Battery device and electric device

Abstract

A battery device and a power utilization device belong to the technical field of batteries. The battery device comprises an electric device, the electric device comprises an electric device body and a connecting piece, the electric device body is provided with a connecting terminal, the connecting piece is arranged outside the electric device body, the connecting piece is connected with the connecting terminal, and the connecting piece comprises a first part, a second part and a third part which are connected. The yield strength of the second portion is less than that of the first portion and less than that of the third portion, the connection terminal is connected with the first portion, and at least the second portion is deformable. In the battery device with the structure, the deformable connecting piece is connected with the connecting terminal of the electric device body, so that the reliability of connection between the connecting piece and the connecting terminal can be ensured, the reliability of assembly between the electric device and other parts can be ensured, the assembly precision and the stability of long-term use are improved, and the service life of the battery device is prolonged. And the requirement of the battery device on high-reliability connection is met.

Description

Technical Field

[0001] This utility model relates to the field of battery technology, and more specifically, to a battery device and an electrical device. Background Technology

[0002] In the field of new energy batteries, battery devices typically include battery cells and electrical components. The electrical components are connected to the battery cells or other structural parts via connectors, and they participate in the charging and discharging process of the battery cells. Typically, the connection between the connectors and electrical components involves through holes in the connectors and threaded holes in the electrical components, secured with bolts. Under long-term vibration conditions, problems such as loose bolts and wear of the connectors can easily occur, leading to unstable connections that fail to meet the high reliability requirements of battery connections. Utility Model Content

[0003] This application aims to at least address one of the technical problems existing in the prior art. Therefore, one object of this application is to provide a battery device that can improve reliability during use.

[0004] In a first aspect, this utility model provides a battery device, comprising: an electrical component, the electrical component including an electrical component body and a connector, the electrical component body having a connection terminal, the connector being disposed outside the electrical component body and connected to the connection terminal, the connector including a first part, a second part and a third part connected together, the yield strength of the second part being less than the yield strength of the first part and the yield strength of the second part being less than the yield strength of the third part, the connection terminal being connected to the first part, and at least the second part being deformable.

[0005] In the battery device with the above-mentioned structure, by connecting the deformable connector to the connection terminal of the electrical component body, the reliability of the connection between the connector and the connection terminal can be guaranteed, as well as the reliability of the assembly of the electrical component with other components. This improves the assembly accuracy and long-term stability, and meets the battery device's requirements for high-reliability connections.

[0006] In some embodiments, the connector is welded to the connecting terminal. In the above technical solution, by welding the connector and the connecting terminal together as a whole, the strength and stability of the connection are improved, avoiding problems such as poor contact and increased resistance caused by loose connections. This reduces safety hazards such as component failures due to connection faults, and also prevents increased resistance from affecting the smooth transmission of current, thus avoiding increased energy loss to a certain extent and improving energy utilization efficiency.

[0007] In some embodiments, the connector and the connecting terminal are integrally formed. In the above technical solution, by forming the connector and the connecting terminal into an integral structure, the overall structural strength and stability can be improved, avoiding problems such as poor contact and increased resistance caused by poor soldering, desoldering, and loose connections. This reduces safety hazards such as component failure caused by connection faults, and at the same time avoids the impact of increased resistance on the smooth transmission of current, thus avoiding increased energy loss to a certain extent and improving energy utilization efficiency.

[0008] In some embodiments, the connector and the connecting terminal are cast together. In the above technical solution, by casting the connector and the connecting terminal, the overall structural strength and stability are guaranteed. Due to the relatively simple casting process, the production efficiency of the electrical components is high, the cost is low, and the dimensional accuracy and surface quality of the connector and connecting terminal structure can be guaranteed.

[0009] In some embodiments, the hardness of the material of the second part is less than the hardness of the material of the first part. In the above technical solution, the hardness of the material of the second part is less than the hardness of the material of the first part. Therefore, the hardness of the second part is less than that of the first part, so that fatigue fracture is less likely to occur at the connection position between the electrical device body and the connector, which is beneficial to extending the service life.

[0010] In some embodiments, the second part includes multiple layers of foil, one edge of each layer of foil being connected to the first part, and another edge of each layer of foil being connected to the third part. In the above technical solution, the multi-layered foil structure offers good flexibility, facilitates uniform current distribution, reduces local current density, improves the conductivity of the connector, reduces the risk of overheating, avoids adverse effects on electrical components and connected external structures, and prevents safety hazards.

[0011] In some embodiments, any two adjacent foil layers are interconnected. In the above technical solution, interconnecting multiple foil layers can improve the structural stability of the connector to a certain extent, while also improving the conductivity of the connector.

[0012] In some embodiments, the first part includes a main body and a transition part, the transition part being connected between the main body and the second part; the transition part includes a first segment and a second segment, the main body, the first segment, the second segment, and the second part being connected sequentially, the hardness of the first segment being less than the hardness of the main body, the hardness of the first segment being greater than the hardness of the second segment, and the hardness of the second segment being greater than the hardness of the second part. In the above technical solution, the hardness of the main body, the transition part, and the second part can gradually transition, reducing the risk of stress concentration at locations where hardness changes drastically due to large changes, thus reducing the risk of fatigue fracture and improving the service life of the connector.

[0013] In some embodiments, the main body, the transition portion, and the second portion are sequentially arranged along a first direction, and the main body and the second portion are staggered, with the first direction perpendicular to the thickness direction of the second portion. In the above technical solution, the staggered arrangement of the main body and the second portion allows some of the stress to be absorbed by the deformation of the transition portion when the connector is subjected to stress along the first direction, thereby reducing the direct compression or impact of the second portion on the main body and lowering the risk of damage to the main body.

