Battery profiling resistor and manufacturing method thereof

Abstract

The invention discloses a battery profiling resistor and a manufacturing method thereof.The battery profiling resistor comprises a resistor assembly and a shell, the resistor assembly comprises a resistor body, a cylindrical electrode, an annular electrode, an insulating part and a connecting piece, one end of the resistor body is connected with the cylindrical electrode, the other end of the resistor body is conductively connected with the annular electrode through the connecting piece, and one end of the cylindrical electrode protrudes out of the annular electrode; the shell comprises a cylinder body and a cover body, the resistor body and the connecting piece are located in the cylinder body, the annular electrode and the cylindrical electrode are exposed to form a battery-like positive electrode structure, the cover body is assembled at the other end of the cylinder body and seals the cylinder body to form a battery-like negative electrode structure, and insulation paste is poured into the cylinder body to wrap and fix the resistor assembly in the cylinder body. According to the invention, the appearance of the resistor and the appearance of the battery in the battery pack are uniform through the design of the shell and the electrodes, an accommodating space does not need to be additionally designed for the resistor, the production cost of the battery pack is reduced, meanwhile, the resistor assembly and the shell are bonded into a whole through the insulating paste in the cylinder, and the overall firmness and the insulating safety of the resistor are improved.

Description

Technical Field

[0001] This invention relates to the field of electronic device manufacturing technology, and in particular to a battery-contouring resistor and its manufacturing method. Background Technology

[0002] A battery pack unit is a core energy storage component used in applications such as electric vehicles. The battery pack typically integrates multiple standardized batteries, such as cylindrical lithium-ion batteries, and a resistor module for monitoring battery operating conditions. The resistor module primarily collects real-time signals such as current and voltage from the batteries, working with the control system to determine if the batteries are in abnormal conditions such as overcharging, over-discharging, or overload. It is a crucial component for ensuring the safe operation of the battery pack. In current technology, the design of the resistor module neglects the compatibility with the shape of the standardized batteries within the battery pack unit. Most resistor modules on the market are non-standardized structures such as cuboids or irregular blocks, while the batteries in the battery pack mostly use a uniform cylindrical structure. This lack of dimensional compatibility necessitates separate planning for the assembly of the resistor module within the battery pack, independent of the battery array.

[0003] The incompatibility between existing resistor modules and battery pack designs has brought significant drawbacks to battery pack design, production, and practical applications. On one hand, due to the significant differences in shape between resistor modules and batteries, the battery pack casing requires an additional irregularly shaped space to accommodate the resistor modules. This necessitates the separate development of battery pack casing molds for different resistor module specifications, increasing mold design cycles and costs. Furthermore, the irregularly shaped space occupied by non-standard resistor modules is incompatible with other components, resulting in wasted internal space in the battery pack and a reduction in the number of batteries within the same volume, negatively impacting the battery pack's energy density. On the other hand, placing the resistor modules externally to circumvent mold design issues leads to complex wiring, poor environmental adaptability, and additional space requirements. Moreover, the robustness and safety of the resistor modules assembled into the battery pack are also technical issues that require attention. Summary of the Invention

[0004] The main objective of this invention is to propose a battery conformal resistor with reduced production costs and a safe and reliable structure, as well as its manufacturing method.

[0005] To achieve the above objectives, the present invention proposes a battery conformal resistor, comprising: A resistor assembly includes a resistor body, a cylindrical electrode, a ring electrode, an insulator, and a connector. The resistor body extends axially. The cylindrical electrode, the insulator, and the ring electrode are sequentially distributed along inner and outer rings. The cylindrical electrode has a first end side and a second end side that are axially opposed to each other. One axial end of the resistor body is welded and fixed to the first end side. The second end side protrudes from the end side of the ring electrode away from the resistor body. The other axial end of the resistor body is connected and fixed to the connector, and is electrically connected to the ring electrode through the connector. The outer casing includes a cylindrical body and a cover. The cylindrical body extends axially and one end is circumferentially disposed around the outer periphery of the annular electrode, such that the resistor and the connector are located inside the cylindrical body, and the connector is spaced apart from the cylindrical body. The end of the annular electrode away from the resistor and the second end protruding from the annular electrode are exposed outside the cylindrical body. The cylindrical body is filled with insulating adhesive so that the resistor assembly is fixed to the cylindrical body by adhesive, and the insulating adhesive completely covers the portion of the resistor assembly located inside the cylindrical body. The cover is assembled to the end of the cylindrical body away from the resistor assembly to seal the cylindrical body.

[0006] Optionally, the connector includes a connecting piece and a connecting assembly. The connecting piece is spaced apart from the annular electrode in the axial direction. The end of the resistor away from the cylindrical electrode in the axial direction is welded and fixed to the connecting piece. The connecting assembly extends in the axial direction and is arranged around the outer periphery of the resistor, while maintaining a distance from the resistor. One end of the connecting assembly in the axial direction is welded and fixed to the annular electrode, and the connecting assembly is also welded and fixed to the connecting piece.

[0007] Optionally, the connecting piece has a first connecting hole and a second connecting hole, the resist being fixedly and adjustablely inserted through the first connecting hole, and the connecting group being fixedly and adjustablely inserted through the second connecting hole.

