Patent Description:
Electrical connection means for connecting terminals of battery units in a battery pack are already known. The electrical connection means is generally welded by spot welding to the terminals of the battery units. When currents generated in the spot welding process pass through the various parts of the electrical connection means, there might be a chance of blackening or even melt-through at a part or position of the electrical connection means or at the periphery thereof. Some electrical connection means are provided with a fuse or fusible part for cutting off excessively high currents. Because the fuse or fusible part has a very small cross section, it is quite common for blackening or even melt-through to occur when the fuse or fusible part is undergoing the spot welding process.

<CIT> discloses a battery module comprising a plurality of cylindrical battery cells and a busbar plate. The basbar plate comprising a portion that protrudes and extends from an inner edge of a connection opening and makes contact with a cathode terminal or an anode terminal of a battery module and thereby electrical connects the plurality of the cylindrical battery cells. Furthrmore, <CIT> discloses a parallelly connected grid that comprises several battery cell connection pads disposed on the same plane. Several connection pieces are also connected in between the battery connection cells at intervals. Each connection piece is provided with a fuse protection structure that melts under high temperature. This fuse protection features serves as a safety feature.

The present invention is intended to eliminate or at least reduce local blackening or even melt-through caused by the high temperatures that occur when an electrical connection means is welded. The electrical connection means comprises a body made of an electrically conductive material. Each body at least has a first body part and a second body part, and at least one terminal connection part provided by the first body part or the second body part, for connecting to the terminal of the battery unit. The terminal connection part comprises at least one connection component, each connection component comprising a contact part for contacting the terminal of the battery unit. The terminal connection part further comprises at least one stem connecting the contact part to the first body part or the second body part. Multiple bodies are connected to each other by at least one connection part. Each connection part has at least one fusible part, which has a smaller cross section than the stem <NUM> and is used as a fuse for cutting off an excessively high current.

According to one embodiment, the at least one terminal connection part comprises a first connection component and a second connection component which are two in number and spaced apart, and which are respectively connected to the body via respective said stems.

According to one embodiment, the at least one connection part is provided with a locally narrow part as the at least one fusible part.

According to one embodiment, an opening is provided in the at least one connection part to form the at least one fusible part.

According to one embodiment, the opening is a through-hole.

According to another embodiment of the present invention, an electrical connection means for connecting terminals of battery units in a battery pack is provided, comprising a body made of an electrically conductive material, the body at least having a first body part and a second body part; and at least one terminal connection part provided by the first body part or the second body part, for connecting to the terminal of the battery unit. The at least one terminal connection part comprises a first connection component and a second connection component which are at least two in number and spaced apart; and each of the connection components comprises a contact part for contacting the terminal of the battery unit, and a stem connecting the contact part to the body. The stem has a smaller cross section than the contact part, and the stem is used as a fuse for cutting off an excessively high current.

According to one embodiment, the contact parts of the first connection component and the second connection component extend in the same direction, or extend in different directions relative to each other.

According to one embodiment, the contact part of the first connection component is connected to the body by the stem via a strip.

According to one embodiment, the strip has an outwardly projecting first end connected to the body, and the strip has a second end as a far end, which is connected to the stem.

According to one embodiment, the strip extends along a partly circular or approximately semicircular path.

According to one embodiment, the contact parts of the first connection component and the second connection component are arranged adjacent (close) to each other.

According to one embodiment, the contact parts of the first connection component and the second connection component have respective straight edges, which extend together in parallel on two opposite sides of the gap.

According to one embodiment, the contact parts of the first connection component and the second connection component have shapes that are substantially mirror images of each other.

According to one embodiment, the contact parts of the first connection component and the second connection component are configured to form a substantially circular or disk-like combined shape.

According to one embodiment, the angle at which the contact parts of the first connection component and the second connection component extend in different directions relative to each other is <NUM>° - <NUM>°.

