Battery module, battery pack, electric equipment and manufacturing method of battery module

Abstract

The invention provides a battery module, a battery pack, electric equipment and a manufacturing method of the battery module. The battery module comprises a battery cell assembly, a first circuit board, a first component, a wire harness assembly, a glue blocking piece, first potting resin and second potting resin. The battery cell assembly comprises a battery cell. The first component comprises a bottom wall, a side wall, a first convex part, a first space, a first opening and a second opening, the bottom wall and the side wall form a concave part, parts of the first circuit board and the electrode terminal are located in the concave part, and the first convex part is connected to the surface, opposite to the battery cell assembly, of the bottom wall. The first opening penetrates through the bottom wall. The second opening penetrates through the side wall and the first convex part. The wire harness assembly comprises a wire harness, a wire harness terminal and an insulating base, the wire harness terminal is fixed to the insulating base and connected to the first circuit board, and the wire harness penetrates through the first space and the first opening. The glue blocking piece is fixed to the first protruding part and the side wall and covers the second opening. The first potting resin is at least partially located in the first space. The second potting resin is at least partially disposed in the recess.

Description

Technical Field

[0001] The present application relates to the field of batteries, and in particular to a battery module, a battery pack, an electrical device, and a method for manufacturing the battery module. Background Art

[0002] A battery pack is a device that can be used continuously by recharging the active materials after the battery cell is discharged. Battery packs are widely used in electrical devices such as mobile phones, laptops, power tools, vehicles, etc. In the development of battery technology, how to improve the energy density of battery packs is one of the research directions in battery technology. Summary of the invention

[0003] In view of the above problems, the present application provides a battery module, a battery pack, an electrical device and a method for manufacturing the battery module, which are beneficial to improving the energy density of the battery pack.

[0004] The present application provides a battery module, which includes a battery cell assembly, a first circuit board, a first component, a wiring harness assembly, a rubber stopper, a first potting resin and a second potting resin.

[0005] The battery cell assembly includes a plurality of battery cells, and the battery cell includes an electrode terminal. The first circuit board is connected to the electrode terminal. The first component and the battery cell assembly are arranged along a first direction, the first component includes a bottom wall, a side wall connected to the bottom wall, a first convex portion, a first space, a first opening, and a second opening, the bottom wall and the side wall form a recess, the recess faces the battery cell assembly, the first circuit board and a portion of each electrode terminal are located in the recess, the first convex portion is connected to the surface of the bottom wall facing away from the battery cell assembly, and the first convex portion serves as at least a partial component forming the first space. Along the first direction, the first opening passes through the bottom wall. Along the second direction, the second opening passes through the side wall and the first convex portion, and the first opening, the first space and the second opening are connected. The first direction is perpendicular to the second direction. The wiring harness assembly includes a wiring harness, a wiring harness terminal and an insulating base, the wiring harness is connected to the wiring harness terminal, the wiring harness terminal is fixed to the insulating base and connected to the first circuit board, the wiring harness passes through the first space and the first opening and is led out, and the wiring harness assembly is configured to transmit power and / or electrical signals of the battery cell assembly. The rubber stopper is fixed to the first convex portion and the side wall, and the rubber stopper covers the second opening. The first potting resin is at least partially located in the first space, and the first potting resin bonds the first convex part and the wiring harness. The second potting resin is at least partially located in the concave part, and the second potting resin bonds the electrode terminal and the concave part.

[0006] In the embodiment of the present application, when the first component and the battery cell assembly are assembled, the wiring harness assembly passes through the second opening, and then the wiring harness assembly can enter the first opening and the first space. The way in which the wiring harness assembly enters the first convex portion through the second opening can reduce the size of the first space and the first opening, and a relatively small amount of the first potting resin can be poured into the first space and the first opening to seal the gap between the wiring harness and the first convex portion, which is beneficial to reducing the amount of the first potting resin used and is beneficial to improving the energy density of the battery module and the energy density of the battery pack.

[0007] In one or more of the above optional embodiments, the first space includes a contraction area and a first expansion area, the first opening is connected to the first expansion area, at least part of the first potting resin is located in the contraction area; the insulating base is located in the first expansion area, and the wiring harness passes through the first expansion area and the contraction area.

[0008] After the first potting resin and the second potting resin are poured, the portion of the wire harness passing through the first convex portion needs to be bent. When the portion of the wire harness passing through the first convex portion is bent, the first convex portion can limit the position of the wire harness in the contraction area, thereby reducing the displacement of the wire harness in the first space. The wire harness and the first potting resin will not separate, thereby reducing the possibility of water vapor intruding from the gap between the wire harness and the first potting resin due to the separation between the wire harness and the first potting resin.

[0009] In one or more of the above optional embodiments, part of the second potting resin is located in the first expansion region and covers the insulating base, and the second potting resin exceeds the insulating base in a direction opposite to the first direction.

[0010] The second potting resin bonds the insulating base and the first protrusion. The first potting resin and the second potting resin can block external water vapor from contacting the wiring harness terminal, reduce the possibility of water vapor contacting the wiring harness terminal and corroding the wiring harness terminal, and make the connection state between the wiring harness terminal and the first circuit board stable and reliable.

[0011] In one or more of the above optional embodiments, part of the first potting resin is located in the first expansion region, and the first potting resin and the second potting resin are bonded.

[0012] The first potting resin and the second potting resin can bond the wiring harness assembly and the first protrusion. The first potting resin and the second potting resin exist simultaneously in the first expansion region. The first potting resin and the second potting resin are connected to each other, increasing the connection force between the first potting resin and the second potting resin, and improving the connection stability between the first potting resin and the second potting resin. The first protrusion has a limiting and restraining effect on the first potting resin, so that the first potting resin will not fall out of the first space.

