Cells contact system and cells contact system support, and battery module

Abstract

A cells contact system, comprising: a busbar assembly (a), configured to be electrically connected to a plurality of battery cells (01); and a cells contact system support (b), comprising a fixing support (4) and a mounting frame (5) which are separately arranged. The two ends of the busbar assembly (a) are mounted to the fixing support (4), and the middle part of the busbar assembly (a) is mounted to the mounting frame (5). A battery module comprising the cells contact system.

Description

Integrated busbar and its bracket, battery module

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on November 6, 2023, with application number 202323000242.4. The entire contents of the above application are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of battery technology, and in particular to an integrated busbar and its bracket, and a battery module. Background Art

[0003] The Cell Contact System (CCS) is primarily composed of signal acquisition components (FPC, PCB, FFC, etc.), plastic structural components, and copper and aluminum busbars. Typically, an integrated tray is used as the mounting carrier for the CCS of large cylindrical batteries. Therefore, different molds are required to create matching trays for different CCS structures, and UV adhesive coating is also required for protection. SUMMARY OF THE INVENTION

[0004] The CCS assembly process in the related art is complicated, the processing cycle is long, and the processing cost is high.

[0005] In a first aspect, the present application provides an integrated busbar. The integrated busbar comprises:

[0006] a busbar assembly configured to be electrically connected to the plurality of battery cells; and

[0007] Integrated busbar bracket, including separate fixed bracket and mounting frame;

[0008] The two ends of the busbar assembly are installed on the fixing brackets, and the middle part of the busbar assembly is installed on the mounting frame.

[0009] In a second aspect, the present application further provides an integrated busbar bracket. The integrated busbar bracket is applied to an integrated busbar, the integrated busbar including a busbar assembly configured to be electrically connected to a plurality of battery cells, and the integrated busbar bracket including a separately arranged fixing bracket and a mounting frame;

[0010] The fixing bracket is configured to be installed at both ends of the busbar assembly, and the mounting frame is configured to be installed at the middle portion of the busbar assembly.

[0011] In a third aspect, the present application further provides a battery module, which includes an integrated busbar and multiple battery packs, wherein the integrated busbar is provided on the multiple battery packs. Beneficial effects

[0012] The integrated busbar provided by the present application is configured to have an integrated busbar bracket as a split fixed bracket and mounting frame, so that different parts of the busbar assembly are installed and fixed in different areas. The split design can provide space for flexible adjustment when installing the busbar assembly, reducing the limitations of the integrated design in the related art. At the same time, for the upgrade and change of part of the structure of the busbar assembly, the fixed bracket or mounting frame that matches it can be replaced to adapt to different busbar assemblies. For damage to different parts of the integrated busbar bracket, the fixed bracket or mounting frame can also be replaced to reduce the replacement cost. This improves the technical problems of the inconvenience of disassembly and assembly and the high replacement cost of the integrated tray of the integrated busbar in the related art. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG1 is a schematic diagram of the installation of an integrated busbar and battery cells provided by some implementations of the present application.

[0014] FIG2 is an exploded schematic diagram of an integrated busbar and battery cells provided by some implementations of the present application.

[0015] FIG3 is an exploded schematic diagram of an integrated busbar provided by some implementations of the present application.

[0016] FIG4 is an enlarged view of point A in FIG3 .

[0017] FIG5 is a schematic structural diagram of a bus assembly provided by some implementations of the present application.

[0018] FIG6 is a schematic structural diagram of a fixing bracket provided in some implementations of the present application.

[0019] FIG7 is a schematic structural diagram of a first bracket, a series row, and an output row provided by some implementations of the present application.

[0020] FIG8 is an exploded schematic diagram of a first bracket, a series row, and an output row provided by some implementations of the present application.

[0021] FIG9 is a top view of a first bracket, a series row, and an output row provided by some implementations of the present application.

[0022] FIG10 is a schematic structural diagram of battery cells, connecting bars, and mounting frames provided by some implementations of the present application.

[0023] FIG11 is an exploded view of a battery cell, a connecting bar, and a mounting frame provided by some implementations of the present application.

