Battery profiling laminated resistor and manufacturing method thereof

Abstract

The invention discloses a battery profiling laminated resistor and a manufacturing method thereof, the battery profiling laminated resistor comprises an insulating shell and a resistor structure, the resistor structure comprises sheet resistors packaged in the insulating shell, separators and two pin pieces extending out of the insulating shell, the plurality of sheet resistors and separators are alternately stacked in a first direction, and the two pin pieces extend out of the insulating shell. And the plurality of chip resistors between the two pin pieces are connected in series. In the invention, the shape of the insulating shell is matched with the specification of the vehicle battery, and when the battery profiling laminated resistor with the target resistance value needs to be manufactured, the target resistance values required by the prefabricated sheet resistors with different resistance values can be selected for combination, so that on one hand, the size and shape of the prepared resistor product meet the requirements of the vehicle battery pack; and on the other hand, corresponding to different resistance requirements, a resistor product does not need to be prepared through a fine resistance adjusting processing mode, only assembling operation needs to be carried out, the production efficiency is high, and the production cost can be reduced.

Description

Technical Field

[0001] The invention relates to the field of electronic devices, and in particular to a battery-shaped laminated resistor and a manufacturing method thereof. Background Art

[0002] At present, the high-power alloy resistors on the market are all single-layer resistor structures. Therefore, when facing some resistor products with high resistance and high performance requirements, the production needs of the products can only be met by increasing the size of the device. In addition, different materials need to be selected and finely adjusted to meet the production needs of battery contour resistors with the same specifications and different target resistance values, resulting in low production efficiency and high production costs. Summary of the invention

[0003] The present invention aims to provide a battery-shaped laminated resistor and a manufacturing method thereof which can meet the requirements of different resistance values ​​with the same specification and size, improve production efficiency and reduce production cost.

[0004] In order to solve the above technical problems, the present invention provides a battery profile laminated resistor, comprising:

[0005] an insulating housing configured to fit the specifications of a vehicle battery; and,

[0006] A resistor structure, comprising a sheet resistor encapsulated in the insulating housing, a separator, and two pins extending from the insulating housing, wherein a plurality of sheet resistors are provided, the plurality of sheet resistors are arranged side by side in a first direction, and each sheet resistor is pre-set with a resistance adjustment structure, a plurality of separators are provided, each separator comprises an insulating layer and a conductive layer sequentially distributed in a second direction, and each separator is sandwiched between each two adjacent sheet resistors in the first direction, so that the plurality of sheet resistors and the plurality of separators are alternately stacked in the first direction;

[0007] Among them, the multiple sheet resistors include two first resistor sheets arranged side by side in the first direction, and at least one second resistor sheet arranged between the two first resistor sheets, the lower end of each first resistor sheet is connected to the pin components respectively, and the conductive layers of each two adjacent separators in the first direction are staggered with each other so that the multiple sheet resistors between the two pin components are connected in series with each other.

[0008] In one embodiment, the material of the plurality of chip resistors are all alloy materials and are of the same material.

[0009] In one embodiment, the insulating layer is an insulating patch attached to one side of the corresponding chip resistor; or,

[0010] The insulating layer is an insulating coating coated on one side of the corresponding sheet resistor.

[0011] In one embodiment, each of the chip resistors has a resistance tuning area in the projection area covered by the corresponding insulating layer, and the resistance tuning structure is a resistance tuning groove opened in the resistance tuning area of ​​the corresponding chip resistor, and the resistance tuning areas of each two adjacent chip resistors in the first direction are staggered with each other.

[0012] In one embodiment, each of the chip resistors also has a connecting area distributed at both ends of the resistance adjustment area in the second direction, one of the two connecting areas is used to abut against the conductive layer, the connecting areas of the multiple chip resistors have the same size, and among the multiple chip resistors, at least two of the chip resistors have different sizes of the resistance adjustment areas.

[0013] In one embodiment, the battery-shaped laminated resistor further includes thermally conductive silica gel filled between the resistor structure and the insulating shell, and the insulating shell is made of thermally conductive ceramic.

