Battery packs, battery pack manufacturing methods, and electrical devices.

Abstract

This application provides a battery pack, a method for manufacturing the battery pack, and an electrical device, belonging to the field of battery technology. The battery pack includes a battery assembly and a tray. The battery assembly has a first end with a welding area. The tray includes a base plate and a frame. The base plate is connected to the frame and forms a receiving cavity. The battery assembly is located in the receiving cavity. The frame includes connected end beams and side beams. The end beams are opposite to the first end, and in the height direction of the tray, the top surface of the end beams is lower than at least part of the welding area. In this way, the battery assembly can be pre-installed into the receiving cavity of the tray, so that the welding area of ​​the first end of the battery assembly is located on one side of the end beam. At this time, laser beam welding of connectors and functional boards is used, eliminating the need to flip the tray, thereby effectively improving the assembly efficiency of the battery pack. Furthermore, the forward-mounted battery assembly can adaptively assemble according to the edge position of the tray, ensuring consistent assembly gaps.

Description

Technical Field

[0001] This application relates to the field of battery technology, specifically to a battery pack, a method for manufacturing the battery pack, and an electrical device. Background Technology

[0002] The battery pack consists of a tray and battery modules located within the tray. Currently, in the battery pack assembly process, battery cells are usually stacked first, and connectors are welded to connect the battery cells to form modules. Then, the tray is lifted and inverted to assemble with the modules. After that, it is flipped over and other components are installed. This assembly process is cumbersome and complex, which reduces the assembly efficiency of the battery pack. Summary of the Invention

[0003] This application provides a battery pack, a method for manufacturing the battery pack, and an electrical device, which can effectively simplify the battery pack assembly process and thus effectively improve the assembly efficiency of the battery pack.

[0004] The embodiments of this application provide the following technical solutions to solve the above-mentioned technical problems:

[0005] In the first part, embodiments of this application provide a battery pack, including:

[0006] A battery pack having a first end, on which a welding area is provided;

[0007] The tray includes a receiving cavity in which the battery pack is located, and the tray includes an end beam disposed near the first end, wherein, in the height direction of the tray, the top surface of the end beam is lower than at least a portion of the welding area.

[0008] This embodiment shortens the height of the end beam of the tray, so that the top surface of the end beam opposite the first end of the battery pack is lower than at least part of the welding area. When the battery pack is welded within the receiving cavity, the height of the end beam is sufficient for welding operations at the welding area of ​​the first end of the battery pack. During battery pack assembly, the battery pack can be pre-installed into the receiving cavity of the tray, with the welding area of ​​the first end of the battery pack located on one side of the end beam, at which point laser beam welding is performed. This forward-mounted insertion of the battery module into the receiving cavity of the tray eliminates the need to flip the tray, saving the flipping process. This reduces the number of assembly steps and simplifies the operation, effectively simplifying the battery pack assembly process and thus significantly improving assembly efficiency. Furthermore, forward-mounted battery pack assembly can adaptively assemble according to the edge position of the tray, ensuring consistent assembly gaps.

[0009] In one possible implementation, the battery pack includes a plurality of batteries and connectors, wherein the connectors are welded to the terminals of a plurality of batteries such that the plurality of batteries are connected in series.

[0010] In one possible implementation, the welding area includes a first welding area located on the connector disposed at the first end, and the top surface of the end beam is lower than the first welding area.

[0011] In one possible implementation, a sampling component is also included, the sampling component comprising a functional board and a plurality of first sampling pieces, the functional board being located at the first end and some of the first sampling pieces being located at the top of the functional board;

[0012] The first sampling plate located at the top of the functional board is connected to the connector.

[0013] In one possible implementation, the welding area further includes a second welding area, wherein a portion of the first sampling piece is located at the bottom end of the functional board and is welded to the casings of the plurality of batteries respectively, the second welding area is located on the portion of the first sampling piece, and the top surface of the end beam is higher or lower than the second welding area.

[0014] In one possible implementation, along the height direction of the tray, the distance between the top surface of the end beam and the inner bottom wall of the tray is a, the distance between the connection point on the portion of the first sampling piece near the inner bottom wall of the tray and the inner bottom wall of the tray is d, the distance between the connection point on the portion of the first sampling piece near the inner bottom wall of the tray and the top surface of the end beam is c, and a≤d+c.

[0015] In one possible implementation, the distance between the connection point on the first sampling piece and the side of the end beam facing the receiving cavity is b, and b ≥ 10c.

[0016] In one possible implementation, each of the first sampling pieces has a bent portion, and the multiple bent portions are respectively welded to the casings of the multiple batteries.

[0017] In one possible implementation, along the extension direction of the battery, the height of the first sampling piece is e, the distance between the connection point on the bent portion near the inner bottom wall of the tray and the top of the bent portion is f, and e < 10f.

[0018] In one possible implementation, the pallet further includes a side beam that is angularly connected to the end beam, wherein the top surface of the side beam is higher than the top surface of the end beam in the height direction of the pallet.

[0019] In one possible implementation, the side beam has an inclined transition surface, and the top surface of the side beam is connected to the top surface of the end beam through the transition surface.

[0020] In one possible implementation, the angle between the transition surface and the top surface of the side beam is α, and 120°≤α≤180°.

[0021] In one possible implementation, a support plate is provided on the side of the transition surface facing the receiving cavity.

[0022] In one possible implementation, the support plate is provided with reinforcing ribs, and the reinforcing ribs extend in the height direction of the tray.

[0023] In one possible implementation, the battery pack has a second end opposite to the first end, and the sampling assembly further includes a circuit board and a plurality of second sampling plates, the circuit board being connected to the second end of the battery pack via the second sampling plates.

[0024] In one possible implementation, a plurality of second sampling pieces are respectively located at the top and bottom of the circuit board, and the second sampling piece located at the top of the circuit board is connected to the connector at the second end;

[0025] The second sampling chip, located at the bottom of the circuit board, is connected to the battery casing.

[0026] In one possible implementation, the battery pack further includes a plurality of brackets, each located at one end of the battery, the brackets being used to secure the battery;

[0027] And / or, the battery pack further includes a plurality of protective covers, which are respectively disposed at the first end and the second end. The protective cover at the first end is used to protect the functional board, and the protective cover at the second end is used to protect the circuit board.

[0028] In one possible implementation, there are two end beams, which are a front beam and a rear beam arranged opposite each other. The front beam and the rear beam are respectively connected by two opposite side beams to form a frame to enclose and form the receiving cavity.

[0029] The number of battery packs is multiple, and two of the battery packs are spaced apart along the direction from the front beam to the rear beam. The front beam is opposite to the first end of one of the two battery packs, and the rear beam is opposite to the first end of the other battery pack.

