Encapsulation method for battery pack, battery pack and electric equipment

Abstract

The invention relates to a potting method for a battery pack, the battery pack and electric equipment, and the potting method for the battery pack comprises the following steps: before a cover body is installed, a containing cavity is filled with polystyrene foam for multiple times, so that a pre-potting structure formed by at least one time of filling of the polystyrene foam and a post-potting structure formed by at least one time of filling of the polystyrene foam are formed, the battery assembly is connected to the cover body through a rear potting structure. By means of the technical scheme, the potting method for the battery pack can solve the problem that in the related technology, after the battery pack is subjected to potting operation, poor buckling between the cover body and the shell of the battery pack is likely to occur, the structural strength of the whole battery pack is effectively improved, and the structural design of the whole battery pack is facilitated.

Description

Technical Field

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

[0002] In related technologies, after the battery pack is potted, poor fit may occur between the cover and the battery pack housing. Summary of the Invention

[0003] The purpose of this disclosure is to provide a potting method, battery pack, and electrical equipment for battery packs, so as to solve the problem of poor fastening between the cover and the battery pack shell after the battery pack potting operation in the related art, and improve the feasibility and process stability of the overall battery pack potting design.

[0004] To achieve the above objectives, a first aspect of this disclosure provides a potting method for a battery pack, the battery pack including a housing, a battery assembly, and a cover, the housing including a receiving cavity with an opening, the battery assembly being located in the receiving cavity, and the cover closing the opening, the method comprising: filling the receiving cavity with expanding foam in multiple stages before installing the cover to form a pre-potting structure formed by filling the expanding foam at least once and a post-potting structure formed by filling the expanding foam at least once, the battery assembly being connected to the cover through the post-potting structure.

[0005] Optionally, the step of filling the cavity with expanding foam in multiple stages to form a pre-filled structure formed by filling the expanding foam at least once and a post-filled structure formed by filling the expanding foam at least once includes: filling at least a portion of the space between the battery assembly and the sidewall of the cavity with expanding foam to form the pre-filled structure.

[0006] Optionally, the battery assembly includes battery cells, the receiving cavity has a first cavity located at at least one end of the battery assembly along a first direction, and the pre-filled structure is at least partially located within the first cavity.

[0007] Optionally, the receiving cavity has a third cavity located at at least one end of the battery assembly along a second direction, wherein the volume of the first cavity is larger than the volume of the third cavity.

[0008] Optionally, in the height direction of the battery pack, the highest point of the top surface of the pre-filled structure is located below the top of the battery cell, or the highest point of the top surface of the pre-filled structure is flush with the top of the battery cell.

[0009] Optionally, the distance between the lowest point of the top surface of the pre-filled structure and the top of the battery cell in the height direction is h, and the dimension of the battery cell in the height direction is H, where h ≤ H*1 / 2.

[0010] Optionally, the dimension of the receiving cavity in the height direction of the battery pack is H', and the height of the highest or lowest point of the top surface of the pre-filled structure relative to the inner bottom surface of the receiving cavity is L, where L≥H'*1 / 3.

[0011] Optionally, the dimension of the battery cell in the battery assembly in the height direction of the battery pack is H, where H'*1 / 2 < L < H.

[0012] Optionally, the dimension of the battery cell in the battery assembly in the height direction of the battery pack is H, where H ≥ H'*2 / 3.

[0013] Optionally, the distance between the highest and lowest points of the top surface of the pre-filled structure in the height direction is less than a preset distance.

[0014] Optionally, the preset distance is 15mm.

[0015] Optionally, filling at least a portion of the space between the battery assembly and the sidewall of the receiving cavity with the expanding foam to form the pre-filled structure includes: filling the at least a portion of the space with the expanding foam along a first preset trajectory.

[0016] Optionally, the battery pack further includes a second sealing structure for dividing the at least a portion of the space into a plurality of sub-fill cavities.

[0017] Optionally, the plurality of sub-filling cavities are arranged at intervals along the first preset trajectory.

[0018] Optionally, the pre-filled structure is formed by the free expansion of the foam.

[0019] Optionally, the receiving cavity includes a second cavity located between the battery assembly and the cover and between adjacent battery cells in the battery assembly, and the post-filling structure includes a first post-filling structure located within the second cavity; the step of filling the receiving cavity with expanding foam in multiple stages to form a pre-filling structure formed by filling the expanding foam at least once and a post-filling structure formed by filling the expanding foam at least once includes: filling the second cavity with expanding foam along a second preset trajectory to form the first post-filling structure.

[0020] Optionally, the method further includes: determining the second preset trajectory based on the arrangement of the battery cells of the battery assembly.

[0021] Optionally, the battery assembly includes multiple sets of battery cells arranged side by side along the length direction of the battery cells, each set of battery cells includes multiple sets of battery cells arranged side by side along the thickness direction of the battery cells, and the second preset trajectory includes a first main trajectory and a first turning trajectory. Multiple first main trajectories extend along the thickness direction of the battery cells and are arranged side by side along the length direction of the battery cells. Adjacent first main trajectories are connected by the first turning trajectory, so that the second preset trajectory forms a serpentine trajectory.

[0022] Optionally, a first gap is provided between two adjacent battery cells spaced apart along the length direction, the first gap forming a portion of the second cavity, the first gap extending along the thickness direction, and at least one of the first main tracks passing through the first gap.

[0023] Optionally, the upper surface of the battery cell is provided with a terminal post and a surface area adjacent to the terminal post, and at least one first main trajectory passes through the terminal post and at least one first main trajectory passes through the surface area.

[0024] Optionally, the battery assembly includes a busbar assembly located above the battery cell, the busbar assembly having a second gap between itself and the cover, the busbar assembly having a third gap between itself and the battery cell, the busbar assembly having an injection port communicating with the second gap and the third gap, and at least one first main trajectory passing through the injection port.

[0025] Optionally, the first main trajectory has a first end and a second end opposite to each other, the battery assembly has a first sidewall adjacent to the first end and a second sidewall adjacent to the second end along the thickness direction, the first end and the first sidewall have a first preset distance, and the second end and the second sidewall have a second preset distance.

