Busbar integrated structure and battery pack

Abstract

The application provides a busbar integrated structure and a battery pack. The busbar integrated structure comprises a busbar and a heating insulation film. The busbar comprises a connecting surface, and the heating insulation film is integrated with the connecting surface of the busbar. The application integrates the heating insulation film on the connecting surface of the busbar. The heating insulation film replaces the double-layer thermal PI film on one side of the busbar in the prior art, and the separately designed heating film component is omitted, so that the material cost is reduced and the system integration is improved. The application has the advantages of high integration and low cost.

Description

Technical Field

[0001] This application relates to the field of battery technology, specifically to busbar integration structures and battery packs. Background Technology

[0002] Current battery pack technologies typically require a separately designed heating film for cell heating under low-temperature conditions. The heating film and insulation film are often separate designs, necessitating separate installation of the heating film within a housing. This not only increases production line costs but also necessitates custom-designed heating films, further raising production costs. Furthermore, the traditional CellsContact System (CCS) using a double-layer hot-pressed polyimide film (PI) process suffers from high cost and complex manufacturing processes. Therefore, there is an urgent need to develop a novel structural solution that achieves high integration and reduced costs. Utility Model Content

[0003] Embodiments of this application provide a highly integrated and low-cost bus integration structure and battery pack.

[0004] In a first aspect, embodiments of this application provide a bus integrated structure, which includes a bus and a heating insulating film. The bus includes a connecting surface, and the heating insulating film is integratedly connected to the connecting surface of the bus.

[0005] In some embodiments of this application, the heating insulating film includes an insulating layer and a heating element, wherein the insulating layer is integrated and connected to the connection surface of the busbar, and the heating element is located within the insulating layer.

[0006] In some embodiments of this application, the insulating layer includes a first sub-insulating layer and a second sub-insulating layer. The first sub-insulating layer is integrated and connected to the connection surface of the busbar, and the second sub-insulating layer is located on the side of the first sub-insulating layer away from the busbar. The heating element is located between the first sub-insulating layer and the second sub-insulating layer.

[0007] In some embodiments of this application, the busbar includes a connecting busbar, which includes a first end, a second end connected to the first end, and a first connecting portion connecting the first end and the second end. The first end and the second end are respectively configured to be electrically connected to the positive and negative terminals of the battery cell, and the positive and negative terminals of the battery cell are located at the same end of the battery cell. The heating insulating film includes a first opening and a second opening. The position of the first end is opposite to the position of the first opening, and the position of the second end is opposite to the position of the second opening. The first connecting portion is attached to the heating insulating film located between the first opening and the second opening.

[0008] In some embodiments of this application, a plurality of first openings and a plurality of second openings are arrayed and form a plurality of opening rows; within the same opening row, the first openings and the second openings are alternately arranged.

[0009] In some embodiments of this application, a first opening located in one of the opening rows is staggered with a first opening located in another adjacent opening row; and / or a second opening located in one of the opening rows is staggered with a second opening located in another adjacent opening row.

[0010] In some embodiments of this application, the bus also includes an output bus, which is located on the side connected to the bus; the output bus includes a third end and a second connecting portion, the second connecting portion is connected to the third end, and the third end is disposed close to the first end or the second end; the third end is used to connect to the terminal or negative terminal of the battery cell; the heating insulating film includes a third opening, the third end is positioned opposite to the third opening, and the second connecting portion is attached to the heating insulating film.

[0011] In some embodiments of this application, the battery pack further includes a flexible circuit board connected to the busbar and located on the side of the busbar away from the heating insulating film.

[0012] Secondly, this application provides a battery pack, which includes the bus integrated structure as described above.

[0013] In some embodiments of this application, the battery pack further includes a cell module, which includes multiple cells. Each cell includes a terminal post and a cell body. The terminal post is disposed on the cell body. The cell also includes a positive electrode and a negative electrode. The terminal post is either the positive or negative electrode of the cell. The end face of the cell body connected to the terminal post is either the negative or positive electrode of the cell. The busbar integrated structure is located on the side of the terminal post away from the cell body.

[0014] In some embodiments of this application, the busbar includes a connecting busbar, which includes a first end, a second end connected to the first end, and a first connecting portion connecting the first end and the second end; the heating insulating film includes a first opening and a second opening, the first end being positioned opposite to the first opening, the second end being positioned opposite to the second opening, and the first connecting portion being in contact with the heating insulating film located between the first opening and the second opening; wherein, the end of the electrode post furthest from the cell body is connected to the first end through the first opening, and the second end is housed within the second opening and electrically connected to the negative electrode.

[0015] In some embodiments of this application, the battery pack further includes a first connector connected to a heating element of the heating insulating film.

