CN219226537U

CN219226537U - Bus bar

Info

Publication number: CN219226537U
Application number: CN202320008645.4U
Authority: CN
Inventors: 邵宇光; 杨晓枫; 陈昊祺; 谢孝文; 崔超
Original assignee: Shanghai Ruipu Energy Co Ltd; Rept Battero Energy Co Ltd
Current assignee: Shanghai Ruipu Energy Co Ltd; Rept Battero Energy Co Ltd
Priority date: 2023-01-03
Filing date: 2023-01-03
Publication date: 2023-06-20
Anticipated expiration: 2033-01-03

Abstract

The utility model provides a busbar, which comprises an aluminum layer and a copper layer, wherein the aluminum layer and the copper layer are rolled and compounded to form the busbar; the aluminum layer comprises an integrally formed all-aluminum layer and a composite connecting layer, the all-aluminum layer comprises a pole connecting part, and the upper surface of the pole connecting part is adjacent to the upper surface of the composite connecting layer and is positioned on the same plane; the lower surface of the composite connecting layer is attached to the upper surface of the copper layer; the composite connecting layer and the copper layer are rolled and compounded to form a copper-aluminum composite layer; the lower surface of the copper layer is adjacent to and located on the same plane as the lower surface of the pole connection part. The utility model has reasonable structure, high reliability and lower cost; the copper-aluminum connecting bus bar is manufactured by directly utilizing a stamping forming process, CNC processing is not needed, the problem of contact corrosion between copper and aluminum is solved, the defect of copper-aluminum welding is avoided, and the production efficiency is high.

Description

Bus bar

Technical Field

The utility model relates to the field of batteries, in particular to a busbar.

Background

The current square battery module, output electrode busbar need connect the aluminum product matter utmost point post and the external copper bar of electric core simultaneously, relate to dissimilar metal connection technique, but current several processes all have different reliability, production efficiency or cost problem. The processing technology of the copper-aluminum connecting busbar comprises the following steps: 1. ultrasonic welding: the method has the advantages that the welding strength is high, no intermetallic brittle compound or less intermetallic brittle compound is produced, but the production yield is low, the cost is high, the equipment is limited, the aluminum material with the thickness of more than 1.5mm cannot be welded generally, and the production efficiency is low; 2. copper aluminum thermal pressure welding, resistance welding or other welding modes: the equipment cost is lower, the production process is simple, but in the production process, brittle compounds are generated at the copper-aluminum interface, so that the product has low bonding strength, poor toughness and reduced reliability; 3. conventional copper-aluminum composite material punching, no welding is needed, after a semi-finished product is manufactured by punching, later CNC processing is needed, a connection area or a hole between an aluminum material and a pole and between copper and an external copper bar is reserved, the cost is increased, and the efficiency is reduced by 4: parts can be produced by stamping, the production efficiency is high, the scale is easy, but the materials are very expensive, the composite area is small, and the bonding strength is lower.

Chinese patent publication No. CN 203466249U discloses an electrode sheet structure and a battery module. The electrode plate structure comprises a copper electrode plate and an aluminum electrode plate which are welded together from top to bottom, wherein the aluminum electrode plate is used for being electrically connected with a pole of a battery, the center of the copper electrode plate is provided with a round hollow part, the aluminum electrode plate is round, the diameter of the round hollow part of the copper electrode plate is smaller than the outer diameter of the aluminum electrode plate, and the central axis of the round hollow part of the copper electrode plate and the central axis of the aluminum electrode plate are coaxial. The battery module includes: the plurality of batteries are sequentially stacked, and the poles of the plurality of batteries are correspondingly connected in series to form a battery pack, wherein the terminal positive pole of the pole series connection is used as the total positive output pole of the module, and the terminal negative pole of the pole series connection is used as the total negative output pole of the module; two end plates respectively positioned at both ends of the stack direction of the battery pack; and two side plates respectively positioned at both sides of the battery pack with the two end plates; and the electrode plate structure is connected with the total positive output electrode and the total negative output electrode. The electrode plate structure in the scheme has the following defects in the actual use process: the copper sheet and the aluminum sheet are fixed by torque ultrasonic welding, the welding quality cannot be ensured, the structure is easy to be loose under a long-time vibration environment, and the conductive reliability of the electrode sheet structure is low.

