Battery pack copper bar of new energy vehicle

Abstract

The utility model relates to new energy vehicle electrical assembly technical field especially, a kind of battery pack copper bar of new energy vehicle, including several settings in the frame inside battery pack body, the end of battery pack body is fixedly installed on frame by mounting bracket, and the connecting place of battery pack body and output copper bar is provided with insulating sleeve assembly, and insulating sleeve assembly includes insulating shell, insulating shell is sleeved in the connecting place outside of battery pack body and output copper bar, its resistance to vibration and stress ability is enhanced, also by the insulating material characteristics of itself, prevent the risk of current leakage or short circuit with peripheral metal parts;Two positioning cylinders are fixedly installed in the top of insulating shell, two pairs of through connecting holes are set up on battery pack body and output copper bar, connecting hole is set up in the upper and lower side of insulating shell in corresponding position, and positioning cylinder ensures that the hole position of all components can be quickly, accurately aligned in assembly process, provide convenience and precision for subsequent fastening operation.

Description

Technical Field

[0001] This utility model relates to the field of electrical assembly technology for new energy vehicles, and in particular to a copper busbar for a battery pack of a new energy vehicle. Background Technology

[0002] In the field of new energy vehicles, the battery pack is the core power source, and it consists of multiple battery modules. The transmission and collection of electrical energy between modules are mainly achieved through large-section copper busbars. Due to the compact internal space of the battery pack and the presence of various metal structural components, ensuring the absolute insulation and connection reliability of the high-voltage copper busbar connection points is crucial for preventing short circuits and ensuring the safe operation of the entire vehicle.

[0003] Currently, the common practice in the industry is to first mechanically connect and electrically connect the copper busbar to the electrode terminals of the battery module using bolts and nuts. Then, an additional independent insulating protective sleeve is installed on the outside of the connected bolts, nuts, and exposed metal connection sections. Since the insulating protective sleeve is a separate process following the connection, this requires an additional step on the production line to pick up, align, and install the sleeve. This not only reduces the number of steps involved in connection and assembly, thus reducing production efficiency, but also increases the complexity and cost of manual or robotic operations on the production line. Utility Model Content

[0004] The purpose of this invention is to provide a copper busbar for a battery pack in a new energy vehicle to solve the problems mentioned in the background art.

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

[0006] A battery pack copper busbar for a new energy vehicle includes several battery pack bodies disposed inside a frame. The connecting terminals of the battery pack bodies pass through a mounting bracket and are connected to the output copper busbar. An insulating sleeve assembly is provided at the connection between the battery pack bodies and the output copper busbar. The insulating sleeve assembly includes an insulating shell, which is sleeved on the outside of the connection between the battery pack bodies and the output copper busbar. Two positioning cylinders are fixedly installed on the top of the insulating shell. Two pairs of through connecting holes are opened on the battery pack bodies and the output copper busbar. The insulating shell is also opened with connecting holes. Screws are provided inside the positioning cylinders. The screws sequentially press the battery pack bodies and the output copper busbar into the inside of the insulating shell.

[0007] Preferably, a mounting hole is provided at the top of the positioning cylinder, and an isolation plate is slidably provided on the inner side of the top of the positioning cylinder. After the battery pack body and the output copper busbar are connected, the isolation plate automatically slides and closes the mounting hole.

[0008] Preferably, an adhesive plate is slidably disposed inside the insulating shell. The adhesive plate is initially positioned on the side of the insulating shell away from the battery pack body. When the output copper busbar is inserted into the insulating shell, it squeezes and pushes the adhesive plate to slide toward the battery pack body. When the adhesive plate is close to one end of the battery pack body, the connection hole of the battery pack body and the output copper busbar are aligned, and the screw is aligned with the connection hole.

[0009] Preferably, when the bonding plate is in the initial position, the bottom of the screw is above the bonding plate, and the screw prevents the bonding plate from falling downwards. When the output copper busbar is inserted and pushes the bonding plate away from its initial position, the screw, which loses the support of the bonding plate, automatically falls downwards and passes through the mounting holes on the insulating shell, the battery pack body and the output copper busbar in sequence.

