Supporting assembly, battery box body, battery and electric equipment

Abstract

The invention discloses a supporting assembly, a battery box body, a battery and electric equipment. The supporting assembly comprises at least two plate layers (20a, 20b and 20c), the at least two plate layers (20a, 20b and 20c) are arranged in a stacked mode, and interval spaces (g1 and g2) are formed between the adjacent plate layers in the at least two plate layers (20a, 20b and 20c). And a support structure (30) disposed in the spaced spaces (g1, g2), the support structure (30) comprising a plurality of cavity portions (31), at least a portion of the plurality of cavity portions (31) extending in a first direction (r1), the first direction (r1) intersecting the opposing surfaces (S1, S2) of the adjacent sheet layers.

Description

Support components, battery boxes, batteries and electrical equipment Technical Field

[0001] The present disclosure relates to the field of battery technology, and in particular to a support assembly, a battery box, a battery, and an electrical device. Background Art

[0002] Secondary batteries, especially lithium-ion batteries, offer advantages such as high voltage, high specific energy, long cycle life, environmental friendliness, a wide operating temperature range, and low self-discharge. They are widely used in portable electronic devices and large-scale new energy electric vehicles, playing a significant role in addressing environmental pollution and the energy crisis. However, there is a need for further improvements in the housings that hold the battery cells.

[0003] Summary of the Invention

[0004] In one aspect of the present disclosure, there is provided a support assembly comprising:

[0005] At least two sheet material layers, the at least two sheet material layers are stacked, and a space is provided between adjacent sheet material layers in the at least two sheet material layers; and

[0006] A support structure is arranged in the spacing space, and the support structure includes a plurality of cavity portions, at least a portion of the plurality of cavity portions extends along a first direction, and the first direction intersects with the opposite surfaces of the adjacent plate layers.

[0007] By arranging a plurality of cavity portions in the interval space between adjacent stacked plate layers, and making at least a portion of the plurality of cavity portions extend along a first direction intersecting with the relative surfaces of the adjacent plate layers, the support assembly can provide reliable support to the plate layers through the solid material forming the cavity portions in the support structure when subjected to external pressure, and the plurality of cavity portions can be distributed over a larger range in the interval space, thereby improving the overall support effect of the support assembly while reducing the weight of the support structure, making the support assembly lighter.

[0008] In some embodiments, the first direction intersects perpendicularly with opposite surfaces of adjacent sheet layers.

[0009] By extending at least a portion of the multiple cavity portions along a first direction perpendicular to the relative surfaces of adjacent plate layers, the pressure bearing capacity of the support assembly can be greatly improved, which is conducive to further weight reduction or thinning of the support assembly.

[0010] In some embodiments, the first direction intersects opposite surfaces of adjacent sheet layers at acute angles.

[0011] By extending at least a portion of the plurality of cavities along a first direction intersecting with opposite surfaces of adjacent sheet material layers at acute angles, the distribution range of the support assembly in the spacing space can be increased while meeting the pressure bearing requirements of the support assembly.

[0012] In some embodiments, the first direction intersects one of the opposing surfaces of the adjacent sheet layers at an acute angle and intersects the other of the opposing surfaces of the adjacent sheet layers at right angles.

[0013] According to the actual needs of the application, at least a portion of the multiple cavity portions can be extended along a first direction that intersects the relative surfaces of adjacent plate layers at acute angles and right angles respectively, thereby matching different pressure distribution and thickness distribution requirements of the plate layers.

[0014] In some embodiments, an angle Q formed by the intersection of the first direction and the relative surface satisfies: 75°≤Q≤90°.

[0015] For the angle Q between the first direction and any of the opposing surfaces, when the angle Q is 90°, the direction of the pressure exerted by the multiple cavities on the opposing surface is parallel to the first direction, achieving a greater pressure-bearing effect. However, when the angle Q is too small, the pressure exerted by the multiple cavities on the opposing surface is decomposed into a smaller component perpendicular to the opposing surface, weakening the support effect. Therefore, by ensuring that the angle Q satisfies 75°≤Q≤90°, the support structure's support for the sheet material layer can be improved, thereby effectively enhancing the support effectiveness of the support assembly.

[0016] In some embodiments, the plurality of cavity portions are spaced apart along one or more second directions parallel to one of the opposing surfaces.

[0017] By arranging the multiple cavity portions at intervals along one or more second directions parallel to the relative surfaces, the multiple cavity portions can be distributed over a larger range and more evenly between adjacent plate layers, which helps to disperse the pressure when the support component is under pressure, reducing the risk of the support component being crushed, and can also meet the pressure requirements while correspondingly reducing the requirements for the material strength and amount of the support structure.

[0018] In some embodiments, the support structure is integrally formed.

[0019] The support structure can be integrally formed before being placed in the spacing space between adjacent sheet material layers. This not only helps to improve assembly efficiency, but also can utilize the integrally formed support structure to obtain a more stable support effect.

[0020] In some embodiments, on a cross section parallel to one of the opposing surfaces, a minimum distance d between two adjacent cavity portions among the plurality of cavity portions is smaller than a maximum cross-sectional width W1 of any one of the two adjacent cavity portions.

[0021] Among multiple cavity portions, the portion between two adjacent cavity portions may include solid materials that form the cavity portions. By making the maximum width W1 of the hollow cross-section of the cavity portion greater than the minimum spacing d between two adjacent cavity portions, the amount of solid materials in the supporting structure can be reduced, thereby reducing the amount of materials that form the supporting structure while satisfying the supporting effect, thereby reducing cost and weight.

[0022] In some embodiments, the minimum spacing d satisfies: 0.5 mm ≤ d ≤ 4 mm; and / or, the maximum width W1 of the cross section satisfies: 2.3 mm ≤ W1 ≤ 17.3 mm.

[0023] If the minimum spacing d between two adjacent cavity parts is too small, they are prone to deformation or damage when subjected to pressure; if the minimum spacing d is too large, more solid materials need to be used, resulting in increased cost and weight. Therefore, by making the minimum spacing d meet the following conditions: 0.5mm≤d≤4mm, it is possible to achieve both good pressure-bearing effect and reduced cost and weight. If the maximum width W1 of the cross section is too small, more cavity parts need to be arranged per unit area, making the support structure more complex, increasing the difficulty of manufacturing, and easily increasing the amount of material of the support assembly, making the overall weight heavier; if the maximum width W1 of the cross section is too large, it may affect the support structure's dispersion effect on the supporting force, thereby weakening the support function of the support structure. Therefore, by making the maximum width W1 of the cross section meet the following conditions: 2.3mm≤W1≤17.3mm, it is possible to achieve both simplification and weight reduction of the support structure, as well as the dispersion effect of the support structure.

[0024] In some embodiments, in a cross section parallel to one of the opposing surfaces, the cross-sectional shape of at least a portion of the plurality of cavity portions is a regular hexagon, and the cross-sectional dimensions are equal.

[0025] By making the cross-sectional shape of at least a portion of the hollow holes regular hexagons and having equal cross-sectional dimensions, a honeycomb-type local or overall support structure can be formed. This honeycomb-type support structure is very stable and has good supporting performance, and can effectively improve the overall supporting performance of the support assembly.

[0026] In some embodiments, the support structure includes a plurality of tubes, at least some of which are independently formed, and the plurality of cavity portions include a first cavity surrounded by an inner wall of each tube.

[0027] Forming the support structure by independently forming at least a portion of the tube body and utilizing the first cavity enclosed by the inner wall of the tube body as the cavity portion helps reduce the difficulty of forming the support structure. Moreover, the tube body is easy to obtain or manufacture, which also helps reduce the manufacturing cost of the support assembly.

[0028] In some embodiments, the plurality of cavity portions further include a second cavity surrounded by outer walls of adjacent tubes among the plurality of tubes.

[0029] For a plurality of tubes in which gaps can be formed between adjacent tubes, the second cavity surrounded by the outer walls of the adjacent tubes can be used as a cavity portion, thereby forming more cavity portions in a more convenient manner.

[0030] In some embodiments, in a cross section parallel to one of the opposing surfaces, a maximum cross-sectional width W2 of the first cavity is greater than a minimum wall thickness t of the tube body.