[0026] Optionally, the method further includes: determining the values ​​of the first preset distance and the second preset distance based on the difference between the actual running time of the dispensing device's outlet at the first turning trajectory and the set running time.

[0027] Optionally, the thickness of the battery cell is D, and the value of the first preset distance and the second preset distance is D', where D'≥D*1 / 2 and D'≤3D.

[0028] Optionally, the receiving cavity has a first cavity located at at least one end of the battery assembly along a first direction, the receiving cavity includes a third cavity located at at least one end of the battery assembly along a second direction, the pre-filled structure is located within the first cavity, and the post-filled structure includes a second post-filled structure located within the third cavity and above the pre-filled structure; the step of filling the receiving cavity with expanding foam in multiple stages to form a pre-filled structure formed by filling the expanding foam at least once and a post-filled structure formed by filling the expanding foam at least once includes: filling the first cavity and the third cavity with expanding foam along a third preset trajectory to form the second post-filled structure.

[0029] Optionally, the third preset trajectory is a circular trajectory extending circumferentially around the battery assembly.

[0030] Optionally, the method further includes: after filling the second cavity with the expanding foam along the second preset trajectory, filling the first cavity and the third cavity with the expanding foam along the third preset trajectory.

[0031] Optionally, the method includes: after the expanding foam forming the pre-filled structure expands to its maximum volume, filling the first cavity and the third cavity with the expanding foam along a third preset trajectory.

[0032] Optionally, the method includes: after the expanding foam forming the pre-filled structure has expanded to its maximum volume, and before the top surface of the pre-filled structure is surface dry, starting to fill the expanding foam into the first cavity and the third cavity along a third preset trajectory.

[0033] A second aspect of this disclosure provides a battery pack that employs the potting method provided in the first aspect.

[0034] A third aspect of this disclosure provides a battery pack comprising: a housing including a receiving cavity with an opening; a battery assembly located in the receiving cavity; a cover closing the opening; a pre-filled structure formed of expanding foam and located in the receiving cavity; and a post-filled structure formed of expanding foam and located in the receiving cavity, the battery assembly being connected to the cover via the post-filled structure.

[0035] Optionally, the projection of the post-filled structure in the height direction of the battery pack covers the pre-filled structure.

[0036] Optionally, the pre-filled structure and the post-filled structure are bonded together.

[0037] Optionally, the bonding strength at the interface between the pre-filled structure and the post-filled structure is E, and the bonding strength between the post-filled structure and the cap is F, where E > F.

[0038] Optionally, the pull-out / shear strength at the interface between the pre-filled structure and the post-filled structure is A, and the pull-out / shear strength of the potting structure when the foamed adhesive-formed potting structure has no interface is B, where A > 0.5B.

[0039] Optionally, the battery assembly includes battery cells, the receiving cavity has a first cavity located at at least one end of the battery assembly along a first direction, and the pre-filled structure is at least partially located within the first cavity.

[0040] Optionally, in the height direction of the battery pack, the highest point of the top surface of the pre-filled structure is located below the top of the battery cell, or the highest point of the top surface of the pre-filled structure is flush with the top of the battery cell.

[0041] Optionally, the distance between the lowest point of the top surface of the pre-filled structure and the top of the battery cell in the height direction is h, and the dimension of the battery cell in the height direction is H, where h ≤ H*1 / 2.

[0042] Optionally, the dimension of the receiving cavity in the height direction of the battery pack is H', and the height of the highest or lowest point of the top surface of the pre-filled structure corresponding to the inner bottom surface of the receiving cavity is L, where L≥H'*1 / 3.

[0043] Optionally, the dimension of the battery cell in the battery assembly in the height direction of the battery pack is H, where H'*1 / 2 < L < H.

[0044] Optionally, the dimension of the battery cell in the battery assembly in the height direction of the battery pack is H, where H ≥ H'*2 / 3.

[0045] Optionally, the distance between the highest and lowest points of the top surface of the pre-filled structure in the height direction is less than a preset distance.

[0046] Optionally, the preset distance is 15mm.

[0047] Optionally, the receiving cavity includes a second cavity located between the battery assembly and the cover and between adjacent battery cells in the battery assembly, and a third cavity located at at least one end of the battery assembly along a second direction. The post-filling structure includes a first post-filling structure located within the second cavity, and a second post-filling structure located within the third cavity and above the pre-filling structure.

[0048] Optionally, the densities of the first post-filling structure, the second post-filling structure, and the pre-filling structure decrease sequentially.

[0049] Optionally, the second post-filling structure includes a first structure located within the third cavity and a second structure above the pre-filling structure, wherein the densities of the first post-filling structure, the first structure, the second structure, and the pre-filling structure decrease sequentially.

[0050] Optionally, the battery pack further includes a first sealing structure for separating the first cavity, the second cavity, and the third cavity.

[0051] Optionally, the battery pack further includes a second sealing structure for dividing at least a portion of the first cavity and / or at least a portion of the third cavity into a plurality of sub-filled cavities.

[0052] A fourth aspect of this disclosure provides an electrical device including the battery pack provided in the second aspect or the battery pack provided in the third aspect.

[0053] Optionally, the electrical equipment is a vehicle.

[0054] The above-described technical solution, namely the battery pack potting method provided in this disclosure, includes filling the cavity with expanding foam multiple times before installing the cover to form a pre-potting structure formed by filling the expanding foam at least once and a post-potting structure formed by filling the expanding foam at least once. This ensures that the battery components are stably connected to the cover through the post-potting structure, effectively improving the overall structural strength of the battery pack and facilitating the overall structural design. It also helps to improve the insulation performance of the entire pack and the consistency of thermal management and thermal safety. Furthermore, it reduces the problem of poor fastening between the cover and the battery pack shell that easily occurs after the battery pack potting operation, such as in related technologies, thereby improving the feasibility and process stability of the overall battery pack potting design.