[0014] In some embodiments, the hardness of the transition portion gradually decreases along the direction from the main body to the second portion. This technical solution further allows for a more natural load transfer between the main body and the second portion, avoiding localized overload, improving the overall structural load-bearing efficiency, reducing abrupt changes in hardness at the interface, and lowering the risk of crack formation.

[0015] In some embodiments, the transition portion includes a first metal layer and a second metal layer connected together. The hardness of the material of the first metal layer is greater than that of the material of the second metal layer. Along the direction from the main body to the second portion, the ratio of the thickness of the first metal layer to the thickness of the second metal layer gradually decreases. In the above technical solution, by changing the thickness ratio between the first metal layer and the second metal layer, the transition portion has a gradually decreasing hardness along the direction from the main body to the second portion. This allows for flexible control of the range of hardness gradient in the transition portion.

[0016] In some embodiments, the third part and the first part have the same yield strength. In the above technical solution, the third part and the first part have the same yield strength, resulting in low processing cost and good performance consistency for the connector.

[0017] In some embodiments, the third part and the first part have the same structure. In the above technical solution, by adopting the same structural design, the yield strength of the third part is ensured to be greater than that of the second part, making the third part less prone to deformation compared to the second part, thereby ensuring the reliability of the connection between the third part and the external structural component. Furthermore, since the first and third parts are located at the ends of the connector, the connecting terminal can be connected to either part without distinction, improving assembly efficiency.

[0018] In some embodiments, the third part has fastener holes. In the above technical solution, the third part can be connected to an external structural component by bolt fastening, which is convenient and reliable.

[0019] In some embodiments, the connector is plate-shaped. In the above technical solution, the connector has a large connection area with the connecting terminal, good connection stability, good current handling performance, small space occupation, and a simple structure.

[0020] In some embodiments, the electrical component body is one of a relay, a fuse, a connector, and a shunt. By adopting the above-described structural form for the relay, fuse, connector, or shunt, the reliability of the electrical component and its assembly with other components is ensured, assembly accuracy and long-term stability are improved, and the high reliability connection requirements of the battery device are met.

[0021] Secondly, this utility model embodiment also provides an electrical device, including the battery device described above, wherein the battery device is used to provide electrical energy to the electrical device. Attached Figure Description

[0022] Figure 1 This application provides structural schematic diagrams of vehicles for some embodiments;

[0023] Figure 2 Exploded views of battery devices provided in some embodiments of this application;

[0024] Figure 3 This is a schematic diagram of the structure of an electrical device provided in some embodiments of this application;

[0025] Figure 4 This is a schematic diagram of the structure of the connector provided in some embodiments of this application;

[0026] Figure 5 Partial schematic diagram of connectors provided in some embodiments of this application;

[0027] Figure 6 Partial schematic diagram of connectors provided in other embodiments of this application;

[0028] Figure 7Partial schematic diagram of a connector provided in some embodiments of this application;

[0029] Figure 8 A partial side view of a connector provided for some embodiments of this application;

[0030] Figure 9 This is a schematic diagram of the structure of the transition portion in a connector provided in some embodiments of this application.

[0031] Figure label:

[0032] 1000 vehicles;

[0033] Battery device 100; controller 200; motor 300;

[0034] Box 30;

[0035] First housing 301; Second housing 302;

[0036] 20 battery cells;

[0037] Electrical components 10;

[0038] Connector 101; First part 1011; Second part 1012; Foil 10121; Third part 1013; Fastener hole 10131;

[0039] Main body 1014; Transition section 1015; First section 1016; Second section 1017;

[0040] First metal layer 1018; second metal layer 1019; electrical component body 102; connecting terminal 1021. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0042] Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the terms "comprising" and "having," and any variations thereof, in the specification, claims, and accompanying drawings of this invention are intended to cover non-exclusive inclusion. The terms "first," "second," etc., in the specification, claims, or accompanying drawings of this invention are used to distinguish different objects, not to describe a specific order or hierarchy.

[0043] In this invention, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this invention. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments.

[0044] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "attachment," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0045] In this invention, 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, or B existing alone. Additionally, in this invention, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0046] In the embodiments of this utility model, the same reference numerals denote the same components, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments. It should be understood that the thickness, length, width, and other dimensions of various components in the embodiments of this utility model shown in the drawings, as well as the overall thickness, length, width, and other dimensions of the integrated device, are merely illustrative and should not constitute any limitation on this utility model.

[0047] In this utility model, "multiple" refers to two or more (including two).

[0048] The battery device 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, which are connected in series, parallel, or mixed connections via a busbar.

[0049] In some embodiments, a battery cell assembly is typically formed by arranging multiple battery cells.

[0050] 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.

[0051] In some embodiments, the battery device may be a battery pack, which includes a housing and one or more individual battery cell assemblies housed within the housing.

[0052] 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.

[0053] As an example, battery cell assemblies can also be housed in a housing by directly fixing multiple battery cells to the housing.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] In this application, the battery cell may include lithium-ion secondary batteries, lithium-ion primary batteries, lithium-sulfur batteries, sodium-lithium-ion batteries, sodium-ion batteries, magnesium-ion batteries, or solid-state batteries, etc., and the embodiments of this application are not limited thereto. The battery cell may be cylindrical, cuboid, or other shapes, etc., and the embodiments of this application are not limited thereto.

[0058] Currently, judging from market trends, the application of batteries is becoming increasingly widespread. Batteries are not only used in energy storage power systems such as hydropower, thermal power, wind power, and solar power plants, but also widely used 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 the application areas of power batteries, the market demand for them is also constantly increasing.

