Battery top cover, single battery and battery module

Abstract

The utility model discloses a battery top cover, single battery and battery module are related, and the utility model discloses a battery top cover includes top cover body and monitoring module, and through the circuit board is provided with first connector and second connector, and the first connector of any single battery is inserted with the second connector of adjacent single battery and carries out the communication to transmission single battery's pressure signal and / or temperature signal. The utility model realizes the direct transmission between the pressure and temperature signal of adjacent battery, has solved the problem of complex wiring, low reliability in traditional scheme, has the advantages such as simplifying structure, improving signal acquisition stability and facilitating scale assembly.

Description

Technical Field

[0001] This utility model relates to the field of battery manufacturing technology, specifically to a battery top cover, a single battery cell, and a battery module. Background Technology

[0002] In existing battery management system (BMS) data acquisition solutions, wiring harnesses and flexible printed circuits (FPCs) are mainly used to acquire and transmit signals such as voltage and temperature. However, both of these technologies have certain limitations, making it difficult to achieve an ideal balance in terms of reliability, cost, space utilization, and safety, thus hindering further improvements in the overall performance of the battery management system.

[0003] Wiring harness solutions, as a traditional data acquisition method, rely on a large number of wires and connectors to physically connect sensors and acquisition units. Their wiring structure is complex, especially in scenarios with a large number of modules and compact battery packs. This results in demanding installation processes and long installation times, increasing manufacturing costs and complicating subsequent maintenance. More importantly, excessive and densely packed wiring harnesses can easily cause mutual interference, leading to problems such as localized overheating, increased contact resistance, or signal distortion. In severe cases, this can even cause electrical short circuits or connection failures, posing significant safety hazards. Under extreme conditions such as mechanical vibration or vehicle collisions, wiring harnesses are prone to displacement, pulling, or wear, potentially causing insulation damage or loosening of connectors, further increasing system failure and safety risks.

[0004] The FPC (Flexible Printed Circuit) solution uses flexible substrates and printed circuits to replace traditional copper wires, enabling customized topography design based on the battery module structure. This achieves higher integration and better space adaptability, helping to reduce system weight and internal volume. However, this solution still faces many challenges in practical applications. On the one hand, FPC requires special flexible materials, and its manufacturing process involves precision etching and multi-layer lamination, resulting in high technical barriers and high production costs. On the other hand, although it has good flexibility, repeated bending in dynamic stress environments such as long-term vibration and high / low temperature cycling can cause conductor fatigue, plating cracking, or interface detachment, thus affecting the stability and lifespan of electrical connections. In addition, FPC is relatively weak in its resistance to mechanical shock and external puncture, and its overall structural strength is insufficient, limiting its application in certain high-reliability scenarios.

[0005] Therefore, the current signal acquisition architecture of battery management systems still urgently needs a new technical solution that integrates high reliability, low cost, excellent space adaptability and higher safety to overcome the shortcomings of existing wiring harness and FPC solutions. Summary of the Invention

[0006] In view of the above problems, this utility model provides a battery top cover, a single battery cell, and a battery module to solve the defects of existing wiring harness and FPC solutions.

[0007] In a first aspect, this utility model provides a battery top cover, comprising: The top cover body is provided with a measuring hole for measuring the pressure and / or temperature of individual cells; The monitoring module includes a circuit board and a sensor. The circuit board is fixed on the top cover body. The first end of the sensor is electrically connected to the circuit board, and the second end of the sensor extends into the first mounting hole and is sealed to the measuring hole. The circuit board is provided with a first connector and a second connector, and the first connector of any single cell can be plugged into and communicated with the second connector of the adjacent single cell to transmit the pressure signal and / or temperature signal of the single cell.

[0008] In some optional embodiments, the first connector and the second connector are respectively disposed on both sides of the circuit board along a first direction, and the first connector and the second connector are in opposite directions.

[0009] In some optional embodiments, the first connector is a female connector with a slot and a pin inside the slot, the pin being electrically connected to the circuit board; the second connector is a male connector with an insert and a socket inside the insert, the socket containing a connecting sleeve electrically connected to the circuit board; when the insert of one single battery is inserted into the slot of another single battery, the pin is inserted into the socket and electrically connected to the connecting sleeve located in the socket.

[0010] In some optional embodiments, the top cover body is further provided with a first pole and a second pole, and the circuit board is provided with a first power connector and a second power connector along a second direction, wherein the first power connector is connected to the first pole and the second power connector is connected to the second pole.

[0011] In some optional embodiments, the top cover body is provided with an explosion-proof valve; the circuit board is provided with a void relief groove, which is located above the explosion-proof valve.

[0012] In some alternative embodiments, the circuit board is also provided with a marking area.

[0013] In some alternative embodiments, the circuit board is fixed to the upper end of the top cover body by soldering or gluing.

[0014] Secondly, this utility model provides a single-cell battery, comprising: The housing includes a receiving cavity with an opening; Electrode assemblies are installed within the accommodating cavity; and The aforementioned battery top cover closes to the opening.