[0031] In the multiple cavity portions formed by multiple tubes, by making the maximum cross-sectional width W2 of the first cavity greater than the minimum wall thickness t of the tube, the amount of material of the tube in the support structure can be reduced while meeting the support effect, thereby reducing the cost and weight of the support structure.

[0032] In some embodiments, the maximum width W2 of the cross section satisfies: 3mm≤W2≤15mm; and / or, the minimum wall thickness t satisfies: 0.5mm≤t≤4mm.

[0033] If the maximum cross-sectional width W2 is too small, more cavities will need to be arranged per unit area, making the support structure more complex, increasing the difficulty of manufacturing, and easily increasing the amount of material in the tube body, making the overall weight heavier; if the maximum cross-sectional width W2 is too large, it may affect the support structure's dispersion effect on the supporting force, thereby weakening the support function of the support structure. Therefore, by making the maximum cross-sectional width W2 satisfy: 3mm≤W1≤15mm, the simplification and weight reduction of the support structure, as well as the dispersion effect of the support structure, can be taken into account. If the minimum wall thickness t is too small, it is easy to deform or break when subjected to pressure; if the minimum wall thickness t is too large, more material is required, resulting in an increase in cost and weight. Therefore, by making the minimum wall thickness t satisfy: 0.5mm≤t≤4mm, a good pressure-bearing effect and a reduction in cost and weight can be taken into account.

[0034] In some embodiments, in a cross section parallel to one of the opposing surfaces, the cross-sectional shape of at least a portion of the plurality of tubes is circular, and the cross-sectional dimensions are equal.

[0035] A circular tube with a circular cross-sectional shape is easier to obtain or manufacture, and compared with other shapes, it can obtain stronger supporting performance with the same amount of material.

[0036] In some embodiments, the opposing surfaces of the adjacent sheet materials have a first area and a second area, the opposing surfaces of the adjacent sheet materials form the separation space in the first area, and are arranged in close contact in the second area.

[0037] In order to improve the connection reliability between the support component and other structures, a first area is set on the relative surfaces of adjacent plate layers to accommodate the support structure, and a second area is set to fit the relative surfaces. In this way, the part of the support component corresponding to the second area can be used to connect other structures to improve the connection strength, while the first area can be used to bear pressure, thereby meeting the usage requirements of different parts of the support component.

[0038] In some embodiments, the second region is located at an outer edge of the first region and encloses the first region.

[0039] By setting the second area on the outer edge of the first area and enclosing the first area, the surface-contacted second area can be used to form a closed separation space for accommodating the first area of ​​the support structure, so that the support structure is more stably constrained in the separation space, thereby improving the overall pressure-bearing capacity and stability of the support assembly.

[0040] In some embodiments, the first area is provided in plurality, the plurality of first areas are separated from each other, and the second area is provided on the outer edge of each first area.

[0041] Depending on the form of other structures connected to the support assembly, multiple first areas can be set, and the multiple first areas are separated from each other, while the second area surrounds the outer edge of each first area. In this way, different parts of other structures (such as the outer edge or the middle beam, etc.) can be connected through the second area, and the pressure requirements of different areas can be met through multiple first areas.

[0042] In some embodiments, in the stacking direction of the at least two sheet material layers, a portion of an outer surface of at least one side of the at least two sheet material layers corresponding to the first area is raised relative to a portion corresponding to the second area.

[0043] For the outer surface of at least two plate layers, the part corresponding to the first area is raised relative to the part corresponding to the second area so that the pressure is mainly borne by the part of the support component containing the support structure, thereby improving the support effect. In addition, the raised structure can also achieve a rough positioning effect when the support component is connected to other structures.

[0044] In some embodiments, in the stacking direction of the at least two sheet material layers, the outer surface of at least one side of the at least two sheet material layers is a plane.

[0045] By setting the outer surface of at least one side of at least two plate layers to be a plane, the plate can be placed more stably on a flat surface through the side plane, and the force is more uniform, thus avoiding stress concentration.

[0046] In some embodiments, at least a portion of the at least two sheet materials are made of metal, and the support structure is made of metal, so that the support structure can be welded to at least one of the opposing surfaces of the adjacent sheet materials.

[0047] By making at least a portion of at least two plate layers comprise metal and the support structure also comprise metal, tight and fixed connections between different plate layers and between adjacent plate layers of the support structure can be achieved by welding.

[0048] In some embodiments, the material of at least a portion of the at least two sheet materials comprises plastic, and the material of the support structure comprises plastic, so that the support structure can be heat-fused connected to at least one of the opposing surfaces of the adjacent sheet materials.

[0049] By making at least a portion of at least two sheet material layers comprise plastic and the support structure also comprise plastic, a tight and fixed connection between different sheet material layers and between adjacent sheet material layers of the support structure can be achieved by hot melting.

[0050] In some embodiments, the support assembly further comprises:

[0051] The strengthening layer covers the outer surface of at least one side of the at least two plate layers along the stacking direction of the at least two plate layers.

[0052] By covering the outer surfaces of at least two plate layers with a strengthening layer, the surface strength of the support component can be further increased, and the wear resistance and scratch resistance of the support component can be improved.

[0053] In one aspect of the present disclosure, a battery box is provided, comprising the aforementioned support assembly,

[0054] Wherein, the support assembly is configured to form at least one wall of the battery box.

[0055] Using the aforementioned support assembly to form at least one wall of the battery box can improve the supporting performance of the battery box and reduce the weight of the battery box.

[0056] In some embodiments, the battery case includes:

[0057] The box body has a receiving groove; and

[0058] A box cover is provided at the open end of the receiving groove and is configured to cover the receiving groove.

[0059] Wherein, the support assembly is configured to form the bottom wall of the box body.

[0060] Setting the support component as the bottom wall of the box body can simplify the structure of the battery box and improve the supporting performance of the bottom wall, so as to better protect the battery box itself and the battery cells inside it when the battery box is squeezed or collided from one side of the bottom wall.

[0061] In some embodiments, the box body includes a box frame, and at least two plate layers in the support assembly are stacked to form a stacked structure, and the stacked structure includes:

[0062] a first stacking region, wherein the support structure is provided between at least a portion of adjacent layer materials in the first stacking region; and

[0063] A second stacking area, wherein all adjacent sheet materials in the second stacking area are sequentially laminated along a stacking direction;

[0064] Wherein, the second stacking area is fixedly connected to the box frame.

[0065] Different stacking areas of the stacking structure are divided according to setting a support structure between adjacent layer materials or setting them in sequence, and the second stacking area where all adjacent layer materials are sequentially fitted along the stacking direction is fixedly connected to the box frame, so that the support component serving as the bottom wall can be fixedly connected to the box frame more reliably.

[0066] In some embodiments, at least a portion of the second lamination region is welded to the box frame.

[0067] By achieving fixed connection between at least a portion of the second stacking area and the box frame by welding, assembly efficiency can be improved.

[0068] In some embodiments, at least a portion of the second stacking region is fixedly connected to the lower surface of the box frame by friction stir welding.

[0069] The friction stir welding method can form a dense weld between the second stacking area and the lower surface of the box frame, making the connection more reliable. Moreover, the welding process can be achieved through a single-sided operation without the use of auxiliary materials such as welding wire, so it is more convenient and quick.

[0070] In some embodiments, at least a portion of the second stacking region is fixedly connected to the box frame by screws.

[0071] At least part of the second stacking area can also be fixedly connected to the box frame by screws. This connection method does not require special requirements on materials or connection positions like welding, nor does it require pre-setting threaded holes or nuts like bolt connection. Therefore, it is more convenient and quick to use.

[0072] In some embodiments, at least a portion of the second stacking area is fixedly connected to the lower surface of the box frame by flow drill screws.

[0073] The fixed connection method using flow drill screws can achieve fixed connection between different materials without pre-drilling holes, and the connection can be completed through single-sided operation. Therefore, the connection is more convenient and suitable for fixed connection in different positions.

[0074] In some embodiments, the second stacking area includes a plurality of outer edge areas located on the outer edge of the support assembly and a connection area connected between the plurality of outer edge areas and separating the first stacking area. The plurality of outer edge areas are welded to the box frame and / or fixedly connected by screws, and the connection area is fixedly connected to the box frame by screws.

