CTP module structure convenient for soft package battery cell grouping and boxing method

Abstract

The invention relates to the technical field of soft package batteries, and discloses a CTP module structure facilitating soft package battery cell grouping and a boxing method.The CTP module structure comprises a CTP module composed of a plurality of soft package battery cells, the sealing edge of each soft package battery cell is subjected to whole-edge full rubberizing treatment, the thickness of a used adhesive tape is smaller than or equal to 0.05 mm, and the width of the used adhesive tape is larger than or equal to 3 cm; the bonding gap of the sealing edge is improved through the whole-edge full-gluing; the CTP module structure further comprises a lower liquid cooling plate, and the liquid cooling plate is integrated with the box body and used for guaranteeing the flatness of the module. By improving the boxing speed and the yield of the CTP module, the production efficiency and the yield of the soft package battery are effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of soft-pack batteries, and particularly relates to a CTP module structure and a method for putting into a box that facilitate the grouping of soft-pack battery cells. Background Art

[0002] CTP module, namely CellToPack, is a technology that directly integrates battery cells into a battery pack, omitting the traditional module assembly link, and can effectively improve the space utilization rate and energy density of the battery pack.

[0003] There are mainly two technical routes for the existing CTP (CelltoPack) module structure: one is to completely cancel the module and directly integrate the battery cells into the battery pack; the other is to integrate small modules into large modules and then integrate the large modules into the battery pack. For the CTP structure of soft-pack battery cells, there are the following types:

[0004] Side-entry soft-pack battery CTP structure: It includes a lower battery box shell and a side cover plate. Inside the lower battery box shell, there is a battery compartment for installing multiple soft-pack battery cells. Along the end of the lower battery box shell in the length direction, there is a connector assembly. The central axis in the width direction of the stack of soft-pack battery cells is aligned with the central axis in the length direction of the lower battery box shell, and the side cover plate fixes the soft-pack battery cells in the battery compartment.

[0005] Soft-pack battery cell CTP power battery top-mounted liquid cooling plate structure: It includes a box body assembly, a CTP module, and a bottom guard plate. The box body assembly is composed of a box body frame and a top liquid cooling plate. The top liquid cooling plate is integrated above the box body frame through FDS. The CTP module is arranged inside the box body frame, and the bottom guard plate is arranged at the lower end of the box body frame. High-voltage copper bars and low-voltage wire harnesses are arranged at the bottom of the CTP module.

[0006] Baoneng soft-pack lithium battery CTP structure: After multiple soft-pack battery cells are horizontally stacked, series-parallel connection within the group is achieved through one-step welding to form small stacked sheets. Multiple long battery cell stacked sheets form a large unit, and side plates are placed outside the unit to separate them. There is a buffer foam between the stacked sheets and the side plates, and insulating plates are placed on the upper and lower sides to form a large module. An integrated liquid cooling plate is placed at the bottom, and a plate with explosion-proof and pressure relief functions is placed at the top, which is connected to the four surrounding frames to form an integrated structure to ensure strength.

[0007] Among them, the soft-pack battery cell CTP power battery top-mounted liquid cooling plate structure is widely used. It is a battery thermal management structure that places the liquid cooling plate on the top of the battery module, and it has the following advantages:

[0008] 1. High space utilization: By setting the liquid cooling plate at the top, the space at the top of the battery pack can be effectively utilized, and there is no need to set complex cooling pipelines between or at the bottom of the battery modules, making the internal structure of the battery pack more compact, which is beneficial to improving the energy density of the battery pack. More battery cells can be accommodated in a limited space, thereby increasing the cruising range of the battery pack.

[0009] 2. Good cooling uniformity: The top-mounted liquid cooling plate can cover the entire top of the battery module, enabling more uniform cooling of the soft-pack battery cells. Soft-pack battery cells usually have a large surface area, and heat is mainly dissipated through the top and sides. The top-mounted liquid cooling plate can directly contact the top of the battery cells, bringing the coolant closer to the heat source, improving the heat dissipation efficiency, reducing the temperature difference within the battery pack, and helping to extend the service life of the battery and improve the performance consistency of the battery.

[0010] 3. Convenient maintenance: The liquid cooling plate is located at the top. When maintenance, repair, or component replacement of the liquid cooling system is required, there is no need to disassemble the entire battery pack or remove a large number of battery modules. The operation is relatively convenient, which can reduce the maintenance cost and time.

[0011] 4. Improved safety: This structure helps to promptly remove the heat generated by the battery during charging and discharging, avoiding overheating of the battery, thereby reducing the risk of thermal runaway and improving the safety of the battery pack. At the same time, the liquid cooling plate, as a protective layer on the top of the battery pack, can also play a role in blocking external heat from entering the interior of the battery pack to a certain extent, further enhancing the safety of the battery.

[0012] However, after this type of CTP module is grouped, the sealed edge faces downward when put into the box, and the liquid cooling plate is placed on the non-sealed edge surface. The independent large-area liquid cooling plate is fitted and assembled with the non-sealed edge surface. During the operation of putting it into the battery box, the following problems will occur:

[0013] 1. Since the existing CTP modules are stacked with the sealed edge face downward with good flatness of the battery cells, when the grouped CTP modules are put into the box, the entire module needs to be flipped 180° before being put in; during the flipping process, there is a risk of the module sliding and displacing within the tooling fixture.

