Battery packaging assembly method, battery package and tooling

Abstract

The application provides a battery package assembly method, a battery package and a tooling, wherein the battery package assembly method comprises the following steps: placing a battery support on a working plane of a reference platform, and placing single batteries on the battery support to form a battery module main body; welding a CCS assembly on the top of the battery module main body to form a battery module; and driving a ring frame outside the reference platform so that the ring frame reaches an assembly position of the battery support. In the application, the working plane of the reference platform can provide good flatness guarantee for the battery support, the possibility of a gap between the reference platform and the bottom surface of the battery support due to poor flatness of the reference platform can be reduced, the possibility of bending deformation of the battery support after the single batteries are assembled can be reduced, the CCS assembly can be fully attached to the positive and negative poles of each single battery in the longitudinal direction, and the probability of a virtual welding phenomenon during welding of the CCS assembly can be reduced.

Description

Technical Field

[0001] This invention relates to the field of battery technology, and in particular to a battery packaging assembly method, battery pack, and tooling. Background Technology

[0002] In existing technologies, cylindrical battery packs typically include a housing and battery modules housed within the housing. The housing includes a ring frame and a bottom protective plate at the bottom of the ring frame. The battery module includes a battery support frame at the bottom of the housing, individual cells mounted on the battery support frame, and a CCS (Computer-Controlled System) module mounted on each individual cell. The CCS module is welded to the individual cells. In traditional assembly processes, the battery support frame is first assembled into the housing, then the individual cells are arranged on the battery support frame to form the main body of the battery module, and finally the CCS module is welded onto the main body of the battery module to form the battery module.

[0003] There are generally two existing methods for assembling battery brackets and housings. One is that the two ends of the battery bracket overlap the housing, leaving the main body of the battery bracket suspended. The other is that the bottom of the battery bracket abuts against the inner side of the bottom of the housing, i.e., against the inner side of the bottom protective plate. In the first assembly method, the weight of the battery module easily causes the middle of the battery bracket to bend towards the bottom protective plate. In the second assembly method, the bottom protective plate can provide some support to the battery bracket, but because it is usually a thin-walled steel plate with its fixing points located around the perimeter, the support it can provide to the battery bracket is limited. Furthermore, due to limitations in assembly and manufacturing precision, the battery bracket abutting against the bottom protective plate cannot achieve a perfectly flat surface. In other words, in both assembly methods, the battery bracket is at risk of bending and deformation to varying degrees, which increases the probability of incomplete soldering during the welding of CCS components. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the first objective of the present invention is to provide a battery pack assembly method that can effectively reduce the probability of poor soldering between CCS modules and individual cells.

[0005] The second objective of this invention is to provide a battery pack with high overall strength, reliable connection between the CCS component and the individual battery cells, and high safety.

[0006] The third objective of this invention is to provide a tooling that can effectively assist in battery pack assembly and improve battery pack assembly efficiency.

[0007] The embodiments of the present invention are achieved through the following technical solutions:

[0008] A battery pack assembly method includes: step S101, placing a battery bracket on the working plane of a reference platform and placing individual batteries on the battery bracket to form a battery module body; step S102, welding a CCS assembly on the top of the battery module body to form a battery module; and step S103, driving a ring frame fitted outside the reference platform so that the ring frame reaches the assembly position with the battery bracket.

[0009] According to a preferred embodiment, before step S101, the method further includes: fitting the ring frame outside the reference platform.

[0010] According to a preferred embodiment, after step S103, the method further includes a curing operation to cure the battery module and the ring frame.

[0011] According to a preferred embodiment, the curing operation includes injecting expanding foam between the battery module and the ring frame, between two adjacent battery modules, and between the individual cells of the battery module.

[0012] According to a preferred embodiment, before the curing operation, the method further includes: step S401, laying a thermally conductive structural adhesive on the top of the CCS assembly; step S402, laying a liquid cooling plate on the thermally conductive structural adhesive.

[0013] According to a preferred embodiment, steps S401 and S402 are located between steps S102 and S103.

[0014] According to a preferred embodiment, after the curing operation, the method further includes: step S501, driving the ring frame so that the ring frame and the battery module are separated from the working plane of the reference platform; step S502, assembling a bottom protective plate at the bottom of the ring frame to form a housing.

[0015] According to a preferred embodiment, after step S502, the method further includes: assembling a cover on the top of the ring frame.