[0013] In one or more optional embodiments above, the first space includes a second expansion region, and the second expansion region, the contraction region and the first expansion region are arranged in sequence, and the first potting resin is arranged in the second expansion region, the contraction region and the first expansion region.

[0014] The opening of the second expansion area is relatively large. Resin is poured into the first space through the second expansion area to form a first potting resin, which reduces the difficulty of the resin pouring process, improves the pouring work efficiency, and also reduces the possibility of the resin flowing to the outside of the first convex part during the resin pouring process.

[0015] In one or more optional embodiments above, the second expansion region has an opening away from the contraction region along a direction opposite to the first direction, and along the second direction or the third direction, a spacing between the opening and the wiring harness is greater than 0 mm and less than or equal to 4 mm.

[0016] In one or more optional embodiments above, there is a spacing between the first protrusion and the edge of the bottom wall along the second direction, the second opening passes through the side wall, the bottom wall and the first protrusion, and the rubber stopper is fixed to the first protrusion, the bottom wall and the side wall.

[0017] Along the second direction, the area on the rubber stopper connected to the first protrusion can be closer to the wiring harness, reducing the spatial volume between the rubber stopper and the wiring harness, and the first spatial volume of the first protrusion can be reduced, which is beneficial to reducing the amount of the first potting resin, reducing the overall weight of the battery module, and improving the energy density of the battery module.

[0018] In one or more of the above optional embodiments, at 25 degrees Celsius, the viscosity of the first potting resin before curing is greater than the viscosity of the second potting resin before curing, which is conducive to the first potting resin filling the gap between the wiring harness and the first space and the gap between the wiring harness and the second opening more quickly. The second potting resin has a higher viscosity, which is conducive to better filling the first space, the first opening, and the second opening.

[0019] In one or more of the above optional embodiments, the wiring harness assembly is configured to transmit signals of the battery cell assembly, and the wiring harness assembly includes a plug located outside the first space.

[0020] In one or more of the above optional embodiments, the wire harness is bent relative to the first protrusion, and a projected portion of the wire harness is separated from a projection of the first protrusion along the first direction.

[0021] In one or more of the above optional embodiments, the side wall is connected to the edge of the bottom wall around the side wall.

[0022] In one or more optional embodiments above, the side wall includes a first side wall and a second side wall arranged opposite to each other along the second direction, and a third side wall and a fourth side wall arranged opposite to each other along the third direction. The first direction, the second direction and the third direction are perpendicular to each other. The second opening passes through the first side wall and the first convex portion.

[0023] In one or more of the above optional embodiments, the rubber stopper is bonded to the first protrusion and the side wall.

[0024] In one or more optional embodiments above, along the third direction, the wiring harness includes multiple groups of wires. Along the third direction, the spacing between two adjacent groups of wires ranges from 0 mm to 3 mm. Along the second direction or the third direction, the spacing between the contraction area and the wiring harness ranges from greater than 0 mm to less than or equal to 2 mm.

[0025] In one or more of the above optional embodiments, the first protrusion and the bottom wall are an integrally formed structure.

[0026] In one or more of the above optional embodiments, along the first direction, the rubber blocking member is not lower than the side wall.

[0027] When the second potting resin is poured in the inverted state, the rubber blocking member can prevent the second potting resin from flowing out from the area where the second opening is located on the side wall, thereby reducing the possibility of resin leakage at the side wall.

[0028] In one or more of the above optional embodiments, along a direction opposite to the first direction, the rubber stopper is not lower than the first protrusion.

[0029] When the battery cell assembly is in an upright state and the first potting resin is poured, the rubber stopper can limit the first potting resin from flowing out of the area where the second opening is located at the first convex portion, thereby reducing the possibility of resin leakage at the first convex portion.

[0030] In one or more optional embodiments above, at 25° C., the viscosity of the first potting resin before curing is in the range of 35000±5000 mPa·s.

[0031] An embodiment of the present application provides a battery pack, which includes the above-mentioned battery module and a shell, and the battery module is located in the shell.

[0032] In one or more of the above optional embodiments, the battery pack includes a second circuit board, the second circuit board is located on a side of the bottom wall facing away from the battery cell assembly, and the wiring harness assembly connects the first circuit board and the second circuit board.

[0033] An embodiment of the present application provides an electrical device, which includes the above-mentioned battery pack.

[0034] The present invention provides a method for manufacturing a battery module, which includes:

[0035] Provide battery cell components;

[0036] Providing a first circuit board, and connecting the electrode terminal to the first circuit board;

[0037] Providing a wiring harness assembly, connecting the wiring harness terminal to the first circuit board;

[0038] Providing a first member, pushing the first member toward the wiring harness assembly, and the wiring harness assembly passes through the second opening and enters the first space and the first opening;

[0039] Moving the first component toward the battery cell assembly to a predetermined position along a first direction;

[0040] Providing a rubber stopper, fixed to the first convex portion and the side wall, the rubber stopper covering the second opening;

[0041] Providing a first potting resin, pouring the flowing first potting resin into the first space, the first potting resin filling the gap between the first protrusion and the wiring harness;

[0042] After the first potting resin is cured, the battery cell assembly and the first component are turned over 180 degrees along the first direction;

[0043] providing a second potting resin, and pouring the flowing second potting resin into the concave portion;

[0044] After the second potting resin is cured, the battery cell assembly and the first component are turned over 180 degrees along the first direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present application. Also, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0046] Figure 1 is a schematic structural diagram of a battery pack provided in one embodiment of the present application;