[0030] In one possible implementation, a cover plate is also included, the cover plate having a connecting surface on one side facing the frame, the connecting surface including a front sealing surface, a rear sealing surface and two side sealing surfaces, the front sealing surface being connected to the top surface of the front beam, the rear sealing surface being connected to the top surface of the rear beam, and the side sealing surfaces being connected to the top surface of the side beam.

[0031] In one possible implementation, an annular groove is provided on the top surface of the frame surrounding the receiving cavity, the annular groove being used to receive sealant so that the top surface of the frame forms a seal with the connecting surface of the cover plate.

[0032] In one possible implementation, a heat exchange channel is provided inside the cover plate, and a heat exchange medium is circulated in the heat exchange channel for heat exchange of the battery pack.

[0033] In one possible implementation, an insulating film is provided on the side of the cover plate facing the receiving cavity, the insulating film being designed to withstand high temperatures;

[0034] And / or, the cover plate has an anti-corrosion layer on the side facing away from the receiving cavity.

[0035] In the second part, embodiments of this application provide a method for manufacturing a battery pack, including:

[0036] A tray is provided, the tray including a receiving cavity;

[0037] A battery pack is provided having a first end and a second end disposed opposite to each other, the first end having a welding area, and the battery pack is placed in the receiving cavity of the tray in a forward-facing manner, the first end being opposite to an end beam of the tray, and the top surface of the end beam being lower than at least a portion of the welding area.

[0038] A functional board is installed on the welding area at the first end, and the welding area at the first end is connected to the functional board through a first sampling plate.

[0039] In one possible implementation, each of the battery packs includes two edge modules arranged opposite to each other, and each edge module includes a plurality of batteries;

[0040] Before placing the battery pack in the receiving cavity of the tray in an upright position, the following steps are included:

[0041] A circuit board is installed at the second end of each edge module, and the two edge modules with the circuit board installed are respectively placed face up in the receiving cavity of the tray near the side beam of the battery pack.

[0042] In one possible implementation, each of the battery packs further includes an intermediate module comprising an even number of batteries, the intermediate module being located between the two edge modules;

[0043] Before placing the battery pack in the receiving cavity of the tray in an upright position, the method further includes:

[0044] The circuit board is installed at the second end of the intermediate module, and the intermediate module with the circuit board installed is placed between the two edge modules in a forward orientation.

[0045] In one possible implementation, prior to mounting the functional board on the welding area at the first end, the process includes:

[0046] The pole on the first end of the edge module is connected in series with the pole on the first end of the middle module through multiple connectors;

[0047] The first sampling piece located at the top of the functional board is connected to the first welding area on the connector at the first end, and the first sampling piece located at the bottom of the functional board is connected to the second welding area on the first end.

[0048] In one possible implementation, after installing the functional board at the first end of the battery pack, the method further includes:

[0049] A cover plate is provided to cover the tray, and the cover plate is connected to the edge of the tray by fasteners.

[0050] Thirdly, embodiments of this application provide an electrical device, including:

[0051] The electrical device and the battery pack manufactured by the above-described battery pack or battery pack manufacturing method, wherein the battery pack is connected to the electrical device and is used to provide electrical energy to the electrical device.

[0052] In addition to the technical problems solved by this application, the technical features constituting the technical solutions, and the beneficial effects brought about by the technical features of these technical solutions as described above, other technical problems solved by a battery pack, a method for manufacturing a battery pack, and an electrical device provided by this application, other technical features included in the technical solutions, and the beneficial effects brought about by these technical features will be further described in detail in the specific embodiments. Attached Figure Description

[0053] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments of this application or the prior art will be briefly introduced below. Obviously, the drawings described below are only a part of the embodiments of this application. These drawings and text descriptions are not intended to limit the scope of the concept of this application in any way, but to illustrate the concept of this application to those skilled in the art by referring to specific embodiments. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0054] Figure 1 This is a schematic diagram of the battery pack structure provided in an embodiment of this application;

[0055] Figure 2 This is a schematic diagram of the structure of the tray of the battery pack provided in the embodiments of this application;

[0056] Figure 3 A partial detailed view of the front view of the tray of the battery pack provided in an embodiment of this application;

[0057] Figure 4 A partial detailed view of the front beam of the battery pack provided in an embodiment of this application;

[0058] Figure 5 An exploded view of the first end of the battery pack of the battery pack provided in an embodiment of this application;

[0059] Figure 6 An exploded view of the second end of the battery pack in an embodiment of this application;

[0060] Figure 7 This is a front view of the battery pack assembly provided in an embodiment of this application;

[0061] Figure 8 This is an assembly dimension drawing of the battery pack in the battery module provided in the embodiments of this application;

[0062] Figure 9 A schematic flowchart illustrating the manufacturing method of the battery pack provided in this application embodiment;

[0063] Figure 10 A schematic diagram illustrating the circuit board mounting process of the battery pack provided in this application embodiment;

[0064] Figure 11 This is a schematic diagram illustrating the process of installing the functional board of the battery pack provided in the embodiments of this application.

[0065] Explanation of reference numerals in the attached figures:

[0066] 100-Battery pack; 110-Battery; 120-Welding area; 121-First welding area; 122-Second welding area; 130-Functional board; 140-First sampling piece; 141-Bending part; 150-Circuit board; 160-Second sampling piece; 170-Connector; 180-Bracket; 190-Protective cover;

[0067] 200-Pallet; 210-Receiving cavity; 220-Base plate; 230-Frame; 231-Annular groove; 232-Mounting hole; 240-End beam; 241-Front beam; 242-Rear beam; 250-Side beam; 251-Transition surface; 252-Support plate; 253-Reinforcing rib; 260-Crossbeam;

[0068] 300-cover plate;

[0069] 410 - Edge module; 420 - Middle module. Detailed Implementation

[0070] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0071] This application provides an electrical device, which includes an electrical component and a battery pack, the battery pack providing electrical energy to the electrical component. For example, the electrical device can be a vehicle or an energy storage device. When the electrical device is a vehicle, the vehicle can be a new energy vehicle, such as a pure electric vehicle (PEV / BEV), a range-extended electric vehicle (REEV), a hybrid electric vehicle (HEV), or a fuel cell electric vehicle. The vehicle can also be any vehicle equipped with a battery.

[0072] Electrical devices can also be electric motors, control systems, lighting systems, etc. When an electrical device is an energy storage device, it can be an inverter, controller, etc. A battery pack can include multiple batteries. In one possible implementation, the batteries can be cylindrical, prismatic, or contain several batteries internally. These multiple batteries are connected in a specific way and controlled by a control system to store and output electrical energy. The battery pack or individual batteries can provide the electrical energy to the electrical device to meet its normal operation requirements.