According to one embodiment, the angle at which the contact parts of the first connection component and the second connection component extend in different directions relative to each other is in the range of <NUM>° - <NUM>°.

According to one embodiment, the angles at which the contact parts of the first connection component and the second connection component extend in different directions relative to each other differ by approximately <NUM>°.

According to one embodiment, the respective positions of the stems of the first connection component and the second connection component are radially opposite each other.

According to one embodiment, the electrical connection means further comprises two said terminal connection parts; the terminal connection part is provided by the corresponding first body part or second body part, and used for connecting to a corresponding terminal of a battery unit adjacent to said battery unit.

According to one embodiment, the electrical connection means further comprises a circuit connection part provided by the first body part or the second body part, for connecting to an operating circuit of the battery pack.

The technical solution of the present invention is explained further below based on preferred embodiments, wherein:.

Before explaining any embodiment of the present invention in detail, it should be understood that the applications of the present invention are not limited to the structural details and component arrangements expounded in the following description or shown in the drawings. Similarly, it should be understood that the words and terms used herein are intended to describe, and should not be regarded as limiting. General terms, terms relating to extent, such as "substantially" or "about" are to be understood as indicating a suitable range outside a given value, for example a general tolerance associated with the manufacture, assembly and use of the embodiment described. In addition, the use of "comprises", "provided with" or "has" and variants thereof herein is intended to encompass the subsequently listed items.

<FIG> all show electrical connection means for connecting terminals of battery units in a battery pack, in multiple embodiments according to the present invention. An electrical connection means <NUM> is used to connect multiple battery units in a battery pack, connecting ends of the battery units in series and/or in parallel.

<FIG> show an electrical connection means <NUM> according to a first embodiment of the present invention, used to connect terminals <NUM> of multiple battery units. Each electrical connection means <NUM> can simultaneously connect ten battery units in a specific arrangement. The electrical connection means <NUM> mainly comprises multiple bodies <NUM>; each body <NUM> can at least be divided into a first body part 102a and a second body part 102b. The first body part 102a is substantially flat, and is provided with a circuit connection part <NUM> for connecting to an operating circuit of the battery pack. In general, the circuit connection part <NUM> may be integrally formed with the first body part 102a of at least one body <NUM>, but may also be connected to the first body part 102a by welding. The circuit connection part <NUM> is electrically connected by welding to a port (not shown) on a circuit board having the operating circuit. The other part of the body <NUM> is the second body part 102b, which is connected to the first body part <NUM>. The first body part 102a and second body part 102b are integrally formed. Preferably, the electrical connection means <NUM> is made of an elastically deformable electrically conductive material. As shown in <FIG>, the electrical connection means <NUM> has five bodies <NUM> arranged in parallel, each body <NUM> being connected to terminals <NUM> of two battery units.

As shown in <FIG>, the second body part 102b has at least one terminal connection part <NUM> for connecting to a battery unit terminal <NUM>. Specifically, the second body part 102b has two terminal connection parts <NUM>; the terminal connection part <NUM> is provided by the corresponding second body part 102b, and used for connecting to the corresponding terminal <NUM> of a battery unit adjacent to said battery unit. The shape of the terminal connection part <NUM> may depend on the shape of the terminal <NUM> of the battery unit. The area of the terminal connection part <NUM> should be smaller than that of the terminal <NUM> of the battery unit.