[0047] Figure 2 is a schematic diagram of the exploded structure of a battery pack provided in one embodiment of the present application;

[0048] Figure 3 is a partial structural schematic diagram of a battery module provided in one embodiment of the present application;

[0049] Figure 4 It is a schematic diagram of a partial exploded structure of a battery module provided in one embodiment of the present application;

[0050] Figure 5 is a partial structural schematic diagram of a battery module provided in one embodiment of the present application;

[0051] Figure 6 is a structural schematic diagram of a first component provided by an embodiment of the present application;

[0052] Figure 7 is a structural schematic diagram of a first component provided by an embodiment of the present application;

[0053] Figure 8 is a structural schematic diagram of a first component provided by an embodiment of the present application;

[0054] Fig. 9 yes Figure 8 The enlarged schematic diagram of the middle W;

[0055] Fig.10 is a schematic diagram of the structure of a battery cell provided in one embodiment of the present application;

[0056] Fig.11 is a schematic structural diagram of an inverted battery pack provided in one embodiment of the present application;

[0057] Fig.12 is a partial structural schematic diagram of a battery module provided in one embodiment of the present application;

[0058] Fig.13 is a partial cross-sectional structural schematic diagram of a battery module provided in one embodiment of the present application;

[0059] Fig.14 yes Fig.13 The enlarged schematic diagram of the M in the middle;

[0060] Fig.15 is a partial cross-sectional structural schematic diagram of a battery module provided in one embodiment of the present application;

[0061] Fig.16 It is a schematic diagram of a manufacturing method of a battery module provided in one embodiment of the present application;

[0062] Fig.17 It is a schematic diagram of the assembly process of a battery cell assembly and a first component provided in one embodiment of the present application.

[0063] Description of reference numerals:

[0064] 10. Battery pack; 10a. Battery module; 11. Housing; 1011. Front wall; 1012. Rear wall; 1013. Right wall; 1014. Left wall; 1015. Lower wall; 1016. Top wall; 12. Filling hole;

[0065] 20. battery cell assembly; 2001. first battery cell group; 2002. second battery cell group; 21. battery cell; 211. housing; 212. electrode terminal;

[0066] 30. first member; 301. bottom wall; 3011. first opening; 302. side wall; 302a. first side wall; 302b. second side wall; 302c. third side wall; 302d. fourth side wall; 31. recess; 32. first convex portion; 321. first space; 3211. contraction region; 3212. first expansion region; 3213. second expansion region; 3213a. opening; 33. second opening; 34. second convex portion; 35. third convex portion;

[0067] 40. Wiring harness assembly; 41. Wiring harness; 42. Wiring harness terminal; 43. Insulating base; 44. Plug;

[0068] 50. Rubber stopper;

[0069] 60. First potting resin;

[0070] 70. Second potting resin;

[0071] 80. Radiator; 81. Diversion hole;

[0072] 90. a first circuit board;

[0073] 100. second circuit board; 101. connector;

[0074] 110. a first conductive member;

[0075] 120. a second conductive member;

[0076] 130, third potting resin;

[0077] 140, fourth potting resin;

[0078] X, first direction;

[0079] Y, second direction;

[0080] Z. Third direction. DETAILED DESCRIPTION

[0081] The following embodiments of the technical solution of the present application are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and are therefore only used as examples, and cannot be used to limit the scope of protection of the present application.

[0082] It should be noted that, unless otherwise specified, the technical terms or scientific terms used in the embodiments of the present application should have the common meanings understood by technicians in the field to which the embodiments of the present application belong.

[0083] In the description of the embodiments of the present application, the orientations or positional relationships indicated by technical terms such as "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they should not be understood as limitations on the embodiments of the present application.

[0084] In addition, the technical terms "first", "second", etc. are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. In the description of the embodiments of the present application, the meaning of "multiple" is more than two, unless otherwise clearly and specifically defined.

[0085] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "installed", "connected", "connected", "fixed" and the like 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 a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of the present application can be understood according to the specific circumstances.

[0086] See also Figures 1 to 9 As shown, the battery pack 10 mentioned in the embodiment of the present application refers to a module including a battery module 10a. The battery pack 10 includes a housing 11 and a battery module 10a disposed in the housing 11.

[0087] The embodiment of the present application provides a battery module 10 a , which includes a battery cell assembly 20 , a first circuit board 90 and a first component 30 .

[0088] The battery cell assembly 20 includes a plurality of battery cells 21. Each battery cell 21 includes an electrode terminal 212. The first circuit board 90 is connected to the electrode terminal 212. The first component 30 and the battery cell assembly 20 are arranged along a first direction X. The first component 30 includes a bottom wall 301 and a side wall 302 connected to the bottom wall 301. The bottom wall 301 and the side wall 302 form a recess 31. The recess 31 faces the battery cell assembly 20. The first circuit board 90 and a portion of each electrode terminal 212 are located in the recess 31. In some achievable embodiments, the first component 30 includes a first protrusion 32, a first opening 3011, and a second opening 33. The first protrusion 32 is connected to the surface of the bottom wall 301 facing away from the battery cell assembly 20. Along the first direction X, the first opening 3011 penetrates the bottom wall 301. Along the second direction Y, the second opening 33 penetrates the side wall 302 and the first protrusion 32.

[0089] In some possible implementations, see Figure 6 As shown, the side wall 302 is connected to the edge of the bottom wall 301 around the periphery.

