A CCS assembly integrally formed with a calendered copper and injection molded spacer plate

Abstract

The utility model discloses a kind of CCS assembly of integrally formed with calendered copper and injection moulding isolation plate, comprising: aluminium bar, for with electric core welding realizes electrical connection;Injection moulding isolation plate, bearing and fixed the aluminium bar;Calendered copper strip, integrally formed with the isolation plate by insert injection molding process, and be partially encapsulated in the body of isolation plate to transmit electric signal;Calendered copper strip has at least one calendered copper welding site exposed to the outside of the isolation plate, and the calendered copper welding site is configured to be directly electrically connected with the corresponding part of aluminium bar by welding. This patent eliminates the cumbersome previous procedures such as cutting, stripping and crimping of traditional wire harness;At the same time, by using solid calendered copper conductor and high-precision welding site design, the product qualification rate and service life are improved;In addition, the flat conductor structure and the wiring method that can be folded at right angles greatly optimize the internal space utilization rate of battery pack, and reduce the weight of the assembly.

Description

Technical Field

[0001] This utility model relates to CCS components, and more particularly to a CCS component made by integrally molding rolled copper and injection molded isolation plate. Background Technology

[0002] With the development of the new energy vehicle and energy storage market, the market has placed increasingly stringent demands on the energy density, production efficiency, and manufacturing cost of power batteries and energy storage batteries. As a key component in battery modules, CCS modules undertake important functions such as electrical connection between cells, signal acquisition and transmission, and structural insulation isolation.

[0003] Currently, traditional CCS (Computer-Controlled System) components mostly employ wire harness solutions, using FPC (Flexible Printed Circuit) or conventional wire harnesses to achieve signal acquisition and transmission. This traditional approach has several inherent drawbacks. First, wire harness solutions require multiple pre-processing steps, including wire cutting, stripping, and terminal crimping. These steps not only require specialized equipment and manpower, increasing direct costs, but also lengthen the production cycle due to the numerous processes. The cumbersome process leads to high costs. Second, the terminal crimping stage of the wire harness is highly susceptible to problems such as insufficient crimping cross-section, excessive burrs, or broken wires due to mismatch between the wire core and the terminal or fluctuations in equipment parameters. This can cause serious quality issues such as increased contact resistance, localized overheating, or even connection failure. Furthermore, the inherent flexibility and size of the wire harness make it difficult to arrange within the limited compact space of the battery pack. Bending and fixing the wire harness requires additional space and clip structures, which is detrimental to improving the energy density of the battery pack.

[0004] Therefore, the industry urgently needs a new type of CCS component structure that can simplify the process, improve connection reliability and optimize spatial layout. Utility Model Content

[0005] To address the shortcomings of the aforementioned technologies, this invention provides a CCS assembly integrally formed from rolled copper and injection-molded isolation plate.

[0006] To solve the above technical problems, the technical solution adopted by this utility model is: a CCS component integrally formed from rolled copper and injection-molded isolation plate, comprising: Aluminum foil is used for welding to the battery cell to achieve electrical connection; Injection-molded isolation plate, supporting and fixing the aluminum bar; The rolled copper strip is integrally formed with the isolation plate through an insert injection molding process and is partially encapsulated within the body of the isolation plate to transmit electrical signals. The rolled copper strip has at least one rolled copper weld point exposed outside the isolation plate, which is configured to achieve direct electrical connection with a corresponding part of the aluminum bar by welding.

[0007] Furthermore, the injection-molded isolation plate is provided with hot riveting points, which position and pre-fix the aluminum bar through hot melting deformation.

[0008] Furthermore, rolled copper strips are flat copper conductors produced through a rolling process.

[0009] Furthermore, the rolled copper strip is integrated inside the partition plate and the rolled copper welding position is constructed as a right-angle bend with a bending angle of 90°±0.5°.

[0010] Furthermore, during the injection molding of the separator plate, the outer end of the rolled copper strip is constructed as an exposed insert extending out of the edge of the separator plate.

[0011] Furthermore, the outer end of the rolled copper strip is flat and surface treated, and a flexible circuit board is connected to the outer end by laser welding. The copper foil lines carried by the FPC combine the signals and connect to the external BMS through the integrated FPC connector.

[0012] This patent revolutionarily simplifies the production process of CCS modules by integrally molding rolled copper strips and injection-molded separator plates. It completely eliminates the tedious pre-processes of traditional wire harnesses, such as wire cutting, stripping, and crimping, significantly reducing labor and equipment costs and greatly improving production efficiency. At the same time, the use of solid rolled copper conductors and high-precision welding position design fundamentally eliminates quality risks such as poor crimping. Combined with hot riveting point positioning, it ensures the consistency and reliability of welding, greatly improving the product qualification rate and service life. In addition, the flat conductor structure and the right-angle bendable wiring method greatly optimize the internal space utilization of the battery pack, reduce the weight of the module, and provide key technical support for high energy density and high reliability power batteries and energy storage battery modules. Attached Figure Description

[0013] Figure 1 This is a structural schematic diagram of Embodiment 1 of the present utility model.

