Diverter, battery pack and vehicle

Abstract

The utility model provides a current divider, a battery pack and a vehicle. The current divider comprises a conducting bar, a main control board and a connector, the conducting bar comprises a first surface and a second surface, and the first surface and the second surface are oppositely arranged along the thickness direction of the conducting bar; wherein a welding area is arranged on the first surface; the main control board is connected to the second surface. The connector is connected to the side, away from the conducting bar, of the main control board. According to the shunt, the welding area on the first surface is welded with the external connecting terminal, so that current transmission between the shunt and the external connecting terminal is realized, the influence caused by assembly tolerance and manufacturing tolerance can be effectively avoided, the contact internal resistance of a connecting part is reduced, and the service life of the shunt is prolonged. Meanwhile, connection between the shunt and the BMS board card is changed into direct connection through the connector, so that the connection process between the shunt and the BMS board card is simplified, the risk of electromagnetic interference is reduced, and the integration rate of components in the battery pack is improved.

Description

Technical Field

[0001] This application relates to the field of power battery technology, and in particular to a shunt, a battery pack, and a vehicle. Background Technology

[0002] A shunt is a current sensor and an important component of a battery pack. It can collect the current in the circuit during the charging and discharging process of the battery pack in real time and feed the current back to the BMS (Battery Management System) to monitor the current and ensure that the current during the charging and discharging process of the battery pack is within a safe range. This avoids abnormal situations such as overcharging, over-discharging, and short circuits, thereby helping to protect the battery and other electrical components in the battery pack.

[0003] The connection terminals of the shunt are usually made of copper busbars. The copper busbars have connection holes for fasteners such as bolts to pass through. The bolts pass through the connection holes and the connection holes on the external connection terminals to connect the copper busbars to the external connection terminals, thereby realizing the current transmission between the shunt and the external connection terminals.

[0004] However, when the copper busbar is connected to the external connection terminal by bolts, the connection part is prone to contact stress due to the influence of assembly tolerance and manufacturing tolerance, which leads to an increase in the internal resistance of the connection, and thus affects the service life of the shunt and the discharge performance of the battery pack. Utility Model Content

[0005] In view of this, this application provides a shunt, a battery pack, and a vehicle to at least solve the problem in the prior art where the connection resistance between the shunt and the external connection terminal is large, affecting the service life of the shunt.

[0006] To achieve the above objectives, the technical solution of this application is implemented as follows:

[0007] This application provides a shunt, including a conductive bus, a main control board, and a connector; the conductive bus includes a first surface and a second surface, which are disposed opposite to each other along the thickness direction of the conductive bus; wherein, a soldering area is provided on the first surface, which is adapted to be soldered to an external connection terminal; the main control board is disposed on the second surface and connected to the second surface; the connector is connected to the side of the main control board away from the conductive bus, and the connector is adapted to connect to a BMS board.

[0008] Optionally, the area of ​​the welding zone accounts for 50% to 100% of the area of ​​the first surface.

[0009] Optionally, the connector is a floating connector, which includes a mating slot adapted to connect a BMS board.

[0010] Optionally, the slot opening of the plug-in slot is perpendicular to the plane of the main control board.

[0011] Optionally, the opening of the plug slot is parallel to the plane of the main control board, and the opening of the plug slot extends at least beyond the edge of the main control board.

[0012] Optionally, the connector is welded and fixed to the main control board.

[0013] Optionally, both the first surface and the second surface are flat surfaces.

[0014] Optionally, the number of conductive bars is two, the main control board is connected to the two conductive bars respectively, and the two conductive bars are arranged symmetrically along the center of the main control board.

[0015] This application also provides a battery pack, including a BMS board and a shunt as described in any of the preceding claims, wherein the BMS board is electrically connected to the shunt.

[0016] This application also provides a vehicle including the aforementioned battery pack.

[0017] Compared to existing technologies, the shunt, battery pack, and vehicle described in this application have the following advantages:

[0018] The shunt in this application eliminates the connection holes on the conductive busbar. Instead, a welding area is provided on the first surface of the conductive busbar. Current transfer between the shunt and external connection terminals is achieved through welding to the external connection terminals via this welding area. This design effectively avoids the impact of assembly and manufacturing tolerances, reduces the contact resistance at the connection points, and thus helps extend the shunt's lifespan and improve the battery pack's discharge performance. Furthermore, this application replaces the connection between the shunt and the BMS board with a direct connector connection, eliminating the need for wiring harnesses and simplifying the connection process between the shunt and the BMS board. This helps reduce the risk of electromagnetic interference, saves costs, and improves the integration rate of internal components in the battery pack, facilitating the miniaturization of the battery pack design.

