CCS busbar beneficial to automation production

Abstract

A CCS busbar beneficial to automatic production comprises a PCB signal acquisition assembly, an aluminum bar assembly, and an insulating cover plate. The aluminum bar assembly comprises an input aluminum bar, an output aluminum bar, and a plurality of series aluminum bars. Each of the series aluminum bars comprises an aluminum bar body, a mounting protrusion, a mounting hole, and a first fixing hole. The series aluminum bars are fixedly connected with the PCB signal acquisition assembly. The insulating cover plate comprises an upper cover plate and a lower cover plate. The upper cover plate comprises an upper cover plate body, a gap hole, and a second fixing hole. The lower cover plate is provided with a third fixing hole. The first fixing hole, the second fixing hole, and the third fixing hole correspond to each other. When the CCS busbar beneficial to automatic production is assembled, screws are used to pass through the first fixing hole, the second fixing hole, and the third fixing hole, so as to fix and clamp the PCB signal acquisition assembly between the upper cover plate and the lower cover plate.

Description

Technical Field

[0001] This utility model relates to the field of composite busbars, and in particular to a CCS busbar that is conducive to automated production. Background Technology

[0002] With the acceleration of the global energy transition, the importance of energy storage systems in energy management is becoming increasingly prominent. In recent years, the continuous reduction in the cost of energy storage systems has made grid parity for residential solar-to-storage energy gradually a reality, leading to explosive growth in the residential energy storage market. Cylindrical lithium batteries, due to their stability, reliability, small size, and environmental friendliness, have been widely used in residential energy storage battery modules.

[0003] However, in the existing production of cylindrical battery modules, the production efficiency of CCS (Cell Connection System) busbars has become a limiting factor. Traditional CCS busbars mostly use manual welding or ultrasonic welding processes, which have shortcomings in terms of automated production, reliability, and accurate temperature acquisition, making it difficult to meet the requirements of high efficiency, reliability, and low cost for home energy storage modules.

[0004] Therefore, in order to meet the demand of the home energy storage market for high-efficiency production of cylindrical battery modules, it is urgent to develop a new type of CCS busbar to achieve automated production, improve production efficiency, reduce production costs, and at the same time ensure product stability and consistency. Summary of the Invention

[0005] In view of this, the present invention provides a CCS busbar that facilitates automated production to solve the above problems.

[0006] A CCS busbar for automated production includes a PCB signal acquisition component, an aluminum busbar assembly fixedly mounted on the PCB signal acquisition component, and an insulating cover plate covering both sides of the PCB signal acquisition component. The PCB signal acquisition component includes a PCB substrate. The aluminum busbar assembly includes an input aluminum busbar fixed to one end of the PCB substrate, an output aluminum busbar disposed opposite to the input aluminum busbar at the other end of the PCB substrate, and multiple series aluminum buses arranged on the PCB substrate. Each series aluminum busbar includes an aluminum busbar body fixedly connected to the PCB signal acquisition component, a mounting protrusion disposed in the middle of the aluminum busbar body, a mounting hole disposed in the middle of the mounting protrusion, and two first fixing holes respectively disposed at both ends of the aluminum busbar body. The series aluminum buses are fixedly connected to the PCB signal acquisition component through the mounting holes. The insulating cover plate includes an upper cover plate located on one side of the PCB signal acquisition component and a lower cover plate located on the other side of the PCB signal acquisition component. The upper cover plate includes an upper cover plate body, multiple clearance holes formed on the upper cover plate body, and multiple second fixing holes disposed at both ends of the clearance holes. The lower cover plate is provided with a third fixing hole corresponding to the second fixing hole. The first fixing hole, the second fixing hole, and the third fixing hole correspond to each other. When assembling the CCS busbar that facilitates automated production, screws are used to pass through the first fixing hole, the second fixing hole, and the third fixing hole to fix the PCB signal acquisition component between the upper cover plate and the lower cover plate.

[0007] Furthermore, the PCB signal acquisition component includes a connector disposed at one end of the PCB substrate and multiple nickel plates fixedly disposed on both sides of the PCB substrate.

[0008] Furthermore, the input aluminum bar, the output aluminum bar, and the series aluminum bar are all made of 1060 aluminum material.

[0009] Furthermore, the mounting hole is located in the middle of the mounting protrusion.

[0010] Furthermore, the first fixing hole is provided at two corners of the aluminum bar body along the same side of the aluminum bar body.