[0010] Preferably, an anti-rotation cylinder is fixedly installed below the mounting hole at the bottom of the insulating shell, and a nut is snapped into the inside of the anti-rotation cylinder, so that the bottom end of the screw falling downward passes through the anti-rotation cylinder and contacts the nut.

[0011] Preferably, a hollow plate is fixedly installed on the top side wall of the insulating shell, an isolation plate is disposed inside the hollow plate, and a spring is provided between the isolation plate and the bottom of the hollow plate.

[0012] Compared with the prior art, the advantages of this utility model are as follows:

[0013] 1. By designing the insulating shell and positioning cylinder as an integral insulating sleeve assembly, it automatically wraps around and protects the connection point while the screws complete the fastening connection between the battery pack body and the output copper busbar. This combines the previously separate connection and sleeve installation steps, simplifies the assembly process, and directly improves production and maintenance efficiency.

[0014] 2. During the initial and tightening stages, the screw head or the inserted installation tool physically obstructs the lateral movement of the isolation plate under the action of the spring, forcibly keeping the mounting hole unobstructed and ensuring that the assembly operation can be carried out normally. After tightening is completed and the installation tool is removed, the screw head has moved down to a position where it can no longer form an obstruction, thereby releasing the constraint on the isolation plate, allowing it to automatically slide out under the drive of the spring and close the mounting hole, realizing automatic closure of the mounting hole and ensuring the automaticity and reliability of the protection. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2 This is a partial structural diagram of the overall structure of this utility model;

[0018] Figure 3 This is one of the exploded schematic diagrams of the insulating sleeve assembly structure of this utility model;

[0019] Figure 4 This is the second exploded view of the insulating sleeve assembly structure of this utility model;

[0020] Figure 5 This is one of the cross-sectional schematic diagrams of the insulating sleeve assembly of this utility model;

[0021] Figure 6 This is the second sectional view of the insulating sleeve assembly of this utility model.

[0022] The attached figures are labeled as follows:

[0023] 1. Insulating sleeve assembly; 11. Insulating shell; 12. Positioning cylinder; 13. Hollow plate; 14. Screw; 15. Nut; 16. Adhesive plate; 17. Anti-rotation cylinder; 18. Isolation plate;

[0024] 2. Mounting bracket; 3. Battery pack body; 4. Output copper busbar. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention.

[0026] A type of copper busbar for a battery pack in a new energy vehicle, such as Figures 1-6 As shown, the system includes several battery pack bodies 3 housed within a frame. The ends of the battery pack bodies 3 are fixedly mounted on the frame via mounting brackets 2. The connection terminals of the battery pack bodies 3 pass through the mounting brackets 2 and connect to the output copper busbars 4. The output copper busbars 4 draw current from the battery pack bodies 3 and transmit electrical energy to the high-voltage electrical system of the entire vehicle. An insulating sleeve assembly 1 is provided at the connection between the battery pack bodies 3 and the output copper busbars 4. The insulating sleeve assembly 1 includes an insulating shell 11, which is fitted over the connection between the battery pack bodies 3 and the output copper busbars 4. This fitting structure not only provides mechanical support for the fragile connection point, enhancing its resistance to vibration and stress, but also prevents the risk of current leakage or short circuit with surrounding metal components through its own insulating material properties. Two positioning cylinders 12 are fixedly installed on the top of the insulating shell 11. Two pairs of through-holes are provided on the battery pack bodies 3 and the output copper busbars 4. Connection holes are provided on the upper and lower sides of the insulating shell 11 at corresponding positions. The positioning cylinders 12 ensure that the holes of all components can be quickly and accurately aligned during assembly, providing convenience and precision for subsequent fastening operations.