[0055] Other features and advantages of this disclosure will be described in detail in the following detailed description section. Attached Figure Description

[0056] The accompanying drawings are provided to further illustrate the present disclosure and form part of the specification. They are used together with the following detailed description to explain the present disclosure, but do not constitute a limitation thereof. In the drawings:

[0057] Figure 1 This is an exploded schematic diagram of a battery pack provided in an exemplary embodiment of this disclosure;

[0058] Figure 2This is an exploded view of the battery pack after the cover has been removed, provided in an exemplary embodiment of this disclosure.

[0059] Figure 3 yes Figure 2 A magnified view of a portion of location A in the diagram;

[0060] Figure 4 This is a top view of the battery pack after the cover has been removed, as provided in an exemplary embodiment of this disclosure, showing the sealing structure;

[0061] Figure 5 yes Figure 4 Schematic diagram of the cross section at position BB;

[0062] Figure 6 This is a top view of the battery pack after the cover has been removed, provided in an exemplary embodiment of this disclosure, showing a second preset trajectory;

[0063] Figure 7 This is a top view of the battery pack after the cover has been removed, provided in an exemplary embodiment of this disclosure, showing a fourth preset trajectory;

[0064] Figure 8 This is a partial structural schematic diagram of the battery assembly provided in the second embodiment of this disclosure;

[0065] Figure 9 This is a partial structural schematic diagram of the battery assembly provided in the third embodiment of this disclosure;

[0066] Figure 10 This is a partial structural schematic diagram of the battery assembly provided in the fourth embodiment of this disclosure.

[0067] Explanation of reference numerals in the attached figures

[0068] 1-Housing; 110-Opening; 120-Receiving cavity; 121-First cavity; 122-Second cavity; 123-Third cavity; 124-Sub-filling cavity; 2-Battery assembly; 210-Battery cell; 211-Terminal post; 212-Surface area; 220-Bus assembly; 221-Injection port; 230-First sidewall; 240-Second sidewall; 250-First gap; 260-Second gap; 270-Third gap; 280-Battery module; 3-Cover; 4-Second preset track Track; 410-First main track; 411-First end; 412-Second end; 420-First turning track; 5-First sealing structure; 6-Second sealing structure; 7-Head cavity; 8-Fourth preset track; 810-Second main track; 820-Second turning track; 9-Expanding foam; 910-Pre-filled structure; 920-Post-filled structure; 921-First post-filled structure; 922-Second post-filled structure; 9221-First structure; 9222-Second structure; 10-Rear cavity. Detailed Implementation

[0069] The specific embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure.

[0070] It should be noted that all actions involving the acquisition of signals, information, or data in this disclosure are carried out in compliance with the relevant data protection laws and policies of the country where the location is situated, and with authorization from the owner of the relevant device.

[0071] In this disclosure, for ease of description, a three-coordinate system, namely the XYZ coordinate system, is defined for the battery pack, wherein, with reference to... Figure 1 As shown, the Y direction corresponds to the width direction of the battery pack, and a second direction or reference can also be used. Figure 4 The vertical direction of the middle image; the X direction corresponds to the length direction of the battery pack, or you can refer to the first direction or the reference direction. Figure 4 The left and right directions in the middle of the image; the Z direction corresponds to the height direction of the battery pack, or you can refer to the direction perpendicular to the center. Figure 4 Direction or reference of the drawing Figure 5 The vertical orientation in the drawing. Unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the upper and lower dimensions within the space of the battery pack when it is in use. "Inner" and "outer" refer to the inner and outer dimensions relative to the outline of the component or structure itself. Furthermore, it should be noted that terms such as "first" and "second" are used to distinguish one element from another and do not indicate sequence or importance. Additionally, in the description referring to the accompanying drawings, the same reference numerals in different drawings denote the same element.

[0072] The inventors discovered that in related technologies, battery packs are typically potted using a single full-filling method. However, due to the large total potting volume within the battery pack, the expansion time of the expanding foam is usually shorter than the total time for potting, capping, and pressing the fixtures. In other words, it is understandable that the expanding foam has already begun to expand, or even reached its maximum volume, during the capping operation, and there is even a risk that it may expand outside the battery pack's cavity. As a result, when personnel on-site perform the capping operation, it is easy to cause poor fastening between the cap and the battery pack shell.

[0073] Based on this, according to the first aspect of this disclosure, a potting method for a battery pack is provided, with reference to... Figures 1 to 7 As shown, the battery pack includes a housing 1, a battery assembly 2, and a cover 3. The housing 1 includes a receiving cavity 120 with an opening 110. The battery assembly 2 is located in the receiving cavity 120. The cover 3 closes the opening 110. The potting method for the battery pack includes filling the receiving cavity 120 with expanding foam 9 multiple times before installing the cover 3 to form a pre-potting structure 910 formed by filling the expanding foam 9 at least once and a post-potting structure 920 formed by filling the expanding foam 9 at least once. The battery assembly 2 is connected to the cover 3 through the post-potting structure 920.

[0074] The above-described technical solution, namely the battery pack potting method provided in this disclosure, includes filling the receiving cavity 120 with expanding foam 9 multiple times before installing the cover 3 to form a pre-potting structure 910 formed by filling the expanding foam 9 at least once and a post-potting structure 920 formed by filling the expanding foam 9 at least once. This ensures that the battery assembly 2 is stably connected to the cover 3 through the post-potting structure 920, effectively improving the overall structural strength of the battery pack and facilitating the overall structural design. It also helps to improve the insulation performance of the entire pack and the consistency of thermal management and thermal safety. Furthermore, it can reduce the problem of poor fastening between the cover and the battery pack shell after potting operations, which is common in related technologies, and improves the feasibility and process stability of the overall battery pack potting design.

[0075] It should be noted that, due to the large volume of the area requiring foam filling within the battery pack's cavity in the single-stage full-sealing method, the foam expansion time within the battery pack is typically shorter than the total time for single-stage full-sealing, including filling, capping, and tooling. This can easily lead to poor capping of the battery pack cover. In other words, it is understandable that the single-stage full-sealing method typically includes at least filling, capping, and tooling operations. However, because the area requiring foam filling within the battery pack is large, the total time for single-stage filling usually accounts for a significant portion of the total time for filling, capping, and tooling. Thus, when personnel perform the capping operation on-site, the foam has already begun to expand, even reaching its maximum volume, and there is a risk that it may expand outside the battery pack's cavity, causing poor capping between the cover and the battery pack shell.