[0024] FIG12 is a schematic structural diagram of a clamping member close to a battery cell provided in some implementations of the present application.

[0025] Description of reference numerals:

[0026] 0. Battery pack; 10. Cell group; 01. Cell; 1. Output row; 11. Second limiting hole; 2. Series row; 21. Third limiting hole; 3. Connecting row; 31. Connecting piece; 4. Fixing bracket; 41. First bracket; 42. Second bracket; 43. Fixing hole; 44. Connecting hole; 45. Limiting column; 46. Wiring harness slot; 47. Avoidance path; 48. Avoidance slot; 49. Mounting seat; 5. Mounting frame; 51. Clamp; 511. First hole; 512. Second hole; 513. First limiting hole; 514. Mounting hole; 6. First line; 61. Main body; 62. Collection unit; 7. Second line; 8. Temperature sensor; a. Busbar assembly; b. Integrated busbar bracket; c. Collection harness. Modes for Carrying Out the Invention

[0027] Example 1

[0028] 1, 2 and 3, an integrated busbar provided in an embodiment of the present application includes:

[0029] A busbar assembly a, configured to be electrically connected to the plurality of battery cells 01; and

[0030] The integrated busbar bracket b includes a fixed bracket 4 and a mounting bracket 5 which are separately arranged;

[0031] The two ends of the busbar assembly a are mounted on the fixing bracket 4 , and the middle portion of the busbar assembly a is mounted on the mounting frame 5 .

[0032] By configuring the integrated busbar bracket b as a split fixed bracket 4 and mounting frame 5, different parts of the busbar assembly a are installed and fixed in different areas. The split design can provide space for flexible adjustment during the installation of the busbar assembly a, reducing the limitations of the integrated design in the related art. At the same time, for upgrades to some structures of the busbar assembly a, the matching fixed bracket 4 or mounting frame 5 can be replaced to adapt to different busbar assemblies a. For damage to different parts of the integrated busbar bracket b, the fixed bracket 4 or mounting frame 5 can also be replaced to reduce the replacement cost. This improves the technical problems of the inconvenience of disassembly and assembly and the high replacement cost of the integrated tray of the integrated busbar in the related art.

[0033] Example 2

[0034] 1 , 2 and 3 , an integrated busbar provided in an embodiment of the present application includes a busbar assembly a, an integrated busbar bracket b and a collection harness c.

[0035] Referring to Figures 3, 4, and 5, busbar assembly a is configured to electrically connect to multiple battery packs 0. Each battery pack 0 includes multiple battery cells 01. In this embodiment, battery cells 01 are cylindrical power cells, and battery pack 0 is a cylindrical power battery pack. Busbar assembly a includes two output bars 1, multiple series bars 2, and multiple connecting bars 3.

[0036] 4 and 5 , a connecting bar 3 includes two connecting tabs 31 connected in series. The two connecting tabs 31 are respectively connected to cells 01 in different columns of the same battery pack 0. The first ends of the two connecting tabs 31 are configured to connect to the positive electrodes of the cells 01, and the second ends of the two connecting tabs 31 are configured to connect to the negative electrodes of adjacent cells 01. Any connecting tab 31 is connected in series with adjacent cells 01 via its first and second ends to connect the cells 01 in the same column in series. The two connecting tabs 31 in the same connecting bar 3 connect cells 01 in different columns of the same battery pack 0 in parallel. A connecting bar 3 connects multiple cells 01 in the same battery pack 0 in series and in parallel.

[0037] Referring to Figures 3 and 4 , in this embodiment, battery pack 0 is a cylindrical power battery pack, and a series row 2 is configured to connect two adjacent cylindrical power battery packs in series. In this embodiment, there are two series rows 2, and two series rows 2 are configured to connect three cylindrical power battery packs in series. Series row 2 includes a positive electrode module and a negative electrode module. The positive electrode module is configured to connect the positive terminal of cell 01 at the output end of the cylindrical power battery pack, and the negative electrode module is configured to connect the negative terminal of cell 01 at the output end of an adjacent cylindrical power battery pack.