[0016] This application provides a busbar integrated structure and battery pack. The busbar integrated structure includes a busbar and a heating insulating film. The busbar includes a connecting surface, and the heating insulating film is integrated and connected to the connecting surface of the busbar. By integrating the heating insulating film into the connecting surface of the busbar, this application replaces the double-layer hot-pressed PI film on one side of the busbar in the prior art, eliminating the need for separately designed heating film components. This reduces material costs and improves system integration, offering advantages such as high integration and cost reduction. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a three-dimensional schematic diagram of the bus integrated structure provided in some embodiments of this application.

[0019] Figure 2 for Figure 1 The top view of the integrated bus structure shown.

[0020] Figure 3 for Figure 1 The cross-sectional view of the membrane structure of the busbar integrated structure shown.

[0021] Figure 4 for Figure 1 A three-dimensional schematic diagram of the heating insulation film of the integrated bus structure shown.

[0022] Figure 5 for Figure 1 A three-dimensional schematic diagram of the connecting busbars in the integrated busbar structure shown.

[0023] Figure 6 for Figure 1 The exploded view of the integrated bus structure shown.

[0024] Figure 7 for Figure 1 Another exploded view of the busbar integrated structure shown.

[0025] Figure 8 A partial cross-sectional view of the battery pack provided in this application.

[0026] Explanation of reference numerals in the attached figures: 100. Battery pack; 110. Busbar integrated structure; 120. Cell module; 10. Busbar; 11. Connecting surface; 12. Connecting busbar; 121. First end; 122. Second end; 123. First connecting part; 13. Output busbar; 131. Third end; 132. Second connecting part; 20. Heating insulating film; 21. Insulating layer; 211. First sub-insulating layer; 212. Second sub-insulating layer; 22. Heating element; 23. First opening; 24. Second opening; 201. Opening row; 25. Third opening; 30. Flexible circuit board; 50. First connector; 60. Second connector; 40. Battery cell; 41. Terminal post; 42. Battery cell body; 43. End face. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. In addition, it should be understood that the specific embodiments described herein are only for illustration and explanation of this application and are not intended to limit this application. In this application, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the upper and lower positions of the device in actual use or operation, specifically the drawing directions in the accompanying drawings; while "inner" and "outer" refer to the outline of the device.

[0028] In related technologies, commonly used battery packs typically require a separately designed heating film for cell heating under low-temperature conditions. The heating film and insulating film are often separate designs, requiring the heating film to be installed separately in a housing. This not only increases additional production line costs but also necessitates custom-designed heating films, further raising production costs. Furthermore, the traditional double-layer hot-pressed PI film process used in CCS also suffers from high cost and complex manufacturing processes. In cylindrical battery module applications, the connection area between the busbar and the cell terminals requires multiple layers of insulation protection, further exacerbating the issues of component stacking thickness and interface contact thermal resistance.

[0029] To address the aforementioned issues, and considering the additional assembly steps and component costs associated with separate heating films, as well as the complexity of the double-layer insulation film process, the design focuses on functional integration and structural simplification. Analysis of the heat conduction path reveals that the busbar, as the cell connection carrier, possesses direct heat transfer capabilities, making it possible to integrate heating functionality and insulation protection into a single film layer. Based on this, a proposal is made to embed the heating element into the insulating substrate, forming a composite film layer with dual functions, and directly integrating it onto the busbar surface through a hot-pressing process. Therefore, this application proposes an integrated busbar structure.

[0030] Specifically, please refer to Figures 1 to 7 This application provides a bus integrated structure 110, which includes a bus 10 and a heating insulating film 20. The bus 10 includes a connection surface 11, and the heating insulating film 20 is integrated and connected to the connection surface 11 of the bus 10. The connection surface 11 is the surface of the bus 10 used to connect the battery cell.

[0031] Busbar 10 refers to a metallic conductor that carries current transmission, and can be made of materials such as aluminum or copper alloy by stamping. This component serves as the connection carrier for the terminal post 41 of the battery cell 40, and simultaneously functions as a heat conduction medium during current transmission. Heating insulation film 20 is a composite film layer with dual functions of electrothermal conversion and electrical isolation. It can be made of a polyimide substrate with embedded metal heating wires, and physically bonded to the surface of busbar 10 through a hot-pressing process. This heating insulation film 20 provides insulation protection between busbar 10 and external components while generating heat energy through the Joule effect.

