Electrode body, electrical connection assembly and heater for a vehicle

Abstract

The application relates to the technical field of electric connection structures, in particular to an electrode body, an electric connection assembly and a heater of a vehicle. The electrode body comprises a contact terminal and a conductive sheet, the contact terminal comprises a first connecting section, a second connecting section and a limiting part. The conductive sheet comprises a first conductive section and a second conductive section, the first conductive section is curled and wrapped on the multi-side surface of the first connecting section to limit the displacement of the first connecting section in the first direction, and the limiting part is used for limiting the displacement of the first conductive section in the second direction. Through the structure that the first conductive section is curled and wrapped on the multi-side surface of the first connecting section, the contact area of the two is effectively increased to reduce the contact resistance, and the stable transmission of the current is facilitated. Moreover, the double displacement limiting structure is adopted, so that the electrode body does not need additional welding, the assembly process is simplified, and the influence of high temperature welding on the mechanical properties and electrical properties of the metal material is avoided.

Description

Technical Field

[0001] This application relates to the field of electrical connection structure technology, and in particular to an electrode body, an electrical connection assembly, and a heater for a vehicle. Background Technology

[0002] In a vehicle's thermal management system, the core function of the electrical connection assembly is to efficiently and reliably introduce the high current from the vehicle's battery system into the heating system and distribute it evenly and with low loss to multiple internal heat-generating elements. Simultaneously, the electrical connection assembly provides these heat-generating elements with a robust physical mounting platform and low-impedance electrical connection points, ensuring the stability and reliability of high-current transmission.

[0003] Electrical connection components generally consist of several electrode bodies. In related technologies, the conductive plates in the electrode bodies and the contact terminals are usually electrically connected by welding. However, this will have an adverse effect on the mechanical and electrical properties of the heater, including the electrode bodies, during actual use. Utility Model Content

[0004] Based on this, it is necessary to provide an electrode body, an electrical connection assembly, and a vehicle heater that are beneficial to improving mechanical and electrical performance, addressing at least one of the above-mentioned technical problems.

[0005] In a first aspect, embodiments of this application provide an electrode body comprising:

[0006] The contact terminal includes a first connecting section, a second connecting section, and a limiting part;

[0007] Conductive sheet.

[0008] The conductive sheet includes a first conductive segment and a second conductive segment, which are connected to each other. The first conductive segment is curled and covers multiple surfaces of the first connecting segment to restrict the displacement of the first connecting segment in a first direction. The limiting part is used to restrict the displacement of the first conductive segment in a second direction. The first direction is perpendicular to the second direction, and the second direction is the direction from the first connecting segment to the second connecting segment.

[0009] In some embodiments, the first conductive segment and the first connecting segment are crimped together and not welded.

[0010] In some embodiments, the first conductive segment and the first connecting segment are cold-pressed together, such that the first conductive segment curls up and covers multiple sides of the first connecting segment, and such that the connecting area does not generate an oxide layer due to the temperature effect of the connecting method.

[0011] In some embodiments, the first conductive segment includes a first curled portion and a second curled portion that are curled in opposite directions, and there is a gap between the opposing sides of the first curled portion and the second curled portion.

[0012] In some embodiments, the conductive sheet further includes a transition section with a first end connected to a first conductive segment and a second end connected to a second conductive segment;

[0013] The surface of the transition section includes a first side surface and a second side surface located on opposite sides of the transition section and extending from the first end to the second end of the transition section;

[0014] The first and second side curved surfaces are twisted planes;

[0015] The inner edge of the first side surface and the inner edge of the second side surface extend from the contact point with the outer edge of the first surface of the second conductive segment to the contact point with the inner surface of the first conductive segment.

[0016] The outer edges of the first side surface and the second side surface extend from the contact point with the outer edge of the second surface of the second conductive segment to the contact point with the outer surface of the first conductive segment.

[0017] In some embodiments, the first connecting segment and / or the second connecting segment are cylindrical;

[0018] The limiting part is an annular protrusion, and / or the limiting part is located at the connection between the first connecting section and the second connecting section.

[0019] In some embodiments, the second conductive segment is flat;

[0020] The electrode body also includes a positioning body that protrudes or penetrates the flat surface of the second conductive segment;

[0021] The positioning element is made of insulating material and is used to provide positioning and protection when an insulating shell is applied to the electrode body.

[0022] In some embodiments, the second conductive segment includes a first conductive portion and a second conductive portion connected together;

[0023] The first end of the first conductive part is connected to the first conductive segment, and the second end is connected to the first end of the second conductive part.

[0024] The extension direction of the first end of the second conductive portion intersects the extension direction of the second end of the first conductive portion.

[0025] In some embodiments, the contact terminal is integrally formed, and / or the conductive sheet is integrally formed.

[0026] In a second aspect, embodiments of this application provide an electrical connection assembly comprising:

[0027] Several electrode bodies provided in any embodiment of the first aspect of this application;

[0028] An insulating shell that at least covers the first connecting section, the limiting part, and the first conductive section of the electrode body.