The chinese patent with the publication number CN 207572446U discloses a battery box and a conductive module and a conductive connecting piece thereof, the battery box comprises a box body and a battery module located in the box body, the battery module comprises a plurality of cells arranged side by side, the cells located at the end of the battery module are connected with a connecting wire harness through the conductive connecting piece, the conductive connecting piece is a copper-aluminum composite connecting piece, the upper layer of the conductive connecting piece is a copper layer, the lower layer of the conductive connecting piece is an aluminum layer, and the conductive connecting piece is provided with a copper layer blank area for electrically connecting a cell pole with the aluminum layer and a copper layer connecting area for connecting the connecting wire harness with the copper layer. The above scheme adopts the structure of the abdication hole, so that the whole structure can not completely achieve the effect of the same thickness.

Chinese patent with publication number CN 215896775U discloses an integrated copper-aluminum bar electric connection terminal and an integrated copper-aluminum bar electric connector, the integrated copper-aluminum bar electric connection terminal comprises a copper bar and an aluminum bar, the aluminum bar comprises a sheet external end part, a middle connection bar part and a copper bar connection part, and the copper bar connection part are connected in an explosion welding or integral casting forming manner, thereby forming an integrated structure. The electric connector comprises a copper sleeve, a connecting base and an integrated copper-aluminum bar electric connecting terminal, wherein the copper sleeve is positioned on the surface of a copper bar and is directly abutted against the copper bar, the connecting base is positioned on the back of a copper bar connecting part, a connecting pipe part of the connecting base sequentially penetrates through the copper bar connecting part and the copper bar and then is inserted into a central hole of the copper sleeve, and internal threads are arranged on the inner wall of a penetrating hole of the connecting base. The scheme is complex in structure, and the welding mode is adopted to produce the high-cost steel plate.

The Chinese patent with the publication number of CN216563430U discloses a total positive and total negative through-flow connection row structure of a storage battery, the storage battery and electric equipment, wherein the total positive and total negative through-flow connection row structure of the storage battery comprises a copper row module and an aluminum row module, one end of the aluminum row module is connected with an aluminum pole of an electric core, and an insulating partition plate is arranged between the aluminum row module and the electric core; one end of the copper bar module is connected with the external copper bar; the other end of the aluminum bar module is connected with the other end of the copper bar module through a copper-aluminum composite part formed by inserting and rolling. However, the above proposal has complicated process by rolling after wire connection.

Disclosure of Invention

In view of the drawbacks of the prior art, an object of the present utility model is to provide a bus bar.

According to the utility model, a busbar is provided, comprising an aluminum layer and a copper layer, wherein:

the aluminum layer and the copper layer are rolled and compounded to form the busbar;

the aluminum layer comprises an integrally formed all-aluminum layer and a composite connecting layer, the all-aluminum layer comprises a pole connecting part, and the upper surface of the all-aluminum layer and the upper surface of the composite connecting layer are adjacent and positioned on the same plane;

the lower surface of the composite connecting layer is attached to the upper surface of the copper layer; the lower surface of the composite connecting layer is rolled and compounded with the copper layer to form a copper-aluminum composite layer; the lower surface of the copper layer is adjacent to and located on the same plane as the lower surface of the pole connection part.

Preferably, the copper-aluminum composite layer comprises a first horizontal layer, a transition layer and a second horizontal layer which are sequentially connected, wherein:

and the first horizontal layer and the transition layer and/or the transition layer and the second horizontal layer are connected in a rounded transition manner.

Preferably, the second horizontal layer is provided with a fixing hole. When the bus bar is fixedly connected with the copper bar between the modules, the copper layer is attached to the copper bar, and the bolts penetrate through the fixing holes to connect and fasten the bus bar and the copper bar.

Preferably, the transition layer is a vertical layer perpendicular to the first horizontal layer and the second horizontal layer.

Preferably, the all-aluminum layer further comprises a positioning part, the positioning part is formed by locally recessing the all-aluminum layer, and a positioning hole is formed in the positioning part. Specifically, the locating part and the full aluminum layer can have height difference, the transition connection is realized through the transition surface between the locating part and the full aluminum layer, the transition surface is the cambered surface, and the locating part is preferably arranged at the corner of the full aluminum layer, so that the processing is convenient.