[0015] Secondly, this utility model provides a battery module, comprising: The battery assembly includes multiple individual cells as described above, the multiple individual cells are arranged in sequence, and the first connector of any of the individual cells is connected to the second connector of the adjacent individual cell for communication. Structural components for mounting on the outside of the battery assembly to secure the individual battery cells; And a controller, located on the outside of the structure and connected to the first and second connectors of the battery assembly, for acquiring monitoring signals of each individual battery cell.

[0016] In some alternative embodiments, multiple individual cells in the battery assembly are connected in series via a busbar.

[0017] This invention provides a battery top cover, a single battery cell, and a battery module. Its advantages are as follows: The battery top cover includes a top cover body and a monitoring module. A first connector and a second connector are provided on a circuit board. The first connector of any single battery cell can be plugged into and communicate with the second connector of an adjacent single battery cell to transmit the pressure signal and / or temperature signal of the single battery cell. This invention achieves direct transmission of pressure and temperature signals between adjacent batteries, solving the problems of complex wiring and low reliability in traditional solutions. It has the advantages of simplified structure, improved signal acquisition stability, and ease of large-scale assembly.

[0018] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model embodiment, it can be implemented according to the contents of the specification. In order to make the above and other objects, features and advantages of this utility model embodiment more obvious and understandable, specific embodiments of this utility model are given below. Attached Figure Description

[0019] The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A top view schematic diagram of the battery top cover of Embodiment 1 of this utility model is shown; Figure 2 A perspective view of the battery top cover of Embodiment 1 of this utility model is shown; Figure 3 A three-dimensional schematic diagram of the monitoring module of Embodiment 1 of this utility model is shown; Figure 4 A three-dimensional schematic diagram of a single cell of Embodiment 2 of this utility model is shown; Figure 5 An exploded front view of a single cell of Embodiment 2 of this utility model is shown; Figure 6 A three-dimensional schematic diagram of the battery module of Embodiment 3 of this utility model is shown; Figure 7 A front view schematic diagram of the battery module of Embodiment 3 of this utility model is shown; Figure label: 10. Battery assembly; 100. Single cell; 110. Top cover body; 111. Measuring hole; 112. First terminal; 113. Second terminal; 120. Monitoring module; 130. Circuit board; 131. First connector; 132. Second connector; 133. First electrical connector; 134. Second electrical connector; 135. Clearance groove; 136. Marking area; 140. Sensor; 150. Housing; 200. Busbar; 20. Structural components; 30. Controller. Detailed Implementation

[0020] Exemplary embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention may be implemented in various forms and should not be limited to the embodiments set forth herein.

[0021] Example 1: Figure 1-3 This invention illustrates one embodiment of the battery top cover, providing a signal acquisition architecture for a current battery management system that integrates high reliability, low cost, excellent space adaptability, and enhanced safety. Applied to individual battery cells, this invention allows for modular assembly into groups, reducing reliance on wiring harnesses and enabling synchronous data transmission via a highly efficient bus system. Compared to traditional solutions, it reduces wiring harness usage by approximately 90%, significantly simplifying the system structure and reducing wiring complexity and related safety hazards. Simultaneously, the modular architecture improves system maintainability and scalability, making cell assembly more convenient. This innovative solution not only optimizes space utilization but also significantly reduces costs.

[0022] Specifically, this utility model proposes a battery top cover including a top cover body 110 and a monitoring module 120. The top cover body 110 is provided with a measuring hole 111. The monitoring module 120 includes a circuit board 130 fixed on the top cover and a sensor 140 connected to the circuit board 130. One end of the sensor 140 extends into the measuring hole 111 and is sealed to the hole. The circuit board 130 is provided with two types of connectors. Adjacent individual cells 100 are connected through the connectors to transmit pressure and temperature signals. The first connector of any individual cell is connected to the second connector of the adjacent individual cell for communication to transmit the individual cell's pressure signal and / or temperature signal. Each individual cell can be assigned a coded address. The individual cell sends pressure and / or temperature signals along with the coded address, and the controller identifies the individual cell's signal through the coded address.

[0023] In this embodiment, the measuring hole 111 refers to a through hole in the top cover body 110, which can be achieved by laser drilling or stamping. It is used to accommodate the detection end of the sensor 140 and maintain the internal seal of the battery. The monitoring module 120 is a component that integrates the sensor 140 and the signal processing circuit. Specifically, the sensor 140 can be soldered onto the circuit board 130 using surface mount technology to achieve electrical signal conversion and transmission. The first connector 131 and the second connector 132 refer to electronic interfaces with complementary plug-in structures. Specifically, they can be implemented using board-to-board connectors or wire-to-board connectors, and the electrical connection between adjacent circuit boards 130 is completed through metal contacts.

[0024] Specifically, the top cover body 110 has a measuring hole 111 formed by machining, through which the sensor 140's detection end directly contacts the internal environment of the battery. The circuit board 130 is fixed to the top cover surface by soldering or bonding, and the sensor 140 signal is transmitted to the connector after circuit processing. When multiple individual batteries 100 are arranged and assembled, the connectors of adjacent batteries form a series communication link through plugging, and pressure and temperature signals are transmitted step by step through metal contacts without the need for additional cable connections. The sensor 140 and the measuring hole 111 are sealed with epoxy resin or silicone to prevent electrolyte leakage.