[0029] In some embodiments, the insulating housing is bonded to the electrode body via an injection molding process.

[0030] In some embodiments, the insulating shell is bonded to the electrode body by injection molding, and no holes pointing to the conductive sheet are formed on the side surface of the insulating shell.

[0031] In some embodiments, the insulating housing includes a mounting hole and a metal bushing located in the mounting hole.

[0032] The metal bushing includes an opening slit, with matching, arc-shaped protrusions and recesses on opposite sides of the opening slit; and / or, the metal bushing includes an annular body and a protrusion on the outer side of the end of the annular body to improve overall strength, the protrusion including a first outer surface and a second outer surface, the first outer surface being perpendicular to the second outer surface, and the protrusion and the opening slit being located on opposite sides.

[0033] In a third aspect, embodiments of this application provide a heater for a vehicle, the vehicle heater comprising:

[0034] The electrical connection component provided in any embodiment of the second aspect of this application;

[0035] A control circuit board electrically connected to the second connection segment of the electrical connection assembly;

[0036] A heating plate electrically connected to the second conductive segment of an electrical connection assembly.

[0037] In the embodiments provided in this application, the electrode body includes contact terminals and conductive sheets. The contact terminals include a first connecting segment, a second connecting segment, and a limiting portion. The conductive sheet includes a first conductive segment and a second conductive segment. The first conductive segment is curled and covers multiple surfaces of the first connecting segment to limit the displacement of the first connecting segment in a first direction. The limiting portion is used to limit the displacement of the first conductive segment in a second direction. By curling and covering multiple surfaces of the first connecting segment with the first conductive segment, the contact area between the two is effectively increased to reduce contact resistance, while also facilitating stable current transmission for high-current applications. Moreover, the dual displacement limiting structure facilitates electrode body assembly and improves the mechanical and electrical properties of the electrode body and even the heater using the electrode body. Furthermore, the mating method between the contact terminals and the first conductive segment is highly compatible, making it suitable for different application scenarios. Attached Figure Description

[0038] Figure 1 These are schematic diagrams of the electrode body in some embodiments;

[0039] Figure 2 This is a schematic diagram of the electrode body from another perspective in some embodiments;

[0040] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0041] Figure 4 This is a schematic diagram of the structure of the electrical connection assembly in some embodiments;

[0042] Figure 5 This is a schematic diagram of the structure of the metal bushing in some embodiments.

[0043] Explanation of reference numerals in the attached drawings: 10-Electrode body; 100-Contact terminal; 110-First connecting section; 120-Second connecting section; 130-Limiting part; 200-Conductive sheet; 210-First conductive section; 211-First curled part; 212-Second curled part; 213-Gap; 220-Second conductive section; 221-First conductive part; 222-Second conductive part; 230-Transition section; 231-First side curved surface; 232-Second side curved surface; 300-Positioning body; 400-Insulating shell; 410-Mounting hole; 420-Metal bushing; 421-Opening gap; 422-Protrusion; 423-Recess; 424-Protrusion; 425-First outer surface; 426-Second outer surface; 430-Positioning post; 440-Side surface of insulating shell. Detailed Implementation

[0044] To make the technical solutions and advantages of this application clearer, the embodiments and related technical content of this application will be further described in detail below with reference to the accompanying drawings and text description. It should be understood that the embodiments described below are only used to explain the technical solutions of the embodiments of this application and are not intended to limit more possible implementations of this application.

[0045] It should be noted that relational terms such as "first" and "second" appearing in this document are used only to distinguish things, states, or actions, and do not necessarily indicate or imply relative importance or order. The terms "including," "comprising," or any other variations thereof are used to indicate non-exclusive inclusion, and the included objects may not be limited to those listed in this document. The terms "multiple" or other variations are used to indicate that the number of objects is two or more.

[0046] This application provides an electrode body 10, which is generally used in heaters, particularly in vehicle (e.g., automobile) heaters. A heater generally refers to an electrical device that transmits current output from a circuit board to a heating plate via the electrode body 10, causing the heating plate to generate heat through electrical heating. Of course, the electrode body 10 can also be applied to other types of electronic devices or electrical systems to achieve electrical connections and signal / current transmission between electrical components; therefore, no particular limitation is placed on the specific application scenarios of the electrode body 10.

[0047] In the first aspect, such as Figures 1 to 3As shown, the electrode body 10 provided in the embodiments of this application mainly includes a contact terminal 100 and a conductive sheet 200. The contact terminal 100 may include a first connecting segment 110, a second connecting segment 120, and a limiting portion 130. The conductive sheet 200 may include a first conductive segment 210 and a second conductive segment 220, with the first conductive segment 210 connected to the second conductive segment 220. The first conductive segment 210 is curled and covers multiple surfaces of the first connecting segment 110 to limit the displacement of the first connecting segment 110 in a first direction. The limiting portion 130 is used to limit the displacement of the first conductive segment 210 in a second direction. The first direction is perpendicular to the second direction, and the second direction is the direction from the first connecting segment 110 to the second connecting segment 120.