[0059] In the field of new energy batteries, battery devices typically include battery cells, electrical components, and other parts. The electrical components are connected to the battery cells or other structural components via connectors, and can participate in the charging and discharging process of the battery cells. Typically, the connection between the connectors and electrical components involves through holes in the connectors and threaded holes in the electrical components, secured with bolts. Under long-term vibration conditions, problems such as loose bolts and wear of the connectors can easily occur, leading to unstable connections that fail to meet the high reliability requirements of battery connections.

[0060] Based on this, this application proposes a battery device, including an electrical component. The electrical component includes an electrical component body and a connector. The electrical component body has a connector terminal. The connector is disposed outside the electrical component body and is connected to the connector terminal. A portion of the connector is deformable. The connector includes a first part, a second part, and a third part connected together. The yield strength of the second part is less than the yield strength of the first part and the yield strength of the second part is less than the yield strength of the third part. The connector terminal is connected to the first part. At least the second part is deformable.

[0061] In electrical devices with the above-mentioned structure, by connecting the deformable connector to the connection terminal of the electrical device body, the reliability of the connection between the connector and the connection terminal can be guaranteed, as well as the reliability of the assembly of the electrical device with other components. This improves the assembly accuracy and long-term stability, and meets the requirements of battery devices for high-reliability connections.

[0062] The technical solutions described in the embodiments of this application are applicable to battery devices and electrical devices that use battery devices.

[0063] Electrical devices can include vehicles, mobile phones, portable devices, laptops, ships, spacecraft, electric toys, power tools, and energy storage devices. Vehicles can be gasoline-powered cars, natural gas-powered cars, or new energy vehicles; new energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles. Spacecraft include airplanes, rockets, space shuttles, and spacecraft. Electric toys include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys. Power tools include metal cutting power tools, grinding power tools, assembly power tools, and railway power tools, such as electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete vibrators, and electric planers. Energy storage devices can be used in energy storage power stations, wind power generation systems, solar power generation systems, mobile power systems, or temporary power supply systems. Energy storage devices can store electrical energy as needed and output it when appropriate. For example, energy storage devices can store electrical energy during off-peak hours and provide power to relevant users or electrical equipment during peak hours. This application does not impose any special restrictions on the specific type of electrical device.

[0064] For ease of explanation, the following embodiments will use a vehicle as an example of an electrical device.

[0065] Please refer to Figure 1 , Figure 1 The diagram below illustrates the structure of a vehicle 1000 according to some embodiments of this application. The vehicle 1000 is equipped with a battery device 100, which may be located at the bottom, front, or rear of the vehicle 1000. The battery device 100 can be used to power the vehicle 1000; for example, the battery device 100 can serve as the operating power source for the vehicle 1000.

[0066] The 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, for the power needs of the vehicle 1000 during startup, navigation and driving.

[0067] 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.

[0068] Please refer to Figure 2 , Figure 2 The image shows an exploded view of a battery device 100 provided in some embodiments of this application. The battery device 100 includes a battery cell 20 and a housing 30 for housing the battery cell 20. The housing 30 can have various structural forms.

[0069] In some embodiments, the housing 30 may include a first housing 301 and a second housing 302, which overlap each other, and together define a receiving space for accommodating the battery cell 20. A sealing element may also be provided at the connection point between the first housing 301 and the second housing 302 to achieve a sealed connection between them. For example, refer to... Figure 2 The first housing 301 and the second housing 302 can both be hollow structures with an opening on one side. The opening side of the first housing 301 covers the opening side of the second housing 302, thus forming a housing 30 with a storage space. Alternatively, the second housing 302 can be a hollow structure with an opening on one side, and the first housing 301 can be a lid that covers the opening side of the second housing 302. The housing 30 can have various shapes, such as a cylindrical housing or a cuboid housing. Electrical components 10 are installed inside the housing 30.

[0070] Please refer to Figures 3-9 , Figure 3 This is a schematic diagram of the structure of an electrical device 10 provided in some embodiments of this application. Figure 4 This is a schematic diagram of the structure of the connector 101 provided in some embodiments of this application; Figures 5-9 This is a partial structural diagram of the connector 101 provided in some embodiments of this application.

[0071] like Figure 3 and Figure 4 As shown, the battery device according to the embodiment of this application includes an electrical component 10. The electrical component 10 includes an electrical component body 102 and a connector 101. The electrical component body 102 has a connection terminal 1021. The connector 101 is disposed outside the electrical component body 102. The connector 101 is connected to the connection terminal 1021, and a portion of the connector 101 is deformable.

[0072] The electrical device 10 includes an electrical device body 102 and a connector 101. The electrical device body 102 is the main body of the electrical device 10, and the connector 101 is the part outside the main body used for connection. The electrical device 10 can be a relay, a fuse, a connector, or a shunt, etc. Taking a relay as an example, the electrical device body 102 includes an electromagnetic drive system, a contact system, and a connection terminal 1021. The electromagnetic drive system has a coil, an iron core, an armature, and a return spring. When the coil is energized, it generates a magnetic field to provide energy for the action. The iron core is a magnet that can concentrate magnetic flux. The armature is driven by magnetic force, which drives the moving contact of the contact system to move. The connection terminal 1021 can connect to the stationary contact of the contact system. The stationary contact can be a part of the connection terminal 1021, that is, a part of the connection terminal 1021 is located inside the housing of the electrical device body 102 and is used to connect or disconnect with the moving contact. A part of the connection terminal 1021 can extend outside the housing of the electrical device body 102 or be flush with the surface of the housing so that the connection terminal 1021 can be connected to the connector 101.