[0019] The battery pack and vehicle of this application have the same or similar advantages as the prior art and the aforementioned shunt compared to the prior art, which will not be repeated here. Attached Figure Description

[0020] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0021] Figure 1 This is one of the schematic diagrams of the splitter in the embodiments of this application;

[0022] Figure 2 This is the second schematic diagram of the splitter in the embodiments of this application;

[0023] Figure 3 This is one of the schematic diagrams showing the connection between the splitter and the BMS board in the embodiments of this application;

[0024] Figure 4 This is the second schematic diagram of the connection between the splitter and the BMS board in the embodiments of this application.

[0025] Explanation of reference numerals in the attached figures:

[0026] 1-Conductive busbar, 11-First surface, 12-Second surface, 2-Main control board, 3-Connector, 30-Plug-in slot, 4-Alloy resistor, 5-Thermistor, 6-External connection terminal, 7-BMS board. Detailed Implementation

[0027] 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, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0028] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0029] It should be understood that the phrase "some embodiments" throughout the specification means that a specific feature, structure, or characteristic related to an embodiment is included in at least one embodiment of this application. Therefore, "some embodiments" appearing throughout the specification does not necessarily refer to the same embodiment. Furthermore, these specific features, structures, or characteristics can be combined in any suitable manner in one or more embodiments.

[0030] The following detailed description of a shunt, battery pack, and vehicle provided in this application is illustrated with specific embodiments.

[0031] This application provides a current splitter, which has intersecting X, Y, and Z directions, as shown in the figure. Figure 1 and Figure 2 As shown, the X direction represents the width direction of the splitter, the Y direction represents the length direction of the splitter, and the Z direction represents the height direction of the splitter.

[0032] Figure 1 and Figure 2 Schematic diagrams of the splitter are shown below, for reference. Figure 1 and Figure 2 As shown, the shunt includes a busbar 1, a main control board 2, and a connector 3; the busbar 1 includes a first surface 11 and a second surface 12, which are arranged opposite to each other along the thickness direction of the busbar 1; wherein, the first surface 11 is provided with a soldering area, which is suitable for soldering to an external connection terminal 6; the main control board 2 is disposed on the second surface 12 and connected to the second surface 12; the connector 3 is connected to the side of the main control board 2 away from the busbar 1, and the connector 3 is suitable for connecting to a BMS board 7.

[0033] In this embodiment, the main function of the busbar 1 in the shunt is to carry and transmit current, guiding the current during the charging and discharging process of the battery pack to the shunt for measurement. It also ensures the stability and reliability of current transmission, reduces resistance and heat generation, and guarantees that the shunt can accurately measure the current. The busbar 1 can be made of copper or aluminum. Copper has high electrical and thermal conductivity, low resistance, and can effectively reduce energy loss and heat generation during transmission. Aluminum has low density and light weight, effectively reducing the overall weight of the shunt, and is also less expensive and has better machinability. In some embodiments, the busbar 1 can also be made of composite materials such as copper-clad aluminum or tin-plated copper. Copper-clad aluminum uses aluminum as the core and is covered with copper on the outside, combining the high conductivity of copper with the advantages of aluminum's light weight and low cost. Tin-plated copper involves plating a layer of tin on the surface of the copper busbar, which improves its corrosion resistance and oxidation resistance. In practical applications, the type of busbar 1 can be flexibly selected according to requirements, and this embodiment does not impose any limitations on this.

[0034] The conductive bus 1 includes a first surface 11 and a second surface 12, which are disposed opposite to each other along the thickness direction of the conductive bus 1, as shown in the figure. Figure 1 and Figure 2As shown in the Z direction, generally speaking, the first surface 11 serves as the lower surface of the conductive bus 1, and the second surface 12 serves as the upper surface of the conductive bus 1. The first surface 11 has a welding area, which can be a portion of the first surface 11 through which it is welded to the external connection terminal 6. Alternatively, the entire first surface 11 can be designated as a welding area, allowing the entire first surface 11 to be welded to the external connection terminal 6. Laser welding can be used, as it offers high welding speed, high energy density, a small heat-affected zone, and minimal welding deformation, resulting in high-quality welds and enabling high-precision welding between the conductive bus 1 and the external connection terminal 6.

[0035] In addition, the external connection terminal 6 in the above embodiment is a conductive component in other electrical equipment, mainly used to carry and transmit current. The external connection terminal 6 can also be made of copper busbar, aluminum busbar, copper-clad aluminum busbar or tin-plated copper busbar, etc. The conductive busbar 1 is welded to the external connection terminal 6 through the welding area to realize the electrical connection between the conductive busbar 1 and the external connection terminal 6, thereby realizing the electrical connection between the shunt and other electrical equipment.

