Flexible overcurrent device and battery test system

Abstract

The utility model discloses a flexible overcurrent device and a battery test system, and relates to the technical field of battery test. The flexible over-current device comprises an over-current sheet body, the over-current sheet body comprises a plurality of over-current sheet layers which are arranged in a stacked mode, the over-current sheet body is divided into a first connecting part, a second connecting part and a third connecting part in the length direction, the first connecting part is used for being connected with a battery, and the third connecting part is used for being connected with a test line. An insulating protection layer is arranged on the surface of the second connecting part. The flexible overflowing device can solve the problem that a soft overflowing device in the prior art is easy to tear and pollute after being bent for multiple times.

Description

Technical Field

[0001] This application relates to the field of battery testing technology, and more specifically, to a flexible overcurrent device and a battery testing system. Background Technology

[0002] Battery terminals cannot be directly connected to conventional testing equipment; an external adapter is required to connect them to the testing lines. Currently, current-carrying devices on the market are generally divided into soft current-carrying devices and hard current-carrying devices. Soft current-carrying devices are easy to bend and have a wider range of applications. However, bending them results in a multi-layered structure, the outermost layer of which is easily torn after folding. Furthermore, this multi-layered structure has gaps that are easily contaminated and difficult to clean, affecting the stability, accuracy, and reliability of test results. Retesting batteries with abnormal results also increases testing costs and wastes resources. Therefore, there is an urgent need for a current-carrying device that can be bent multiple times and is not easily torn or contaminated. Utility Model Content

[0003] The purpose of this application is to provide a flexible overcurrent device and a battery testing system that can solve the problems of easy tearing and contamination after repeated bending of existing soft overcurrent devices.

[0004] The embodiments of this application are implemented as follows:

[0005] A first aspect of this application provides a flexible current-carrying device, including a current-carrying plate body. The current-carrying plate body includes multiple stacked current-carrying plate layers. The current-carrying plate body is divided along its length into a first connecting portion, a second connecting portion, and a third connecting portion. The first connecting portion is used to connect to a battery, the third connecting portion is used to connect to a test lead, and an insulating protective layer is provided on the surface of the second connecting portion. This flexible current-carrying device can solve the problems of easy tearing and contamination after repeated bending in existing soft current-carrying devices.

[0006] As one possible implementation, the lower surface of the first connecting part is provided with a slot, which is used to engage and fix with the terminal post of the battery.

[0007] In one possible implementation, the shape of the slot matches the shape of the battery terminals.

[0008] In one possible implementation, the diameter of the slot is equal to the diameter of the battery terminal.

[0009] In one possible implementation, the upper surface of the first connecting part is divided into a welded part and a non-welded part along the center to the outer edge, and the surface roughness of the welded part and the surface roughness of the non-welded part are different.

[0010] As one possible implementation, the third connecting part is provided with a locking hole, which is used to cooperate with a fastener to lock the test line.

[0011] As one possible implementation, the plurality of flow-through layers are cold-pressed structures.

[0012] As one possible implementation, the material of the flow-through layer is copper or aluminum.

[0013] As one possible implementation, the insulating protective layer is made of silicone rubber, butyl rubber, jelly adhesive, hot melt adhesive, or flexible epoxy resin.

[0014] A second aspect of this application provides a battery testing system including the aforementioned flexible current-carrying device. This flexible current-carrying device solves the problems of existing soft current-carrying devices being prone to tearing and contamination after repeated bending.

[0015] The beneficial effects of the embodiments of this application include:

[0016] This flexible current-carrying device includes a current-carrying plate body, which connects to both the battery and the test leads of the testing equipment, enabling the testing equipment to measure and monitor relevant battery parameters. The current-carrying plate body comprises multiple stacked current-carrying plate layers. Along its length, the current-carrying plate body is divided into a first connecting portion, a second connecting portion, and a third connecting portion. The first connecting portion connects to the battery, the third connecting portion connects to the test leads, and the second connecting portion has an insulating protective layer on its surface. This layer protects the second connecting portion from multiple bends and potential issues such as delamination, tearing, and contamination after bending, without affecting the flexible current-carrying device's transfer function. Furthermore, the insulating protective layer prevents electrical contact between the second connecting portion and objects in the external environment, avoiding leakage and other safety issues, thus improving testing safety. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is one of the structural schematic diagrams of the flexible current-carrying device provided in the embodiments of this application;

[0019] Figure 2 This is a second schematic diagram of the flexible flow device provided in the embodiments of this application.