[0025] Compared to existing technologies, wire harness solutions require separate signal line arrangements and multiple connectors. This invention eliminates the problem of crisscrossing wire harnesses by using a top-cover integrated circuit board 130 and plug-in connectors. Compared to flexible printed circuits that rely on bent lines for connections, this invention uses a rigid circuit board 130 and standardized connectors, enhancing vibration resistance and structural stability.

[0026] Through the above technical solutions, this utility model reduces the complexity of internal wiring of the battery module and reduces the number of connectors used; the combination of rigid circuit board 130 and plug-in connector improves the stability of signal transmission; the design of sensor 140 directly integrated into top cover body 110 realizes direct monitoring of the internal state of the battery and avoids the delay and distortion of external signal acquisition.

[0027] In some alternative embodiments, the present invention proposes that the first connector 131 and the second connector 132 are respectively disposed on both sides of the circuit board 130 along a first direction, and the first connector 131 and the second connector 132 are in opposite directions.

[0028] In this embodiment, the first direction refers to the length extension direction of the circuit board 130, which can be implemented using the long side of the circuit board 130 as the reference direction. This direction is consistent with the arrangement direction of the individual battery cells 100. "Set on both sides" means that the first connector 131 and the second connector 132 are respectively arranged at the two end regions of the circuit board 130 along the first direction. This can be achieved by reserving mounting positions on both sides of the circuit board 130 and configuring corresponding connector interfaces to ensure that the connectors of adjacent individual battery cells 100 can be aligned along the arrangement direction. "Opposite directions" means that the insertion direction of the first connector 131 and the insertion direction of the second connector 132 are arranged 180 degrees opposite. This can be achieved by having the insertion surfaces of the male and female connectors face opposite directions to avoid directional misalignment when connecting adjacent batteries.

[0029] Specifically, a first connector 131 and a second connector 132 are fixed to both sides of the circuit board 130 along the first direction, with the insertion surface of the first connector 131 facing outwards and the insertion surface of the second connector 132 facing inwards. When multiple individual battery cells 100 are arranged along the first direction, the first connector 131 of one battery and the second connector 132 of the adjacent battery are on the same axis. Since their directions are opposite, the male connector can be directly inserted into the slot of the female connector along a straight path without adjusting the connector angle or performing rotation. This arrangement allows the connectors of adjacent batteries to automatically align and connect during the assembly of multiple individual battery cells 100, significantly reducing assembly complexity.

[0030] Compared to existing technologies, traditional wiring harness solutions require manual terminal matching and fixing for connecting wires between adjacent batteries, which carries the risk of poor contact due to incorrect insertion direction. Furthermore, in FPC solutions, the folding direction of flexible circuitry is limited by the substrate's deformation capacity, making it difficult to achieve straight-line insertion between multiple batteries. This invention addresses this by arranging connectors in opposite directions, creating a complementary insertion structure between connectors of adjacent batteries. This ensures reliable electrical connections while enabling modular and rapid assembly.

[0031] Through the above technical solution, this utility model effectively solves the problem of difficult alignment of signal transmission interfaces between adjacent individual cells 100 in a battery module. By standardizing the direction and position of the connector, it improves the assembly efficiency of the battery module, eliminates the risk of contact failure caused by incorrect insertion direction, and enhances the stability of signal acquisition in the battery management system.

[0032] In some optional embodiments, the present invention provides a battery top cover, wherein the first connector 131 is a female connector, the first connector 131 is provided with a slot, and a pin is provided in the slot, the pin being electrically connected to the circuit board 130; the second connector 132 is a male connector, the second connector 132 is provided with a plug, the plug is provided with a socket, and a connecting sleeve electrically connected to the circuit board 130 is provided in the socket; when the plug of one single battery 100 is inserted into the slot of another single battery 100, the pin is inserted into the socket and the pin is electrically connected to the connecting sleeve provided in the socket.

[0033] In this embodiment, the female connector refers to a connector with a slot structure. A conductive pin can be installed in the slot, and the pin is electrically connected to the circuit board 130 by soldering or crimping to establish a signal transmission channel. The male connector refers to a connector with a plug-in structure. A socket is provided inside the plug-in, and a flexible metal sleeve can be installed in the socket. The sleeve is electrically connected to the circuit board 130 by soldering or crimping to form a contact interface with the pin. The cooperation between the pin and the connecting sleeve enables self-alignment during the insertion process, avoiding poor contact due to assembly deviations. The connecting sleeve can be made of elastic materials such as phosphor bronze or beryllium copper, which generates radial elastic deformation when the pin is inserted, thereby forming a stable multi-point contact.