[0036] In the battery pack, external connection terminal 6 can be the positive and negative terminals of the battery pack. The conductor 1 in the shunt is soldered to the positive and negative terminals of the battery pack to collect the current signal output by the battery pack, thereby enabling monitoring and management of the battery pack status. Alternatively, external connection terminal 6 can also be a relay terminal. The conductor 1 in the shunt is soldered to the relay terminal, allowing real-time monitoring of the input or output current when the relay is activated, thus protecting the circuit and equipment. Alternatively, external connection terminal 6 can also be a connector terminal. The connector is the interface between the BDU (Battery Disconnect Unit) module in the battery pack and the external circuit. The conductor 1 in the shunt is soldered to the connector terminal, allowing the measured current signal to be transmitted to the external circuit, enabling monitoring and control of the battery pack current.

[0037] In existing technologies, the conductive busbar 1 of a shunt typically has connecting holes for fasteners such as bolts and screws to pass through. These fasteners pass through these connecting holes and matching connecting holes on the external connecting terminal 6, connecting the conductive busbar 1 to the external connecting terminal 6, thus enabling current transmission between the shunt and the external connecting terminal 6. However, with this connection method, contact stress is easily generated at the connection points due to assembly and manufacturing tolerances, leading to increased internal resistance and affecting the shunt's lifespan and the battery pack's discharge performance. The shunt in this application eliminates the connecting hole design on the conductive busbar 1. Instead, a welding area is provided on the first surface 11 of the conductive busbar 1. Current transmission between the shunt and the external connecting terminal 6 is achieved through welding to this welding area. This design effectively avoids the influence of assembly and manufacturing tolerances, reduces the contact resistance at the connection points, and thus helps extend the shunt's lifespan and improve the battery pack's discharge performance. Furthermore, it facilitates automated production of the shunt, improving production efficiency and reducing costs. In addition, the shunt eliminates the connection hole design on the conductor bus 1, which helps maintain the structural integrity of the conductor bus 1, improves the strength and rigidity of the conductor bus 1, and thus improves the situation of the conductor bus 1 being twisted and deformed.

[0038] In this embodiment, the main control board 2 is a PCB (Printed Circuit Board). The main control board 2 is equipped with integrated circuits, as well as electronic components such as resistors, capacitors, analog-to-digital converters, and differential amplifiers. As the core component of the shunt, the main control board 2 mainly plays the roles of signal acquisition, conditioning, transmission, and system protection.

[0039] The main control board 2 is located on and connected to the second surface 12 of the conductive busbar 1, allowing it to obtain current signals from the external connection terminal 6 via the conductive busbar 1. Alternatively, the main control board 2 and the second surface 12 can be connected by laser welding to ensure reliable connection and thus guarantee the normal operation of the shunt. A connector 3 is connected to the side of the main control board 2 facing away from the conductive busbar 1. The connector 3 is suitable for connecting to the BMS board 7, the core circuit board of the BMS system. The main control board 2, connected to the BMS board 7 via connector 3, converts the collected current into a voltage signal and feeds it back to the BMS board 7. The BMS board 7 accurately calculates the real-time current value during the battery pack's charging and discharging process based on this voltage signal, enabling current monitoring. When the battery pack's output current exceeds a safety threshold, the signal transmitted from the shunt to the BMS board 7 triggers its protection mechanism. The BMS board 7 then controls relevant relays to cut off the circuit, preventing damage to the battery pack and other equipment due to overcurrent, thus ensuring the safe operation of the battery pack and the entire system.

[0040] In existing technologies, the connection between the shunt and the BMS board 7 typically uses a wire harness. This connection method is susceptible to interference from external signals and usually requires special wiring arrangements, which is not conducive to simplified design. This application replaces the connection between the shunt and the BMS board 7 with a direct connection using connector 3, eliminating the need for a wire harness, simplifying the connection process between the shunt and the BMS board 7, helping to reduce the risk of electromagnetic interference, save costs, and simultaneously improve the integration rate of components within the battery pack, facilitating the miniaturization of the battery pack design.

[0041] Optionally, in some embodiments of the application, the area of ​​the welding area accounts for 50% to 100% of the area of ​​the first surface 11. For example, the proportion of the area of ​​the welding area to the area of ​​the first surface 11 is 60%, 70%, 80%, 90%, etc. Within the above proportion range, the welding reliability between the conductive bus 1 and the external connection terminal 6 can be guaranteed, and the risk of open circuit caused by unreliable welding can be reduced. At the same time, the larger the proportion of the area of ​​the welding area to the area of ​​the first surface 11, the more it helps to ensure the welding reliability between the conductive bus 1 and the external connection terminal 6.

