Battery connection system based on overall flip of FPC and battery module thereof

Abstract

The utility model discloses a kind of battery connection systems based on FPC overall overturning, including aluminium bar;FPC assembly includes flexible circuit board and multiple nickel sheets integrated on flexible circuit board;Bearing disc is used for the setting of aluminium bar and FPC assembly;FPC assembly overall overturning setting and being lifted by bearing disc, make the bottom surface of flexible circuit board and the upper surface of aluminium bar keep apart, to form a lifting gap with height H;Nickel sheet is located at lifting gap and overlaps above aluminium bar, and by nickel sheet welding connection flexible circuit board and aluminium bar.This new type will signal acquisition branch and the nickel sheet welded overall overturning, and overlap together with aluminium bar, make multiple nickel sheet reliable connection with aluminium bar one-time, break through the limitation of traditional nickel sheet and aluminium bar welding to layout space.And, ingeniously use overturning and lifting structure design, form gap between FPC signal acquisition branch and aluminium bar edge, eliminate potential wear risk.

Description

Technical Field

[0001] This utility model relates to battery connection systems, and more particularly to a battery connection system (CCS) based on FPC overall flipping and its battery module, belonging to the field of new energy vehicle power battery technology. Background Technology

[0002] In power battery modules, the Battery Connection System (CCS) is responsible for the current return, voltage, and temperature signal acquisition of the battery cells. Traditional CCS modules typically use a "single nickel sheet + aluminum bar" bonding method, where each sampling point is bonded to an independent nickel sheet, which is then laser-welded to the aluminum bar one by one. However, the above structure has the following main drawbacks: Low space utilization: Each nickel sheet requires independent welding space and safety spacing, which seriously encroaches on layout space and limits the design space of CCS and the current carrying capacity of aluminum bar in the trend of increasingly compact module design.

[0003] The assembly process is complex: multiple nickel sheets need to be aligned and welded one by one, the assembly steps are complicated, the precision requirements are high, and the production efficiency is limited.

[0004] There is a risk of wear and tear: After assembly, the FPC or its wiring harness may come into contact with the sharp edges of the aluminum bus. Under long-term vehicle vibration, the insulation layer may be worn through, leading to safety hazards such as short circuits.

[0005] To address the aforementioned technical shortcomings, there is an urgent need to provide a new CCS structure that can balance compact layout, high assembly efficiency, and high reliability. Utility Model Content

[0006] To address the shortcomings of the aforementioned technologies, this invention provides a battery connection system and its battery module based on an overall FPC flip.

[0007] To solve the above technical problems, the technical solution adopted by this utility model is: a battery connection system based on FPC overall flipping, which includes: Aluminum bar; FPC assembly, the FPC assembly includes a flexible circuit board and multiple nickel sheets integrated on the flexible circuit board; Carrier tray, used for mounting aluminum bus and FPC components; The FPC assembly is flipped up and lifted by a support plate, so that the bottom surface of the flexible circuit board is separated from the top surface of the aluminum bar to form a lifting gap of height H. The nickel sheet is located at the lifting gap and overlaps the aluminum bar, and the flexible circuit board and the aluminum bar are welded together by the nickel sheet.

[0008] Preferably, the carrier plate has a recessed aluminum bar groove, and the aluminum bar is installed in the aluminum bar groove.

[0009] Preferably, the flexible circuit board is fixed to the lifting platform of the support plate by adhesive bonding or snap-fit.

[0010] Preferably, the flexible circuit board is welded to the nickel sheet via a raised signal acquisition branch.

[0011] Preferably, the height H of the lifting gap is consistent with the thickness of the nickel sheet.

[0012] Preferably, the lower surface of the nickel sheet is seamlessly bonded to the upper surface of the aluminum bar.

[0013] Preferably, the lifting gap between the signal acquisition branch and the edge of the aluminum bar also serves as an anti-wear gap.

[0014] A battery module includes a battery connection system in which the above-mentioned FPC is flipped up and down.

[0015] This invention discloses a battery connection system based on the overall flipping of an FPC (Flexible Printed Circuit). Compared to traditional battery connection systems, this system flips the signal acquisition branch and the soldered nickel strip as a whole, and overlaps it with the aluminum busbar. This allows multiple nickel strips integrated on the flexible circuit board to achieve a reliable connection with the aluminum busbar in one go, overcoming the space limitations imposed by traditional nickel strip and aluminum busbar soldering. Furthermore, by cleverly utilizing the flipping and raising structural design, a gap is created between the FPC signal acquisition branch and the edge of the aluminum busbar, eliminating potential wear risks. Therefore, this novel battery connection system solution combines the advantages of high space utilization, convenient assembly, and good long-term reliability. Attached Figure Description

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

[0017] Figure 2 for Figure 1 The main view.