[0075] When the second stacking area includes both the outer edge area and the connection area separating the first stacking area, the outer edge area can be fixedly connected to the box frame by welding or by screws, while the connection area can be fixedly connected to the box frame by screws. This makes the fixed connection operation of the connection area between the outer edge areas and the crossbeams or longitudinal beams in the box frame more convenient.

[0076] In some embodiments, the battery case includes:

[0077] The box body has a receiving groove; and

[0078] A box cover is provided at the open end of the receiving groove and is configured to cover the receiving groove.

[0079] Wherein, the support assembly is configured to form a side wall of the box body.

[0080] The support assembly can form the side walls of the box body to simplify the structure of the battery box and improve the supporting performance of the side walls, so as to better protect the battery box itself and the battery cells inside it when the battery box is subjected to lateral extrusion or collision.

[0081] In some embodiments, the battery case includes:

[0082] The box body has a receiving groove; and

[0083] A box cover is provided at the open end of the receiving groove and is configured to cover the receiving groove.

[0084] Wherein, the support assembly is configured to form the box cover.

[0085] The support assembly can form a box cover to simplify the structure of the battery box and improve the supporting performance of the box cover, so as to better protect the battery box itself and the battery cells inside it when the battery box is squeezed or collided from one side of the box cover.

[0086] In one aspect of the present disclosure, there is provided a battery comprising:

[0087] battery cells; and

[0088] The aforementioned battery box is configured to accommodate the battery cells.

[0089] The battery using the aforementioned battery box can achieve better safety in use.

[0090] In one aspect of the present disclosure, there is provided an electric device, comprising:

[0091] The aforementioned battery is used to provide electrical energy.

[0092] Electrical equipment using the aforementioned battery can achieve better safety in use.

[0093] In some embodiments, the power-consuming device further comprises:

[0094] a battery receiving compartment configured to receive the battery; and

[0095] The operating compartment is separated from the battery accommodating compartment by the supporting assembly.

[0096] For electrical equipment with an operating compartment, the support assembly can serve as a cover or bottom wall of the battery box to separate the battery storage compartment and the operating compartment, thereby reducing the battery space occupied and improving the safety of the electrical equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0097] In order to more clearly illustrate the technical solutions of the embodiments of the present disclosure, the following briefly introduces the drawings required for use in the embodiments of the present disclosure. Obviously, the drawings described below are only some embodiments of the present disclosure. For ordinary technicians in this field, other drawings can be obtained based on the drawings without any creative work.

[0098] The present disclosure can be more clearly understood from the following detailed description with reference to the accompanying drawings, in which:

[0099] FIG1 is a schematic structural diagram of some embodiments of an electric device according to the present disclosure;

[0100] FIG2 is an exploded schematic diagram of some embodiments of batteries according to the present disclosure;

[0101] FIG3A is a schematic structural diagram of some embodiments of a support assembly according to the present disclosure;

[0102] FIG3B is an exploded schematic diagram of FIG3A ;

[0103] 4A and 4B are schematic structural diagrams of other embodiments of the support assembly according to the present disclosure;

[0104] FIG5A is a schematic structural diagram of further embodiments of a support assembly according to the present disclosure;

[0105] FIG5B is an exploded schematic diagram of FIG5A ;

[0106] FIG6A is a schematic structural diagram of a support structure in some embodiments of a support assembly according to the present disclosure;

[0107] FIG6B is an enlarged schematic diagram of area A in FIG6A ;

[0108] FIG6C is an enlarged schematic diagram of a portion of a support structure in some embodiments of a support assembly according to the present disclosure;

[0109] FIG7A is a schematic diagram of partitions of opposing surfaces of adjacent sheet materials in some embodiments of a support assembly according to the present disclosure, viewed parallel to the opposing surfaces;

[0110] 7B and 7C are schematic diagrams of partitions of opposite surfaces of adjacent sheet materials in some embodiments of the support assembly according to the present disclosure, viewed from a perspective perpendicular to the opposite surfaces;

[0111] FIG8 is a schematic structural diagram of further embodiments of a support assembly according to the present disclosure;

[0112] FIG9 is an exploded schematic diagram of some embodiments of a battery case according to the present disclosure;

[0113] 10 and 11 are schematic diagrams of the connection structure between the box frame and the support assembly in some embodiments of the battery box according to the present disclosure;

[0114] FIG12A is an exploded schematic diagram of another embodiment of a battery case according to the present disclosure;

[0115] FIG12B is a schematic diagram of the structure of the battery box installation structure shown in FIG12A when viewed from above;

[0116] FIG12C is a schematic structural diagram of the AA section in FIG12B;

[0117] FIG12D is a schematic structural diagram of the BB section in FIG12B .

[0118] It should be understood that the size of each part shown in the drawings is not drawn according to the actual proportional relationship.In addition, the same or similar reference numerals represent the same or similar components.

[0119] Description of reference numerals:

[0120] 10: Battery box; 11: Box body; 12: Box cover; 111: Bottom wall; 112: Side wall; 113: Box frame; 13: Flow drill screw;

[0121] 20a, 20b, 20c: sheet material layer;

[0122] 30: Support structure; 31: Cavity; 32: Tube; 311: First cavity; 312: Second cavity;

[0123] 40: Strengthening layer;

[0124] 50: battery; 51: battery cell;

[0125] 60: Vehicle; 61: Battery compartment; 62: Operation compartment. DETAILED DESCRIPTION

[0126] The following detailed description of the embodiments of the present disclosure is provided in conjunction with the accompanying drawings and examples. The detailed description of the following embodiments and the accompanying drawings are used to illustrate the principles of the present disclosure, but are not intended to limit the scope of the present disclosure, that is, the present disclosure is not limited to the described embodiments.

[0127] In the description of the present disclosure, it should be noted that, unless otherwise specified, "multiple" means more than two; the terms "upper", "lower", "left", "right", "inside", "outside", etc., indicating directions or positional relationships, are only for the convenience of describing the present disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present disclosure. In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. "Vertical" is not strictly perpendicular, but is within the allowable error range. "Parallel" is not strictly parallel, but is within the allowable error range.

[0128] The directional words appearing in the following description are all directions shown in the figures and do not limit the specific structure of the present disclosure. In the description of the present disclosure, it should also be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected or indirectly connected through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the present disclosure can be understood according to the specific circumstances.

[0129] The following describes some embodiments of the present invention in detail with reference to the accompanying drawings. In the absence of conflict, the features of the following embodiments can be combined with each other.

[0130] In some related technologies, the battery box's floor assembly includes a floor, cushioning foam, and a bottom guard. The floor is welded to the box frame, and the bottom guard is bolted to the box frame, with the cushioning foam filling the gap between the floor and the guard. Research has found that this floor assembly involves a large number of parts, and the bolted connections require pre-machined holes and rivet nuts, making the assembly process time-consuming, complex, and costly.

[0131] In view of this, the embodiments of the present disclosure provide a support assembly, a battery box, a battery and an electrical device, which can meet the support requirements of the battery box, improve the safety of use, and simplify the assembly process of the battery box, improve assembly efficiency and reduce costs.

[0132] The support assembly of the embodiment of the present disclosure can be applied to a battery box, for example, the support assembly forms at least one wall of the battery box. The support assembly can also be applied to other equipment, such as a box for carrying goods.

[0133] The battery case of the embodiment of the present disclosure can be applied to various types of batteries to accommodate battery cells or battery modules. The battery can be used in various types of electrical equipment that use batteries. Electrical equipment can be mobile phones, portable devices, laptops, electric vehicles, electric cars, ships, spacecraft, electric toys and electric tools, etc. For example, spacecraft include airplanes, rockets, space shuttles and spacecraft, etc. Electric toys include fixed or mobile electric toys, such as game consoles, electric car toys, electric ship toys and electric airplane toys, etc. Electric tools include metal cutting power tools, grinding power tools, assembly power tools and railway power tools, such as electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete vibrators and electric planers. The embodiment of the present disclosure does not impose any special restrictions on the above-mentioned electrical equipment.