[0020] Icons: 100-Flexible flow device; 10-Flow plate body; 11-First connecting part; 111-Slot; 112-Welding part; 113-Non-Welding part; 12-Second connecting part; 121-Insulating protective layer; 13-Third connecting part; 131-Locking hole. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0022] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0023] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0024] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this application is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0025] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0026] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" 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 mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0027] Please refer to the reference. Figure 1 and Figure 2 This application provides a flexible current-carrying device 100, including a current-carrying plate body 10. The current-carrying plate body 10 includes multiple stacked current-carrying plate layers. The current-carrying plate body 10 is divided along its length into a first connecting portion 11, a second connecting portion 12, and a third connecting portion 13. The first connecting portion 11 is used to connect to a battery, the third connecting portion 13 is used to connect to a test lead, and an insulating protective layer 121 is provided on the surface of the second connecting portion 12. This flexible current-carrying device 100 can solve the problems of easy tearing and easy contamination after repeated bending of existing soft current-carrying devices.

[0028] It should be noted that the flexible overcurrent device 100 can serve as an adapter to connect the battery terminals to the test leads of the testing equipment, thereby enabling the testing equipment to test the battery's performance in terms of current, voltage, and other aspects. Specifically, as shown... Figure 1 and Figure 2 As shown, the flexible current-carrying device 100 includes a current-carrying plate body 10, which is connected to the test lines of the battery and the test equipment respectively.

[0029] The current-carrying plate body 10 comprises multiple stacked current-carrying plate layers; in other words, the current-carrying plate body 10 is constructed by stacking multiple current-carrying plate layers one after another. This stacked structure allows for adjustment of the performance of the current-carrying plate body 10 according to actual needs. For example, the current-carrying capacity of the flexible current-carrying device 100 can be changed by increasing or decreasing the number of current-carrying plate layers. Regarding the specific number of current-carrying plate layers, those skilled in the art can use formula (1) to make a reasonable selection and design based on test requirements.

[0030]

[0031] Where I represents the current-carrying capacity of the metal, and K is a coefficient. Δ T is the heating temperature, R is the resistance value, and S is the cross-sectional area.

[0032] like Figure 1 and Figure 2As shown, the current-carrying plate body 10 can be artificially divided into three parts along its length: a first connecting part 11, a second connecting part 12, and a third connecting part 13. The first connecting part 11 is located at one end of the current-carrying plate body 10, and its main function is to connect to the battery. Through the first connecting part 11, current can flow from the battery into the flexible current-carrying device 100, thereby enabling subsequent testing and other operations. The third connecting part 13 is located at the other end of the current-carrying plate body 10, and its main function is to connect to test leads. Through the test leads, the flexible current-carrying device 100 can be connected to testing equipment to measure and monitor relevant battery parameters (such as current and voltage). The second connecting part 12 is located between the first connecting part 11 and the third connecting part 13, serving as a connection.

[0033] Since the first connecting part 11 and the third connecting part 13 are connected to the battery and the test line respectively, in order to facilitate the connection relationship between the first connecting part 11 and the third connecting part 13 in terms of space, it is often necessary to bend the second connecting part 12. In other words, the bending operation of the flow plate body 10 often occurs at the second connecting part 12. After the second connecting part 12 is bent multiple times, the multiple flow plate layers located at the second connecting part 12 will inevitably delaminate. At the same time, the outermost flow plate layer is prone to tearing after folding, and the gap between two adjacent flow plate layers is prone to contamination, which presents many problems such as difficulty in cleaning.

[0034] To solve the above problems, such as Figure 1 and Figure 2 As shown, an insulating protective layer 121 is provided on the surface of the second connection part 12. In this way, without affecting the transfer function of the flexible overcurrent device 100, the second connection part 12, which is prone to delamination, tearing, contamination and other problems after bending, can be protected to a certain extent. In addition, the insulating protective layer 121 can also prevent the second connection part 12 from making electrical contact with objects in the external environment, avoid safety problems such as leakage, and improve the safety of the test.

[0035] It should be understood that the above-mentioned flow plate body 10 can be artificially divided into three parts along the length direction, which means that the flow plate body 10 can be divided into three regions with different functions along the length direction, and does not mean that the flow plate body 10 is physically separated by some structure along the length direction.