[0018] Figure 3 This is a schematic cross-sectional view of the connection between the signal acquisition branch and the aluminum bar of the FPC of this utility model.

[0019] Figure 4 for Figure 1 A schematic diagram of the structure of the central bearing plate.

[0020] Figure 5 This is a diagram of a traditional CCS scheme.

[0021] In the diagram: 1. Aluminum bar; 2. Nickel sheet; 3. Support plate; 31. Aluminum bar groove; 32. Lifting platform; 4. Flexible circuit board; 41. Signal acquisition branch; 5. Lifting gap. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0023] To address the issues of low space utilization, complex assembly processes, and potential wear risks associated with traditional CCS (Computer-on-Chip) systems due to their single-nickel sheet overlapping method, particularly the limited design space required for short-blade cells, this invention proposes a battery connection system based on the overall flipping of an FPC (Flexible Printed Circuit). Through the integration of nickel sheets and flexible circuit boards, and the innovative overall flipping structure, this system not only simplifies assembly steps and achieves a more compact battery module layout, significantly reducing the space occupied by the CCS, but also effectively protects the FPC circuitry from friction with the aluminum foil edges through the naturally formed cantilevered lifting gap after flipping. This significantly improves the long-term durability and safety margin of the battery connection system.

[0024] like Figure 1 The diagram shows the overall structure of a structural unit of the battery connection system based on FPC overall flipping disclosed in this utility model. The main structure includes: aluminum bar 1, FPC component and carrier plate 3. Among them, the carrier plate 3 is mainly used for setting up the aluminum bus 1 and the FPC components; such as Figure 4 As shown, the support plate 3 is an insulating plastic part formed by vacuum forming or injection molding, and has a recessed aluminum bar groove 31 and a raised platform 32 located on one side of the aluminum bar groove 31 and higher than the bottom surface of the aluminum bar groove 31.

[0025] Among them, the aluminum bar groove 31 is used for the installation of aluminum bar 1, and the raised platform 32 is used for the installation and setting of FPC components.

[0026] For the FPC component, it includes a flexible circuit board 4 and multiple nickel sheets 2 integrated on the flexible circuit board 4; such as Figure 1 and Figure 2 As shown, the flexible circuit board 4 of the FPC component is specifically connected to the nickel sheet 2 by welding the signal acquisition branch 41, so that the nickel sheet 2 is integrated on the flexible circuit board 4.

[0027] The flexible circuit board 4 is fixed to the raised platform 32 of the carrier plate 3 by adhesive or snap-fit, and the entire FPC assembly is flipped upside down. Since the aluminum bar 1 is located in the recessed aluminum bar groove 31, the signal acquisition branch 41 of the flexible circuit board 4 is at the raised position relative to the aluminum bar 1, so that the bottom surface of the flexible circuit board 4 is separated from the upper surface of the aluminum bar 1 to form a raised gap 5 with a height of H. After the FPC component is flipped, such as Figure 1-3 As shown, the flexible circuit board 4 is at the top, and the nickel sheet 2 contacts and overlaps the aluminum bar 1 in the space provided by the lifting gap 5. The flexible circuit board 4 and the aluminum bar 1 are welded together by the nickel sheet 2. The height H of the lifting gap 5 should be consistent with the thickness of the nickel sheet 2 so that the lower surface of the nickel sheet 2 fits seamlessly with the upper surface of the aluminum bar 1. Typically, the nickel sheet 2 and the aluminum bar 1 are electrically connected and mechanically fixed by laser welding.

[0028] Furthermore, due to the formation of the lifting gap 5, the bottom surface of the signal acquisition branch 41 of the flexible circuit board 4 is also kept separate from the edge or upper surface of the aluminum bar 1, which can serve as an anti-wear gap.

[0029] Therefore, for the battery connection system based on the overall flipping of the FPC disclosed in this utility model, a support plate is set up to raise and flip the signal acquisition branch of the FPC component, so that a lifting gap of height H is formed between the lower surface of the FPC component and the upper surface of the aluminum foil. This height H is precisely designed to be equal to the thickness of the nickel sheet. Through the ingenious design of the above-mentioned flipping and raising structure, the following can be achieved: Seamless overlap: When the FPC component is flipped and overlapped on the aluminum bar, thanks to the fact that the lifting gap H is equal to the thickness of the nickel sheet, the lower surface of all nickel sheets can achieve a complete, uniform, and seamless fit with the upper surface of the aluminum bar, providing optimal interface conditions for subsequent laser welding.