[0034] Specifically, when a single cell 100 needs to establish a communication connection with an adjacent cell, the male connector insert is pushed into the female connector slot. The pin is automatically guided to the socket position during insertion and then inserted into the connecting sleeve. The elastic deformation of the connecting sleeve applies uniform contact pressure to the pin, eliminating gaps caused by vibration or temperature changes. The contact area between the pin and the sleeve can be optimized by adjusting the ratio of the sleeve's inner diameter to the pin's diameter; for example, the sleeve's inner diameter can be 0.05-0.1 mm smaller than the pin's diameter to form an interference fit. The pin surface can be gold-plated or silver-plated to reduce contact resistance, and the inner wall of the sleeve can be designed with spiral grooves to increase the number of contact points.

[0035] Compared to existing technologies, traditional wire harness connectors typically use single-point contact methods such as welding or screw fixing, which are prone to contact failure under vibration. This invention, through the interference fit between the pins and the elastic sleeve, forms a connection interface with redundant contact points. Even if a single contact point loosens due to mechanical stress, the remaining contact points can still maintain stable conductivity. Furthermore, the connector layout with opposite insertion directions prevents mis-insertion. Compared to the fragile interface of flat cables in FPC solutions, the insertion structure of this invention has significant advantages in terms of bending and impact resistance.

[0036] Through the above technical solution, this utility model solves the problems of loose connectors and unstable contact resistance in existing battery modules. The mating design of the pins and elastic sleeve maintains a low-impedance path under dynamic operating conditions, avoiding signal transmission interruption or distortion. The self-alignment characteristic of the plug structure simplifies the battery module assembly process, reduces manual calibration steps, and eliminates the risk of equipment damage caused by misaligned plugging. The elastic deformation of the connecting sleeve compensates for manufacturing tolerances and improves the compatibility of parts from different batches.

[0037] In some alternative embodiments, the present invention proposes that the top cover body 110 is further provided with a first pole post 112 and a second pole post 113, and the circuit board 130 is provided with a first power connector 133 and a second power connector 134 along the second direction. The first power connector 133 is connected to the first pole post 112, and the second power connector 134 is connected to the second pole post 113.

[0038] In this embodiment, the first terminal 112 refers to the positive conductive structure disposed on the top cover body 110, which can be implemented using a copper alloy pillar and an insulating sealing ring, and is used to establish the positive terminal of the single cell 100. The second terminal 113 refers to the negative conductive structure disposed on the top cover body 110, which can be implemented using an aluminum pillar and a sealing assembly, and is used to establish the negative terminal of the single cell 100. The first contact component 133 refers to the conductive connection component disposed on the circuit board 130, which can be implemented using an elastic contact piece or a soldered terminal, and is used to establish a current path between the circuit board 130 and the first terminal 112. The second contact component 134 refers to the conductive component disposed on the circuit board 130 that matches the second terminal 113, which can be implemented using a stamped metal part or a conductive adhesive bonding structure, and is used to establish a current path between the circuit board 130 and the second terminal 113. The second direction refers to the spatially intersecting layout axis within the plane of the circuit board 130 and the arrangement direction of the first connector 131. Specifically, it can be achieved by a horizontal or vertical arrangement perpendicular to the first direction, in order to optimize the space utilization of the circuit board 130.

[0039] Specifically, the first contact 133 and the second contact 134, arranged along the second direction on the circuit board 130, form direct physical connections with the first terminal 112 and the second terminal 113 on the top cover body 110, respectively. When the circuit board 130 is fixed to the top cover body 110, the first contact 133 forms a conductive contact with the top surface of the first terminal 112 through elastic contact or welding, and the second contact 134 forms a conductive contact with the side wall of the second terminal 113 through plug-in or crimping. This layout allows the circuit board 130 to directly obtain the positive and negative power supply from the single battery 100 without additional wiring harnesses. At the same time, the second-direction arrangement strategy ensures that the contact points between the contact 133 and the terminal avoid the connector insertion area, thus preventing spatial interference.

[0040] Compared to existing technologies, traditional wiring harness solutions require separate wires to connect the terminals and the acquisition module, resulting in numerous connection nodes and a large space occupation. FPC solutions, on the other hand, require conductive lines running through the terminal area on a flexible substrate, leading to insufficient structural strength. This invention integrates the connecting components onto the circuit board 130 and directly connects them to the terminals, eliminating the need for intermediate wires or flexible lines, reducing the risk of connection failure. Simultaneously, the second-direction layout optimizes the space allocation of the circuit board 130, creating physical isolation between the terminal connection structure and the signal transmission structure.

[0041] Through the above technical solution, this utility model achieves direct power connection between the circuit board 130 and the battery terminal, eliminating the problems of unstable contact resistance and excessive number of connectors in traditional wiring harnesses or FPC solutions, and reducing the probability of poor contact caused by vibration. The second-direction layout strategy spatially separates the electrical components and connectors, avoiding the impact of insertion operations on the stability of the terminal connection and improving the structural compactness of the circuit board 130 within a limited space.

[0042] In some optional embodiments, this invention proposes that the top cover body 110 is provided with an explosion-proof valve; the circuit board 130 is provided with a relief groove 135, which is located above the explosion-proof valve. In this embodiment, the explosion-proof valve refers to a pressure relief device provided on the top cover body 110, which can be implemented using a thin-walled structure or a rupture disc structure. When the internal pressure of the battery exceeds a threshold, it automatically ruptures to release the pressure. The relief groove 135 refers to a notch or recessed area opened on the circuit board 130, which can be implemented using stamping or laser cutting processes, and its position is perpendicularly projected to the opening area of ​​the explosion-proof valve.

