Battery device, power consuming device, and method for manufacturing an electrical connection assembly

Abstract

The application relates to the technical field of battery production, in particular to a battery device, an electric equipment and a preparation method of an electric connection assembly. The battery device comprises an electric connection assembly, the electric connection assembly comprises an electric connection piece and an insulating layer, the electric connection piece comprises a main body part and a connecting part connected with each other, and the insulating layer is arranged on the outer surface of the main body part through a molding process. The material of the insulating layer comprises silicone rubber, functional fillers and a curing agent, the weight percentage of the silicone rubber in the insulating layer is 50%-70%, the weight percentage of the functional fillers in the insulating layer is 20%-45%, and the weight percentage of the curing agent in the insulating layer is 5%-10%. The battery device can improve the utilization rate of raw materials of the insulating layer, and the material of the insulating layer comprises silicone rubber, functional fillers and a curing agent, so that the insulating layer can have insulation performance and high-temperature resistance.

Description

Technical Field

[0001] This application relates to the field of battery manufacturing technology, and in particular to a method for preparing a battery device, an electrical appliance, and an electrical connection component. Background Technology

[0002] This section provides only background information relevant to this disclosure and is not necessarily prior art.

[0003] With the increasing maturity of new energy technologies, new energy vehicles and other electrical equipment are gradually entering the public eye. The core technology of new energy vehicles lies in the battery device, and the safety and stability of the battery device directly determine the performance of the entire vehicle.

[0004] The battery device includes an electrical connection assembly for connecting different battery cells. The electrical connection assembly includes an electrical connector and an insulating layer. The electrical connector includes a main body and a connecting part that are connected to each other. The insulating layer is usually applied to the outer surface of the main body by spraying, which results in low utilization of the raw materials of the insulating layer. Summary of the Invention

[0005] In view of the above problems, this application provides a method for manufacturing a battery device, an electrical device, and an electrical connection component, which solves the problem that the insulating layer in the prior art is usually applied to the outer surface of the main body by spraying, resulting in low utilization of the raw materials of the insulating layer.

[0006] A first aspect of the embodiments of this application provides a battery device, the battery device comprising:

[0007] An electrical connection assembly includes an electrical connector and an insulating layer. The electrical connector includes a main body and a connecting part that are connected to each other. The insulating layer is formed on the outer surface of the main body by a molding process. The insulating layer is made of silicone rubber, functional filler and curing agent. The weight percentage of silicone rubber in the insulating layer is 50%-70%, the weight percentage of functional filler in the insulating layer is 20%-45%, and the weight percentage of curing agent in the insulating layer is 5%-10%.

[0008] The embodiments of this application include an electrical connection assembly in the battery device. The electrical connection assembly includes an electrical connector and an insulating layer. The electrical connector includes a main body and a connecting part that are connected to each other. The insulating layer is disposed on the outer surface of the main body by a molding process. The insulating layer is made of silicone rubber, functional filler and curing agent. Since the insulating layer is disposed on the outer surface of the main body by a molding process, the utilization rate of the raw materials of the insulating layer can be improved. In addition, since the insulating layer is made of silicone rubber, functional filler and curing agent, the insulating layer can have insulation properties and high temperature resistance.

[0009] In some embodiments of this application, the weight percentage of silicone rubber in the insulating layer is 55%-65%.

[0010] The embodiments of this application, by setting the weight percentage of silicone rubber in the insulating layer to 55%-65%, can give the insulating layer a certain insulating strength, and enable the insulating layer to have a certain degree of flexibility and good processing performance.

[0011] In some embodiments of this application, the functional filler has a weight percentage of 25%-38% in the insulating layer.

[0012] The embodiments of this application, by setting the weight percentage of functional filler in the insulation layer to 25%-38%, can not only significantly improve the voltage withstand performance of the insulation layer, but also enhance the anti-aging ability and thermal stability of the insulation layer.

[0013] In some embodiments of this application, the curing agent has a weight percentage of 6%-8% in the insulating layer.

[0014] The embodiments of this application, by setting the weight percentage of the curing agent in the insulating layer to 6%-8%, can adjust the curing speed of the raw materials, so that the composite material formed by these materials can be uniformly cured during the molding process to form a dense insulating layer.

[0015] In some embodiments of this application, the main body includes a conductor body and a plating layer disposed on the surface of the conductor body.

[0016] The embodiments of this application include a main body comprising a conductor body and a plating layer disposed on the surface of the conductor body. The conductor body can serve as the core component for carrying current, and the plating layer can enhance the surface energy and adhesion of the main body, thereby increasing the bonding force between the main body and the insulating layer and improving the structural stability and reliability of the main body.

[0017] In some embodiments of this application, the thickness of the coating ranges from 0.1 mm to 2 mm.

[0018] The embodiments of this application achieve uniform coverage of the conductor body surface by setting the thickness of the plating layer in the range of 0.1 mm to 2 mm, while avoiding excessive waste of materials, thus achieving a balance between performance and cost.

[0019] In some embodiments of this application, the thickness of the insulating layer is in the range of 1 mm to 10 mm.

[0020] The embodiments of this application, by setting the thickness of the insulating layer in the range of 1 mm to 10 mm, enable the insulating layer to achieve the function of insulation and meet the insulation requirements under different usage scenarios.

[0021] In some embodiments of this application, the silicone rubber includes one of high-temperature vulcanized silicone rubber and fluorosilicone rubber; and / or, the functional filler includes one of mica and ceramic; and / or, the curing agent includes one of polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate and polycaprolactone.