[0048] The electrode body 10 mainly consists of two parts: a contact terminal 100 and a conductive sheet 200. The contact terminal 100 is the carrier for current or signal transmission and is typically made of metals with excellent conductivity, such as copper or copper alloys; other materials can also be used. The first connecting section 110 of the contact terminal 100 is directly connected to the conductive sheet 200, while the second connecting section 120 is used for connection to external components (such as circuit boards or loads). The limiting part 130 can be a continuous or discontinuous annular or non-annular object disposed on the contact terminal 100, including but not limited to structures such as protrusions or steps, to limit displacement. Optionally, the limiting part 130 can also be the sidewall of a groove or hole capable of limiting movement.

[0049] The conductive sheet 200 can be made of a metal material with good ductility and conductivity, such as copper or aluminum; of course, other materials can also be used. The first conductive segment 210 can be the part that mates with the first connecting segment 110 of the contact terminal 100, and the second conductive segment 220 can be the part used to establish an electrical connection with other electrical components.

[0050] The first conductive segment 210 may be a curved or multifaceted structure formed by bending to fit the shape of the first connecting segment 110, thereby wrapping multiple sides of the first connecting segment 110. For example, in some possible examples, the first conductive segment 210 may wrap most of the circumferential area of ​​the cylindrical first connecting segment 110. In some possible examples, the first conductive segment 210 may wrap the rectangular faces of the ends of the square first connecting segment 110. Of course, in some possible examples, the cross-section of the sides of the first connecting segment 110 may also have other regular or irregular shapes, and the first conductive segment 210 may be matched to these shapes for wrapping.

[0051] The aforementioned encapsulation connection method can limit the displacement of the first connecting segment 110 in the first direction through the frictional force and structural constraints between the first conductive segment 210 and the first connecting segment 110, such as... Figure 1As shown, the first direction is any direction within the plane formed by the X-axis and Y-axis.

[0052] The second direction can be the direction from the first connecting segment 110 to the second connecting segment 120. In some cases, the second direction can be the direction in which the first connecting segment 110 extends towards the second connecting segment 120, for example... Figure 1 The direction shown is parallel to the Z-axis, extending from the first connecting segment 110 to the second connecting segment 120. In some cases, the second direction can also be understood as... Figure 1 The first connecting segment 110, parallel to the Z-axis, points towards the second connecting segment 120. In some cases, the limiting part 130 is used to restrict the first conductive segment 210 from moving closer to the second connecting segment 120 (e.g., by sliding displacement), and the direction in which this tendency to move closer can also be understood as the second direction.

[0053] In some cases, the limiting portion 130 abuts against the end face of the first conductive segment 210 to prevent the first conductive segment 210 from sliding in the second direction, thereby ensuring a stable connection between the contact terminal 100 and the conductive sheet 200 and preventing relative displacement caused by external forces such as vibration and impact, which would affect the stability of the electrical connection. Understandably, the limiting portion 130 can typically abut against the end face of one end of the first conductive segment 210; however, in other examples, the limiting portion 130 can also abut against the end faces of both ends of the first conductive segment 210.

[0054] The structure of the first conductive segment 210 curling and covering multiple surfaces of the first connecting segment 110 effectively increases the contact area between the two, thereby reducing contact resistance and facilitating stable current transmission, making it suitable for high-current applications. Furthermore, the dual displacement limiting structure facilitates the assembly of the electrode body 10, improving the mechanical and electrical properties of the electrode body 10 and even the heaters using it. In addition, the mating method between the contact terminal 100 and the first conductive segment 210 is highly compatible, making it suitable for various application scenarios.

[0055] In some embodiments, such as Figure 2 As shown, the first conductive segment 210 and the first connecting segment 110 are crimped together and not welded.

[0056] In some embodiments, the first conductive segment 210 and the first connecting segment 110 are cold-pressed together, so that the first conductive segment 210 is rolled up and covered on multiple sides of the surface, and so that the connecting area does not generate an oxide layer due to the temperature effect of the connecting method.

[0057] Crimping refers to the process of using external pressure to tightly fit the first conductive section 210 and the first connecting section 110 to form a mechanical and electrical connection. Unlike welding (which achieves connection by melting metal at high temperature), crimping can achieve a tight fit without high temperature, relying solely on the plastic deformation of the metal.

[0058] Cold pressing is a specific form of crimping, in which the first conductive segment 210 is rolled and wrapped around the surface of the first connecting segment 110 using a crimping die, forming an interference fit or a transition fit. Typically, the effective connection surface of a cold-pressed connection can cover the entire wrapped area. It is important to emphasize that the inventors recognized that the rolled-up, wrapped structure formed by cold pressing is particularly suitable for the electrode body 10 of a vehicle heater, or for applications with similar operating conditions or process requirements.