[0042] Optionally, refer to Figure 1 and Figure 2 As shown, in some embodiments of the application, connector 3 is a floating connector, which includes a insertion slot 30 adapted to connect the BMS board 7. In actual connection, the BMS board 7 has insertion terminals that mate with the insertion slot 30. The insertion terminals are directly inserted into the insertion slot 30 to achieve electrical connection between the main control board 2 and the BMS board 7. Floating connectors typically introduce a certain floating space between the socket and the pin, allowing the two ends of the connection to float slightly within a certain range. Its floating terminal design can absorb and correct tolerances in different axial directions to minimize alignment errors and maintain good electrical contact. The shunt in this application uses a floating connector to connect the BMS board 7, which can effectively absorb tolerances, prevent excessive relative movement between the shunt and the BMS board 7 from causing connection failure, and improve the reliability of electrical connections between components.

[0043] In addition, in the actual production process of the battery pack, the conductive busbar 1 in the shunt is usually first soldered to the external connection terminal 6, and then the plug-in terminal on the BMS board 7 is inserted into the plug-in slot 30 on the floating connector to realize the electrical connection between the main control board 2 of the shunt and the BMS board 7.

[0044] Optionally, refer to Figure 1 As shown, in some embodiments of the application, the slot 30 of the floating connector is oriented perpendicular to the plane of the main control board 2. Figure 1In the shunt shown, the slot 30 of the floating connector is oriented in the same direction as the Z-direction, which is perpendicular to the plane of the main control board 2. After the connector terminals on the BMS board 7 are inserted into the slot 30, the BMS board 7 and the main control board 2 are parallel to each other, as shown in the diagram. Figure 3 As shown.

[0045] Optionally, refer to Figure 2 As shown, in some embodiments of the application, the slot 30 of the floating connector is oriented parallel to the plane of the main control board 2. Figure 2 In the shunt shown, the slot 30 of the floating connector faces the same direction as the X direction, which is parallel to the plane of the main control board 2. After the connector terminals on the BMS board 7 are inserted into the slot 30, the BMS board 7 and the main control board 2 are perpendicular to each other, as shown in the diagram. Figure 4 As shown.

[0046] In this embodiment, the slot opening of the connector 30 extends at least beyond the edge of the main control board 2. For example, the slot opening of the connector 30 can extend beyond the edge of the main control board 2 by approximately 10mm to 100mm. This arrangement prevents interference between the BMS board 7 and the main control board 2, the busbar 1, or the external connection terminal 6 during the insertion of the connector terminals on the BMS board 7 into the connector 30, ensuring smooth insertion. However, the extension of the slot opening of the connector 30 beyond the edge of the main control board 2 should not be too large to avoid wasting space and hindering integrated design between components. In practical applications, the extension of the slot opening of the connector 30 beyond the edge of the main control board 2 can be flexibly set; this embodiment does not impose any limitations on this.

[0047] In practical applications, the orientation of the floating connector slot can be adapted to the structure within the battery pack to facilitate the connection between the main control board 2 on the shunt and the BMS board 7. Furthermore, it should be noted that the "perpendicularity" in the above embodiments includes not only absolute perpendicularity but also generally understood approximately perpendicularity, such as when the angle between the slot orientation of the connector 30 and the plane of the main control board 2 is 89° to 91°, it is considered perpendicular to the plane of the main control board 2. Similarly, the "parallelism" in the above embodiments also includes not only absolute parallelism but also generally understood approximately parallelism, such as when the angle between the slot orientation of the connector 30 and the plane of the main control board 2 is -1° to 1°, it is considered parallel to the plane of the main control board 2.

[0048] Optionally, in some embodiments of the application, the connector 3 is soldered to the main control board 2. Regardless of whether the connector 3 is a floating connector or another type of connector, it can be fixed to the main control board 2 by soldering. The soldering can employ a reflow soldering process, which utilizes the heating system within a reflow oven to allow the solder paste pre-printed on the pads of the main control board 2 to undergo preheating, melting, and wetting stages, forming a metallurgical bond between the pins of the connector 3 and the pads of the main control board 2. This achieves the electrical and mechanical connection between the connector 3 and the main control board 2, offering advantages such as reliable connection and high stability.