[0030] Anti-wear gap formation: While the nickel sheet and the aluminum bar are bonded together, the body of the FPC component (non-nickel sheet area) is supported by the bearing plate and raised above the surface of the aluminum bar, thus forming an inherent anti-wear gap between the edges of the FPC component and the aluminum bar. This gap effectively avoids direct contact and friction between the FPC insulation layer and the sharp edges of the aluminum bar under vehicle vibration conditions.

[0031] Optimized spatial layout: The overall flip-over and overlapping structure of the FPC component allows multiple nickel strip collection points to be integrated and arranged on the flexible circuit board. The nickel strips integrated on the flexible circuit board FPC can achieve a reliable connection with the aluminum bus in one go, eliminating the need for independent operation space for each nickel strip in the traditional method. Figure 5 Compared to traditional CCS solutions, this new design significantly reduces the width dimension of the CCS, greatly improving space utilization.

[0032] Therefore, when this novel FPC-based overall flip-type battery connection system is applied to battery modules, it has the following technical advantages: Significantly improves space utilization and helps achieve high energy density in batteries: The integrated design of the FPC flipping and aluminum bar connection breaks the spatial layout limitations of traditional single nickel sheet welding, making the CCS structure more compact and creating conditions for packing more cells in a limited volume and improving the overall energy density of the battery pack.

[0033] Fundamentally eliminate the risk of wear and tear and enhance long-term reliability: The "wear-resistant gap" actively formed by the structural design physically isolates the edge contact between the FPC and the aluminum battery, eliminating the hidden danger of short circuit caused by the insulation layer being worn through, and greatly improving the safety and reliability of the power battery throughout its entire life cycle.

[0034] Simplify assembly process and improve production efficiency and consistency: The complex process of aligning and welding multiple nickel sheets one by one in the traditional way is simplified into a single process of placing the whole sheet and welding it at once. This reduces the difficulty of alignment and the number of welding steps, which not only improves production efficiency, but also reduces the consistency risk caused by multiple welding and improves product yield.

[0035] High compatibility and low implementation cost: This innovative structure does not require changes to the fixing method of the FPC itself and retains the mature and reliable laser welding process, making it easy to upgrade and promote on existing production lines. It has extremely high engineering feasibility and economy.

[0036] The above embodiments are not intended to limit the present utility model, nor is the present utility model limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present utility model are also within the protection scope of the present utility model.

Claims

1. A battery connection system based on FPC overall flipping, characterized in that: It includes: Aluminum bar (1); The FPC assembly includes a flexible circuit board (4) and a plurality of nickel sheets (2) integrated on the flexible circuit board (4). Carrying plate (3), the carrying plate (3) is used for setting up aluminum bar (1) and FPC assembly; The FPC assembly is flipped up and lifted by the support plate (3), so that the bottom surface of the flexible circuit board (4) is separated from the upper surface of the aluminum bar (1) to form a lifting gap (5) with a height of H. The nickel sheet (2) is located at the lifting gap (5) and overlaps the aluminum bar (1), and the flexible circuit board (4) and the aluminum bar (1) are welded together by the nickel sheet (2).

2. The FPC overall flip-up battery connection system according to claim 1, characterized in that: The bearing plate (3) has a recessed aluminum bar groove (31), and the aluminum bar (1) is installed in the aluminum bar groove (31).

3. The FPC overall flip-up battery connection system according to claim 2, characterized in that: The flexible circuit board (4) is fixed to the lifting platform (32) of the bearing plate (3) by adhesive or snap-fit.

4. The FPC overall flip-up battery connection system according to claim 3, characterized in that: The flexible circuit board (4) is welded to the nickel sheet (2) through the raised signal acquisition branch (41).

5. The FPC-based overall flip-up battery connection system according to claim 4, characterized in that: The height H of the lifting gap (5) is consistent with the thickness of the nickel sheet (2).

6. The FPC-based overall flip-up battery connection system according to claim 5, characterized in that: The lower surface of the nickel sheet (2) is seamlessly attached to the upper surface of the aluminum bar (1).

7. The FPC integral flipping battery connection system according to claim 6, characterized in that: The lifting gap (5) between the signal acquisition branch (41) and the edge of the aluminum bar (1) also serves as an anti-wear gap.

8. A battery module, characterized in that: Includes a battery connection system with an FPC that can be flipped as described in any one of claims 1-7.

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