[0022] The embodiments of this application, by including one of high-temperature vulcanized silicone rubber and fluorosilicone rubber in the silicone rubber, can utilize either high-temperature vulcanized silicone rubber or fluorosilicone rubber to give the insulating layer excellent insulation resistance, high-temperature resistance, and good elasticity, meeting the insulation requirements of electrical connection components in complex working environments. The embodiments of this application, by including one of mica and ceramic as the functional filler, can utilize the properties of mica or ceramic to improve the voltage withstand performance of the insulating layer, and also enhance the aging resistance and thermal stability of the insulating layer. The embodiments of this application, by including one of polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate, and polycaprolactone as the curing agent, can use polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate, or polycaprolactone to adjust the curing speed of the raw materials, allowing the composite material formed by these materials to cure uniformly during the molding process, forming a dense insulating layer.

[0023] A second aspect of the embodiments of this application provides an electrical device that includes the battery device mentioned in the above embodiments, the battery device being used to supply power to the electrical device.

[0024] A third aspect of the embodiments of this application provides a method for fabricating an electrical connection component, which is applied to the battery device mentioned in the above embodiments. The method for fabricating the electrical connection component includes:

[0025] An electrical connector is provided, wherein the electrical connector includes a main body;

[0026] An insulating layer is formed on the outer surface of the main body using a molding process. The insulating layer is made of silicone rubber, functional fillers, and curing agents.

[0027] The embodiments of this application provide an electrical connector and an insulating layer is formed on the outer surface of the main body by a molding process. The insulating layer is made of silicone rubber, functional filler and curing agent. Since the insulating layer is formed on the outer surface of the main body by a molding process, the utilization rate of the raw materials of the insulating layer can be improved. In addition, since the insulating layer is made of silicone rubber, functional filler and curing agent, the insulating layer can have insulation properties and high temperature resistance.

[0028] In some embodiments of this application, the step of forming an insulating layer on the outer surface of the main body using a molding process specifically includes:

[0029] Weigh out the specified amounts of silicone rubber, functional filler, and curing agent respectively;

[0030] Mix the specified amounts of silicone rubber, functional filler, and curing agent evenly to obtain a mixture;

[0031] The mixture is refined at a specified temperature to obtain a matured intermediate product;

[0032] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0033] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material;

[0034] The vulcanized raw material is coated onto the outer surface of the main body to obtain the intermediate product;

[0035] The intermediate product is hot-pressed to obtain an electrical connection component.

[0036] Through these steps, embodiments of this application can provide an insulating layer on the outer surface of the main body of the electrical connector, thereby obtaining a compliant electrical connection assembly.

[0037] In some embodiments of this application, the weight percentage of silicone rubber in the insulating layer is 50%-70%, the weight percentage of functional filler in the insulating layer is 20%-45%, and the weight percentage of curing agent in the insulating layer is 5%-10%.

[0038] The embodiments of this application, by setting the weight percentage of silicone rubber in the insulating layer to 50%-70%, can give the insulating layer a certain insulating strength, as well as a certain degree of flexibility and good processability. The embodiments of this application, by setting the weight percentage of functional filler in the insulating layer to 20%-45%, can not only significantly improve the voltage withstand performance of the insulating layer, but also enhance its anti-aging ability and thermal stability. The embodiments of this application, by setting the weight percentage of curing agent in the insulating layer to 5%-10%, can adjust the curing speed of the raw materials, allowing the composite material formed from these materials to cure uniformly during the molding process, forming a dense insulating layer.

[0039] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0040] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0041] Figure 1 This application provides a schematic diagram of the structure of an electrical device according to some embodiments;

[0042] Figure 2 This is a schematic diagram of the structure of a battery device provided in some embodiments of this application;

[0043] Figure 3 This is a schematic diagram of the structure of an electrical connection assembly provided in some embodiments of this application;

[0044] Figure 4 A flowchart illustrating a method for fabricating an electrical connection component provided in some embodiments of this application;

[0045] Figure 5 This is a schematic flowchart illustrating the specific process of fabricating an electrical connection component provided in some embodiments of this application.

[0046] The attached figures are labeled as follows:

[0047] 1000, vehicles;

[0048] 100. Battery assembly; 200. Controller; 300. Motor;

[0049] 10. Battery cells;

[0050] 20. Box; 21. First box; 22. Second box; 23. Storage space;

[0051] 30. Electrical connection assembly; 31. Electrical connector; 311. Main body; 312. Connecting part; 32. Insulating layer. Detailed Implementation

[0052] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0053] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0054] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0055] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0056] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0057] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0058] In the description of the embodiments of this application, the technical terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0059] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0060] Currently, judging from market trends, the application of battery devices is becoming increasingly widespread. Battery devices are not only used in energy storage power systems such as hydropower, thermal power, wind power, and solar power plants, but also widely applied in electric vehicles such as electric bicycles, electric motorcycles, and electric cars, as well as in military equipment and aerospace. With the continuous expansion of battery device applications, market demand is also constantly increasing.

[0061] The battery devices described in this application can be used, but are not limited to, in electrical equipment such as vehicles, ships, or aircraft. Such electrical equipment can be composed of battery cells and battery devices as described in this application.

[0062] In this application embodiment, the electrical devices using battery devices as power sources can be, but are not limited to, mobile phones, tablets, laptops, electric toys, power tools, electric vehicles, electric cars, ships, spacecraft, etc. Among them, electric toys can include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc., and spacecraft can include airplanes, rockets, space shuttles, and spacecraft, etc.

[0063] It should be understood that the technical solutions described in the embodiments of this application are not limited to the battery devices and electrical equipment described above, but can also be applied to all batteries including housings and electrical equipment using batteries.