[0059] The core advantage of not using welding lies in avoiding the impact of high welding temperatures on the metal material. At high temperatures, metals easily react with oxygen in the air to form an oxide layer. The resistivity of this oxide layer may be higher than the material used in the connecting terminal or conductive sheet 200. Furthermore, welding leaves solder or auxiliary materials on or near the contact surface, which can cause the contact resistance between the contact terminal 100 and the conductive sheet 200 to differ significantly from the corresponding process standards or expected performance. Cold pressing connections help avoid the formation of oxide layers caused by high-temperature welding. Simultaneously, cold pressing achieves a tight fit through metal plastic deformation, resulting in high connection strength. The metal microstructure in the connection area remains unchanged due to high temperatures, avoiding the metal embrittlement problems that can occur with welding and improving the mechanical stability of the connection. Moreover, compared to welding connections which require welding materials, cold pressing connections help save costs.

[0060] In some cases, especially in harsh environments, the first conductive segment 210 and the first connecting segment 110 are connected by cold pressing, which can maintain high connection stability even at high temperatures. In contrast, methods such as welding can lead to instability due to the melting or detachment of solder or auxiliary materials.

[0061] In some embodiments, such as Figure 2 and Figure 3 As shown, the first conductive segment 210 includes a first curled portion 211 and a second curled portion 212 that are curled in opposite directions, and there is a gap 213 on the side of the first curled portion 211 and the second curled portion 212 that are facing each other.

[0062] The first curled portion 211 and the second curled portion 212 can be two independent curled parts of the first conductive segment 210, which can be curled circumferentially along the first connecting segment 110 by a crimping process to form a basically symmetrical structure similar to a "C". Optionally, the first curled portion 211 and the second curled portion 212 can also be an asymmetrical structure. The first conductive segment 210 has a gap 213, which is formed between the side edges of the first curled portion 211 and the second curled portion 212 near each other. This gap 213 is not a processing error, but a structural space designed in place. Even in some processing cases where the first curled portion 211 and the second curled portion 212 are in close contact, the narrow gap formed by the close contact can still be regarded as the gap 213.

[0063] First, the gap 213 provides tolerance for the assembly of the first connecting segment 110. The diameter or size of the first connecting segment 110 may have slight tolerances; the gap 213 avoids assembly difficulties caused by dimensional deviations and facilitates the smooth coverage of the first coiled portion 211 and the second coiled portion 212 with the first connecting segment 110. Second, the gap 213 provides space for thermal expansion and contraction due to temperature changes. Under certain operating conditions, the electrode body 10 may expand due to heat generated by the current during operation. This expansion generates internal stress, which may cause deformation of the first coiled portion 211 and the second coiled portion 212, or damage to the first connecting segment 110 due to pressure. The gap 213 helps absorb the expansion and release internal stress.

[0064] In some embodiments, such as Figure 2 and Figure 3 As shown, the conductive sheet 200 may include a transition section 230 with a first end connected to the first conductive segment 210 and a second end connected to the second conductive segment 220. The transition section 230 is the intermediate region on the conductive sheet 200 connecting the first conductive segment 210 and the second conductive segment 220. It can be integrally formed with the first conductive segment 210 and the second conductive segment 220 and made of the same material. Its main function is to achieve a smooth transition between the first conductive segment 210 and the second conductive segment 220 in different directions or with different shapes.

[0065] In some embodiments, the surface of the transition segment 230 may include a first side surface 231 and a second side surface 232 disposed on opposite sides of the transition segment 230 and extending from a first end to a second end of the transition segment 230. The first side surface 231 and the second side surface 232 are twisted planes. The inner edges of the first side surface 231 and the second side surface 232 extend from their contact points with the outer edge of the first surface of the second conductive segment 220 to their contact points with the inner surface of the first conductive segment 210. The outer edges of the first side surface 231 and the second side surface 232 extend from their contact points with the outer edge of the second surface of the second conductive segment 220 to their contact points with the outer surface of the first conductive segment 210.

[0066] The first side surface 231 and the second side surface 232 are the surfaces on opposite sides of the transition section 230. There is a certain twist angle between the two surfaces. This twist is to adapt to the spatial angle difference between the first conductive section 210 (curled shape) and the second conductive section 220 (usually flat shape).

[0067] The inner edge of the first side curved surface 231 can extend from the outer edge of the first surface of the second conductive segment 220 to the inner side of the first curled portion 211 and the second curled portion 212. The outer edge of the first side curved surface 231 can extend from the outer edge of the second surface of the second conductive segment 220 to the outer side of the first curled portion 211 and the second curled portion 212, forming a complete curved surface transition. This edge extension method is beneficial because the connection between the transition segment 230 and the first conductive segment 210 and the second conductive segment 220 is free of obvious steps or gaps, and the current can flow along the material defined by the curved surface, which helps to avoid abrupt changes in electrical characteristics at the connection. At the same time, the design of the tortuous plane makes the stress distribution of the transition segment 230 more uniform, avoiding stress concentration caused by abrupt changes in direction.