[0073] The connector 101 can be a copper or aluminum structural component, or other conductive material component, used to transmit the current of the electrical device body 102 to the next level component (motor, charger or battery cell, etc.). The connector 101 is connected to the connection terminal 1021, and a part of the connector 101 is deformable. For example, a part of the connector 101 can be made of a material with low hardness and good flexibility, so that the connector 101 can undergo a certain degree of deformation.

[0074] A portion of the connector 101 is deformable. On the one hand, when assembling the electrical device 10 with other components, the connector 101 can adaptively deform according to actual manufacturing tolerances, reducing assembly stress. The connector 101 can absorb the tolerances between components within the battery device 100, improving assembly accuracy and reliability. On the other hand, during actual use of the battery device 100, the connector 101 can absorb the mechanical stress under long-term vibration or thermal cycling conditions, and can adapt to changes in component dimensions caused by temperature variations, thereby ensuring the connection stability between the connector 101 and the connecting terminal 1021. This avoids problems such as loosening and cracking at the connection between the connector 101 and the connecting terminal 1021, leading to increased contact resistance, and meets the high reliability connection requirements of the battery device 100. Furthermore, through its adaptive deformation, the connector 101 is less prone to cracking, breakage, or separation, reducing the probability of damage to the connector 101 and connecting terminal 1021, as well as failures in other components, thus increasing the service life of the electrical device 10 and connected components, and improving the reliability and stability of the battery device 100.

[0075] like Figure 3 and Figure 4As shown, in some embodiments, the connector 101 includes a first part 1011, a second part 1012 and a third part 1013 connected together. The yield strength of the second part 1012 is less than the yield strength of the first part 1011 and the yield strength of the second part 1012 is less than the yield strength of the third part 1013. The connecting terminal 1021 is connected to the first part 1011. At least the second part 1012 is deformable.

[0076] It should be noted that yield strength refers to the stress value at which the specimen begins to undergo significant plastic deformation during the stress process.

[0077] The first part 1011 is connected to the connecting terminal 1021. The yield strength of the first part 1011 is greater than that of the second part 1012. The first part 1011 is less prone to deformation than the second part 1012, thus ensuring the reliability of the connection between the first part 1011 and the connecting terminal 1021. The second part 1012 can absorb the mechanical stress under long-term vibration or thermal cycling conditions of the battery device 100, which helps to reduce the stress on the first part 1011, thereby further improving the connection stability between the first part 1011 and the connecting terminal 1021.

[0078] The first part 1011 can be welded to the connecting terminal 1021, or the first part 1011 and the connecting terminal 1021 can be integrally formed to improve the connection stability between the first part 1011 and the connecting terminal 1021.

[0079] The third part 1013 can be connected to other external structural components, thereby realizing the connection between the electrical device 10 and the external structural components. For example, the third part 1013 can be welded to the external structural components or connected to the external structural components by fasteners. The yield strength of the third part 1013 is greater than that of the second part 1012. The third part 1013 is less prone to deformation than the second part 1012, thereby ensuring the reliability of the connection between the third part 1013 and the external structural components. The second part 1012 can absorb the mechanical stress under the long-term vibration or thermal cycling conditions of the battery device 100, which helps to reduce the stress on the third part 1013, thereby further improving the connection stability between the third part 1013 and the external structural components.

[0080] The second part 1012 is located between the first part 1011 and the third part 1013. The yield strength of the second part 1012 is lower than that of the first part 1011 and the third part 1013, making the second part 1012 relatively easy to deform. On the one hand, when the electrical device 10 is assembled with other components, the second part 1012 can adaptively deform according to the actual manufacturing tolerances, reducing assembly stress. The second part 1012 can absorb the tolerances between the components in the battery device 100, improving assembly accuracy and reliability. On the other hand, during the actual use of the battery device 100, the second part 1012 can absorb the mechanical stress under long-term vibration or thermal cycling conditions of the battery device 100, and can adapt to changes in component dimensions caused by factors such as temperature changes. This ensures the connection stability between the first part 1011 and the connecting terminal 1021, and between the third part 1013 and the external structural components, avoiding problems such as loosening and cracking at the connection points causing increased contact resistance, and meeting the high reliability connection requirements of the battery device 100.

[0081] According to the embodiments of this application, the electrical device 10, by connecting the deformable connector 101 to the connection terminal 1021, can ensure the reliability of the connection between the connector 101 and the connection terminal 1021, as well as the reliability of the assembly of the electrical device 10 with other components, thereby improving the assembly accuracy and long-term stability, and meeting the requirements of the battery device 100 for high-reliability connection.

[0082] In some embodiments, the connector 101 is welded to the connector terminal 1021.

[0083] For example, the connection surfaces of the connector 101 and the connection terminal 1021 to be welded are subjected to strict pretreatment. Chemical cleaning solution is used to remove oil and impurities from the surface, and then mechanical grinding or chemical etching is used to remove the oxide layer on the surface to expose the fresh metal surface to ensure a good weld bond.

[0084] For example, based on the material properties and dimensions of the connector 101 and the connecting terminal 1021, a suitable welding material is selected, such as silver-based solder or copper-based solder. Pulse welding technology is used to precisely control the magnitude of the welding current, the pulse frequency, and the welding time. During the welding process, the welding temperature is monitored in real time to ensure that the welding temperature is within a suitable range and to avoid overheating that could lead to a decline in material properties.

[0085] In other words, when welding the connector 101 to the connector terminal 1021, by precisely controlling the welding process parameters, such as welding current, voltage, time, and temperature, and by selecting appropriate welding materials, the welded joint is ensured to have high strength and low resistance.