[0014] 2. The deformation problem caused by the insufficient stiffness of the large-area (same size as the pack) liquid cooling plate. In order to avoid the deformation problem, only glue is applied to the liquid cooling plate, resulting in a glue thickness > 3 mm after pressing the glue for some grouped CTP modules, which fails to meet the design requirements, making the qualification rate of the grouped CTP modules relatively low; at the same time, due to the large size design of the production line, the current workshop space design layout may not support it; 3. The concave and convex unevenness of the sealed edge face of the battery cells does not support suction cup adsorption into the box, and only the relatively flat non-sealed edge face can be placed upward into the box. Summary of the Invention

[0015] The present invention aims to provide a CTP module structure that facilitates the grouping of soft-pack battery cells to solve various problems encountered when the existing top-mounted liquid cooling plate structure of soft-pack battery CTP power batteries is put into the box.

[0016] To solve the above problems, the present invention adopts the following technical solutions:

[0017] Solution 1: A CTP module structure facilitating the grouping of pouch cells, including a CTP module composed of multiple pouch cells. The edge sealing of each pouch cell is treated with full-edge adhesive pasting. The tape used has a thickness less than or equal to 0.05 mm and a width greater than or equal to 3 cm. The full-edge adhesive pasting reduces the edge bonding gap. The CTP module structure further includes a lower liquid cooling plate. The liquid cooling plate is integrally provided with the box body to ensure the flatness of the module.

[0018] Preferably, the multiple pouch cells are stacked, and the thickness is consistent at each position in the length direction of the fully adhesive-bonded edge surface after stacking. Electrical connection between adjacent pouch cells is achieved through a connection structure, and the connection structure ensures stable current transmission between cells.

[0019] Preferably, the box body includes a bottom plate, side plates, and an upper cover. The bottom plate is located below the pouch cells to provide support for the pouch cells. The side plates and the upper cover are respectively arranged on the sides and above the pouch cells to protect the pouch cells. The liquid cooling plate is integrated with the bottom plate.

[0020] Preferably, the tape for full-edge adhesive pasting is made of a material with good flexibility and adhesiveness, which can closely adhere to the concave and convex surfaces of the edge of the pouch cell, fill the edge bonding gap, and make the gap less than or equal to 1.5 mm.

[0021] Solution 2: The present invention also provides a method for inserting a CTP module structure facilitating the grouping of pouch cells into a box. When inserting the CTP module structure facilitating the grouping of pouch cells into the battery box as described above, the following steps are included:

[0022] Step 1, carry the CTP module with pouch cells having full-edge adhesive pasting, and ensure the stable posture of the module during carrying.

[0023] Step 2, place the CTP module into the battery box with a lower liquid cooling plate in a manner that the edge is facing up and the non-edge is facing down, so that the non-edge surface of the module contacts the liquid cooling plate.

[0024] Step 3, apply glue to the inner surface of the battery box before the CTP module is inserted into the box. After the CTP module is inserted into the box, perform fixation and sealing treatment between the module and the battery box.

[0025] Preferably, when carrying the CTP module, use a sponge suction cup to adsorb the full-edge adhesive pasting surface of the pouch cell for carrying. Since the full-edge adhesive pasting of the pouch cell improves the edge bonding gap, the vacuum can be maintained during the adsorption of the sponge suction cup, so that the module can be stably lifted and carried.

[0026] Preferably, for the pouch cell with full-edge adhesive pasting, the gap between the tape and the cell body is ≤1.5 mm. Such an adhesive pasting surface can be adsorbed by the suction cup.

[0027] During the fixing process, structural adhesive is used to bond the module and related components inside the battery box. The application thickness of the structural adhesive is uniform and within the design range to ensure that the glue thickness meets the design requirements and at the same time ensure that the module is firmly fixed. During the sealing process, the upper cover plate and bottom guard plate of the battery box are installed to ensure good sealing of the battery box and prevent foreign impurities from entering.

[0028] Preferably, the whole-edge full-adhesive process is as follows: Before the edge sealing treatment of the soft-pack battery cell, first clean the edge sealing surface to remove impurities and oil stains, then paste the tape along the edge of the soft-pack battery cell to ensure that the tape covers the entire edge sealing area, and the thickness of the edge sealing surface of the soft-pack battery cell wrapped by the tape is uniform; press to make the tape fit tightly with the edge sealing to expel the air bubbles between the battery cell body and the tape.

[0029] Preferably, during the adhesive pasting process, the air bubbles in the tape should meet the following requirements:

[0030] The length of the air bubbles in the large surface of the battery cell ≤ 10 mm, and the number of air bubbles in a square area with a side length of 5 - 10 mm on the single side of the main body ≤ 8;

[0031] The width of the air bubbles in the side edge sealing direction of the battery cell ≤ 3 mm.

[0032] The advantages of this solution are:

[0033] 1. Improve production efficiency and product qualification rate: The whole-edge full-adhesive of the soft-pack battery cell improves the edge sealing fit gap, enables the sponge suction cup to maintain vacuum during adsorption, stably pick up the module, reduces the risk of dropping during handling, reduces the scrap rate, and improves production efficiency. At the same time, the standardized whole-edge full-adhesive process, with the help of automated equipment, realizes precise operation, ensures the consistency and stability of production, and further improves the product qualification rate.

[0034] 2. Optimize the module structure and performance: The CTP module adopts the design of integrating the liquid cooling plate at the bottom with the box body, which ensures the flatness of the module, controls the flatness error within a very small range, ensures that the glue thickness is within the design range, and improves the stability and reliability of the assembly of the module and the battery box. Good flatness and glue thickness control enhance the structural stability of the module, reduce the performance degradation caused by structural problems, and extend the service life of the module.