Each terminal connection part <NUM> has at least one connection component <NUM>. According to this embodiment, each terminal connection part <NUM> has two connection components, i.e. a first connection component <NUM> and a second connection component <NUM>. The first connection component <NUM> and second connection component <NUM> are arranged individually. The second connection component <NUM> and the first connection component <NUM> are located in substantially the same plane, and are configured to adjoin a surface of the terminal <NUM> of the battery unit or to be biased towards the surface of the terminal <NUM> of the battery unit. The first connection component <NUM> and second connection component <NUM> may be offset towards the terminal of the battery unit in relation to the second body part 102b, in order to weld the terminal connection part <NUM> to the terminal of the battery unit. The terminal connection part <NUM> further comprises a stem <NUM> connecting the contact part <NUM> to the first body part 102a. The first connection component <NUM> and second connection component <NUM> are spaced apart by a certain distance and extend in the same direction. The first connection component <NUM> and second connection component <NUM> are respectively connected to the second body part 102b by their respective stems <NUM>. The stem <NUM> is the only connection path connecting each connection component <NUM>, <NUM> to the second body part 102b. The stem <NUM> has a smaller cross section than the contact part <NUM>. As shown in <FIG>, the stem <NUM> is narrower than the first and second connection components <NUM>, <NUM>. The stems <NUM> of the first connection component <NUM> and second connection component <NUM> are spaced apart by a certain distance and form a gap <NUM>.

The multiple bodies <NUM> are connected to each other by at least one connection part <NUM>. As shown in <FIG>, one body <NUM> is connected to another body <NUM> by one connection part <NUM>. <FIG> shows another embodiment, in which one body <NUM> and another body <NUM> may also be connected by two connection parts <NUM>, so that the overall rigidity of the electrical connection means <NUM> is increased. Preferably, the connection part <NUM> is connected to the bodies <NUM> in an integrally formed manner. Each connection part <NUM> may be provided with at least one fusible part <NUM>, the fusible part <NUM> having a smaller cross section than the stem <NUM> (this difference is not shown in the figures). Alternatively, each of, or one of, the connection parts <NUM> may also be provided with a locally narrow part (not shown in the figures), this part having a smaller cross section than any part of the body <NUM>, including the stem <NUM>, in order to form a fuse for cutting off an excessively high current. Advantageously, at least one locally narrow part may be formed in the connection part <NUM> by a hole-opening process step, for use as a fuse for cutting off an excessively high current. In addition, multiple connection parts <NUM> may extend along substantially Z-shaped paths, and connect multiple bodies <NUM> in a staggered arrangement, to match the way in which multiple battery units are arranged.

<FIG> show an electrical connection means <NUM> in a second embodiment of the present invention. Similarly, the electrical connection means <NUM> comprises multiple bodies <NUM>; each can at least be divided into a first body part 202a and a second body part 202b. Specifically, the electrical connection means <NUM> has five bodies <NUM> arranged in parallel, each body <NUM> being connected to terminals of two battery units. The first body part 202a of each body <NUM> extends in a plane, and is provided with a circuit connection part <NUM> for connecting to an operating circuit of the battery pack. The circuit connection part <NUM> may be integrally formed with the first body part 202a, and the circuit connection part <NUM> may be electrically connected by welding to a port (not shown in the figures) on a circuit board having the operating circuit. The other part of the body <NUM> is the second body part 202b, which is electrically connected to the first body part <NUM>. The first body part 202a and second body part 202b are connected in an integrally formed manner. Preferably, the electrical connection means <NUM> is made of an elastically deformable electrically conductive material.

The second body part 202b of each body <NUM> is configured to be electrically connected to an end of a battery unit. As shown in <FIG>, the second body part 202b has at least one terminal connection part <NUM> for connecting to a battery unit terminal. The second body part 202b may have two terminal connection parts <NUM>; the terminal connection part <NUM> is provided by the corresponding second body part 202b, and used for connecting to the corresponding terminal of a battery unit adjacent to said battery unit. The shape of the connection part <NUM> substantially corresponds to the shape of the terminal of the battery unit, e.g. circular as shown in the figures. The area of the terminal connection part <NUM> should be smaller than that of the terminal of the battery unit.