[0090] In some possible implementations, see Figure 7 , Figure 8 and Fig. 9 As shown, the side wall 302 includes a first side wall 302a and a second side wall 302b arranged opposite to each other along the second direction Y, and a third side wall 302c and a fourth side wall 302d arranged opposite to each other along the third direction Z. The first direction X, the second direction Y and the third direction Z are perpendicular to each other. The second opening 33 passes through the first side wall 302a and the first protrusion 32.

[0091] In some achievable embodiments, the first member 30 includes a first space 321. The first protrusion 32 is at least a part of a member forming the first space 321. Exemplarily, the first protrusion 32 is connected to an edge of the first opening 3011, and the first protrusion 32 forms the first space 321. In other embodiments, the first protrusion 32 and a portion of the bottom wall 301 form the first space 321. The first opening 3011 and the first space 321 are in communication with the second opening 33.

[0092] In some achievable embodiments, the battery module 10a includes a wiring harness assembly 40. The wiring harness assembly 40 includes a wiring harness 41, a wiring harness terminal 42, and an insulating base 43. The wiring harness 41 is connected to the wiring harness terminal 42. The wiring harness terminal 42 is fixed to the insulating base 43, and the wiring harness terminal 42 is connected to the first circuit board 90. The wiring harness 41 passes through the first space 321 and the first opening 3011 and is led out. The wiring harness assembly 40 is configured to transmit power and / or electrical signals of the battery cell assembly 20. For example, the wiring harness terminal 42 is welded to the first circuit board 90.

[0093] In some possible implementations, see Figure 3 , Figure 4 and Figure 5 As shown, the battery module 10a includes a rubber stopper 50. The rubber stopper 50 is fixed to the first protrusion 32 and the outer side of the side wall 302. The rubber stopper 50 covers the second opening 33.

[0094] In some possible implementations, see Figure 2 and Fig.15As shown, the battery module 10a includes a first potting resin 60. The first potting resin 60 is at least partially located in the first space 321. The first potting resin 60 seals the gap between the first protrusion 32 and the wiring harness 41. The first potting resin 60 bonds the wiring harness 41 and the first protrusion 32. The rubber stopper 50 is configured to limit the first potting resin 60 from overflowing from the second opening 33. In other embodiments, a portion of the first potting resin 60 is located outside the first space 321 and wraps the wiring harness 41 to further strengthen the sealing of the wiring harness assembly 40.

[0095] In some possible implementations, see Figure 2 and Fig.15 As shown, the battery module 10a includes a second potting resin 70. The second potting resin 70 is at least partially disposed in the recess 31. The second potting resin 70 bonds the electrode terminal 212 and the recess 31. The rubber stopper 50 is configured to limit the second potting resin 70 from overflowing from the second opening 33.

[0096] In the present application examples, see Figure 3 and Fig.10 As shown, the battery cell assembly 20 may include a plurality of battery cells 21 arranged side by side. The plurality of battery cells 21 are arranged in a second direction Y. The battery cell 21 includes a shell 211 and an electrode terminal 212. During the manufacturing process of the battery pack 10, the battery module 10a is infused with resin and a second potting resin 70 is formed. The electrode terminal 212 is insulated and isolated from other conductive structural parts by the second potting resin 70. Exemplarily, the battery cell 21 may be a soft-pack battery cell 21. The shell 211 of the battery cell 21 may be an aluminum-plastic film. The battery cell 21 includes two electrode terminals 212. One electrode terminal 212 serves as a positive terminal, and the other electrode terminal 212 serves as a negative terminal.

[0097] In the embodiment of the present application, the first opening 3011 , the first space 321 , and the second opening 33 are connected to each other, which means that they are connected to each other when the first potting resin 60 and the second potting resin 70 are not provided.

[0098] When the first component 30 and the battery cell assembly 20 are assembled, the wiring harness assembly 40 passes through the second opening 33, and then the wiring harness assembly 40 can enter the first opening 3011 and the first space 321. The way in which the wiring harness assembly 40 enters the first protrusion 32 through the second opening 33 can reduce the size of the first space 321 and the first opening 3011, and a relatively small amount of the first potting resin 60 can be poured into the first space 321 and the first opening 3011 to seal the gap between the wiring harness 41 and the first protrusion 32, which is conducive to reducing the use of the first potting resin 60 and is conducive to improving the energy density of the battery module 10a and the energy density of the battery pack 10.

[0099] When the first potting resin 60 is poured into the first space 321, the uncured first potting resin 60 has fluidity. The first potting resin 60 flows in the first space 321. During the flow of the first potting resin 60, the fluidity of the first potting resin 60 may deteriorate and solidify. When the first potting resin 60 is poured into the first space 321, the rubber stopper 50 may limit the first potting resin 60 from flowing out of the second opening 33, thereby reducing the possibility of the first potting resin 60 flowing to the outside of the first component 30 or flowing onto the battery cell assembly 20.

[0100] See also Fig.11 As shown, after the first potting resin 60 is cured, the battery cell assembly 20 and the first component 30 are turned 180° in an inverted state along the first direction X, so that the recess 31 of the first component 30 faces upward, and the second potting resin 70 is poured into the recess 31. When the second potting resin 70 is poured into the recess 31, the cured first potting resin 60 restricts the second potting resin 70 from flowing out of the first space 321. After the second potting resin 70 is cured, the battery cell assembly 20 and the first component 30 are turned 180°. The rubber stopper 50 can prevent the second potting resin 70 from flowing out of the second opening 33, reducing the possibility of the second potting resin 70 overflowing from the second opening 33.

[0101] In some possible implementations, see Fig.15 As shown, the first circuit board 90 is located in the recess 31 . The second potting resin 70 covers the entire first circuit board 90 .