Preferably, the thickness of all regions of the busbar is the same. Thereby being convenient for production control and improving the assembly efficiency of the battery module.

Preferably, the surface of the copper layer is plated with a nickel layer. The wear resistance and corrosion resistance of the copper layer can be improved by plating nickel on the surface of the copper layer.

Preferably, the nickel layer has a thickness of 5-15 μm. Thereby avoiding overlarge resistance caused by overlarge nickel layer and not effectively improving the wear resistance and corrosion resistance caused by overlarge nickel layer thickness.

Preferably, the total thickness of the copper-aluminum composite layer is 1.0-4.0mm, wherein the thickness of the copper layer is 0.5-3.0mm.

Preferably, when the thickness of the copper-aluminum composite layer is 1-3mm, the thickness of the copper layer is 50% -75% of the thickness of the copper-aluminum composite layer; when the thickness of the copper-aluminum composite layer is 3-4mm, the thickness of the copper layer is 40-60% of the thickness of the copper-aluminum composite layer. The thickness of the copper layer and the copper-aluminum composite layer is set so as to avoid the influence of the too thin copper layer on the current carrying capacity of the copper-aluminum composite layer, and simultaneously avoid the damage of the composite connecting layer of the aluminum layer when the aluminum layer is too thin to be rolled.

Compared with the prior art, the utility model has the following beneficial effects:

1. the utility model has reasonable structure, high reliability and lower cost;

2. the utility model can directly utilize the stamping forming process to manufacture the copper-aluminum connecting busbar, does not need CNC processing, solves the problem of contact corrosion between copper and aluminum, avoids the defect of copper-aluminum welding, and has high production efficiency.

3. The utility model improves the design through the structures and the processes of the aluminum layer and the copper layer, and improves the toughness and the reliability of the busbar.

Drawings

Other features, objects and advantages of the present utility model will become more apparent upon reading of the detailed description of non-limiting embodiments, given with reference to the accompanying drawings in which:

fig. 1 is a schematic structural diagram of an embodiment of the present utility model.

Fig. 2 is a front view of an embodiment of the present utility model.

Fig. 3 is a cross-sectional view of the embodiment of the utility model at B-B in fig. 2.

Fig. 4 is a bottom view of an embodiment of the present utility model.

Fig. 5 is a top view of an embodiment of the present utility model.

Fig. 6 is a back view of an embodiment of the present utility model.

The figure shows:

aluminum layer 1

All-aluminum layer 11

Composite tie layer 12

Copper layer 2

Positioning hole 3

Fixing hole 4

Pole connection region 5

First horizontal layer 101

Transition layer 102

Second horizontal layer 103

Detailed Description

The present utility model will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the present utility model, but are not intended to limit the utility model in any way. It should be noted that variations and modifications could be made by those skilled in the art without departing from the inventive concept. These are all within the scope of the present utility model.

As shown in figures 1 to 6, the busbar is made of copper-aluminum composite material by directly stamping a metal coiled material, so that the connection reliability is good, the production efficiency is greatly improved, meanwhile, the welding process (such as ultrasonic welding) and the corresponding cost of copper materials and aluminum materials are saved, the thicknesses of all parts of parts are consistent, the production control is convenient, and the assembly efficiency of the battery module can be improved.

The busbar disclosed by the utility model comprises an aluminum layer 1 and a copper layer 2, wherein: rolling and compounding the aluminum layer 1 and the copper layer 2 to form a composite layer; the aluminum layer 1 comprises an integrally formed all-aluminum layer 11 and a composite connecting layer 12, the all-aluminum layer 11 comprises a pole connecting part (not labeled in the figure), and the upper surface of the pole connecting part is adjacent to the upper surface of the composite connecting layer 12 and is positioned on the same plane; the shape of the composite connecting layer 12 is the same as that of the copper layer 2; the lower surface of the composite connecting layer 12 and the copper layer 2 are rolled and compounded to form a copper-aluminum composite layer; the lower surface of the copper layer is adjacent to and located on the same plane as the lower surface of the pole connection part.