[0032] Specifically, the connection surface 11 of the busbar 10 serves as a functional integration interface, forming a non-detachable connection with the heating insulation film 20 through a hot-pressing process. The heating insulation film 20 generates heat when energized, and this heat is directly conducted to the busbar 10 body. The busbar 10, acting as a heat transfer medium, transfers heat to the connection area with the terminal post 41 of the battery cell 40, and then conducts it into the battery cell 40 through the terminal post 41. In this process, the heating insulation film 20 both acts as a heat source, generating heat energy, and as an insulating layer 21, prevents electrical contact between the busbar 10 and adjacent components. This integrated structure eliminates the physical separation between the heating film and the insulating film in traditional solutions, achieving dual functions through a single-layer composite film.

[0033] Compared to existing technologies, traditional solutions require separate installation of the heating film and double-layer insulation film, leading to increased component stacking thickness and more complex assembly processes. This solution replaces the traditional double-layer insulation film with a single-layer heating insulation film 20, integrating heating functionality while maintaining insulation performance, thus reducing material usage and the number of hot-pressing processes. In existing technologies, the heating film needs to be installed separately; this solution achieves simultaneous molding of the heating insulation film 20 and the busbar 10 through a hot-pressing integration process, simplifying the production process.

[0034] Through the above technical solution, this application achieves the physical integration of the heating functional component and the insulating protective layer, eliminating the assembly process of the independent heating film component. Using a single-layer heating insulating film 20 instead of the traditional double-layer insulating film structure reduces material costs and process complexity. The direct heat conduction path between the busbar 10 and the heating insulating film 20 improves thermal efficiency and reduces interfacial thermal resistance loss. This integrated structure reduces the number of components within the battery pack 100 and optimizes module space utilization.

[0035] Please see Figure 3 In some embodiments of this application, the heating insulating film 20 includes an insulating layer 21 and a heating element 22. The insulating layer 21 is integrated and connected to the connection surface 11 of the busbar 10, and the heating element 22 is located inside the insulating layer 21.

[0036] The insulating layer 21 refers to the dielectric material layer that is in direct contact with the surface of the busbar 10. It can be made of polyimide film or epoxy resin composite material, with a thickness, for example, ranging from 0.05 to 0.2 mm. It forms an irreversible physical bond with the surface of the busbar 10 through a hot-pressing process, providing structural support while achieving electrical isolation. The heating element 22 refers to the heating element embedded within the insulating layer 21. It can be made of etched nickel-chromium alloy foil, carbon fiber conductive layer, or printed conductive ink, with a resistance value, for example, ranging from 5 to 20 ohms. It achieves its heating function by generating a Joule heating effect through the application of electricity.

[0037] Specifically, the insulating layer 21 is directly attached to the surface of the busbar 10 through a hot-pressing process to form an integrated structure, replacing the traditional double-layer insulating film structure that requires a separate installation. The heating element 22 is encapsulated within the insulating layer 21 during its molding process, creating a three-dimensional functional integration. When current flows through the heating element 22, the heat generated is directly conducted to the busbar 10 through the insulating layer 21, and then transferred to the inside of the battery cell 40 through the contact interface between the busbar 10 and the terminal post 41 of the battery cell 40. This structure achieves the heating function while utilizing the dielectric properties of the insulating layer 21 to maintain electrical isolation between the busbar 10 and surrounding components.

[0038] Compared to existing technologies, traditional solutions require separate insulating and heating films, resulting in two hot-pressing processes and the assembly of two separate components. This solution embeds the heating function unit inside the insulating layer 21, enabling the insulating layer 21 to simultaneously perform the triple functions of structural support, electrical isolation, and heat conduction. This eliminates the need for a separate heating film and integrates the functions that originally required two components into a single structure.

[0039] Through the above technical solution, this application integrates the heating film and insulating film, which originally required separate installations, into a single functional layer, thereby reducing the number of components in the busbar integrated structure 110. The separate assembly process for the heating film is eliminated during production, and the material consumption per unit area is reduced by replacing the traditional double-layer insulating film with a single-layer structure.

[0040] Please see Figure 3In some embodiments of this application, the insulating layer 21 includes a first sub-insulating layer 211 and a second sub-insulating layer 212. The first sub-insulating layer 211 is integrated and connected to the connection surface 11 of the busbar 10, and the second sub-insulating layer 212 is located on the side of the first sub-insulating layer 211 away from the busbar 10. The heating element 22 is located between the first sub-insulating layer 211 and the second sub-insulating layer 212.

[0041] The first sub-insulation layer 211 refers to the insulation material layer that is in direct contact with the surface of the busbar 10. Specifically, it can be an integrated connection between a polyimide film and the busbar 10 achieved through a hot pressing process. This layer serves to provide basic insulation and a mounting base for the heating element 22.