[0014] Figure 2 for Figure 1 A magnified schematic diagram of the structure in the middle circle.

[0015] Figure 3 This is a structural schematic diagram of Embodiment 2 of the present invention.

[0016] Figure 4 for Figure 3 A magnified schematic diagram of the structure in the middle circle.

[0017] In the diagram: 1. Aluminum bar; 2. Injection molded partition plate; 3. Rolled copper strip; 4. Rolled copper welding position; 5. Hot riveting point; 6. Right angle bend; 7. Exposed insert. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0019] Example 1: like Figure 1 and Figure 2 As shown, this embodiment discloses a basic integrated CCS component solution, which is a basic CCS component with compact structure and high manufacturing efficiency. The component includes an aluminum bar 1, an injection-molded isolation plate 2, and a rolled copper strip 3.

[0020] Specifically, the aluminum bar 1 is stamped from aluminum and positioned above the injection-molded isolation plate 2. Both ends of the aluminum bar have welding areas for laser welding to the battery cell tabs. The injection-molded isolation plate 2 is made of insulating engineering plastic (such as flame-retardant PC) through injection molding. This isolation plate is the structural carrier of this component. The rolled copper strip 3 serves as the signal transmission conductor; it is a flat copper conductor produced through a rolling process. The key aspect is that during the molding stage of the injection-molded isolation plate 2, the rolled copper strip 3 is placed into the mold as an insert and integrally molded with the molten plastic through an insert injection molding process. Its main body is firmly encapsulated within the body of the injection-molded isolation plate 2, thereby achieving structural fixation and electrical insulation.

[0021] Among them, a specific part of the rolled copper strip 3 is designed to be exposed outside the injection molding isolation plate 2 during injection molding, forming a clean and flat welding surface, which is the rolled copper welding position 4.

[0022] On the injection-molded isolation plate 2, below the aluminum bar 1, there are multiple cylindrical hot-fitting points 5. During assembly, the top of the hot-fitting points 5 is melted and deformed by a hot-melt tool, thereby covering the edge or protrusion of the aluminum bar 1, achieving precise positioning and pre-fixation of the aluminum bar 1 in the left-right and up-down directions, ensuring the relative positional accuracy of the aluminum bar 1 and the battery cell during subsequent laser welding.

[0023] The assembly and operation process in this embodiment involves first placing the aluminum bar 1 in the predetermined mounting position of the injection-molded isolation plate 2. Then, the hot riveting point 5 is heated and pressurized using a hot riveting device, causing it to melt and deform, thus fixing the aluminum bar 1. Subsequently, the entire assembly is moved to the laser welding station, where the vision system of the welding equipment accurately identifies the area to be welded on the aluminum bar 1 and the rolled copper welding position 4 on the rolled copper strip 3. Finally, the laser is activated, forming a high-quality laser weld point between the aluminum bar 1 and the rolled copper welding position 4, completing the electrical connection. This solution eliminates all pre-wiring process steps, achieving efficient and reliable automated production.

[0024] Example 2: like Figure 3 and Figure 4As shown, this embodiment discloses an enhanced CCS assembly with right-angle bends and external connections. Based on Embodiment 1, it further demonstrates the flexibility of rolled copper strips in terms of spatial layout and external interfaces. This embodiment also includes an aluminum bar 1, an injection-molded isolation plate 2, and a rolled copper strip 3. Its improvement mainly lies in the structural design and external connection method of the rolled copper strip 3.

[0025] In this embodiment, to accommodate the compact and complex layout within the battery module, the rolled copper strip 3 is pre-stamped and bent into a right-angle bend 6 within the routing integrated inside the injection-molded separator 2. The angle of this bend is controlled at 90°±0.5°, enabling the CCS assembly to efficiently utilize corner space and achieve compact wiring in a two-dimensional direction.

[0026] The end of the rolled copper strip 3 extends beyond the edge of the injection-molded isolation plate 2, forming an exposed insert 7. This exposed insert 7 is formed during injection molding, and its positional accuracy is ensured by the mold. The surface of the exposed insert 7 can be tin-plated to enhance its solderability and corrosion resistance. This insert can be directly used as an output interface, inserted into an external connector, or soldered to a PCB board.