[0102] The second potting resin 70 can achieve the function of insulating and isolating the first circuit board 90, so that the first circuit board 90 can be isolated from other conductive structures by the second potting resin 70, reducing the possibility of the first circuit board 90 being electrically connected to other conductive structures and causing the first circuit board 90 to fail. In some achievable embodiments, the first potting resin 60 can include but is not limited to silicone glue. The second potting resin 70 can include but is not limited to polyurethane glue.

[0103] In some practicable embodiments, the rubber stopper 50 is an insulating sheet. The material of the rubber stopper 50 may include but is not limited to polycarbonate.

[0104] In some possible implementations, see Figure 6 As shown, the first protrusion 32 is disposed near the edge of the bottom wall 301. The rubber stopper 50 is bonded to the first protrusion 32 and the side wall 302. For example, the rubber stopper 50 can be bonded to the first protrusion 32 and the side wall 302 by double-sided tape or glue.

[0105] In some possible implementations, see Fig. 9 , Fig.13 , Fig.14 and Fig.15As shown, the first space 321 includes a contraction area 3211 and a first expansion area 3212. The first opening 3011 is connected to the first expansion area 3212. At least a portion of the first potting resin 60 is located in the contraction area 3211. At least a portion of the insulating base 43 is located in the first expansion area 3212. The wiring harness 41 passes through the first expansion area 3212 and the contraction area 3211 and is led out. The first opening 3011 and the first expansion area 3212 are connected to each other when the first potting resin 60 and the second potting resin 70 are not provided.

[0106] See also Fig.12 As shown, after the first potting resin 60 and the second potting resin 70 are poured, the portion of the wire harness 41 passing through the first convex portion 32 needs to be bent. When the portion of the wire harness 41 passing through the first convex portion 32 is bent, the first convex portion 32 can limit and constrain the wire harness 41 in the contraction area 3211, reduce the displacement of the wire harness 41 in the first space 321, and reduce the possibility of water vapor intruding from the gap between the wire harness 41 and the first potting resin 60 due to separation between the wire harness 41 and the first potting resin 60.

[0107] In some possible implementations, see Fig.14 and Fig.15 As shown, part of the second potting resin 70 is located in the first expansion area 3212 and covers the insulating base 43. In the direction opposite to the first direction X, the second potting resin 70 exceeds the insulating base 43, further strengthening the sealing of the wiring harness assembly 40.

[0108] The second potting resin 70 bonds the insulating base 43 and the first protrusion 32. The first potting resin 60 and the second potting resin 70 can prevent external water vapor from contacting the wiring harness terminal 42, reduce the possibility of water vapor contacting the wiring harness terminal 42 and corroding the wiring harness terminal 42, and make the connection between the wiring harness terminal 42 and the first circuit board 90 stable and reliable.

[0109] In some possible implementations, see Figure 2 and Fig.15 As shown, part of the first potting resin 60 is located in the first expansion region 3212. The first potting resin 60 and the second potting resin 70 are bonded.

[0110] The first potting resin 60 and the second potting resin 70 bond the wiring harness assembly 40 and the first protrusion 32. The first potting resin 60 and the second potting resin 70 exist simultaneously in the first expansion region 3212. The first potting resin 60 and the second potting resin 70 are connected to each other, increasing the connection force between the first potting resin 60 and the second potting resin 70 and improving the connection stability between the first potting resin 60 and the second potting resin 70.

[0111] In some achievable ways, the portion of the harness 41 located in the contraction area 3211 abuts against the first protrusion 32. In other embodiments, there is a gap between the portion of the harness 41 located in the contraction area 3211 and the first protrusion 32, and the gap is filled with the first potting resin 60 to strengthen the fixation of the harness 41.

[0112] In some possible implementations, see Fig. 9 and Fig.15 As shown, the first space 321 includes a second expansion area 3213. The second expansion area 3213, the contraction area 3211 and the first expansion area 3212 are arranged in sequence. The second expansion area 3213, the contraction area 3211 and the first expansion area 3212 are connected. The first potting resin 60 is arranged in the second expansion area 3213, the contraction area 3211 and the first expansion area 3212. The second expansion area 3213, the contraction area 3211 and the first expansion area 3212 are connected to each other when the first potting resin 60 and the second potting resin 70 are not arranged.

[0113] The opening of the second expansion area 3213 is relatively large. Resin is poured into the first space 321 through the second expansion area 3213 to form the first potting resin 60, which reduces the difficulty of the resin pouring process, improves the pouring efficiency, and also reduces the possibility of the resin flowing to the outside of the first convex portion 32 during the resin pouring process.

[0114] In some examples, the second expansion region 3213 has an opening 3213 a away from the contraction region 3211 in a direction opposite to the first direction X. The area of ​​the opening 3213 a of the second expansion region 3213 may be smaller than that of the first opening 3011 .

[0115] In some possible implementations, see Fig. 9 and Fig.15 As shown, along the second direction Y or the third direction Z, the distance H between the opening 3213a and the harness 41 may be greater than 0 mm and less than or equal to 4 mm.

[0116] Along the third direction Z, the wiring harness 41 includes multiple groups of wires, and the distance D between two adjacent groups of wires ranges from 0 mm to 3 mm. The first direction X and the second direction Y are perpendicular to the third direction Z in pairs.

[0117] Along the second direction Y or the third direction Z, the distance H between the opening 3213 a and the harness 41 is greater than 0 mm, which facilitates the injection of resin through the gap between the second expansion region 3213 and the harness 41 to form the first potting resin 60 .