[0035] 3. Enhance heat dissipation and protection performance: The integrated liquid cooling plate at the bottom and the box body, combined with the reasonable design of strip-shaped grooves, liquid inlets and outlets, can effectively take away the heat generated by the soft-pack battery cell, maintain the appropriate working temperature of the module, and improve the battery performance and safety. Auxiliary structures such as the bottom plate, side plates and upper cover, as well as the application of tape and structural adhesive, protect the soft-pack battery cell from external factors, prevent impurities such as dust and moisture from entering, and improve the protection performance of the module.

[0036] 4. Facilitate the assembly and maintenance of the battery box: The method of inserting the CTP module into the box is clear and easy to operate. The method of inserting the module into the box with the sealed edge facing up and the non-sealed edge facing down, combined with stable adsorption and handling and precise positioning and installation, reduces the assembly difficulty and improves the assembly efficiency. The fixing and sealing treatment between the module and the battery box not only ensures the stability of the module in the box but also facilitates later maintenance. The upper cover plate and the bottom protection plate of the battery box can be opened to inspect and repair the module. Description of the Drawings

[0037] Figure 1 FIG. is a schematic structural diagram of a battery pack formed by a CTP module with a top-mounted liquid cooling plate structure for an existing soft-pack battery cell CTP power battery.

[0038] Figure 2 FIG. is a real-shot picture of the sealing edge gluing of an existing single soft-pack battery cell.

[0039] Figure 3 FIG. is a real-shot picture of the sealing edge gluing when multiple existing soft-pack battery cells are stacked to form a CTP module.

[0040] Figure 4 FIG. is a real-shot picture of the sealing edge gluing of a single soft-pack battery cell in an embodiment of the present invention.

[0041] Figure 5 FIG. is a real-shot picture of the sealing edge gluing when single and multiple soft-pack battery cells are stacked to form a CTP module in an embodiment of the present invention.

[0042] Figure 6 FIG. is a schematic structural diagram of a battery pack formed by a CTP module facilitating the grouping of soft-pack battery cells in an embodiment of the present invention, which can be opened up and down.

[0043] Figure 7 FIG. is a partial schematic structural diagram of a battery pack formed by a CTP module facilitating the grouping of soft-pack battery cells in an embodiment of the present invention after disassembly.

[0044] Figure 8 FIG. is a flowchart of inserting a CTP module for grouping soft-pack battery cells in an embodiment of the present invention.

[0045] Figure 9 FIG. is a real-shot picture of the battery box before inserting the CTP module in an embodiment of the present invention.

[0046] The reference numerals in the drawings of the specification include: upper cover plate 1, upper liquid cooling plate 2, CTP module 3, bottom plate 4, lower box body 5, lower liquid cooling plate 6, and soft-pack battery cell 7. Detailed Description of the Invention

[0047] The following is further detailed through specific embodiments:

[0048] The existing soft-pack battery cell CTP power battery with a top-mounted liquid cooling plate structure is basically as shown in the attached Figure 1As shown: The existing grouping structure of this type of CTP module includes an upper cover plate 1, an upper liquid cooling plate 2, a CTP module 3, a bottom plate 4, and a lower box body 5, which are installed in sequence from top to bottom. Among them, the existing CTP module includes a battery cell module assembly, a low-voltage wire harness assembly, a BDU, and a BMS that are connected in sequence.

[0049] The battery cell module assembly, the low-voltage wire harness assembly, the BDU (Battery Disconnect Unit), and the BMS (Battery Management System) form the existing CTP module unit in the following way:

[0050] Battery cell module assembly: This is the core part of the CTP module unit, which is composed of multiple battery cells combined in a specific arrangement (such as series, parallel, or series-parallel combination) and is responsible for storing and releasing electrical energy. The battery cells are electrically connected through connection plates, welding, etc. to meet the voltage and capacity requirements of the battery pack.

[0051] Low-voltage wire harness assembly: The low-voltage wire harness assembly is mainly used to transmit control signals and low-voltage power. It connects the BMS to the battery cell module assembly and other related components (such as the BDU), enabling the BMS to monitor the voltage, temperature, and other parameters of each battery cell in real time and perform operations such as charge and discharge control on the battery cells. The reasonable layout and connection of the low-voltage wire harness assembly ensure the accuracy and stability of signal transmission.

[0052] BDU: The BDU plays a key role in circuit protection and control in the CTP module unit. It contains multiple relays, fuses, and other components, which can quickly cut off the circuit in case of abnormal situations such as overcurrent and short circuit in the battery system to protect the battery cells and other components from damage. At the same time, the BDU can also control the on and off of the charge and discharge circuit of the battery system according to the instructions of the BMS to achieve the safety management of the battery system.

[0053] BMS: The BMS is the "brain" of the CTP module unit. It collects the state information (such as voltage, temperature, SOC - State of Charge, etc.) of each battery cell in the battery cell module assembly, performs data analysis and processing, and controls the BDU, adjusts the charge and discharge process, etc. according to preset algorithms and strategies. The BMS can also communicate with other control systems of the vehicle to achieve the overall management and optimization of the battery system to ensure that the battery system operates in a safe and efficient state.

[0054] During the process of forming a battery pack with the CTP module 3 and the liquid cooling plate and other structures together, it is necessary to place the CTP module into the box body of the battery box. As Figure 1 shown, it is necessary to place 4 CTP modules 3 into the lower box body 5. Since the size of a single CTP module 3 is large and the number of modules put into the box at the same time is large, designing the CTP module structure to be convenient for manipulator operation can greatly reduce various problems generated during the process of grouping and putting the CTP modules into the box.