[0014] In one embodiment, each of the pin components includes a pin portion and a conductive portion wrapped around the outer periphery of the pin portion, the pin portion is integrally formed at the lower end of the corresponding first resistor sheet, and each of the pin portion slots is welded in the corresponding conductive portion.

[0015] In one embodiment, two spaced-apart mounting holes are provided at the lower end of the insulating shell, and the two pin portions extend out from the two mounting holes one by one. The conductive portion is made of brass or copper, and its specifications are compatible with the mounting structure of the vehicle battery.

[0016] In one embodiment, each of the conducting layers is a solder layer coated on one side of the corresponding chip resistor.

[0017] In order to solve the above technical problems, the present invention provides a method for manufacturing the battery profile laminated resistor as described above, comprising:

[0018] An insulating shell adapted to the specifications of a vehicle battery is provided, and a plurality of sheet resistors are provided according to the specifications of the insulating shell and a target resistance value, wherein the plurality of sheet resistors include two first resistor sheets and a plurality of second resistor sheets, wherein a pin portion is integrally formed at the lower end of each of the first resistor sheets, and each of the first resistor sheets and / or the second resistor sheets is pre-processed with a corresponding resistance adjustment structure, wherein an insulating patch is pre-attached to one side of one of the first resistor sheets and each of the second resistor sheets;

[0019] A portion of the insulating patch is removed by laser, and a solder layer is coated on the area where the insulating patch is removed, so as to form an insulating layer covered with the insulating patch and a conductive layer coated with the solder layer, wherein the insulating layer and the conductive layer together constitute a separator;

[0020] Alternately stacking a plurality of sheet resistors and separators in a manner that the conductive layers of each two adjacent separators in the first direction are staggered with each other, so that a plurality of the second resistor sheets are sandwiched between two of the first resistor sheets to form a resistor body;

[0021] Placing the resistor body in a heating device for heating so that a plurality of the sheet resistors are welded together and connected in series;

[0022] Encapsulating the resistor formed by welding in the insulating housing, and making the two pins extend out of the insulating housing correspondingly;

[0023] Filling thermally conductive silica gel between the insulating shell and the resistor;

[0024] Two conductive parts adapted to the mounting structure of the vehicle battery are provided, and the two pin parts are slot-welded to the two conductive parts in a one-to-one correspondence to manufacture the battery-shaped laminated resistor.

[0025] The technical solution provided by the present invention has the following advantages:

[0026] The battery profile stacked resistor provided by the present invention is applied to vehicle batteries, and includes an insulating shell and a resistor structure, wherein the resistor structure includes a sheet resistor encapsulated in the insulating shell, a separator, and two pins extending out of the insulating shell, wherein a plurality of sheet resistors and separators are alternately stacked in a first direction, and each separator includes an insulating layer and a conductive layer sequentially distributed in a second direction, and the conductive layers of each two adjacent separators in the first direction are staggered, so that a plurality of sheet resistors between the two pins are connected in series. In the embodiment provided by the present invention, the shape of the insulating shell is adapted to the specifications of the vehicle battery, and when it is necessary to manufacture a battery profile stacked resistor with a target resistance value, the target resistance value required by the prefabricated sheet resistors of different resistance values ​​can be selected for combination, and a plurality of sheet resistors and separators are alternately stacked in a manner that the conductive layers of each two adjacent separators in the first direction are staggered, and the plurality of sheet resistors and separators are encapsulated in the insulating shell, so that, on the one hand, the size and shape of the prepared resistor product meet the requirements of the vehicle battery pack, and on the other hand, corresponding to different resistance requirements, there is no need to prepare the resistor product through a fine resistance adjustment processing method, and only assembly operations need to be performed, so that the production efficiency is high and the production cost can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0028] Figure 1 A front view of an embodiment of a battery-shaped laminated resistor provided by the present invention;

[0029] Figure 2 for Figure 1 Side view of the mid-cell contoured laminated resistor;

[0030] Figure 3 for Figure 1 A front view of an embodiment of a mid-cell contoured laminate resistor, wherein the insulating housing is not shown;