[0068] In some embodiments, such as Figure 1 and Figure 2 As shown, the first connecting segment 110 and the second connecting segment 120 are cylindrical. The cylindrical shape of the first connecting segment 110 and the second connecting segment 120 facilitates the circumferential coverage of the first conductive segment 210, resulting in a larger contact area and lower contact resistance, thus making current transmission more stable. Simultaneously, the cylindrical structure has a mature manufacturing process, high production efficiency, and low cost. The uniform circumferential shape of the cylindrical structure facilitates the circumferential coverage of most of the first conductive segment 210. Compared to a square structure, the coverage stress is more uniform, avoiding excessive local stress that could cause the conductive sheet 200 to crack.

[0069] Of course, in some other examples, the first connecting segment 110 or the second connecting segment 120 may take other shapes, or only the first connecting segment 110 or only the second connecting segment 120 may be cylindrical, without any particular limitation.

[0070] In some embodiments, such as Figure 1 As shown, the limiting portion 130 is an annular protrusion. Of course, in some other examples, the limiting portion 130 may take other shapes or structures.

[0071] In some embodiments, such as Figure 1 and Figure 2 As shown, the limiting part 130 is provided at the connection between the first connecting segment 110 and the second connecting segment 120. Of course, in some other examples, the limiting part 130 may take other shapes or structures.

[0072] The limiting portion 130 is an annular protrusion, meaning it can be a ring-shaped structure surrounding the outer periphery of the contact terminal 100. The limiting portion 130 can be integrally formed with other parts of the contact terminal 100 using processes such as turning, stamping, or forging, and is made of the same material. The circumferential continuity of the annular protrusion facilitates a more uniform limiting effect on the first conductive segment 210, avoiding localized limiting failure. The limiting portion 130 is located at the transition position between the first connecting segment 110 and the second connecting segment 120, forming a stepped structure. When the first conductive segment 210 covers the first connecting segment 110, its end face directly abuts against the annular protrusion, thereby limiting the displacement of the first conductive segment 210 along the axial direction of the contact terminal 100.

[0073] The annular protrusion serves as a limiting part 130, providing uniform circumferential limiting. In some cases, it offers higher limiting reliability compared to localized protrusions (such as two symmetrical protrusions). Furthermore, the limiting part 130 is located at the connection between the first connecting segment and the second connecting segment 120, ensuring precise positioning and being integrally formed with both segments, preventing the limiting part 130 from detaching and failing. In addition, the cylindrical second connecting segment 120 facilitates mating with external components (such as the circular aperture of a circuit board), making insertion, removal, or soldering more convenient and offering strong adaptability.

[0074] In some embodiments, such as Figure 1 As shown, the second conductive segment 220 is flat. Correspondingly, the electrode body 10 may also include a positioning body 300 protruding from or penetrating the flat surface of the second conductive segment 220. The positioning body 300 is made of insulating material and is used to provide positioning and protection when an insulating shell 400 is applied to the electrode body 10.

[0075] The second conductive segment 220 can be a thin sheet structure. Its flat design facilitates bonding with external flat components (such as the conductive contacts of a heating plate), increasing the contact area and also facilitating the installation of the positioning body 300. The positioning body 300 is a raised or columnar structure made of insulating material. Optionally, the positioning body 300 can be fixed to the surface of the second conductive segment 220 by injection molding, bonding, or by passing through mounting holes 410 in the second conductive segment 220. For example, the cross-section of the positioning body 300 can be cylindrical or square.

[0076] In related technologies, during the injection molding of the insulating shell 400 for the electrode body 10, the traditional injection molding method uses ejector pins on the mold to hold and position the electrode body 10. This leaves a channel on the insulating shell 400 (usually the side surface 440 of the insulating shell) after injection molding, causing the electrode body 10 to be exposed in the channel, which can easily have an adverse effect on electrical performance in a moisture environment. This situation may also lead some related technologies to seal the channel later or use additional structures to prevent moisture penetration, increasing costs or complicating the structure. The inventors realized that by cooperating the positioning body 300 with the second conductive segment 220, the injection mold can easily abut, hold, or clamp the positioning body 300, thereby accurately fixing the position of the second conductive segment 220 and even the entire electrode body 10 within the injection mold, preventing the electrode body 10 from shifting during injection molding, and effectively avoiding the adverse effects of the opening. The protective function of the positioning body 300 is reflected in its ability to prevent damage to the second conductive segment 220 caused by injection pressure and to help maintain the flatness of the second conductive segment 220. In addition, the positioning body 300 helps to keep the second conductive segment 220, and even the electrode body 10 as a whole, in a fixed position with the insulating shell 400 after its formation, preventing slippage. The injection molding process described in this article can utilize existing technology and will not be discussed in detail here.

[0077] In some embodiments, the positioning body 300 passes through the flat surface of the second conductive segment 220, which can be manifested as the positioning body 300 passing through a through hole in the flat surface of the second conductive segment 220. In some specific cases, the positioning body 300 can pass through the flat surface of the second conductive segment 220 along the thickness direction of the second conductive segment 220 to achieve the aforementioned "passing through".

[0078] In some embodiments, the positioning body 300 may be a column that passes through the flat surface of the second conductive segment 220.