[0049] Optionally, in some embodiments of the application, both the first surface 11 and the second surface 12 are flat surfaces. Specifically, a flat surface means that no through holes, blind holes, or grooves are formed on the first surface 11 and the second surface 12. That is, the shunt eliminates the design of connection holes on the conductive busbar 1, which helps to maintain the structural integrity of the conductive busbar 1, improves the strength and rigidity of the conductive busbar, and thus improves the situation of the conductive busbar being twisted and deformed.

[0050] Optionally, refer to Figure 1 and Figure 2 As shown, in some embodiments of the application, the number of conductive busbars 1 is two, and the main control board 2 is connected to the two conductive busbars 1 respectively, and the two conductive busbars 1 are symmetrically arranged along the center of the main control board 2. Figure 1 and Figure 2 In the shunt shown, the two conductor bars 1 are symmetrically arranged about the center line of the main control board 2 along the X direction. The current flows in opposite directions on the two symmetrically arranged conductor bars 1, which helps to reduce the impact of electromagnetic interference on current detection; it also helps to achieve current balance and improve the current measurement accuracy of the shunt; it also helps to achieve uniform heat dissipation of the main control board 2 and conductor bars 1, improving the working performance of the shunt; and it also helps to achieve stress balance and improve the structural stability of the shunt.

[0051] Furthermore, the shunt in this embodiment also includes an alloy resistor 4 and a thermistor 5. The alloy resistor 4 is disposed between the two conductive bars 1 and connected to the surface of the main control board 2 near the conductive bars 1. When the shunt is working, the main control board 2 collects the voltage across the alloy resistor 4 and divides it by the internal resistance of the alloy resistor 4 to obtain the current flowing through the shunt. However, since the internal resistance of the alloy resistor 4 changes at different temperatures, a thermistor 5 is also provided on the surface of the main control board 2 away from the conductive bars 1 to collect the temperature of the alloy resistor 4, and then converts it into the actual internal resistance of the alloy resistor 4 through the temperature coefficient, ensuring the accuracy of the shunt's current detection.

[0052] This application also provides a battery pack, which includes a BMS board 7 and a shunt from any of the foregoing embodiments. The BMS board 7 is electrically connected to the shunt. Specifically, the BMS board 7 is connected to the main control board 2 in the shunt via a floating connector. Because the shunt eliminates the connection holes on the conductive busbar 1 and instead directly solders the conductive busbar 1 to the external connection terminal 6, it helps to extend the service life of the shunt and improve the discharge performance of the battery pack.

[0053] This application also provides a vehicle including the battery pack of the aforementioned embodiments, wherein the vehicle can be a pure electric vehicle, a hybrid vehicle, a range-extended vehicle, etc.

[0054] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0055] The above description is merely a preferred embodiment of this application and is not intended to limit this application. 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.

Claims

1. A flow diverter, characterized by, It includes a busbar (1), a main control board (2), and a connector (3); The conductive bus (1) includes a first surface (11) and a second surface (12), and the first surface (11) and the second surface (12) are arranged opposite to each other along the thickness direction of the conductive bus (1); The first surface (11) is provided with a welding area, which is suitable for welding with an external connection terminal (6); The main control board (2) is disposed on the second surface (12) and connected to the second surface (12); The connector (3) is connected to the side of the main control board (2) away from the conductive bar (1), and the connector (3) is adapted to connect to the BMS board (7).

2. The shunt of claim 1, wherein, The area of ​​the welding zone accounts for 50% to 100% of the area of ​​the first surface (11).

3. The shunt according to claim 1 or 2, characterized in that The connector (3) is a floating connector, which includes a plug slot (30) adapted to connect a BMS board (7).

4. The shunt of claim 3, wherein, The slot of the plug-in slot (30) is perpendicular to the plane of the main control board (2).

5. The shunt of claim 3, wherein, The slot of the plug-in slot (30) is parallel to the plane of the main control board (2), and the slot of the plug-in slot (30) extends at least beyond the edge of the main control board (2).

6. The shunt according to any one of claims 1 to 5, characterized in that The connector (3) is welded and fixed to the main control board (2).

7. The shunt according to any one of claims 1 to 6, wherein, Both the first surface (11) and the second surface (12) are flat surfaces.

8. The shunt according to any one of claims 1 to 7, characterized in that The number of conductive busbars (1) is two, and the main control board (2) is connected to the two conductive busbars (1) respectively, and the two conductive busbars (1) are arranged symmetrically along the center of the main control board (2).

9. A battery pack, characterized by, It includes a BMS board (7) and a shunt as described in any one of claims 1 to 8, wherein the BMS board (7) is electrically connected to the shunt.

10. A vehicle characterized by comprising: Includes the battery pack as described in claim 9.

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