[0086] For example, after welding is completed, the welded joint is subjected to visual inspection and non-destructive testing, such as ultrasonic testing and X-ray testing, to ensure that the welding quality meets the requirements.

[0087] In the above embodiments, by welding the connector 101 and the connector terminal 1021 together as a whole, the strength and stability of the connection are improved, and problems such as poor contact and increased resistance caused by loose connection are avoided. This reduces safety hazards such as failure of electrical components 10 caused by connection failure. At the same time, it avoids the impact of increased resistance on the smooth transmission of current, and to a certain extent avoids the increase of energy loss and improves energy utilization efficiency.

[0088] like Figure 3 As shown, in some embodiments, the connector 101 and the connector terminal 1021 are integrally formed.

[0089] For example, the connector 101 and the connector terminal 1021 can be formed into an integral structure by additive manufacturing, that is, by melting metal powder with a laser and stacking it layer by layer into an integral structure; the connector 101 and the connector terminal 1021 can also be metallurgically bonded in a molten state by electroslag remelting process to form an integral structure, and the integral structure formed is installed on the electrical device body 10.

[0090] In the above embodiments, by forming the connector 101 and the connector terminal 1021 into an integral structure, the overall structural strength and stability can be improved, and problems such as poor contact and increased resistance caused by poor soldering, desoldering and loose connection can be avoided. This reduces safety hazards such as failure of electrical components 10 caused by connection failure, and at the same time avoids the increase of resistance from affecting the smooth transmission of current, thus avoiding the increase of energy loss to a certain extent and improving energy utilization efficiency.

[0091] In some embodiments, the connector 101 and the connector terminal 1021 are cast.

[0092] For example, the connecting terminal 1021 is placed in a specific mold (the mold of the connector 101), and then molten copper liquid (or other material) is injected into the mold, so that it solidifies around the connecting terminal 1021 to form an integrated structure, namely an integrated connector 101 and connecting terminal 1021.

[0093] For example, during the casting process, parameters such as the temperature, pouring speed, and cooling rate of the molten copper are strictly controlled. Refined molten copper can be used to reduce impurities and improve casting quality. Appropriate alloying elements, such as tin and zinc, can be added to the molten copper to enhance the strength of the joints. After casting, the formed integrated structure is processed and treated to remove excess parts and ensure dimensional accuracy and surface quality.

[0094] In the above embodiments, by casting the connector 101 and the connecting terminal 1021, the production efficiency of the electrical device 10 is high and the cost is low, and the dimensional accuracy and surface quality of the connector 101 and the connecting terminal 1021 can be guaranteed on the substrate that ensures the overall structural strength and stability.

[0095] In some embodiments, the hardness of the material of the second portion 1012 is less than the hardness of the material of the first portion 1011, thereby making the yield strength of the second portion 1012 less than the yield strength of the first portion 1011.

[0096] The hardness and yield strength of a material are usually positively correlated. In the process of material selection and preparation, it is often more convenient to select or control based on hardness. Therefore, by selecting materials with different hardness or using different processing techniques, different parts of the same material can have different hardness, thereby achieving the purpose of making the yield strength of the first part 1011 and the second part 1012 different.

[0097] For example, the first part 1011 is a conductive metal material with high hardness, such as brass, copper, or nickel-plated copper, and the second part 1012 is a conductive metal material with low hardness, such as gold, silver, or tin-plated copper.

[0098] For example, along the direction from the first portion 1011 to the second portion 1012, the hardness of the first portion 1011 can gradually decrease, and the hardness of the second portion 1012 can also gradually decrease.

[0099] For example, the connector 101 may include a first layer and a second layer stacked together. The material hardness of the first layer is greater than that of the second layer. The thickness ratio of the first layer and the second layer gradually decreases along the direction from the first portion 1011 to the second portion 1012, thereby making the yield strength of the second portion 1012 less than that of the first portion 1011.

[0100] In the above embodiment, the hardness of the material of the second part 1012 is less than that of the material of the first part 1011. Therefore, the hardness of the second part 1012 is less than that of the first part 1011. As a result, fatigue fracture is less likely to occur at the connection position between the electrical device body 102 and the connector 101, which helps to extend the service life.

[0101] like Figure 5 and Figure 6 As shown, in some embodiments, the second part 1012 includes multiple layers of foil 10121, one edge of each layer of foil 10121 is connected to the first part 1011, and the other edge of each layer of foil 10121 is connected to the third part 1013.

[0102] This results in the yield strength of the second part 1012 being less than that of the first part 1011. The multilayer foil 10121 is stacked, which gives the second part 1012 better flexibility and deformability, which is beneficial to improving the degree of deformation of the second part 1012 and thus improving tolerance adaptability.

[0103] For example, the first part 1011 and the third part 1013 can be constructed as integrally formed by heat treatment of foil 10121. In other words, during the preparation of connector 101, multiple layers of foil 10121 can be overlapped along their thickness direction, and a portion of foil 10121 can be heat treated to fuse the foil 10121 to form the first part 1011 and the third part 1013, while the unfused portion forms the second part 1012.

[0104] For example, the first part 1011 and the third part 1013 can be soldered to the multilayer foil 10121. Before soldering the multilayer foil 10121 and the first part 1011 and the third part 1013, the foil 10121 can be surface treated to remove the oxide film and impurities on the surface and to perform anti-oxidation treatment, such as plating treatment (e.g., tin plating, silver plating), to suppress high-temperature oxidation, ensure soldering quality, reduce porosity and cold solder joints, and ensure the conductivity of the interface.

