Battery modules and vehicles equipped with them

Abstract

This invention provides a battery module and a vehicle having the same. The battery module includes: a housing, within which multiple controller cavities and cell cavities are disposed; multiple cell groups, each cell group being disposed within a cell cavity, each cell group comprising at least multiple cells stacked along its thickness direction; multiple high- and low-voltage integrated components, each high- and low-voltage integrated component connected to at least two cell groups, extending along the thickness direction of the cells, and connected to a busbar; and a controller, disposed within a controller cavity, connected to the high- and low-voltage integrated components. By applying this solution, high- and low-voltage wiring harnesses are integrated within the battery module, reducing the space occupied by the wiring harnesses, reducing the number of connectors and the frequency of connection, improving the cell space utilization rate, and solving the problem of low vehicle range caused by the limited number of cells that can be accommodated within the battery in existing technologies.

Description

Technical Field

[0001] This invention relates to the field of vehicle power battery design technology, and more specifically, to a battery module and a vehicle having the same. Background Technology

[0002] The driving range of electric vehicles has always been an important indicator of consumer concern. Due to the limited energy density of the cells and the envelope size of the battery pack, the number of cells that can be accommodated in the battery is limited. Under the premise of ensuring safety, the industry has implemented some measures to increase the space occupancy rate of cells in the battery pack. These measures mainly revolve around the physical and functional integration of components other than cells in order to reduce the space occupancy rate of components.

[0003] There is currently no effective solution to the problem of low vehicle range caused by the limited number of battery cells that can be accommodated in existing technologies. Summary of the Invention

[0004] The main objective of this invention is to provide a battery module and a vehicle having the same, in order to solve the problem of low driving range in vehicles due to the limited number of battery cells that can be accommodated in the prior art.

[0005] To achieve the above objectives, according to one aspect of the present invention, a battery module is provided, comprising: a housing, wherein a plurality of controller cavities and cell cavities are disposed within the housing; a plurality of cell assemblies, each cell assembly being disposed within a cell cavity, the cell assembly comprising at least a plurality of cells, the plurality of cells being stacked along the thickness direction of the cells; a plurality of high- and low-voltage integrated components, each high- and low-voltage integrated component being connected to at least two cell assemblies, the high- and low-voltage integrated components extending along the thickness direction of the cells, and the high- and low-voltage integrated components being connected to a busbar; and a controller, wherein the controller is disposed within a controller cavity and is connected to the high- and low-voltage integrated components.

[0006] Furthermore, the high- and low-voltage integrated component includes: an insulating film, which is a sheet structure, and there are two insulating films, both of which extend along the thickness direction of the battery cell; an inter-cell bus assembly, which is disposed between the two insulating films and extends along the thickness direction of the battery cell, with one end of the inter-cell bus assembly closer to the controller connected to the busbar; a flexible circuit board assembly, which is disposed between the two insulating films and extends along the thickness direction of the battery cell, with one end of the flexible circuit board assembly connected to the controller; a skeleton structure, which is multiple and expandable along the width direction of the insulating film, and is disposed on one of the insulating films; and a support assembly, which is multiple and extends along the width direction of the insulating film.

[0007] Furthermore, the inter-cell bus assembly is a multi-layer aluminum sheet press-fit structure.

[0008] Furthermore, at least some of the high and low voltage integrated components are covered with insulating material.

[0009] Furthermore, the battery module includes: an end plate, which is connected to the battery cells located at the end of the battery cell assembly; end plate positioning structures are provided at both ends of the end plate; at least a portion of the surface of the end plate is provided with abutting structures; both the end plate positioning structures and the abutting structures are abutting against the cavity wall of the battery cell cavity; and a busbar fixing position is provided on the end plate, which is used to connect the busbar assembly and the busbar between the battery cells.

[0010] Furthermore, the end plate includes: an end plate body, an end insulation pad provided on the surface of the end plate body near the battery cell, an abutment structure provided on the surface of the end plate body away from the battery cell, and end plate positioning structures provided at both ends of the end plate body; at least one connecting structure is provided on the end plate body, and a first side, a second side, a third side, and a fourth side are sequentially provided along the circumference of the connecting structure, the first side facing the battery cell, the third side opposite to the first side, and the second side opposite to the fourth side, wherein the third side is provided with a snap-fit ​​hole, and the second and fourth sides are both provided with a first locking structure; a busbar fixing position is provided on the end face of the connecting structure.