[0016] According to a preferred embodiment, after step S102, the method further includes assembling electrical components.

[0017] A battery pack, said battery pack being manufactured using the battery pack assembly method described above.

[0018] A tooling includes: a reference platform, the top of which is provided with a working plane for supporting a battery bracket, the end of which can extend out of the working plane; and a telescopic component disposed on the periphery of the reference platform, the telescopic component being capable of longitudinal extension and retraction to support a battery pack.

[0019] According to a preferred embodiment, the telescopic end of the telescopic component is provided with a support plate.

[0020] According to a preferred embodiment, a fixing hole is provided through the support plate.

[0021] The technical solutions of the embodiments of the present invention have at least the following advantages and beneficial effects:

[0022] In the battery pack assembly method provided by the present invention, the working plane of the reference platform can provide good flatness assurance for the battery bracket, which can reduce the possibility of gaps between the reference platform and the bottom surface of the battery bracket due to the flatness difference of the reference platform. This can reduce the possibility of bending deformation of the battery bracket at the gap after assembling individual cells, and ensure that the CCS module can be fully attached to the positive and negative electrodes of each individual cell in the longitudinal direction, so that the CCS module and the positive and negative electrodes of each individual cell are firmly welded, thereby reducing the probability of cold solder joints when welding the CCS module. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 A flowchart of a battery pack assembly method provided in an embodiment of the present invention;

[0025] Figure 2 This is a top view of the battery packaging assembly provided in an embodiment of the present invention.

[0026] Figure 3 for Figure 2 A partially enlarged schematic diagram of the structure at point A;

[0027] Figure 4 This is a schematic diagram of the first state structure of the battery packaging assembled with the tooling according to an embodiment of the present invention;

[0028] Figure 5 This is a schematic diagram of the second state structure of the battery packaging assembled with the tooling according to an embodiment of the present invention;

[0029] Figure 6 This is a schematic diagram of the third state structure of the battery packaging assembly provided in an embodiment of the present invention.

[0030] Icons: 200-Battery pack, 201-Ring frame, 202-Battery module, 2021-CCS module, 2022-Single cell, 2023-Battery bracket, 2024-Bottom cover plate, 203-Overlap beam, 204-Mounting beam, 2041-Mounting hole, 300-Base platform, 301-Telescopic assembly, 302-Working plane. Detailed Implementation

[0031] To better understand and implement this invention, the technical solutions in the embodiments of the invention will be clearly and completely described below with reference to the accompanying drawings.

[0032] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" used to indicate orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0033] In the description of this invention, unless otherwise expressly specified and limited, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more; and the term "and / or" includes any and all combinations of one or more of the associated listed items. In particular, references to "the / described" object or "an" object are also intended to indicate one of a possible plurality of such objects.

[0034] Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used in the specification of this application is for the purpose of describing particular embodiments only and is not intended to limit this application; the terms "comprising" and "having" and any variations thereof in the specification, claims and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0035] Furthermore, in the description of this invention, it should be understood that the directional terms such as "upper," "lower," "inner," and "outer" are used to describe the angles shown in the accompanying drawings and should not be construed as limiting specific embodiments. It should also be understood that, in the context of an element or feature being connected "upper," "lower," "inner," or "outer" of another element (one or more), it can be directly connected to the other element (one or more) "upper," "lower," "inner," or "outer," or indirectly connected to the other element (one or more) "upper," "lower," "inner," or "outer" through an intermediate element.

[0036] Please refer to Figures 1 to 6 A battery packaging method, applied to, for example Figures 2 to 6 The battery pack 200 shown includes a housing and battery modules 202 disposed within the housing. The housing includes a ring frame 201 and a bottom protective plate 2024 disposed at the bottom of the ring frame 201. The battery module 202 includes a battery bracket 2023 disposed at the bottom of the housing, individual battery cells 2022 disposed on the battery bracket 2023, and a CCS assembly 2021 disposed on the individual battery cells 2022. Further, the inner sidewall of the ring frame 201 is provided with an overlapping beam 203 for overlapping the battery bracket 2023 or the battery module 202, and the outer sidewall of the ring frame 201 is provided with a mounting beam 204 for mounting the battery pack 200 with electrical equipment.