[0043] Specifically, the explosion-proof valve is positioned at a predetermined location on the top cover body 110, corresponding to a pressure concentration area inside the battery. The layout of the vent groove 135 on the circuit board 130 is designed to completely cover the opening path of the explosion-proof valve, ensuring that its rupture action is not physically obstructed by the circuit board 130 when the explosion-proof valve is activated due to abnormal pressure. The circuit board 130 is mounted at a fixed distance from the top cover body 110, and the depth of the vent groove 135 is designed to be at least equal to the vertical distance between the circuit board 130 and the explosion-proof valve.

[0044] Compared to existing technologies, the circuit board 130 of a traditional battery top cover typically covers the explosion-proof valve directly. When the explosion-proof valve needs to operate, the circuit board 130 may obstruct the pressure release, causing delays or failure. This invention, through the opening of the clearance groove 135, reserves the necessary space for the opening action of the explosion-proof valve while maintaining the complete functionality of the circuit board 130, without adding additional structural layers or changing the thickness of the top cover body 110.

[0045] Through the above technical solution, this utility model effectively avoids the interference of the circuit board 130 on the working state of the explosion-proof valve, ensuring that the explosion-proof valve can respond in a timely manner when the internal pressure of the battery is abnormal. The structural design of the anti-cavity groove 135, while realizing the pressure release channel, maintains the stable connection between the circuit board 130 and the top cover body 110, preventing electrical connection failure caused by local structural weakening.

[0046] In some optional embodiments, this invention proposes that the circuit board 130 also include an identification area 136. In this embodiment, the identification area 136 refers to a specific area reserved on the circuit board 130 for carrying identifiable marking information. This can be achieved through laser engraving, screen printing, or labeling. This area is typically located at the edge of the circuit board 130 or in a non-conductive area to avoid interfering with circuit functionality. The identification area 136 plays a role in rapid identification and positioning in the solution. Through preset coding rules or graphic symbols, it facilitates accurate differentiation of different circuit boards 130 during assembly, maintenance, or replacement, reducing manual verification time and the risk of misoperation.

[0047] Specifically, the marking area 136 is integrated into the surface of the circuit board 130, and can be pre-marked with information such as batch number, serial number, or QR code during the production stage. During battery module assembly, operators can quickly identify the location and parameter configuration of the individual battery 100 corresponding to the circuit board 130 by scanning or reading the contents of the marking area 136, ensuring that the monitoring modules 120 of each individual battery 100 are correctly matched. At the same time, when a specific circuit board 130 needs to be replaced or repaired, the marking area 136 provides a clear physical identification, allowing the target to be located without disassembling adjacent components, significantly improving maintenance efficiency.

[0048] Compared to existing technologies, traditional wire harness or FPC solutions lack a unified marking design for the circuit board 130, relying on manual recording or external labels for management. This is prone to information loss due to label detachment or illegible writing, and makes it difficult to quickly identify target components in densely packed scenarios. This invention, through a built-in marking area 136, directly embeds key information into the circuit board 130 body, forming a permanent mark. This solves the reliability problem of traditional reliance on external markings and simplifies assembly and maintenance processes.

[0049] Through the above technical solution, this utility model reduces the risk of incorrect installation of circuit board 130 due to human identification errors, shortens the module assembly and troubleshooting time, and avoids maintenance difficulties caused by the failure of external tags in high temperature and vibration environments, thereby improving the overall operation and maintenance efficiency and reliability of the battery management system.

[0050] In some alternative embodiments, the present invention proposes that the circuit board 130 be fixed to the upper end of the top cover body 110 by welding or gluing.

[0051] Welding refers to the metallurgical connection method of forming a bond between the circuit board 130 and the top cover body 110 by molten metal or alloy. Specifically, it can be achieved by laser welding, resistance welding or tin soldering, which can provide a rigid connection and meet the structural stability requirements in high-temperature environments.

[0052] Among them, adhesive bonding refers to the method of bonding and fixing the circuit board 130 to the surface of the top cover body 110 with an adhesive. Specifically, epoxy resin glue, silicone or acrylic glue can be used to achieve this, which can adapt to complex surface morphology and reduce the impact of mechanical stress on the circuit board 130.

[0053] Specifically, the welding or adhesive fixing methods directly act on the contact area between the circuit board 130 and the top cover body 110, without the need for additional fixing structures. During welding, localized heating melts and solidifies the connecting materials, forming an irreversible physical bond. During adhesive bonding, the adhesive wets the surface and, after curing, generates adhesion, achieving the positioning and fixing of the circuit board 130. Both methods avoid the installation complexity caused by mechanical fixing structures such as screws and clips in traditional wire harness solutions, while also resolving the connection failure risk caused by repeated bending of the flexible substrate in FPC solutions.