[0073] This application provides a battery pack, such as... Figure 1 As shown, the battery pack includes a battery pack 100 and a tray 200. The battery pack 100 has a first end with a welding area 120. The tray 200 includes a base plate 220 and a frame 230. The base plate 220 is connected to the frame 230 and forms a receiving cavity 210. The battery pack 100 is located in the receiving cavity 210. The frame 230 includes a connected end beam 240 and a side beam 250. The end beam 240 is opposite to the first end, and in the height direction of the tray 200, the top surface of the end beam 240 is lower than at least a portion of the welding area 120.

[0074] The receiving cavity 210 can be used to accommodate the components forming the battery pack. The battery pack 100 and other components forming the battery pack can be placed in the receiving cavity 210. The tray 200 includes a base plate 220 and a frame 230. The base plate 220 and the frame 230 together form the receiving cavity 210. The tray 200 can safely fix and support the battery pack 100, ensuring the stability of the battery pack 100, reducing or avoiding external impact forces acting on the battery pack 100, effectively reducing the damage to the batteries 110 of the battery pack 100 caused by external impact forces, helping to improve the service life of the battery pack 100, and also facilitating the overall handling and installation of the battery pack 100.

[0075] The battery pack 100 can be multiple, and multiple battery packs 100 can be electrically connected to form a larger battery pack 100 assembly to provide power to the electrical device. In this embodiment, the number of battery packs 100 is two, but it is not limited to two; for example, it can be one, three, or more, which will not be elaborated here. It should be noted that each battery pack 100 has a first end, and the first end is disposed opposite to the end beam 240 of the tray 200. In this way, after the battery pack 100 is placed in the receiving cavity 210 of the tray 200, related components can be welded to the first end of the battery pack 100 using a laser outside the tray 200.

[0076] The frame 230 includes end beams 240 and side beams 250, which are closely connected to form the frame 230. The top surface of the end beam 240 is lower than the top surface of the side beam 250, meaning the height of the end beam 240 is less than the height of the side beam 250. Thus, the welding area 120 at the first end of the battery pack 100 is at least partially higher than the top surface of the end beam 240. In other words, the first end of the battery pack 100 is not completely blocked by the end beams 240 of the frame 230; a portion of the first end of the battery pack 100 can protrude from the top surface of the end beams 240 of the frame 230. When the battery pack 100 is mounted upright in the receiving cavity 210 of the tray 200, the first end of the battery pack 100 can be welded together to complete the battery pack assembly.

[0077] For example, when there is only one battery pack 100, the first end of the battery pack 100 is positioned opposite to the end beam 240 of the frame 230. Alternatively, when there are multiple battery packs 100, the first end of each battery pack 100 is positioned opposite to the end beam 240 of the frame 230.

[0078] In this embodiment, the base plate 220 can be a cooling plate, a composite material plate, or a metal plate. The cooling plate helps with the thermal management of the battery pack 100 during operation, the composite material plate can provide better strength and weight support, and the metal plate has excellent electrical and thermal conductivity. It should be noted that the base plate 220 can be made of the above-mentioned materials, but is not limited to them, and will not be elaborated here. The material of the base plate 220 can be selected according to the actual battery pack requirements.

[0079] In this embodiment, each battery pack 100 includes multiple batteries 110. The batteries 110 can be used to store and release electrical energy. The multiple batteries 110 of the battery pack 100 can be connected in series via connectors 170 to provide the required voltage and current to the electrical device. Multiple batteries 110 form a battery pack 100. The number of batteries 110 can be determined and adjusted according to the size of the tray 200 and the electrical energy specifications required by the electrical device, which will not be elaborated here. The terminals of two adjacent batteries 110 are connected via a connector 170. The connector 170 can be connected to the terminals of the battery 110 by welding to achieve series connection between the batteries.

[0080] In the example of this application, the welding area 120 at the first end of the battery pack 100 includes a first welding area 121, which is located on the connector 170 disposed at the first end of the battery pack, and the top surface of the end beam 240 is lower than the first welding area 121. It is understood that when the first welding area 121 is higher than the top surface of the end beam 240, the battery 110 is installed in the receiving cavity 210, and the top surface of the end beam 240 will not affect the welding operation of the first welding area 121.

[0081] In the example of this application, the welding area 120 at the first end of the battery pack 100 also includes a second welding area 122, and the top surface of the end beam 240 is higher or lower than the second welding area 122. It is understood that when the top surface of the end beam 240 is lower than the second welding area 122, the second welding area 122 is exposed outside the top surface of the end beam 240, and in this case, the second welding area 122 will not be obstructed by the top surface of the end beam 240, thus not affecting the welding operation of the second welding area 122. When the top surface of the end beam 240 is higher than the second welding area 122, the second welding area 122 will be partially obstructed by the top surface of the end beam 240. To meet the welding operation requirements, the height of the end beam 240 is limited, which will be explained in detail below.

[0082] In some embodiments of this application, such as Figure 4 and Figure 5 As shown, the battery pack 100 includes a sampling component, which includes a function board 130 and a first sampling piece 140. The function board 130 is disposed at the first end of the battery pack 100 and is connected to the battery pack 100 through the first sampling piece 140. The sampling piece 140 is located at the top and bottom ends of the function board 130, respectively.

[0083] Function board 130 can be a Battery Information Controller (BIC). Function board 130 can be used to monitor the voltage, current, temperature and other related information of battery pack 100 in real time to ensure the safe and efficient operation of battery pack 100. First sampling plates 140 are located at the top and bottom of function board 130, and the number of first sampling plates 140 matches the number of batteries 110 in battery pack 100. First sampling plates 140 can serve as voltage sampling lines for batteries 110 and can also play a role in heat dissipation. First sampling plates 140 can be made of nickel sheets but are not limited to nickel sheets; other metal sheets can also be used.

[0084] It should be noted that the first sampling piece 140 located at the top of the function board 130 is electrically connected to the first welding area 121 on the connector 170 at the first end of the battery pack 100. The first sampling piece 140 located at the bottom of the function board 130 is connected to the second welding area 122 on the first end casing of the battery 110 to ensure that the function board 130 and the battery 110 casing of the battery pack 100 are electrically connected.

[0085] In some embodiments of this application, such as Figure 5 As shown, the first sampling piece 140 located at the bottom of the functional board 130 has a bent portion 141. The first sampling piece 140 is welded to the second welding area 122 through the bent portion 141, and the connection point on the first sampling piece 140 is located on the bent portion 141.

[0086] The first sampling piece 140 located at the bottom of the functional board 130 has a bending portion 141, through which the first sampling piece 140 is connected to the second welding area 122 at the first end of the battery pack 100. The bending portion 141 allows the first sampling piece 140 to be more securely welded to the second welding area 122 at the first end of the battery pack 100. The bending portion 141 increases the welding area and provides additional mechanical support, making the connection more robust and reliable.