[0118] Along the second direction Y or the third direction Z, the distance H between the opening 3213a and the harness 41 is greater than 0 mm, which facilitates the injection of resin through the gap between the second expansion area 3213 and the harness 41 and the gap between two adjacent groups of wires to form the first potting resin 60.

[0119] In some examples, each group of wires includes a plurality of wires. The plurality of wires in each group of wires are arranged along the second direction Y.

[0120] In some examples, along the second direction Y, the distance between the wire harness 41 and the rubber stopper 50 may be greater than or equal to 0 mm and less than or equal to 4 mm.

[0121] In some achievable embodiments, the wiring harness 41 includes multiple groups of wires along the third direction Z. The spacing D between two adjacent groups of wires along the third direction Z ranges from 0 mm to 3 mm. Along the second direction Y or the third direction Z, the spacing between the contraction area 3211 and the wiring harness 41 ranges from greater than 0 mm to less than or equal to 3 mm.

[0122] When the spacing D between two adjacent groups of wires along the third direction Z is 0 mm, the spacing between the contraction area 3211 and the wiring harness 41 along the second direction Y or the third direction Z is greater than 0 mm, and the injected resin can flow into the contraction area 3211 through the gap between the contraction area 3211 and the wiring harness 41.

[0123] When the spacing D between two adjacent groups of wires along the third direction Z is greater than 0 mm, the spacing between the contraction area 3211 and the wiring harness 41 along the second direction Y or the third direction Z can be greater than 0 mm, and the poured resin can flow into the contraction area 3211 through the gap between the contraction area 3211 and the wiring harness 41 and the gap between the two adjacent groups of wires.

[0124] In some examples, along the third direction Z, the wiring harness 41 includes two groups of wires.

[0125] In some possible implementations, see Figure 3 and Fig. 9 As shown, there is a gap between the first protrusion 32 and the edge of the bottom wall 301 along the second direction Y. The second opening 33 penetrates the first protrusion 32, the side wall 302 and the bottom wall 301 and communicates with the first opening 3011. The rubber stopper 50 is fixed to the first protrusion 32, the bottom wall 301 and the side wall 302.

[0126] Along the second direction Y, the area on the rubber stopper 50 connected to the first protrusion 32 can be closer to the wiring harness 41, reducing the volume of the space between the rubber stopper 50 and the wiring harness 41, and the volume of the first space 321 of the first protrusion 32 can be reduced, which is beneficial to reduce the amount of the first potting resin 60, reduce the overall weight of the battery module 10a, and improve the energy density of the battery module 10a.

[0127] In some practicable embodiments, the rubber stopper 50 is an insulating sheet. The material of the rubber stopper 50 may include but is not limited to polycarbonate.

[0128] In some practicable embodiments, the rubber stopper 50 is bonded to the first protrusion 32, the bottom wall 301 and the side wall 302. For example, the rubber stopper 50 can be bonded to the first protrusion 32, the bottom wall 301 and the side wall 302 by double-sided tape or glue.

[0129] In some achievable embodiments, the first protrusion 32 and the bottom wall 301 are integrally formed, and the connection strength between the first protrusion 32 and the bottom wall 301 is relatively large, which is beneficial for preventing water vapor from entering the first space 321 .

[0130] In some achievable ways, the rubber stopper 50 is not lower than the side wall 302 along the first direction X. When the second potting resin 70 is poured in the inverted state, the rubber stopper 50 can prevent the second potting resin 70 from flowing out of the area where the second opening 33 is located on the side wall 302, reducing the possibility of resin leakage at the side wall 302.

[0131] In the direction opposite to the first direction X, the rubber stopper 50 is not lower than the first protrusion 32. When the battery cell assembly 20 is in an upright state and the first potting resin 60 is poured, the rubber stopper 50 can limit the first potting resin 60 from flowing out of the area where the second opening 33 is located at the first protrusion 32, thereby reducing the possibility of resin leakage at the first protrusion 32.

[0132] In some achievable ways, at 25 degrees Celsius (°C), the viscosity of the first potting resin 60 before curing is greater than the viscosity of the second potting resin 70 before curing, which is conducive to the first potting resin 60 filling the gap between the harness 41 and the first space 321 and the gap between the harness 41 and the second opening 33 more quickly. The second potting resin 70 has a higher viscosity, which is conducive to better filling the first space 321, the first opening 3011 and the second opening 33. For example, at 25°C, the viscosity of the first potting resin 60 before curing is in the range of 35000±5000 millipascals·seconds (mPa·s).

[0133] In some achievable embodiments, the wiring harness assembly 40 is configured to transmit signals of the battery cell assembly 20, including but not limited to voltage signals and temperature signals. The voltage signal and / or temperature signal of the battery cell 21 can be transmitted to the battery management system (BMS) through the wiring harness assembly 40, so that the battery management system can monitor the working status of the battery cell 21.

[0134] See also Figure 2 and Fig.12 As shown, the wiring harness assembly 40 includes a plug 44 located outside the first space 321. The plug 44 is connected to the wiring harness 41. The plug 44 itself is relatively large. When the first component 30 and the battery cell assembly 20 are assembled, the wiring harness 41 passes through the second opening 33, and then the wiring harness 41 can enter the first opening 3011 and the first space 321, and the plug 44 is located outside the first space 321.

[0135] In some possible implementations, see Fig.12 As shown, the wire harness 41 is bent relative to the first protrusion 32 , and along the first direction X, the projected portion of the wire harness 41 is separated from the projection of the first protrusion 32 .