[0037] Specifically, the assembly method of the battery pack 200 includes the following steps;

[0038] In step S101, the battery bracket 2023 is placed on the working plane 302 of the reference platform 300, and the individual battery 2022 is placed on the battery bracket 2023 to form the main body of the battery module 202. In this step, the working plane 302 of the reference platform 300 can provide a good flatness guarantee for the battery bracket 2023, which can reduce the possibility of gaps between the reference platform 300 and the bottom surface of the battery bracket 2023 due to the flatness difference of the reference platform 300, thereby reducing the possibility of bending deformation of the battery bracket 2023 at the gap after assembling the individual battery 2022.

[0039] In step S102, CCS component 2021 is welded to the top of the main body of battery module 202. Based on step S101, after CCS component 2021 is installed on the top of the main body of battery module 202, CCS component 2021 can fully fit with the positive and negative electrodes of each individual battery 2022 in the longitudinal direction, which can ensure that CCS component 2021 is firmly welded to the positive and negative electrodes of each individual battery 2022, thereby effectively reducing the probability of poor soldering when welding CCS component 2021.

[0040] Step S103: Drive the ring frame 201 fitted outside the reference platform 300, so that the ring frame 201 reaches the assembly position with the battery holder 2023. Specifically, after the CCS assembly 2021 is welded in step S102, the ring frame 201 is moved to the assembly position with the battery holder 2023 for the next operation. In this embodiment, as... Figure 4 and Figure 5As shown, the battery bracket 2023 is placed on the working plane 302 of the reference platform 300 as a fixed reference position. The battery bracket 2023 is moved longitudinally from bottom to top until the overlapping beam 203 comes infinitely close to the lower side of the battery bracket 2023. Ideally, the overlapping beam 203 should just touch the lower side of the battery bracket 2023 without exerting a longitudinal force on it. That is, the longitudinal upward support force of the reference platform 300 on the battery bracket 2023 is equal to the downward longitudinal gravity acting on the battery bracket 2023. At this point, the ring frame 201 reaches the assembly position with the battery bracket 2023, i.e., as shown... Figure 5 The assembly state is shown.

[0041] Furthermore, after step S103, that is, after driving the ring frame 201 fitted outside the reference platform 300 to the assembly position with the battery bracket 2023, the process further includes a curing operation to cure the battery module 202 and the ring frame 201. In this embodiment, by designing the curing of the battery module 202 and the ring frame 201, the two are connected as a whole, which helps to improve the overall structural strength of the battery pack 200.

[0042] Specifically, the curing operation, which involves curing the battery module 202 and the ring frame 201, includes injecting expanding foam between the battery module 202 and the ring frame 201, between two adjacent battery modules 202, and between the individual cells 2022 of the battery module 202. This expanding foam can fully fill the gaps between the battery module 202 and the ring frame 201, the gaps between two adjacent battery modules 202, and the gaps between the individual cells 2022 of the battery module 202. After a certain period of settling, the expanding foam cures, thereby bonding the individual cells 2022 within the battery module 202 to each other as a whole, bonding two adjacent battery modules 202 to a whole, and bonding the battery module 202 and the ring frame 201 to a whole. This allows the components inside the battery pack 200 to be bonded to the ring frame 201 as a whole after being encapsulated with foam. This design eliminates the need for the crossbeam structure in the traditional battery box without affecting the overall strength of the battery pack 200, which helps to reduce the material and production costs of the box.

[0043] Furthermore, the curing operation, which is the step before curing the battery module 202 and the ring frame 201, also includes:

[0044] Step S401: Apply thermally conductive structural adhesive to the top of CCS component 2021;

[0045] Step S402: Lay a liquid cooling plate (not shown in the figure) on the thermally conductive structural adhesive.

[0046] It should be noted that steps S401 and S402 are performed between steps S102 and S103. That is, the steps of laying thermally conductive structural adhesive on top of the CCS component 2021 and laying liquid cooling plate on the thermally conductive structural adhesive are performed after the step of welding the CCS component 2021 on top of the battery module 202 body to form the battery module 202, and before the step of driving the ring frame 201, which is sleeved outside the reference platform 300, to reach the assembly position with the battery bracket 2023. By performing step S103 after steps S401 and S402, it is possible to prevent the ring frame 201 from causing spatial interference to the execution of steps S401 and S402, and to facilitate the execution of steps S401 and S402. Here, the liquid cooling plate is bonded to the top of the CCS module 2021 using thermally conductive structural adhesive. This not only secures the liquid cooling plate to the battery module 202 but also efficiently transfers the heat generated by the battery module 202 to the liquid cooling plate, improving the heat dissipation efficiency of the battery pack 200.