[0031] Figure 4 for Figure 3 Sectional view at AA in the middle;

[0032] Figure 5 for Figure 3 A rear view of an embodiment of a mid-cell contoured laminate resistor, wherein the insulating housing is not shown;

[0033] Figure 6 for Figure 3 Schematic diagram of the decomposition of the resistor structure;

[0034] Figure 7 for Figure 6 Sectional view at the middle BB;

[0035] Figure 8 for Figure 6 Sectional view at CC;

[0036] Fig. 9 for Figure 7 An exploded schematic diagram of the first resistor and the pin member;

[0037] Fig.10 for Figure 7 An exploded schematic diagram of another first resistor sheet and a lead member;

[0038] Fig.11 for Figure 5 Schematic diagram of the decomposition of the resistor structure;

[0039] Fig.12 for Figure 3 Schematic diagram of another embodiment of the middle resistor structure.

[0040] Description of reference numerals:

[0041] 100-battery-shaped laminated resistor; 10-insulating shell; 20-resistance structure; 21-chip resistor; 211-first resistor sheet; 212-second resistor sheet; 22-separator; 221-insulating layer; 222-conductive layer; 30-resistance adjustment area; 31-resistance adjustment structure; 32-connection area; 40-pin member; 41-pin portion; 42-conductive portion. DETAILED DESCRIPTION

[0042] The technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of the embodiments. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments. It should be noted that the embodiments of the present invention and the features in the embodiments can be combined with each other without conflict.

[0043] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence.

[0044] See also Figures 1 to 12 The present invention provides a battery-shaped laminated resistor 100, which is applied to a vehicle battery pack and includes an insulating housing 10 and a resistor structure 20 encapsulated in the insulating housing 10. The shape and size of the insulating housing 10 are adapted to the specifications of the vehicle battery, so that it can be installed in an existing vehicle battery pack to detect the working status of the vehicle battery pack.

[0045] The material of the insulating shell 10 can be selected as needed. In a preferred embodiment, the insulating shell 10 is made of thermally conductive ceramics, preferably high thermally conductive ceramics, so that the battery-shaped laminated resistor 100 has good heat dissipation performance to reduce the adverse effects of heat during its operation.

[0046] The resistor structure 20 includes a sheet resistor 21 encapsulated in the insulating housing 10, a separator 22, and two pins 40 extending out of the insulating housing 10, and the sheet resistor 21 is provided in plurality. Preferably, the materials of the plurality of sheet resistors 21 are all alloy materials, and the materials are the same, so that they can be combined according to design requirements. The plurality of sheet resistors 21 are arranged side by side in the first direction, and each sheet resistor 21 is pre-set with a resistance adjustment structure 31, and the resistance adjustment structure 31 can be pre-cut with a resistance adjustment groove, so that each sheet resistor 21 can have a different resistance value as required. The separator 22 is provided in plurality, and each separator 22 includes an insulating layer 221 and a conductive layer 222 distributed in sequence in the second direction. Each separator 22 is sandwiched between each adjacent two sheet resistors 21 in the first direction, so that the plurality of sheet resistors 21 and the plurality of separators 22 are alternately stacked in the first direction, and the plurality of sheet resistors 21 are connected in series.

[0047] In this embodiment, when it is necessary to manufacture a battery-shaped laminated resistor 100 with a target resistance value, the target resistance value required by prefabricated sheet resistors 21 with different resistance values ​​can be selected and combined, and a plurality of sheet resistors 21 and separators 22 are alternately stacked in a manner that the conductive layers 222 of each two adjacent separators 22 in the first direction are staggered with each other, and are packaged in an insulating housing 10. In this way, on the one hand, the size and shape of the prepared resistor product meet the requirements of the vehicle battery pack, and on the other hand, corresponding to different resistance value requirements, there is no need to prepare the resistor product through a sophisticated resistance adjustment processing method, only assembly operations are required, the production efficiency is high, and the production cost can be reduced.