[0038] One of the two output rows 1 is a positive output row, and the other is a negative output row. The positive output row is connected to the positive end of the battery cell 01 at the positive output end of the battery pack 0, and the negative output row is connected to the negative end of the battery cell 01 at the negative output end of the battery pack 0.

[0039] 1-3 , the integrated busbar support b includes a fixed support 4 and a mounting frame 5 that are separately arranged.

[0040] Taking the first direction in Figure 2 as an example, the second direction intersects the first direction in a horizontal plane. Battery pack 0 includes multiple cell groups 10, which are arranged along the first direction. Each cell group 10 includes multiple cells 01, which are arranged along the second direction. There are multiple series rows 2 and two output rows 1, respectively a positive output row and a negative output row. Adjacent cell groups 10 are electrically connected via the series rows 2, thereby connecting the multiple cell groups 10 in series. Taking the first direction as an example, of the two outermost cell groups 10 in the first direction, one cell group 10 is electrically connected to the positive output row, and the other cell group 10 is electrically connected to the negative output row.

[0041] Please continue to refer to Figures 1, 2 and 3. Taking the battery pack 0 in Figures 1, 2 and 3 as an example, the battery pack 0 includes three battery cell groups 10, and the three battery cell groups 10 are arranged along the first direction. The three battery cell groups 10 are respectively the first battery cell group, the second battery cell group and the third battery cell group. There are two series rows 2 and two output rows 1. The two output rows 1 are respectively the positive output row and the negative output row. One end of the second battery cell group is connected in series with one end of the first battery cell group through a series row 2, and the other end of the second battery cell group is connected in series with the other end of the third battery cell group through a series row 2. The other end of the first battery cell group is electrically connected to the positive output row, and the other end of the third battery cell group is electrically connected to the negative output row.

[0042] Referring to Figure 6 , the fixing bracket 4 comprises two opposing first brackets 41 and second brackets 42. The positive output busbar and one of the series busbars 2 are mounted on the first bracket 41, while the negative output busbar and the other series busbar 2 are mounted on the second bracket 42. Both the first bracket 41 and the second bracket 42 are provided with multiple fixing holes 43 and multiple connection holes 44. The fixing bracket 4 is made of plastic to achieve the goal of lightweight integrated busbar bracket b.

[0043] 6, 7, 8 and 9, the fixing holes 43 are sleeved on the positive poles of the battery cells 01 at both ends of the battery pack 0, and at least one fixing hole 43 exposes the connection position between the corresponding output row 1 and the positive pole of the battery cell 01. At the same time, at least one fixing hole 43 exposes the connection position between the corresponding series row 2 and the positive pole of the battery cell 01, and at least one fixing hole 43 also exposes the connection position between the corresponding connecting piece 31 and the positive pole of the battery cell 01.

[0044] At least one connection hole 44 exposes the connection position between the corresponding output row 1 and the negative pole of the battery cell 01, and at least one connection hole 44 exposes the connection position between the corresponding series row 2 and the negative pole of the battery cell 01. At least one connection hole 44 also exposes the connection position between the corresponding connecting piece 31 and the negative pole of the battery cell 01.

[0045] 10 and 11 , the mounting frame 5 includes two opposing clamping members 51 , which clamp portions of the plurality of connection banks 3 , portions of the plurality of series banks 2 , and portions of the two output banks 1 . Each clamping member 51 is provided with a plurality of escape holes, including a first hole 511 and a second hole 512 , which are connected to each other.

[0046] 2 and 3 , at least one first hole 511 exposes the connection location between the first end of the connecting piece 31 and the positive electrode of cell 01, at least one first hole 511 exposes the connection location between the positive electrode module of series row 2 and the positive electrode of cell 01, and at least one first hole 511 exposes the connection location between the positive electrode output row 1 and the positive electrode of cell 01. At least one second hole 512 exposes the connection location between the second end of the connecting piece 31 and the negative electrode of cell 01, at least one second hole 512 exposes the connection location between the negative electrode module of series row 2 and the negative electrode of cell 01, and at least one second hole 512 exposes the connection location between the negative electrode output row 1 and the negative electrode of cell 01.