[0047] In this embodiment, the curing operation, that is, after the curing step of the battery module 202 and the ring frame 201, also includes:

[0048] Step S501, drive the ring frame 201 so that the ring frame 201 and the battery module 202 are removed from the working plane 302 of the reference platform 300;

[0049] Step S502: Assemble the bottom protective plate 2024 at the bottom of the ring frame 201 to form the box body.

[0050] The above steps are specifically as follows: Figure 5 and Figure 6 As shown, the telescopic component 301 located around the reference platform 300 drives the ring frame 201, that is, drives the battery pack 200 to move upward to separate from the working plane 302 of the reference platform 300, so that the bottom of the ring frame 201 is exposed, thereby facilitating the installation of the bottom guard plate 2024 at the bottom of the ring frame 201.

[0051] In this embodiment, when performing step S501, since the ring frame 201 and the battery module 202 have been cured by foaming adhesive, the structural strength of the battery pack 200 can be guaranteed. After the battery bracket 2023 is removed from the working plane 302, it will not bend downward due to gravity, which can effectively prevent the individual battery 2022 from desoldering from the CCS component 2021 during the transfer process.

[0052] In this embodiment, optionally, the telescopic end of the telescopic component 301 abuts against the lower side of the mounting beam 204.

[0053] Optionally, the telescopic component 301 can be a cylinder, hydraulic system, or a linear module capable of longitudinal drive. When a linear module is selected, the drive end of the linear module (generally a slider that cooperates with a lead screw) abuts against the mounting beam 204.

[0054] Of course, in other embodiments, the telescopic component 301 can also be abutted to other positions of the housing, as long as it does not affect the assembly of the bottom guard plate 2024.

[0055] Furthermore, after step S502, that is, after assembling the bottom protective plate 2024 at the bottom of the ring frame 201 to form the housing, the method further includes assembling a top cover at the top of the ring frame 201. After performing the above steps, the top cover is installed to form a complete battery pack 200 structure. After subsequent steps of battery pack 200 airtightness testing and PACK EOL testing, labels can be affixed and the pack can be packaged and shipped.

[0056] In this embodiment, after step S102, that is, after welding the CCS assembly 2021 to the top of the battery module 202 body to form the battery module 202, the method further includes: electrical component assembly. After the electrical component assembly step is completed, the battery module 202 and the ring frame 201 are cured, so that all components in the area of ​​the battery pack 200 that needs to be filled with expanding foam can be encapsulated and cured with expanding foam.

[0057] In this embodiment, before step S101, which involves placing the battery bracket 2023 on the working plane 302 of the reference platform 300 and placing the individual battery 2022 on the battery bracket 2023 to form the main body of the battery module 202, the method further includes: fitting the ring frame 201 around the reference platform 300. In this embodiment, when performing this step, the ring frame 201 is required to fit around the reference platform 300 and abut against the telescopic end of the telescopic component 301. It can be understood that the ring frame 201 is located on the underside of the battery bracket 2023, specifically as follows... Figure 4 As shown.

[0058] In summary, the assembly method of the battery pack 200 provided in this embodiment includes the following steps:

[0059] Step 1: Fit the ring frame 201 onto the reference platform 300;

[0060] Step 2: Place the battery bracket 2023 on the working plane 302 of the reference platform 300, and place the individual battery 2022 on the battery bracket 2023 to form the main body of the battery module 202.

[0061] Step 3: Weld CCS assembly 2021 to the top of the main body of battery module 202 to form battery module 202;

[0062] Step 4, electrical component assembly;

[0063] Step 5: Apply thermally conductive structural adhesive to the top of the CCS component 2021;

[0064] Step 6: Lay the liquid cooling plate on the thermally conductive structural adhesive;

[0065] Step 7: Drive the ring frame 201 fitted outside the reference platform 300 so that the ring frame 201 reaches the assembly position with the battery bracket 2023.

[0066] Step 8: Inject expanding foam between the battery module 202 and the ring frame 201, between two adjacent battery modules 202, and between the individual cells 2022 of the battery module 202.

[0067] Step 9: Drive the ring frame 201 so that the ring frame 201 and the battery module 202 are removed from the working plane 302 of the reference platform 300.