[0087] Understandably, the bend 141 on the first sampling piece 140 can better adapt to the internal spatial layout of the battery pack. The first sampling piece 140 with the bend 141 can meet the connection requirements of the shape and angle of the second welding area 122 on the outer shell of the battery 110, ensuring a smooth and compact connection.

[0088] In one possible implementation, the first sampling piece 140 is connected to the welding area 120 at the first end by laser beam welding. A solder joint is formed on the bent portion 141 of the first sampling piece 140, which is the connection point. The connection point can be rectangular, circular or other shapes. The size and shape of the solder joint are not described in detail here. The solder joint only needs to satisfy the stability of the first sampling piece 140 and the welding area 120.

[0089] In some embodiments of this application, such as Figure 7 and Figure 8 As shown, along the height direction of the battery pack, the height of the end beam 240 is a, the shortest distance between the connection point on the first sampling piece 140 and the base plate 220 is d, and the shortest distance between the connection point on the bent part 141 near the base plate 220 and the top surface of the end beam 240 is c, and a≤d+c.

[0090] It should be noted that the height 'a' of the end beam 240 is large enough to provide good support and protection for the battery pack 100. If the height 'a' of the end beam 240 is too large, it will affect the laser welding of the first end of the battery pack 100 after it is assembled in the receiving cavity 210, and will also cause waste of internal space in the battery pack, increasing the weight of the battery pack.

[0091] Understandably, the shortest distance d between the connection point on the first sampling piece 140 and the base plate 220 depends on the internal design dimensions of the battery pack 100 and the space utilization within the battery pack. The shortest distance c between the connection point on the bent portion 141 of the first sampling piece 140 near the base plate 220 and the top surface of the end beam 240 depends on the relative position between the first sampling piece 140 and the end beam 240. The shortest distance c between the connection point on the bent portion 141 near the base plate 220 and the top surface of the end beam 240 needs to meet the welding requirements of the laser beam and avoid interference during the welding process.

[0092] Please refer to some embodiments of this application. Figure 7 and Figure 8 The shortest distance between the bent portion 141 and the side of the end beam 240 facing the receiving cavity 210 is b, and b ≥ 10c. It is understood that, to ensure that the galvanometer of the laser welding equipment can smoothly guide the laser beam to the welding area 120 of the first sampling piece 140 and the first end of the battery pack 100 during the welding process, setting a larger b value can avoid welding misalignment caused by equipment precision, material differences, processing errors, etc., thereby improving the reliability and stability of the welding of the first sampling piece 140.

[0093] Please refer to some embodiments of this application. Figure 7 and Figure 8 Along the direction perpendicular to the end beam 240, the height of the first sampling piece 140 is e, and the shortest distance between the connection point near the bottom plate 220 on the bent portion 141 and the top of the bent portion 141 is f, where e < 10f. It is understood that limiting the height of the first sampling piece 140 ensures that it provides sufficient connection strength and does not occupy too much space within the receiving cavity 210 due to excessive size, while also maintaining the flexibility and reliability of the bent portion 141.

[0094] In some embodiments of this application, such as Figure 3 As shown, the side beam 250 is provided with an inclined transition surface 251. The side beam 250 and the end beam 240 are connected through the transition surface 251. The angle between the transition surface 251 and the top surface of the side beam 250 is α, and 120°≤α≤180°. For example, the angle between the transition surface 251 and the top surface of the side beam 250 can be 120°, 135°, 165°, 180°, etc., which can be adjusted according to the height of the battery pack 100 and the number of batteries 110.

[0095] The inclined transition surface 251 makes the connection between the side beam 250 and the end beam 240 smoother, which helps reduce stress concentration. When subjected to external forces, the inclined transition surface 251 on the side beam 250 can disperse and transfer stress, thereby enhancing the strength of the connection, improving the stability of the overall structure, helping to extend the service life of the tray 200, and improving the safety and reliability of the battery pack. Furthermore, the smooth and continuous sealing surface on the side beam 250 also helps to reduce or eliminate the possibility of battery pack leakage caused by unevenness in the connection.

[0096] In some embodiments of this application, such as Figure 2 and Figure 3As shown, a support plate 252 is provided on the side of the transition surface 251 facing the receiving cavity 210. The support plate 252 is provided with a reinforcing rib 253, and the reinforcing rib 253 is perpendicular to the bottom plate 220. In this way, the support plate 252 and the reinforcing rib 253 can be used to support the battery 110 inside the battery pack 100 near the side beam 250.

[0097] In the battery pack 100, the battery 110 closest to the side beam 250 is the edge module 410. Due to its position, the edge module 410 may be subject to uneven pressure or temperature distribution, causing the battery 110 in the edge module 410 to expand excessively. The support plate 252 and the reinforcing rib 253 can effectively limit the expansion range of the edge module 410, preventing the battery 110 in the edge module 410 from affecting the performance and lifespan of the entire battery pack 100 due to expansion.

[0098] Reinforcing ribs 253 are disposed on the support plate 252 and are perpendicular to the inner bottom wall of the base plate 220. This enhances the structural strength of the support plate 252, enabling it to better withstand the pressure and vibration from the edge module 410 battery 110. The reinforcing ribs 253 also disperse stress, reducing the possibility of deformation and damage to the support plate 252, thereby improving the overall stability and reliability of the battery pack 100. In this embodiment, each support plate 252 is provided with four reinforcing ribs 253, and the top of each reinforcing rib 253 is flush with the top of the support plate 252. It should be noted that the number and length of the reinforcing ribs 253 can be, but are not limited to, the above-described arrangement and can be set according to the actual needs of the battery pack.

[0099] In some embodiments of this application, such as Figure 1 and Figure 2 As shown, there are two end beams 240, namely a front beam 241 and a rear beam 242 arranged opposite to each other, and two opposing side beams 250 are provided between the front beam 241 and the rear beam 242. There are multiple battery packs 100, and two of the multiple battery packs 100 are spaced apart along the direction from the front beam 241 to the rear beam 242, with the front beam 241 facing the first end of one of the two battery packs 100, and the rear beam 242 facing the first end of the other battery pack 100.

[0100] In this embodiment, the two end beams 240 include a front beam 241 and a rear beam 242 disposed opposite to each other, and two side beams 250 disposed opposite to each other between the front beam 241 and the rear beam 242. The front beam 241, the side beams 250 and the two side beams 250 are connected to form a frame 230, thereby achieving the stability of the overall structure and providing reliable support and protection for the battery pack 100.

[0101] In one possible implementation, there are two battery packs 100, with the first end of one battery pack 100 facing the front beam 241 and the first end of the other battery pack 100 facing the rear beam 242. In another possible implementation, there can be multiple battery packs 100, with two battery packs 100 spaced apart along the Y-axis, and the first end of one of these two battery packs 100 facing the front beam 241, while the first end of the other battery pack 100 facing the rear beam 242. In this way, the battery packs 100 can be first inserted into the receiving cavity 210 of the tray 200 for device connection at the first end of each battery pack 100.

