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CN-122026011-A - Reinforcing structure and method for ultrasonic welding of FPC and aluminum bar in vehicle-mounted power battery CCS

CN122026011ACN 122026011 ACN122026011 ACN 122026011ACN-122026011-A

Abstract

The invention discloses a reinforcing structure and a reinforcing method for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS, comprising a CCS-insulating layer, wherein a welding port is formed in the CCS-insulating layer, CCS-aluminum bar is arranged at the position of the top of the CCS-insulating layer, FPC is arranged at the top of the CCS-aluminum bar, a welding area is arranged at one end of FPC-copper foil in the FPC, the welding area of FPC-copper foil is positioned at the welding port of the CCS-insulating layer, a foldable double-layer copper foil structure is arranged at the welding area of FPC-copper foil, and the double-layer copper foil structure formed at the welding area of FPC-copper foil has the advantages of improving peeling strength, widening process window and reinforcing structural reliability, allowing a wider range of welding power and time parameters, improving production yield, and providing mechanical redundancy and electrical redundancy by double-layer copper design, thereby meeting severe environmental requirements of vehicle-scale vibration, thermal cycle and the like.

Inventors

  • TAO GANG
  • Liang Fubing
  • ZHU RONGXIANG

Assignees

  • 湖州东尼新能源有限公司

Dates

Publication Date
20260512
Application Date
20260120

Claims (7)

  1. 1. The reinforcing structure for ultrasonic welding of the FPC and the aluminum bar in the vehicle-mounted power battery CCS is characterized by comprising a CCS-insulating layer (1), wherein a welding port is formed in the CCS-insulating layer (1), a CCS-aluminum bar (2) is arranged at the position, located at the welding port, of the top of the CCS-insulating layer (1), and an FPC (3) is arranged at the top of the CCS-aluminum bar (2); The FPC (3) comprises a lower-layer FPC-PI (301), the top of the lower-layer FPC-PI (301) is provided with an FPC-copper foil (302), the top of the FPC-copper foil (302) is provided with an upper-layer FPC-PI (303), one end of the FPC-copper foil (302) is provided with a welding area (3021), the welding area (3021) of the FPC-copper foil (302) is located at the welding opening of the CCS-insulating layer (1), and the welding area (3021) of the FPC-copper foil (302) is provided with a foldable double-layer copper foil structure.
  2. 2. The reinforcing structure for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS according to claim 1, wherein the upper layer FPC-PI (303) and the lower layer FPC-PI (301) are identical in structure and respectively cover the top and the bottom of the FPC-copper foil (302).
  3. 3. The reinforcing structure for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS according to claim 1, wherein the foldable double-layer copper foil structure comprises folding notches (3022) symmetrically formed on two sides of the middle of a welding area (3021), reserved crease lines are formed between the two folding notches (3022) and located on the welding area (3021), and the welding area (3021) is folded along the reserved crease lines to form the double-layer copper foil.
  4. 4. A reinforcing structure for ultrasonic welding of FPC and aluminum bar in a vehicular power battery CCS according to claim 3, wherein the total thickness of the double-layer copper foil of the welding area (3021) is 50-70 μm.
  5. 5. The reinforcing structure for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS according to claim 4, wherein the foldable double-layer copper foil structure further comprises an omega-shaped loop (3023) arranged outside a welding area (3021) of the FPC-copper foil (302), when the welding area (3021) is folded along a reserved crease line, the omega-shaped loop (3023) is also folded synchronously, and two ends of the omega-shaped loop (3023) are connected to the same electrical node to form an electrical double backup.
  6. 6. A method for ultrasonic welding of FPC to aluminum bar in a vehicle power battery CCS according to any one of claims 1-5, comprising the steps of: S1, preparing an FPC (3), namely preparing the FPC (3) by arranging an upper layer FPC-PI (303) on the top of an FPC-copper foil (302), arranging a lower layer FPC-PI (301) on the bottom of the FPC-copper foil (302), designing a welding area (3021) of the FPC-copper foil (302) into a foldable double-layer copper foil structure in the process of preparing the FPC (3), and folding the welding area (3021) of the FPC-copper foil (302) along a reserved crease line to form the double-layer copper foil; S2, performing ultrasonic welding operation on the FPC (3) and the CCS-aluminum bar (2), namely placing the CCS-insulating layer (1) on ultrasonic equipment, enabling an ultrasonic base (4) of the ultrasonic equipment to penetrate through a welding opening on the CCS-insulating layer (1), placing the FPC (3) on the top of the CCS-aluminum bar (2), ensuring that a welding area (3021) of an FPC-copper foil (302) in the FPC (3) corresponds to a welding head (5) on ultrasonic waves, and performing ultrasonic welding on the FPC (3) and the CCS-aluminum bar (2).
  7. 7. The method for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS according to claim 6, characterized in that in step S1, an Ω -shaped loop (3023) is designed on the welding area (3021) of the FPC-copper foil (302), and the Ω -shaped loop (3023) is folded synchronously along with the welding area (3021) along the reserved crease line, so that when the FPC (3) is manufactured, both ends of the Ω -shaped loop (3023) are connected to the same electrical node, forming an electrical double backup.