[0042] The second sub-insulating layer 212 refers to the insulating material layer covering the outside of the first sub-insulating layer 211. Specifically, it can be a polyester film that is composited with the first sub-insulating layer 211 through a hot-pressing process to encapsulate the heating element 22 and form a complete insulating barrier.

[0043] Specifically, the first sub-insulating layer 211 forms an irreversible physical bond with the surface of the busbar 10 through a hot-pressing process, ensuring a gapless interface between the insulating layer 21 and the metal busbar 10. The second sub-insulating layer 212 covers the surface of the first sub-insulating layer 211 after the heating element 22 is arranged. A secondary hot-pressing process fuses the two insulating layers, completely encasing the heating element 22 within the insulating layer 21. The heating circuit is arranged between the two insulating layers along the extension direction of the busbar 10, with the first sub-insulating layer 211 directly contacting the busbar 10 to minimize the heat conduction path.

[0044] Compared with existing technologies, the traditional solution uses a double-layer hot-pressed insulating film only to achieve insulation isolation between the busbar 10 and the battery cell 40. It requires an additional independent heating film and is superimposed and installed through an adhesive process, resulting in an increase in the number of components and an increase in thermal resistance. This solution splits the insulating layer 21 into two sub-layers and embeds a heating element 22 between them, so that the insulating layer 21 simultaneously undertakes the functions of structural support and heat transfer, eliminating the assembly process required by the independent heating film.

[0045] Through the above technical solution, this application achieves the integrated integration of the busbar 10 insulation layer 21 and the heating film, reducing the number of parts and assembly steps, and lowering material costs and process complexity. The heating element 22 is completely encapsulated inside the insulation layer 21, avoiding the risk of short circuits caused by external mechanical damage. At the same time, the direct contact between the first sub-insulation layer 211 and the busbar 10 ensures efficient heat conduction, enabling the terminal post 41 of the battery cell 40 to quickly and uniformly obtain heating.

[0046] Please see Figure 1-2 and Figure 6-7In some embodiments of this application, the busbar 10 includes a connecting busbar 12, which includes a first end 121, a second end 122 connected to the first end 121, and a first connecting portion 123 connecting the first end 121 and the second end 122. The first end 121 and the second end 122 are respectively configured to be electrically connected to the positive and negative terminals of the battery cell 40, and the positive and negative terminals of the battery cell 40 are located at the same end of the battery cell 40. The heating insulating film 20 includes a first opening 23 and a second opening 24. The position of the first end 121 is opposite to the position of the first opening 23, and the position of the second end 122 is opposite to the position of the second opening 24. The first connecting portion 123 is attached to the heating insulating film 20 located between the first opening 23 and the second opening 24.

[0047] Among them, the connecting bus 12 refers to the conductive structure used to realize the electrical connection between the battery cells 40. Specifically, it can be realized by stamping a metal sheet. Its first end 121 contacts the pole post 41 to form a positive electrode passage, and the second end 122 forms a loop with the end face 43 area.

[0048] The first opening 23 refers to the notch on the heating insulating film 20 that is directly opposite the position of the first end 121. Specifically, it can be formed by laser cutting process to ensure that the first end 121 is in direct contact with the pole post 41 and to avoid the insulating film from hindering the conduction.

[0049] The second opening 24 refers to the notch on the heating insulation film 20 that is directly opposite the position of the second end 122. Specifically, it can be formed by die-cutting process so that the second end 122 and the end face 43 of the battery cell 40 form a stable mechanical connection and electrical conduction.

[0050] The first connecting portion 123 refers to the middle area connecting the two ends of the busbar 12. It can be formed by bending or integral molding. It heats the battery cell 40 by transferring heat through the bonding surface with the heating insulating film 20. The bending position can be located between the first end 121 and the first connecting portion 123, or between the second end 122 and the first connecting portion 123. That is, the surface of the first connecting portion 123 facing the heating insulating film 20 is flat.

[0051] Specifically, the first end 121 of the busbar 12 directly contacts the terminal 41 of the battery cell 40 through the first opening 23, forming a low-impedance positive conductive path; the second end 122 contacts the end face 43 of the battery cell 40 through the second opening 24, forming a closed-loop circuit; the first connection portion 123 covers the surface of the heating insulating film 20, and heat is transferred to the terminal 41 and the end face 43 through the contact surface between the film of the heating insulating film 20 and the busbar 10. While retaining the opening areas (the first opening 23 and the second opening 24), the heating insulating film 20 maintains the insulation protection between the busbar 10 and the battery cell 40 through the part of the film not covered by the openings (the first connection portion 123), and optimizes the heat conduction path by adhering to the first connection portion 123. In this embodiment, the first end 121 can be embedded in the first opening 23, and the second end 122 can be embedded in the second opening 24.