[0008] Optionally, the connecting group includes multiple connecting rods, which are spaced apart along the outer periphery of the resist body. Multiple second connecting holes are provided, which are spaced apart circumferentially and allow the multiple connecting rods to pass through one by one.

[0009] Optionally, the insulating member is cylindrical, with its inner wall fitting against the outer periphery of the cylindrical electrode and its outer wall fitting against the inner periphery of the annular electrode. One axial end of the insulating member is flush with the end of the annular electrode away from the resistive body, and the other axial end of the insulating member abuts against the connecting piece.

[0010] Optionally, the connection group includes a plurality of connecting rods, which are spaced apart along the outer periphery of the resist.

[0011] Optionally, the connecting assembly is arranged in a cylindrical shape.

[0012] Optionally, the cover includes a first cover and at least one second cover. The first cover is solid, and each second cover is hollow cylindrical. Each second cover has a matching internal thread and an external thread at both ends in the axial direction. One end of one second cover is threaded to the cylindrical body, and the other end of the second cover is threaded to another second cover or the first cover.

[0013] To achieve the above objectives, the present invention provides a method for manufacturing a battery conformal resistor, comprising the following steps: A resistor and a cylindrical electrode are provided, wherein the resistor is welded and fixed to a first end of the cylindrical electrode, and the resistor and the cylindrical electrode are coaxial; A connecting piece, a connecting assembly, and an annular electrode are provided. The connecting assembly is passed through a second connecting hole on the connecting piece, and the connecting assembly and the connecting piece are welded and fixed at a preset position according to a preset resistance value to form a connector. The annular electrode and the connecting assembly are then welded together. The cylindrical electrode is fitted into the annular electrode, and the resistor is inserted through the first connecting hole, so that the first end side is flush with the end side of the annular electrode facing the connecting piece, and the resistor and the connecting piece are welded and fixed. An insulating adhesive is applied to the insulating component, and the insulating component is sleeved between the cylindrical electrode and the annular electrode. The insulating adhesive is then cured so that the insulating component seals the gap between the cylindrical electrode and the annular electrode, thereby assembling a resistor assembly. A cylindrical body is provided, an insulating adhesive is coated on the outer periphery of the annular electrode, the resistor assembly is sleeved on the cylindrical body, and the insulating adhesive is cured so that the annular electrode seals one end of the cylindrical body, the resistor and connector are located inside the cylindrical body, and the second end side and the end side of the annular electrode facing away from the connector are exposed outside the cylindrical body. Insulating adhesive is poured into the cylinder so that the connector and the resistor are both immersed in the insulating adhesive; After the insulating adhesive has cured, the cover is assembled onto the end of the cylinder away from the resistor assembly to seal the cylinder.

[0014] Optionally, after the steps of fitting the cylindrical electrode into the annular electrode and passing the resistor through the first connecting hole such that the first end is flush with the end of the annular electrode facing the connecting piece, and welding the resistor and the connecting piece together, and before the steps of applying insulating adhesive to the insulating member, fitting the insulating member between the cylindrical electrode and the annular electrode, and curing the insulating adhesive to seal the gap between the cylindrical electrode and the annular electrode to assemble the resistor assembly, the manufacturing method further includes: Power is supplied to the cylindrical electrode and the annular electrode to detect the resistance value of the resistor; Based on the difference between the preset resistance value and the detected resistance value, the periphery of the resistor is ground through the gaps between multiple connecting rods to adjust the resistance value of the resistor so that the resistance value of the resistor is within the preset resistance value range.

[0015] This invention provides a battery-contouring resistor and its manufacturing method. The battery-contouring resistor includes a resistor assembly and a housing. The resistor assembly includes a resistor, a cylindrical electrode, a ring electrode, an insulating component, and a connector. One end of the resistor is connected to the cylindrical electrode, and the other end is electrically connected to the ring electrode through the connector. One end of the cylindrical electrode protrudes from the ring electrode. The housing includes a cylindrical body and a cover. The resistor and connector are located inside the cylindrical body, and part of the ring electrode and cylindrical electrode are exposed to form a structure similar to the positive electrode of a standard battery. The cover is assembled to the other end of the cylindrical body and closes the cylindrical body to form a structure similar to the negative electrode of a standard battery. Insulating glue is poured into the cylindrical body to cover and fix the resistor assembly inside the cylindrical body.

[0016] In the embodiments provided by this invention, the overall shape of the battery-contouring resistor is made completely uniform with the standardized batteries (such as cylindrical lithium-ion batteries) inside the battery pack through the design of the outer shell and the cylindrical and ring electrodes. This not only eliminates the need to design additional irregularly shaped housing space for the resistor within the battery pack shell, saving the cost and time of developing shell molds separately for different specifications of resistor modules, but also allows the battery-contouring resistor to be integrated into the battery array for assembly like a standardized battery, avoiding the waste of internal battery pack space caused by non-standardized space and eliminating the adverse effects of the resistor on the energy density of the battery pack.