[0027] The positioning cylinder 12 is equipped with screws 14 inside. The screws 14 pass through the connection holes in sequence to tightly press the battery pack body 3 and the output copper busbar 4 into the interior of the insulating shell 11. The positioning cylinder 12 not only plays a positioning role, but its cylindrical structure also isolates the metal body of the screws 14 through it from the external environment. This effectively avoids the risk that the screws 14 may become an accidental conductive path. While the mechanical connection is completed through the screws 14, the insulation protection is also completed automatically. This eliminates the need for the subsequent separate installation of the insulating sleeve, simplifies the assembly process, and significantly improves production and maintenance efficiency. The components of the insulating sleeve assembly 1, such as the insulating shell 11 and the positioning cylinder 12, can be made of suitable engineering plastics according to the specific electrical insulation requirements.

[0028] The top of the positioning cylinder 12 has an installation hole for the installation tool to enter. This installation hole provides an operating channel for the installation tool or other fastening tools, allowing the operator to directly tighten the screws 14 inside from the outside of the insulating shell 11, thereby completing the mechanical connection and electrical conduction between the battery pack body 3 and the output copper busbar 4. An isolation plate 18 is slidably installed on the inner side of the top of the positioning cylinder 12. When the fastening operation is completed and the installation tool is withdrawn from the installation hole, the isolation plate 18 automatically slides and closes the installation hole. Through the automatic closure of the isolation plate 18, external dust or other foreign objects can be effectively prevented from entering the interior of the insulating sleeve assembly 1 through the installation hole, avoiding the risk of electrical short circuit that may be caused by this, and improving the safety and reliability of long-term use. At the same time, this automatic closing design eliminates the need for the subsequent manual installation of the dust cover, ensuring safety while maintaining the efficiency of the assembly process.

[0029] An insert plate 16 is slidably disposed inside the insulating shell 11. Deformation grooves are formed on both sides of the insert plate 16, giving it a certain degree of elasticity. A pair of protrusions are provided on the outer side of the deformation grooves, and these protrusions are positioned in corresponding sliding grooves formed on the inner wall of the insulating shell 11. The protrusions on both sides cooperate with the sliding grooves on the inner wall of the insulating shell 11, forming a sliding guide and positioning mechanism for the insert plate 16. A small gap exists between the protrusions and the sliding grooves. Utilizing the elasticity of the deformation grooves, the protrusions are always pressed against the sliding groove wall with a slight preload, ensuring... To ensure smooth sliding of the bonding plate 16 and prevent looseness within the groove, thus ensuring motion stability, the bonding plate 16 presses against the inner wall of the insulating shell 11 through several protrusions and in the opposite direction against the deformation groove, so that the deformation groove provides elastic force to the protrusions, allowing the bonding plate 16 to slide inside the insulating shell 11. In the initial stage of assembly, the bonding plate 16 is initially positioned on the side of the insulating shell 11 away from the battery pack body 3, with the bottom of the bonding plate 16 in contact with the top surface of the battery pack body 3, and the battery pack body 3 supporting the bonding plate 16.

[0030] When the output copper busbar 4 is inserted into the insulating shell 11, it squeezes and pushes the bonding plate 16 to slide towards the battery pack body 3. The groove has a recess at one end near the battery pack body 3. When the protrusion slides to this position, it will be embedded in the slot under the elastic force of the deformation groove, achieving precise positioning. At this time, the movement of the bonding plate 16 makes the connection holes on the battery pack body 3, the output copper busbar 4 and the insulating shell 11 automatically aligned, eliminating the need for repeated manual adjustment and visual alignment of the connection holes during the assembly process. Through mechanical limiting and guiding, the connection holes are automatically aligned, which significantly improves the accuracy and speed of assembly, and allows the subsequent fastening operation to be completed quickly.

[0031] When the bonding plate 16 is in the initial position, the bottom of the screw 14 is above the bonding plate 16. The screw 14 prevents the bonding plate 16 from falling downwards, temporarily fixes the screw 14, and prevents it from accidentally sliding down due to gravity or vibration, thus playing a limiting role.