[0076] To address the aforementioned issues, this disclosure employs a potting method that involves filling the receiving cavity 120 of the battery pack with expanding foam 9 in stages. This method pre-fills a portion of the space within the receiving cavity 120 with expanding foam 9, for example, to form the aforementioned pre-filled structure 910. Since the pre-filling involves filling a portion of the space within the battery pack with expanding foam 9, and subsequent potting operations are also required, the potting time for pre-filling in this staged potting method is designed independently compared to the single-stage full potting method in related technologies. In other words, the total time for single-stage full potting, including potting, capping, and pressing, is equivalent in this disclosure to the potting time required for the amount of adhesive needed for the post-filling potting structure 920 (which can be understood as the last potting operation before capping) plus the total time for capping and pressing. Normally, the time for capping and pressing the tooling is fixed. By using a multi-stage potting solution, the time required for potting is significantly shortened, greatly reducing the risk of poor fastening between the cap 3 and the shell 1 due to premature expansion of the foaming adhesive.

[0077] In summary, because the multi-stage potting method in this disclosure allows for partial pre-potting of the entire battery pack, it reduces the volume of the area requiring the expansion joint 9 within the battery pack's cavity 120 for the next potting operation (the amount of adhesive needed for the post-potting structure 920). Thus, during the next potting operation (which can be understood as the final potting operation before capping), the significantly reduced volume of the area requiring the expansion joint 9 within the battery pack's cavity 120 effectively shortens the potting time for this next potting operation. Therefore, the potting time for the post-potting structure 920 (which can be understood as the final potting operation before capping) plus the capping time in the multi-stage potting method of this disclosure is reduced. The total time for the pressing and pressing fixture is significantly less than the total time for single full-filling and capping in related technologies, especially the glue filling time is greatly reduced. Thus, when the capping operation is performed on site, the foam 9 used to form the post-filling structure 920 has not yet started to expand, or has just started to expand, so there will be no problem of poor capping. After the cap 3 is installed, since the foam 9 can form a high-strength adhesive connection with the inner surface of the cap 3 after it expands, it can also ensure that the battery component 2 is stably connected to the cap 3 through the foam 9. This effectively improves the overall structural strength of the battery pack and is conducive to the overall structural design of the pack. It also helps to improve the insulation performance of the pack and the consistency of thermal management and thermal safety.

[0078] In addition, it should be noted that in the above-mentioned potting method of filling the cavity 120 with expanding foam 9 in multiple stages, there is no specific limitation on the total number of stages. The following disclosure will exemplify the filling of the cavity 120 with expanding foam 9 in two stages. That is, the cavity 120 is filled with expanding foam 9 in the first stage to form the pre-filled structure 910, and the cavity 120 is filled with expanding foam 9 in the second stage to form the post-filled structure 920. This ensures that the bonding interface between the pre-filled structure 910 and the post-filled structure 920 has high bonding strength, which effectively improves the overall structural strength of the battery pack. Of course, this disclosure is not limited to this. For example, in some other embodiments, the total number of times mentioned above can also be, for example, three or four times, and the disclosure does not specifically limit the number of times the foaming adhesive 9 is filled to form the corresponding number of pre-filled structures 910 and the corresponding number of times the foaming adhesive 9 is filled to form the corresponding number of post-filled structures 920. Those skilled in the art can make adaptive adjustments according to the total number of times. The purpose is to ensure that the bonding interface between the pre-filled structures 910 and the pre-filled structures 910, or the bonding interface between the pre-filled structures 910 and the post-filled structures 920, or the bonding interface between the post-filled structures 920 and the post-filled structures 920 all have high bonding strength, thereby improving the overall structural strength of the battery pack.

[0079] In addition, since this disclosure fills the battery pack cavity 120 with expanding foam 9 in stages, it can achieve saturated filling of various gap areas in the battery pack, improve the filling effect, and help improve the overall structural strength of the battery pack.

[0080] In some implementations, reference Figure 4 and Figure 5 As shown, the above-mentioned process of filling the receiving cavity 120 with expanding foam 9 in multiple stages to form a pre-filled structure 910 formed by at least one filling of expanding foam 9 and a post-filled structure 920 formed by at least one filling of expanding foam 9 includes: filling at least a portion of the space between the battery assembly 2 and the sidewall of the receiving cavity 120 with expanding foam 9 to form the pre-filled structure 910. Thus, by pre-filling at least a portion of the space between the battery assembly 2 and the sidewall of the receiving cavity 120 with expanding foam 9, this disclosure can effectively reduce the volume of the remaining space area in the battery pack that needs to be filled with expanding foam 9, thereby effectively shortening the filling time required for filling the amount of adhesive needed for the post-filled structure 920, reducing the problem of poor fastening of the cover 3, improving the feasibility and process stability of the overall battery pack filling design, effectively improving the overall structural strength of the battery pack, and facilitating the overall structural design of the pack.

[0081] For example, such as Figure 4 and Figure 5 As shown, the battery assembly 2 may include a battery cell 210, and the receiving cavity 120 has a first direction (see reference). Figure 4 The first cavity 121 (located at least at one end of the battery assembly 2 in the left-right direction of the middle drawing) has a pre-filled structure 910 located at least partially within the first cavity 121 to achieve the purpose of pre-filling. This can effectively reduce the volume of the remaining space area in the battery pack that needs to be filled with foam 9, effectively shorten the filling time required for the amount of glue needed for the filling structure 920 after filling, and reduce the problem of poor fastening of the cover 3.