[0017] Furthermore, the insulating adhesive injected into the cylinder completely covers the resistor components inside and bonds them to the cylinder as a whole. This adhesive effect significantly improves the overall structural robustness of the battery conformal resistor, effectively ensuring the stability of current and voltage acquisition signals. It also forms a reliable insulating layer, isolating the conductive parts of the resistor components from the outside, preventing battery pack safety hazards caused by resistor leakage, electrode short circuits, etc., thus solving the problems of insufficient assembly robustness and insulation safety in existing resistor modules. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of an embodiment of the battery conformal resistor provided by the present invention; Figure 2 for Figure 1 A three-dimensional structural diagram of the conformal resistor in the battery from another perspective; Figure 3 for Figure 1 An exploded three-dimensional structural diagram of the first embodiment of the conformal resistor for the battery; Figure 4 for Figure 3 A three-dimensional structural diagram of the intermediate resistor assembly; Figure 5 for Figure 4 3D exploded view of the resistor assembly; Figure 6 for Figure 5 A schematic diagram of the assembly of the connecting component and the ring electrode; Figure 7 for Figure 5 A three-dimensional structural diagram of the connecting component; Figure 8 for Figure 7 A three-dimensional structural diagram of the connecting piece; Figure 9 for Figure 1 An exploded three-dimensional structural diagram of the second embodiment of the conformal resistor for the battery; Figure 10 for Figure 9 A three-dimensional structural diagram of the medium-resistance component; Figure 11 for Figure 10 3D exploded view of the resistor assembly; Figure 12 for Figure 1 An exploded view of the three-dimensional structure of the inner and outer shell; Figure 13 This is a schematic flowchart of the first embodiment of the battery conformal resistor manufacturing method provided by the present invention.

[0020] Explanation of icon numbers: 100-Battery contour resistor; 10-Resistor assembly; 11-Resistor body; 12-Cylindrical electrode; 121-First end side; 122-Second end side; 13-Annular electrode; 14-Insulator; 15-Connector; 151-Connecting piece; 1511-First connecting hole; 1512-Second connecting hole; 152-Connecting assembly; 1521-Connecting rod; 20-Outer shell; 21-Cylinder; 22-Cover; 221-First cover; 222-Second cover.

[0021] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0022] It should be noted that if the embodiments of the present invention involve directional indication, the directional indication is only used to explain the relative positional relationship and movement of the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0023] Furthermore, if the embodiments of the present invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text is to include three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B.

[0024] Please see Figures 1 to 12 This invention provides a battery conformal resistor 100. It can be used, for example, in the battery pack of a new energy vehicle to detect the battery's operating status. In this embodiment, the battery conformal resistor 100 includes a resistor assembly 10 and a housing 20.

[0025] It should be noted that in this embodiment, the axial direction refers to the length extension direction of the resistor 11, which is also the reference direction for the assembly of each component in the battery conformal resistor 100. The resistor assembly 10 includes a resistor 11, a cylindrical electrode 12, a ring electrode 13, an insulator 14, and a connector 15. The resistor 11 extends axially and is preferably cylindrical, and the cylindrical electrode 12 is also preferably cylindrical, thereby simulating the positive electrode convex shape of a cylindrical battery. The cylindrical electrode 12, the insulator 14, and the ring electrode 13 are distributed sequentially along the inner and outer rings and are coaxial. In this way, it not only adapts to the battery conformal structure of the product after the subsequent casing 20 is assembled, but also isolates the cylindrical electrode 12 and the ring electrode 13 through the insulator 14 to prevent them from directly contacting and short-circuiting.

[0026] Preferably, such as Figure 5As shown, the insulating member 14 is cylindrical, with its inner wall fitting against the outer periphery of the cylindrical electrode 12 and its outer wall fitting against the inner periphery of the annular electrode 13. This fitting design maximizes the insulating contact area, ensuring no conductive gap between the cylindrical electrode 12 and the annular electrode 13, thus completely blocking short-circuit paths. One axial end of the insulating member 14 is flush with the axial end of the annular electrode 13 away from the resistor 11, while the other axial end of the insulating member 14 abuts against the connecting piece 151. This design ensures that the ends of the insulating member 14 and the annular electrode 13 form a unified assembly reference, preventing the insulating member 14 from protruding or recessing into the annular electrode 13 after assembly. Furthermore, the insulating member 14 further isolates the connecting assembly 152 from the resistor 11.

[0027] The cylindrical electrode 12 has a first end side 121 and a second end side 122 arranged opposite each other in the axial direction. One end of the resistor 11 in the axial direction is welded and fixed to the first end side 121. The second end side 122 protrudes from the end side of the annular electrode 13 away from the resistor 11. This protrusion conforms to the battery structure and facilitates the rapid docking of the subsequent resistor assembly 10 with the battery pack detection circuit. The other end of the resistor 11 in the axial direction is connected and fixed to the connector 15, and is electrically connected to the annular electrode 13 through the connector 15. It can be understood that the connector 15 is a component with good conductivity (such as brass or copper).

[0028] Please continue reading. Figure 1 , Figure 9 and Figure 12 The outer casing 20 includes a cylindrical body 21 and a cover 22. The cylindrical body 21 extends axially and its shape is consistent with the standardized battery inside the battery pack. One end of the cylindrical body 21 is arranged around the outer periphery of the annular electrode 13 and can be initially fixed to the annular electrode 13 by means of, for example, interference fit or adhesive. After assembly, the resistor 11 and the connector 15 are completely located inside the cylindrical body 21, and the connector 15 is spaced from the cylindrical body 21, thereby reserving space for subsequent injection of insulating glue and ensuring that the insulating glue can fully fill and cover the connector 15 and the resistor 11. The end side of the annular electrode 13 away from the resistor 11 and the second end side 122 of the cylindrical electrode 12 protruding from the annular electrode 13 are exposed outside the cylindrical body 21, forming the structure of the positive electrode of the conformal standard battery. The exposed design facilitates direct connection of the resistor 11 to the detection circuit inside the battery pack without the need for additional lead wires. The cover 22 is fitted to the end of the cylinder 21 away from the resistor assembly 10 to seal the cylinder 21. On the one hand, it can prevent external dust and moisture from entering the inside of the cylinder 21 and protect the resistor assembly 10 from environmental influences. On the other hand, it also forms the structure of the standard electrode negative electrode in the battery conformal resistor 100.