[0036] The connection between the first connecting part 11 and the battery can be achieved by snap-fit ​​or plug-in connection. For example, such as... Figure 2As shown, in this embodiment, a slot 111 is provided on the lower surface of the first connecting part 11, which is used to engage and fix with the battery terminal. The shape of the slot 111 should match the shape of the battery terminal so that the battery terminal can be smoothly engaged into the slot 111, thereby realizing the connection between the first connecting part 11 and the battery.

[0037] For example, in some embodiments, the diameter of the slot 111 is slightly larger than the diameter of the battery terminal, and a clearance fit can be achieved between the battery terminal and the slot 111 to ensure that the battery terminal can be smoothly inserted into the slot 111; or, in other embodiments, the diameter of the slot 111 is equal to the diameter of the battery terminal, which can prevent the battery terminal from shaking with the slot 111 and improve the stability and reliability of the connection; or, in other embodiments, the diameter of the slot 111 is slightly smaller than the diameter of the battery terminal, and an interference fit can be achieved between the battery terminal and the slot 111 to ensure that the first connecting part 11 is tightly connected to the battery.

[0038] The connection between the first connecting part 11 and the battery can also be achieved by welding or crimping. Welding provides a robust electrical connection, ensuring stable current transmission; crimping offers advantages such as ease of operation and reusability. For example, in this embodiment, the upper surface of the first connecting part 11 is divided into a welding part 112 and a non-welding part 113 along its center outwards. The surface roughness of the welding part 112 and the non-welding part 113 differs, allowing the welding part 112 to be welded to the battery terminal using a laser welding device. Furthermore, the difference in surface roughness between the welding part 112 and the non-welding part 113 enables visual positioning welding without the need for welding fixtures, thereby improving the ease of welding operations.

[0039] For example, the surface roughness of the welded portion 112 is significantly lower than that of the non-welded portion 113. For instance, the surface roughness Ra value of the welded portion 112 can be controlled between 0.2 and 0.8 μm. This smoother surface can effectively reduce energy loss during laser welding, allowing the laser energy to be more concentrated on the welding area, thereby improving the quality and strength of the weld. On the other hand, the surface roughness Ra value of the non-welded portion 113 can be controlled within the range of 1.6 to 6.3 μm. The relatively rough surface is mainly to provide visual and tactile differentiation during the welding process.

[0040] The connection between the third connecting part 13 and the test lead can be a detachable fixed connection to facilitate the replacement and maintenance of the test lead. For example, such as... Figure 1 and Figure 2As shown, in this embodiment, the third connecting part 13 is provided with a locking hole 131, which is used to lock the test line in conjunction with a fastener. The fastener can be a bolt, screw, etc.

[0041] Multiple flow layers can be bonded together using a special process. For example, in some embodiments, the multiple flow layers are cold-pressed structures; in other words, the multiple flow layers can be manufactured using a cold-pressing process. Alternatively, in other embodiments, the multiple flow layers can be bonded together using an adhesive to ensure a tight bond between the multiple flow layers and reduce contact resistance.

[0042] The current-carrying plate layer of the current-carrying plate body 10 can be made of a material with good conductivity and flexibility. As one possible implementation, the material of the current-carrying plate layer is copper or aluminum. Copper has high conductivity and good mechanical strength, which can ensure the smooth flow of current while withstanding a certain degree of bending; aluminum is relatively light, has a lower cost, and also has a certain degree of flexibility and conductivity.

[0043] Different flow plates can be made of the same or different materials to achieve different electrical performance. Regarding the actual materials of the multiple flow plates included in the flow plate body 10, those skilled in the art should be able to make reasonable selections and designs based on actual conditions, and no specific limitations are made here. For example, the number of flow plates is 20. In some embodiments, all 20 flow plates are made of copper; or, in other embodiments, all 20 flow plates are made of aluminum; or, in still other embodiments, 10 flow plates are made of copper and 10 flow plates are made of aluminum.

[0044] As one possible implementation, the insulating protective layer 121 is made of silicone rubber, butyl rubber, jelly adhesive, hot melt adhesive, or flexible epoxy resin.

[0045] Silicone rubber possesses excellent resistance to high and low temperatures, maintaining stable physical properties within a temperature range of -50℃ to 200℃. This allows the insulating protective layer 121 to operate reliably in various extreme environments. Simultaneously, it exhibits good electrical insulation properties, effectively preventing current leakage and ensuring the safe operation of equipment. Furthermore, silicone rubber has high chemical stability, is resistant to aging and ozone, significantly extending the service life of the insulating protective layer 121.