[0047] Both clamps 51 are equipped with a first hole 511 and a second hole 512 to facilitate laser welding of the battery cell 01 to the busbar assembly. Both clamps 51 are made of hot-pressed film, which integrates the multiple connecting bars 3, the multiple series bars 2, and the two output bars 1 into a single unit through hot pressing, facilitating installation. The hot-pressed film reduces the mass of the integrated busbar, achieving a lightweight design.

[0048] The integrated busbar support b is constructed with a separate fixed bracket 4 and mounting bracket 5, allowing for the installation and securing of different parts of the busbar assembly a in separate areas. This split design allows for flexible adjustment during the installation of the busbar assembly a, alleviating the limitations of the integrated design in related technologies. Furthermore, upgrades to parts of the busbar assembly a can be accommodated by replacing the matching fixed bracket 4 or mounting bracket 5. Damage to different parts of the integrated busbar support b can also be addressed by replacing the fixed bracket 4 or mounting bracket 5, reducing replacement costs.

[0049] Referring to Figures 8 and 12, both clamping members 51 are provided with multiple first limiting holes 513, the output row 1 is provided with multiple second limiting holes 11, the series row 2 is provided with multiple third limiting holes 21, and the fixed bracket 4 is provided with multiple limiting posts 45. At least one limiting post 45 passes through the first limiting hole 513 and the second limiting hole 11, and at least one limiting post 45 passes through the second limiting hole 11. At least one limiting post 45 passes through the first limiting hole 513 and the third limiting hole 21, and at least one limiting post 45 passes through the third limiting hole 21.

[0050] 4 , the collection harness c includes a first wire 6 , a plurality of second wires 7 , and a plurality of temperature sensors 8 .

[0051] The first cable 6 comprises a main body 61 and multiple collecting sections 62 connected to the main body 61. Each collecting section 62 is connected to the middle of a corresponding connection bar 3 and is configured to collect the voltage of the battery cell 01. Both clamps 51 cover the collecting sections 62 to protect the welds between the collecting sections 62 and the battery cells 01. In the related art, integrated trays fail to cover the welds between the collecting sections 62 and the battery cells 01, requiring additional coating with UV adhesive for protection. This solution utilizes a hot-pressed film to both facilitate busbar installation and protect the welds between the collecting sections 62 and the battery cells 01, saving significant steps.

[0052] Multiple temperature sensors 8 are connected to multiple second wires 7 in a one-to-one correspondence. The clamping member 51 positioned near the battery cell 01 is provided with multiple mounting holes 514. The temperature sensors 8 are bonded to the other clamping member 51 using structural adhesive. The mounting holes 514 expose the corresponding temperature sensors 8. The temperature sensors 8 are positioned near the battery cell 01 to collect the temperature of the battery cell 01. In this embodiment, the temperature sensors 8 are NTC thermistors. Three temperature sensors 8 are provided in this embodiment.

[0053] Referring to Figure 6, one of the temperature sensors 8 and the part of the clamping member 51 covering the temperature sensor 8 interfere with the second bracket 42, so an avoidance path 47 is set on the second bracket 42. The avoidance path 47 includes a first avoidance path and a second avoidance path. The part of the clamping member 51 covering the temperature sensor 8 is set in the first avoidance path, and the temperature sensor 8 is set in the second avoidance path.

[0054] Each of the first bracket 41 and the second bracket 42 is provided with a mounting seat 49, and the two mounting seats 49 are respectively configured to accommodate the positive output bar 1 corresponding to the first bracket 41 and the negative output bar 1 corresponding to the second bracket 42. In other embodiments, two mounting seats 49 are provided on the first bracket 41 or the second bracket 42, depending on the number of battery cells and the current flow.

[0055] 7 , the fixing bracket 4 is provided with a plurality of harness grooves 46 , and the collection harness c is disposed in the harness grooves 46 and fixed with a cable tie.