[0029] In this embodiment, insulating adhesive is poured into the cylinder 21, completely covering the portion of the resistor assembly 10 located inside the cylinder 21, and fixing the resistor assembly 10 to the cylinder 21 through adhesive action. The insulating adhesive can be epoxy resin, silicone rubber, or polyurethane insulating adhesive, which serves both a structural fixing function to prevent the resistor assembly 10 from shaking inside the cylinder 21, and forms an insulating sealing layer to prevent short circuits between the conductive parts of the resistor assembly 10 and the outside environment.

[0030] This embodiment, through the design of the outer casing 20 and the cylindrical electrode 12 and ring electrode 13, ensures that the overall shape of the battery-contouring resistor 100 is completely consistent with the standardized battery (such as a cylindrical lithium-ion battery) within the battery pack. This eliminates the need for additional irregularly shaped storage space within the battery pack casing, saving the cost and time of developing separate casing molds for different resistor modules. Furthermore, it allows the battery-contouring resistor 100 to be integrated into the battery array like a standardized battery, avoiding wasted internal space due to non-standardized design and eliminating the adverse effects of the resistor on the battery pack's energy density.

[0031] Furthermore, the insulating adhesive poured into the cylinder 21 completely covers the resistor assembly 10 inside the cylinder 21 and bonds it to the cylinder 21 as a whole. This adhesive effect significantly improves the overall structural robustness of the battery conformal resistor 100, effectively ensuring the stability of current and voltage acquisition signals. It also forms a reliable insulating layer, isolating the conductive parts of the resistor assembly 10 from the outside, preventing battery pack safety hazards caused by leakage of the resistor 11, electrode short circuits, etc., and solving the problems of insufficient assembly robustness and insulation safety of existing resistor modules.

[0032] Furthermore, the specific structure of the connector 15 can be varied. Please refer to [link / reference]. Figures 3 to 5 ,as well as Figure 10 and Figure 11 The connector 15 includes a connecting piece 151 and a connecting assembly 152. The connecting piece 151 is spaced apart from the annular electrode 13 in the axial direction and is arranged side by side with the annular electrode 13, preferably being circular. One end of the resistor 11 is welded to the cylindrical electrode 12 in the axial direction, and the other end away from the cylindrical electrode 12 is welded and fixed to the connecting piece 151. The connecting assembly 152 extends axially and is arranged around the outer periphery of the resistor 11, while maintaining a distance from the resistor 11. One end of the connecting assembly 152 is welded and fixed to the annular electrode 13 in the axial direction, and the other end is welded and fixed to the connecting piece 151. Through this assembly method, the connecting assembly 152, the connecting piece 151, and the annular electrode 13 together establish a conductive path between the resistor 11, the cylindrical electrode, and the annular electrode 13.

[0033] In this embodiment, the inductance can be significantly reduced through the symmetrical design of the current path, achieving a non-inductive effect. Specifically, after the current flows from the cylindrical electrode into the resistor 11, it is shunted by the connecting piece 151 to the connecting group 152 surrounding the resistor 11, and finally flows to the annular electrode 13, forming a symmetrical current path of "center inflow and outer periphery return". This path makes the magnetic field generated by the central current and the magnetic field generated by the outer periphery current opposite in direction, and the two cancel each other out, greatly reducing the overall inductance. This non-inductive characteristic ensures that the transmission of high-frequency transient signals by the battery conformal resistor 100 in the dynamic detection of the battery pack is not affected by the resistor inductance, which can ensure that the detection circuit obtains the true current and / or voltage waveforms, providing an accurate basis for battery status monitoring and avoiding misjudgments caused by signal distortion due to inductance.

[0034] Based on the previous embodiment, please continue to refer to... Figures 6 to 8 The connecting piece 151 has a first connecting hole 1511 and a second connecting hole 1512. The design of the first connecting hole 1511 and the second connecting hole 1512 serves two purposes: firstly, it provides radial limiting, ensuring the coaxiality of the resistor 11 and the connecting assembly 152 after assembly; secondly, the assembly positions between the resistor 11 and the connecting piece 151, and between the connecting assembly 152 and the connecting piece 151, can be adjusted during assembly to adjust the length of the resistor 11 connected to the circuit according to a preset resistance value. Specifically, this can be achieved during assembly by using snap-fit ​​mechanisms and multi-position slots, followed by welding fixation.