[0055] As Figure 2 shown, in the existing single soft-pack battery cell 7, the edge sealing and gluing only discontinuously paste local positions in a fractured manner, which will cause the thickness of the soft-pack battery cell 7 itself to be uneven at various positions. As Figure 3 shown, when multiple soft-pack battery cells 7 are stacked and connected to form a CTP module, the thickness of each module also varies due to the edge sealing and gluing problem of the single soft-pack battery cell 7, resulting in inconsistent thickness at various positions along the length direction of the edge sealing surface.

[0056] The CTP module is grouped by stacking the edge sealing surface with acceptable cell flatness facing downwards. Acceptable cell flatness means that the flatness of the cell surface meets the pre-set standard. During the production process of the soft-pack battery cell 7, the cell flatness is one of the key indicators to measure product quality. Since the cell surface may be uneven during manufacturing, handling, etc., and the uneven cell surface may affect the fit between cells, the assembly stability of the module, and the overall performance of the subsequent battery pack.

[0057] When the cell flatness is acceptable, it indicates that the cell surface has good flatness, which can ensure that during the module grouping process, the cells are in close and uniform contact, reducing problems such as uneven local pressure and inconsistent contact resistance caused by poor flatness, and thus guaranteeing the structural stability and electrical performance consistency of the module.

[0058] Currently, it is usually required to stack with the edge sealing surface with acceptable cell flatness facing downwards. This is based on the consideration that a surface with better flatness is more conducive to achieving stable stacking of the module. The edge sealing surface is relatively flatter and has higher strength. Stacking with the edge sealing surface facing downwards can make the cells contact more closely and stably, reducing the displacement, deformation, etc. of the cells due to uneven force during the stacking process, which is beneficial to ensuring the stability and consistency of the overall structure of the module.

[0059] As Figure 1 shown, in the existing battery pack structure, the CTP module unit needs to be flipped 180° when entering the box. Because in the traditional design, the liquid cooling plate is installed on the non-edge-sealing surface side, and the internal structure design of the box requires the non-edge-sealing surface with the liquid cooling plate installation surface to face upwards when entering the box to meet the subsequent integration and related assembly requirements with the box. This series of operations is the result of comprehensive consideration of structural stability, assembly convenience, heat dissipation, etc. under past technical conditions.

[0060] Based on the existing CTP module structure and battery pack structure, there are some significant problems during the process of putting the CTP module 3 into the box after connecting single soft-pack battery cells 7 with adhesive tape. In the traditional module grouping method, the stacked modules have the edge surface with qualified flatness facing downwards. When putting the modules into the box, the modules need to be flipped by 180°. This makes the production line size design huge, and it is difficult for the existing workshop space layout to support it. Moreover, there is a risk of sliding displacement of the module in the tooling fixture during flipping. At the same time, the liquid cooling plate has a large area (the same size as the pack) and insufficient stiffness, which is prone to deformation, resulting in the adhesive thickness > 3 mm after pressing the adhesive tape, unable to meet the design requirements. In addition, the edge surface of the battery cell is uneven, and it does not support suction cup adsorption into the box. Only the relatively flat non-edge surface can be faced upwards into the box, which is contrary to the traditional way of putting the edge surface downwards into the box.

[0061] In view of the above problems, the present invention proposes two key improvements. First, fully paste adhesive tape on the uneven parts of the edge of the battery cell, effectively solving the problem that the suction cup cannot adsorb due to vacuum breakage during adsorption. Second, change the way of putting the module into the box, adopt the method of putting the edge surface upwards and the non-edge surface downwards into the box, and press the adhesive tape with the cold plate with higher flatness after integrating the relatively flat non-edge surface with the box body.

[0062] The present invention has significant advantages. In terms of production line design, it realizes the minimum design, greatly improves the space utilization rate, and solves the problem of insufficient workshop space. In terms of the integration of the cold plate and the box body, the flatness can reach the design index, and the adhesive thickness after the module is put into the box also meets the design requirements, effectively overcoming the problem that the adhesive thickness does not meet the standard due to the deformation of the liquid cooling plate, and improving the product quality and performance.

[0063] Specifically, in this embodiment, the entire CTP module structure is changed starting from the adhesive taping of a single soft-pack battery cell 7.

[0064] As Figure 4 shown, in this embodiment, the edge of a single soft-pack battery cell 7 is fully taped to solve the problems of uneven edge of the battery cell and inconsistent thickness at each position in the length direction of the battery cell. Through full taping, the problem that the suction cup cannot adsorb due to vacuum breakage during the CTP module 3 being put into the box is eliminated.

[0065] As Figure 5 shown, in this embodiment, when multiple soft-pack battery cells 7 are stacked to form the CTP module 3, before connecting other structures, the thicknesses at each position of the soft-pack battery cells 7 stacked inside the module are consistent, without unevenness, concavity and convexity, and the adhesive coating thickness can also meet the design requirements.

[0066] The process of forming the CTP module from the soft-pack battery cells 7 involves multiple links such as battery cell processing, stacking, connection, and fixation. It is necessary to strictly control the quality of each link to ensure the performance and safety of the CTP module. The following is the detailed process:

[0067] Cell pretreatment: Check the soft-packed cells 7 and remove defective cells. Then, glue the edges of the single soft-packed cells 7, using tape with a thickness of less than or equal to 0.05 mm and a width of greater than or equal to 3 cm, to ensure that the glue is firm and smooth, so as to solve the problem of uneven edges and inconsistent thickness of the cells, and avoid the vacuum being broken during subsequent suction cup adsorption, resulting in failure to adsorb.

[0068] Cell stacking: Multiple pre-processed soft-pack cells 7 are stacked according to design requirements to form a CTP group. When stacking, the thickness of each position must be consistent to avoid unevenness and concave-convexity, and the glue coating thickness must meet the design requirements so that the cells fit tightly together.