[0046] Butyl rubber has extremely low gas permeability, effectively preventing the intrusion of moisture and corrosive gases, thus enabling the insulating protective layer 121 to form a good protective barrier for the second connection 12. Its excellent electrical insulation properties effectively prevent electrical faults. Furthermore, butyl rubber has good damping properties, absorbing and buffering certain mechanical vibrations, reducing damage to equipment caused by vibration.

[0047] The jelly adhesive possesses excellent flexibility and adhesion, enabling it to tightly conform to surfaces of various shapes, ensuring a seamless connection between the insulating protective layer 121 and the second connecting part 12, thereby providing a more reliable insulation effect. Its curing process is simple, requiring no complex processes or equipment, reducing production costs and time. Simultaneously, the jelly adhesive also exhibits certain moisture-proof properties, preventing moisture from corroding the equipment.

[0048] Hot melt adhesive cures quickly, enabling bonding and insulation protection to be completed in a short time, thus improving production efficiency. It exhibits good adhesion to a variety of materials, firmly adhering to the insulating protective layer 121 and the second connecting part 12. Furthermore, hot melt adhesive demonstrates good stability at room temperature, is not easily affected by environmental factors, and ensures the durability of insulation performance.

[0049] Flexible epoxy resin combines excellent flexibility with high strength, allowing it to adapt to slight deformations of components while providing reliable mechanical protection. Its superior electrical insulation properties effectively isolate electric fields and prevent leakage. Furthermore, flexible epoxy resin exhibits strong chemical resistance, resisting the erosion of various chemicals and ensuring the proper functioning of the insulating protective layer 121 in harsh chemical environments.

[0050] The aforementioned materials possess excellent insulation properties, high-temperature resistance, and flexibility, providing reliable protection for the second connection 12 under various environmental conditions. Therefore, the insulating protective layer 121 not only prevents leakage at the second connection 12 but also protects it from erosion by dust, moisture, and other contaminants, extending the service life of the flexible overcurrent device 100.

[0051] Example 1

[0052] This embodiment uses a 300A conventional overcurrent device to conduct bending and charge / discharge tests at 25°C, including the following steps:

[0053] (1) Take 3 individual battery cells and weld a conventional overcurrent device, and measure the internal resistance of the welding point to ensure that the internal resistance is ≤0.2mΩ. Measure the internal resistance of the cable to the welding point to ensure that the internal resistance is ≤0.08mΩ.

[0054] (2) The conventional overcurrent device was bent 20, 50 and 100 times respectively, and the resistance of the welding point and the input and output cables of the test equipment was measured. The test results are shown in Table 1.

[0055] (3) Place the battery cell in a constant temperature and humidity test chamber and perform a charge and discharge test;

[0056] (4) The temperature sampling points of the battery cells are connected to the test equipment through temperature data sampling lines to form a temperature data acquisition loop;

[0057] (5) The positive and negative terminals of the battery cell are connected to the test equipment through a voltage data acquisition line to form a voltage data acquisition circuit;

[0058] (6) Charge at 0.5P constant power until 3.65V cutoff;

[0059] (7) Let it stand still for 10 minutes;

[0060] (8) Discharge at 0.5P constant power until 2.5V cutoff;

[0061] (9) Let it stand still for 10 minutes;

[0062] (10) Repeat steps (7)-(9) 4 times;

[0063] Comparative Example 1

[0064] This comparative example uses a 300A flexible current-carrying device 100. The specific manufacturing parameters are as follows:

[0065] (1) The material of the flow-through layer is aluminum, and the thickness of each flow-through layer is 0.1 mm;

[0066] (2) The flow plate body 10 is made of 20 flow plate layers by cold pressing;

[0067] (3) An insulating protective layer 121 is provided on the surface of the second connecting part 12 of the flow plate body 10;

[0068] (4) A slot 111 is provided on the lower surface of the first connecting part 11 of the flow plate body 10, and the shape of the slot 111 is the same as the shape of the positive and negative terminals of the battery cell. The slot 111 and the battery terminals are fitted with a clearance to ensure that the positive and negative terminals of the battery can be inserted into the slot 111 completely and smoothly.

[0069] (5) Welding parts 112 and non-welding parts 113 with different surface roughness are respectively provided at the center and outer edge of the upper surface of the first connecting part 11 of the flow plate body 10, so as to realize tooling removal and visual positioning welding.