[0064] The battery apparatus mentioned in the embodiments of this application may include one or more battery cell assemblies for providing voltage and capacity. A battery cell assembly may include multiple battery cells connected in series, parallel, or mixed connections via a busbar.

[0065] In some embodiments, a battery cell assembly is typically formed by arranging multiple battery cells.

[0066] As an example, a battery cell assembly can be a battery module, which is formed by arranging and fixing multiple battery cells together to form an independent module. As another example, a battery module can be formed by bundling multiple battery cells together with cable ties.

[0067] In some embodiments, the battery device may be a battery pack, which includes a housing and one or more individual battery cells housed within the housing.

[0068] As an example, the battery cell assembly can be a battery module, which can be housed in a housing by fixing the battery module in the housing.

[0069] As an example, battery cell assemblies can also be housed in a housing by directly fixing multiple battery cells to the housing.

[0070] As an example, the enclosure may include a first enclosure and a second enclosure. The first enclosure and the second enclosure are fastened together to form a closed space inside the enclosure to house the individual battery cells. Here, "closed" refers to covering or closing, and can be either sealed or unsealed. The first enclosure may be a top cover or a bottom plate.

[0071] As an example, the enclosure may include a top cover, a frame, and a bottom plate. The top cover and bottom plate are connected to the frame, creating an enclosed space inside the enclosure to house the individual battery cells.

[0072] In some embodiments, the housing may be part of the vehicle's chassis structure. For example, a portion of the housing may be at least a part of the vehicle's floor, or a portion of the housing may be at least a part of the vehicle's crossbeams and longitudinal beams.

[0073] A battery cell includes an electrode assembly and an electrolyte. The electrode assembly consists of a positive electrode, a negative electrode, and a separator. The battery cell primarily functions by the movement of metal ions between the positive and negative electrodes. The positive electrode includes a positive current collector and a positive active material layer. The positive active material layer is coated on the surface of the positive current collector. Current collectors without the positive active material layer protrude beyond those with the coating. These uncoated current collectors are stacked together to form the positive electrode tab. Taking a lithium-ion battery as an example, the positive current collector can be made of aluminum, and the positive active material can be lithium cobalt oxide, lithium iron phosphate, ternary lithium, or lithium manganese oxide, etc. The negative electrode includes a negative current collector and a negative active material layer. The negative active material layer is coated on the surface of the negative current collector. Current collectors without the negative active material layer protrude beyond those with the coating. These uncoated current collectors are stacked together to form the negative electrode tab. The negative current collector can be made of copper, and the negative active material can be carbon or silicon, etc. The separator can be made of PP (polypropylene) or PE (polyethylene), etc. Furthermore, the electrode assembly can be a wound structure or a stacked structure; the embodiments of this application are not limited to these.

[0074] The technical solutions described in the embodiments of this application are applicable to various electrical devices that use individual battery cells, such as mobile phones, portable devices, laptops, electric vehicles, electric toys, power tools, vehicles, ships, and spacecraft. For example, spacecraft include airplanes, rockets, space shuttles, and spacecraft.

[0075] The battery device includes an electrical connection assembly for connecting different battery cells. The electrical connection assembly includes an electrical connector and an insulating layer. The electrical connector includes a main body and a connecting part that are connected to each other. The insulating layer is usually applied to the outer surface of the main body by spraying, which results in low utilization of the raw materials of the insulating layer.

[0076] To address this problem, embodiments of this application propose a battery device including an electrical connection assembly. The electrical connection assembly includes an electrical connector and an insulating layer. The electrical connector includes a main body and a connecting portion that are interconnected. The insulating layer is formed on the outer surface of the main body using a molding process. The insulating layer is made of silicone rubber, functional fillers, and a curing agent. By including the electrical connection assembly in the battery device, comprising an electrical connector and an insulating layer, with the electrical connector including an interconnected main body and a connecting portion, and the insulating layer formed on the outer surface of the main body using a molding process, the embodiments of this application improve the utilization rate of the raw materials for the insulating layer. Furthermore, since the insulating layer is made of silicone rubber, functional fillers, and a curing agent, it possesses both insulating properties and high-temperature resistance.

[0077] The battery device in the embodiments of this application can be used in electrical equipment such as vehicles, or can be installed in electrical equipment that requires the installation of a battery device in advance.

[0078] The structures in the embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0079] Combination Figure 1 As shown, vehicle 1000 can be a gasoline-powered vehicle, a natural gas-powered vehicle, or a new energy vehicle. New energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles, etc. A battery device 100 is installed inside vehicle 1000, and the battery device 100 can be located at the bottom, front, or rear of vehicle 1000. The battery device 100 can be used to power vehicle 1000; for example, the battery device 100 can serve as the operating power source for vehicle 1000. Vehicle 1000 may also include a controller 200 and a motor 300. The controller 200 is used to control the battery device 100 to supply power to the motor 300, for example, to meet the power needs of vehicle 1000 during starting, navigation, and driving.

[0080] In some embodiments of this application, the battery device 100 can not only serve as the operating power source for the vehicle 1000, but also as the driving power source for the vehicle 1000, replacing or partially replacing fuel or natural gas to provide driving power for the vehicle 1000.

[0081] like Figure 2 As shown, an embodiment of this application also provides a battery device 100, including a battery housing 20 and a battery cell 10. The battery housing 20 has a receiving space 23, and the battery cell 10 is installed in the receiving space 23.