[0102] In some embodiments of this application, such as Figure 2 As shown, a crossbeam 260 is provided inside the receiving cavity 210. The crossbeam 260 is arranged opposite to the front beam 241 and the rear beam 242, and both ends of the crossbeam 260 are connected to the side beams 250. The crossbeam 260 divides the receiving cavity 210 into multiple sub-cavities, each of which houses one or more battery packs 100. In this way, the crossbeam 260 provides a stable lateral support structure, effectively distributing the weight and vibration of the battery pack during use, thereby protecting the battery pack 100 from damage.

[0103] The crossbeam 260 acts as a partition element, dividing the housing cavity 210 into multiple sub-cavities. Each sub-cavity is relatively independent, facilitating management and maintenance within each sub-cavity. Each sub-cavity can house one or more battery packs 100, allowing for independent monitoring, control, and maintenance of each battery pack 100, thereby improving the overall system's response speed and accuracy. Furthermore, when a battery pack 100 in a sub-cavity malfunctions or experiences an abnormality, the system can limit the spread of the fault or abnormality, preventing it from having a greater impact on the entire battery pack.

[0104] In some embodiments of this application, combined with Figure 1 and Figure 2 As shown, the battery pack 100 has a second end opposite to the first end, the second end being opposite to the crossbeam 260, and the second end of the battery pack 100 also has a welding area 120.

[0105] In some embodiments of this application, such as Figure 6As shown, the sampling assembly also includes a circuit board 150 and a second sampling plate 160. The circuit board 150 is connected to the second terminal of the battery pack 100 via the second sampling plate 160. The circuit board 150 can be a flexible printed circuit (FPC), and the circuit board 150 is connected to the second terminal of the battery pack 100 via the second sampling plate 160. The circuit board 150 can be responsible for signal transmission, power management, temperature monitoring, and safety protection within the battery pack 100. By setting up the circuit board 150, the overall performance and safety of the battery pack 100 can be improved.

[0106] Each circuit board 150 is provided with two second sampling pieces 160, which are located at the top and bottom of the circuit board 150 respectively. The second sampling piece 160 located at the top of the circuit board 150 is electrically connected to the connector 170 at the second end of the battery pack 100, and the second sampling piece 160 located at the bottom of the circuit board 150 is connected to the outer casing at the second end of the battery 110.

[0107] In some embodiments of this application, such as Figures 3 to 6 As shown, each battery pack 100 includes a bracket 180 and a protective cover 190. The bracket 180 is located at both ends of the battery 110 and is used to fix the battery 110. The protective cover 190 is respectively disposed at the first end and the second end of the battery pack 100. The protective cover 190 located at the first end is used to protect the functional board 130, and the protective cover 190 located at the second end is used to protect the circuit board 150.

[0108] The bracket 180 can provide stable support for the battery 110, preventing the battery pack from being displaced or damaged due to vibration or impact from the external environment during use. By setting the bracket 180, the stability of the internal structure of the battery pack 100 can be maintained, ensuring good contact and electrical connection between the batteries 110.

[0109] The functional board 130 houses various electronic components, such as controllers and sensors. By providing a protective cover 190 at the first end of the battery pack 100, damage to the functional board 130 caused by external impacts, water splashes, dust, and other factors can be reduced, ensuring the normal operation of the functional board 130 and contributing to the normal operation of the battery pack 100. The protective cover 190 is located on the side of the functional board 130 facing the end beam 240, and there is a certain buffer gap between the protective cover 190 and the functional board 130. This reduces the direct impact of external impacts on the functional board 130 and provides a certain space for thermal expansion when the internal temperature of the battery pack 100 changes, preventing mechanical stress damage caused by thermal expansion and contraction.

[0110] The electronic circuitry on circuit board 150 is very delicate and easily damaged. By installing a protective cover 190 at the second end of battery pack 100, the possibility of physical damage to circuit board 150 at the second end of battery pack 100 during transportation, installation, and use can be significantly reduced. Furthermore, the protective cover 190 also provides a certain degree of electromagnetic shielding, reducing the impact of external electromagnetic interference on circuit board 150. The protective cover 190 is located on the side of circuit board 150 facing the front beam 241, and there is a certain buffer gap between the protective cover 190 and circuit board 150. This helps reduce damage to circuit board 150 from external impacts and also provides a buffer space for vibrations and temperature changes generated during circuit board 150 operation, protecting circuit board 150 from mechanical stress.

[0111] In some embodiments of this application, such as Figure 1 As shown, the battery pack also includes a cover plate 300, which is connected to the frame 230 by fasteners. The frame 230 is integrally die-cast, or the frame 230 is spliced ​​and welded.

[0112] The cover plate 300 seals the receiving cavity 210 of the tray 200, protecting the components of the battery pack 100, such as the battery 110, functional board 130, and circuit board 150, from external environmental influences. The cover plate 300 is connected to the frame 230 by fasteners, effectively preventing the cover plate 300 from loosening or falling off under vibration, impact, or other conditions. Fasteners can be screws, bolts, clips, etc., and the specific selection can be based on the actual battery pack design requirements and usage environment.

[0113] In one possible implementation, the frame 230 can be manufactured using a one-piece die-casting process. The frame 230 is a monolithic structure, with no seams or welding points between the front beam 241, rear beam 242, and side beam 250. The frame 230 has high structural strength, good sealing performance, and can withstand large mechanical stresses, making it less prone to deformation or cracking, thereby ensuring the overall stability and safety of the battery pack.

[0114] In another possible implementation, the frame 230 can also be spliced ​​and welded together. The frame 230 is composed of a front beam 241, a rear beam 242, and two side beams 250, which are connected together by welding or other methods. The splicing and welding method has a greater advantage in terms of manufacturing flexibility of the tray 200, and the shape and size of the tray 200 can be adjusted according to the actual needs of the specific battery pack.

[0115] In some embodiments of this application, the cover plate 300 has a connecting surface on the side facing the tray 200 that mates with the frame 230 of the tray 200, and the cover plate 300 is connected to the frame 230 through the connecting surface. The connecting surface includes a front sealing surface, a rear sealing surface, and two side sealing surfaces. The front sealing surface is connected to the top surface of the front beam 241, the rear sealing surface is connected to the top surface of the rear beam 242, and the side sealing surfaces are connected to the top surface of the side beam 250.

[0116] Understandably, to ensure the connection stability and sealing effect between the cover plate 300 and the frame 230, the side of the cover plate 300 facing the receiving cavity 210 is provided with a front sealing surface that mates with the top surface of the front beam 241, a rear sealing surface that mates with the top surface of the rear beam 242, and a side sealing surface that mates with the top surface of the side beam 250. Adaptively, a transition slope sealing surface can also be provided on the cover plate 300 opposite to the transition surface 251 of the side beam 250. The tight fit between the transition slope sealing surface and the transition surface 251 ensures the sealing performance between the cover plate 300 and the tray 200.