[0052] Compared with existing technologies, traditional solutions require separate insulating layers 21 and heating films between the busbar 10 and the battery cell 40, resulting in an increased number of components and higher assembly complexity. This solution integrates the heating insulating film 20 with the busbar 10, using an open design to directly expose the conductive contact area, eliminating the need for an additional insulating layer 21. At the same time, the heating function is achieved through the contact surface between the film and the busbar 10, reducing the number of components and simplifying the assembly process.

[0053] Through the above technical solution, this application realizes the integrated integration of heating function and bus 10 structure, avoiding the contact problem caused by insulating film covering conductive area, while improving heating efficiency by optimizing heat conduction path, and reducing material and process costs caused by separately setting heating film and insulating layer 21.

[0054] Please see Figure 4 In some embodiments of this application, a plurality of first openings 23 and a plurality of second openings 24 are arrayed and form a plurality of opening rows 201; within the same opening row 201, the first openings 23 and the second openings 24 are alternately arranged.

[0055] The array distribution refers to the orderly arrangement of the first opening 23 and the second opening 24 in rows and columns on a plane, improving machining accuracy through uniform spacing. The opening row 201 refers to a linear structure formed by multiple openings continuously arranged in the same direction, which can be implemented using a parallel arrangement to provide a reference for batch processing. Alternating arrangement means that the first opening 23 and the second opening 24 are arranged alternately within the same row, avoiding a decrease in structural strength caused by excessively small spacing between adjacent openings.

[0056] Specifically, multiple first openings 23 and second openings 24 are arranged in an array to form a transverse row of openings 201, with the first openings 23 and second openings 24 alternating within each row of openings 201. This layout ensures that the different ends connecting the busbar 12 are spaced apart in the transverse dimension, avoiding insufficient local strength of the insulating film caused by excessively small spacing between adjacent openings. Simultaneously, the transverse arrangement of the opening rows 201 simplifies mold design and facilitates consistency during batch processing. In the longitudinal dimension, adjacent rows of openings 201 can achieve spatial complementarity through staggered arrangement, reducing waste of insulating film material.

[0057] Compared to existing technologies, traditional solutions typically employ disordered or unidirectional arrangement of openings, leading to difficulties in processing and positioning, as well as low material utilization. This solution combines array distribution with alternating placement, ensuring a regular opening layout to improve installation efficiency while reducing material waste through complementary horizontal and vertical arrangements, and simultaneously maintaining the structural strength of the insulating film.

[0058] Through the above technical solution, this application solves the problems of low installation efficiency and insufficient material utilization caused by unreasonable opening layout when integrating heating film and busbar 10, and realizes the improvement of insulation film processing accuracy, reduction of material waste and effective maintenance of structural strength.

[0059] Please see Figure 4 In some embodiments of this application, a first opening 23 located in one of the opening rows 201 is staggered with a first opening 23 located in another adjacent opening row 201; and / or a second opening 24 located in one of the opening rows 201 is staggered with a second opening 24 located in another adjacent opening row 201.

[0060] Specifically, the first openings 23 within adjacent rows of openings 201 are staggered in both the horizontal and vertical dimensions, while the second openings 24 are similarly staggered. This arrangement spatially disperses the connection points between the heating insulation film 20 and the busbar 10, preventing uneven distribution of heating elements in localized areas due to excessive opening density. The staggered relationship between the rows of openings 201 creates a mesh-like coverage of the heat conduction path of the heating film, achieving uniform heat diffusion within a limited planar area, while simultaneously reducing the overall structural thickness requirement due to the spacing between the rows of openings 201.

[0061] Compared with existing technologies, the traditional solution uses an aligned arrangement of the opening rows 201, resulting in a straight-line distribution of the connection points between the heating film and the busbar 10, which easily leads to a single heat conduction path. This solution breaks the symmetry of the opening rows 201 through an interlaced layout, causing the heat conduction direction to shift at an angle between adjacent rows, forming a multi-directional heat flow transfer network.

[0062] Through the above technical solution, this application achieves uniform thermal field coverage at the interface between the heating insulation film 20 and the busbar 10, eliminating the local overheating or underheating caused by the linear arrangement of the opening rows 201. The staggered layout of the opening rows 201 maximizes the distribution of the contact area between the heating film and the busbar 10 in three-dimensional space, effectively improving the heat exchange efficiency per unit area, while reducing the mechanical strength loss caused by the concentration of openings.

