the safety, reliability and refined management of the battery system.

[0029] like Figure 2 and Figure 4 As shown, the integrated busbar also includes a temperature sensing element 7 and a safety valve detection element 8. Both the temperature sensing element 7 and the safety valve detection element 8 are electrically connected to the flexible circuit assembly 2, and the temperature sensing element 7 is electrically connected to the circuit connection part 3. The bottom of the temperature sensing element 7 contacts the nickel plate 32, and the battery voltage supplies power to the temperature sensing element 7, which then outputs a temperature and voltage signal to the flexible circuit assembly 2. When a leak occurs in the battery safety valve, the internal wiring of the safety valve detection element 8 contacts the battery electrolyte liquid, and a corresponding electrical signal is output to the flexible circuit assembly 2, improving the safety of equipment operation.

[0030] like Figure 4 As shown, the safety valve detection component 8 includes a safety valve detection sensor 81, a first safety valve detection acquisition line 82, and a second safety valve acquisition line 83. Both the first and second safety valve detection acquisition lines 82 and 83 are mounted on the safety valve detection component 8 and are separated from each other. When the battery safety valve malfunctions, internal liquid leaks between the first and second safety valve detection acquisition lines 82 and 83, forming a resistance. This allows for real-time detection of any abnormalities in the battery safety valve, improving the stability and safety of the equipment operation. The safety valve detection component 8 is electrically connected to the flexible circuit assembly 2. The first and second safety valve detection acquisition lines 82 and 83 are arranged in a fan-shaped pattern and in a crisscrossing but unconnected manner on the corresponding area of ​​the battery cell's safety valve portion, and are connected to the flexible circuit assembly via an S-shaped winding connection path. This prevents the safety valve detection sensor 81 from being torn or damaged due to battery deformation, improving the structural stability.

[0031] The above description of embodiments of the present invention, through which those skilled in the art are able to implement or use the present invention, will be readily apparent to those skilled in the art. Various modifications to these embodiments will be readily apparent to those skilled in the art. The general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novelty disclosed herein.

Claims

1. An integrated busbar with battery expansion detection function, characterized in that, include: The first insulating layer (1) is disposed at the topmost position; A flexible circuit assembly (2) is disposed below the first insulating layer (1) and is used for electrical connection and signal transmission; The circuit connection part (3) is disposed below the flexible circuit assembly (2) and connected to the battery terminal for electrical conduction; The second insulating layer (4) is disposed below the circuit connection part (3) and does not cover the contact between the circuit connection part (3) and the battery terminal. Together with the first insulating layer (1), it covers the flexible circuit assembly (2) and the circuit connection part (3). An expansion detection element (5) is fixed to the negative electrode position of the first insulating layer (1) corresponding to the battery cell and is electrically connected to the flexible circuit assembly (2). When the first insulating layer (1) deforms, the expansion detection element (5) outputs an electrical signal caused by resistance to the flexible circuit assembly (2). Output port (6), which is electrically connected to the flexible circuit assembly (2), is used to receive the electrical signal emitted by the expansion detection element (5) and output the expansion status information of the battery.

2. The integrated busbar with battery expansion detection function according to claim 1, characterized in that, When the expansion detection device (5) detects battery expansion, it sends an expansion alarm signal to the external control unit through the flexible circuit assembly (2).

3. The integrated busbar with battery expansion detection function according to claim 1, characterized in that, The flexible circuit assembly (2) includes a flexible printed circuit board, which is electrically connected to the expansion detection element (5) through an electrical signal filtering circuit and electrically connected to the output port (6) for transmitting and stabilizing expansion state signals.

4. The integrated busbar with battery expansion detection function according to claim 1, characterized in that, The circuit connection part (3) is an aluminum sheet, and the circuit connection part (3) is welded to the battery terminal; the flexible circuit assembly (2) has a number of nickel sheets (21) on both sides corresponding to the circuit connection part (3), and the nickel sheets (21) are electrically connected to the circuit connection part (3).

5. The integrated busbar with battery expansion detection function according to claim 1, characterized in that, The expansion detection element (5) is connected to the flexible circuit assembly (2) in series with the resistor R1 and grounded, and is connected to the external battery management system through the output port (6) via the RC filter circuit composed of capacitor C1.

6. The integrated busbar with battery expansion detection function according to claim 1, characterized in that, The flexible circuit assembly (2) is connected to an external battery management system through the output port (6). The output port (6) includes an independent signal transmission channel for outputting expansion state signals and battery voltage and temperature information respectively.

7. The integrated busbar with battery expansion detection function according to claim 1, characterized in that, The integrated busbar also includes a temperature measuring element (7) and a safety valve detection element (8), which are electrically connected to the flexible circuit assembly (2) respectively, and the temperature measuring element (7) is electrically connected to the circuit connection part (3).

8. The integrated busbar with battery expansion detection function according to claim 7, characterized in that, The safety valve detection component (8) includes a safety valve detection sensor (81), a first safety valve detection acquisition line (82), and a second safety valve detection acquisition line (83). The first safety valve detection acquisition line (82) and the second safety valve detection acquisition line (83) are both disposed on the safety valve detection component (8) and are separated from each other. The safety valve detection component (8) is electrically connected to the flexible circuit assembly (2). The first safety valve detection acquisition line (82) and the second safety valve detection acquisition line (83) are arranged in a fan shape on the corresponding area of ​​the battery cell safety valve and are arranged in a cross but not connected manner. They are respectively connected to the flexible circuit assembly (2) through an S-shaped winding connection path.

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