[0117] In some embodiments of this application, such as Figure 2 As shown, the side of the frame 230 facing away from the receiving cavity 210 has an annular groove 231 for accommodating sealant, which forms a seal with the top surface of the frame 230 through the connecting surface of the sealant cover plate 300. The frame 230 has a mounting hole 232 for accommodating lifting lugs.

[0118] Understandably, filling the annular groove 231 with sealant can improve the sealing effect between the connecting surface of the cover plate 300 and the top surface of the frame 230, effectively preventing the penetration of liquids, gases, or solid particles from the external environment. The sealant can be made of a material with good adhesion, elasticity, and aging resistance; no restrictions are placed here. After filling the annular groove 231 with sealant, fasteners are used to connect the frame 230 to the top cover, ensuring the reliability and sealing of the connection.

[0119] The mounting holes 232 provided on the frame 230 are used to accommodate lifting lugs, so as to connect the battery pack to lifting equipment (such as cranes, hooks, etc.) during lifting, transportation, or installation, thereby improving work efficiency and ensuring the safety and stability of the lifting process. It should be noted that the position, number, and size of the mounting holes 232 should be reasonably designed according to actual needs to ensure the stable installation of the lifting lugs and the safe conduct of the lifting process.

[0120] In some embodiments of this application, a heat exchange channel is provided within the cover plate 300, and a heat exchange medium is contained within the heat exchange channel for heat exchange with the battery pack 100. It is understood that the battery pack 100 generates heat during operation, and in extreme cases, abnormal situations such as short circuits or overheating may occur inside the battery pack. The heat exchange medium within the heat exchange channel rapidly absorbs heat, reducing the temperature of the battery pack 100, thereby preventing thermal runaway to a certain extent and improving the safety of the battery pack. It should be noted that the heat exchange medium can be water, ethylene glycol solution, or other low-boiling-point liquids; there are no limitations here, and adjustments can be made according to actual operating conditions.

[0121] In some embodiments of this application, an insulating film is provided on the side of the cover plate 300 facing the receiving cavity 210, and the insulating film is used to resist high temperatures. An anti-corrosion layer is provided on the side of the cover plate 300 facing away from the receiving cavity 210. It is understood that the battery pack 100 inside the battery pack will generate heat during charging and discharging. The high-temperature resistant insulating film on the side of the cover plate 300 facing the receiving cavity 210 ensures that stable insulation performance is maintained in high-temperature environments, thereby enhancing the safety and reliability of the battery pack 100.

[0122] Battery packs are typically installed inside vehicles, and during daily use, they are exposed to external environments such as moisture, corrosive gases, and ultraviolet radiation, which can cause corrosion to the battery pack cover 300. An anti-corrosion layer is provided on the side of the cover 300 facing away from the receiving cavity 210, effectively resisting the damage caused by harmful substances in the external environment and maintaining the integrity and aesthetics of the cover 300.

[0123] See Figure 9 As shown, this application embodiment also includes a method for manufacturing a battery pack, which can produce the above-mentioned battery pack. The method for manufacturing a battery pack includes:

[0124] S10. Provide a pallet 200, which includes a base plate 220 and a frame 230. The base plate 220 is connected to the frame 230 and forms a receiving cavity 210. The frame 230 includes a connected end beam 240 and a side beam 250. The height of the end beam 240 is less than the height of the side beam 250.

[0125] S20. A battery pack 100 is provided, the battery pack 100 having a first end and a second end disposed opposite to each other, the first end having a welding area 120, and the battery pack 100 is placed in the receiving cavity 210 of the tray 200 in a forward-facing manner, and the first end is opposite to the end beam 240, and the top surface of the end beam 240 is lower than at least part of the welding area 120.

[0126] S30. Install the function board 130 on the welding area 120 at the first end, and place the battery pack 100 in the receiving cavity 210. The welding area 120 at the first end and the function board 130 are connected through the first sampling piece 140.

[0127] S40. Provide a cover plate 300, cover the tray 200 with the cover plate 300, and connect the cover plate 300 to the frame 230 of the tray 200 with fasteners.

[0128] The tray 200 provided in this embodiment is used to fix and support the battery pack 100. The tray 200 consists of a base plate 220 and a frame 230. The frame 230 includes end beams 240 and side beams 250, which together form a receiving cavity 210 for accommodating the battery pack 100. The tray 200 can improve the stability of the battery pack 100, reduce damage to the battery pack 100 caused by external impacts, and extend the service life of the battery pack 100.

[0129] The battery pack 100 provided in this embodiment includes multiple batteries 110, each battery 110 having a bracket 180 at both ends, and the multiple batteries 110 being fixed by the brackets 180. Connectors 170 are also provided at both ends of the multiple batteries 110, and the multiple batteries 110 are connected in series through the connectors 170. A circuit board 150 is mounted on the second end of the multiple batteries 110 to realize signal transmission, power management, temperature monitoring, and safety protection within the battery pack 100, and a protective cover 190 is mounted on one side of the circuit board 150 to protect the circuit board 150. (See reference...) Figure 10 As shown, the battery pack 100 mounting circuit board 150 includes:

[0130] S21. Connect the terminal post on the second end of the battery 110 to the connector 170 by laser welding.

[0131] S22. Connect the second sampling piece 160 located at the top of the circuit board 150 to the connector 170 on the second end, and connect the second sampling piece 160 located at the bottom of the circuit board 150 to the casing of the second end of the battery.

[0132] S23. Provide a protective cover 190 and install the protective cover 190 on the second end of the battery pack 100 to protect the circuit board 150.

[0133] S24. Place the battery pack 100 with the mounting circuit board 150 facing forward in the receiving cavity 210 of the tray 200, so that the second end of the battery pack 100 is close to the crossbeam 260 and the first end of the battery pack 100 is close to the end beam 240.

[0134] Understandably, the proximity of the first end of the battery pack 100 to the end beam 240 facilitates the installation of the function board 130. The function board 130 monitors the voltage, current, temperature, and other relevant information of the battery pack 100 in real time to ensure its safe and efficient operation. (See also...) Figure 11 As shown, the battery pack 100 mounting function board 130 includes:

[0135] S31. Connect the terminal post on the first end of the battery 110 to the connector 170 by laser welding.

[0136] S32. Connect the first sampling piece 140 located at the top of the function board 130 to the first welding area 121 on the connector 170 at the first end of the battery pack 100, and connect the first sampling piece 140 located at the bottom of the function board 130 to the second welding area 122 on the first end.

[0137] S33. Provide a protective cover 190 and install the protective cover 190 at the first end of the battery pack 100 to protect the functional board 130.