[0063] Please see Figure 1-2 and Figure 6-7 In some embodiments of this application, the bus 10 further includes an output bus 13, which is located on the side connected to the bus 12. The output bus 13 includes a third end 131 and a second connecting portion 132, the second connecting portion 132 being connected to the third end 131, and the third end 131 being disposed close to the first end 121 or the second end 122. The third end 131 is used to connect to the terminal post 41 or end face 43 of the battery cell 40. The heating insulation film 20 includes a third opening 25, the third end 131 being opposite to the third opening 25, and the second connecting portion 132 being attached to the heating insulation film 20.

[0064] The output busbar 13 is a conductive component used to output electrical energy from the battery module 120. It can be made of materials such as aluminum or copper and is formed by stamping. Its third end 131 forms electrical contact with the terminal post 41 of the battery cell 40 through welding or bolts. The third opening 25 is a through hole or notch on the heating insulation film 20 corresponding to the third end 131 of the output busbar 13. It can be formed by laser cutting or die stamping. The edge of the opening maintains a gap with the outer contour of the third end 131 to achieve insulation isolation. The second connection part 132 is the part of the output busbar 13 that connects the third end 131 to the external circuit. It can be a bent structure or a planar extension structure, and its surface is physically bonded to the heating insulation film 20 through a hot-pressing process.

[0065] Specifically, the output bus 13 is arranged in the side area connecting the bus 12, and the third end 131 is spatially adjacent to the first end 121 or the second end 122 connecting the bus 12. During assembly, the third end 131 is positioned and guided by the third opening 25 to directly align with the terminal post 41 of the battery cell 40. When the second connecting part 132 extends on the surface of the heated insulating film 20, it forms a fixed connection with the insulating layer 21 through a hot pressing process, so that while maintaining the conductivity function, the bottom of the output bus 13 is electrically isolated from the battery cell 40 through the insulating layer 21. The size of the third opening 25 is set to be slightly larger than the projected area of ​​the third end 131, so as to avoid direct contact between the conductive parts and the insulating film while ensuring assembly tolerance.

[0066] Compared to existing technologies, traditional output busbar 13 requires a separate insulating gasket and secondary positioning during assembly. This solution, however, achieves the installation and positioning of the output busbar 13 through a pre-fabricated third opening 25 on the heating insulating film 20, eliminating the need for a separate insulating component. In existing technologies, the output busbar 13 and the heating film are separate structures, requiring additional fixing clips. This solution, however, achieves integrated fixing through the flat bonding of the second connecting part 132 with the heating insulating film 20 using a hot-pressing process, simplifying the assembly process.

[0067] Through the above technical solution, this application achieves integrated assembly of the output busbar 13 and the heating insulation film 20, avoiding the installation steps of independent insulating gaskets and reducing the number of parts. The prefabricated structure of the third opening 25 ensures precise alignment of the output busbar 13 and the terminal post 41 of the battery cell 40, reducing the risk of poor contact caused by assembly errors. The planar contact design between the second connecting part 132 and the heating insulation film 20 establishes a heat conduction path while maintaining insulation performance, allowing the heat generated by the heating insulation film 20 to be quickly transferred to the terminal post 41 of the battery cell 40 through the metal busbar 10.

[0068] Please see Figure 1-2 and Figure 6-7 In some embodiments of this application, the battery pack 100 further includes a flexible circuit board 30, which is connected to the busbar 10 and located on the side of the busbar 10 away from the heating insulating film 20.

[0069] Among them, the flexible circuit board 30 refers to a circuit carrier with bendable characteristics. Specifically, it can be made by using a polyimide substrate in combination with copper foil etched circuits, and is used to carry signal transmission functions.

[0070] The side of the busbar 10 away from the heating insulation film 20 refers to the non-contact surface formed after the busbar 10 and the heating insulation film 20 are stacked. Specifically, the heating insulation film 20 can be fixed to the connection surface 11 of the busbar 10 by hot pressing, so that the flexible circuit board 30 is arranged on the second surface to avoid physical interference with the heating component.

[0071] Specifically, the flexible circuit board 30 is electrically connected to the second surface of the bus 10 by bonding or soldering, and its wiring area covers the non-heated area on the back of the bus 10. Since the heating insulation film 20 is integrated into the connection surface 11 of the bus 10, the flexible circuit board 30 and the heating component form a spatially layered layout, isolating the signal transmission path from the heat conduction path. For example, the connection terminals of the flexible circuit board 30 can be aligned with pre-drilled holes on the bus 10, achieving electrical conductivity through conductive adhesive or solder, while maintaining physical separation from the heating insulation film 20. Therefore, circuit routing does not need to bypass the heating film structure; it can directly utilize the unoccupied planar area on the back of the bus 10 for layout, reducing the need for independent support structures.