[0032] When the output copper busbar 4 is inserted and pushes the bonding plate 16 away from its initial position, the screw 14 loses its support below. At this time, the screw 14 will automatically fall downward under its own weight. With the aforementioned automatically aligned connection hole, the falling screw 14 passes through the insulating shell 11, the output copper busbar 4, and the battery pack body 3 in sequence, and finally reaches the position to be tightened. This realizes the automatic pre-positioning of the screw 14, further simplifying the operation. There is no need to manually find and align the hole to insert the screw 14. You can simply tighten it directly after the screw 14 is in place, which improves the convenience of assembly.

[0033] An anti-rotation cylinder 17 is fixedly installed below the mounting hole at the bottom of the insulating shell 11. A nut 15 is pre-installed and snapped into the inside of the anti-rotation cylinder 17, which is coaxially aligned with the connection hole. The bottom end of the screw 14, which falls downward, passes through the anti-rotation cylinder 17 and contacts the nut 15. By rotating the screw 14, it is screwed into the nut 15, thus completing the final tightening and tightly pressing the battery pack body 3 and the output copper busbar 4 together. Several deformation slots are opened on the side wall of the anti-rotation cylinder 17, giving it a certain radial elasticity. When the nut 15, whose outer size is slightly larger than the inner cavity of the anti-rotation cylinder 17, is pressed in, it will force the side wall of the anti-rotation cylinder 17 to undergo slight elastic deformation, resulting in an increase in the gap of the deformation slot. The elastic deformation of the anti-rotation cylinder 17 generates a clamping force and static friction force on the outer wall of the nut 15. This friction force prevents the nut 15 from rotating when the screw 14 is screwed in, so that the assembler only needs to tighten the screw 14 at the top, without having to use tools to fix the nut 15 at the bottom, simplifying the assembly operation in a narrow space and improving efficiency.

[0034] A hollow plate 13 is fixedly installed on the top side wall of the insulating shell 11. An isolation plate 18 is disposed inside the hollow plate 13, and a spring is provided between the isolation plate 18 and the bottom of the hollow plate 13. The spring provides a driving force for the isolation plate 18 to move laterally, giving it a tendency to close automatically. In the initial state, the head of the supported screw 14 is located near the mounting hole of the positioning cylinder 12. Its position blocks the lateral movement path of the isolation plate 18 under the action of the spring force, forcing the isolation plate 18 to stay in the open position, thereby ensuring that the mounting hole is unobstructed and facilitating the entry of installation tools.

[0035] When screw 14 falls off due to loss of support from the bonding plate 16, its head position moves down but remains in contact with the isolation plate 18. After the installation tool is inserted, it occupies the space and continues to block the movement of the isolation plate 18, ensuring that the mounting hole channel is not accidentally closed during the tightening operation.

[0036] Once assembly is complete and the installation tools are removed, the isolation plate 18 is no longer obstructed by the screw 14 or the installation tools. At this point, the energy stored in the spring is released, driving the isolation plate 18 to slide automatically laterally until it completely covers the mounting hole. This achieves sealing and insulation protection of the internal space of the positioning cylinder 12. The inner wall of the positioning cylinder 12 and the head of the screw 14 are fitted with a clearance. This structure provides guidance for the falling screw 14, ensuring that it remains vertical during its descent and subsequent tightening. This allows its threads to be precisely aligned with the nut 15 at the bottom, avoiding thread damage or inability to screw in due to the screw 14 being tilted.

[0037] The working principle of the copper busbar in the battery pack of a new energy vehicle provided by this utility model is as follows:

[0038] The insulating sleeve assembly 1 is pre-fitted onto the wire core of the battery pack body 3. At this time, the internal bonding plate 16 is in the initial position, the screw 14 above it is temporarily supported, the nut 15 at the bottom is locked in the anti-rotation cylinder 17, and the top isolation plate 18 is in the open state because it is blocked by the head of the screw 14.

[0039] When the output copper busbar 4 is inserted into the insulating shell 11, during the insertion process, the output copper busbar 4 pushes the bonding plate 16 to slide towards the battery pack body 3. The elastic protrusions on both sides of the bonding plate 16 move along the slide groove until they are inserted into the locking position at the end, which automatically completes the precise alignment of the connection holes between the battery pack body 3, the output copper busbar 4 and the insulating shell 11.