[0056] During the actual installation process, the busbar assembly a and the welded first wire 6 are first positioned using a tool. Two hot-pressed films are then clamped together to form the busbar assembly a and the collection harness c, completing the integrated installation of the two output buses 1, the multiple series buses 2, and the multiple connection buses 3. This also covers the welds between the first wire 6 and the battery cell 01. The first and second limiting holes 513 and 11 are then fitted over the corresponding limiting posts 45, completing the integrated busbar installation.

[0057] This embodiment of the present application also provides an integrated busbar bracket (B) for use in an integrated busbar assembly. The integrated busbar assembly includes a busbar assembly (A) electrically connected to multiple battery cells (O1). The integrated busbar bracket (B) comprises a fixed bracket (4) and a mounting bracket (5) arranged separately. The fixed bracket (4) is configured to accommodate the busbar assembly at both ends, while the mounting bracket (5) is configured to accommodate the busbar assembly in the middle.

[0058] The embodiment of the present application further provides a battery module, including an integrated busbar and a plurality of battery packs 0. The battery pack 0 includes a plurality of battery cells 01, and the battery cells 01 may be cylindrical power battery cells 01.

Claims

1. An integrated busbar, comprising: A busbar assembly (a) is configured to be electrically connected to a plurality of battery cells (01); as well as An integrated busbar support (b) comprises a separately arranged fixing support (4) and a mounting frame (5); Wherein, both ends of the busbar assembly (a) are mounted on the fixing bracket (4), and the middle part of the busbar assembly (a) is mounted on the mounting frame (5).

2. The integrated busbar according to claim 1, wherein: The mounting frame (5) comprises two clamping members (51) arranged opposite to each other, and the two clamping members (51) clamp the middle part of the busbar assembly.

3. The integrated busbar according to claim 2, wherein: The busbar assembly (a) comprises two output bars (1), a plurality of series bars (2) and a plurality of connecting bars (3), wherein the plurality of connecting bars (3) are connected between the two output bars (1) via the plurality of series bars (2), the two clamping members (51) clamp a portion of the plurality of connecting bars (3), a portion of the plurality of series bars (2) and a portion of the two output bars (1), and another portion of the plurality of series bars (2) and another portion of the two output bars (1) are mounted on the fixing bracket (4).

4. The integrated busbar according to claim 3, wherein: The two clamping members (51) are each provided with a plurality of avoidance holes, and each of the avoidance holes is configured to expose a connection position between the connection row (3) and the battery cell (01).

5. The integrated busbar according to claim 4, wherein: The connecting bar (3) comprises a connecting sheet (31), a first end of the connecting sheet (31) being configured to connect to the positive electrode of the battery cell (01), and a second end of the connecting sheet (31) being configured to connect to the negative electrode of an adjacent battery cell (01); The avoidance hole comprises a first hole (511) and a second hole (512) which are connected to each other, wherein the first hole (511) exposes the first end of the corresponding connecting piece (31), and the second hole (512) exposes the second end of the adjacent connecting piece (31).

6. The integrated busbar according to claim 4, further comprising a collection harness (c), wherein the collection harness (c) is configured to be electrically connected to the battery cell (01) and the busbar assembly, and the two clamping members (51) clamp the collection harness (c).

7. The integrated busbar according to claim 6, wherein: The collecting wire harness (c) comprises a first wire (6), the first wire (6) comprises a main body (61) and a plurality of collecting parts (62) connected to the main body (61), each of the collecting parts (62) is connected to a corresponding connecting row (3), and the two clamping members (51) both cover the collecting parts (62).

8. The integrated busbar according to claim 6, wherein: The acquisition harness (c) further comprises a second wire (7) and a plurality of temperature sensors (8) connected to the plurality of second wires (7), at least one of the temperature sensors (8) being arranged close to the corresponding battery cell (01), and a plurality of mounting holes (514) being provided on a clamping member (51) close to the battery cell (01), and each of the mounting holes (514) exposing the corresponding temperature sensor (8).

9. The integrated busbar according to claim 6, wherein: The fixed bracket (4) is provided with a plurality of wire harness grooves (46), and the portion of the collection wire harness (c) is arranged in the wire harness grooves (46).