[0072] In some specific embodiments, the edge of the flexible circuit board 30 may extend to the side area of ​​the busbar 10 and be connected to an external control module by bending. For example, one end of the flexible circuit board 30 is fixed to the surface of the busbar 10, and the other end is bent downward along the side wall of the busbar 10 to form a docking interface with other components inside the battery pack 100.

[0073] Compared with the prior art, this application reduces the interlayer alignment steps by placing the flexible circuit board 30 on the side of the busbar 10 away from the heating insulating film 20, while avoiding electromagnetic interference between the signal lines and the heating elements.

[0074] Through the above technical solutions, this application achieves a compact integration of the flexible circuit board 30 and the bus 10, eliminating the need for independent mounting brackets and reducing the complexity of the assembly process. The spatial separation of the flexible circuit board 30 and the heating insulating film 20 avoids the impact of heat conduction on circuit performance and improves signal transmission stability. In addition, the full utilization of the space on the back of the bus 10 reduces the volume occupied by the internal wiring of the battery pack 100 and optimizes the overall structural space utilization.

[0075] Please see Figure 6-7 The bus integrated structure 110 also includes a second connector 60, nickel strips, etc. The second connector 60 is the physical interface between the flexible printed circuit assembly (FPCA) and the battery management system (BMS) or other external circuits. It is responsible for efficiently and stably transmitting the collected voltage and temperature signals from the battery cell 40 to the subsequent processing unit, ensuring data real-time performance and accuracy. The second connector 60 is electrically connected to the flexible circuit board 30 and is located at one end of the output bus 13.

[0076] Please see Figure 8Secondly, this application provides a battery pack 100, which includes the busbar integrated structure 110 as described above. Since this battery module adopts all the technical solutions of the busbar integrated structure 110 of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.

[0077] In some embodiments of this application, the battery pack 100 further includes a cell module 120, which includes a plurality of cells 40. Each cell 40 includes a terminal post 41 and a cell body 42. The terminal post 41 is disposed on the cell body 42, and the cell body 42 has an end face 43, which is the surface of the cell body 42 to which the terminal post 41 is connected. The cell 40 also includes a positive electrode and a negative electrode, with the terminal post 41 being either the positive or negative electrode, and the end face 43 being either the negative or positive electrode. The busbar integrated structure 110 is located on the side of the terminal post 41 away from the cell body 42. The end of the terminal post 41 away from the cell body 42 is connected to a first end 121 through a first opening 23, and a second end 122 is received within a second opening 24 and electrically connected to the end face 43.

[0078] Among them, the battery cell module 120 refers to a modular unit composed of multiple battery cells 40. Specifically, it can be formed by arranging cylindrical or square battery cells 40. The separate layout of its terminals 41 and end faces 43 provides a spatial basis for the positioning of the bus integrated structure 110.

[0079] Among them, the terminal 41 refers to the conductive terminal on the top of the battery cell body 42, which can be made of aluminum or copper and is used to realize the electrical connection between the battery cell 40 and the external circuit.

[0080] The position of end face 43 as the positive or negative electrode refers to the conductive area set on the side of the cell body 42. Specifically, it can be achieved by nickel plating or welding conductive sheets on the surface of the cell shell 40, forming a current loop with the terminal post 41.

[0081] Specifically, the separate layout of the terminal post 41 and end face 43 in the cell module 120 provides the basis for the positioning of the bus integrated structure 110. The bus 10 is located on the side of the terminal post 41 away from the cell body 42, allowing the heating insulation film 20 to directly cover the current transmission path. The first end 121 of the bus 12 is directly connected to the terminal post 41 through the first opening 23, and the second end 122 is electrically connected to the end face 43 through the second opening 24. This opening alignment design ensures the reliability of the electrical connection while maximizing the contact area between the first connection part 123 and the heating insulation film 20. The double-opening structure of the heating insulation film 20 not only provides a physical channel for the connection between the terminal post 41 and the end face 43, but the part covering the surface of the bus 10 also realizes the heating function of the cell 40 through heat conduction. This structure integrates the heating film function into the insulation layer 21 of the bus 10 through spatial layout reconstruction, replacing the traditional double-layer PI film structure.

[0082] Compared to existing technologies, traditional solutions require separate installation of the heating film and the use of double-layer hot-pressed PI film for insulation, resulting in a large number of components and complex assembly processes. This solution integrates the heating insulation film 20 with the busbar 10, achieving heating functionality while maintaining insulation performance. This eliminates the need for separate heating film installation and reduces the use of one PI film layer. The opening alignment design directly utilizes the existing layout relationship between the terminal posts 41 and end faces 43 of the battery cell 40, avoiding the need for additional positioning structures.