[0069] Tab connection: According to the design, the tabs of the battery cells are connected to realize the series and parallel connection of the battery cells. The connection method must ensure that the electrical connection is stable and can meet the current and voltage output requirements of the module.

[0070] In this embodiment, the CTP module 3 structure includes a plurality of stacked soft-packed cells 7, each of which is glued with a full-edge-sealed tape, wherein the thickness of the tape is less than or equal to 0.05 mm, and the width of the tape is greater than or equal to 3 cm.

[0071] Battery cell part: It is composed of multiple stacked soft-pack battery cells 7, which is the core part of the module and is responsible for the storage and release of electric energy. Each soft-pack battery cell 7 is fully edge-sealed and glued to solve the problems of uneven edge sealing and inconsistent thickness.

[0072] Connection structure: used to connect the battery cell tabs to achieve series and parallel connection of the battery cells, ensuring that the current can be stably transmitted between the battery cells and meeting the overall electrical performance requirements of the module.

[0073] Auxiliary structure: including bottom plate 4, side plates and upper cover, etc. The bottom plate 4 provides support for the CTP module to ensure the stability of the module; the side plates and upper cover protect the battery cell group to prevent external factors from damaging the battery cells.

[0074] Heat dissipation structure: This embodiment is a lower liquid cooling plate, which is arranged above the bottom plate and below the CTP module. There are strip grooves on the lower liquid cooling plate, which are connected to the external coolant circulation system through the liquid inlet and outlet, which can effectively remove the heat generated by the battery cell during the charging and discharging process and maintain the temperature stability of the module.

[0075] like Figure 7 As shown in the figure, after opening the upper cover of the battery pack of this embodiment, two CTP modules can be seen in the box. Figure 7 As shown, by removing the auxiliary structure on the top surface of the CTP module, multiple stacked battery modules underneath are exposed. By removing some of the battery modules, the summer night cold plate underneath is exposed.

[0076] likeFigure 6 and Figure 7 As shown in Figure 7 , in this embodiment, the battery pack structure formed after the CTP module 3 is put into the box is: the upper cover plate 1, the CTP module 3, the box body, the lower cold plate and the bottom guard plate.

[0077] As Figure 8 shown, the process of putting the CTP module into the battery box in this embodiment is as follows:

[0078] Battery box preparation: Check the battery box to ensure that it is free of damage, deformation, and the inside is clean without debris. Install relevant components such as the lower cold plate in the battery box to ensure its accurate position and firm installation.

[0079] Module handling: Carry the CTP module with the full-edge fully adhered soft-pack battery cells 7 adsorbed by the suction cup, ensuring a stable attitude during handling; use a suitable handling device to smoothly carry the CTP module above the battery box, strictly controlling the module attitude during the handling process, and carry it in the way of "sealed edge up, non-sealed edge down" to prevent the module from being damaged.

[0080] Module into the box: As Figure 9 shown, after applying glue on the lower liquid cooling plate 6 of the battery box, put the CTP module into the battery box with a lower liquid cooling plate in the way of "sealed edge up, non-sealed edge down", making the non-sealed edge surface of the module contact with the lower liquid cooling plate; slowly put the CTP module into the battery box, making the non-sealed edge surface of the module contact with the cold plate with a higher flatness in the battery box, accurately adjust the position of the module to ensure that the relative positions of the module and each component in the battery box meet the design requirements.

[0081] Fixing and sealing: After the CTP module is put into the box, the structural glue bonds and fixes the module to the relevant components in the battery box to ensure the stability of the module and prevent shaking or displacement. When applying the structural glue, it should be uniform to ensure that the glue thickness meets the design requirements and avoid the problem of unqualified glue thickness. Install components such as the upper cover plate 1 and the bottom guard plate to seal the battery box to prevent impurities such as dust and moisture from entering and affecting the battery performance and safety.

[0082] Testing and debugging: Conduct a comprehensive inspection on the battery box after putting the CTP module, including electrical performance testing, sealing performance testing, structural integrity testing, etc. If any problems are detected, debug and repair them in time to ensure that the battery box meets the design standards and usage requirements.

[0083] Test example:

[0084] Edge sealing and gluing aims to reduce gaps and avoid the problem of vacuum breakage and inability to suck. The soft-pack battery cells 7 that are edge-sealed and glued using this method and the soft-pack battery cells 7 that are only intermittently and discontinuously glued and edge-sealed to the soft-pack battery cells 7 without using this method are used as a control group, and a comparison is made during the gluing process. After forming the CTP module 3 with the same structure, a comparison is also made for its process of being put into the box and the corresponding battery pack obtained after the box is completed.

[0085] Samples: For the 2 modules used as the control group, both adopt the structure of 10 soft-pack battery cells 7 + 9 pieces of foam + 2 pieces of mica sheets. During the process of being put into the box, in this embodiment: the suction cup adsorbs the fully edge-sealed and glued surface, and in the comparative example: the suction cup adsorbs the non-edge-sealed surface with intermittent gluing.

[0086] Dimensions: The width of the stack of soft-pack battery cells 7 adsorbed in one CTP module 3 is 144.5 mm.

[0087] Figure 2 For the gluing of a single soft-pack battery cell 7 in the comparative example, the gaps are very large, and the surface of the side to be glued is uneven and the thickness is not uniform. The thickness and gaps at the glued part are significantly smaller than those at the non-glued positions. After stacking with the structure of 10 soft-pack battery cells 7 + 9 pieces of foam + 2 pieces of mica sheets, the CTP module 3 as shown in Figure 3 is formed. When adsorbing with the suction cup, it can be clearly seen that the black suction cup cannot penetrate between each soft-pack battery cell 7 and cannot adsorb the CTP module 3 in the comparative example.