[0138] In this application example, the bracket 180 can be a plastic bracket 180. A circuit board 150 is mounted on one end of the multiple batteries 110 to connect the multiple batteries 110 in series. Adjacent batteries 110 are electrically connected through connectors 170 to transfer electrical energy from one battery 110 to another, thus achieving the series connection between the batteries 110. It should be noted that the number of batteries 110 in each battery pack 100 is not limited, and the number and size of the batteries 110 can be adjusted according to the actual power requirements and design scheme of the battery pack.

[0139] In this embodiment of the application, each battery pack 100 includes two edge modules 410. The two edge modules 410 are arranged opposite to each other and are respectively close to the side beam 250 of the battery pack. The battery 110 on the side of the edge module 410 closest to the side beam 250 is led out with high voltage and electrically connected to the adjacent edge module 410.

[0140] It should be noted that the number of batteries 110 in each edge module 410 can be arbitrary. When the edge module 410 has an odd number of batteries 110, two adjacent battery packs 100 near the same side beam 250 can be directly electrically connected from the second end near the crossbeam, so that the two adjacent battery packs 100 are connected in series, reducing the connection path between the two adjacent battery packs 100 and improving the energy transfer efficiency of the battery pack 100. Figure 2As shown in the example of this application, the edge module 410 has three batteries 110. Of course, the edge module 410 can have, but is not limited to, an odd number of batteries 110, and can also have an even number of batteries 110. There is no restriction here, and the number of batteries 110 in the edge module 410 can be adjusted according to the installation requirements of the battery pack.

[0141] Each battery pack 100 also includes an intermediate module 420, which comprises an even number of batteries 110 and is located between two edge modules 410. The batteries 110 at both ends of the intermediate module 420 are electrically connected to the adjacent edge modules 410. This electrical connection between the batteries 110 at both ends of the intermediate module 420 and the batteries 110 of the adjacent edge modules 410 ensures the integrity of the electrical connections and the continuity of the current path in the entire battery pack 100, reduces current loss during transmission, and improves the energy transfer efficiency of the battery pack 100. Figure 2 As shown, the intermediate module 420 of this application example has two batteries 110. It should be noted that the number of batteries 110 in the intermediate module 420 is an even number because a circuit board 150 at the second end of the battery 110 can only connect two batteries 110.

[0142] In one possible implementation, the battery pack 100 may also include only two edge modules 410, the sum of the number of batteries 110 in the two edge modules 410 being equal to the number of batteries 110 in the battery pack 100. In this case, the intermediate module 420 may not be provided to meet the usage scenarios of space-constrained battery packs or other battery packs, which is the case where the two edge modules 410 have an even number of batteries 110.

[0143] Taking a battery pack containing two battery groups 100 as an example, each battery group 100 includes two edge modules 410 and one intermediate module 420. The two edge modules 410 are respectively the first edge module and the second edge module. The first edge module and the second edge module are arranged opposite to each other, and the first edge module and the second edge module are respectively close to the two side beams 250 of the tray 200. The intermediate module 420 is located between the first edge module and the second edge module.

[0144] Two batteries 110 in the intermediate module 420, located near the two edge modules 410, are electrically connected at their second ends to the two edge modules 410 respectively. A connector 170 and a circuit board 150 are welded to the terminals at the second ends of the batteries 110, thus electrically connecting both ends of the intermediate module 420 to the first edge module and the second edge module respectively. After placing the battery pack 100 with the circuit board 150 mounted upright in the receiving cavity 210, the batteries 110 in the intermediate module 420, located near the two edge modules 410, are electrically connected at their first ends to the two edge modules 410 respectively. A connector 170 and a functional board 130 are welded to the terminals at the first ends of the batteries 110. The intermediate module 420 is connected in series with the first edge module and the second edge module, thus achieving forward assembly of the battery pack 100.

[0145] It is understandable that the series connection between the two battery packs 100 allows the edge module 410 of one battery pack 100 to be electrically connected to the edge module 410 of the other battery pack 100. When the edge modules 410 of the two battery packs 100 on the same side are directly connected after being led out from the side beam 250 with high voltage, and both are led out from the second end of each battery pack 100 with high voltage, the transmission path of current between the two battery packs 100 can be reduced, thereby improving energy transmission efficiency. However, it is not limited to the above high voltage lead-out method and can be adjusted according to the number of batteries 110 in the battery pack 100, which will not be elaborated here.

[0146] The terms "upper" and "lower" are used to describe the relative positions of the various structures in the accompanying drawings. They are only for clarity of description and are not intended to limit the scope of implementation of this application. Any changes or adjustments to the relative positions without substantially altering the technical content shall also be considered within the scope of implementation of this application.

[0147] It should be noted that, in this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0148] Furthermore, in this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0149] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0150] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A battery pack, characterized in that, include: A battery pack (100) has a first end on which a welding area (120) is provided. The tray (200) includes a receiving cavity (210) in which the battery pack (100) is located. The tray (200) includes an end beam (240) disposed near the first end and, in the height direction of the tray (200), the top surface of the end beam (240) is lower than at least a portion of the welding area (120). It also includes a sampling component, which includes a plurality of first sampling pieces (140) connected to the welding area (120); The pallet (200) also includes a side beam (250), which is angularly connected to the end beam (240). In the height direction of the pallet (200), the top surface of the side beam (250) is higher than the top surface of the end beam (240). The side beam (250) is provided with an inclined transition surface (251), and the top surface of the side beam (250) is connected to the top surface of the end beam (240) through the transition surface (251). The transition surface (251) is provided with a support plate (252) on the side facing the receiving cavity (210).

2. The battery pack according to claim 1, characterized in that, The battery pack (100) includes a plurality of batteries (110) and connectors (170), wherein the plurality of connectors (170) are welded to the terminals of the plurality of batteries (110) so that the plurality of batteries (110) are connected in series.

3. The battery pack according to claim 2, characterized in that, The welding area (120) includes a first welding area (121), which is located on the connector (170) disposed at the first end, and the top surface of the end beam (240) is lower than the first welding area (121).

4. The battery pack according to claim 2, characterized in that, The sampling component includes a function board (130), which is located at the first end, and a portion of the first sampling piece (140) is located at the top of the function board (130); The first sampling piece (140) located at the top of the function board (130) is connected to the connector (170).

5. The battery pack according to claim 4, characterized in that, The welding area (120) further includes a second welding area (122), a portion of the first sampling piece (140) is located at the bottom end of the functional board (130) and is welded to the outer casing of the plurality of batteries (110) respectively, the second welding area (122) is located on the portion of the first sampling piece (140), and the top surface of the end beam (240) is higher or lower than the second welding area (122).