[0070] This comparative example uses a 300A flexible overcurrent device 100 to conduct bending and charge / discharge tests at 25°C, including the following steps:

[0071] (1) Take 3 individual battery cells and weld a flexible overcurrent device 100, and measure the internal resistance of the welding point to ensure that the internal resistance is ≤0.2mΩ. Measure the internal resistance of the cable to the welding point to ensure that the internal resistance is ≤0.08mΩ.

[0072] (2) The flexible overcurrent device 100 was bent 20, 50 and 100 times respectively, and the resistance of the welding point and the input and output cables of the test equipment was measured. The test results are shown in Table 1.

[0073] (3) Place the battery cell in a constant temperature and humidity test chamber and perform a charge and discharge test;

[0074] (4) The temperature sampling points of the battery cells are connected to the test equipment through temperature data sampling lines to form a temperature data acquisition loop;

[0075] (5) The positive and negative terminals of the battery cell are connected to the test equipment through a voltage data acquisition line to form a voltage data acquisition circuit;

[0076] (6) Charge at 0.5P constant power until 3.65V cutoff;

[0077] (7) Let it stand still for 10 minutes;

[0078] (8) Discharge at 0.5P constant power until 2.5V cutoff;

[0079] (9) Let it stand still for 10 minutes;

[0080] Repeat steps (10)(7)-(9) 4 times;

[0081] According to the test results, the conventional overcurrent device in Example 1 showed varying degrees of tearing after repeated bending, and the resistance of the welding points and the input and output cables of the test equipment increased. The test results are shown in Table 1.

[0082] Table 1

[0083]

[0084] The battery was charged and discharged at a constant power (3.65V~2.5V). The ratio of the discharge energy to the charge energy is the charge-discharge energy efficiency. The higher the charge-discharge energy efficiency, the higher the energy utilization rate of the battery. Batteries using conventional overcurrent devices and flexible overcurrent devices 100 were compared according to the obtained charge-discharge energy efficiency and maximum temperature rise. The test results are shown in Table 2.

[0085] Table 2

[0086]

[0087] According to the test results, the flexible current flow device 100 provided in this application can effectively solve the tearing and contamination problems that exist after conventional current flow devices are bent multiple times, improve the stability of the test, ensure reliable test data, and reduce costs, which is conducive to improving test efficiency and product test reliability.

[0088] This application also provides a battery testing system, including the flexible current-carrying device 100 described above. Since the structure and beneficial effects of the flexible current-carrying device 100 have been described in detail in the foregoing embodiments, they will not be repeated here.

[0089] The above description is merely an optional embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

[0090] It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, this application will not describe the various possible combinations separately.

Claims

1. A flexible current-carrying device, characterized in that, The device includes a flow plate body, which comprises multiple flow plate layers stacked together. The flow plate body is divided into a first connecting portion, a second connecting portion, and a third connecting portion along its length. The first connecting portion is used to connect to a battery, the third connecting portion is used to connect to a test lead, and the surface of the second connecting portion is provided with an insulating protective layer.

2. The flexible current-carrying device according to claim 1, characterized in that, The lower surface of the first connecting part is provided with a slot, which is used to engage and fix with the terminal post of the battery.

3. The flexible current-carrying device according to claim 2, characterized in that, The shape of the slot matches the shape of the battery terminals.

4. The flexible current-carrying device according to claim 2, characterized in that, The diameter of the slot is equal to the diameter of the battery terminal.

5. The flexible current-carrying device according to claim 1, characterized in that, The upper surface of the first connecting part is divided into a welded part and a non-welded part along the center to the outer edge, and the surface roughness of the welded part and the surface roughness of the non-welded part are different.

6. The flexible current-carrying device according to claim 1, characterized in that, The third connecting part is provided with a locking hole, which is used to cooperate with a fastener to lock the test line.

7. The flexible current-carrying device according to claim 1, characterized in that, The multiple flow-through layers are cold-pressed structures.

8. The flexible current-carrying device according to claim 1, characterized in that, The material of the flow-through layer is copper or aluminum.

9. The flexible current-carrying device according to claim 1, characterized in that, The insulating protective layer is made of silicone rubber, butyl rubber, jelly glue, hot melt adhesive, or flexible epoxy resin.

10. A battery testing system, characterized in that, Includes the flexible flow device as described in any one of claims 1 to 9.

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