10. The integrated busbar according to claim 3, wherein: The two output rows (1), one of which is a positive output row and the other is a negative output row, the positive output row is electrically connected to the positive ends of the plurality of battery cells, and the negative output row is electrically connected to the negative ends of the plurality of battery cells.

11. The integrated busbar according to claim 10, wherein: The integrated busbar is applied to a battery pack (0), wherein the battery pack (0) comprises a plurality of battery cell groups (10), wherein the plurality of battery cell groups (10) are arranged at intervals, each of the battery cell groups (10) comprises a plurality of battery cells (01), and the plurality of battery cell groups (10) are electrically connected via a plurality of series rows (2), wherein one of the two battery cell groups (10) located at the outermost ends is connected to the positive output row, and the other is connected to the negative output row.

12. The integrated busbar according to claim 11, wherein: The fixed bracket (4) comprises a first bracket (41) and a second bracket (42) which are arranged opposite to each other; There are two series connection rows (2), one of which and the positive output row are mounted on the first bracket (41), and the other series connection row (2) and the negative output row are mounted on the second bracket (42).

13. The integrated busbar according to claim 12, wherein: The first bracket (41) and the second bracket (42) are both provided with a plurality of fixing holes (43) and a plurality of mounting holes (44), each of the fixing holes (43) corresponds to one mounting hole (44), and the mounting holes (44) are provided on one side of the fixing holes (43).

14. The integrated busbar according to claim 13, wherein: At least one of the fixing holes (43) is configured to expose the connection position between the output row (1) and the positive electrode of the corresponding battery cell (01); and / or, At least one of the fixing holes (43) is configured to expose the connection position between the series row (2) and the positive electrode of the corresponding battery cell (01); and / or, At least one of the fixing holes (43) is configured to expose a connection position between the connecting piece (31) and the positive electrode of the corresponding battery cell (01).

15. The integrated busbar according to claim 13, wherein: At least one of the connection holes (44) is configured to expose the connection position between the output row (1) and the negative electrode of the corresponding battery cell (01); and / or, At least one of the connection holes (44) is configured to expose the connection position between the series row (2) and the negative electrode of the corresponding battery cell (01); and / or, At least one of the connection holes (44) is configured to expose a connection position between the connection sheet (31) and the negative electrode of the corresponding battery cell (01).

16. The integrated busbar according to claim 3, wherein: Each of the clamping members (51) is provided with at least one first limiting hole (513), each of the output rows (1) is provided with at least one second limiting hole (11), and each of the series rows (2) is provided with at least one third limiting hole (21); At least one limiting column (45) is provided on the fixed bracket (4), and the limiting column (45) passes through at least one of the first limiting hole (513), the second limiting hole (11) and the third limiting hole (21) to fix the clamping member (51), the output row (1) and the series row (2) on the fixed bracket.

17. The integrated busbar according to any one of claims 2 to 16, wherein: The fixing bracket (4) comprises a plastic bracket, and the clamping piece (51) is a hot pressing film.

18. The integrated busbar according to any one of claims 1 to 16, wherein: One end or both ends of the fixing bracket (4) are provided with a mounting seat (49) for mounting an output bar (1) electrically connected to the busbar assembly.

19. An integrated busbar support, applied to an integrated busbar, the integrated busbar comprising a busbar assembly configured to be electrically connected to a plurality of battery cells (01), the integrated busbar support (b) comprising a separately arranged fixing support (4) and a mounting frame (5); in, The fixing bracket (4) is configured to be installed at both ends of the busbar assembly (a), and the mounting frame (5) is configured to be installed at the middle of the busbar assembly (a).

20. A battery module, comprising the integrated busbar according to any one of claims 1 to 18 and a plurality of battery packs (0), wherein the integrated busbar is arranged on the plurality of battery packs (0).

21. The battery module according to claim 20, wherein: Each of the battery packs (0) comprises a plurality of battery cells (01), and the plurality of battery cells (01) are cylindrical power battery cells.

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