[0136] In some possible implementations, see Figure 2 As shown, the battery pack 10 includes a second circuit board 100. The second circuit board 100 is located on the side of the bottom wall 301 facing away from the battery cell assembly 20. The wiring harness assembly 40 connects the first circuit board 90 and the second circuit board 100. The second circuit board 100 can be a battery management circuit board. Data signals can be exchanged between the first circuit board 90 and the second circuit board 100 through the wiring harness assembly 40.

[0137] In some examples, the second circuit board 100 includes a connector 101 , and the connector 101 is configured to be connected to an electric device.

[0138] In some examples, the first circuit board 90 and the second circuit board 100 may both be printed circuit boards (PCBs).

[0139] In some possible implementations, see Figure 2 and Figure 3As shown, the battery module 10a includes a first conductive member 110 and a second conductive member 120. The first conductive member 110 and the second conductive member 120 are respectively connected to the positive electrode and the negative electrode of the battery cell assembly 20. The first component 30 includes a second protrusion 34 and a third protrusion 35. The first conductive member 110 and the second conductive member 120 pass through the second protrusion 34 and the third protrusion 35 respectively and are led out. A third potting resin 130 is filled between the first conductive member 110 and the second protrusion 34. A fourth potting resin 140 is filled between the second conductive member 120 and the third protrusion 35. The third potting resin 130 seals the gap between the first conductive member 110 and the second protrusion 34. The fourth potting resin 140 seals the gap between the second conductive member 120 and the second protrusion 34.

[0140] After the first potting resin 60, the third potting resin 130 and the fourth potting resin 140 are cured, the battery cell assembly 20 and the first component 30 are turned over 180° to an inverted state so that the concave portion 31 of the first component 30 faces upward, and the second potting resin 70 is poured into the concave portion 31. When pouring the second potting resin 70 into the concave portion 31, the cured first potting resin 60, the third potting resin 130 and the fourth potting resin 140 restrict the second potting resin 70 from flowing out of the first space 321. After the second potting resin 70 is cured, the battery cell assembly 20 and the first component 30 are turned over 180°.

[0141] In some examples, the first conductive member 110 and the second conductive member 120 may both be copper bars.

[0142] In some possible implementations, see Fig.11 As shown, the battery pack 10 has a pouring hole 12 configured to pour resin. Resin can be poured into the battery pack 10 through the pouring hole 12. When pouring resin, the battery pack 10 is first placed upside down, and the first component 30 is located below the battery cell assembly 20. The resin poured into the battery pack 10 can flow into the recess 31 of the first component 30 under the action of gravity.

[0143] For some examples, see Figure 2 As shown, the battery pack 10 includes a housing 11 and a battery module 10 a. The battery module 10 a is located inside the housing 11.

[0144] For some examples, see Figure 2 As shown, the housing 11 includes a front wall 1011 and a rear wall 1012 that are oppositely arranged, a right wall 1013 and a left wall 1014 that are oppositely arranged, and a lower wall 1015 and a top wall 1016 that are oppositely arranged.

[0145] For some examples, see Figure 3 and Fig.11As shown, the battery module 10a includes a heat sink 80. The battery cell assembly 20 includes a first battery cell group 2001 and a second battery cell group 2002 spaced apart along a third direction Z. The first direction X, the second direction Y and the third direction Z are perpendicular to each other. Along the third direction Z, the heat sink 80 is located between the first battery cell group 2001 and the second battery cell group 2002. The heat sink 80 is provided with a guide hole 81, and the front wall 1011 is provided with a pouring hole 12, and the guide hole 81 and the pouring hole 12 are configured to pour the second potting resin 70 into the recess 31. In other embodiments, the pouring hole 12 may be provided on the rear wall 1012.

[0146] In some conceivable embodiments, the battery module 10a may be configured as follows: Fig.11 The battery cell assembly 20 is placed upside down, and then the second potting resin 70 is poured through the gap between the recess 31 and the battery cell assembly 20 .

[0147] The present application also provides an electric device, including the battery module 10a of any of the above solutions, and the battery module 10a is used to provide power to the electric device. The electric device can be, but is not limited to, electronic equipment, drones, backup power supplies, electric vehicles, electric motorcycles, electric power-assisted bicycles, electric tools, large household power storage modules, etc.

[0148] See also Fig.16 As shown, the embodiment of the present application provides a method for manufacturing a battery module 10a, which includes:

[0149] A battery cell assembly 20 is provided, wherein the battery cell 21 includes an electrode terminal 212;

[0150] Providing a first circuit board 90, and connecting the electrode terminal 212 to the first circuit board 90;

[0151] Providing a wiring harness assembly 40 , electrically connecting the wiring harness terminal 42 to the first circuit board 90 ;

[0152] Provide a first member 30, push the first member 30 toward the wiring harness assembly 40, and the wiring harness assembly 40 passes through the second opening 33 and enters the first space 321 and the first opening 3011;

[0153] Along the first direction X, move the first component 30 toward the battery cell assembly 20 to a predetermined position;

[0154] A rubber stopper 50 is provided, fixed to the first protrusion 32 and the side wall 302, and the rubber stopper 50 covers the second opening 33;

[0155] Providing a first potting resin 60, pouring the flowing first potting resin 60 into the first space 321, the first potting resin 60 filling the gap between the first protrusion 32 and the wiring harness 41;

[0156] After the first potting resin 60 is cured, the battery cell assembly 20 and the first component 30 are turned over 180° along the first direction X;

[0157] Providing a second potting resin 70 and pouring the flowing second potting resin 70 into the recess 31;

[0158] After the second potting resin 70 is cured, the battery cell assembly 20 and the first component 30 are turned over 180 degrees along the first direction X.