[0088] Figure 4 For the gluing of a single soft-pack battery cell 7 in this embodiment, compared with the Figure 2 comparative example, it can be seen that the gaps at the glued edges are significantly reduced, and the surface of the side to be glued is flat and the thickness is uniform. When applying the adhesive tape, the whole yellow high-temperature adhesive tape is pasted on the edge. If manually applying the glue, the right hand needs to straighten it, and the left hand presses on the edge and flattens the tape in the width direction against both sides of the battery cell; if automatically applying the glue, after straightening the tape, the tape is pasted along the length direction of the battery cell and then the width direction of the tape is flattened. After the continuous whole tape is pasted on a single soft-pack battery cell 7, the following conditions can be met: the gap between the tape and the battery cell body ≤ 1.5 mm, the length of the bubbles in the large surface of the battery cell ≤ 10 mm, the number of bubbles in the square area with a side length of 5 - 10 mm on the single side of the main body ≤ 8; the width of the bubbles in the side edge-sealing direction of the battery cell ≤ 3 mm. Among them, the large surface of the battery cell refers to the front side and the rear side of the soft-pack battery cell 7 as shown in Figure 4 ; the single side of the main body refers to any side of the soft-pack battery cell 7.

[0089] In this embodiment, after the full-edge sealing and gluing of the above single soft-pack battery cell 7 is completed, after stacking with the same structure of 10 soft-pack battery cells 7 + 9 pieces of foam + 2 pieces of mica sheets as in the comparative example, the one as shown in Figure 5The CTP module 3 shown. When sucking with the suction cup, it can be clearly seen that the black suction cup can penetrate between each soft-pack battery cell 7, and the suction cup is in close contact with the glued surface of each soft-pack battery cell 7 that is fully edge-glued, and can suck up the CTP module 3.

[0090] In the comparative example, since the CTP module 3 cannot be sucked into the box with the suction cup, each single CTP module 3 weighs at least 60 - 70 kilograms, and it is impossible to complete the operation of putting it into the box, and thus impossible to complete the final battery pack.

[0091] For Figure 6 As shown, performance tests were conducted on the battery packs formed by the CTP module 3 composed of this embodiment and the comparative example, and the test result table shown in Table 1 was obtained:

[0092] Table 1

[0093]

[0094]

[0095] It can be seen from Table 1 that through the analysis of the above screening test items, it can be known that the CTP module and battery pack of the present invention have various advantages, covering fields such as electrical performance, management system, temperature control, sealing performance, and safety, and exhibit good comprehensive performance.

[0096] Stable electrical performance: The test results of the 12V voltage detection and total voltage detection functions are all within the standard range, indicating that the battery pack can stably supply power to each internal component and meet the operation requirements of the equipment. At the same time, the positive electrode insulation performance is good, effectively preventing leakage, ensuring the safe and stable operation of the electrical system, avoiding short-circuit faults caused by leakage, and ensuring the reliable operation of the CTP module and the battery pack.

[0097] Efficient battery management ability: The working current and sleep current of the BMS meet the standards, indicating that the BMS can effectively manage the battery pack. The reasonable working current ensures the normal control and monitoring of the battery state by the BMS, and the low sleep current reduces the power consumption in the non-working state, prolongs the battery life, improves the battery use efficiency, and ensures the stable operation of the CTP module and the battery pack.

[0098] Good temperature control performance: The test results of the environmental temperature difference show that the battery pack can maintain its own temperature stability at different environmental temperatures. The small temperature difference indicates that its heat dissipation and heat insulation performance are good, which can effectively avoid affecting the battery performance due to too high or too low temperature, ensure that the CTP module and the battery pack can work normally in different environments, and improve the adaptability and stability of the battery.

[0099] Reliable sealing and protection performance: The leakage rates of the direct cooling plate, liquid cooling, and the entire package in the airtightness test all meet the standards, indicating that the battery pack has good airtight performance. This can effectively prevent external substances from entering the interior, protect the battery cells and other components from erosion, extend the service life of the battery pack, and improve the protection performance and reliability.

[0100] Perfect safety protection mechanism: The interlock status confirmation, heating stamp function test, and high-voltage interlock function test are all normal, indicating that the safety protection mechanism of the battery pack is effective. These interlock functions can prevent high-voltage hazards in abnormal situations, ensure the safety of personnel and equipment, and further improve the safety of the CTP module and the battery pack.

[0101] Specifically,

[0102] A CTP module structure facilitating the grouping of 7 soft-pack battery cells, characterized in that it includes a plurality of soft-pack battery cells 7. The sealing edge of each soft-pack battery cell 7 is treated with full-edge adhesive pasting. The thickness t of the tape used satisfies t ≤ 0.05 mm and the width w satisfies w ≥ 3 cm. The gap between the sealing edge and the battery cell body is less than or equal to 1.5 mm. The CTP module structure also includes a liquid cooling plate disposed below, which is integrally provided with the box body to ensure the flatness of the module. The flatness error δ of the module is controlled within ±0.05 mm.

[0103] The plurality of soft-pack battery cells 7 are stacked, and the thicknesses at each position of the fully adhesive-pasted sealing surface after stacking are consistent, and the thickness deviation Δh does not exceed ±0.03 mm. The adjacent soft-pack battery cells 7 are electrically connected through a connection structure. The resistance R of the connection structure satisfies R ≤ 0.01 Ω to ensure stable current transmission between the battery cells, and the voltage drop ΔU during the current transmission process does not exceed I × 0.01 V (where I is the current passing through the connection structure).