[0082] Additionally, in some implementations, references Figure 4 As shown, the receiving cavity 120 may have a second direction (see reference). Figure 4 The third cavity 123 (located at at least one end of the battery assembly 2 in the vertical direction of the middle figure) and the volume of the first cavity 121 is larger than the volume of the third cavity 123. In this way, by pre-filling the relatively large first cavity 121 with glue, the volume of the remaining space area in the battery pack that needs to be filled with foam 9 can be effectively reduced, so as to effectively shorten the glue filling time required for the glue amount of the potting structure 920 after filling, and reduce the problem of poor fastening of the cover 3.

[0083] It should be noted that the battery assembly 2 can be placed in the receiving cavity 120 of the housing 1, for example, upright or inverted. Figure 4 The illustration exemplarily shows that after the battery assembly 2 and the housing 1 are assembled, the receiving cavity 120 can be formed with two first cavities 121 located at opposite ends of the battery assembly 2 along a first direction, i.e., as shown in the example. Figure 4 The diagram shows a front cavity 7 on the left and a rear cavity 10 on the right. The receiving cavity 120 also forms two third cavities 123 located at opposite ends of the battery assembly 2 along a second direction, i.e., as shown... Figure 4 As shown, the slit area on the side of the battery assembly 2 has a larger volume of space requiring foam filling in the two first cavities 121 (e.g., the front cavity 7 and the rear cavity 10) compared to the two third cavities 123 (e.g., the slit area on the side of the battery assembly 2). Therefore, pre-filling the two larger spaces requiring foam filling in the front cavity 7 and the rear cavity 10 can effectively reduce the remaining volume of space requiring foam filling in the battery pack. This effectively shortens the filling time required for the amount of glue needed for the encapsulation structure 920 after filling, reduces the problem of poor cover 3 fastening, improves the feasibility and process stability of the overall battery pack encapsulation design, effectively improves the overall structural strength of the battery pack, and is beneficial to the overall structural design of the pack.

[0084] Furthermore, considering that during the pre-filling operation in the two first cavities 121, since the expanding foam 9 is usually a fluid liquid when injected into the first cavity 121 and before it expands, in order to reduce the possibility of abnormal flow of the expanding foam 9 to other areas (such as the second cavity 122 between the battery assembly 2 and the cover 3), in some embodiments, in the height direction of the battery pack (which can be referred to as perpendicular to the height direction), the expanding foam 9 is used to fill the two first cavities 121. Figure 4 In the direction shown in the diagram, the highest point of the top surface of the pre-filled structure 910 is located below the top of the battery cell 210, or the highest point of the top surface of the pre-filled structure 910 is flush with the top of the battery cell 210. This reduces the problem of abnormal flow of adhesive to other areas, ensures uniform distribution of adhesive, and improves the filling effect. The top of the battery cell 210 can be understood as the top wall surface of the cell's casing in the height direction of the battery pack. Figure 5 As shown, the distance between the top / top wall of the battery cell 210 and the inner wall of the receiving cavity 120 is H (or can be understood as the dimension H of the battery cell 210 in the height direction, which will be described below).

[0085] Furthermore, considering that in order to better achieve multi-stage potting and shorten the potting time for, for example, the final potting, in some embodiments, the lowest point of the top surface of the pre-potting structure 910 is aligned with the top of the battery cell 210 in the height direction of the battery pack (refer to perpendicular to). Figure 4 Direction or reference of the drawing Figure 5 The distance in the vertical direction of the drawing can be h, and the distance of the battery unit 210 in the height direction of the battery pack (which can be referenced to the direction perpendicular to the height of the battery pack) can be h. Figure 4 Direction or reference of the drawing Figure 5 The dimension in the vertical direction of the drawing can be H, h≤H*1 / 2. By controlling the position of the lowest point of the top surface of the pre-filled structure, it is possible to achieve multi-stage filling, thereby shortening the filling time for the last filling, improving the feasibility and process stability of the battery pack filling design, effectively improving the structural strength of the battery pack and facilitating the structural design of the entire pack.

[0086] In addition, in some embodiments, the dimension of the receiving cavity 120 in the height direction of the battery pack can be H', and the height of the highest or lowest point of the top surface of the pre-filled structure 910 relative to the inner bottom surface of the receiving cavity 120 is L, where L≥H'*1 / 3. In this way, after the pre-filling operation, the volume of the remaining space area in the battery pack that needs to be filled with foam 9 can be effectively reduced, so as to effectively shorten the filling time required for the amount of glue in the filling structure 920 after filling.

[0087] For example, in some embodiments, since the dimension of the battery cell 210 of the battery assembly 2 in the height direction of the battery pack is H, it is possible to make H'*1 / 2 < L < H to facilitate on-site potting operations and effectively shorten the potting time required for the amount of adhesive needed for the potting structure 920 after filling. Furthermore, for the structural and lightweight design of the entire battery pack, in some embodiments, when the dimension of the battery cell 210 of the battery assembly 2 in the height direction of the battery pack is H, it is possible to make H ≥ H'*2 / 3 to facilitate the structural and lightweight design of the entire battery pack.

[0088] In addition, considering the fluidity of the adhesive, if there is a large depression on the top surface of the pre-filled structure 910 when filling the adhesive above the pre-filled structure 910, the adhesive will flow into the depression, causing the adhesive to accumulate and resulting in poor uniform distribution of the adhesive. When the adhesive is foaming adhesive 9, after the foaming adhesive 9 expands to form part of the post-filled structure 920, the top surface of this part of the post-filled structure 920 will be more uneven, thereby reducing the bonding area between the post-filled structure 920 and the cover 3. Therefore, in the embodiments provided in this disclosure, the distance between the highest and lowest points of the top surface of the pre-filled structure 910 in the height direction can be less than a preset distance. For example, the preset distance can be 10mm or 15mm. This allows the flatness of the top surface of the pre-filled structure 910 to meet the requirements, thereby reducing the flow of adhesive when filling the top surface of the pre-filled structure 910 and improving the uniform distribution of adhesive. This allows the adhesive to expand and form a portion of the post-filled structure 920, increasing the bonding area between the portion of the post-filled structure 920 and the cover 3, ensuring a high bonding strength at the bonding interface between the pre-filled structure 910 and the post-filled structure 920, and improving the overall structural strength of the battery pack.