[0068] Step 10: Assemble the bottom protective plate 2024 at the bottom of the ring frame 201 to form the box body;

[0069] Step 11: Assemble the cover on the top of the ring frame 201;

[0070] Step 12, Battery Pack 200 airtightness test;

[0071] Step 13, PACK EOL detection;

[0072] Step 14, paste the label;

[0073] Step 15: Pack and ship.

[0074] This embodiment also provides a battery pack 200, which is manufactured by the battery pack 200 assembly method described above. The CCS component 2021 of the battery pack 200 is reliably connected to the individual battery cells 2022, ensuring high safety.

[0075] This embodiment also provides a tooling for assembling the battery pack 200, comprising at least the aforementioned reference platform 300 and the aforementioned telescopic component 301. The top of the reference platform 300 is provided with a working plane 302 for supporting the battery bracket 2023, and the end of the battery bracket 2023 can extend out of the working plane 302. The telescopic component 301 is disposed around the periphery of the reference platform 300 and can extend and retract longitudinally to support the battery pack 200. In this embodiment, the telescopic end of the telescopic component 301 abuts against the mounting beam 204 to drive the battery pack 200. This tooling can effectively assist in the assembly of the battery pack 200 and improve the assembly efficiency of the battery pack 200.

[0076] Furthermore, to improve structural stability, the telescopic end of the telescopic component 301 is provided with a support plate that fits against the mounting beam 204. This support plate can increase the contact area between the telescopic component 301 and the battery pack 200, thereby improving the stability of the tooling during operation.

[0077] Furthermore, the support plate is provided with fixing holes (not shown in the figure) that correspond to the mounting holes 2041 on the support beam. In use, the mounting holes 2041 can be aligned with the fixing holes, and bolts can be passed through them to fix the battery pack 200 to the telescopic assembly 301, which can further improve the stability of the assembly after the battery pack 200 is assembled.

[0078] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications are also considered within the scope of protection of this invention.

Claims

1. A battery packaging method, characterized in that, The steps include the following: Step S101: Place the battery bracket (2023) on the working plane (302) of the reference platform (300), and place the individual battery (2022) on the battery bracket (2023) to form the main body of the battery module (202), wherein the end of the battery bracket (2023) can extend out of the working plane (302); Step S102: Weld CCS assembly (2021) to the top of the battery module (202) body to form battery module (202); Step S103: Drive the ring frame (201) sleeved outside the reference platform (300) so that the ring frame (201) reaches the assembly position with the battery bracket (2023); The curing operation solidifies the battery module (202) and the ring frame (201); Step S501: Drive the ring frame (201) so that the ring frame (201) and the battery module (202) are separated from the working plane (302) of the reference platform (300); Step S502: Assemble a bottom protective plate (2024) at the bottom of the ring frame (201) to form a box; A cover is fitted on top of the ring frame (201).

2. The battery packaging method according to claim 1, characterized in that, Before step S101, the method further includes: The ring frame (201) is fitted over the reference platform (300).

3. The battery packaging method according to claim 1, characterized in that, The curing process includes: Foaming adhesive is injected between the battery module (202) and the ring frame (201), between two adjacent battery modules (202), and between the individual cells (2022) of the battery module (202).

4. The battery packaging method according to claim 3, characterized in that, Prior to the curing operation, the following steps are also included: Step S401: Apply thermally conductive structural adhesive to the top of the CCS assembly (2021); Step S402: Lay a liquid cooling plate on the thermally conductive structural adhesive.

5. The battery packaging method according to claim 4, characterized in that, Steps S401 and S402 are located between steps S102 and S103.

6. The battery packaging method according to claim 1, characterized in that, After step S102, the method further includes: Assembly of electrical components.

7. A battery pack (200), characterized in that, The battery pack (200) is made by the battery pack assembly method as described in any one of claims 1-6.

8. A tooling, characterized in that, The battery pack assembly method according to any one of claims 1-6 includes: A reference platform (300) is provided with a working plane (302) on its top for supporting a battery bracket (2023), the end of which can extend out of the working plane (302); A telescopic component (301) is disposed on the periphery of the reference platform (300), and the telescopic component (301) is capable of longitudinal extension and retraction to support the battery pack (200).

9. The tooling according to claim 8, characterized in that, The telescopic component (301) is provided with a support plate at its telescopic end.

10. The tooling according to claim 9, characterized in that, The support plate has a through-hole for fixing.

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