[0011] Furthermore, a fastening nut is provided at the fixed position of the busbar.

[0012] Furthermore, the battery module also includes a protective cover, which includes: an end cover extending along the length of the battery cell; a first side cover connected to the end cover at an angle, extending along the length of the battery cell, and having a cantilever that extends into a snap-fit ​​hole; and two second side covers, each located on one side of the first side cover, connected to the end cover at an angle, extending along the thickness of the battery cell, and each having a second locking structure. The second side covers are connected to the connecting structure via the second locking structure and the first locking structure. Both the end cover and the second side covers have an opening structure.

[0013] Furthermore, the first locking structure includes at least a limiting groove that extends along the height direction of the end plate body, and the second locking structure includes at least a guide structure that extends along the height direction of the battery cell. When the second side cover is connected and engaged with the connecting structure, at least a portion of the guide structure extends into the limiting groove.

[0014] Furthermore, buffer pads and heat insulation pads are alternately placed between multiple battery cells.

[0015] According to another aspect of the present invention, a vehicle is provided, the vehicle having a power battery, wherein the battery module of the power battery is the battery module described above.

[0016] By applying the technical solution of this invention, high and low voltage wiring harnesses are integrated into the battery module, reducing the space occupied by the wiring harnesses, reducing the number of connectors and the frequency of docking, reducing costs and improving safety, and increasing the cell space utilization rate. To a certain extent, this solves the problem of low vehicle range caused by the limited number of cells that can be accommodated in the battery in the prior art. The slave controller is placed separately in the slave controller cavity, which reduces the risk of failure of the slave controller in the event of a frontal impact on the car and improves the safety of vehicle use. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0018] Figure 1 A schematic diagram of an embodiment of a battery module according to the present invention is shown;

[0019] Figure 2 It shows Figure 1 An enlarged schematic diagram of part A in the middle;

[0020] Figure 3 A schematic diagram of a high-low voltage integrated component according to an embodiment of the present invention is shown;

[0021] Figure 4 A schematic diagram of an embodiment of the insulating film according to the present invention is shown;

[0022] Figure 5 It shows Figure 4 Enlarged schematic diagram of part B in the middle;

[0023] Figure 6 A structural schematic diagram of an embodiment of the housing according to the present invention is shown;

[0024] Figure 7 A schematic diagram of an embodiment of the battery cell assembly according to the present invention is shown;

[0025] Figure 8 A structural schematic diagram of an embodiment of the end plate according to the present invention is shown;

[0026] Figure 9 A schematic diagram of an embodiment of the connection between the high- and low-voltage integrated assembly and the battery cell according to the present invention is shown;

[0027] Figure 10 A structural schematic diagram of an embodiment of the protective cover according to the present invention is shown;

[0028] Figure 11 A schematic diagram of an embodiment of the connection between the busbar and the end plate according to the present invention is shown;

[0029] Figure 12 A schematic diagram of an embodiment of the skeleton structure according to the present invention is shown;

[0030] Figure 13 A schematic diagram of an embodiment of the inter-cell bus assembly according to the present invention is shown;

[0031] Figure 14 A flowchart illustrating the selection method for the heat insulation pad and cushioning pad according to the present invention is shown.

[0032] The above figures include the following reference numerals:

[0033] 1. Battery cell; 2. Buffer pad; 3. Heat insulation pad;

[0034] 4. End plate; 41. End plate body; 401. End insulation pad; 402. End plate positioning structure; 403. Fastening nut; 404. Abutment structure; 405. Snap-fit ​​hole; 406. Snap-fit ​​interface; 407. Limiting structure; 408. Limiting groove;

[0035] 5. High and low voltage integrated components; 501. Insulating film; 5010. Bending structure; 502. Inter-cell busbar assembly; 503. Flexible circuit board assembly; 505. Support assembly; 506. Skeleton structure; 5061. Telescopic structure;

[0036] 6. Insulation materials;

[0037] 7. Housing; 101. Cell cavity; 102. Controller cavity;

[0038] 8. From the controller;

[0039] 9. Protective cover; 90. End cover; 91. First side cover; 901. Opening structure; 902. Second side cover; 903. Guide structure; 904. Cantilever;

[0040] 10. Busbar. Detailed Implementation

[0041] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0042] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0043] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0044] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0045] Combination Figures 1 to 13 As shown, according to a specific embodiment of this application, a battery module is provided.