[0134] The battery module disposed within the battery housing may include multiple battery cells connected in series, parallel, or hybrid. A battery cell is the smallest unit of a battery. A battery cell includes an electrode assembly capable of undergoing an electrochemical reaction. Battery cells may include lithium-ion secondary batteries, lithium-ion primary batteries, lithium-sulfur batteries, sodium-lithium-ion batteries, sodium-ion batteries, or magnesium-ion batteries, among others, although this disclosure is not intended to limit this. Battery cells may be cylindrical, flat, rectangular, or have other shapes, among others, although this disclosure is not intended to limit this.

[0135] Figure 1 is a schematic diagram of the structure of some embodiments of electrical devices according to the present disclosure. For convenience, the description uses a vehicle as an example. Vehicle 60 can be a fuel-powered vehicle, a gas-powered vehicle, or a new energy vehicle. The new energy vehicle can be a pure electric vehicle or a hybrid vehicle. A battery 50 can be installed at the bottom, front, or rear of vehicle 60.

[0136] The battery 50 can be used to power the vehicle 60. For example, the battery 50 can serve as the operating power source of the vehicle 60 and be used for the circuit system of the vehicle 60, such as the power requirements for starting, navigating, and operating the vehicle 60. The battery 50 can not only serve as the operating power source of the vehicle 60, but also as the driving power source of the vehicle 60, replacing or partially replacing fuel or natural gas to provide driving force for the vehicle 60.

[0137] The vehicle 60 may also be provided with axles, wheels, a motor, and a controller. The controller is used to control the power supplied by the battery 50 to the motor. For example, when the vehicle 60 is powered by the battery 50, the controller can provide the motor with the power required for a constant speed and acceleration. The motor is used to drive the axles to rotate, thereby driving the wheels to rotate.

[0138] Referring to Figure 1, in some embodiments, the electrical equipment further includes: a battery accommodating compartment 61 and an operating compartment 62. The battery accommodating compartment 61 is configured to accommodate the battery 50. The operating compartment 62 can be the cab of the vehicle 60 (schematically shown by a dotted box in Figure 1, and the battery accommodating compartment 61 (schematically shown by a double-dotted box in Figure 1) can be arranged under the cab of the vehicle 60. The operating compartment 62 can be separated from the battery accommodating compartment 61 by a support assembly. In this way, for electrical equipment with an operating compartment, a support assembly with good supporting performance can be used as a box cover or bottom wall of the battery box to separate the operating compartment 62 and the battery accommodating compartment 61, thereby reducing the battery space occupied while improving the safety of the electrical equipment.

[0139] Figure 2 is a schematic structural diagram of some embodiments of the battery according to the present disclosure. Referring to Figure 2, in some embodiments, the battery 50 includes a battery cell 51 and a battery case 10. The battery case 10 is configured to accommodate the battery cell 51 and can provide the battery cell with functions such as cooling, sealing, and impact protection, or prevent liquids or other foreign matter from adversely affecting the charging and discharging or safety of the battery cell. The battery cell 51 may include a plurality of battery cells, which are electrically connected to each other (for example, in series, in parallel, or in mixed connection) to achieve the required electrical performance parameters of the battery 50. A plurality of battery cells 51 can be arranged in rows, and one or more rows of battery cells 51 can be arranged in the battery case 10 as needed.

[0140] In some embodiments, multiple battery cells 51 may be arranged along at least one of the length and width of the battery case 10. Depending on actual needs, at least one row or column of battery cells 51 may be provided. Alternatively, one or more layers of battery cells 51 may be provided along the height of the battery 50.

[0141] In some embodiments, multiple battery cells 51 may be connected in series, parallel, or hybrid to form a battery module, and then the multiple battery modules may be connected in series, parallel, or hybrid to form a whole, and then housed in the battery case 10. In other embodiments, all battery cells 51 may be directly connected in series, parallel, or hybrid, and then the whole formed by all battery cells 51 may be housed in the battery case 10.

[0142] The battery cell 51 may include a housing, an electrode assembly, and an end cap assembly. The battery cell 51 also contains an electrolyte. The housing has a chamber and an end opening communicating with the chamber, the chamber being used to house the electrode assembly. The housing may be a hollow rectangular parallelepiped, a hollow cube, or a hollow cylinder, depending on the shape of the electrode assembly or assemblies. The housing may be made of a conductive metal or plastic, and may alternatively be made of aluminum or an aluminum alloy.

[0143] An end cap assembly is disposed at the end opening to form a sealed cavity with the housing to accommodate the electrode assembly. The end cap assembly may include two poles having opposite polarities and electrically connected to the tabs on the pole pieces of corresponding polarity in the electrode assembly via a connecting assembly or directly.

[0144] The electrode assembly may include a positive electrode sheet, a negative electrode sheet, and a separator located between the positive and negative electrode sheets. The operation of the battery cell is achieved by the movement of metal ions inside between the positive and negative electrode sheets.

[0145] The positive electrode sheet includes a positive current collector and a positive active material layer. The positive electrode tab is connected to or formed on the positive current collector. For lithium-ion batteries, for example, the positive current collector can be made of aluminum, and the positive active material can be a lithiated material that can provide lithium ions, such as lithium cobalt oxide, lithium iron phosphate, ternary lithium, or lithium manganese oxide. When a bonding material is used to bond the positive current collector and the positive active material layer, the bonding material can be polyvinylidene fluoride (PVDF).

[0146] The negative electrode sheet consists of a negative current collector and a negative active material layer. The negative electrode tab is connected to the negative current collector. For lithium-ion batteries, for example, the negative current collector can be made of copper, and the negative active material can be materials capable of storing lithium ions, such as graphite, silicon, or lithium titanate. When a binder is used to bond the negative current collector and the negative active material layer, the binder can be carboxymethyl cellulose, epoxy resin, or styrene-butadiene rubber.

[0147] The material of the diaphragm can be PP (polypropylene) or PE (polyethylene). The electrolyte includes an electrolyte and a solvent. The electrolyte is an organic metal salt, an inorganic salt, etc., which can provide metal ions that shuttle between the positive electrode and the negative electrode. In order to ensure sufficient overcurrent capacity, the number of positive electrode tabs can be multiple and stacked together, and the number of negative electrode tabs can be multiple and stacked together. In addition, the electrode assembly can be a wound structure or a laminated structure, and the embodiments of the present disclosure are not limited to this.

[0148] FIG3A is a schematic diagram of the structure of some embodiments of the support assembly according to the present disclosure. FIG3B is an exploded schematic diagram of FIG3A. FIG4A and FIG4B are schematic diagrams of the structure of other embodiments of the support assembly according to the present disclosure. FIG5A is a schematic diagram of the structure of still other embodiments of the support assembly according to the present disclosure. FIG5B is an exploded schematic diagram of FIG5A.

[0149] With reference to Figures 3A to 5B , the present disclosure provides a support assembly comprising at least two sheet material layers and a support structure 30. The at least two sheet material layers are stacked, with spaces provided between adjacent sheet material layers. The sheet material layers are thin, plate-shaped materials having a certain surface area and thickness, such as metal or plastic sheets. The at least two sheet material layers can be stacked along a predetermined stacking direction, such as the two sheet material layers 20a and 20b shown in Figure 3A stacked along stacking direction z, or the three sheet material layers 20a, 20b, and 20c shown in Figure 5A stacked along stacking direction z.

[0150] The number of sheet material layers can be selected based on actual needs, for example, two or three. The three stacked sheet material layers and the support structure 30 can be integrally formed by a single hot pressing or brazing process, achieving improved load-bearing performance. The support structure formed by the two stacked sheet material layers is lighter and more convenient to manufacture.

[0151] Depending on the number of sheet material layers, at least two sheet material layers can form at least one group of adjacent sheet material layers, such as adjacent sheet material layers 20a and 20b shown in FIG3A , where a gap g1 is provided between adjacent sheet material layers 20a and 20b. For another example, in FIG5A , two groups of adjacent sheet material layers are shown. Along the stacking direction z, a gap g1 is provided between the first group of adjacent sheet material layers 20a and 20b, and a gap g2 is provided between the second group of adjacent sheet material layers 20b and 20c.

[0152] It should be noted that, for multiple board layers, there may be a spacing space between each group of adjacent board layers, or there may be a spacing space between some groups of adjacent board layers, while other groups of adjacent board layers are directly bonded together without a spacing space.