[0082] In some embodiments, such as Figure 2As shown, the battery housing 20 may include a first housing 21 and a second housing 22, which are mutually capped, and together define a receiving space 23 for accommodating the battery cell 10. Both the first housing 21 and the second housing 22 can be hollow structures with one end open, with the second housing 22 capping the open end of the first housing 21, so that the first housing 21 and the second housing 22 jointly define the receiving space; alternatively, the second housing 22 can be a plate-like structure, and the first housing 21 can be a hollow structure with one side open, with the open side of the second housing 22 capping the open side of the first housing 21. Of course, the battery housing 20 formed by the first housing 21 and the second housing 22 can be of various shapes, such as a cylinder or a cuboid.

[0083] The battery cell 10 can be a secondary battery or a primary battery, and can also be a lithium-sulfur battery, a sodium-ion battery, or a magnesium-ion battery, but is not limited to these. The battery cell 10 can be cylindrical, flat, cuboid, or other shapes.

[0084] like Figure 3 As shown, the battery device 100 includes an electrical connection assembly 30, which includes an electrical connector 31 and an insulating layer 32. The electrical connector 31 includes a main body portion 311 and a connecting portion 312 that are connected to each other. The insulating layer 32 is disposed on the outer surface of the main body portion 311 by a molding process. The insulating layer 32 is made of silicone rubber, functional filler and curing agent.

[0085] It should be noted that the electrical connector 31 here is a conductor, capable of carrying current, and the insulating layer 32 is a material with insulating properties, which can cover at least a portion of the outer surface of the main body 311. In this application, the insulating layer 32 is formed on the outer surface of the main body 311 by a molding process, which improves the utilization rate of the raw materials for the insulating layer 32 compared to a spraying process. Furthermore, the molding process for forming the insulating layer 32 on the outer surface of the main body 311 in this application, compared to a heat-shrink tubing method, improves the efficiency of forming the insulating layer 32 on the main body 311, facilitates the automated production of the electrical connector assembly 30, and results in better product consistency and quality stability.

[0086] Furthermore, the material of the insulating layer 32 mentioned here, including silicone rubber, functional filler and curing agent, means that the insulating layer 32 is a component made by mixing the three materials of silicone rubber, functional filler and curing agent.

[0087] The embodiments of this application include an electrical connection assembly 30 in the battery device 100. The electrical connection assembly 30 includes an electrical connector 31 and an insulating layer 32. The electrical connector 31 includes a main body portion 311 and a connecting portion 312 that are connected to each other. The insulating layer 32 is disposed on the outer surface of the main body portion 311 by a molding process. The insulating layer 32 is made of silicone rubber, functional fillers and curing agents. Since the insulating layer 32 is disposed on the outer surface of the main body portion 311 by a molding process, the utilization rate of the raw materials of the insulating layer 32 can be improved. In addition, since the insulating layer 32 is made of silicone rubber, functional fillers and curing agents, the insulating layer 32 can have insulation properties and high temperature resistance properties.

[0088] Continue to refer to Figure 3 As shown, the connecting portion 312 of the electrical connector 31 is located at both ends of the main body 311, facilitating electrical connection between the electrical connector 31 and other components. The insulating layer 32 is provided on at least a portion of the outer surface of the main body 311. For example, the insulating layer 32 can be provided on the entire outer surface of the main body 311, or it can be provided on a portion of the outer surface of the main body 311.

[0089] Optionally, the weight percentage of silicone rubber in the insulating layer 32 is 50%-70%, preferably, the weight percentage of silicone rubber in the insulating layer 32 is 55%-65%, specifically, the weight percentage of silicone rubber in the insulating layer 32 can be 50%, 52%, 55%, 60%, 65% or 70%, etc.

[0090] The silicone rubber mentioned here refers to rubber whose main chain is composed of alternating silicon and oxygen atoms, with two organic groups usually attached to the silicon atoms.

[0091] In the embodiments of this application, by setting the weight percentage of silicone rubber in the insulating layer 32 to 50%-70%, the insulating layer 32 can possess a certain insulating strength, as well as a certain degree of flexibility and good processability. Here, silicone rubber is the main material of the insulating layer 32. If the weight percentage of silicone rubber in the insulating layer 32 is too low, the construction difficulty during processing will increase, and fluid will not flow easily within the channels. Conversely, if the weight percentage of silicone rubber in the insulating layer 32 is too high, the insulating layer 32 is prone to deformation or scratches during processing.

[0092] Optionally, the functional filler has a weight percentage of 20%-45% in the insulation layer 32. Preferably, the functional filler has a weight percentage of 25%-38% in the insulation layer 32. Specifically, the weight percentage of the functional filler in the insulation layer 32 can be 20%, 25%, 30%, 35%, or 40%, etc.

[0093] The functional fillers mentioned here are additives used in materials such as rubber and plastics to improve or impart specific properties to the materials. Functional fillers enhance the mechanical properties, heat resistance, electrical conductivity, and other characteristics of materials through physical or chemical processes.

[0094] The embodiments of this application set the weight percentage of functional filler in the insulation layer 32 to 20%-45%, which can not only significantly improve the voltage withstand performance of the insulation layer 32, but also enhance the anti-aging ability and thermal stability of the insulation layer 32. If the content of functional filler is too low, the high voltage withstand performance of the insulation layer 32 will decrease, and the thermal shock resistance performance will decrease, failing to meet the requirement of temperature resistance of 800°C.

[0095] Optionally, the curing agent has a weight percentage of 5%-10% in the insulation layer 32; preferably, the curing agent has a weight percentage of 6%-8% in the insulation layer 32. Specifically, the weight percentage of the curing agent in the insulation layer 32 can be...