[0046] The battery module includes a housing 7, a cell assembly, a high- and low-voltage integrated assembly 5, and a slave controller 8. The housing 7 is provided with multiple slave controller cavities 102 and cell cavities 101. There are multiple cell assemblies, which are disposed in the cell cavities 101. Each cell assembly includes at least multiple cells 1, which are stacked along the thickness direction of the cells 1. There are multiple high- and low-voltage integrated assemblies 5, each of which is connected to at least two cell assemblies. The high- and low-voltage integrated assemblies 5 extend along the thickness direction of the cells 1 and are connected to a busbar 10. The slave controller 8 is disposed in the slave controller cavity 102 and is connected to the high- and low-voltage integrated assembly 5.

[0047] By applying the technical solution of this embodiment, high and low voltage wiring harnesses are integrated into the battery module, reducing the space occupied by the wiring harnesses, reducing the number of connectors and the frequency of docking, reducing costs and improving safety, and increasing the cell space utilization rate. This solves to some extent the problem of low vehicle range caused by the limited number of cells that can be accommodated in the battery in the prior art. The slave controller 8 is placed separately in the slave controller cavity 102, which reduces the risk of failure of the slave controller 8 in the event of a frontal impact on the vehicle and improves the safety of vehicle use.

[0048] Specifically, such as Figure 2 As shown, in an exemplary embodiment of this application, the housing 7 includes a crossbeam and longitudinal beams. There is at least one crossbeam extending along a first preset direction, which divides the housing 7's accommodating cavity into a controller cavity 102 and a cell cavity 101. There are multiple longitudinal beams extending along a second preset direction, which divide the cell cavity 101 into multiple single-row cell group cavities, each accommodating a single-row cell group. It should be noted that in this embodiment, the first preset direction is the length direction of the cell 1, and the second preset direction is the thickness direction of the cell 1. Through the structural arrangement of the housing 7, multiple rows of single-row cells 1 can be accommodated simultaneously, improving the structural strength of the battery pack. Furthermore, the longitudinal beams act as a barrier between the multiple rows of cells 1, reducing the cell heat diffusion rate. In this embodiment, by coordinating the positions of the controller 8 and the cells 1, the length of the low-voltage wiring harness from the cells 1 to the controller 8 can be reduced, thereby reducing costs and improving safety.

[0049] Preferably, in this embodiment, the controller 8 is connected to two rows of battery cells. The housing 7 is provided with a total of 8 battery cells and 4 controllers 8. The battery pack components and the controllers correspond one-to-one in space. A high-low voltage integrated component 5 is arranged on the upper part of the battery pack components. The high-low voltage integrated component 5 is connected to the battery cells 1 to realize the series and parallel connection between the battery cells 1. The high-low voltage integrated component 5 is connected to the controllers 8 to realize the direct transmission of low voltage signals.

[0050] Preferably, the slave controller cavity 102 is arranged at the rear of the electric vehicle and the slave controller 8 is placed separately in the slave controller cavity 102, which reduces the risk of the slave controller 8 failing during a vehicle impact.

[0051] Furthermore, the high and low voltage integrated assembly 5 includes an insulating film 501, a cell-to-cell bus assembly 502, a flexible circuit board assembly 503, a frame structure 506, and a support assembly 505. The insulating film 501 has a sheet-like structure, and there are two insulating films 501, both extending along the thickness direction of the cell 1. The cell-to-cell bus assembly 502 is disposed between the two insulating films 501, extending along the thickness direction of the cell 1. The proximity of the cell-to-cell bus assembly 502 to the controller 8... One end of the flexible circuit board assembly 503 is connected to the busbar 10; the flexible circuit board assembly 503 is disposed between two insulating films 501, extending along the thickness direction of the cell 1, and one end of the flexible circuit board assembly 503 is connected to the slave controller 8; there are multiple skeleton structures 506, which are telescopically arranged along the width direction of the insulating film 501 and are disposed on one of the insulating films 501; there are multiple support assemblies 505, which extend along the width direction of the insulating film 501. The insulating film 501 has the functions of safety protection, insulation protection, and physical integration. The inter-cell busbar assembly 502 is the channel for current transmission between cells, and the support assembly 505 is the skeleton and positioning device of the high and low voltage integrated assembly 5. The flexible circuit board assembly 503 is directly connected to the slave controller 8 inside the package, saving the arrangement space of the intermediate wire harness and the number of connectors, which reduces both cost and the risk of connector connection failure. Figure 9 As shown, the high and low voltage integrated assembly 5 is directly connected to the controller 8, saving low voltage wiring harnesses, reducing the number of connectors, achieving cost reduction and improved space utilization. The skeleton structure 506 is extendable along the width direction of the insulating film 501, allowing the skeleton structure 506 to span multiple rows of cell groups while providing support for the entire high and low voltage integrated assembly 5.