[0105] For example, the thickness of the foil 10121 can be 0.1mm-0.5mm. Setting the thickness of the foil 10121 to be greater than or equal to 0.1mm prevents the thickness of the foil 10121 from being too small, which helps to reduce the processing difficulty and improve the structural strength of the foil 10121. Setting the thickness of the foil 10121 to be less than or equal to 0.5mm prevents the thickness of the foil 10121 from being too large, which helps to improve the flexibility of the foil 10121.

[0106] In the above embodiments, the multi-layered foil 10121 has good structural flexibility, which is conducive to uniform current distribution, reducing local current density, improving the conductivity of connector 101, reducing the risk of overheating, avoiding adverse effects on electrical device 10 and connected external structures, and avoiding safety hazards.

[0107] In some embodiments, any two adjacent foil layers 10121 are interconnected.

[0108] For example, the second part 1012 includes multiple layers of foil 10121. The second part 1012 needs to be pre-fixed with foil 10121 so that any two adjacent layers of foil 10121 can be connected to each other.

[0109] At least one edge of multiple foil sheets 10121 can be connected to each other by solder joints, so that any two adjacent foil sheets 10121 can be connected to each other, thereby arranging the multiple foil sheets 10121 in a stacked state. This facilitates subsequent connection with the first part 1011 or the third part 1013, and also results in a large flow area and good flow performance at the multiple foil sheets 10121. Alternatively, the multiple foil sheets 10121 can be pre-pressed so that the multiple foil sheets 10121 can be at least partially bonded together, and the multiple foil sheets 10121 can be arranged in a stacked state.

[0110] For example, multiple layers of foil 10121 are stacked and arranged according to design requirements, and then welded using special welding processes, such as resistance welding or ultrasonic welding, to ensure a strong weld between the foils 10121. During the welding process, parameters such as welding pressure, welding time, and welding energy are controlled. For example, in resistance welding, the welding current and energizing time are precisely controlled to form a good metallurgical bond between the foils 10121. In ultrasonic welding, the frequency, amplitude, and welding time of the ultrasonic waves are adjusted to ensure welding quality.

[0111] After welding is completed, the welded structure of the multilayer foil 10121 is inspected, such as by tensile testing and conductivity testing, to ensure that its performance meets the design requirements.

[0112] In the above embodiments, the interconnection of multiple foils 10121 can improve the structural stability of the connector 101 to a certain extent, and at the same time improve the conductivity of the connector 101.

[0113] In some embodiments, the annealing temperature of the first portion 1011 is lower than the annealing temperature of the second portion 1012.

[0114] It should be noted that, generally, the higher the annealing temperature, the lower the metal hardness can be due to recrystallization and grain coarsening. Therefore, the first part 1011 and the second part 1012, which are annealed at different temperatures, exhibit different hardnesses. The first part 1011 can be harder than the second part 1012, and visually, this difference in color is noticeable.

[0115] In the above embodiments, the annealing temperatures of the first part 1011 and the second part 1012 are controlled to make the first part 1011 and the second part 1012 have different hardnesses. In this way, the processing cost of the connector 101 is low, the processing flexibility is good, and other properties of the material itself can be preserved without having to consider the problem of alloying defects.

[0116] like Figure 7 and Figure 8As shown, in some embodiments, the first part 1011 includes a main body 1014 and a transition part 1015, with the transition part 1015 connected between the main body 1014 and the second part 1012; the transition part 1015 includes a first segment 1016 and a second segment 1017, with the main body 1014, the first segment 1016, the second segment 1017 and the second part 1012 connected in sequence, the hardness of the first segment 1016 being less than the hardness of the main body 1014, the hardness of the first segment 1016 being greater than the hardness of the second segment 1017, and the hardness of the second segment 1017 being greater than the hardness of the second part 1012.

[0117] The main body 1014 and the second part 1012 are connected by a transition part 1015. The transition part 1015 reduces the problem of abrupt stiffness changes when the main body 1014 and the second part 1012 are directly connected, reduces stress concentration, lowers the risk of cracking, and extends service life. The second part 1012 absorbs energy, while the main body 1014 maintains strength. Combined with the transition part 1015, a coordinated response under dynamic loads can be achieved, improving the vibration resistance of the connector 101.

[0118] In the above embodiments, the hardness of the main body 1014, the transition part 1015, and the second part 1012 can gradually transition, reducing the risk of stress concentration at locations where the hardness changes drastically due to large changes in hardness, which could easily lead to fatigue fracture, and thus improving the service life of the connector 101.

[0119] In some embodiments, the main body 1014 of the connector 101 is a copper alloy component.

[0120] For example, the main body 1014 is a cold-pressed copper alloy part, that is, the main body 1014 is cold-pressed from a copper alloy. For example, the main body 1014 is a heat-treated reinforced copper alloy part, that is, the main body 1014 is a copper alloy part that has been heat-treated to strengthen it. In this way, the main body 1014 has higher structural strength, better connection stability when welded or bolted to the connecting end, and higher connection strength.

[0121] Furthermore, the main body 1014 is constructed with a surface that has been precision machined to ensure the flatness of the surface of the main body 1014 and to adapt to high-precision processes such as laser welding.

[0122] like Figure 7 As shown, in some embodiments, the main body 1014, the transition portion 1015, and the second portion 1012 are arranged sequentially along the first direction, and the main body 1014 and the second portion 1012 are staggered, with the first direction perpendicular to the thickness direction of the second portion 1012.

[0123] Here, the meaning of the main body 1014 and the second part 1012 being misaligned along the first direction is that when the connector 101 is viewed along the first direction, there is a height difference between the main body 1014 and the second part 1012 relative to the same reference plane.