[0153] The support structure 30 is disposed in the spacing to support the opposing surfaces of adjacent sheet material layers. For example, in FIG3B , opposing surfaces S1 and S2 of adjacent sheet material layers 20a and 20b are supported by the support structure 30. For another example, in FIG5B , opposing surfaces S1 and S2 of a first set of adjacent sheet material layers 20a and 20b and a second set of adjacent sheet material layers 20b and 20c along the stacking direction z are both supported by the support structure 39.

[0154] Referring to Figures 3B and 5B , the support structure 30 includes a plurality of cavities 31. At least a portion of the cavities 31 extend along a first direction r1, intersecting the opposing surfaces of adjacent sheet material layers. The cavities 31 may be through-holes extending along the first direction r1, blind holes extending along the first direction r1 and closed at one end or in the middle, or at least one enclosed tubular cavity extending along the first direction r1.

[0155] By arranging a plurality of cavity portions in the interval space between adjacent stacked plate layers, and making at least a portion of the plurality of cavity portions extend along a first direction intersecting with the relative surfaces of the adjacent plate layers, the support assembly can provide reliable support to the plate layers through the solid material forming the cavity portions in the support structure when subjected to external pressure, and the plurality of cavity portions can be distributed over a larger range in the interval space, thereby improving the overall support effect of the support assembly while reducing the weight of the support structure, making the support assembly lighter.

[0156] Referring to Figures 3A, 3B, and 5B, in some embodiments, the first direction r1 intersects perpendicularly with the opposing surfaces S1 and S2 of the adjacent sheet material layers. As can be seen in Figure 3A, the angle Q between the first direction r1 and the opposing surfaces S1 and S2 is 90°. By extending at least a portion of the multiple cavities along the first direction perpendicularly intersecting the opposing surfaces of the adjacent sheet material layers, the pressure-bearing capacity of the support assembly can be greatly enhanced, further reducing the weight or thickness of the support assembly.

[0157] Referring to Figure 4A , in some embodiments, the first direction r1 intersects the opposing surfaces S1 and S2 of the adjacent sheet material layers at acute angles. As can be seen in Figure 4A , the angles Q formed between the first direction r1 and the opposing surfaces S1 and S2 are both acute angles. By extending at least a portion of the multiple cavities along the first direction, which intersects the opposing surfaces of the adjacent sheet material layers at acute angles, the distribution range of the support assembly within the space can be increased while meeting the pressure-bearing requirements of the support assembly.

[0158] 4A , the first direction r1 is inclined relative to the stacking direction z of the at least two plate layers and is at a predetermined angle, such as an acute angle. In other embodiments, the first direction r1 may also be parallel to the stacking direction z.

[0159] Referring to FIG4B , in some embodiments, the first direction r1 intersects one of the opposing surfaces S1 and S2 of the adjacent sheet layers at an acute angle and intersects the other of the opposing surfaces S1 and S2 of the adjacent sheet layers at right angles. In FIG4B , the first direction r1 intersects the surface S1 of sheet layer 20a on the side adjacent to sheet layer 20b at right angles and intersects the surface S2 of sheet layer 20b on the side adjacent to sheet layer 20a at an acute angle. Thus, depending on the actual needs of the application, at least a portion of the multiple cavity portions can be extended along the first direction that intersects the opposing surfaces of the adjacent sheet layers at acute angles and right angles, respectively, to accommodate different pressure distribution and thickness distribution requirements of the sheet layers.

[0160] In the above embodiment, the angle Q formed by the intersection of the first direction r1 and the relative surfaces S1 and S2 can satisfy the following: 75°≤Q≤90°. For the angle Q formed between the first direction and any one of the relative surfaces, when the angle Q is 90°, the direction of the pressure exerted by the multiple cavities on the relative surface is parallel to the first direction, and a greater pressure-bearing effect can be achieved. However, when the angle Q is too small, the pressure exerted by the multiple cavities on the relative surface is decomposed into a smaller component perpendicular to the relative surface, and the supporting effect is weakened. Therefore, by ensuring that the angle Q satisfies 75°≤Q≤90°, the supporting effect of the support structure on the plate layer can be improved, thereby effectively enhancing the supporting effect of the support assembly.

[0161] Figure 6A is a schematic diagram of the structure of a support structure in some embodiments of a support assembly according to the present disclosure. Figure 6B is an enlarged schematic diagram of area A in Figure 6A. Figure 6C is an enlarged schematic diagram of a portion of a support structure in some embodiments of a support assembly according to the present disclosure.

[0162] Referring to FIG. 6A , in some embodiments, multiple cavities 31 are spaced apart along one or more second directions, which may be parallel to one of the opposing surfaces of adjacent sheet material layers. In FIG. 6A , the overall profile of support structure 30 in a cross-section perpendicular to stacking direction z may be rectangular, with one set of opposing sides parallel to direction x and another set of opposing sides parallel to direction y.

[0163] In FIG6B , the plurality of cavities 31 may be arranged at intervals along two second directions r2 and r3, wherein the two second directions r2 and r3 form an acute angle, and the second direction r2 may be parallel to the direction x. For another example, in FIG6C , the plurality of cavities 31 may be arranged at intervals along two second directions r2 and r3, wherein the two second directions r2 and r3 are perpendicular to each other and parallel to the directions x and y, respectively.

[0164] For embodiments in which the relative surfaces S1 and S2 are parallel to each other, the second direction may be parallel to either of the relative surfaces S1 and S2. For embodiments in which the relative surfaces S1 and S2 are not parallel to each other, the second direction may be parallel to either surface S1 or surface S2.

[0165] This embodiment arranges the multiple cavity portions at intervals along one or more second directions parallel to the relative surfaces, so that the multiple cavity portions can be distributed over a larger range and more evenly between adjacent plate layers, which helps to disperse the pressure when the support component is under pressure, reducing the risk of the support component being crushed, and can also meet the pressure requirements while correspondingly reducing the requirements for the material strength and amount of the support structure.

[0166] 6A and 6B , in some embodiments, the support structure 30 is integrally formed. In other words, the support structure 30 can be integrally formed before being placed in the space between adjacent sheet materials. This not only helps improve assembly efficiency, but also provides a more stable support effect by utilizing the integrally formed support structure.

[0167] Referring to FIG. 6B , in some embodiments, in a cross section parallel to one of the opposing surfaces S1 and S2, the minimum spacing d between two adjacent cavity sections 31 in the plurality of cavity sections 31 is less than the maximum cross-sectional width W1 of any of the two adjacent cavity sections 31. Among the plurality of cavity sections, the portion between two adjacent cavity sections may include solid material forming the cavity sections. By ensuring that the maximum width W1 of the hollow cross section of the cavity section is greater than the minimum spacing d between the two adjacent cavity sections, the amount of solid material in the support structure can be reduced, thereby reducing the amount of material forming the support structure while still achieving the desired support effect, thereby lowering cost and weight.

[0168] In Figure 6B , the minimum spacing d can satisfy the following conditions: 0.5mm ≤ d ≤ 4mm. For example, d can take values ​​of 1mm, 1.5mm, 2.4mm, 3.2mm, and so on. If the minimum spacing d between two adjacent cavities is too small, deformation or damage may occur when subjected to pressure. If the minimum spacing d is too large, more material is required, increasing cost and weight. Therefore, by ensuring that the minimum spacing d satisfies the following conditions: 0.5mm ≤ d ≤ 4mm, both good pressure-bearing performance and reduced cost and weight can be achieved.

[0169] In Figure 6B, the maximum cross-sectional width W1 can satisfy the following: 2.3mm≤W1≤17.3mm. For example, W1 can take values ​​of 3.5mm, 6mm, 8.4mm, 12.5mm, 15.7mm, etc. If the maximum cross-sectional width W1 is too small, more cavities will need to be arranged per unit area, making the support structure more complex, increasing the difficulty of manufacturing, and easily increasing the amount of material used in the support assembly, making the overall weight heavier. If the maximum cross-sectional width W1 is too large, it may affect the support structure's ability to disperse the supporting force, thereby weakening the support structure's supporting function. Therefore, by ensuring that the maximum cross-sectional width W1 satisfies the following: 2.3mm≤W1≤17.3mm, both the simplification and weight reduction of the support structure and the dispersion effect of the support structure can be achieved.