[0052] In one exemplary embodiment of this application, the high-low voltage integrated assembly 5 further includes a thermal pad, which is a thermally conductive medium for transferring the cell temperature to the temperature sensor in the flexible circuit board assembly 503.

[0053] In one exemplary embodiment of this application, the insulating film 501 has a sheet-like structure. The upper and lower insulating films 501 are bonded together with the inter-cell bus assembly 502, flexible circuit board assembly 503, and support assembly 505 encapsulated in between by a hot-pressing process and adhesive bonding. Preferably, the insulating film 501 has a bending structure 5010, which extends along the width direction of the insulating film 501 to make the overall assembly and pressing fit more closely.

[0054] In one exemplary embodiment of this application, the skeleton structure 506 includes two telescopic structures 5061 that can be stretched in opposite directions to adjust the length of the skeleton structure 506.

[0055] Preferably, the inter-cell bus assembly 502 has a multi-layer aluminum sheet press-fit structure. This design makes the inter-cell bus assembly 502 less prone to breakage and improves its durability.

[0056] In conjunction with the above embodiments, preferably, the insulating film 501 is a heat-pressed film. The high-low voltage integrated assembly 5 has an adjustable skeleton structure 506 along the width direction of the insulating film 501, allowing the high-low voltage integrated assembly 5 to span multiple rows of independent cell groups. The overall adjustment function of the assembly is achieved through the multi-layer structure of the bending structure 5010 of the insulating film 501, the skeleton structure 506, and the inter-cell bus assembly 502, enabling the bridging of multiple independent cell groups. This saves on components such as intermediate busbars, bases, and protective covers used for bridging adjacent cell groups, thus saving costs and improving space utilization.

[0057] Furthermore, at least a portion of the high- and low-voltage integrated assembly 5 is covered with an insulating material 6. The insulating material 6 may be in the form of a film. By providing the insulating material 6, the exposed metal parts in the high- and low-voltage integrated assembly 5 can be covered, which improves the space utilization rate of the battery pack in the Z direction (i.e., the height direction of the cell 1) and reduces costs compared with conventional solutions. The insulating material 6 reduces the risk of metal shavings falling off the metal parts.

[0058] Furthermore, the battery module includes an end plate 4, which is connected to the battery cell 1 located at the end of the battery cell assembly. The two ends of the end plate 4 are provided with end plate positioning structures 402, and at least a portion of the surface of the end plate 4 is provided with abutment structures 404. Both the end plate positioning structures 402 and the abutment structures 404 are abutted against the cavity wall of the battery cell cavity 101. The end plate 4 is provided with a busbar fixing position, which is used to connect the inter-cell busbar assembly 502 and the busbar 10.

[0059] In this embodiment, the end plate positioning structure 402 is a mating structure that cooperates with the housing 7 during the battery cell assembly process. It has guiding and positioning functions. After the battery cells are assembled into the battery cell cavity 101, the end plate positioning structure 402 is connected to the corresponding structure set on the longitudinal beam to achieve positioning and fixation of the battery cell assembly. The abutment structure 404 is used to contact and fix with the crossbeam inside the housing 7. It should be noted that in this embodiment, the end plate 4 has no adhesive relationship with the crossbeam and longitudinal beam inside the housing 7; they abut against each other after assembly.