Further, the upper surface of the pole connection portion and the upper surface of the composite connection layer 12 are integrally formed, and referring to fig. 1, the upper surface of the first horizontal layer 101 in fig. 1 includes the upper surface of the composite connection layer 12 and the upper surface of the pole connection portion.

In some embodiments, the pole connection portion is provided with a pole connection area 5, the pole connection area 5 does not need additional processing, the size and the position of the pole connection area 5 are adjusted according to the structural design of the battery core and the module, the pole connection area 5 is used for being connected with the battery core pole, and a specific connection mode can be laser welding.

Further, the pole connecting part is arranged on the pole connecting region 5, and the pole connecting region 5 is arranged on the all-aluminum layer 11, so that the utility model adds the all-aluminum layer 11 part through structural optimization and adopts the copper-aluminum separation mode of partial areas, thereby avoiding the need of processing a yielding hole on the traditional copper layer and processing the pole connecting hole on the aluminum layer when connecting the poles, and greatly simplifying the processing technology.

In some embodiments, the copper-aluminum composite layer includes a first horizontal layer 101, a transition layer 102, and a second horizontal layer 103 connected in sequence, wherein: rounded transitions between the first horizontal layer 101 and the transition layer 102 and/or between the transition layer 102 and the second horizontal layer 103. The shape of the composite layer formed by the combination may be configured as a Z-shape, and in some implementations, the transition layer 102 is a vertical layer perpendicular to the first and second

horizontal layers

101, 103.

Further, in this embodiment, as shown in fig. 1, the transition layer 102 is formed by extending the first horizontal layer 101 in the clockwise 90 ° direction, the second horizontal layer 103 is formed by extending the transition layer 102 in the counterclockwise 90 ° direction, and the first horizontal layer 101, the transition layer 102, and the second horizontal layer 103 are integrally formed.

In some embodiments, the second horizontal layer 103 is provided with fixing holes 4. When the bus bar is fixedly connected with the copper bar between the modules, the copper layer 2 is attached to the copper bar, and the bolts penetrate through the fixing holes 4 to connect and fasten the bus bar and the copper bar. In some implementations, the fixation hole 4 is a waist hole.

In some embodiments, the all-aluminum layer 11 further includes a positioning portion (not labeled in the figure), the positioning portion is formed by partially recessing the all-aluminum layer 11, and the positioning portion is provided with a positioning hole 3, where the positioning hole 3 is used to fix the busbar on the harness isolation board of the module.

Further, in this embodiment, as shown in fig. 1, the positioning portion and the all-aluminum layer 11 have a height difference, and the positioning portion and the all-aluminum layer 11 are in transitional connection through a transitional surface, where the transitional surface is an arc surface. The locating part is preferably arranged at the corner of the all-aluminum layer 11, so that the processing is convenient.

In some embodiments, the thickness of all regions of the composite layer is the same, and space utilization is improved by providing the same thickness. The thickness of all the whole areas is the same, no additional machining process is needed after stamping, and the process is simple. In the utility model, the whole thickness of the whole aluminum layer 11 area is the same, the whole thickness of the composite connecting layer 12 is the same, the thickness difference between the whole aluminum layer 11 and the composite connecting layer 12 is equal to the thickness of the copper layer 2, and the thickness of all the whole areas is the same.

In some embodiments, the copper aluminum composite layer has a total thickness of 1.0 to 4.0mm, wherein the copper layer 2 has a thickness of 0.5 to 3.0mm. Further, when the thickness of the copper-aluminum composite layer is 1-3mm, the thickness of the copper layer 2 is 50% -75% of the thickness of the copper-aluminum composite layer; when the thickness of the copper-aluminum composite layer is 3-4mm, the thickness of the copper layer 2 is 40-60% of the thickness of the copper-aluminum composite layer. The thickness of the copper layer and the copper-aluminum composite layer is set so as to avoid the influence of the too thin copper layer on the current carrying capacity of the copper-aluminum composite layer, and simultaneously avoid the damage of the composite connecting layer of the aluminum layer when the aluminum layer is too thin to be rolled.