[0079] In some embodiments, such as Figure 1 and Figure 2 As shown, the second conductive segment 220 may include a first conductive portion 221 and a second conductive portion 222 connected together. A first end of the first conductive portion 221 is connected to the first conductive segment 210, and a second end is connected to the first end of the second conductive portion 222. The extending direction of the first end of the second conductive portion 222 intersects the extending direction of the second end of the first conductive portion 221.

[0080] The first conductive portion 221 and the second conductive portion 222 can be two parts of the second conductive segment 220. The first end of the first conductive portion 221 is connected to the first conductive segment 210 through a transition segment 230 to form a continuous current transmission path. The second end of the first conductive portion 221 is connected to the first end of the second conductive portion 222. Optionally, the extension direction of the first end of the second conductive portion 222 is perpendicular to the extension direction of the second end of the first conductive portion 221. Understandably, due to limitations in actual manufacturing processes, "perpendicular" in this embodiment is not necessarily 90°, but can also refer to a value close to 90°; similarly, expressions such as "parallel" in this document can allow for certain processing or assembly errors. The first conductive portion 221 and the second conductive portion 222 can be connected by a bending transition, and the connection can be designed as a rounded transition to reduce stress concentration.

[0081] In some embodiments, the end of the second conductive portion 222 may be provided with an opening to facilitate the adaptation of the object to be electrically connected, such as to facilitate the bolting connection of some circuit boards during electrical connection.

[0082] In some embodiments, the second conductive portion 222 may include a plurality of adjacent flat segments, the thickness, length or width of which may vary to accommodate different electrical specifications or electrical connection specifications; similarly, the first conductive portion 221 may also be designed accordingly.

[0083] In some embodiments, the positioning body 300 may protrude from or pass through the flat surface of the first conductive portion 221. Protrusion can be understood as protruding from the flat surface and being fixed to the first conductive portion 221.

[0084] In some embodiments, such as Figure 1 As shown, the contact terminal 100 and the conductive sheet 200 are integrally formed.

[0085] The first connecting segment 110, the second connecting segment 120, and the limiting portion 130 of the contact terminal 100 can be formed by the same or multiple consecutive processes, rather than by post-assembly. Common processes include turning, stamping, and forging. The first conductive segment 210, the transition segment 230, and the second conductive segment 220 of the conductive sheet 200 can be integrally formed by stamping and bending processes without welding or bonding, forming a complete conductive sheet 200 structure.

[0086] Optionally, both the contact terminal 100 and the conductive sheet 200 are integrally formed. Of course, only the contact terminal 100 or only the conductive sheet 200 can be integrally formed; no particular limitation is made here. The integral forming process eliminates the connection interface between the components, which can effectively avoid the disadvantages of increased contact resistance or insufficient structural strength at the interface.

[0087] Of course, in some other embodiments, one of the contact terminal 100 or the conductive sheet 200 may be integrally formed.

[0088] In the second aspect, such as Figure 4 As shown, an embodiment of this application provides an electrical connection component, which includes:

[0089] A plurality of electrode bodies 10, wherein the electrode body 10 is the electrode body 10 provided in any embodiment of the first aspect of this application; and

[0090] An insulating shell 400 that at least covers the first connecting section 110, the limiting part 130 and the first conductive section 210 of the electrode body 10.

[0091] The electrical connection assembly is an integrated component that combines multiple (i.e., two or more) electrode bodies 10 to achieve insulation protection. Optionally, the electrical connection assembly mainly consists of several electrode bodies 10 and an insulating housing 400. Optionally, the number of electrode bodies 10 can be three to facilitate connection to three-phase power. Of course, the number of electrode bodies 10 can be determined according to actual needs and is not particularly limited here. The multiple electrode bodies 10 are arranged at a certain interval to avoid electrical interference between them. Understandably, the shape of each electrode body 10 can be determined according to spatial requirements, so the shapes of each electrode body 10 do not have to be exactly the same.

[0092] The insulating shell 400 can be made of high temperature resistant and aging resistant insulating material. Its core function is to provide insulation protection for the key connection parts of the electrode body 10. The insulating shell 400 must completely cover the core conductive connection areas of the electrode body 10, such as the first connection section 110, the limiting part 130 and the first conductive section 210, to prevent these areas from contacting external metal parts and causing short circuits. At the same time, it protects the connection parts from dust and moisture corrosion and improves weather resistance.

[0093] In some embodiments, such as Figure 4 and Figure 5 As shown, the insulating housing 400 may include a mounting hole 410 and a metal bushing 420 located in the mounting hole 410. The metal bushing 420 may be made of steel.

[0094] like Figure 5 As shown, the metal bushing 420 may include an opening slit 421, with a matching, arc-shaped protrusion 422 and a recess 423 on opposite sides of the opening slit 421.

[0095] In some embodiments, the metal bushing 420 may further include an annular body and a protrusion 424 disposed on the outer side of the end of the annular body to improve the overall strength. The protrusion 424 includes a first outer surface 425 and a second outer surface 426, the first outer surface 425 and the second outer surface 426 being perpendicular to each other. The protrusion 424 and the opening slit 421 are disposed on two opposite sides.