[0054] Compared to existing technologies, traditional wiring harness solutions rely on bolts or clips to fix the circuit board 130, requiring pre-drilled mounting holes and adding assembly steps. Soldering or gluing, on the other hand, directly utilizes the surface of the top cover body 110 for fixation, simplifying the installation process and reducing the number of parts. In FPC solutions, the flexible circuit board 130 is typically fixed with screws or clamps, which poses a risk of loosening due to vibration. The connection interface formed by welding or gluing has higher vibration resistance, avoiding signal transmission abnormalities caused by mechanical loosening.

[0055] Through the above technical solution, the present invention achieves reliable fixation of the circuit board 130 on the top cover body 110, reduces the complexity of the installation process, avoids connection failure caused by loosening of the mechanical fixing structure or fatigue of the flexible substrate, and improves the long-term stability of the battery monitoring module 120 under dynamic working conditions.

[0056] Example 2: Figure 4-5 An embodiment of a single-cell battery 100 according to the present invention is shown. The single-cell battery 100 includes a housing 150, an electrode assembly, and a battery top cover. The housing 150 includes a receiving cavity with an opening, the electrode assembly is installed in the receiving cavity, and the battery top cover closes to the opening. The battery top cover includes a top cover body 110 and a monitoring module 120. The top cover body 110 is provided with a measuring hole 111 for measuring the pressure and / or temperature of the single-cell battery 100. The monitoring module 120 includes a circuit board 130 and a sensor 140. The circuit board 130 is fixed on the top cover body 110. The first end of the sensor 140 is electrically connected to the circuit board 130, and the second end of the sensor 140 extends into a first mounting hole and is sealed to the measuring hole 111. The circuit board 130 is provided with a first connector 131 and a second connector 132, and the first connector 131 of any single-cell battery 100 is plugged into and communicates with the second connector 132 of the adjacent single-cell battery 100 to transmit the pressure signal and / or temperature signal of the single-cell battery 100.

[0057] The housing 150 refers to the structural component 20 used to house the electrode assembly and provide mechanical support. It can be made of aluminum alloy or stainless steel through a stamping process. An internal cavity is formed within the housing 150 to secure the electrode assembly. The cavity is the space within the housing 150 used to install the electrode assembly; its opening can be sealed by the battery top cover. It can be rectangular or cylindrical to accommodate electrode assemblies of different shapes. The electrode assembly is an energy storage unit composed of positive and negative electrode plates, a separator, and an electrolyte. It can be assembled using a winding or stacking process and inserted into the cavity, with current output achieved through tabs connected to the terminals of the battery top cover. The battery top cover is a component used to seal the opening of the housing 150 and integrate monitoring functions. It can be made of metal or composite materials. The top cover body 110 and the housing 150 are connected for airtightness through laser welding or sealant.

[0058] Specifically, after the electrode assembly is inserted into the housing 150 through the opening, the battery top cover covers the opening and is fixed by welding or adhesive, forming a closed internal environment for the battery. The measuring hole 111 on the top cover body 110 allows the sensor 140 to extend into the battery, directly contacting the electrolyte or the surface of the electrode assembly to collect pressure or temperature data in real time. The circuit board 130 of the monitoring module 120 is fixed to the upper surface of the top cover body 110, and the sensor 140 is sealed to the measuring hole 111 through the first mounting hole to prevent electrolyte leakage. The first connector 131 and the second connector 132 of the circuit board 130 are respectively arranged on both sides. The connectors of adjacent individual cells 100 transmit signals through insertion, eliminating the need for additional wiring harnesses or flexible circuit boards 130. For example, when multiple individual cells 100 are arranged, the second connector 132 of the previous cell is directly inserted into the first connector 131 of the next cell, forming a series communication link. Pressure or temperature signals are transmitted to the external controller 30 through conductive components within the connectors.

[0059] Compared to existing technologies, current solutions rely on wire harnesses or flexible circuit boards 130 for signal transmission, which suffers from complex wiring and susceptibility to mechanical stress damage. This invention, however, integrates a monitoring module 120 with a plug-in connector, directly embedding the signal transmission path into the battery top cover structure, reducing reliance on external cables. For example, traditional wire harness solutions require numerous wires within the module, occupying space and prone to poor contact. This invention, on the other hand, uses connectors on adjacent battery top covers to interlock, forming a compact serial communication link, saving space and reducing the risk of connection failure.

[0060] Through the above technical solutions, this utility model can avoid signal interruption caused by loose wiring harness or fatigue of flexible circuit board 130, thus improving signal transmission stability. Meanwhile, the use of plug-in connectors simplifies the battery module assembly process and reduces manual wiring costs. Furthermore, the sealed connection between sensor 140 and measuring hole 111 effectively prevents electrolyte leakage, enhancing the operational safety of individual battery cells 100.