[0048] On the basis of the previous embodiment, the insulating layer 221 and the conducting layer 222 can be designed as required. Specifically, the insulating layer 221 is an insulating patch attached to one side of the corresponding chip resistor 21 or an insulating coating coated on one side of the corresponding chip resistor 21. Therefore, when manufacturing the battery-shaped laminated resistor 100, the insulating layer 221 can be processed onto the corresponding chip resistor 21 in sequence, and then assembled and processed, which is simple and reliable to operate.

[0049] The conductive layer 222 is preferably a solder layer coated on one side of the corresponding chip resistor 21. When assembling the resistor structure 20, solder can be coated on the corresponding area, and then multiple chip resistors 21 are stacked and assembled together. The combination is sent to a heating device for heating to solidify the solder, thereby completing the assembly of the resistor structure 20.

[0050] In order to further improve the heat dissipation performance of the battery-shaped laminated resistor 100, preferably, each of the chip resistors 21 has a resistance adjustment area 30 in the projection area covered by the corresponding insulating layer 221, and the resistance adjustment structure 31 is a resistance adjustment groove opened in the resistance adjustment area 30 of the corresponding chip resistor 21, and the resistance adjustment areas 30 of each two adjacent chip resistors 21 in the first direction are staggered. In this embodiment, the resistance adjustment area 30 with the resistance adjustment groove generates a high amount of heat when the battery-shaped laminated resistor 100 is working. By assembling the resistance structure 20 in a manner that the resistance adjustment areas 30 of the multiple chip resistors 21 are staggered, the heat distribution of the resistance structure 20 can be made more uniform, and the heat can be dissipated more easily, thereby further reducing the working heat of the battery-shaped laminated resistor 100.

[0051] For further information, please refer to Figure 6 and Fig.12 It can be understood that the inner size of the insulating housing 10 can be designed to be larger than the resistor structure 20, and each of the sheet resistors 21 also has a connection area 32 distributed at both ends of the resistance adjustment area 30 in the second direction, one of the two connection areas 32 is used to abut against the conductive layer 222, and the connection areas 32 of the plurality of sheet resistors 21 have the same size, and among the plurality of sheet resistors 21, at least two of the sheet resistors 21 have different sizes of the resistance adjustment areas 30. In this way, the resistor structure 20 can have more possible combinations, and the resistance adjustment areas 30 can be designed to be staggered in multiple directions as needed, further improving its heat dissipation performance.

[0052] Preferably, the battery-shaped laminated resistor 100 further includes thermally conductive silicone rubber filled between the resistor structure 20 and the insulating shell 10. The thermally conductive silicone rubber not only plays a role in fixing and packaging the resistor structure 20, but also enhances the heat dissipation characteristics of the battery-shaped laminated resistor 100 by utilizing its high thermal conductivity.

[0053] On the basis of the above embodiment, the structure of the pin member 40 can be designed as needed. Specifically, each pin member 40 includes a pin portion 41 and a conductive portion 42 wrapped around the outer periphery of the pin portion 41, wherein the conductive portion 42 is made of brass or copper. The pin portion 41 is integrally formed at the lower end of the corresponding first resistor sheet 211, and each of the pin portions 41 is slot-welded in the corresponding conductive portion 42, so that the pin member 40 has a reliable structure. And the conductive portion 42 of suitable specifications can be selected for assembly according to the installation conditions provided by the vehicle battery assembly, so that the battery profile laminated resistor 100 has a stronger versatility, can be adapted to battery assemblies of more specifications, and further reduce its production cost.

[0054] Specifically, two spaced-apart mounting holes are provided at the lower end of the insulating housing 10 , and the two pin portions 41 extend out from the two mounting holes in a one-to-one correspondence. The conductive portion 42 is made of brass or copper, and its specifications are compatible with the mounting structure of the vehicle battery.