[0096] In the embodiments of this application, by setting the weight percentage of the curing agent in the insulating layer 32 to 5%-10%, the curing speed of the raw materials can be adjusted so that the composite material formed by these materials can be uniformly cured during the molding process to form a dense insulating layer 32. If the content of the curing agent is too low, the adhesion between the insulating layer 32 and the main body 311 will be reduced, and the design requirements for the adhesion of the electrical connection assembly 30 cannot be met.

[0097] Optionally, the main body 311 includes a conductor body and a plating layer disposed on the surface of the conductor body.

[0098] The conductor body here can be made of copper alloy or aluminum alloy and has the function of conducting electricity. The plating here is a coating applied to the surface of the conductor body using an electroplating process. It can be a nickel plating layer to significantly improve the surface energy and adhesion of the main body 311. In addition, the plating here can also improve the physical properties of the surface of the main body 311, such as surface roughness, smoothness and hardness.

[0099] The embodiments of this application include a conductor body and a plating layer on the surface of the conductor body in the main body 311. The conductor body can serve as the core component for carrying current. In addition, the plating layer can improve the surface energy and adhesion of the main body 311, which facilitates the increase of the bonding force between the main body 311 and the insulating layer 32, thereby improving the structural stability and reliability of the main body 311.

[0100] Optionally, the thickness of the coating is in the range of 0.1 mm to 2 mm. Specifically, the thickness of the coating is in the range of 0.5 mm to 1.5 mm, such as 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm, 1 mm, or 1.5 mm.

[0101] The embodiments of this application achieve uniform coverage of the conductor body surface by setting the thickness of the plating layer in the range of 0.1 mm to 2 mm, while avoiding excessive waste of plating material, thus achieving a balance between performance and cost.

[0102] Optionally, the thickness of the insulating layer 32 is in the range of 1 mm to 10 mm. Specifically, the thickness of the insulating layer 32 is in the range of 2 mm to 8 mm, such as 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm, etc.

[0103] The embodiments of this application, by setting the thickness of the insulating layer 32 in the range of 1 mm to 10 mm, enable the insulating layer 32 to achieve the function of insulation and meet the insulation requirements under different usage scenarios.

[0104] Specifically, the Shore hardness of the insulating layer 32 can be less than 90, which enables the insulating layer 32 to have flexibility and impact resistance, and allows the insulating layer 32 to adapt to the deformation requirements of the electrical connection assembly 30 in complex working environments.

[0105] Optionally, the silicone rubber includes one of high-temperature vulcanized silicone rubber and fluorosilicone rubber, and / or the functional filler includes one of mica and ceramic, and / or the curing agent includes one of polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate and polycaprolactone.

[0106] The high-temperature vulcanized silicone rubber mentioned here, also known as high-temperature compounded silicone rubber, is a high-performance elastomer material based on high-molecular-weight polyorganosiloxanes, with added reinforcing fillers, vulcanizing agents, and other components, which is then vulcanized at high temperatures. The fluorosilicone rubber mentioned here is a type of rubber with good physical and mechanical properties and chemical stability.

[0107] In embodiments of this application, by including either high-temperature vulcanized silicone rubber or fluorosilicone rubber in the silicone rubber, the use of high-temperature vulcanized silicone rubber or fluorosilicone rubber can give the insulation layer 32 excellent insulation resistance, high-temperature resistance, and good elasticity, meeting the insulation requirements of the electrical connection assembly 30 in complex working environments. In embodiments of this application, by including either mica or ceramic as the functional filler, the properties of mica or ceramic can be used to improve the voltage withstand performance of the insulation layer 32, and also enhance its anti-aging ability and thermal stability. In embodiments of this application, by including either polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate, or polycaprolactone as the curing agent, the use of polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate, or polycaprolactone can adjust the curing speed of the raw materials, allowing the composite material formed by these materials to cure uniformly during the molding process, forming a dense insulation layer 32.

[0108] It is important to note that in the embodiments of this application, the electrical connector and the insulating layer 32 are formed into an electrical connector assembly 30 using a molding process. This allows the electrical connector assembly 30 to form a highly integrated structure, enabling a tight fit between the insulating layer 32 and the main body 311 of the electrical connector, reducing the possibility of gaps or delamination between the insulating layer 32 and the main body 311. Furthermore, the main body 311 and the insulating layer 32 have a double-layer structure. This molding process ensures a stable bond between the inner and outer layers, meaning that the molding process provides strong support for the lightweight design and cost reduction of the battery device 100.

[0109] like Figures 4 to 5 As shown, embodiments of this application also propose a method for fabricating an electrical connection component 30. The electrical connection component 30 is applied to the battery device 100 mentioned in the above embodiments. The method for fabricating the electrical connection component 30 includes:

[0110] S41. Provide an electrical connector 31, wherein the electrical connector 31 includes a main body 311;

[0111] S42. An insulating layer 32 is formed on the outer surface of the main body 311 by a molding process. The insulating layer 32 is made of silicone rubber, functional filler and curing agent.

[0112] In S41, the electrical connector 31 can be made of copper or aluminum plate as raw material. It is made by stamping with a press or by laser cutting with a laser cutting machine to obtain an electrical connector 31 of a specified size. Then, the electrical connector 31 of the specified size is electroplated to form a plating layer.

[0113] In S42, setting the insulating layer 32 on the outer surface of the main body 311 by means of using a molding process means mixing raw materials such as silicone rubber, functional filler and curing agent in a certain proportion and then forming them on the outer surface of the main body 311 by means of a molding process. The molding process will be described in detail later.