Each terminal connection part <NUM> has a first connection component <NUM> and a second connection component <NUM> which are at least two in number. The first connection component <NUM> and second connection component <NUM> are arranged individually. The second connection component <NUM> is located in substantially the same plane as the first connection component <NUM>. The first connection component <NUM> and second connection component <NUM> are in the form of semicircles facing each other, and are configured to adjoin a surface of the terminal of the battery unit, or to be biased towards the surface of the terminal <NUM> of the battery unit. The first connection component <NUM> and second connection component <NUM> may be offset towards the terminal of the battery unit in relation to the second body part 202b, as shown in <FIG>, in order to connect the terminal connection part <NUM> to the terminal of the battery unit.

Each connection component <NUM>, <NUM> comprises a contact part <NUM> for contacting the terminal <NUM> of the battery unit, and a stem <NUM> connecting the contact part <NUM> to the remainder of the body <NUM>. The stem <NUM> is the only connection path connecting each connection component <NUM>, <NUM> to the second body part 202b. Specifically, the stem <NUM> has a smaller cross section than the contact part <NUM>. According to <FIG>, the stem <NUM> is narrower than the first and second connection components <NUM>, <NUM>; for example, the stem <NUM> is only about <NUM>/<NUM> of the width of the connection component. The contact parts <NUM> of the first and second connection components <NUM>, <NUM> extend in different directions relative to each other, such that the respective stems <NUM> of the first and second connection components <NUM>, <NUM> are at positions remote from one another on the terminal connection part <NUM>. The angles at which the contact parts <NUM> of the first connection component <NUM> and second connection component <NUM> extend in different directions relative to each other differ by approximately <NUM>°. That is to say, the contact parts <NUM> of the first connection component <NUM> and second connection component <NUM> extend in opposite directions relative to each other. In this way, the stems <NUM> of the first connection component <NUM> and second connection component <NUM> are located at maximally spaced-apart positions. The respective contact parts <NUM> of the first and second connection components <NUM>, <NUM> are connected by the stems <NUM> to the remainder of the body <NUM> via a strip <NUM>. The strip <NUM> has an outwardly projecting first end 221a connected to the remainder of the body <NUM>, and the strip <NUM> has a second end 221b as a far end, which is connected to the stem <NUM>. Alternatively, as shown in <FIG>, the contact parts <NUM> of the first connection component <NUM> and second connection component <NUM> may extend in the same or substantially the same direction. However, the respective stems <NUM> of the first and second connection components <NUM>, <NUM> are spaced apart by at least a certain distance and form a gap <NUM>.

According to <FIG>, surfaces of the respective contact parts <NUM> of the first and second connection components <NUM>, <NUM> may be offset by a distance D, about <NUM> - <NUM>, relative to a surface of the remainder of the body <NUM>, such that a surface of the contact part <NUM> abuts a surface of the terminal of the battery unit, to facilitate welding. In addition, the strip <NUM> extends along an approximately circular or approximately semicircular path, and a cross section of the strip <NUM> is configured to be larger than a cross section of the stem <NUM>. The respective contact parts <NUM> of the first and second connection components <NUM>, <NUM> are arranged adjacent to each other, and the contact parts <NUM> of the first connection component <NUM> and the second connection component <NUM> are spaced apart by a narrow gap <NUM>, e.g. <NUM> - <NUM>.

The contact parts <NUM> of the first connection component <NUM> and second connection component <NUM> are in the form of semicircles facing each other, and have respective straight edges <NUM>; the two straight edges <NUM> define the abovementioned gap <NUM>, and extend together in parallel on two opposite sides of the gap <NUM>. The gap <NUM> causes the contact part <NUM> of the first connection component <NUM> to be substantially independent of the contact part <NUM> of the second connection component <NUM>, and the contact parts <NUM> of the first connection component <NUM> and second connection component <NUM> have shapes that are substantially mirror images or reversed mirror images of each other. Alternatively, the angle at which the contact parts <NUM> of the first connection component <NUM> and the second connection component <NUM> extend in different directions relative to each other may be <NUM>° - <NUM>°, i.e. at least <NUM>° clockwise or anticlockwise. Alternatively, the angle at which the contact parts <NUM> of the first connection component <NUM> and the second connection component <NUM> extend in different directions relative to each other may also be reduced to the range of <NUM>° - <NUM>°. Advantageously, the positions of the respective stems <NUM> of the first connection component <NUM> and the second connection component <NUM> are radially opposite each other, as shown in <FIG>.