[0083] Through the above technical solution, this application solves the problem of increased production line costs caused by separate installation of the heating film in the box. By integrating the structure, the heating film replaces the traditional CCS double-layer PI film, reducing the number of parts and simplifying the assembly process. The opening alignment design ensures the reliability of the electrical connection while maintaining effective coverage of the heating insulation film 20 on the busbar 10, realizing the integration of heating and insulation functions.

[0084] Please see Figure 1-2 and Figure 6-7 In some embodiments of this application, the battery pack 100 further includes a first connector 50, which is connected to the heating element 22 of the heating insulating film 20.

[0085] Furthermore, this utility model also proposes an electrical device, which includes a battery module. The specific structure of the battery module is described in the above embodiments. Since this electrical device adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, and will not be elaborated further here.

[0086] It is understood that electrical equipment includes, but is not limited to, electric toys, power tools, electric vehicles, automobiles, ships, spacecraft, etc. Electric toys can include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc. Spacecraft can include airplanes, rockets, space shuttles, and spacecraft, etc. Automobiles can include gasoline-powered cars, natural gas-powered cars, and new energy vehicles.

[0087] The embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A busbar integrated structure, characterized in that, include: Busbar, including connection surfaces; and A heating insulating film is integrated and connected to the connection surface of the busbar; The heating insulation film includes an insulation layer and a heating element. The insulation layer is integrated and connected to the connection surface of the busbar, and the heating element is located within the insulation layer.

2. The bus integrated structure as described in claim 1, characterized in that, The insulating layer includes a first sub-insulating layer and a second sub-insulating layer. The first sub-insulating layer is integrated and connected to the connection surface of the busbar. The second sub-insulating layer is located on the side of the first sub-insulating layer away from the busbar. The heating element is located between the first sub-insulating layer and the second sub-insulating layer.

3. The bus integrated structure as described in claim 1, characterized in that, The busbar includes a connecting busbar, which includes a first end, a second end connected to the first end, and a first connecting portion connecting the first end and the second end. The first end and the second end are respectively configured to be electrically connected to the positive and negative terminals of the battery cell, and the positive and negative terminals of the battery cell are located at the same end of the battery cell. The heating insulation film includes a first opening and a second opening. The position of the first end is opposite to the position of the first opening, and the position of the second end is opposite to the position of the second opening. The first connecting portion is attached to the heating insulation film located between the first opening and the second opening.

4. The bus integrated structure as described in claim 3, characterized in that, Multiple first openings and multiple second openings are arrayed and form multiple rows of openings; Within the same row of openings, the first opening and the second opening are alternately arranged.

5. The bus integrated structure as described in claim 4, characterized in that, The first opening located in one of the opening rows is staggered with the first opening located in the adjacent opening row; and / or The second opening located in one of the opening rows is staggered with the second opening located in the other adjacent opening row.

6. The bus integrated structure as described in any one of claims 3-5, characterized in that, The busbar also includes an output busbar, which is located on one side of the connecting busbar; the output busbar includes a third end and a second connecting portion, the second connecting portion being connected to the third end, and the third end being disposed close to the first end or the second end; the third end is used to connect to the terminal post or end face of the battery cell; The heating insulation film includes a third opening, the third end is positioned opposite to the third opening, and the second connecting portion is attached to the heating insulation film.

7. The bus integrated structure as described in any one of claims 1-5, characterized in that, Also includes: A flexible circuit board is connected to the busbar and located on the side of the busbar away from the heating insulation film.

8. A battery pack, characterized in that, include: The bus integration structure as described in any one of claims 1-7.

9. The battery pack as described in claim 8, characterized in that, Also includes: A battery cell module includes multiple battery cells. Each battery cell includes a terminal and a cell body. The terminal is disposed on the cell body. Each battery cell also includes a positive electrode and a negative electrode. The terminal is either the positive or negative electrode of the battery cell. The cell body has an end face. The end face of the cell body connected to the terminal is either the negative or positive electrode of the battery cell. The busbar integrated structure is located on the side of the electrode that is away from the main body of the battery cell.

10. The battery pack as claimed in claim 9, characterized in that, The busbar includes a connecting busbar, which includes a first end, a second end connected to the first end, and a first connecting portion connecting the first end and the second end; the heating insulating film includes a first opening and a second opening, the position of the first end is opposite to the position of the first opening, the position of the second end is opposite to the position of the second opening, and the first connecting portion is attached to the heating insulating film located between the first opening and the second opening; Wherein, the end of the electrode that is away from the main body of the cell is connected to the first end through the first opening, and the second end is housed in the second opening and electrically connected to the end face.

11. The battery pack as claimed in claim 8, characterized in that, It also includes a first connector, which is connected to the heating element of the heating insulation film.

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