[0114] The embodiments of this application provide an electrical connector 31 and an insulating layer 32 is formed on the outer surface of the main body 311 by a molding process. The insulating layer 32 is made of silicone rubber, functional filler and curing agent. Since the insulating layer 32 is formed on the outer surface of the main body 311 by a molding process, the utilization rate of the raw materials of the insulating layer 32 can be improved. In addition, since the insulating layer 32 is made of silicone rubber, functional filler and curing agent, the insulating layer 32 can have insulation performance and high temperature resistance performance.

[0115] Optionally, such as Figure 5 As shown, the process of setting the insulating layer 32 on the outer surface of the main body 311 using a molding process specifically includes:

[0116] S51. Weigh out the specified amounts of silicone rubber, functional filler and curing agent respectively;

[0117] S52. Mix the specified amounts of silicone rubber, functional filler and curing agent evenly to obtain a mixture;

[0118] S53. The mixture is refined at a specified temperature to obtain a matured intermediate product.

[0119] S54. Vacuum and filter the intermediate product to obtain a purified semi-finished product.

[0120] S55. The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material.

[0121] S56. The vulcanized raw material is coated on the outer surface of the main body 311 to obtain an intermediate product;

[0122] S57. The intermediate product is hot-pressed to obtain the electrical connection component 30.

[0123] It should be noted that in S51, the silicone rubber, functional filler, and curing agent are all raw materials that have passed inspection, and the specific proportions of silicone rubber, functional filler, and curing agent can be determined according to weight percentage.

[0124] In S52, the mixing method involves placing these raw materials into a reactor and mixing them at room temperature to obtain a homogeneous mixture.

[0125] In S53, the refining process can be carried out using an internal mixer. An internal mixer is an industrial piece of equipment used for plasticizing and mixing rubber or plastics, primarily applied in industries such as tires, seals, cables, and hoses. The specified temperature can be a range, such as 130°C to 160°C, or a fixed value, such as 150°C. Of course, to ensure temperature accuracy, an error can be set within the specified temperature range, such as 150°C ± 2°C. The refining time can be determined based on the particle size of the raw materials. Finer particle sizes result in a faster reaction rate and shorter refining time, while coarser particle sizes result in a slower reaction rate and faster refining time.

[0126] In S54, vacuuming is achieved using a vacuum pump, and filtration is achieved using a filter machine. The filter machine is set to filter the raw material at the point where it flows out.

[0127] Between S54 and S55, the filtered raw materials can be mixed again, and the mixed raw materials can be further processed, namely, the vulcanization process in S55.

[0128] In S55, the semi-finished product is vulcanized to obtain the vulcanized raw material. This is done using a flat vulcanizing machine. The vulcanization temperature is around 170 degrees Celsius, such as 175 degrees Celsius, 170 degrees Celsius, or 180 degrees Celsius. After vulcanizing the semi-finished product, not only can the mechanical strength of the semi-finished product be improved, but the insulation resistance of the semi-finished product can also be further optimized.

[0129] In S56, the vulcanized raw material is precisely coated onto the surface of the main body 311 using an injection device to form a uniform insulating layer 32. It is necessary to strictly control the temperature and pressure of the injection process to avoid the formation of bubbles or voids. The temperature and pressure of the injection process can be adjusted with reference to conventional methods.

[0130] In S57, the process of hot-pressing the intermediate product to obtain the electrical connection assembly 30 can be achieved using a hot-pressing machine. The intermediate product is placed in a mold, and under high temperature and high pressure, the material of the insulating layer 32 undergoes a cross-linking reaction within the mold, forming a dense and uniform insulating layer 32. Hot pressing not only ensures a tight fit between the insulating layer 32 and the main body 311, but also gives the molded electrical connection assembly 30 the required specific shape and size. Specifically, the temperature during the hot pressing process is set between 460 degrees Celsius and 500 degrees Celsius, and the hot pressing time is maintained between 5 and 10 minutes. The hot pressing time can be determined according to the thickness of the insulating layer 32; when the insulation layer 32 is thicker, the hot pressing time can be longer, and vice versa.

[0131] Through these steps, the embodiments of this application can provide an insulating layer 32 on the outer surface of the main body 311 of the electrical connector 31, thereby obtaining a satisfactory electrical connection assembly 30.

[0132] Optionally, the method for preparing the electrical connection component 30 may further include post-processing the electrical connection component 30 to obtain a finished product that meets the application scenario.

[0133] The post-processing mentioned here includes edge trimming, bending and riveting, which can meet the installation and connection requirements of electrical connector 31 in different application scenarios.

[0134] The embodiments of this application, by performing post-processing on the electrical connection component 30, can obtain a finished product that meets the usage scenario by performing corresponding post-processing on the electrical connection component 30.

[0135] In some embodiments of this application, the weight percentage of silicone rubber in the insulating layer 32 is 50%-70%, the weight percentage of functional filler in the insulating layer 32 is 20%-45%, and the weight percentage of curing agent in the insulating layer 32 is 5%-10%.

[0136] In embodiments of this application, by setting the weight percentage of silicone rubber in the insulating layer 32 to 50%-70%, the insulating layer 32 can possess a certain insulating strength, as well as a certain degree of flexibility and good processability. In embodiments of this application, by setting the weight percentage of functional filler in the insulating layer 32 to 20%-45%, not only can the voltage withstand performance of the insulating layer 32 be significantly improved, but its anti-aging ability and thermal stability can also be enhanced. In embodiments of this application, by setting the weight percentage of curing agent in the insulating layer 32 to 5%-10%, the curing speed of the raw materials can be adjusted, allowing the composite material formed from these materials to cure uniformly during the molding process, forming a dense insulating layer 32.