[0104] The CTP module structure facilitating the grouping of 7 soft-pack battery cells further includes a bottom plate 4, side plates, and an upper cover. The bottom plate 4 is located below the soft-pack battery cells 7 to provide support for the soft-pack battery cells 7. The thickness h1 of the bottom plate 4 is 2 - 3 mm, and the compressive strength σ1 of its material is not less than 100 MPa. The side plates and the upper cover are respectively disposed on the side and above the soft-pack battery cells 7 to protect the soft-pack battery cells 7. The thickness h2 of the side plates is 1.5 - 2 mm, and the thickness h3 of the upper cover is 1 - 1.5 mm. The tensile strength σ2 of the materials of the side plates and the upper cover is not less than 280 Mpa.

[0105] The tape for full-edge adhesive pasting is made of a material with good flexibility and adhesiveness, and can closely fit the concave and convex surfaces of the sealing edge of the soft-pack battery cell 7, effectively filling the gap between the sealing edge and the battery cell body. The flexibility of the tape is measured by the bending modulus E, and the value range of E is 1 - 5 MPa; the bonding strength τ between the tape and the sealing edge surface is not less than 5 N / cm².

[0106] For the fully edge - adhered soft - package battery cell 7, the gap between the tape and the battery cell body is ≤ 1.5 mm. The fully edge - adhered process is as follows: Before the edge - sealing treatment of the soft - package battery cell 7, first clean the edge - sealing surface to remove impurities and oil stains. Then paste the tape along the edge of the soft - package battery cell 7 to ensure that the tape covers the entire edge - sealing area, and the thickness of the edge of the soft - package battery cell 7 wrapped by the tape is uniform. By means of rolling or the like, make the tape closely adhere to the edge - sealing, and expel the air bubbles between the battery cell body and the tape. During the taping process, ensure that the air bubbles in the tape meet the following requirements:

[0107] The length of the air bubbles in the large surface of the battery cell is ≤ 10 mm, and the number of air bubbles in a square area with a side length of 5 - 10 mm on the single side of the main body is ≤ 8;

[0108] The width of the air bubbles in the side - edge - sealing direction of the battery cell is ≤ 3 mm. In this way, the taped surface obtained by taping has fewer air bubbles, the taped surface is flat and has strong adhesion, which is convenient for being adsorbed by the suction cup and then transported into the battery box, making it possible for the suction cup to adsorb multiple soft - package battery cells 7 at the same time. At the same time, unlike the current situation where it is necessary to clamp the soft - package battery cell 7, without applying force to clamp the soft - package battery cell 7, the present invention can evenly adsorb multiple soft - package battery cells 7 through the suction cup to perform the operation of putting them into the battery box, which is more accurate, more efficient, and has a higher yield rate.

[0109] A method for putting a CTP module structure facilitating the grouping of soft - package battery cells 7 into a box includes the following steps: Carry the CTP module with the fully edge - adhered soft - package battery cell 7, and ensure the stable attitude of the module during transportation, and the inclination angle θ of the module does not exceed ± 3°. Put the CTP module into the battery box with a lower - placed liquid - cooling plate in the way that the edge - sealing is upward and the non - edge - sealing is downward. Compared with the existing stacking method with the edge - sealing downward and the non - edge - sealing upward, the coating thickness is about 3 - 4 mm, resulting in a larger thermal resistance. However, through the opposite way of putting it into the box in the present invention, the coating thickness after stacking can be ensured to be below 2 mm, which can greatly reduce the thermal resistance, make the non - edge - sealing surface of the module contact with the liquid - cooling plate, and the contact area S is not less than 95% of the area of the non - edge - sealing surface of the module. Before the CTP module is put into the box, apply glue on the battery box and the liquid - cooling plate. After the CTP module is put into the box, directly fix and seal the area between the module and the battery box to ensure the stable position of the module in the box and the good sealing of the battery box.

[0110] When carrying the CTP module 3, use the method of adsorption by a sponge suction cup for transportation. Since the full - edge adhesion of the soft - package battery cell 7 improves the edge - adhesion fitting gap, the vacuum degree P during the adsorption of the sponge suction cup can be maintained between 50 kPa and 60 kPa (if this method is not used, according to the structure of the CTP module 3 with the existing structure, the vacuum degree of the sponge suction cup is very low and is not enough to support the suction cup to adsorb the module and put it into the battery box, and the processing operation of the battery pack cannot be completed). Thus, the module can be stably sucked up and transported, and the adsorption force F satisfies F ≥ G (where G is the gravity of the CTP module).

[0111] During the fixation process, before the CTP module 3 is placed into the battery box, the inner surface of the battery box is first coated with glue, and structural glue is used to bond the relevant components inside the module and the battery box. The coating thickness h of the structural glue g is uniform and satisfies 1.5 mm ≤ h g ≤ 2 mm. After the CTP module 3 is placed into the battery box, the CTP module 3 is fixedly connected to the battery box through the glue. After the connection, ensure that the glue thickness meets the design requirements and at the same time ensure that the module is firmly fixed. The shear strength τ of the structural glue g is not less than 15 MPa. During the sealing process, install the upper cover plate 1 and the bottom guard plate of the battery box to ensure good sealing of the battery box, prevent foreign impurities from entering, and the protection level inside the battery box reaches the IP67 standard.