[0040] Once the bonding plate 16 slides away from its initial position, the screw 14 loses its support and falls automatically under gravity, smoothly passing through all the aligned connection holes. Its threaded end finally contacts the nut 15 at the bottom. At this point, the operator only needs to use the installation tool to tighten the screw 14 from the top. Since the anti-rotation cylinder 17 has firmly fixed the nut 15 to prevent it from rotating, the tightening operation can be easily completed from one side.

[0041] During the tightening of screw 14, the screw 14 rod or the installation tool itself will block the isolation plate 18 from closing. After tightening is completed and the installation tool is removed, this blockage disappears, and the isolation plate 18 automatically slides laterally under the action of the internal spring, immediately sealing the mounting hole at the top of the positioning cylinder 12, thereby achieving permanent insulation and protection for the inside of the connector.

[0042] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A copper busbar for a battery pack of a new energy vehicle, comprising a plurality of battery pack bodies (3) disposed within a frame, characterized in that, The connection terminal of the battery pack body (3) passes through the mounting bracket (2) and is connected to the output copper busbar (4). An insulating sleeve assembly (1) is provided at the connection between the battery pack body (3) and the output copper busbar (4). The insulating sleeve assembly (1) includes an insulating shell (11). The insulating shell (11) is sleeved on the outside of the connection between the battery pack body (3) and the output copper busbar (4). Two positioning cylinders (12) are fixedly installed on the top of the insulating shell (11). Two pairs of through connection holes are opened on the battery pack body (3) and the output copper busbar (4). The insulating shell (11) is opened with connection holes. Screws (14) are provided inside the positioning cylinders (12). The screws (14) press the battery pack body (3) and the output copper busbar (4) into the inside of the insulating shell (11) in sequence.

2. The copper busbar of a battery pack for a new energy vehicle according to claim 1, characterized in that, The top of the positioning cylinder (12) has an installation hole, and an isolation plate (18) is slidably provided on the inner side of the top of the positioning cylinder (12). After the battery pack body (3) and the output copper busbar (4) are connected, the isolation plate (18) automatically slides and closes the installation hole.

3. The copper busbar of a battery pack for a new energy vehicle according to claim 1, characterized in that, An adhesive plate (16) is slidably disposed inside the insulating shell (11). The adhesive plate (16) is initially positioned on the side of the insulating shell (11) away from the battery pack body (3). When the output copper busbar (4) is inserted into the insulating shell (11), it squeezes and pushes the adhesive plate (16) to slide toward the battery pack body (3). When the adhesive plate (16) is close to one end of the battery pack body (3), the connection hole of the battery pack body (3) and the output copper busbar (4) are aligned, and the screw (14) is aligned with the connection hole.

4. The copper busbar of a battery pack for a new energy vehicle according to claim 3, characterized in that, When the bonding plate (16) is in the initial position, the bottom of the screw (14) is above the bonding plate (16), and the screw (14) prevents the bonding plate (16) from falling down. When the output copper busbar (4) is inserted and pushes the bonding plate (16) to slide away from its initial position, the screw (14) loses the support of the bonding plate (16) and automatically falls down, passing through the mounting holes on the insulating shell (11), the battery pack body (3) and the output copper busbar (4) in sequence.

5. The copper busbar of a battery pack for a new energy vehicle according to claim 3, characterized in that, An anti-rotation cylinder (17) is fixedly installed below the mounting hole at the bottom of the insulating shell (11). A nut (15) is snapped into the inside of the anti-rotation cylinder (17). The bottom end of the screw (14) that falls downward passes through the anti-rotation cylinder (17) and contacts the nut (15).

6. The copper busbar of a battery pack for a new energy vehicle according to claim 2, characterized in that, A hollow plate (13) is fixedly installed on the top side wall of the insulating shell (11), an isolation plate (18) is disposed inside the hollow plate (13), and a spring is provided between the isolation plate (18) and the bottom of the hollow plate (13).

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