[0089] In some embodiments, filling at least a portion of the space between the battery assembly 2 and the sidewall of the receiving cavity 120 with expanding foam 9 to form a pre-filled structure 910 includes filling the space with expanding foam 9 along a first preset trajectory. Thus, by controlling the outlet of a filling device, for example, to follow the first preset trajectory, the filling is achieved to form the pre-filled structure 910, which facilitates operation.

[0090] In this disclosure, the specific trajectory of the first preset trajectory is not specifically limited. Those skilled in the art can design it adaptively according to actual application needs. For example, the glue-filling operation of the receiving cavity 120 can be achieved by controlling the robotic arm of the glue-filling equipment along the first preset trajectory, which is a straight line, to form the aforementioned pre-filled structure 910. That is, it can be understood that, as Figure 4 As shown, the dispensing nozzle of the potting equipment can follow a straight trajectory (e.g., along...). Figure 4 The drawing (from top to bottom or bottom to top) can respectively realize the pre-filling operation of the two first cavities 121 (e.g., the front cavity 7 and the rear cavity 10) that need to be filled with expanding foam 9. Furthermore, the pre-filling operation along a straight trajectory can also reduce the problem of uneven distribution of the glue and improve the filling effect.

[0091] Additionally, in some implementations, references Figure 4As shown, the battery pack may also include a second sealing structure 6, which is used to divide at least a portion of the space into multiple sub-filling cavities 124. The multiple sub-filling cavities 124 are arranged at intervals along a first preset trajectory, which helps to improve the uniformity of adhesive distribution in the area of ​​each sub-filling cavity 124. This ensures the high uniformity of the foam 9 after expansion, so as to ensure that the bonding interface between the pre-filling structure 910 and the post-filling structure 920 has a high bonding strength.

[0092] Furthermore, the aforementioned pre-filled structure 910 is formed by the free expansion of the foam 9 (for example, by allowing the foam 9 to automatically expand in an open space to reach its maximum volume and then solidify, thereby forming the aforementioned pre-filled structure 910). In this way, compared with the method of limiting the expansion by the upper mold, the bonding strength at the bonding interface formed by the foam 9 in multiple operations is higher and it is easier to carry out continuous production on site. This is because the method of limiting the expansion by the upper mold controls the expansion height of the foam 9. The disadvantage is that demolding is required. Before demolding, the foam 9 needs to be cured to a certain strength, which requires several hours of curing time, which is not conducive to continuous production. In addition, in order to facilitate the demolding operation, a release agent needs to be placed between the foam 9 and the mold, which will result in the bonding strength of the foam interface formed after demolding being lower than that of the foam interface formed by the free expansion method.

[0093] In addition, in some embodiments, before filling at least a portion of the space with expanding foam 9 along the first preset trajectory, the process may include: test-running the dispensing equipment along the first preset trajectory. For example, the first preset trajectory and the moving speed of the dispensing equipment's outlet can be adjusted. During the test run, the dispensing equipment may not dispense any foam. This way, after ensuring that the trajectory parameters and moving speed are correct, the pre-filling operation can be carried out formally. This helps to control the dispensing equipment to perform the filling operation in the first cavity 121 according to the predetermined first preset trajectory and the moving speed of the dispensing equipment's outlet.

[0094] In some implementations, reference Figure 4 and Figure 5As shown, the accommodation cavity 120 may include a second cavity 122 located between the battery assembly 2 and the cover body 3 and between adjacent battery cells 210 in the battery assembly 2. The post-potting structure 920 includes a first post-potting structure 921 located in the second cavity 122. The above-mentioned method of filling the foaming glue 9 into the accommodation cavity 120 in multiple times to form a pre-potting structure 910 formed by at least one filling of the foaming glue 9 and a post-potting structure 920 formed by at least one filling of the foaming glue 9 includes: filling the foaming glue 9 into the second cavity 122 along a second preset trajectory 4 to form the first post-potting structure 921. In this way, by controlling the glue outlet of, for example, a potting device to move along the second preset trajectory 4 to perform glue filling to form the above-mentioned first post-potting structure 921, it is convenient for operation.

[0095] Among them, Figure 3 FIG. exemplarily shows the arrangement of multiple battery cells 210 of the battery assembly 2. That is, the battery assembly 2 may include multiple groups of battery cells 210 arranged side by side along the length direction of the battery cell 210. Each group of battery cells 210 includes multiple battery cells 210 arranged side by side along the thickness direction of the battery cell 210. The length direction of each battery cell 210 is parallel to the above-mentioned first direction, the thickness direction of the battery cell 210 is parallel to the above-mentioned second direction, and the height direction of the battery cell 210 is parallel to the height direction of the battery pack. In this embodiment, the battery cell 210 is a battery monomer, also known as an electric core, which is the smallest discharge power source in the battery pack and includes a positive and negative isolation film and an electric core housing, etc.

[0096] Of course, the specific embodiments of the above-mentioned battery assembly 2 are exemplary. In some other embodiments, the multiple battery cells 210 of the battery assembly 2 may also be arranged in, for example, Figure 8 the manner shown. That is, the battery assembly 2 may include multiple groups of battery cells 210 arranged side by side along the length direction of the battery cell 210. Each group of battery cells 210 includes multiple battery cells 210 arranged side by side along the height direction of the battery cell 210, and multiple groups of battery cells 210 may be stacked along the height direction of the battery pack. Among them, the length direction of each battery cell 210 is parallel to the above-mentioned first direction, the thickness direction of the battery cell 210 is parallel to the height direction of the battery pack, and the height direction of the battery cell 210 is parallel to the above-mentioned second direction. In this embodiment, the battery cell 210 is a battery monomer, also known as an electric core, which is the smallest discharge power source in the battery pack and includes a positive and negative isolation film and an electric core housing, etc.