[0061] Example 3: Figure 6-7 An embodiment of a battery module according to the present invention is shown. The battery module includes a battery assembly 10, a structural component 20, and a controller 30. The battery assembly 10 includes a plurality of individual battery cells 100 as described in Embodiment 2, which are arranged sequentially. A first connector of any individual battery cell 100 is plugged into and communicates with a second connector of an adjacent individual battery cell 100. The structural component 20 is installed on the outside of the battery assembly 10 for fixing the individual battery cells 100. The controller 30 is disposed on the outside of the structural component 20 and connected to the first and second connectors of the battery assembly 10 for acquiring monitoring signals from each individual battery cell 100.

[0062] The battery assembly 10 refers to a collection of multiple individual cells 100 arranged in sequence. Electrical connections can be achieved through series or parallel connections, and signal transmission is achieved through plug-in communication between adjacent individual cells 100. The structural component 20 refers to a supporting part used to fix the battery assembly 10, which can be implemented using a metal frame or a high-strength plastic bracket to limit the displacement of the individual cells 100 under vibration or impact. The controller 30 refers to a signal processing unit, which can be implemented using an embedded microprocessor. It receives monitoring signals from the individual cells 100 through a connector interface and performs centralized processing.

[0063] Specifically, each individual battery cell 100 is directly connected to the second component of an adjacent individual battery cell 100 via a first component, forming a continuous signal transmission link. For example, when the individual batteries 100 are arranged in a straight line, the first component can be located on the left side of the circuit board 130, and the second component on the right side. The second component on the right side of an adjacent individual battery cell 100 is inserted into the first component on the left side of the next individual battery cell 100 to complete the connection. The structural component 20 surrounds the battery assembly 10 and can be fixed in relative position by bolts or clips. The controller 30 connects to the connectors at both ends of the battery assembly 10 via cables, collects pressure and temperature signals from all individual batteries 100, and uploads the data to the battery management system.

[0064] In some specific embodiments, the individual cells 100 in the battery assembly 10 can be connected in series via a busbar 200, with the copper plates of the busbar 200 welded to the terminals of the individual cells 100 to form a stable current path. The structural component 20 can be designed as an aluminum housing with heat dissipation fins, which enhances heat conduction efficiency while fixing the battery assembly 10. The controller 30 can be installed on the top or side of the structural component 20, and can be connected to a connector via a waterproof joint to adapt to different environmental conditions.

[0065] Compared to existing technologies, conventional wiring harness solutions rely on numerous independent wires to connect each individual battery cell 100, resulting in complex wiring that is susceptible to mechanical stress. This invention, however, utilizes a chain-like transmission path formed by the plug-in communication of adjacent battery cells 100, reducing the number of wiring harnesses and connection nodes. While FPC solutions achieve a compact layout, their flexible substrate is prone to conductor fatigue under long-term vibration. This invention, on the other hand, employs a rigid circuit board 130 and standardized connectors, improving the mechanical stability of the interface connection. Furthermore, existing technologies require separate signal lines to be routed to the controller 30 for each battery cell 100, while this invention, through chain-like connections, only requires connection to the controller 30 at both ends of the battery assembly 10, significantly simplifying the wiring complexity.

[0066] Through the above technical solutions, this utility model solves the problems of complex wiring and susceptibility to mechanical damage in traditional wire harness solutions, and avoids the drawbacks of high material costs and poor fatigue resistance in FPC solutions. Direct plug-in communication between adjacent individual battery cells 100 eliminates the dependence on intermediate wires, reducing contact resistance and signal attenuation risks. Centralized signal acquisition by the controller 30 reduces the number of external connection points and improves data transmission reliability. The rigid fixation of the structural component 20 to the battery assembly 10 effectively suppresses the risk of connector loosening under vibration, ensuring long-term operational stability.

[0067] In some alternative embodiments, the present invention proposes that multiple individual battery cells 100 in a battery module be connected in series via a busbar 200.

[0068] The busbar 200 refers to a flat conductor made of conductive metal material, specifically copper or aluminum, with a surface plated with tin or nickel to enhance corrosion resistance. Series connection refers to sequentially connecting the positive terminal of a single cell 100 to the negative terminal of an adjacent single cell 100 to form a continuous current path, which can be achieved through welding or bolt fastening.

[0069] Specifically, the battery module comprises multiple individual battery cells 100. Each individual battery cell 100 has a circuit board 130 integrated into its top cover. A first connector 131 and a second connector 132 are respectively located on both sides of the circuit board 130. During module assembly, the individual battery cells 100 are arranged sequentially along the arrangement direction. A busbar 200 physically connects the first terminal 112 of each individual battery cell 100 to the second terminal 113 of the adjacent individual battery cell 100, forming a series circuit. The rigid structure of the busbar 200 effectively reduces the risk of displacement caused by mechanical vibration. Its wide cross-sectional area design helps reduce contact resistance and heat generation, while simplifying the internal wiring complexity of the module. Under high voltage and high current conditions, the stable connection of the busbar 200 ensures uniform current distribution, avoiding safety hazards caused by localized overheating.

[0070] Compared with existing technologies, traditional wiring harness solutions rely on multiple independent wires connected in series, resulting in messy wiring and easy loosening of connectors; while FPC solutions can adapt to compact spaces, their flexible substrate is prone to conductor fatigue fracture under long-term vibration. This utility model adopts an integrated 200 busbar structure, which has higher mechanical strength and conductivity reliability. It eliminates the need for complex wiring design during installation, significantly improving assembly efficiency and reducing maintenance costs.