[0112] The whole-edge full-glue process is as follows: Before the edge sealing treatment of the soft-pack battery cell 7, first clean the edge sealing surface to remove impurities and oil stains. The impurity residue rate on the edge sealing surface after cleaning does not exceed 0.01%. Paste the tape along the edge of the soft-pack battery cell 7 to ensure that the tape covers the entire edge area, and the thickness of the edge of the soft-pack battery cell 7 wrapped by the tape is uniform; Make the tape fit tightly with the edge through methods such as rolling to expel the air bubbles between the glue layer and the tape, and the air bubble residue rate does not exceed 0.05%. Ensure that the air bubbles in the tape meet the following requirements:

[0113] The length of the air bubbles in the large surface of the battery cell ≤ 10 mm, and the number of air bubbles in a 5-10 mm side length square area on the main body single side ≤ 8;

[0114] The width of the air bubbles in the side edge sealing direction of the battery cell ≤ 3 mm. At the same time, the gap between the tape and the battery cell body ≤ 1.5 mm.

[0115] Through the whole-edge full-glue of the soft-pack battery cell 7, the present invention improves the edge sealing fitting gap, makes the sponge suction cup adsorb stably, reduces the risk of dropping during handling, and optimizes the handling link in the production process. Moreover, the liquid cooling plate is placed below and integrated with the box body to ensure flatness, make the glue thickness meet the design requirements, and reduce rework caused by process problems. From these advantages, it is speculated that the production process is more smooth and efficient. Compared with the traditional method, it is expected that the production time of each soft-pack battery can be shortened by about 20%-30%. In terms of the qualified product rate, due to solving the problems of unstable adsorption, flatness and glue thickness, the risk of damage and unqualified products during production is reduced, and it is expected that the qualified product rate can be increased to more than 95%.

[0116] The above are only embodiments of the present invention. Specific technical solutions and / or common knowledge such as characteristics well known in the art are not described in detail herein. It should be noted that for those skilled in the art, without departing from the technical solution of the present invention, several modifications and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the implementation effect of the present invention and the practicability of the patent. The protection scope claimed in this application shall be subject to the content of its claims, and the specific implementation manners described in the specification can be used to interpret the content of the claims.

Claims

1. The CTP module structure facilitating the grouping of soft-pack battery cells is characterized in that The CTP module includes multiple soft-pack battery cells. The edge sealing of each soft-pack battery cell adopts a full-edge and full-adhesive treatment. The tape used has a thickness less than or equal to 0.05 mm and a width greater than or equal to 3 cm. The full-edge and full-adhesive treatment reduces the edge sealing fitting gap. The CTP module structure also includes a liquid cooling plate arranged below. The liquid cooling plate is integrally arranged with the box body to ensure the flatness of the module.

2. The CTP module structure facilitating the grouping of soft-pack battery cells according to claim 1, characterized in that, Multiple soft-pack battery cells are stacked, and the thickness at each position in the length direction of the full-adhesive edge sealing surface is the same after stacking.

3. The CTP module structure facilitating the grouping of soft-pack battery cells according to claim 1, characterized in that, The box body includes a bottom plate, side plates and an upper cover. The bottom plate is located below the soft-pack battery cells to provide support for the soft-pack battery cells. The side plates and the upper cover are respectively arranged on the sides and above the soft-pack battery cells to protect the soft-pack battery cells. The liquid cooling plate is integrated with the bottom plate.

4. The CTP module structure facilitating the grouping of soft-pack battery cells according to claim 1, wherein, The tape for full-edge and full-adhesive treatment is made of a material with good flexibility and adhesiveness, which can closely fit the concave and convex surfaces of the edge of the soft-pack battery cell, fill the edge sealing fitting gap, and make the gap less than or equal to 1.5 mm.

5. The method for putting the CTP module structure facilitating the grouping of soft-pack battery cells into a box, characterized in that, When using the CTP module structure for facilitating the grouping of soft-pack battery cells as described in Claim 1 for putting into the battery box, the following steps are included: Step 1, carry the CTP module with soft-pack battery cells having full-edge and full-adhesive treatment, and ensure the stable posture of the module during carrying. Step 2, put the CTP module into the battery box with a liquid cooling plate arranged below in the way that the edge sealing faces upward and the non-edge sealing faces downward, so that the non-edge sealing surface of the module contacts with the liquid cooling plate. Step 3, apply glue to the inner surface of the battery box before the CTP module is put into the box. After the CTP module is put into the box, perform fixing and sealing treatment between the module and the battery box.

6. The method for packing the CTP module structure facilitating the grouping of soft-pack battery cells according to claim 5, characterized in that, When carrying the CTP module, carry it by using a sponge suction cup to adsorb the full-adhesive surface of the edge of the soft-pack battery cell.

7. The method for putting the CTP module structure facilitating the grouping of soft-pack battery cells into a box according to claim 5, characterized in that For the soft-pack battery cell with full-edge and full-adhesive treatment, the gap between the tape and the battery cell body is ≤1.5 mm.

8. The method for putting the CTP module structure facilitating soft-pack battery cell grouping into a box according to claim 5, wherein, The full-edge and full-adhesive process is as follows: Before the edge sealing treatment of the soft-pack battery cell, first clean the edge sealing surface to remove impurities and oil stains, paste the tape along the edge of the soft-pack battery cell to ensure that the tape covers the entire edge sealing area, and the thickness of the edge sealing surface of the soft-pack battery cell wrapped by the tape is uniform. Press to make the tape closely fit the edge sealing, and expel the air bubbles between the battery cell body and the tape.

9. The method for packing the CTP module structure facilitating the grouping of soft-pack battery cells according to claim 8, wherein During the gluing process, ensure that the air bubbles in the tape meet the following requirements: The length of the air bubbles in the large surface of the battery cell is ≤10 mm, and the number of air bubbles in a square area with a side length of 5 - 10 mm on the single side of the main body is ≤8. The width of the air bubbles in the side edge sealing direction of the battery cell is ≤3 mm.

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