[0011] Furthermore, the PCB signal acquisition component also includes an NTC for temperature acquisition.

[0012] Furthermore, the NTC is encapsulated within the upper cover plate body by first applying adhesive and then pressing it under high pressure.

[0013] Furthermore, the lower cover plate is matched with the upper cover plate and has the same structure.

[0014] Compared with existing technologies, the CCS busbar provided by this utility model, which facilitates automated production, has mounting holes and the first positioning holes on the series aluminum busbar. Simultaneously, the upper cover plate of the insulating cover plate has clearance holes and the second fixing hole, and the lower cover plate has a third fixing hole. The third fixing hole corresponds to the second fixing hole and the first fixing hole. When assembling the CCS busbar, which facilitates automated production, the aluminum busbar assembly is first screwed onto the PCB signal acquisition component. Then, the first fixing hole, the second fixing hole, and the third fixing hole are aligned, and the aluminum busbar assembly and the insulating cover plate are fixedly connected together by screws, thereby fixing the PCB signal acquisition component and the aluminum busbar assembly between the upper cover plate and the lower cover plate. Therefore, it can be seen that the assembly of the CCS busbar, which facilitates automated production, is mainly completed by screwing. Compared with manual welding or ultrasonic welding processes, it is more conducive to automated production, has higher reliability, and makes it easier to ensure product stability and consistency during the production process. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of a CCS busbar that facilitates automated production, as provided by this utility model.

[0016] Figure 2 for Figure 1 A schematic diagram of the exploded structure of the CCS busbar, which is conducive to automated production. Detailed Implementation

[0017] The specific embodiments of this utility model will be described in further detail below. It should be understood that the description of this utility model herein is not intended to limit the scope of protection of this utility model.

[0018] like Figures 1 to 2 The diagram shows a structural schematic of a CCS busbar that facilitates automated production, as provided by this utility model. The CCS busbar for automated production includes a PCB signal acquisition component 10, an aluminum busbar assembly 20 fixedly mounted on the PCB signal acquisition component 10, and an insulating cover plate 30 covering both sides of the PCB signal acquisition component 10. It is conceivable that the CCS busbar for automated production should also include other related functional components, such as assembly components and connection components, which are all prior art known to those skilled in the art and will not be described in detail here.

[0019] The PCB signal acquisition component 10 includes a PCB substrate 11, a connector 12 disposed at one end of the PCB substrate 11, and multiple nickel strips 13 fixedly disposed on both sides of the PCB substrate 11. It is conceivable that the PCB signal acquisition component 10 also includes other related functional components, such as an NTC (thermistor) for temperature acquisition, and fuses for preventing circuit overload or short circuits. The PCB signal acquisition component 10 itself is existing technology and will not be described in detail here.

[0020] The PCB substrate 11 supports and carries the nickel sheet 13, the connector 12, and other related components. A conductive layer, typically copper foil, is coated on the surface of the PCB substrate 11, and a specific circuit pattern is formed through an etching process to achieve electrical connection and signal transmission. The PCB substrate 11 not only provides physical support for all components but also functions such as heat dissipation, insulation, and signal integrity management.

[0021] The connector 12 is fixedly disposed at one end of the PCB substrate 11. The connector 12 is used to connect the busbar to other devices, such as external control units or monitoring devices, and to safely and reliably transmit the signals on the PCB signal acquisition component 10 to other devices.

[0022] Multiple nickel plates 13 are spaced apart on both sides of the PCB substrate 11 and are fixed together with the PCB substrate 11 by welding. The nickel plates 13 are used to connect the aluminum bar assembly 20, thereby mounting the aluminum bar assembly 20 on the PCB substrate 11 to realize the acquisition of voltage signals.

[0023] The aluminum bar assembly 20 includes an input aluminum bar 21 fixed to one end of the PCB substrate 11, an output aluminum bar 22 disposed opposite to the input aluminum bar 21 at the other end of the PCB substrate 11, and a plurality of series aluminum bars 23 arranged on the PCB substrate 11. The input aluminum bar 21, the output aluminum bar 22, and the series aluminum bars 23 are all made of 1060 aluminum material, which has good electrical conductivity and mechanical properties.

[0024] The input bar 21 is located at one end of the connector 12 on the PCB substrate 11. The input bar 21 is used to connect to an external power source (such as a battery pack or charger) and introduce the current from the external power source into the PCB signal acquisition component 10.