[0055] On the basis of the above-mentioned embodiment, the present invention further provides a method for manufacturing a battery-shaped laminated resistor 100, comprising the following steps:

[0056] Step S1: Provide an insulating shell 10 that is compatible with the specifications of the vehicle battery, and provide a plurality of sheet resistors 21 according to the specifications of the insulating shell 10 and the target resistance value. The plurality of sheet resistors 21 include two first resistor sheets 211 and a plurality of second resistor sheets 212. The lower end of each of the first resistor sheets 211 is integrally formed with a pin portion 41. Each of the first resistor sheets 211 and / or the second resistor sheets 212 is pre-processed with a corresponding resistance adjustment structure 31, and one side of one of the first resistor sheets 211 and each of the second resistor sheets 212 is pre-attached with an insulating patch.

[0057] In this embodiment, the manufacturer can prefabricate a plurality of chip resistors 21 of different sizes and resistance values ​​as needed. When it is necessary to produce the battery-shaped stacked resistor 100, the chip resistor 21 with the appropriate resistance value is selected as needed and then assembled and processed. In this way, it is avoided to adjust the resistance of different products in response to different design requirements, thereby greatly improving production efficiency and reducing production costs. The size specifications of the insulating patch are pre-cut and prefabricated according to the shape and size of the prefabricated chip resistor 21, and are pre-attached to part of the chip resistor 21, thereby preparing a pre-processed product with an insulating patch and a chip resistor 21.

[0058] Step S2: Use laser to remove part of the insulating patch and apply a solder layer on the area where the insulating patch is removed to form an insulating layer 221 covered with the insulating patch and a conductive layer 222 coated with the solder layer. The insulating layer 221 and the conductive layer 222 together constitute a separator 22.

[0059] In this step, the pre-processed product is processed by laser etching to etch away the insulating patch on the partial area that needs to be coated with the solder layer later, and then solder is coated on the corresponding area to prepare an intermediate product that needs further processing.

[0060] Step S3: alternately stacking a plurality of sheet resistors 21 and separators 22 in such a manner that the conductive layers 222 of each two adjacent separators 22 in the first direction are staggered with each other, so that a plurality of the second resistor sheets 212 are sandwiched between two of the first resistor sheets 211 to form a resistor body.

[0061] Step S4: placing the resistor body in a heating device for heating, so that the plurality of chip resistors 21 are welded together and connected in series.

[0062] In this step, the resistor body is heated by a heating device so that the plurality of chip resistors 21 are welded to each other.

[0063] Step S5: encapsulate the resistor formed by welding in the insulating housing 10 , and make the two pin portions 41 extend out of the insulating housing 10 correspondingly.

[0064] Step S6: filling thermally conductive silica gel between the insulating shell 10 and the resistor.

[0065] Step S7: providing two conductive parts 42 adapted to the mounting structure of the vehicle battery, and slot-welding the two pin parts 41 to the two conductive parts 42 in a one-to-one correspondence to manufacture the battery-shaped laminated resistor 100 .

[0066] In this step, the conductive part 42 can also be prefabricated with various specifications according to the design requirements of the corresponding battery components. During production and assembly, it is only necessary to select the conductive part 42 of the appropriate specifications and the pin part 41 for slot welding to prepare the required battery-shaped laminated resistor 100 finished product, so that the versatility of the various components of the battery-shaped laminated resistor 100 is further enhanced, and the production efficiency is further improved and the production cost is reduced.

[0067] Obviously, the embodiments described above are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, ordinary technicians in this field can make other different forms of changes or modifications without creative work, which should fall within the scope of protection of the present invention.

Claims

1. A battery-shaped laminated resistor, characterized in that: include: an insulating housing configured to match the specifications of a vehicle battery; as well as, A resistor structure, comprising a sheet resistor encapsulated in the insulating housing, a separator, and two pins extending from the insulating housing, wherein a plurality of sheet resistors are provided, the plurality of sheet resistors are arranged side by side in a first direction, and each sheet resistor is pre-set with a resistance adjustment structure, a plurality of separators are provided, each separator comprises an insulating layer and a conductive layer sequentially distributed in a second direction, and each separator is sandwiched between each two adjacent sheet resistors in the first direction, so that the plurality of sheet resistors and the plurality of separators are alternately stacked in the first direction; Among them, the multiple sheet resistors include two first resistor sheets arranged side by side in the first direction, and at least one second resistor sheet arranged between the two first resistor sheets, the lower end of each first resistor sheet is connected to the pin components respectively, and the conductive layers of each two adjacent separators in the first direction are staggered with each other so that the multiple sheet resistors between the two pin components are connected in series with each other.