[0124] In the above embodiment, the main body 1014 and the second part 1012 are misaligned. When the connector 101 is subjected to stress along the first direction, part of the stress is absorbed by the deformation of the transition part 1015, which can reduce the direct compression or impact of the second part 1012 on the main body 1014 and reduce the risk of damage to the main body 1014.

[0125] In some embodiments, the hardness of the transition portion 1015 gradually decreases along the direction from the main body portion 1014 to the second portion 1012.

[0126] For example, along the direction from the main body 1014 to the second part 1012, the annealing temperature of the transition part 1015 gradually increases. For example, the transition part 1015 includes a first metal layer 1018 and a second metal layer 1019 connected together. The hardness of the material of the first metal layer 1018 is greater than the hardness of the material of the second metal layer 1019. Along the direction from the main body 1014 to the second part 1012, the ratio of the thickness of the first metal layer 1018 to the thickness of the second metal layer 1019 gradually decreases.

[0127] In the above embodiments, the load transfer between the main body 1014 and the second part 1012 can be made more natural, avoiding local overload, improving the overall load-bearing efficiency of the structure, reducing the degree of hardness change at the interface, and reducing the risk of cracking.

[0128] In some embodiments, the annealing temperature of the first segment 1016 is lower than the annealing temperature of the second segment 1017.

[0129] It should be noted that generally, the higher the annealing temperature, the lower the metal hardness can be due to recrystallization and grain coarsening. The first segment 1016 and the second segment 1017, which are annealed at different temperatures, exhibit different hardness. Therefore, the first segment 1016 can be harder than the second segment 1017. Visually, the first segment 1016 and the second segment 1017 can be distinguished by their different colors.

[0130] In the above technical solution, the annealing temperature of the first section 1016 and the second section 1017 is controlled so that the hardness of the first section 1016 is greater than that of the second section 1017. In this way, the processing cost of the connector 101 is lower, the processing flexibility is better, and other properties of the material itself can be preserved. There is no need to consider the problem of alloying defects. It can also reduce the hardness abrupt change between the main body 1014 and the second part 1012.

[0131] Figure 9 This is a schematic diagram of the structure of the transition portion 1015 in the connector 10 provided in some embodiments of this application.

[0132] like Figure 9 As shown, in some embodiments, the transition portion 1015 includes a first metal layer 1018 and a second metal layer 1019 connected together. The hardness of the material of the first metal layer 1018 is greater than that of the material of the second metal layer 1019. Along the direction from the main body portion 1014 to the second portion 1012, the ratio of the thickness of the first metal layer 1018 to the thickness of the second metal layer 1019 gradually decreases.

[0133] Because the first metal layer 1018 has a higher hardness, the portion where the ratio of the thickness of the first metal layer 1018 to the thickness of the second metal layer 1019 is larger has a higher hardness; and because the second metal layer 1019 has a lower hardness, the portion where the ratio of the thickness of the first metal layer 1018 to the thickness of the second metal layer 1019 is smaller has a lower hardness.

[0134] In the above embodiments, by changing the thickness ratio between the first metal layer 1018 and the second metal layer 1019, the transition portion 1015 has a gradually decreasing hardness along the direction from the main body portion 1014 to the second portion 1012. In this way, the range of hardness gradient of the transition portion 1015 can be flexibly controlled.

[0135] In some embodiments, the third portion 1013 and the first portion 1011 have the same yield strength.

[0136] For example, the third part 1013 and the first part 1011 are made of the same material and process, so that the third part 1013 and the first part 1011 have the same yield strength, the connection 101 has low processing cost and good performance consistency.

[0137] In some embodiments, the third part 1013 and the first part 1011 have the same structure.

[0138] For example, the third part 1013 includes a main body 1014 and a transition part 1015, with the transition part 1015 connected between the main body 1014 and the second part 1012; the transition part 1015 includes a first segment 1016 and a second segment 1017, with the main body 1014, the first segment 1016, the second segment 1017 and the second part 1012 connected in sequence, the hardness of the first segment 1016 being less than the hardness of the main body 1014, the hardness of the first segment 1016 being greater than the hardness of the second segment 1017, and the hardness of the second segment 1017 being greater than the hardness of the second part 1012.

[0139] In the above embodiments, by adopting the same structural design, the yield strength of the third part 1013 is greater than that of the second part 1012. The third part 1013 is less prone to deformation than the second part 1012, thereby ensuring the reliability of the connection between the third part 1013 and the external structural components.

[0140] Furthermore, since the first part 1011 and the third part 1013 are located at the ends of the connector 101, the connecting terminal 1021 can be connected to either part without distinction, thus improving assembly efficiency.

[0141] like Figure 3 , Figure 4 and Figure 6 As shown, in some embodiments, the third portion 1013 has a fastener hole 10131.

[0142] Therefore, the third part 1013 can be connected to the external structural components by bolt fastening, which is convenient and reliable.

[0143] Of course, the third part 1013 can also be connected to the external structural component by welding. For example, the third part 1013 and the external structural component can be connected by laser welding or ultrasonic welding. For example, when laser welding, a pulse mode is used, and the energy density and scanning speed are matched with the melting point of the third part 1013 to control the heat input and reduce the possibility of performance degradation of the second part 1012.

[0144] like Figure 4 As shown, in some embodiments, the connector 101 is plate-shaped.

[0145] In the above embodiment, the connector 101 is plate-shaped, so the connection area between the connector 101 and the connection terminal 1021 is large, the connection stability is good, the current carrying capacity is good, the space occupied is small, and the structure is simple.

[0146] In some embodiments, the electrical device body 102 has two connection terminals 1021, and the electrical device 10 includes two connectors 101. The first part 1011 of each connector 101 is connected to the connection terminal 1021, and the third part 1013 of each connector 101 is connected to an external structural component.