Description

Reinforcing structure and method for ultrasonic welding of FPC and aluminum bar in vehicle-mounted power battery CCS Technical Field The invention relates to the technical field of power batteries of new energy automobiles, in particular to an enhanced structure and method for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS. Background In a vehicle-mounted power battery module, CCS is used as a key component for connecting a battery cell and BMS, an FPC is generally used for integrating a temperature sampling circuit and a voltage collecting circuit, the FPC is electrically connected with an aluminum bar in an ultrasonic welding mode, as shown in fig. 6, currently, a main-stream FPC adopts a copper foil with a single face of 35 mu m, after front-stage processes such as etching, laminating a covering film and the like, the effective copper thickness is only about 30 mu m, and the thickness has the following problems in the ultrasonic welding process: the process window is narrow, the copper foil is easy to tear or the base material is easy to be damaged due to the slightly high welding energy, and the welding strength is insufficient due to insufficient energy; the peeling strength is low, namely the actually measured peeling strength is often lower than 10N/mm, and the requirements of vehicle-gauge reliability are difficult to meet; the yield is unstable, and partial collapse or fracture is easily caused when the welding heads are pressed due to thin materials and poor rigidity. In the prior art, the improvement is mostly carried out by optimizing welding parameters, but the problem of insufficient bearing capacity of the thin copper foil cannot be fundamentally solved, so that an enhanced structure and a method for ultrasonic welding of FPC and aluminum bar in a vehicle-mounted power battery CCS are required to be designed to improve the problem. Disclosure of Invention In order to overcome the defects, the invention provides a reinforcing structure and a reinforcing method for ultrasonic welding of an FPC and an aluminum bar in a vehicle-mounted power battery CCS, and aims to solve the problem of improving the reliability and process tolerance of ultrasonic welding of the FPC and the aluminum bar on the premise of not remarkably increasing the cost and complexity, and is particularly suitable for thin FPCs with copper thickness less than or equal to 30 mu m. In order to achieve the above purpose, the present invention provides the following technical solutions: The reinforcing structure for ultrasonic welding of the FPC and the aluminum bar in the CCS of the vehicle-mounted power battery comprises a CCS-insulating layer, wherein a welding port is formed in the CCS-insulating layer, the CCS-aluminum bar is arranged at the position, located at the welding port, of the top of the CCS-insulating layer, and the FPC is arranged at the top of the CCS-aluminum bar; The FPC comprises a lower-layer FPC-PI, wherein the top of the lower-layer FPC-PI is provided with an FPC-copper foil, the top of the FPC-copper foil is provided with an upper-layer FPC-PI, one end of the FPC-copper foil is provided with a welding area, the welding area of the FPC-copper foil is positioned at a welding opening of the CCS-insulating layer, and the welding area of the FPC-copper foil is provided with a foldable double-layer copper foil structure. As a preferable scheme of the invention, the upper FPC-PI and the lower FPC-PI have the same structure and are respectively covered on the top and the bottom of the FPC-copper foil. As a preferable scheme of the invention, the foldable double-layer copper foil structure comprises folding notches symmetrically arranged on two sides of the middle part of a welding area, a reserved crease line is formed between the two folding notches and is positioned on the welding area, and the welding area is folded along the reserved crease line to form the double-layer copper foil. As a preferable scheme of the invention, the total thickness of the double-layer copper foil of the welding area is 50-70 mu m. As a preferable scheme of the invention, the foldable double-layer copper foil structure further comprises an omega-shaped loop arranged on the outer side of the welding area of the FPC-copper foil, when the welding area is folded along the reserved crease line, the omega-shaped loop is synchronously folded, and two ends of the omega-shaped loop are connected to the same electrical node to form an electrical double-backup. The invention also provides a method for ultrasonic welding of the FPC and the aluminum bar in the vehicle-mounted power battery CCS, which comprises the following steps: S1, preparing an FPC, namely preparing the FPC by arranging an upper layer FPC-PI on the top of the FPC-copper foil and arranging a lower layer FPC-PI on the bottom of the FPC-copper foil, designing a welding area of the FPC-copper foil into a foldable double-layer copper foil structure