[0035] It is understandable that the length of the resistor element 11 in existing resistor modules is mostly a pre-made fixed value. If the design value of the resistance required for battery pack testing is adjusted, the resistor element 11 needs to be cut to change the effective length. At the same time, the dimensions of the connector 15 also need to be adjusted accordingly, such as the position of the connecting piece 151 and the length of the connecting group 152. This not only prolongs the assembly cycle, but also increases production costs and defect rates because the cutting process can easily cause material damage or dimensional accuracy deviations in the resistor element 11. In contrast, this embodiment achieves resistance adjustment by adjusting the assembly position during the assembly process, eliminating the need to cut the resistor element 11 or the connector 15. This eliminates the cutting process, effectively shortens the assembly cycle for resistance adjustment, and avoids the accuracy loss and material damage caused by cutting.

[0036] Further, in the optional first embodiment, please refer to Figures 4 to 8 The connecting assembly 152 includes multiple connecting rods 1521. These connecting rods 1521 are spaced apart along the outer periphery of the resistor 11. This spaced distribution ensures that the current is evenly distributed across each connecting rod 1521, preventing overheating caused by current concentration. It also allows for future fine-tuning of the resistor 11's resistance. Second connecting holes 1512 are provided corresponding to each connecting rod 1521, and these holes are spaced apart along the circumference of the connecting piece 151.

[0037] In conjunction with the previous embodiment, during the assembly process, the initial resistance value is determined by adjusting the length of the resistor 11 connected to the circuit. Then, using the gaps between the multiple connecting rods 1521 after assembly, the outer periphery of the resistor 11 can be ground to change its cross-sectional area, achieving fine adjustment of the resistance value. Existing resistor modules requiring high-precision resistance values ​​either rely on prefabricated high-precision resistors 11, resulting in high production costs, or rely on a single adjustment method, such as simply cutting the length, leading to a significant reduction in production efficiency. Furthermore, after welding and fixing, changes in resistance value cannot be predicted, easily requiring disassembly and reprocessing. Thus, it is difficult to balance the precision of the resistor 11 with production efficiency and cost. In this embodiment, the gap design between the multiple connecting rods 1521 provides operational space for fine adjustment. Grinding does not require disassembling the assembled connecting rods 1521 and connecting pieces 151; processing can be completed solely through the gaps. This achieves low cost and high assembly efficiency while meeting the high-precision requirements for the resistor module's resistance value.

[0038] In an optional second embodiment, the connecting assembly 152 is cylindrical, meaning it is a conductive tubular structure. Its function is to improve the uniformity of current transmission through the annular conductive surface, while simultaneously forming a protective ring around the resistor 11. The cylindrical connecting assembly 152 extends axially, encircling the outer periphery of the resistor 11 and maintaining a certain distance from it. One end of the cylindrical connecting assembly 152 is welded to the connecting piece 151, and the other end is welded to the annular electrode 13. The annular conductive surface allows the current to be evenly distributed within the connecting assembly 152, preventing localized overheating caused by current concentration.

[0039] Based on the above embodiments, please continue to refer to Figure 12To improve the versatility of the battery conformal resistor 100, the cover 22 includes a first cover 221 and at least one second cover 222. The first cover 221 is a solid structure used to seal the end of the cylindrical body 21, protecting the internal components. The second cover 222 is a hollow cylindrical structure, its function being to adjust the axial length of the outer shell 20 to accommodate standardized batteries of different specifications. In other words, the second cover 222 can be omitted or installed in appropriate quantities depending on the required design length of the outer shell 20. Each second cover 222 has mutually adaptable internal and external threads at both ends in the axial direction. This threaded adaptation design allows for detachable connections between multiple second covers 222, or between a second cover 222 and a first cover 221, or between a second cover 222 and the cylindrical body 21, thereby facilitating adjustment of the outer shell 20 length according to battery specifications. One end of one of the second covers 222 is threaded to the cylinder 21, and the other end of the second cover 222 can be threaded to another second cover 222 or the first cover 221 as needed, so that the total length of the outer shell 20 can be flexibly adjusted so that the battery conformal resistor 100 can be adapted to standardized batteries with different axial lengths.

[0040] In this embodiment, the cover 22 design, through the combination of the first cover 221 and the second cover 222, achieves flexible adjustment of the axial length of the outer casing 20. This allows the battery-conforming resistor 100 of the same structure to be adapted to various standardized batteries, significantly improving the product's versatility and reducing the types and costs of developing the outer casing 20 mold. Furthermore, the threaded connection facilitates assembly and disassembly, making assembly during production convenient as well as subsequent maintenance and component replacement.

[0041] Based on the above-described embodiments of the battery conformal resistor 100, the present invention provides a first embodiment of a method for manufacturing the battery conformal resistor 100. Specifically, in this embodiment, as shown... Figure 13 As shown, the manufacturing method includes the following steps: Step S1: Provide a resistor 11 and a cylindrical electrode 12, wherein the resistor 11 has been welded and fixed to the first end side 121 of the cylindrical electrode 12, and the resistor 11 and the cylindrical electrode 12 are coaxial.

[0042] In this step, such as Figure 5 As shown, the axis of the resistor 11 coincides with the axis of the cylindrical electrode 12. In practice, this can be achieved using a fixture with a coaxial guide to assist welding. Before welding, the resistor 11 and the cylindrical electrode 12 are placed into their corresponding positioning slots in the fixture, and then fixed by laser spot welding or arc welding. Ideally, the coaxiality of the two components should be checked using a coaxiality tester after welding. If the deviation exceeds the allowable range, it should be corrected. This establishes a benchmark for the subsequent overall assembly of the resistor assembly 10, preventing misalignment of the resistor 11 and the cylindrical electrode 12 that could lead to misalignment of subsequent components, affecting conductivity and shape.