[0170] To further enhance the overall support performance of the support assembly, referring to FIG6B , in some embodiments, at least a portion of the plurality of cavities 31, in a cross-section parallel to one of the opposing surfaces S1 and S2, have a regular hexagonal cross-section with equal cross-sectional dimensions. This type of cavity can form a honeycomb-like support structure, either partial or overall. Because honeycomb support structures are highly stable and offer excellent support performance, they can effectively enhance the overall support performance of the support assembly.

[0171] 6C , in some embodiments, the support structure 30 includes a plurality of tubes 32, at least portions of which are independently molded, and the plurality of cavity portions 31 include a first cavity 311 enclosed by the inner wall of each tube 32. Forming the support structure by at least partially independently molded tubes and utilizing the first cavity enclosed by the inner wall of the tubes as the cavity portion helps reduce the difficulty of forming the support structure. Furthermore, the tubes are easy to obtain or manufacture, which also helps reduce the manufacturing cost of the support assembly.

[0172] In FIG6C , the plurality of cavity portions 31 further include second cavities 312 enclosed by outer walls of adjacent tubes 32 among the plurality of tubes 32. For a plurality of tubes in which gaps can be formed between adjacent tubes, the second cavities enclosed by outer walls of adjacent tubes can also be used as cavity portions, thereby forming more cavity portions in a more convenient manner.

[0173] 6C , in some embodiments, in a cross section parallel to one of the opposing surfaces S1 and S2, the maximum cross-sectional width W2 of the first cavity 311 is greater than the minimum wall thickness t of the tube 32. By ensuring that the maximum cross-sectional width W2 of the first cavity in the plurality of cavities formed by the plurality of tubes is greater than the minimum wall thickness t of the tubes, the amount of material used for the tubes in the support structure can be reduced while still providing the desired support effect, thereby lowering the cost and weight of the support structure.

[0174] In Figure 6C, the maximum cross-sectional width W2 satisfies the following: 3mm≤W2≤15mm. For example, W2 can take values ​​of 4.5mm, 7mm, 9.2mm, 12.4mm, 13.6mm, and so on. If the maximum cross-sectional width W2 is too small, more cavities will need to be arranged per unit area, making the support structure more complex, increasing the manufacturing difficulty, and easily increasing the material content of the tube body, making the overall weight heavier. If the maximum cross-sectional width W2 is too large, it may affect the support structure's ability to disperse the supporting force, thereby weakening the support structure's supporting function. Therefore, by ensuring that the maximum cross-sectional width W2 satisfies the following: 3mm≤W1≤15mm, both the simplification and weight reduction of the support structure and the dispersion effect of the support structure can be achieved.

[0175] In Figure 6C , the minimum wall thickness t satisfies the following: 0.5mm ≤ t ≤ 4mm. For example, t can be 1.2mm, 2mm, 3.5mm, and so on. If the minimum wall thickness t is too small, deformation or damage may occur when subjected to pressure. If the minimum wall thickness t is too large, more material is required, increasing cost and weight. Therefore, by ensuring that the minimum wall thickness t satisfies the following: 0.5mm ≤ t ≤ 4mm, good pressure resistance can be achieved while reducing cost and weight.

[0176] To further enhance the overall support performance of the support assembly, referring to FIG6C , in some embodiments, at least a portion of the multiple tubes 32 have a circular cross-sectional shape and equal cross-sectional dimensions in a cross-section parallel to one of the opposing surfaces S1 and S2. Because circular tubes with circular cross-sectional shapes are easier to obtain or manufacture, for example, by cutting the tube to a fixed length to form multiple tube segments of the same size, this type of tube can achieve stronger support performance compared to other shapes using the same amount of material.

[0177] In order to enable the support structure to more effectively support adjacent sheet material layers, in some embodiments, at least a portion of the at least two sheet material layers is made of metal, such as aluminum alloy, and the support structure 30 is made of metal, such as aluminum alloy. In this way, the support structure 30 can be welded to at least one of the opposing surfaces of the adjacent sheet material layers, thereby achieving a tight and fixed connection between different sheet material layers and between adjacent sheet material layers through welding.

[0178] During welding, solder can be applied to the relative surfaces of adjacent plate layers. When brazing is performed, the solid materials between the various cavity parts of the support structure can form a welded structure with the adjacent plate layers, thereby achieving a large-scale one-time welding forming, which is more efficient. Moreover, since the support structure forms a larger range of welding with the adjacent plate layers, better support can be obtained.

[0179] In other embodiments, the material of at least a portion of the at least two sheet material layers includes plastic, and the material of the support structure 30 includes plastic, so that the support structure 30 can be hot-melt connected to at least one of the relative surfaces S1, S2 of the adjacent sheet material layers, thereby achieving a tight and fixed connection between different sheet material layers and between the support structure and adjacent sheet material layers by hot-melt.

[0180] During hot melt connection, the adjacent sheet material layers and the supporting structure can be hot pressed as a whole through the hot melt pressing process to form a large-scale hot melt connection molding, which is more efficient. Moreover, since the supporting structure and the adjacent sheet material layers form a larger range of welding, better support can be obtained.

[0181] FIG7A is a schematic diagram illustrating the partitioning of opposing surfaces of adjacent sheet materials in some embodiments of a support assembly according to the present disclosure, viewed from a perspective parallel to the opposing surfaces. FIG7B and FIG7C are schematic diagrams illustrating the partitioning of opposing surfaces of adjacent sheet materials in some embodiments of a support assembly according to the present disclosure, viewed from a perspective perpendicular to the opposing surfaces.

[0182] To improve the reliability of the connection between the support assembly and other structures, referring to Figures 7A to 7C , in some embodiments, the opposing surfaces of adjacent sheet materials (e.g., surface S1 or S2) have a first region G1 and a second region G2. The opposing surfaces S1 and S2 of the adjacent sheet materials form the separation space in the first region G1 and are aligned in the second region G2. As can be seen in Figure 7A , due to the aligned second region G2 of the opposing surfaces S1 and S2, the portion of the adjacent sheet materials corresponding to the second region G2 is thinner than the portion corresponding to the first region, thereby facilitating the fixed connection of the portion of the adjacent sheet materials corresponding to the second region G2 to other structures.

[0183] In this embodiment, a first area is set on the relative surfaces of adjacent plate layers to accommodate the support structure, and a second area is set on the relative surfaces. In this way, the part of the support component corresponding to the second area can be used to connect other structures to improve the connection strength, while the first area can be used to bear pressure, thereby meeting the usage requirements of different parts of the support component.

[0184] Referring to Figure 7B , in some embodiments, the second region G2 is located at the outer edge of the first region G1 and encloses the first region G1. By arranging the second region at the outer edge of the first region and enclosing the first region, the surface-contacted second region can be used to form a closed compartment for accommodating the first region of the support structure. This allows the support structure to be more stably constrained within the compartment, improving the overall pressure-bearing capacity and stability of the support assembly.

[0185] Referring to Figure 7C , in some embodiments, the first region G1 is provided in a plurality, the plurality of first regions G1 being separated from one another, and the outer edge of each first region G1 being provided with a second region G2. Depending on the configuration of other structures connected to the support assembly, multiple first regions can be provided, each separated from another, while the second region surrounds the outer edge of each first region. This allows for connection to different parts of other structures (e.g., outer edges or central crossbeams) through the second regions, and the pressure-bearing requirements of different regions can be met through the multiple first regions.

[0186] FIG8 is a schematic structural diagram of further embodiments of a support assembly according to the present disclosure. Referring to FIG3A , FIG5A , and FIG8 , the support assembly can have different structural forms. Referring to FIG3A , FIG5A , and FIG8 , in some embodiments, in the stacking direction z of the at least two sheet material layers, the portion of the outer surface of at least one side of the at least two sheet material layers corresponding to the first region G1 is raised relative to the portion corresponding to the second region G2.

[0187] For example, in Figures 3A and 5A, the portions of the upper and lower outer surfaces of at least two plate layers corresponding to the first area G1 are raised relative to the portions corresponding to the second area G2. In Figure 8, the portions of the upper outer surfaces of the at least two plate layers corresponding to the first area G1 are raised relative to the portions corresponding to the second area G2.