[0025] The output aluminum bar 22 is located at the end of the PCB substrate 11 opposite to the connector 12, and is used to transmit current from the electronic device or battery management system to an external load. Both the input aluminum bar 21 and the output aluminum bar 22 are provided with mounting holes, through which they are fixedly screwed onto the PCB substrate 11.

[0026] Each of the series aluminum bars 23 includes an aluminum bar body 231 fixedly connected to the nickel sheet 13, a mounting protrusion 232 disposed in the middle of the aluminum bar body 231, a mounting hole 233 disposed in the middle of the mounting protrusion 232, and two first fixing holes 234 respectively disposed at both ends of the aluminum bar body 231.

[0027] The mounting protrusion 232 is correspondingly disposed to the nickel sheet 13, thereby forming a U-shaped groove on the side of the aluminum bar body 231 facing the PCB substrate 11. When the series aluminum bar 23 is installed, the nickel sheet 13 is inserted into the U-shaped groove formed by the mounting protrusion 232, thereby providing support for the aluminum bar body 231.

[0028] The mounting protrusion 232 is further provided with mounting holes 233, which facilitates the fixing of the series aluminum bar 23 to the nickel sheet 13 with bolts. Preferably, the mounting holes 233 are located in the middle of the mounting protrusion 232.

[0029] The first fixing hole 234 is provided along the same side of the aluminum bar body 231 at two corners of the aluminum bar body 231. It is used to connect the series aluminum bar 23 and the insulating cover plate 30, thereby fixing the series aluminum bar 23 and the insulating cover plate 30 together. The details will be described in detail below with reference to the insulating cover plate 30.

[0030] The insulating cover plate 30 includes an upper cover plate 31 located on one side of the PCB signal acquisition component 10, and a lower cover plate 32 located on the other side of the PCB signal acquisition component 10.

[0031] The upper cover plate 31 includes an upper cover plate body 311, a plurality of clearance holes 312 formed on the upper cover plate body 311, and a plurality of second fixing holes 313 provided at both ends of the clearance holes 312.

[0032] The upper cover plate body 311 is made of insulating material, such as PET, PP, PTFE, etc., pressed into a thin plate to prevent current leakage and avoid short circuits. In this utility model, the NTC opening on the insulating cover plate 30 is eliminated. When installing the NTC, it can be encapsulated within the upper cover plate body 31 by dispensing adhesive or high-pressure pressing, thereby increasing the heat insulation capacity at the NTC, improving the accuracy of temperature acquisition, and also providing a certain degree of dust protection.

[0033] The shape and size of the clearance hole 312 are adapted to the shape and size of the series aluminum bar 23. When the upper cover plate 31 is closed with the PCB signal acquisition component 10, the clearance hole 312 can create clearance at the mounting protrusion 232 of the series aluminum bar 23, thereby facilitating the bonding of the insulating upper cover plate body 311 with the PCB substrate 11. At the same time, the clearance hole 312 also prevents the series aluminum bar 23 and the nickel sheet 13 from being completely covered by the insulating cover plate 30, which is beneficial for heat dissipation.

[0034] The second fixing hole 313 is provided corresponding to the first fixing hole 234 to facilitate connection.

[0035] The lower cover plate 32 is matched with the upper cover plate 31 and has the same structure, thereby increasing the versatility between the upper cover plate 31 and the lower cover plate 32. The lower cover plate 32 includes a lower cover plate body 321 fixedly connected to the upper cover plate 31, a plurality of second clearance holes 322 corresponding to the output aluminum bar 23, and a plurality of third fixing holes 323 corresponding to the second fixing holes 313.

[0036] The lower cover plate body 321 is also made of insulating material, and its shape and size are consistent with those of the upper cover plate body 311.

[0037] The second clearance hole 322 is provided corresponding to the first clearance hole 312 and is matched with the series aluminum bar 23, which can improve the heat dissipation of the series aluminum bar 23.

[0038] The third fixing hole 323 is correspondingly provided with the second fixing hole 313 and the first fixing hole 234. When assembling the CCS busbar that facilitates automated production, the aluminum bar assembly 20 is first screwed onto the PCB signal acquisition assembly 10. Then, the first fixing hole 234, the second fixing hole 313, and the third fixing hole 323 are aligned, and the aluminum bar assembly 20 and the insulating cover plate 30 can be fixedly connected together by screws, thereby fixing the PCB signal acquisition assembly 10 and the aluminum bar assembly 20 between the upper cover plate 31 and the lower cover plate 32.