[0071] Through the above technical solution, this utility model solves the problems of complex wiring and easy failure of existing wire harness solutions and insufficient vibration resistance of FPC solutions. It utilizes the rigid connection characteristics of busbar 200 to achieve stable and reliable series connection between individual cells 100, reducing contact resistance and the risk of local overheating. At the same time, it simplifies the internal structural layout of the module and improves the safety and durability of the battery system under dynamic operating conditions.

[0072] Numerous specific details are set forth in the specification provided herein. However, it will be understood that embodiments of the present invention may be practiced without these specific details. Similarly, for the sake of brevity and to aid in understanding one or more aspects of the invention, in the description of exemplary embodiments of the present invention above, various features of the embodiments of the present invention are sometimes grouped together in a single embodiment, figure, or description thereof. The claims, which follow the detailed description, are hereby expressly incorporated into that detailed description, wherein each claim itself constitutes a separate embodiment of the present invention.

[0073] Those skilled in the art will understand that the modules in the device of the embodiment can be adaptively changed and placed in one or more devices different from that embodiment. Modules, units, or components in the embodiment can be combined into a single module, unit, or component, and further, they can be divided into multiple sub-modules, sub-units, or sub-components, except that at least some of such features and / or processes or units are mutually exclusive.

[0074] It should be noted that the above embodiments are illustrative of the present invention and not restrictive of it, and those skilled in the art can devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses should not be construed as limiting the claims. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The present invention can be implemented by means of hardware comprising several different elements and by means of a suitably programmed computer. In the unit claims listing several means, several of these means may be embodied by the same item of hardware. The use of the words first, second, and third, etc., does not indicate any order. These words can be interpreted as names. The steps in the above embodiments, unless otherwise specified, should not be construed as limiting the order of execution.

Claims

1. A battery top cover, characterized in that, include: The top cover body (110) is provided with a measuring hole (111) for measuring the pressure and / or temperature of the individual battery cells (100). The monitoring module (120) includes a circuit board (130) and a sensor (140). The circuit board (130) is fixed on the top cover body (110). The first end of the sensor (140) is electrically connected to the circuit board (130), and the second end of the sensor (140) extends into the measuring hole (111) and is sealed to the measuring hole (111). The circuit board (130) is provided with a first connector (131) and a second connector (132), and the first connector (131) of any single cell (100) is connected to the second connector (132) of the adjacent single cell (100) for communication to transmit the pressure signal and / or temperature signal of the single cell (100).

2. The battery top cover according to claim 1, characterized in that, The first connector (131) and the second connector (132) are respectively disposed on both sides of the circuit board (130) along the first direction, and the first connector (131) and the second connector (132) are in opposite directions.

3. The battery top cover according to claim 2, characterized in that, The first connector (131) is a female connector, and the first connector (131) is provided with a slot and a pin is provided in the slot. The pin is electrically connected to the circuit board (130). The second connector (132) is a male connector, and the second connector (132) is provided with a plug. The plug is provided with a socket and a connecting sleeve electrically connected to the circuit board (130) is provided in the socket. When the plug of one single battery (100) is inserted into the slot of another single battery (100), the pin is inserted into the socket and the pin is electrically connected to the connecting sleeve provided in the socket.

4. The battery top cover according to claim 1, characterized in that, The top cover body (110) is also provided with a first pole (112) and a second pole (113). The circuit board (130) is provided with a first power connector (133) and a second power connector (134) along the second direction. The first power connector (133) is connected to the first pole (112), and the second power connector (134) is connected to the second pole (113).

5. The battery top cover according to claim 1, characterized in that, The top cover body (110) is provided with an explosion-proof valve; the circuit board (130) is provided with a void relief groove (135), which is located above the explosion-proof valve.

6. The battery top cover according to claim 1, characterized in that, The circuit board (130) is also provided with a marking area (136).

7. The battery top cover according to claim 1, characterized in that, The circuit board (130) is fixed to the upper end of the top cover body (110) by welding or gluing.

8. A single-cell battery, characterized in that, include: The housing (150) includes a receiving cavity with an opening; Electrode assemblies are installed within the accommodating cavity; as well as The battery top cover according to any one of claims 1 to 7, wherein the battery top cover closes to the opening.

9. A battery module, characterized in that, include: The battery assembly (10) includes a plurality of individual cells (100) as described in claim 8, the plurality of individual cells (100) being arranged in sequence, and the first connector (131) of any of the individual cells (100) being plugged into and communicating with the second connector (132) of the adjacent individual cell (100); Structural component (20) for mounting on the outside of the battery assembly (10) for fixing the individual battery cell (100). And a controller (30), located outside the structure (20), connected to the first connector (131) and the second connector (132) of the battery assembly (10), for acquiring monitoring signals of each individual battery cell (100).

10. The battery module according to claim 9, characterized in that, Multiple individual cells (100) in the battery assembly (10) are connected in series via a busbar (200).

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