[0060] Specifically, the end plate 4 includes an end plate body 41. An end insulation pad 401 is provided on the surface of the end plate body 41 near the battery cell 1, and an abutment structure 404 is provided on the surface of the end plate body 41 away from the battery cell 1. An end plate positioning structure 402 is provided at both ends of the end plate body 41. At least one connecting structure is provided on the end plate body 41. A first side, a second side, a third side, and a fourth side are provided sequentially along the circumference of the connecting structure. The first side faces the battery cell 1, the third side is opposite to the first side, and the second side is opposite to the fourth side. A snap-fit ​​hole 405 is provided on the third side, and a first locking structure is provided on both the second and fourth sides. A busbar fixing position is provided on the end face of the connecting structure.

[0061] In one exemplary embodiment of this application, the end insulation pad 401 is bonded to the battery cell 1 along the thickness direction of the battery cell 1. The end insulation pad 401 has a low thermal conductivity, which slows down the temperature drop rate of the battery cell 1. Preferably, the end insulation pad 401 is a soft foam material, which can absorb the battery cell assembly tolerance and provide expansion space during the battery cell 1's expansion. The end plate body 41 is preferably a non-metallic material. The end insulation pad 401 and the end plate body 41 together constitute the insulation layer of the battery cell 1, reducing the heat transfer rate between the battery cell 1 and the housing 7.

[0062] Furthermore, a fastening nut 403 is provided at the fixed position of the busbar. The fastening nut 403 allows the busbar 10 to be connected to the busbar assembly 502 between the cells by bolts after installation, making disassembly and assembly more convenient.

[0063] Specifically, in the embodiments of this application, the fastening nut 403 can move within the end plate 4 to adjust the installation tolerance of the busbar 10.

[0064] Furthermore, the battery module also includes a protective cover 9, which includes an end cover 90, a first side cover 91, and a second side cover 902. The end cover 90 extends along the length of the cell 1. The first side cover 91 is connected to the end cover 90 at an angle and extends along the length of the cell 1. A cantilever 904 is provided on the first side cover 91, which extends into a snap-fit ​​hole 405. There are two second side covers 902, which are respectively provided on both sides of the first side cover 91. The second side covers 902 are connected to the end cover 90 at an angle and extend along the thickness of the cell 1. A second locking structure is provided on both second side covers 902. The second side covers 902 are connected to the connecting structure through the second locking structure and the first locking structure. Both the end cover 90 and the second side cover 902 are provided with an opening structure 901. By providing an opening structure 901 on the end cover 90 and the second side cover 902, the protective cover 9 can accommodate various cable exit directions. The cantilever 904 enhances the height stability of the protective cover 9, ensuring that it will not fall off under external loads.

[0065] Specifically, the opening structure 901 is a virtual connection structure. During installation, the installation side is selected, and the opening structure 901 on the installation side is broken to form an opening, so that the busbar 10 can extend from the installation side into the busbar fixing position and be connected to the fastening nut 403 of the busbar fixing position by bolts.

[0066] Furthermore, the first locking structure includes at least a limiting groove 408, which extends along the height direction of the end plate body 41. The second locking structure includes at least a guide structure 903, which extends along the height direction of the battery cell 1. When the second side cover 902 is connected and engaged with the connecting structure, at least a portion of the guide structure 903 extends into the limiting groove 408. The guide structure 903 can not only guide the installation process, but also, after extending into the limiting groove 408, limit the protective cover 9 horizontally, ensuring that the protective cover 9 will not fall off under external load.

[0067] In one exemplary embodiment of this application, the first locking structure further includes a snap-fit ​​interface 406 and a limiting structure 407. The snap-fit ​​hole 405, snap-fit ​​interface 406, limiting structure 407, and limiting groove 408 together engage and fix the protective cover 9. Taking the side where one of the second side covers 902 is located as the installation side as an example, as follows... Figure 11 As shown, after the busbar 10 is installed, the snap-fit ​​hole 405 and the cantilever 904 form a snap-fit ​​structure. The guide structure 903 extends into the limiting groove 408. After the cantilever 904 snaps into the snap-fit ​​hole 405, the second side cover 902 contacts the limiting structure 407.

[0068] It should be noted that in this embodiment, the second side cover 902 itself is configured as a cover structure that cooperates with the first locking structure. For example, the edge shape of the second side cover 902 is preset so that the second side cover 902 abuts against the limiting structure 407 after assembly.