[0043] Step S2: Provide a connecting piece 151, a connecting group 152 and an annular electrode 13. Pass the connecting group 152 through the second connecting hole 1512 on the connecting piece 151, and weld and fix the connecting group 152 and the connecting piece 151 at a preset position according to a preset resistance value to form a connector 15. Weld the annular electrode 13 and the connecting group 152.

[0044] In this step, the preset resistance value refers to the standard resistance value corresponding to the battery pack testing requirements. Based on the preset resistance value, the preset length of the resistor 11 that needs to be connected to the circuit during assembly can be calculated, thus determining the preset position. After the connecting assembly 152 and the connecting piece 151 are welded to this preset position, it ensures that the length of the resistor 11 meets the requirements after welding and fixing. The connector 15 and the annular electrode 13 after assembly in this step are as follows: Figure 6 As shown, this prepares for the subsequent assembly of the resistor 11 and the connector 15.

[0045] Step S3: The cylindrical electrode 12 is fitted into the annular electrode 13, and the resistor 11 is inserted through the first connecting hole 1511, so that the first end side 121 is flush with the end side of the annular electrode 13 facing the connecting piece 151, and the resistor 11 and the connecting piece 151 are welded and fixed.

[0046] In this step, the first end face 121 is flush with the end face of the annular electrode 13 facing the connecting piece 151. This means that the end face of the first end face 121 of the cylindrical electrode 12 and the corresponding end face of the annular electrode 13 are in the same axial plane. Specifically, a fixture with an end face positioning reference can be used. The annular electrode 13 is placed on the fixture reference surface, and then the cylindrical electrode 12 is fitted and adjusted to be flush with both end faces. At the same time, the resistor 11 is passed through the first connecting hole 1511 and then welded and fixed. In this way, the precise assembly of each core component of the resistor assembly 10 is completed, ensuring that the relative positions of the cylindrical electrode 12 and the annular electrode 13 meet the design requirements, and at the same time, the resistor 11 and the connecting piece 15 are fixed.

[0047] Step S4: Apply insulating adhesive to the insulating component 14, and place the insulating component 14 between the cylindrical electrode 12 and the annular electrode 13. Cure the insulating adhesive so that the insulating component 14 seals the gap between the cylindrical electrode 12 and the annular electrode 13 to assemble and form the resistor assembly 10.

[0048] In this step, the insulating adhesive serves to fix the insulating component 14 to the electrode and seal the gap. Specifically, an insulating adhesive can be evenly applied to the inner and outer walls of the insulating component 14 using a brush or an adhesive applicator. After application, the insulating component 14 is slowly inserted between the cylindrical electrode 12 and the annular electrode 13 and placed in a room temperature environment or a low-temperature oven for curing. A two-component potting compound can also be used as the insulating adhesive. In this way, the insulating component 14 isolates the cylindrical electrode 12 from the annular electrode 13, preventing short circuits. At the same time, the insulating adhesive fixes the insulating component 14 and seals the gap, ultimately assembling a structurally complete and reliably insulated resistor assembly 10.

[0049] Step S5: Provide a cylindrical body 21, coat the outer periphery of the annular electrode 13 with insulating adhesive, fit the resistor assembly 10 onto the cylindrical body 21, and cure the insulating adhesive so that the annular electrode 13 seals one end of the cylindrical body 21, the resistor 11 and the connector 15 are located inside the cylindrical body 21, and the second end side 122 and the end side of the annular electrode 13 facing away from the connector 151 are exposed outside the cylindrical body 21.

[0050] In this step, the outer diameter of the annular electrode 13 is adapted to the inner diameter of the cylinder 21. After the annular electrode 13 is embedded in one end of the cylinder 21, it can cover the opening of the cylinder 21, thereby sealing one end of the cylinder 21. Specifically, an insulating adhesive is coated around the annular electrode 13, and the resistor assembly 10 is pushed axially into the cylinder 21 until the annular electrode 13 is flush with the end of the cylinder 21. After the insulating adhesive has cured, the resistor assembly 10 and the cylinder 21 are initially fixed. The annular electrode 13 seals one end of the cylinder 21, preparing for the subsequent injection of insulating adhesive.

[0051] Step S6: Insulating glue is injected into the cylinder 21 so that the connector 15 and the resistor 11 are both immersed in the insulating glue.

[0052] In this step, the insulating adhesive completely covers the portion of the connector 15 and resistor 11 located inside the cylinder 21 after being poured. Specifically, the cylinder 21 with the resistor assembly 10 mounted can be placed upright with the open side facing upwards. Insulating adhesive is slowly poured into the cylinder 21 using a dispensing machine or dropper, gently shaking the cylinder 21 during the pouring process to remove air bubbles, until the insulating adhesive level covers the highest point of the connector 15 and resistor 11. Ideally, vacuum degassing is performed after the insulating adhesive is poured. In this way, the portion of the resistor assembly 10 located inside the cylinder 21 is completely covered by the insulating adhesive, achieving a strong bond between the resistor assembly 10 and the cylinder 21, and forming an insulating layer to prevent short circuits between the resistor assembly 10 and the cylinder 21, thus improving structural robustness and safety.