The contact parts <NUM> of the first connection component <NUM> and the second connection component <NUM> may be configured to have a substantially circular or disk-like combined shape. Essentially, if it is desired to form the abovementioned shape, a process step of forming a through-hole <NUM> of a specific shape in the second body part 202b will generally be required. Alternatively, the contact parts <NUM> of the first connection component <NUM> and the second connection component <NUM> may be connected to the second body part 202a or remainder via the stems <NUM> directly, thus avoiding the process step of forming the through-hole <NUM> and saving the material forming the strip <NUM>.

Similarly to the previous embodiment, multiple bodies <NUM> are connected to each other by at least one connection part <NUM>. Specifically, as shown in <FIG>, one body <NUM> is connected to another body <NUM> of the electrical connection means <NUM> by two connection parts <NUM>. Preferably, the connection parts <NUM> are integrally formed with the bodies <NUM>. Each connection part <NUM> is provided with at least one fusible part <NUM>, the fusible part <NUM> having a smaller cross section than the stem <NUM>. Each of, or one of, the connection parts <NUM> may be provided with a locally narrow part <NUM>. Similarly, the locally narrow part <NUM> has a smaller cross section than any part of the body <NUM>, including the stem <NUM>, in order to form a fuse for cutting off an excessively high current. Advantageously, a circular through-hole <NUM> may be provided in the connection part <NUM> as shown in <FIG>, or an elongated through-hole <NUM> may be provided in the connection part <NUM> as shown in <FIG>, to form at least two locally narrow parts <NUM>, for use as a fuse for cutting off an excessively high current. <FIG> shows that each connection part <NUM> may be configured as a single narrow part, which similarly can be used as a fuse for cutting off an excessively high current. In addition, multiple connection parts <NUM> may extend along substantially Z-shaped paths, and connect multiple bodies <NUM> in a staggered arrangement, to match the way in which multiple battery units are arranged.

<FIG> show an electrical connection means <NUM> based on a second embodiment. Essentially, each electrical connection means <NUM> simultaneously connects two battery units in a specific arrangement. This embodiment is different in that the electrical connection means <NUM> has a single body <NUM>. Similarly, the body <NUM> can at least be divided into a first body part 302a and a second body part 302b. The first body part 302a is substantially flat, and the body <NUM> is provided with a circuit connection part <NUM> for connecting to an operating circuit of the battery pack. The circuit connection part <NUM> may be integrally formed with the first body part 302a of the body <NUM>, but may also be connected to the first body part 302a by welding. The circuit connection part <NUM> is electrically connected by welding to a port (not shown in the figures) on a circuit board having the operating circuit. The other part of the body <NUM> is the second body part 302b, which is electrically connected to the first body part <NUM>. The first body part 302a and second body part 302b are integrally formed. The electrical connection means <NUM> is made of an elastically deformable electrically conductive material. The electrical connection means <NUM> has only one body <NUM>, the body <NUM> being connected to terminals of two battery units.

<FIG> show another electrical connection means <NUM>; a body <NUM> thereof is simultaneously connected to terminals of as many as ten battery units. The entire battery pack may have multiple electrical connection means <NUM>, and there may be no connection between one body <NUM> and another body <NUM>, so there is no connection part.

Essentially, the electrical connection means <NUM>, <NUM> described above each comprise the body <NUM>, <NUM> made of an electrically conductive material, the body having a first body part 302a, 402a and a second body part 302b, 402b, and the first body part 302a, 402a being provided with a circuit connection part <NUM>, <NUM> for connecting to the operating circuit of the battery pack. The electrical connection means <NUM>, <NUM> also have at least one terminal connection part <NUM>, <NUM> provided by the second body part 302b, 402b, for connecting to the terminal of the battery unit. The terminal connection part <NUM>, <NUM> has a first connection component <NUM>, <NUM> and a second connection component <NUM>, <NUM> which are spaced apart and at least two in number.