[0188] For the outer surface of at least two plate layers, the part corresponding to the first area is raised relative to the part corresponding to the second area so that the pressure is mainly borne by the part of the support component containing the support structure, thereby improving the support effect. In addition, the raised structure can also achieve a rough positioning effect when the support component is connected to other structures.

[0189] Referring to FIG8 , in some embodiments, in the stacking direction z of the at least two sheet material layers, at least one outer surface of the at least two sheet material layers is a flat surface. By configuring at least one outer surface of the at least two sheet material layers as a flat surface, the flat surface allows for more stable placement on a flat surface, more uniform force distribution, and avoids stress concentration.

[0190] To enhance the wear and scratch resistance of the support assembly and meet requirements for deformation and damage resistance during impact, referring to Figure 8 , in some embodiments, the support assembly further includes a reinforcement layer 40. The reinforcement layer 40 covers the outer surface of at least one side of the at least two sheet material layers along the stacking direction z. The reinforcement layer 40 can be a film layer, such as a polyvinyl chloride (PVC) film layer, adhered to the outer surface of the sheet material layers. By coating the outer surfaces of the at least two sheet material layers with the reinforcement layer, the surface strength of the support assembly can be further enhanced, improving the wear and scratch resistance of the support assembly.

[0191] Figure 9 is a schematic diagram of an exploded view of some embodiments of the battery case according to the present disclosure. Figures 10 and 11 are schematic diagrams of the connection structure of the case frame and the support assembly in some embodiments of the battery case according to the present disclosure, respectively. Referring to Figure 2, the present disclosure also provides a battery case 10, comprising a support assembly of any of the aforementioned embodiments. The support assembly can be configured to form at least one wall of the battery case 10. Using the aforementioned support assembly to form at least one wall of the battery case can improve the supporting performance of the battery case and reduce the weight of the battery case. Moreover, compared with the assembly of the battery case in the related art, the battery case using the aforementioned support assembly reduces the number of components and simplifies the assembly process, thereby reducing the assembly time of the battery case by 16 to 20%, improving the assembly efficiency, and thus helping to reduce manufacturing costs.

[0192] In Figure 2, the battery case 10 includes a case body 11 and a case cover 12. The case body 11 has a receiving groove. The case cover 12 is arranged at the open end of the receiving groove and is configured to cover the receiving groove. The support assembly can be configured to form a bottom wall 111 of the case body 11. Setting the support assembly as the bottom wall of the case body can simplify the structure of the battery case and improve the supporting performance of the bottom wall, so that the battery case itself and the battery cells inside can be better protected when the battery case is squeezed or collided from one side of the bottom wall.

[0193] In other embodiments, the support assembly can be configured to form the side wall 112 of the box body 11, which can simplify the structure of the battery box and improve the supporting performance of the side wall, so as to better protect the battery box itself and the battery cells inside it when the battery box is subjected to lateral squeezing or collision.

[0194] The support assembly can also be configured to form the box cover 12, which can simplify the structure of the battery box and improve the support performance of the box cover, so as to better protect the battery box itself and the battery cells inside it when the battery box is squeezed or collided from one side of the box cover.

[0195] Referring to Figures 9 to 11, in some embodiments, the box body 11 includes a box frame 113. At least two plate layers in the support assembly forming the bottom wall 111 of the box body 11 are stacked to form a stacking structure. The stacking structure may include: a first stacking area L1 and a second stacking area L2. The support structure 30 is provided between at least some adjacent layer plates in the first stacking area L1. All adjacent layer plates in the second stacking area L2 are sequentially fitted along the stacking setting direction z. The second stacking area L2 is fixedly connected to the box frame 113. Different stacking areas of the stacking structure are divided according to whether the support structure is provided between adjacent layer plates or they are sequentially fitted, and the second stacking area where all adjacent layer plates are sequentially fitted along the stacking setting direction is fixedly connected to the box frame, so that the fixed connection between the support assembly serving as the bottom wall and the box frame can be made more reliable.

[0196] The second stacking region L2 and the box frame 113 can be fixedly connected using a variety of methods. For example, at least a portion of the second stacking region L2 can be welded to the box frame 113. Welding the second stacking region L2 to the box frame can improve assembly efficiency.

[0197] For example, at least a portion of the second laminated region L2 can be fixedly connected to the lower surface of the box frame 113 by friction stir welding (FSW). FSW can form a dense weld between the second laminated region and the lower surface of the box frame, making the connection more reliable. Moreover, the welding process can be performed from one side without the use of auxiliary materials such as welding wire, making it more convenient and faster.

[0198] For another example, at least a portion of the second stacking area L2 can be fixedly connected to the box frame 113 by screws. This connection method does not require special requirements for materials or connection positions like welding, nor does it require pre-set threaded holes or nuts like bolt connections, making it more convenient and quick to use.

[0199] For example, at least a portion of the second stacking region 12 is fixedly connected to the lower surface of the box frame 113 using flow drill screws (FDS). The FDS method allows for fixed connections between different materials without requiring pre-drilling holes and can be completed through a single-sided operation, making the connection more convenient and suitable for fixed connections in various locations.

[0200] FIG12A is an exploded schematic diagram of another embodiment of a battery case according to the present disclosure. FIG12B is a schematic diagram of the mounting structure of the battery case shown in FIG12A from an upward perspective. FIG12C is a schematic diagram of the structure of the AA section in FIG12B. FIG12D is a schematic diagram of the structure of the BB section in FIG12B.

[0201] 12A and 12B , in some embodiments, the second stacking region L2 may include a plurality of outer edge regions L21 located at the outer edges of the support assembly and a connection region L22 connected between the plurality of outer edge regions L21 and separating the first stacking region L1. The outer edge regions L21 may be used to securely connect to the edge regions of the box frame 113, while the connection regions L22 may be used to securely connect to the crossbeams or longitudinal beams within the box frame 113.

[0202] Referring to Figures 12B and 12C , the multiple outer edge regions L21 are welded and / or fixedly connected to the box frame 113 via screws. As can be seen in Figure 12B , the left-lined region C1 is a welded region, which may employ FSW welding, while the right-lined region C2 is a region fixedly connected via flow drill screws 13. The outer edge regions L21 may be fixedly connected using only welding or only screws, or a portion of the outer edge region L21 may be fixedly connected using welding and another portion using screws.

[0203] 12B and 12D , the connection area L22 is fixedly connected to the box frame 113 by screws. Using screws to fix the connection area to the box frame facilitates the connection between the outer edge areas and the crossbeams or longitudinal beams in the box frame.

[0204] Based on the battery case 10 of the aforementioned embodiment, with reference to FIG2 , the present disclosure provides a battery 50 comprising: a battery cell 51 and the aforementioned battery case 10. The battery case 10 is configured to accommodate the battery cell 51. A battery using the aforementioned battery case can achieve better safety in use.

[0205] Based on the battery of the aforementioned embodiment, with reference to FIG1 , the present disclosure provides an electrical device, comprising: the aforementioned battery 50 for providing electrical energy. Electrical devices using the aforementioned battery can achieve better safety in use. With reference to FIG2 , in some embodiments, the electrical device further comprises: a battery accommodating compartment 61 and an operating compartment 62. The battery accommodating compartment 61 is configured to accommodate the battery 51. The operating compartment 62 is separated from the battery accommodating compartment 61 by the support assembly. For electrical devices with an operating compartment, the support assembly can serve as a cover or bottom wall of the battery box to separate the battery accommodating compartment and the operating compartment, thereby reducing the battery space occupied while improving the safety of the electrical device.

[0206] While the present disclosure has been described with reference to preferred embodiments, various modifications may be made thereto and equivalent components may be substituted without departing from the scope of the present disclosure. In particular, the various technical features described in the various embodiments may be combined in any manner, provided no structural conflicts exist. The present disclosure is not limited to the specific embodiments disclosed herein, but encompasses all technical solutions within the scope of the claims.

Claims

1. A support assembly comprising: At least two sheet material layers (20a, 20b, 20c), the at least two sheet material layers (20a, 20b, 20c) being stacked, with spaces (g1, g2) being provided between adjacent sheet material layers in the at least two sheet material layers (20a, 20b, 20c); and A support structure (30) is arranged in the interval space (g1, g2), and the support structure (30) includes a plurality of cavity portions (31), at least a portion of the plurality of cavity portions (31) extends along a first direction (r1), and the first direction (r1) intersects with the relative surfaces (S1, S2) of the adjacent plate layers.