[0159] In some possible implementations, see Fig.17 As shown, the first component 30 is placed in a flat state. The first component 30 is pushed toward the wiring harness assembly 40 in a direction opposite to the second direction Y, and the wiring harness assembly 40 passes through the second opening 33 and enters the first space 321 and the first opening 3011. Then, the first component 30 is moved toward the battery cell assembly 20 to a predetermined position along the first direction X. The first component 30 is installed.

[0160] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application, and they should all be included in the scope of the claims and specification of the present application. In particular, as long as there is no structural conflict, the various technical features mentioned in the various embodiments can be combined in any way. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions that fall within the scope of the claims.

Claims

1. A battery module, characterized in that: include: A battery cell assembly, comprising a plurality of battery cells, wherein the battery cells include electrode terminals; A first circuit board connected to the electrode terminal; A first component and the cell assembly are arranged along a first direction, the first component includes a bottom wall, a side wall connected to the bottom wall, a first convex portion, a first space, a first opening, and a second opening, the bottom wall and the side wall form a concave portion, the concave portion faces the cell assembly, the first circuit board and a portion of each of the electrode terminals are located in the concave portion, the first convex portion is connected to a surface of the bottom wall facing away from the cell assembly, and the first convex portion serves as at least a part of a component forming the first space; Along the first direction, the first opening penetrates the bottom wall, and along the second direction, the second opening penetrates the side wall and the first convex portion, the first opening, the first space and the second opening are connected, and the first direction is perpendicular to the second direction; A wire harness assembly, comprising a wire harness, a wire harness terminal and an insulating base, wherein the wire harness is connected to the wire harness terminal, the wire harness terminal is fixed to the insulating base and connected to the first circuit board, the wire harness passes through the first space and the first opening and is led out, and the wire harness assembly is configured to transmit power and / or electrical signals of the battery cell assembly; A rubber stopper, fixed to the first convex portion and the side wall, the rubber stopper covers the second opening; a first potting resin, at least partially located in the first space, the first potting resin bonding the first protrusion and the wiring harness; The second potting resin is at least partially disposed in the recessed portion, and the second potting resin bonds the electrode terminal and the recessed portion.

2. The battery module according to claim 1, characterized in that: The first space includes a contraction area and a first expansion area, the first opening is connected to the first expansion area, and at least a portion of the first potting resin is located in the contraction area; The insulating base is located in the first expansion area, and the wiring harness passes through the first expansion area and the contraction area.

3. The battery module according to claim 2, characterized in that: A portion of the second potting resin is located in the first expansion region and covers the insulating base. The second potting resin exceeds the insulating base along a direction opposite to the first direction.

4. The battery module according to claim 3, characterized in that: A portion of the first potting resin is located in the first expansion region, and the first potting resin and the second potting resin are bonded to each other.

5. The battery module according to any one of claims 2 to 4, characterized in that: The first space includes a second expansion area, the second expansion area, the contraction area and the first expansion area are arranged in sequence, and the first potting resin is arranged in the second expansion area, the contraction area and the first expansion area.

6. The battery module according to claim 5, characterized in that: Along a direction opposite to the first direction, the second expansion region has an opening away from the contraction region, and along the second direction or the third direction, a distance between the opening and the wiring harness is greater than 0 mm and less than or equal to 4 mm.

7. The battery module according to any one of claims 1 to 6, characterized in that: Along the second direction, there is a distance between the first protrusion and the edge of the bottom wall, the second opening passes through the side wall, the bottom wall and the first protrusion, and the rubber stopper is fixed to the first protrusion, the bottom wall and the side wall.

8. The battery module according to any one of claims 1 to 7, characterized in that: At 25 degrees Celsius, the viscosity of the first potting resin before curing is greater than the viscosity of the second potting resin before curing.

9. The battery module according to any one of claims 1 to 8, characterized in that: The wiring harness assembly is configured to transmit signals of the battery cell assembly, and the wiring harness assembly includes a plug located outside the first space.

10. The battery module according to any one of claims 1 to 9, characterized in that: The wire harness is bent relative to the first protrusion, and a projected portion of the wire harness is separated from a projection of the first protrusion along the first direction.

11. A battery pack, characterized in that: The invention comprises a battery module and a shell as claimed in any one of claims 1 to 10, wherein the battery module is located in the shell.

12. The battery pack according to claim 11, characterized in that: The battery pack includes a second circuit board, which is located on a side of the bottom wall facing away from the battery cell assembly, and the wiring harness assembly connects the first circuit board and the second circuit board.

13. An electrical equipment, characterized in that: Comprising the battery pack as claimed in claim 12.

14. A method for manufacturing a battery module according to any one of claims 1 to 13, characterized in that: include: Providing the battery cell assembly; Providing the first circuit board, and connecting the electrode terminal to the first circuit board; Providing the wiring harness assembly, connecting the wiring harness terminal to the first circuit board; Providing the first member, pushing the first member toward the wiring harness assembly, the wiring harness assembly passes through the second opening and enters the first space and the first opening; Moving the first member toward the battery cell assembly to a predetermined position along the first direction; Providing the rubber stopper, fixed to the first convex portion and the side wall, the rubber stopper covers the second opening; providing the first potting resin, and pouring the flowing first potting resin into the first space, so that the first potting resin fills the gap between the first protrusion and the wiring harness; After the first potting resin is cured, the battery core assembly and the first component are turned over 180 degrees along the first direction; providing the second potting resin, and pouring the flowing second potting resin into the concave portion; After the second potting resin is cured, the battery core assembly and the first component are turned over 180 degrees along the first direction.

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