[0069] Furthermore, buffer pads 2 and heat insulation pads 3 are alternately arranged between multiple battery cells 1. Buffer pads 2 and heat insulation pads 3 have good elasticity, providing compression space when the battery cells 1 are stacked and placed into the housing 7, making battery cell assembly smoother. Simultaneously, buffer pads 2 and heat insulation pads 3 provide pressure to the battery cells 1 when they are placed into the battery cell cavity 101 and come into contact with the cavity wall. The alternating use of buffer pads 2 and heat insulation pads 3 ensures the safety of the battery module and reduces the cost of the battery module.

[0070] Preferably, the material of the cushioning pad 2 is aerogel pad, MPP foam material, rubber or any other material with cushioning function, and the material of the heat insulation pad 3 is aerogel pad or any other material with heat insulation function. The length of the cushioning pad and the heat insulation pad is 10mm to 1500mm, the width is 10mm to 400mm, and the thickness is 0.5mm to 20mm.

[0071] Specifically, in one exemplary embodiment of this application, the end plate 4, buffer pad 2, heat insulation pad 3, and battery cell 1 are all bonded together by adhesive. In conjunction with the aforementioned embodiments, the end insulation pad 401, buffer pad 2, and heat insulation pad 3 together provide space for the battery cell 1 to enter the casing, increasing the initial compression space, reducing material costs and weight, and improving the cycle life of the battery cell 1.

[0072] Based on the battery pack's thermal diffusion requirements, the internal space of the housing 7, and the cell system, select appropriate thicknesses and materials for the heat insulation pad 3 and the buffer pad 2. Figure 14 A flowchart illustrating a selection method for heat insulation pad 3 and cushioning pad 2 is shown, where the labels represent the following meanings:

[0073] t is the cell cyclic expansion gap, T is the thickness of the thermal insulation material, a is the compression rate of the buffer pad after entering the box, b is the compression rate of the thermal insulation pad after entering the box, N1 is the number of buffer pads, N2 is the number of thermal insulation pads, c is the compression rate of the buffer pad when the cells are assembled, d is the compression rate of the thermal insulation pad when the cells are assembled, e is 1 / 2 of the distance between the cell assembly and the box frame, and Σ is the cumulative tolerance of the components.

[0074] Specifically, the method includes the following steps:

[0075] Step S1: Confirm the heat insulation and cycle requirements based on the internal layout of the battery pack and the cell system;

[0076] Step S2: Determine the insulation material thickness T based on the insulation material properties, and determine the expansion gap value t based on the cyclic requirements;

[0077] Step S3: Based on the appropriate cycling pressure of the battery cell, confirm the compression ratio a of the buffer pad after it is placed in the box and the compression ratio b of the heat insulation pad after it is placed in the box;

[0078] Step S4: Calculate the original thickness of the cushioning pad 2 and the heat insulation pad 3;

[0079] Step S5: Calculate the compression dimensions that the battery cell packs need to meet when being compressed into the box under the battery cell assembly conditions;

[0080] Step S6: Calculate the compression dimensions that the cell pack needs to meet after the pressure is released under the condition of release from the charging box;

[0081] Step S7: Determine the compression rate range of buffer pad 2 and heat insulation pad 3 through two working conditions.

[0082] By following the steps above, the selection of heat insulation pad 3 and cushioning pad 2 is carried out, providing a range of initial thickness and compression ratio selection for heat insulation pad 3 and cushioning pad 2. By comparing and selecting the lower-cost solution, the product cost is saved.

[0083] According to another specific embodiment of this application, a vehicle is provided, the vehicle having a power battery, and the battery module of the power battery is the aforementioned battery module. The power battery having the battery module of the above embodiment has highly integrated module electrical connection components and low-voltage sampling harness, reducing the space occupied by the harness, reducing the number of connectors and the frequency of docking, lowering costs and improving safety. The cells are arranged in a single row and surrounded by a frame, with heat insulation material arranged between the series-connected cells, improving the thermal safety of the entire pack. The increased cell space utilization and improved power battery performance effectively solve the range problem of vehicles in the prior art. Preferably, the vehicle in this embodiment is an electric vehicle.