[0096] Optionally, the mounting holes 410 can be holes formed at both ends of the insulating housing 400 for fixing electrical connection components, and are typically circular. The mounting holes 410 penetrate the insulating housing 400 to allow the electrical connection components to be fixed to pre-installed locations on the heating plate or other electrical components using fasteners such as screws and bolts. The metal bushing 420 can be an annular structure embedded within the mounting holes 410, which can enhance the strength of the mounting holes 410 and prevent the plastic housing from cracking due to pressure generated during the tightening process of screws or other connectors.

[0097] The metal bushing 420 includes an opening slit 421, which is an axial slot formed on the side wall of the metal bushing 420. This opening slit 421 provides the metal bushing 420 with a certain degree of elastic contraction, facilitating its insertion into the mounting hole 410 during installation. Simultaneously, it allows for slight contraction and tight contact with the screw during tightening, improving the stability of the fixation. On opposite sides of the opening slit 421 are respectively provided a protrusion 422 and a recess 423 with matching shapes. The protrusion 422 is a structure that protrudes outward from one side of the opening slit 421; optionally, the protrusion 422 can be a semi-circular protrusion. The recess 423 is a structure that is recessed inward from the other side of the opening slit 421; optionally, the recess 423 can be a semi-circular groove. The recess 423 is used to accommodate the protrusion 422, and the recess 423 and the protrusion 422 do not contact each other. Understandably, the number of recesses 423 and protrusions 422 can be one or more.

[0098] Understandably, traditional bushings typically have straight-line openings, which can easily lead to bushings interlocking during mass production. In this case, manual separation of the connected bushings is usually required, which is time-consuming and labor-intensive. Unlike this traditional method, by providing protrusions 422 and recesses 423 at the openings 421 of the metal bushing 420, the interlocking of metal bushings 420 at the openings 421 can be effectively prevented, saving manpower and improving production efficiency. At the same time, the structure of the metal bushing 420 facilitates better force cushioning during assembly.

[0099] The metal bushing 420 provides resistance to deformation and wear. In addition, during automated production feeding, the metal bushing 420, which includes the arc-shaped protrusions 422 and concave portions 423, helps to prevent multiple metal bushings 420 from sticking together and causing feeding failure.

[0100] In some embodiments, one or both ends of the metal bushing 420 may protrude slightly from the mounting hole 410 (not shown in the figure), so that during the tightening of the screw or bolt, the screw or bolt contacts the metal bushing 420 first, effectively avoiding direct contact with the insulating shell 400 first, which would cause the insulating shell 400 to be squeezed and deformed.

[0101] In some embodiments, such as Figure 4 As shown, positioning posts 430 are provided at both ends of the insulating housing 400. The positioning posts 430 are used to assist in positioning during the installation of electrical connection components. Optionally, the positioning posts 430 are cylindrical, and the positioning posts 430 at both ends of the insulating housing 400 have different diameters to prevent mistaken installation during the installation of electrical connection components.

[0102] In some embodiments, such as Figure 5 As shown, the metal bushing 420 also has a protrusion 424, which can be located on the side of the metal bushing 420 opposite to the opening slit 421. The protrusion 424 can be located at the edge of the metal bushing 420, and can include a first outer surface 425 and a second outer surface 426. The first outer surface 425 and the second outer surface 426 can be perpendicular. The protrusion 424 can strengthen the edge strength of the metal bushing 420 and effectively prevent the edge of the metal bushing 420 from deforming due to force.

[0103] In a third aspect, embodiments of this application provide a vehicle heater (not shown in the figures), the vehicle heater comprising:

[0104] An electrical connection component, which is the electrical connection component provided in any embodiment of the second aspect of this application;

[0105] The control circuit board is electrically connected to the second connection segment 120 of the electrical connection assembly; and

[0106] A heating plate electrically connected to the second conductive segment 220 of the electrical connection assembly.

[0107] The vehicle heater is a heating device used in the vehicle's thermal management system, primarily providing heat for interior heating, battery preheating, or cabin defrosting. Its core components mainly include electrical connection components, circuit boards (such as control circuit boards with control circuitry), and heating plates. The electrical connection components, as the core of the electrical connection structure, provide a stable current transmission path between the heating plates and the control circuit boards.

[0108] The control circuit board is the core of the heater in some vehicles. It typically uses a PCB circuit board and can integrate components such as an MCU (microcontroller), power transistors, or temperature sensors. Through electrical connection with the second connection segment 120 of the electrical connection assembly, it achieves precise control of the heating current. The heating power can be adjusted according to vehicle requirements (such as interior temperature and battery temperature), and it also has overcurrent, overtemperature, and short-circuit protection functions.