[0053] Step S7: After the insulating adhesive has cured, the cover 22 is assembled onto the end of the cylinder 21 away from the resistor assembly 10 to seal the cylinder 21.

[0054] In this step, after the insulating adhesive has cured, the cover 22 is assembled to the end of the cylinder 21 by means of threaded connection, interference fit or snap fastener, sealing the end of the cylinder 21 away from the resistor assembly 10, preventing external dust and moisture from entering the cylinder 21 and damaging the resistor assembly 10, while ensuring the integrity of the outer shell 20 structure, and ensuring that the overall shape of the battery conformal resistor 100 meets the requirements of standardized batteries.

[0055] The manufacturing method of the battery conformal resistor 100 provided in this embodiment first completes the precise assembly of the resistor assembly 10 through steps S1 to S4. In this process, the resistor body 11 is coaxially fixed with the cylindrical electrode 12, and the connector 15 is initially fixed with the annular electrode 13. Then, the connector 15 is assembled with the resistor body 11, and the electrodes are insulated by the insulating component 14, resulting in the assembled resistor assembly 10. Next, in step S5, the resistor assembly 10 is assembled into the conformal cylinder 21, ensuring that the electrodes are exposed and sealed within the cylinder 21. The annular electrode 13 is initially fixed by its cooperation with the cylinder 21. In step S6, insulating glue is injected to fix and seal the resistor assembly 10 to the cylinder 21. Finally, the cover 22 is assembled to seal the outer shell 20, forming a battery conformal resistor 100 with a shape consistent with a standardized battery, a robust structure, and safe insulation.

[0056] Based on the first embodiment described above, a second embodiment of the manufacturing method for the battery conformal resistor 100 is proposed. Specifically, after step S3 and before step S4, the manufacturing method further includes: Step S31: Power is supplied to the cylindrical electrode 12 and the annular electrode 13, and the resistance value of the resistor 11 is detected.

[0057] In practice, a resistance tester can be used. The two probes of the tester are connected to the second end 122 of the cylindrical electrode 12 and the exposed end of the ring electrode 13, respectively. After applying a low-voltage DC voltage, the actual resistance value of the resistor 11 is read. The purpose of this step is to detect the actual resistance value of the resistor 11 before assembling the insulating component 14, confirming whether the current resistance value meets the preset requirements. This provides a basis for possible subsequent resistance value adjustments, avoids finished product scrap due to resistance value deviations, and improves the product qualification rate.

[0058] Step S32: Based on the difference between the preset resistance value and the detected resistance value of the resistor 11, the peripheral side of the resistor 11 is ground through the gap between the multiple connecting rods 1521 to adjust the resistance value of the resistor 11 so that the resistance value of the resistor 11 is within the preset resistance value range.

[0059] In this step, the grinding operation refers to changing the resistance value of the resistor 11 by removing a portion of its material. It can be understood that the resistance value is directly proportional to the material length and inversely proportional to the cross-sectional area; grinding the periphery can reduce the cross-sectional area or adjust the equivalent length. Specifically, a miniature grinding wheel can be used, inserted through the gaps between multiple connecting rods 1521, to lightly grind the periphery of the resistor 11. During the grinding process, the process is paused multiple times, and step S31 is repeated to check the resistance value until the resistance value falls within a preset range.

[0060] In this embodiment, during the assembly of the resistor assembly 10, the initial resistance value is determined by adjusting the length of the resistor 11 connected to the circuit. Then, using the gaps between the multiple connecting rods 1521 after assembly, the outer periphery of the resistor 11 is ground to change its cross-sectional area, achieving fine adjustment of the resistance value. Existing resistor modules requiring high-precision resistance values ​​either rely on prefabricated high-precision resistors 11, resulting in high production costs, or rely on a single adjustment method, such as simply cutting the length, leading to a significant reduction in production efficiency. Furthermore, after welding and fixing, changes in resistance value cannot be predicted, easily requiring disassembly and reprocessing. Thus, it is difficult to balance the precision of the resistor 11 with production efficiency and cost. In this embodiment, the gap design between the multiple connecting rods 1521 provides operational space for fine adjustment. Grinding does not require disassembling the assembled connecting rods 1521 and connecting pieces 151; processing can be completed solely through the gaps. This achieves low cost, high assembly efficiency, and meets the high-precision requirements for the resistor module's resistance value.

[0061] Obviously, the embodiments described above are merely some, not all, embodiments of the present invention. Based on the embodiments of the present invention, those skilled in the art can make other variations or modifications without creative effort, and all such variations or modifications should fall within the scope of protection of the present invention.

Claims

1. A battery conformal resistor, characterized in that, include: A resistor assembly includes a resistor, a cylindrical electrode, a ring electrode, an insulator, and a connector. The resistor extends axially, and the cylindrical electrode, the insulator, and the ring electrode are sequentially distributed along inner and outer rings. The cylindrical electrode has a first end side and a second end side that are axially opposite to each other. One axial end of the resistor is welded and fixed to the first end side, and the second end side protrudes from the end side of the ring electrode away from the resistor. The other axial end of the resistor is connected and fixed to the connector and is electrically connected to the ring electrode through the connector. as well as, The outer casing includes a cylindrical body and a cover. The cylindrical body extends axially and one end is circumferentially disposed around the outer periphery of the annular electrode, such that the resistor and the connector are located inside the cylindrical body, and the connector is spaced apart from the cylindrical body. The end of the annular electrode away from the resistor and the second end protruding from the annular electrode are exposed outside the cylindrical body. The cylindrical body is filled with insulating adhesive so that the resistor assembly is fixed to the cylindrical body by adhesive, and the insulating adhesive completely covers the portion of the resistor assembly located inside the cylindrical body. The cover is assembled to the end of the cylindrical body away from the resistor assembly to seal the cylindrical body.