2. The support assembly according to claim 1, wherein: The first direction (r1) intersects perpendicularly with the opposite surfaces (S1, S2) of the adjacent plate layers.

3. The support assembly according to claim 1, wherein: The first direction (r1) intersects the opposite surfaces (S1, S2) of the adjacent plate layers at acute angles.

4. The support assembly according to claim 1, wherein: The first direction (r1) intersects one of the opposite surfaces (S1, S2) of the adjacent sheet material layers at an acute angle, and intersects the other of the opposite surfaces (S1, S2) of the adjacent sheet material layers at a right angle.

5. The support assembly according to any one of claims 1 to 4, wherein: An angle Q formed by the intersection of the first direction (r1) and the relative surfaces (S1, S2) satisfies: 75°≤Q≤90°.

6. The support assembly according to claims 1 to 5, wherein: The plurality of cavity portions (31) are arranged at intervals along one or more second directions (r2, r3) parallel to one of the opposing surfaces (S1, S2).

7. The support assembly according to any one of claims 1 to 6, wherein: The support structure (30) is integrally formed.

8. The support assembly according to claim 7, wherein: On a cross section parallel to one of the opposing surfaces (S1, S2), a minimum distance d between two adjacent cavity portions (31) among the plurality of cavity portions (31) is smaller than a maximum cross-sectional width W1 of any one of the two adjacent cavity portions (31).

9. The support assembly according to claim 8, wherein: The minimum spacing d satisfies: 0.5 mm ≤ d ≤ 4 mm; and / or the maximum width W1 of the cross section satisfies: 2.3 mm ≤ W1 ≤ 17.3 mm.

10. The support assembly according to any one of claims 7 to 9, wherein: On a cross section parallel to one of the opposing surfaces (S1, S2), the cross-sectional shapes of at least a portion of the plurality of cavity portions (31) are all regular hexagons, and the cross-sectional dimensions are equal.

11. The support assembly according to any one of claims 1 to 6, wherein: The support structure (30) comprises a plurality of tubes (32), at least parts of the plurality of tubes (32) are independently formed, and the plurality of cavity portions (31) comprise a first cavity (311) surrounded by the inner wall of each tube (32).

12. The support assembly according to claim 11, wherein: The plurality of cavity portions (31) further include second cavities (312) surrounded by outer walls of adjacent tube bodies (32) among the plurality of tube bodies (32).

13. A support assembly according to claim 11 or 12, wherein: In a cross section parallel to one of the opposing surfaces (S1, S2), the maximum cross-sectional width W2 of the first cavity (311) is greater than the minimum wall thickness t of the tube body (32).

14. The support assembly according to claim 13, wherein: The maximum cross-sectional width W2 satisfies: 3mm≤W2≤15mm; and / or, the minimum wall thickness t satisfies: 0.5mm≤t≤4mm.

15. The support assembly according to any one of claims 11 to 14, wherein: On a cross section parallel to one of the opposing surfaces (S1, S2), the cross-sectional shape of at least a portion of the plurality of tubes (32) is circular, and the cross-sectional dimensions are equal.

16. The support assembly according to any one of claims 1 to 15, wherein: The relative surfaces (S1, S2) of the adjacent plate layers have a first area (G1) and a second area (G2), and the relative surfaces (S1, S2) of the adjacent plate layers form the separation space (g1, g2) in the first area (G1) and are arranged in a close fit in the second area (G2).

17. The support assembly of claim 16, wherein: The second region (G2) is located at the outer edge of the first region (G1) and encloses the first region (G1).

18. The support assembly of claim 16, wherein: The first regions (G1) are provided in plurality, the plurality of first regions (G1) are separated from each other, and the outer edge of each first region (G1) is provided with the second region (G2).

19. The support assembly according to any one of claims 16 to 18, wherein: In the stacking direction (z) of the at least two sheet material layers (20a, 20b, 20c), the portion of the outer surface of at least one side of the at least two sheet material layers (20a, 20b, 20c) corresponding to the first area (G1) is raised relative to the portion corresponding to the second area (G2).

20. The support assembly according to any one of claims 1 to 19, wherein: In the stacking direction (z) of the at least two plate layers (20a, 20b, 20c), the outer surface of at least one side of the at least two plate layers (20a, 20b, 20c) is a plane.

21. The support assembly according to any one of claims 1 to 20, wherein: The material of at least a portion of the at least two plate layers (20a, 20b, 20c) includes metal, and the material of the support structure (30) includes metal, so that the support structure (30) can be welded to at least one of the opposite surfaces (S1, S2) of the adjacent plate layers.

22. The support assembly according to any one of claims 1 to 20, wherein: The material of at least a portion of the at least two sheet layers (20a, 20b, 20c) includes plastic, and the material of the support structure (30) includes plastic, so that the support structure (30) can be heat-melted to at least one of the opposite surfaces (S1, S2) of the adjacent sheet layers.

23. The support assembly according to any one of claims 1 to 22, further comprising: A strengthening layer (40) covers the outer surface of at least one side of the at least two plate layers (20a, 20b, 20c) along the stacking direction (z) of the at least two plate layers (20a, 20b, 20c).

24. A battery case (10), comprising: The support assembly according to any one of claims 1 to 23, Wherein, the support assembly is configured to form at least one wall of the battery box (10).

25. The battery case (10) according to claim 24, wherein: The battery box (10) comprises: The box body (11) has a receiving groove; and A box cover (12) is provided at the open end of the receiving groove and is configured to cover the receiving groove. Wherein, the support assembly is configured to form a bottom wall (111) of the box body (11).

26. The battery case (10) according to claim 25, wherein: The box body (11) comprises a box frame (113), and at least two plate layers (20a, 20b, 20c) in the support assembly are stacked to form a stacked structure, wherein the stacked structure comprises: a first stacking region (L1), wherein the support structure (30) is provided between at least a portion of adjacent layer materials within the first stacking region (L1); and A second stacking area (L2), wherein all adjacent layer materials in the second stacking area (L2) are sequentially laminated along a stacking direction (z); Wherein, the second stacking area (L2) is fixedly connected to the box frame (113).

27. The battery case (10) according to claim 26, wherein: At least a portion of the second stacking area (L2) is welded to the box frame (113).

28. The battery case (10) according to claim 27, wherein: At least a portion of the second stacking area (L2) is fixedly connected to the lower surface of the box frame (113) by means of stir friction welding.

29. The battery case (10) according to claim 26, wherein: At least a portion of the second stacking area (L2) is fixedly connected to the box frame (113) by screws.

30. The battery case (10) according to claim 29, wherein: At least a portion of the second stacking area (L2) is fixedly connected to the lower surface of the box frame (113) via flow drill screws (13).

31. The battery case (10) according to any one of claims 26 to 30, wherein: The second stacking area (L2) includes a plurality of outer edge areas (L21) located at the outer edge of the support assembly and a connection area (L22) connected between the plurality of outer edge areas (L21) and separating the first stacking area (L1); the plurality of outer edge areas (L21) are welded and / or fixedly connected to the box frame (113) by screws, and the connection area (L22) is fixedly connected to the box frame (113) by screws.

32. The battery case (10) according to claim 24, wherein: The battery box (10) comprises: The box body (11) has a receiving groove; and A box cover (12) is provided at the open end of the receiving groove and is configured to cover the receiving groove. Wherein, the support assembly is configured to form a side wall (112) of the box body (11).

33. The battery case (10) according to claim 24, wherein: The battery box (10) comprises: The box body (11) has a receiving groove; and A box cover (12) is provided at the open end of the receiving groove and is configured to cover the receiving groove. Wherein, the support assembly is configured to form the box cover (12).

34. A battery (50) comprising: Battery cell (51); and The battery case (10) according to any one of claims 24 to 33 is configured to accommodate the battery cell (51).

35. An electrical device comprising: The battery (50) as claimed in claim 34, for providing electrical energy.

36. The powered device according to claim 35, further comprising: a battery receiving compartment (61) configured to receive the battery; and An operating compartment (62) is separated from the battery accommodating compartment (61) by the supporting assembly.

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