6. The battery pack according to claim 5, characterized in that, Along the height direction of the tray (200), the distance between the top surface of the end beam (240) and the inner bottom wall of the tray (200) is a, the distance between the connection point of the portion of the first sampling piece (140) near the inner bottom wall of the tray (200) and the inner bottom wall of the tray (200) is d, and the distance between the connection point of the portion of the first sampling piece (140) near the inner bottom wall of the tray (200) and the top surface of the end beam (240) is c, and a≤d+c.

7. The battery pack according to claim 6, characterized in that, The distance between the connection point on the first sampling piece (140) and the side of the end beam (240) facing the receiving cavity (210) is b, and b ≥ 10c.

8. The battery pack according to claim 6, characterized in that, Each of the first sampling pieces (140) has a bent portion (141), and the multiple bent portions (141) are welded to the outer casings of the multiple batteries (110).

9. The battery pack according to claim 8, characterized in that, Along the extension direction of the battery (110), the height of the first sampling piece (140) is e, the distance between the connection point of the bent portion (141) near the inner bottom wall of the tray (200) and the top of the bent portion (141) is f, and e < 10f.

10. The battery pack according to claim 4, characterized in that, The angle between the transition surface (251) and the top surface of the side beam (250) is α, and 120°≤α≤180°.

11. The battery pack according to claim 4, characterized in that, The support plate (252) is provided with reinforcing ribs (253), and the reinforcing ribs (253) extend in the height direction of the tray (200).

12. The battery pack according to any one of claims 4-11, characterized in that, The battery pack (100) has a second end opposite to the first end. The sampling assembly also includes a circuit board (150) and a plurality of second sampling pieces (160). The circuit board (150) is connected to the second end of the battery pack (100) through the second sampling pieces (160).

13. The battery pack according to claim 12, characterized in that, Multiple second sampling pieces (160) are located at the top and bottom of the circuit board (150) respectively, and the second sampling piece (160) located at the top of the circuit board (150) is connected to the connector (170) at the second end; The second sampling chip (160) located at the bottom of the circuit board (150) is connected to the housing of the battery (110).

14. The battery pack according to claim 13, characterized in that, The battery pack (100) also includes a plurality of brackets (180), which are respectively located at both ends of the battery (110) and are used to fix the battery (110). And / or, the battery pack (100) further includes a plurality of protective covers (190), which are respectively disposed at the first end and the second end. The protective cover (190) located at the first end is used to protect the functional board (130), and the protective cover (190) located at the second end is used to protect the circuit board (150).

15. The battery pack according to any one of claims 4-14, characterized in that, The number of end beams (240) is two, and the two end beams (240) are a front beam (241) and a rear beam (242) arranged opposite to each other. The front beam (241) and the rear beam (242) are respectively connected by two opposite side beams (250) to form a frame (230) to enclose and form the receiving cavity (210). The number of battery packs (100) is multiple, and two of the battery packs (100) are spaced apart along the direction from the front beam (241) to the rear beam (242), with the front beam (241) facing the first end of one of the two battery packs (100) and the rear beam (242) facing the first end of the other battery pack (100).

16. The battery pack according to claim 15, characterized in that, It also includes a cover plate (300), which has a connecting surface on one side facing the frame (230). The connecting surface includes a front sealing surface, a rear sealing surface and two side sealing surfaces. The front sealing surface is connected to the top surface of the front beam (241), the rear sealing surface is connected to the top surface of the rear beam (242), and the side sealing surfaces are connected to the top surface of the side beam (250).

17. The battery pack according to claim 16, characterized in that, An annular groove (231) is provided on the top surface of the frame (230) surrounding the receiving cavity (210). The annular groove (231) is used to accommodate sealant so that the top surface of the frame (230) forms a seal with the connecting surface of the cover plate (300).

18. The battery pack according to claim 16, characterized in that, The cover plate (300) is provided with a heat exchange channel, which is used to circulate a heat exchange medium for heat exchange on the battery pack (100).

19. The battery pack according to claim 16, characterized in that, An insulating film is provided on the side of the cover plate (300) facing the receiving cavity (210), and the insulating film is used to resist high temperature; And / or, the cover plate (300) is provided with an anti-corrosion layer on the side facing away from the receiving cavity (210).

20. A method for manufacturing a battery pack, used to prepare the battery pack according to any one of claims 4-19, characterized in that, The method includes: A tray (200) is provided, the tray (200) including a receiving cavity (210); A battery pack (100) is provided, the battery pack (100) having a first end and a second end disposed opposite to each other, the first end having a welding area (120), the battery pack (100) being placed in the receiving cavity (210) of the tray (200) in a forward-facing manner, the first end being opposite to an end beam (240) of the tray (200), and the top surface of the end beam (240) being lower than at least a portion of the welding area (120). A sampling component is provided, the sampling component including a function board (130) and a plurality of first sampling pieces (140), the function board (130) is mounted on a welding area (120) at the first end, and the welding area (120) at the first end is connected to the function board (130) through the first sampling pieces (140).

21. The method for manufacturing a battery pack according to claim 20, characterized in that, Each of the battery packs (100) includes two edge modules (410) arranged opposite to each other, and each edge module (410) includes a plurality of batteries (110). Before the battery pack (100) is placed upright within the receiving cavity (210) of the tray (200), it includes: A circuit board (150) is mounted on the second end of each edge module (410), and the two edge modules (410) with the circuit board (150) mounted are respectively placed face up in the receiving cavity (210) of the tray (200) near the side beam (250) of the battery pack.

22. The method for manufacturing a battery pack according to claim 21, characterized in that, Each of the battery packs (100) further includes an intermediate module (420) comprising an even number of batteries (110), the intermediate module (420) being located between the two edge modules (410); Before the battery pack (100) is placed in the receiving cavity (210) of the tray (200) in an upright position, it further includes: The circuit board (150) is mounted on the second end of the intermediate module (420), and the intermediate module (420) with the circuit board (150) mounted is placed between the two edge modules (410) in a forward-facing manner.

23. The method for manufacturing a battery pack according to claim 22, characterized in that, Before mounting the functional board (130) on the welding area (120) at the first end, the following steps are included: The pole on the first end of the edge module (410) and the pole on the first end of the middle module (420) are connected in series through multiple connectors (170). The first sampling piece (140) located at the top of the functional board (130) is connected to the first welding area (121) on the connector (170) at the first end, and the first sampling piece (140) located at the bottom of the functional board (130) is connected to the second welding area (122) on the first end.

24. The method for manufacturing a battery pack according to claim 23, characterized in that, After the functional board (130) is installed at the first end of the battery pack (100), it further includes: A cover plate (300) is provided, which covers the tray (200), and the cover plate (300) is connected to the frame (230) of the tray (200) by fasteners.

25. An electrical appliance, characterized in that, include: An electrical device, and a battery pack manufactured by the manufacturing method of the battery pack according to any one of claims 1-19 or any one of claims 20-24, wherein the battery pack is connected to the electrical device and is used to provide electrical energy to the electrical device.

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