2. The battery conformal resistor as described in claim 1, characterized in that, The connector includes a connecting piece and a connecting assembly. The connecting piece is spaced apart from the annular electrode in the axial direction. The end of the resistor away from the cylindrical electrode in the axial direction is welded and fixed to the connecting piece. The connecting assembly extends in the axial direction and is arranged around the outer periphery of the resistor while maintaining a distance from the resistor. One end of the connecting assembly in the axial direction is welded and fixed to the annular electrode, and the connecting assembly is also welded and fixed to the connecting piece.

3. The battery conformal resistor as described in claim 2, characterized in that, The connecting piece has a first connecting hole and a second connecting hole. The resist is fixedly and adjustablely inserted through the first connecting hole, and the connecting group is fixedly and adjustablely inserted through the second connecting hole.

4. The battery conformal resistor as described in claim 3, characterized in that, The connecting group includes multiple connecting rods, which are spaced apart along the outer periphery of the resist body. Multiple second connecting holes are provided, which are spaced apart circumferentially and allow the multiple connecting rods to pass through one by one.

5. The battery conformal resistor as described in claim 2, characterized in that, The insulating component is cylindrical, with its inner wall fitting against the outer periphery of the cylindrical electrode and its outer wall fitting against the inner periphery of the annular electrode. One axial end of the insulating component is flush with the end of the annular electrode away from the resistive body, and the other axial end of the insulating component abuts against the connecting piece.

6. The battery conformal resistor as described in claim 2, characterized in that, The connection group includes multiple connecting rods, which are spaced apart along the outer periphery of the resist body.

7. The battery conformal resistor as described in claim 2, characterized in that, The connecting assembly is arranged in a cylindrical shape.

8. The battery conformal resistor as described in any one of claims 1 to 7, characterized in that, The cover includes a first cover and at least one second cover. The first cover is solid, and each second cover is hollow cylindrical. Each second cover has a matching internal thread and an external thread at both ends in the axial direction. One end of one second cover is threaded to the cylindrical body, and the other end of the second cover is threaded to another second cover or the first cover.

9. A method for manufacturing a battery conformal resistor, characterized in that, The battery conformal resistor is the battery conformal resistor as described in claim 3, and the manufacturing method includes: A resistor and a cylindrical electrode are provided, wherein the resistor is welded and fixed to a first end of the cylindrical electrode, and the resistor and the cylindrical electrode are coaxial; A connecting piece, a connecting assembly, and an annular electrode are provided. The connecting assembly is passed through a second connecting hole on the connecting piece, and the connecting assembly and the connecting piece are welded and fixed at a preset position according to a preset resistance value to form a connector. The annular electrode and the connecting assembly are then welded together. The cylindrical electrode is fitted into the annular electrode, and the resistor is inserted through the first connecting hole, so that the first end side is flush with the end side of the annular electrode facing the connecting piece, and the resistor and the connecting piece are welded and fixed. An insulating adhesive is applied to the insulating component, and the insulating component is sleeved between the cylindrical electrode and the annular electrode. The insulating adhesive is then cured so that the insulating component seals the gap between the cylindrical electrode and the annular electrode, thereby assembling a resistor assembly. A cylindrical body is provided, an insulating adhesive is coated on the outer periphery of the annular electrode, the resistor assembly is sleeved on the cylindrical body, and the insulating adhesive is cured so that the annular electrode seals one end of the cylindrical body, the resistor and connector are located inside the cylindrical body, and the second end side and the end side of the annular electrode facing away from the connector are exposed outside the cylindrical body. Insulating adhesive is poured into the cylinder so that the connector and the resistor are both immersed in the insulating adhesive; After the insulating adhesive has cured, the cover is assembled onto the end of the cylinder away from the resistor assembly to seal the cylinder.

10. The method for manufacturing a battery conformal resistor as described in claim 9, characterized in that, The battery conformal resistor is the battery conformal resistor as described in claim 4. After the steps of fitting the cylindrical electrode into the annular electrode and simultaneously inserting the resistor body through the first connecting hole, such that the first end side is flush with the end side of the annular electrode facing the connecting piece, and welding and fixing the resistor body and the connecting piece, before the steps of coating insulating adhesive on the insulating component, fitting the insulating component between the cylindrical electrode and the annular electrode, and curing the insulating adhesive to seal the gap between the cylindrical electrode and the annular electrode to assemble the resistor assembly, the manufacturing method further includes: Power is supplied to the cylindrical electrode and the annular electrode to detect the resistance value of the resistor; Based on the difference between the preset resistance value and the detected resistance value, the periphery of the resistor is ground through the gaps between multiple connecting rods to adjust the resistance value of the resistor so that the resistance value of the resistor is within the preset resistance value range.

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