[0137] The electrical connection assembly 30 of this application embodiment enables full utilization of raw materials, reducing the manufacturing cost of the electrical connection assembly 30. Furthermore, the automated production mode of the molding process significantly reduces labor costs, further reducing manufacturing costs. In addition, increased production efficiency shortens the production cycle, further reducing the manufacturing cost per unit product. Compared to heat shrink tubing and spray-coated structures, the electrical connection assembly 30 here offers better insulation and withstand voltage performance, better high-temperature resistance, thermal shock resistance, and mechanical reliability.

[0138] The performance of the electrical connection component 30 will now be described in detail using specific embodiments.

[0139] Example 1

[0140] The specific manufacturing process of the electrical connection assembly 30 is as follows:

[0141] Prepare raw materials according to the ratio of 55% silicone rubber, 40% mica, and 5% curing agent;

[0142] The silicone rubber, functional filler and curing agent are placed in a sealed container and mixed evenly to obtain a mixture. The mixing time is 50 minutes.

[0143] The mixture was refined at 150 degrees Celsius for 5 hours to obtain a matured intermediate product.

[0144] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0145] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material. The vulcanization temperature is 175 degrees Celsius.

[0146] The vulcanized raw material is coated onto the outer surface of the main body 311 to obtain an intermediate product;

[0147] The intermediate product was hot-pressed to obtain the electrical connection component 30. The hot-pressing temperature and time were 480 degrees Celsius and 8 minutes, respectively.

[0148] Example 2

[0149] The specific manufacturing process of the electrical connection assembly 30 is as follows:

[0150] Prepare raw materials according to the ratio of 60% silicone rubber, 30% mica, and 10% curing agent;

[0151] The silicone rubber, functional filler and curing agent are placed in a sealed container and mixed evenly to obtain a mixture. The stirring time is 50 minutes.

[0152] The mixture was refined at 150 degrees Celsius for 5 hours to obtain a matured intermediate product.

[0153] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0154] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material. The vulcanization temperature is 175 degrees Celsius.

[0155] The vulcanized raw material is coated onto the outer surface of the main body 311 to obtain an intermediate product;

[0156] The intermediate product was hot-pressed to obtain the electrical connection component 30. The hot-pressing temperature and time were 480 degrees Celsius and 8 minutes, respectively.

[0157] Example 3

[0158] The specific manufacturing process of the electrical connection assembly 30 is as follows:

[0159] Prepare raw materials according to the ratio of 70% silicone rubber, 20% mica, and 10% curing agent;

[0160] The silicone rubber, functional filler and curing agent are placed in a sealed container and mixed evenly to obtain a mixture. The mixing time is 50 minutes.

[0161] The mixture was refined at 150 degrees Celsius for 5 hours to obtain a matured intermediate product.

[0162] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0163] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material. The vulcanization temperature is 175 degrees Celsius.

[0164] The vulcanized raw material is coated onto the outer surface of the main body 311 to obtain an intermediate product;

[0165] The intermediate product was hot-pressed to obtain the electrical connection component 30. The hot-pressing temperature and time were 480 degrees Celsius and 8 minutes, respectively.

[0166] Example 4

[0167] The specific manufacturing process of the electrical connection assembly 30 is as follows:

[0168] Prepare raw materials according to the ratio of 50% silicone rubber, 45% mica, and 5% curing agent;

[0169] The silicone rubber, functional filler and curing agent are placed in a sealed container and mixed evenly to obtain a mixture. The mixing time is 50 minutes.

[0170] The mixture was refined at 150 degrees Celsius for 5 hours to obtain a matured intermediate product.

[0171] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0172] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material. The vulcanization temperature is 175 degrees Celsius.

[0173] The vulcanized raw material is coated onto the outer surface of the main body 311 to obtain an intermediate product;

[0174] The intermediate product was hot-pressed to obtain the electrical connection component 30. The hot-pressing temperature and time were 480 degrees Celsius and 8 minutes, respectively.

[0175] Example 5

[0176] The specific manufacturing process of the electrical connection assembly 30 is as follows:

[0177] Prepare raw materials according to the ratio of 65% silicone rubber, 25% mica, and 10% curing agent;

[0178] The silicone rubber, functional filler and curing agent are placed in a sealed container and mixed evenly to obtain a mixture. The mixing time is 50 minutes.

[0179] The mixture was refined at 150 degrees Celsius for 5 hours to obtain a matured intermediate product.

[0180] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0181] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material. The vulcanization temperature is 175 degrees Celsius.

[0182] The vulcanized raw material is coated onto the outer surface of the main body 311 to obtain an intermediate product;

[0183] The intermediate product was hot-pressed to obtain the electrical connection component 30. The hot-pressing temperature and time were 480 degrees Celsius and 8 minutes, respectively.

[0184] Example 6

[0185] The specific manufacturing process of the electrical connection assembly 30 is as follows:

[0186] Prepare raw materials according to the ratio of 55% silicone rubber, 35% mica, and 10% curing agent;

[0187] The silicone rubber, functional filler and curing agent are placed in a sealed container and mixed evenly to obtain a mixture. The mixing time is 50 minutes.

[0188] The mixture was refined at 150 degrees Celsius for 5 hours to obtain a matured intermediate product.

[0189] The intermediate product is vacuumed and filtered to obtain a purified semi-finished product.

[0190] The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material. The vulcanization temperature is 175 degrees Celsius.

[0191] The vulcanized raw material is coated onto the outer surface of the main body 311 to obtain an intermediate product;

[0192] The intermediate product was hot-pressed to obtain the electrical connection component 30. The hot-pressing temperature and time were 480 degrees Celsius and 8 minutes, respectively.