[0084] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0085] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0086] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0087] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A battery module, characterized by, The battery module comprises: a box (7) provided with a plurality of slave controller cavities (102) and cell cavities (101) inside; a plurality of cell groups, the cell groups are arranged in the cell cavities (101), and each cell group comprises at least a plurality of cells (1) arranged in a thickness direction of the cells (1); a plurality of high-low voltage integrated assemblies (5), each high-low voltage integrated assembly (5) is connected with at least two cell groups, the high-low voltage integrated assemblies (5) are arranged in the thickness direction of the cells (1), and the high-low voltage integrated assemblies (5) are connected with busbars (10); a slave controller (8) arranged in the slave controller cavity (102) and connected with the high-low voltage integrated assemblies (5); the high-low voltage integrated assembly (5) comprises: two insulating films (501) arranged in the thickness direction of the cells (1); a cell-to-cell busbar assembly (502) arranged between the two insulating films (501) and arranged in the thickness direction of the cells (1), one end of the cell-to-cell busbar assembly (502) close to the slave controller (8) being connected with the busbar (10); a flexible circuit board assembly (503) arranged between the two insulating films (501) and arranged in the thickness direction of the cells (1), one end of the flexible circuit board assembly (503) being connected with the slave controller (8); a plurality of framework structures (506) arranged on one of the insulating films (501) and arranged in a width direction of the insulating film (501); a plurality of support assemblies (505) arranged in the width direction of the insulating film (501); the battery module comprises an end plate (4) connected with the cells (1) at an end of the cell group, the end plate (4) comprises an end plate body (41) provided with at least one connecting structure, a first side face, a second side face, a third side face and a fourth side face are sequentially arranged in a circumferential direction of the connecting structure, a buckle hole (405) is arranged on the third side face, and a first clamping structure is arranged on the second side face and the fourth side face; the battery module further comprises a protective cover (9) comprising: an end cover (90) arranged in a length direction of the cells (1). A first side cover (91) is connected with the end cover (90) at an angle, the first side cover (91) is arranged along the length direction of the battery cell (1), and a cantilever (904) is arranged on the first side cover (91) and extends into the buckle hole (405); Two second side covers (902) are arranged on both sides of the first side cover (91), the second side cover (902) is connected with the end cover (90) at an angle, the second side cover (902) is arranged along the thickness direction of the battery cell (1), and a second clamping structure is arranged on each of the two second side covers (902), and the second side cover (902) is connected with the first clamping structure and the connecting structure through the second clamping structure. The end cover (90) and the second side cover (902) are provided with opening structures (901).

2. The battery module of claim 1, wherein, The high-low voltage integrated assembly (5) is coated with an insulating material (6) on at least part of the outer surface.

3. The battery module of claim 1, wherein, The end plate (4) is provided with an end plate positioning structure (402) at both ends, and at least part of the surface of the end plate (4) is provided with an abutting structure (404), and the end plate positioning structure (402) and the abutting structure (404) are arranged in abutment with the cavity wall of the battery cell cavity (101); 4. The battery module of claim 1, wherein, The end plate (4) is provided with a busbar fixing position for connecting the inter-battery cell busbar assembly (502) and the busbar (10). The surface of the end plate body (41) close to the battery cell (1) is provided with an end portion heat preservation pad (401), the surface of the end plate body (41) away from the battery cell (1) is provided with the abutting structure (404), and the two ends of the end plate body (41) are respectively provided with the end plate positioning structure (402).

5. The battery module of claim 4, wherein, The first side surface is arranged towards the battery cell (1), the third side surface is arranged opposite to the first side surface, and the second side surface is arranged opposite to the fourth side surface. The busbar fixing position is arranged on the end surface of the connecting structure. The busbar fixing position is provided with a fastening nut (403).

6. The battery module according to claim 4 or 5, characterized in that, The first clamping structure at least includes a limiting groove (408) arranged along the height direction of the end plate body (41), the second clamping structure at least includes a guide structure (903) arranged along the height direction of the battery cell (1), and at least part of the guide structure (903) extends into the limiting groove (408) when the second side cover (902) is connected and matched with the connecting structure.

7. The battery module of claim 6, wherein, The buffer pads (2) and the heat insulation pads (3) are alternately arranged between the plurality of battery cells (1).

8. The battery module of claim 1, wherein, The battery module of the power battery is the battery module according to any one of claims 1-8.

9. A vehicle having a power battery, characterized by The battery module of the power battery is the battery module according to any one of claims 1-8.

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