[0097] Or, in some other embodiments, the battery assembly 2 may also include multiple battery cells 210 arranged side by side along the above-mentioned first direction and / or the above-mentioned second direction. Among them, referring to Figure 9 FIG., each battery cell 210 is configured as a blade battery monomer, or, referring to Figure 10As shown, each battery cell 210 is constructed as a battery module 280, and each battery module 280 is constructed as including a housing and multiple battery cells disposed within the housing. A battery cell, also known as a battery cell, is the smallest discharge power source in the battery pack. It includes positive and negative electrode separators and a cell housing, etc. This disclosure does not specifically limit the above-mentioned modifications. Those skilled in the art can adaptively design the specific arrangement of the battery assembly 2 according to actual application requirements.

[0098] In some embodiments, the potting method for the battery pack further includes: determining a second preset trajectory 4 based on the arrangement of the battery cells 210 of the battery assembly 2. This disclosure exemplarily uses... Figure 3 The arrangement of the battery cells 210 in the battery assembly 2 shown in the figure is described exemplarily as follows:

[0099] For example, it can be along Figure 6 The second preset trajectory 4 shown in the figure is used for the glue pouring operation, for example, as follows: Figure 6 As shown, the second preset trajectory 4 may include a first main trajectory 410 and a first turning trajectory 420. Multiple first main trajectories 410 extend along the thickness direction of the battery unit 210 and are arranged side by side along the length direction of the battery unit 210. Adjacent first main trajectories 410 are connected by the first turning trajectory 420, so that the second preset trajectory 4 forms a serpentine trajectory.

[0100] Therefore, the specific arrangement of the second preset trajectory 4 is determined based on the arrangement of the battery cells 210 in the battery assembly 2, and the dispensing port of the dispensing equipment is controlled to perform dispensing operation along the second preset trajectory 4. Specifically, as follows: Figures 3 to 6As shown, since there is a first gap 250 between two adjacent battery cells 210 spaced along the length direction, the first gap 250 forms a partial second cavity 122. The first gap 250 extends along the thickness direction. In addition, the upper surface of the battery cell 210 is provided with a terminal post 211 and a surface area 212 adjacent to the terminal post 211. The battery assembly 2 includes a busbar assembly 220 located above the battery cell 210. There is a second gap 260 between the busbar assembly 220 and the cover 3, and a third gap 270 between the busbar assembly 220 and the battery cell 210. The busbar assembly 220 has a connection to the second gap 260. The glue injection port 221 of the first gap 250 and the third gap 270 are used to achieve saturated glue filling in the second cavity 122 formed by the first gap 250, the pole post 211 and the surface area 212 adjacent to the pole post 211, the second gap 260 and the third gap 270, etc., so that at least one first main trajectory 410 passes through the first gap 250, at least one first main trajectory 410 passes through the surface area 212, at least one first main trajectory 410 passes through the pole post 211, and at least one first main trajectory 410 passes through the glue injection port 221, so as to achieve the purpose of saturated glue filling in the second cavity 122.

[0101] Alternatively, in an alternative implementation, for ease of distinction... Figure 6 and Figure 7 The movement trajectory in the second preset trajectory 4 is in Figure 7 The middle can also be represented by the fourth preset trajectory 8. When filling the second cavity 122 with expanding foam 9, the dispensing nozzle edge of the dispensing device can be controlled. Figure 7 The fourth preset trajectory 8 shown in the figure is used for potting operation, wherein the second main trajectory 810 of the fourth preset trajectory 8 extends along the length direction of the battery cell 210 and along the thickness direction of the battery cell 210 (see reference). Figure 4 The two main trajectories 810 are arranged side by side in the vertical direction of the middle map, and adjacent two main trajectories 810 are connected by a second turning trajectory 820.

[0102] It should be noted that, due to the arrangement of the battery cells 210 in the aforementioned battery assembly 2, i.e., as shown... Figure 3 and Figure 4 As shown, at the dispensing port of the dispensing equipment... Figure 7When the fourth preset trajectory 8 shown in the figure performs the above-mentioned glue filling operation, the second main trajectory 810 will pass through, for example, the pole 211, the surface area 212, the first gap 250 and the glue injection port 221 in sequence. However, since the gap areas formed by different structures are all different in size, by controlling the glue outlet of the glue filling device to perform the above-mentioned glue filling operation along the fourth preset trajectory 8, it is easy to cause some areas to be unable to be saturated and other areas to have too much glue. In addition, if it is necessary to control the glue outlet of the glue filling device to run along a single second main trajectory 810 and continuously adjust the running speed and glue volume, which greatly increases the design difficulty of the glue filling process and / or the glue filling trajectory.

[0103] At the dispensing port of the dispensing equipment Figure 6 When the second preset trajectory 4 shown in the figure performs the above-mentioned glue filling operation, since a single trajectory of the first main trajectory 410 passes through multiple electrode posts 211 arranged side by side along the thickness direction of the battery cell 210, or multiple surface areas 212 arranged side by side, or multiple first gaps 250 arranged side by side, or multiple glue inlets 221 arranged side by side, it is possible to achieve saturated filling of glue in the gap areas under the same structure arranged side by side. Moreover, since they are all the same structure, the overall repeatability is better. This makes the glue outlet of the glue filling equipment run along a single first main trajectory 410. The control of the rate and dispensing volume is also simpler and does not require adjustment, reducing the difficulty of operating the dispensing equipment and the design difficulty of the dispensing process and / or dispensing trajectory. Therefore, this disclosure determines the dispensing port of the dispensing equipment to perform the above-mentioned dispensing operation along the second preset trajectory 4 by combining the arrangement of the battery cells 210 of the battery assembly 2. Since the surface features of the same structural area traversed by the single trajectory of the first main trajectory 410 have better overall repeatability, it is possible to achieve saturation filling in the second cavity 122, realize effective potting in narrow gaps, and improve the potting effect.