[0109] The heating plate is the heat-generating component, typically a PTC heating plate (positive temperature coefficient heater) or a resistance wire heating plate. Understandably, the heating plate can have a flat structure or other shapes; no particular limitation is made here. The heating plate is electrically connected to the second conductive section 220 of the electrical connection assembly to receive current from the control circuit board and generate heat. This heat can be transferred to the target area (such as the vehicle interior air or battery pack) through conduction, convection, or radiation.

[0110] The control circuit board can determine the heating demand based on sensor signals and output a specified current to the heating plate through electrical connection components. The heating plate then heats up to achieve the heating function. Optionally, the control circuit board can monitor the heating status in real time and cut off or adjust the current in case of abnormality to ensure safety.

[0111] Those skilled in the art will understand that Figures 1 to 5 The structure shown is merely a schematic diagram of a portion of the structure related to the present application and does not necessarily constitute a limitation on the product form to which the technical solution of the present application is applied. Specific electrode bodies, electrical connection components, and vehicle heater products may include more or fewer components than the structure shown in the figure, or may have a structure that is not exactly the same.

[0112] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this application.

[0113] The above embodiments merely illustrate several implementation methods of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of protection of this application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the appended claims.

Claims

1. An electrode body, characterized in that, include: The contact terminal includes a first connecting section, a second connecting section, and a limiting part; A conductive sheet includes a first conductive segment and a second conductive segment, the first conductive segment being connected to the second conductive segment; the first conductive segment is curled and covers multiple surfaces of the first connecting segment to restrict the displacement of the first connecting segment in a first direction; the limiting portion is used to restrict the displacement of the first conductive segment in a second direction; the first direction is perpendicular to the second direction, and the second direction is the direction from the first connecting segment to the second connecting segment.

2. The electrode body according to claim 1, characterized in that, The first conductive segment and the first connecting segment are crimped together and not welded.

3. The electrode body according to claim 2, characterized in that, The first conductive segment and the first connecting segment are connected by cold pressing, so that the first conductive segment curls up and covers multiple sides of the first connecting segment, and the connecting area does not generate an oxide layer due to the temperature influence of the connecting method.

4. The electrode body according to claim 1, characterized in that, The first conductive segment includes a first curled portion and a second curled portion that are curled in opposite directions, and there is a gap between the first curled portion and the second curled portion on the opposite side.

5. The electrode body according to claim 1, characterized in that, The conductive sheet further includes a transition section with a first end connected to the first conductive segment and a second end connected to the second conductive segment; The surface of the transition section includes a first side surface and a second side surface located on opposite sides of the transition section and extending from the first end to the second end of the transition section. The first side surface and the second side surface are twisted planes; The inner edge of the first side surface and the inner edge of the second side surface extend from the contact point with the outer edge of the first surface of the second conductive segment to the contact point with the inner surface of the first conductive segment. The outer edges of the first side surface and the second side surface extend from the contact point with the outer edge of the second surface of the second conductive segment to the contact point with the outer surface of the first conductive segment.

6. The electrode body according to claim 1, characterized in that, The first connecting segment and / or the second connecting segment are cylindrical; The limiting part is an annular protrusion, and / or the limiting part is located at the connection between the first connecting segment and the second connecting segment.

7. The electrode body according to claim 1, characterized in that, The second conductive segment is flat; The electrode body also includes a positioning body that protrudes or penetrates the flat surface of the second conductive segment; The positioning element is made of insulating material and is used to provide positioning and protection when an insulating shell is applied to the electrode body.

8. The electrode body according to claim 1, characterized in that, The second conductive segment includes a first conductive portion and a second conductive portion connected together. The first end of the first conductive portion is connected to the first conductive segment, and the second end is connected to the first end of the second conductive portion; The extension direction of the first end of the second conductive portion intersects the extension direction of the second end of the first conductive portion.

9. The electrode body according to any one of claims 1-8, characterized in that, The contact terminal is integrally formed, and / or the conductive sheet is integrally formed.

10. An electrical connection assembly, characterized in that, include: Several electrode bodies as described in any one of claims 1-9; An insulating shell that at least covers the first connecting segment, the limiting portion, and the first conductive segment of the electrode body.

11. The electrical connection assembly according to claim 10, characterized in that, The insulating shell is bonded to the electrode body by injection molding, or the insulating shell is bonded to the electrode body by injection molding and the side surface of the insulating shell does not have holes pointing to the conductive sheet.

12. The electrical connection assembly according to any one of claims 10 or 11, characterized in that, The insulating housing includes a mounting hole and a metal bushing located in the mounting hole; The metal bushing includes an open slot, with matching, arc-shaped protrusions and recesses on opposite sides of the open slot; and / or, the metal bushing includes an annular body and a protrusion on the outer side of the end of the annular body to improve overall strength, the protrusion including a first outer surface and a second outer surface, the first outer surface being perpendicular to the second outer surface, the protrusion and the open slot being located on opposite sides.

13. A heater for a vehicle, characterized in that, include: The electrical connection assembly as described in any one of claims 10-12; A control circuit board electrically connected to the second connection segment of the electrical connection assembly; A heating plate electrically connected to the second conductive segment of the electrical connection assembly.

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