[0147] In some embodiments, the electrical component 10 is one of a relay, a fuse, a connector, and a shunt.

[0148] For example, electrical component 10 can be a high-voltage electrical component on battery device 100, and a high-voltage relay can control the on / off state of battery device. Electrical component 10 can also be a low-voltage relay on battery device 100, and a low-voltage relay can be used to control auxiliary functions such as equalization circuit in battery device.

[0149] For example, the electrical component 10 can be a fuse on the battery device 100. When the current exceeds the safety threshold, the fuse will completely cut off the circuit by self-melting, thus achieving overcurrent protection.

[0150] For example, the electrical component 10 can be a connector on the battery device 100, which can establish a fast-plug, reliable electrical or signal interface between the battery device 100 and an external system.

[0151] For example, the electrical component 10 can be a shunt on the battery device 100. The shunt can convert the large current in the main circuit into a small voltage signal, which is then used by the battery management system (BMS) to accurately measure and calculate the charge, power and fault status in real time.

[0152] By adopting the above-described structure for relay fuses, connectors, or shunts, the reliability of electrical components 10 and their assembly with other components is ensured, assembly accuracy and long-term stability are improved, and the requirements of the battery device 100 for high-reliability connections are met.

[0153] This application provides an electrical device, including the battery device 100 of the above embodiment.

[0154] In the above embodiments, by providing the battery device 100, the battery device 100 has better reliability, thereby enabling the electrical device having the battery device 100 to have better reliability.

[0155] In some embodiments, the electrical device is vehicle 1000, please refer to... Figure 1 , Figure 1 This is a schematic diagram of a vehicle 1000 according to some embodiments of this application.

[0156] The vehicle disclosed in this application can be a new energy vehicle, which can be a pure electric vehicle, a hybrid electric vehicle, or a range-extended electric vehicle, etc. A battery device 100 is installed inside the vehicle, and the battery device 100 can be located at the bottom of the vehicle. The battery device 100 can be used to supply power to the vehicle, for example, it can serve as the vehicle's driving power source, replacing or partially replacing fuel or natural gas to provide driving power to the vehicle.

[0157] It should be noted that, where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other.

[0158] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A battery device, characterized in that, include: An electrical device (10) includes an electrical device body (102) and a connector (101). The electrical device body (102) has a connection terminal (1021). The connector (101) is located outside the electrical device body (102) and is connected to the connection terminal (1021). The connector (101) includes a first part (1011), a second part (1012), and a third part (1013) connected together. The yield strength of the second part (1012) is less than that of the first part (1011), and the yield strength of the second part (1012) is less than that of the third part (1013). The connecting terminal (1021) is connected to the first part (1011), and the second part (1012) is deformable.

2. The battery device according to claim 1, characterized in that, The connector (101) is welded to the connector terminal (1021).

3. The battery device according to claim 1, characterized in that, The connector (101) and the connector terminal (1021) are integrally formed.

4. The battery device according to claim 3, characterized in that, The connector (101) and the connector terminal (1021) are cast together.

5. The battery device according to any one of claims 1-4, characterized in that, The hardness of the material of the second part (1012) is less than that of the material of the first part (1011).

6. The battery device according to any one of claims 1-4, characterized in that, The second part (1012) includes multiple layers of foil (10121) arranged in a stacked manner, one edge of each of the multiple layers of foil (10121) is connected to the first part (1011), and the other edge of each of the multiple foil (10121) is connected to the third part (1013).

7. The battery device according to claim 6, characterized in that, Any two adjacent foil layers (10121) are interconnected.

8. The battery device according to any one of claims 1-4, characterized in that, The first part (1011) includes a main body part (1014) and a transition part (1015), the transition part (1015) being connected between the main body part (1014) and the second part (1012); The transition section (1015) includes a first segment (1016) and a second segment (1017). The main body (1014), the first segment (1016), the second segment (1017) and the second part (1012) are connected in sequence. The hardness of the first segment (1016) is less than that of the main body (1014). The hardness of the first segment (1016) is greater than that of the second segment (1017). The hardness of the second segment (1017) is greater than that of the second part (1012).

9. The battery device according to claim 8, characterized in that, Along a first direction, the main body (1014), the transition portion (1015), and the second portion (1012) are arranged sequentially, and the main body (1014) and the second portion (1012) are staggered. The first direction is perpendicular to the thickness direction of the second portion (1012).

10. The battery device according to claim 8, characterized in that, Along the direction from the main body (1014) to the second part (1012), the hardness of the transition part (1015) gradually decreases.

11. The battery device according to claim 8, characterized in that, The transition portion (1015) includes a first metal layer (1018) and a second metal layer (1019) connected together. The hardness of the material of the first metal layer (1018) is greater than that of the material of the second metal layer (1019). Along the direction from the main body portion (1014) to the second portion (1012), the ratio of the thickness of the first metal layer (1018) to the thickness of the second metal layer (1019) gradually decreases.

12. The battery device according to claim 8, characterized in that, The third part (1013) and the first part (1011) have the same yield strength; and / or the third part (1013) and the first part (1011) have the same structure.

13. The battery device according to any one of claims 1-4, characterized in that, The third part (1013) has fastener holes (10131).

14. The battery device according to any one of claims 1-4, characterized in that, The connector (101) is plate-shaped.

15. The battery device according to claim 1, characterized in that, The electrical device body (102) is one of a relay, a fuse, a connector, and a shunt.

16. An electrical appliance, characterized in that, The device includes a battery device according to any one of claims 1-15, the battery device being used to provide electrical energy to the electrical device.

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