[0193] Table 1. Test results of the examples

[0194]

[0195] As can be seen from the data above, the insulation withstand voltage performance of the electrical connection component 30 of this application is far greater than the requirement of 3000V, and the interlayer adhesion, that is, the adhesion between the main body 311 and the insulating layer 32, is far greater than the requirement of 500N, which can achieve a stable bond between the main body 311 and the insulating layer 32.

[0196] The insulation withstand voltage capability of the embodiments of this application is significantly improved compared with the traditional heat shrink tubing and spray coating structures, with an ultimate withstand voltage value greater than 6000V. The ultimate withstand voltage values ​​of the heat shrink tubing and spray coating structures are around 3000V. The high temperature resistance is improved by about 400℃ compared with the traditional heat shrink tubing and spray coating structures, currently reaching a maximum of 800℃. Within 10 minutes, the insulation layer 32 does not smoke or ignite, and the interlayer adhesion of the insulation layer 32 is improved by more than 30%. After 50 cycles of thermal cycling, the appearance of the electrical connection assembly 30 shows no significant change, and both insulation and wear resistance meet the standard requirements. In contrast, after 50 cycles of thermal cycling, the insulation layer 32 of the heat shrink tubing structure shrinks, turns black in some areas, and even cracks, seriously affecting the reliability and service life of the product. Under the same conditions, the edges of the insulation layer 32 of the spray coating structure also shrink, resulting in a certain degree of damage to the overall performance of the product.

[0197] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application.

[0198] A first aspect of this application provides a battery device 100, which includes an electrical connection assembly 30. The electrical connection assembly 30 includes an electrical connector 31 and an insulating layer 32. The electrical connector 31 includes a main body portion 311 and a connecting portion 312 that are interconnected. The insulating layer 32 is disposed on the outer surface of the main body portion 311 by a molding process. The insulating layer 32 is made of silicone rubber, functional fillers, and a curing agent. Further, the weight percentage of silicone rubber in the insulating layer 32 is 50%-70%. Further, the weight percentage of functional fillers in the insulating layer 32 is 20%-45%. Further, the weight percentage of curing agent in the insulating layer 32 is 5%-10%. Further, the main body portion 311 includes a conductor body and a plating layer disposed on the surface of the conductor body. Further, the thickness of the plating layer is in the range of 0.1 mm to 2 mm. Further, the thickness of the insulating layer 32 is in the range of 1 mm to 10 mm. Furthermore, the silicone rubber includes one of high-temperature vulcanized silicone rubber and fluorosilicone rubber, and / or the functional filler includes one of mica and ceramic, and / or the curing agent includes one of polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate and polycaprolactone.

[0199] The above description is merely a preferred embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A battery device, characterized in that, The battery device includes: An electrical connection assembly, comprising an electrical connector and an insulating layer, wherein the electrical connector comprises a main body and a connecting part that are connected to each other, and the insulating layer is disposed on the outer surface of the main body by a molding process, wherein the material of the insulating layer includes silicone rubber, functional filler and curing agent; The silicone rubber comprises 50%-70% by weight in the insulating layer, the functional filler comprises 20%-45% by weight in the insulating layer, and the curing agent comprises 5%-10% by weight in the insulating layer. The silicone rubber includes one of high-temperature vulcanized silicone rubber and fluorosilicone rubber; The functional filler includes either mica or ceramic; The curing agent includes one of polyurethane, polyethylene, polyvinyl chloride, polyethylene terephthalate, and polycaprolactone.

2. The battery device as claimed in claim 1, characterized in that, The silicone rubber comprises 55%-65% by weight in the insulating layer.

3. The battery device as claimed in claim 1, characterized in that, The functional filler has a weight percentage of 25%-38% in the insulation layer.

4. The battery device as claimed in claim 1, characterized in that, The curing agent has a weight percentage of 6%-8% in the insulation layer.

5. The battery device according to any one of claims 1 to 4, characterized in that, The main body includes a conductor body and a plating layer disposed on the surface of the conductor body.

6. The battery device as claimed in claim 5, characterized in that, The thickness of the coating is in the range of 0.1 mm to 2 mm.

7. The battery device according to any one of claims 1 to 4, characterized in that, The thickness of the insulating layer is in the range of 1 mm to 10 mm.

8. An electrical appliance, characterized in that, The battery device includes any one of claims 1 to 7, wherein the battery device is used to supply power to the electrical device.

9. A method for preparing an electrical connection component, said electrical connection component being used in a battery device as described in any one of claims 1 to 7, characterized in that, The method for preparing the electrical connection component includes: An electrical connector is provided, wherein the electrical connector includes a main body portion; An insulating layer is formed on the outer surface of the main body using a molding process. The insulating layer is made of silicone rubber, functional fillers, and a curing agent.

10. The method for preparing the electrical connection component as described in claim 9, characterized in that, The step of setting the insulating layer on the outer surface of the main body by a molding process specifically includes: Weigh out the specified amounts of silicone rubber, functional filler, and curing agent respectively; Mix the specified amounts of the silicone rubber, the functional filler, and the curing agent evenly to obtain a mixture; The mixture is refined at a specified temperature to obtain a matured intermediate product; The intermediate product is subjected to vacuuming and filtration to obtain a purified semi-finished product. The semi-finished product is subjected to vulcanization treatment to obtain the vulcanized raw material; The vulcanized raw material is coated onto the outer surface of the main body to obtain an intermediate product; The intermediate product is hot-pressed to obtain the electrical connection assembly.

11. The method for preparing the electrical connection component as described in claim 10, characterized in that, The silicone rubber comprises 50%-70% by weight in the insulating layer; The functional filler has a weight percentage of 20%-45% in the insulating layer; The curing agent has a weight percentage of 5%-10% in the insulation layer.

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