In some embodiments, the surface of the copper layer 2 is plated with a nickel layer. The wear resistance and corrosion resistance of the copper layer can be improved by plating the nickel layer on the surface of the copper layer 2. Preferably, the thickness of the nickel layer is 5-15 mu m, the excessive thickness of the nickel layer can cause excessive resistance, and the insufficient thickness of the nickel layer can not effectively improve the wear resistance and corrosion resistance.

In more detail, the grade of the material selected for the copper layer 2 is T2, and the grade of the material selected for the aluminum layer 1 is 1060. The widths, i.e. the cross-sectional areas, of the copper layer 2 and the aluminum layer 1 are different, and as shown in fig. 3, the aluminum layer 1 is provided with a region for accommodating the copper layer 2, and the width and thickness of the copper layer 2 can be adjusted according to the current carrying design of the module system, and the typical design width is 20-50mm, and the thickness is 0.5-2.0mm.

The utility model adopts the specially designed copper-aluminum composite material to manufacture the copper-aluminum connecting busbar, avoids contact corrosion caused by direct connection, solves the problems of welding the busbar and the battery core electrode post and connecting the busbar with the external module, and improves the reliability of the system. Meanwhile, because the welding processing between dissimilar metals is not carried out, excessive intermetallic brittle compounds are not generated, the nickel plating layer is not damaged, and the toughness and the reliability of the product are improved. The copper-aluminum composite material belongs to one of upper and lower composite materials, has higher bonding strength (more than or equal to 70 Mpa) than a left-right butt joint type composite material, has adjustable thickness of a copper-aluminum layer, is flexible in design, meets the current carrying requirement of a system, directly utilizes a stamping forming process to prepare a copper-aluminum connecting busbar, has high production efficiency, and is suitable for batch production.

In the description of the present application, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientations or positional relationships illustrated in the drawings, merely to facilitate description of the present application and simplify the description, and do not indicate or imply that the devices or elements being referred to must have a specific orientation, be configured and operated in a specific orientation, and are not to be construed as limiting the present application.

The foregoing describes specific embodiments of the present utility model. It is to be understood that the utility model is not limited to the particular embodiments described above, and that various changes or modifications may be made by those skilled in the art within the scope of the appended claims without affecting the spirit of the utility model. The embodiments of the present application and features in the embodiments may be combined with each other arbitrarily without conflict.

Claims

1. A busbar comprising an aluminum layer and a copper layer, wherein:

the aluminum layer comprises an integrally formed all-aluminum layer and a composite connecting layer, the all-aluminum layer comprises a pole connecting part, and the upper surface of the pole connecting part is adjacent to the upper surface of the composite connecting layer and is positioned on the same plane;

the lower surface of the composite connecting layer is attached to the upper surface of the copper layer; the composite connecting layer and the copper layer are rolled and compounded to form a copper-aluminum composite layer; the lower surface of the copper layer is adjacent to and located on the same plane as the lower surface of the pole connection part.

2. The busbar of claim 1, wherein the copper aluminum composite layer comprises a first horizontal layer, a transition layer, and a second horizontal layer connected in sequence, wherein:

3. The busbar of claim 2, wherein the second horizontal layer has a fixing hole provided thereon.

4. The bus bar of claim 2, wherein the transition layer is a vertical layer perpendicular to the first horizontal layer and the second horizontal layer.

5. The busbar of claim 1, wherein the all-aluminum layer further comprises a positioning portion formed by partially recessing the all-aluminum layer, and wherein the positioning portion is provided with a positioning hole.

6. The bus bar of claim 1, wherein the thickness of all regions of the bus bar is the same.

7. The busbar of claim 1, wherein a surface of the copper layer is plated with a nickel layer.

8. The busbar of claim 7, wherein the nickel layer has a thickness of 5-15 μm.

9. The busbar of claim 1, wherein the copper aluminum composite layer has a total thickness of 1.0 to 4.0mm, and wherein the copper layer has a thickness of 0.5 to 3.0mm.

10. The busbar according to claim 1, wherein when the thickness of the copper-aluminum composite layer is 1 to 3mm, the thickness of the copper layer is 50 to 75% of the thickness of the copper-aluminum composite layer; when the thickness of the copper-aluminum composite layer is 3-4mm, the thickness of the copper layer is 40-60% of the thickness of the copper-aluminum composite layer.