[0039] Compared with the prior art, the CCS busbar provided by this utility model, which is conducive to automated production, has the mounting hole 233 and the first positioning hole 234 on the series aluminum bar 23. Simultaneously, the clearance hole 312 and the second fixing hole 313 are provided on the upper cover plate 31 of the insulating cover plate 30, and the third fixing hole 323 is provided on the lower cover plate 32. The third fixing hole 323 corresponds to the second fixing hole 313 and the first fixing hole 234. When assembling the CCS busbar, which is conducive to automated production, the aluminum bar assembly 20 is first screwed onto the PCB signal acquisition assembly 10. Then, the first fixing hole 234, the second fixing hole 313, and the third fixing hole 323 are aligned, and the aluminum bar assembly 20 and the insulating cover plate 30 can be fixedly connected together by screws, thereby fixing the PCB signal acquisition assembly 10 and the aluminum bar assembly 20 between the upper cover plate 31 and the lower cover plate 32. Therefore, it can be seen that the assembly of the CCS busbar, which is conducive to automated production, is mainly completed by screwing. Compared with manual welding or ultrasonic welding, it is more conducive to automated production and has higher reliability. It is also easier to ensure the stability and consistency of the product during the production process.

[0040] The above are merely preferred embodiments of the present utility model and are not intended to limit the scope of protection of the present utility model. Any modifications, equivalent substitutions or improvements within the spirit of the present utility model are covered within the scope of the claims of the present utility model.

Claims

1. A CCS busbar that facilitates automated production, characterized in that: The CCS busbar, which facilitates automated production, includes a PCB signal acquisition component, an aluminum bus assembly fixedly mounted on the PCB signal acquisition component, and an insulating cover plate covering both sides of the PCB signal acquisition component. The PCB signal acquisition component includes a PCB substrate. The aluminum bus assembly includes an input aluminum bus fixed to one end of the PCB substrate, an output aluminum bus opposite to the input aluminum bus at the other end of the PCB substrate, and multiple series aluminum buses arranged on the PCB substrate. Each series aluminum bus includes an aluminum bus body fixedly connected to the PCB signal acquisition component, a mounting protrusion in the middle of the aluminum bus body, a mounting hole in the middle of the mounting protrusion, and two first fixing holes respectively located at both ends of the aluminum bus body. The aluminum busbar is fixedly connected to the PCB signal acquisition component through the mounting holes. The insulating cover includes an upper cover on one side of the PCB signal acquisition component and a lower cover on the other side of the PCB signal acquisition component. The upper cover includes an upper cover body, multiple clearance holes on the upper cover body, and multiple second fixing holes at both ends of the clearance holes. The lower cover has a third fixing hole corresponding to the second fixing hole. The first fixing hole, the second fixing hole, and the third fixing hole correspond to each other. When assembling the CCS busbar which facilitates automated production, bolts are used to pass through the first fixing hole, the second fixing hole, and the third fixing hole to fix the PCB signal acquisition component between the upper cover and the lower cover.

2. The CCS busbar for automated production as described in claim 1, characterized in that: The PCB signal acquisition component includes a connector disposed at one end of the PCB substrate and multiple nickel plates fixedly disposed on both sides of the PCB substrate.

3. The CCS busbar for automated production as described in claim 1, characterized in that: The input aluminum bar, the output aluminum bar, and the series aluminum bar are all made of 1060 aluminum material.

4. The CCS busbar for automated production as described in claim 1, characterized in that: The mounting hole is located in the middle of the mounting protrusion.

5. The CCS busbar for automated production as described in claim 1, characterized in that: The first fixing hole is provided at two corners of the aluminum bar body along the same side of the aluminum bar body.

6. The CCS busbar for automated production as described in claim 1, characterized in that: The PCB signal acquisition assembly also includes an NTC for temperature acquisition.

7. The CCS busbar for automated production as described in claim 6, characterized in that: The NTC is encapsulated within the upper cover plate body by first applying adhesive and then pressing it under high pressure.

8. The CCS busbar for automated production as described in claim 1, characterized in that: The lower cover plate is matched with the upper cover plate and has the same structure.

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