2. The method according to claim 1, characterized in that: The materials of the plurality of chip resistors are all alloy materials and are of the same material.

3. The battery-shaped laminated resistor according to claim 2, characterized in that: The insulating layer is an insulating patch attached to one side of the corresponding chip resistor; or, The insulating layer is an insulating coating coated on one side of the corresponding sheet resistor.

4. The battery-shaped laminated resistor according to claim 3, characterized in that: Each of the chip resistors has a resistance adjustment region in the projection area covered by the corresponding insulating layer. The resistance adjustment structure is a resistance adjustment groove opened in the resistance adjustment region of the corresponding chip resistor. The resistance adjustment regions of every two adjacent chip resistors in the first direction are staggered.

5. The battery-shaped laminated resistor according to claim 4, characterized in that: Each of the chip resistors also has a connecting area distributed at both ends of the resistance adjustment area in the second direction, one of the two connecting areas is used to abut against the conductive layer, the connecting areas of the multiple chip resistors have the same size, and among the multiple chip resistors, at least two of the chip resistors have different sizes of the resistance adjustment areas.

6. The battery-shaped laminated resistor according to claim 5, characterized in that: The battery-shaped laminated resistor also includes heat-conductive silica gel filled between the resistor structure and the insulating shell, and the insulating shell is made of heat-conductive ceramic.

7. The battery-shaped laminated resistor according to any one of claims 1 to 6, characterized in that: Each of the pin components includes a pin portion and a conductive portion covering the outer periphery of the pin portion, the pin portion is integrally formed at the lower end of the corresponding first resistor sheet, and each of the pin portion slots is welded in the corresponding conductive portion.

8. The battery-shaped laminated resistor according to claim 7, characterized in that: The lower end of the insulating shell is provided with two installation holes which are spaced apart from each other, and the two pin parts extend out from the two installation holes in a one-to-one correspondence. The conductive part is made of brass or copper, and its specifications are compatible with the installation structure of the vehicle battery.

9. The battery-shaped laminated resistor according to any one of claims 1 to 6, characterized in that: Each of the conducting layers is a solder layer coated on one side of the corresponding chip resistor.

10. A method for manufacturing a battery-shaped laminated resistor according to any one of claims 1 to 9, characterized in that: include: An insulating shell adapted to the specifications of a vehicle battery is provided, and a plurality of sheet resistors are provided according to the specifications of the insulating shell and a target resistance value, wherein the plurality of sheet resistors include two first resistor sheets and a plurality of second resistor sheets, wherein a pin portion is integrally formed at the lower end of each of the first resistor sheets, and each of the first resistor sheets and / or the second resistor sheets is pre-processed with a corresponding resistance adjustment structure, wherein an insulating patch is pre-attached to one side of one of the first resistor sheets and each of the second resistor sheets; A portion of the insulating patch is removed by laser, and a solder layer is coated on the area where the insulating patch is removed, so as to form an insulating layer covered with the insulating patch and a conductive layer coated with the solder layer, wherein the insulating layer and the conductive layer together constitute a separator; Alternately stacking a plurality of sheet resistors and separators in a manner that the conductive layers of each two adjacent separators in the first direction are staggered with each other, so that a plurality of the second resistor sheets are sandwiched between two of the first resistor sheets to form a resistor body; Placing the resistor body in a heating device for heating so that a plurality of the sheet resistors are welded together and connected in series; Encapsulating the resistor formed by welding in the insulating housing, and making the two pins extend out of the insulating housing correspondingly; Filling thermally conductive silica gel between the insulating shell and the resistor; Two conductive parts adapted to the mounting structure of the vehicle battery are provided, and the two pin parts are slot-welded to the two conductive parts in a one-to-one correspondence to manufacture the battery-shaped laminated resistor.

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