[0027] In another embodiment, the end of the rolled copper strip 3 is configured as an FPC transition area. This area has a smooth surface and is either cleaned or plated. A section of copper foil from a flexible circuit board is reliably connected to this area via laser welding. The flexible circuit board then aggregates the acquired signals and interfaces with an external battery management system (BMS) through a standard FPC connector integrated at its end. This approach is particularly suitable for applications requiring the aggregation of multiple signals and frequent plugging / unplugging.

[0028] This embodiment significantly improves the space adaptability and layout freedom of the CCS module within the battery pack by introducing a right-angle bend 6. Through two standardized external connection designs—exposed inserts 7 or FPC adapter areas 8—reliable, convenient, and diverse external electrical interface solutions are provided to meet the needs of different customers and application scenarios.

[0029] In summary, this patent addresses the cumbersome and costly process of traditional wire harness solutions by integrally molding rolled copper strips and injection-molded isolation plates, while simultaneously incorporating direct welding at the rolled copper welding points. Through insert injection molding, the rolled copper strip 3 is directly embedded as a conductor into the injection-molded isolation plate 2, forming a structural component in a single step. This eliminates all the pre-processing steps and specialized equipment required in traditional wire harness solutions, such as wire cutting, stripping, shaping, and terminal crimping. Laser direct welding of the aluminum bar 1 and the rolled copper welding points 4 eliminates the need for terminal crimping and related quality inspection. Ultimately, this significantly shortens the production process, reduces manpower and equipment investment, directly lowers production costs, and accelerates the production cycle.

[0030] Meanwhile, a solution addressing the issues of poor connection reliability and high quality risks involves using solid-state rolled copper conductors combined with hot-riveting points for precise positioning. The rolled copper strip 3, a solid-state flat conductor, replaces the multi-strand copper wire harness, fundamentally eliminating risks such as abnormal crimping cross-sections, burrs, and broken wires caused by mismatch between the wire core and the terminal, thus ensuring the initial quality of the connection from the source. The hot-riveting point 5 ensures the precise position of the aluminum bar 1 before welding, preventing poor welding caused by component movement.

[0031] The rolled copper welding position 4 is formed in one step using a mold, resulting in uniform positioning and a clean surface. This provides stable and consistent conditions for automated welding, significantly improving the consistency and reliability of welding quality. Ultimately, this greatly increases the pass rate of product connection points, stabilizes contact resistance throughout the product's lifespan, and avoids safety hazards such as overheating caused by connection failure.

[0032] To address the challenges of limited space and heavy weight, this solution employs a flattened structural design combined with right-angle bends to optimize space utilization. The rolled copper strip itself is a flat conductor, thinner than round wires with the same current-carrying capacity, saving space in the Z-axis. The integrated molding structure makes the entire CCS assembly a compact unit, eliminating the need for extra space for wire bending and fixing, and removing unnecessary clips and cable ties. The right-angle bends allow the conductors to achieve a compact 90° turn in a two-dimensional plane, fully utilizing the corner space of the battery module and achieving extremely high space utilization.

[0033] The above embodiments are not intended to limit the present utility model, nor is the present utility model limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present utility model are also within the protection scope of the present utility model.

Claims

1. A CCS assembly integrally formed from rolled copper and injection-molded separator plate, characterized in that, include: Aluminum foil is used to weld to the battery cell to achieve electrical connection; Injection-molded isolation plate, supporting and fixing the aluminum bar; Rolled copper strips are integrally formed with the isolation plate through an insert injection molding process and are partially encapsulated within the body of the isolation plate to transmit electrical signals; The rolled copper strip has at least one rolled copper weld point exposed outside the isolation plate, which is configured to achieve direct electrical connection with a corresponding part of the aluminum bar by welding.

2. The CCS assembly integrally formed from rolled copper and injection-molded isolation plate according to claim 1, characterized in that: The injection-molded isolation plate is provided with hot riveting points, which position and pre-fix the aluminum bar through hot melting deformation.

3. The CCS assembly integrally formed from rolled copper and injection-molded isolation plate according to claim 1, characterized in that: The rolled copper strip is a flat copper conductor made through a rolling process.

4. The CCS assembly integrally formed from rolled copper and injection-molded isolation plate according to claim 1, characterized in that: The rolled copper strip is integrated inside the partition plate and the rolled copper welding position is constructed as a right-angle bend with a bending angle of 90°±0.5°.

5. The CCS assembly integrally formed from rolled copper and injection-molded isolation plate according to claim 1, characterized in that: When the body of the rolled copper strip is injection molded into the isolation plate, its outer end is constructed as an exposed insert extending out of the edge of the isolation plate.

6. The CCS assembly integrally formed from rolled copper and injection-molded separator plate according to claim 1, characterized in that: The outer end of the rolled copper strip is flat and surface treated. The outer end is connected to a flexible circuit board by laser welding. The copper foil lines carried by the FPC combine the signals and connect to the external BMS through the integrated FPC connector.

Images