Each of the connection components comprises a contact part <NUM>, <NUM> for contacting the terminal of the battery unit, and the terminal connection part <NUM>, <NUM> also has a stem <NUM>, <NUM> connecting the contact part <NUM>, <NUM> to the first body part 302a, 402a, each stem <NUM>, <NUM> having a smaller cross section than the contact part <NUM>, <NUM> thereof or any other part, so that the stem <NUM>, <NUM> is used as a fuse for cutting off an excessively high current. The remaining features of the first connection components <NUM>, <NUM>, the second connection components <NUM>, <NUM>, the contact parts <NUM>, <NUM> and the stems <NUM>, <NUM> have already been described in detail in the relevant paragraphs of the second embodiment, so are not described again here.

According to the process step of assembling the battery pack to which the present invention relates, when the electrical connection means is connected to a battery unit, spot welding will generally be used to weld the first connection component <NUM>, <NUM> and the second connection component <NUM>, <NUM> to an end of the battery unit. Preferably, to facilitate the electric welding process, welding depressions are provided at specific positions on the surfaces of the first connection component <NUM>, <NUM> and the second connection component <NUM>, <NUM>, e.g. at positions close to the middle, in order to guide a welding tool to the specific positions to perform spot welding.

In the process of spot welding, the welding current first flows from the welding head through the respective contact parts <NUM>, <NUM> of the first connection component <NUM>, <NUM> and second connection component <NUM>, <NUM>, and then flows through the stems <NUM>, <NUM> towards the second body part <NUM>, <NUM>. The stems <NUM>, <NUM> are the only paths leading to the second body part <NUM>, <NUM>, and the stems <NUM>, <NUM> have a smaller cross section than the contact parts <NUM>, <NUM>; consequently, when the current passes through the stems <NUM>, <NUM>, a higher temperature will be generated than at other positions.

As shown in <FIG>, generally, when an existing electrical connection means is welded by spot welding to a terminal of a battery unit, the high-voltage current generates a high temperature when passing through a position equivalent to a stem, or might cause blackening or even melt-through at the stem or the periphery thereof. In the electrical connection means <NUM>, <NUM> described above, the positions of the stems <NUM>, <NUM> are configured to be remote from one another, and the two connection components can effectively disperse current and thermal energy, thus avoiding passage of current through the same position; this can reduce situations in which current flow is overly concentrated at the same position, thereby mitigating the problem of blackening or even melt-through at the stem or the periphery thereof.

Claim 1:
Electrical connection means (<NUM>) for connecting terminals of battery units in a battery pack, comprising:
multiple bodies (<NUM>) made of an electrically conductive material, each of the bodies at least having a first body part (102a) and a second body part (102b);
at least one terminal connection part (<NUM>) provided by the first body part (102a) or the second body part (102b), for connecting to the terminal of the battery unit;
characterized in that the at least one terminal connection part (<NUM>) comprises at least one connection component (<NUM>, <NUM>),
each said connection component (<NUM>) comprises a contact part for contacting the terminal of the battery unit, the at least one terminal connection part (<NUM>) further comprises at least one stem (<NUM>) connecting the contact part to the first body part (102a) or the second body part (102b), wherein the stem (<NUM>) has a smaller cross section than the contact part, the multiple bodies (<NUM>) are connected to each other by at least one connection part (<NUM>), each said connection part (<NUM>) has at least one fusible part (<NUM>), the at least one fusible part (<NUM>) has a smaller cross section than the at least one stem (<NUM>), and the at least one fusible part (<NUM>) is used as a fuse for cutting off an excessively high current.