[0104] Furthermore, it should be noted that by decomposing the total filling time of the expanding foam 9 into the second cavity 122 along the second preset trajectory 4 into specific single filling trajectories and times on each row or column of battery components 2 of the second preset trajectory 4, it can be understood that the multiple first main trajectories 410 of the second preset trajectory 4 can be designed to be of equal length and equal filling time, or they can be designed to be of unequal length and different filling times, and the filling trajectory can even be a straight line or an arc; similarly, the length and time of the multiple first turning trajectories 420 of the second preset trajectory 4 can also be adjusted as needed, generally 0.1 to 0.5 seconds. The determining factors are the filling flow rate of the dispensing port of the filling equipment and the flow and spreading ability of the filling adhesive under the actual viscosity state, so as to achieve saturated filling of the second cavity 122, realize effective filling in narrow gaps, and improve the filling effect.

[0105] In addition, such as Figure 6 As shown, each column of the first main trajectory 410 of the second preset trajectory 4 will pass through, for example, pole post 211, surface area 212, first gap 250, and injection port 221. However, since the size of the gap area formed by the surface features at different structural areas is different, the length of each column of the first main trajectory 410 is designed to be the same, but the potting time of each column of the first main trajectory 410 is different. The specific potting time depends on the volume of expanding foam that needs to be filled in the gap area formed by the surface features at the corresponding structural area passed by the corresponding first main trajectory 410. For example, in this disclosure, the trajectory passing through the glue injection port 221 and the first gap 250 among the multiple first main trajectories 410 has the longest potting time, so as to saturate the third gap 270 and the first gap 250; while the length and running time of the multiple first turning trajectories 420 on the surface of each row of battery cells 210 are specifically designed according to the volume required to fill the local area, and may be different. However, from the perspective of the entire row of battery cells 210, since the surface state of each row of battery cells 210 is basically the same, the design of the multiple first turning trajectories 420 may be the same.

[0106] The specific structure of the busbar assembly 220 is not specifically limited in this disclosure. For example, any CCS (Cells Contact System) integrated busbar structure known in the art can be used, such as a plastic bracket, a busbar metal busbar, an FPC / NTC sampling component, etc. This disclosure does not specifically limit it. Those skilled in the art can adaptably design and wrap the weak components of the busbar assembly 220, such as the NTC temperature sensing and sampling solder joints, with foam 9 according to actual application needs, so as to achieve saturated filling of all gap areas between the busbar assembly 220 and the battery cell 210. At the same time, the foam 9 has a sufficient area to contact the inner side of the cover 3 and form structural strength, so as to realize the overall structural design of the battery pack.

[0107] Furthermore, during the actual potting process, when controlling the dispensing nozzle of the potting equipment to perform potting operations along the second preset trajectory 4, due to the unevenness of the surface of the busbar assembly 220 and the different spaces below the busbar assembly 220, the spread width of different single-trajectory potting adhesives on the surface of the busbar assembly 220 is very limited. According to the actual measurement results of single-trajectory potting with different potting flow rates of the potting equipment, the width of the busbar assembly 220 covered by a single trajectory is only the length of the upper surface of the corresponding battery unit 210 (for reference). Figure 4The upper surface of the busbar assembly 220 is to be covered with adhesive liquid, which is 1 / 6 to 1 / 3 of the left and right sides of the middle drawing. The number of turns on each row of battery cells 210 is 2 to 5, and the number of turns of the entire battery assembly 2 can reach dozens. Because the precise calculation of the glue-filling trajectory time is concentrated on multiple first main trajectories 410, the time of multiple first turning trajectories 420 is usually designed to be as short as possible to reduce the adverse effects of additional turning on the overall pack sealing. According to the precision of the glue-filling equipment program settings, the turning time is usually designed to be 0.1 to 0.2 seconds. However, in the actual glue-filling process, due to the weight of the glue-filling equipment's robotic arm and the inertia of its operation, each turning actually involves two changes in direction and two accelerations and decelerations. The actual turning time of the robotic arm is much greater than 0.2 seconds, and the measured time is close to 0.4 to 1 second. In addition, the upper surface of the entire battery pack 2 has a large number of turnings, resulting in the actual glue amount being significantly more than the designed glue amount. Moreover, the excess glue is concentrated at both ends of multiple first main trajectories 410. Such abnormal accumulation of glue will affect the problem of the battery pack cover 3 not being securely fastened.

[0108] To address the issue of adhesive concentration at both ends of multiple first main trajectories 410, in some embodiments, reference is made to... Figure 6 As shown, the first main trajectory 410 has a first end 411 and a second end 412. The battery assembly 2 has a first sidewall 230 adjacent to the first end 411 and a second sidewall 240 adjacent to the second end 412 along the thickness direction. There is a first preset distance between the first end 411 and the first sidewall 230, and a second preset distance between the second end 412 and the second sidewall 240. The values ​​of the first preset distance and the second preset distance are determined based on the difference between the actual running time of the dispensing port of the dispensing equipment at the first turning trajectory 420 and the set running time. For example, the thickness of the battery cell 210 is D, and the value of the first preset distance and the second preset distance is D', where D' ≥ D*1 / 2, and D... '≤3D, so the first main trajectory 410 above the battery assembly 2 is designed to be optimized inward at the turning point along the thickness direction of the battery cell 210 by a certain distance, that is, optimized to the value D' of the first preset distance and the second preset distance, and D'≥D*1 / 2, and D'≤3D. In this way, when the foaming adhesive 9 is sprayed from the dispensing port of the potting equipment, it has inertia along the thickness direction of the battery cell 210 to achieve a uniform spreading effect of the foaming adhesive 9 above the battery assembly 2. This solves the problem that the actual running time of the potting equipment when turning along the second preset trajectory 4 is much longer than the set time, which increases the running time of the trajectory at the turning point, resulting in an abnormal increase in adhesive and accumulation at both ends of multiple first main trajectories 410.

[0109] In addition, after determining the values ​​of the first preset distance and the second preset distance as described above, the potting method for the battery pack further includes: calibrating the values ​​of the first preset distance and the second preset distance based on flow field simulation and / or experimental design, in order to verify the feasibility of the first preset distance and the second preset distance.

[0110] Based on the above description, the reason why the actual amount of glue applied is significantly more than the designed amount, and the excess glue is concentrated at both ends of multiple first main trajectories 410, causing the abnormally accumulated glue to affect the secure fastening of the battery pack cover, is that the robotic arm of the potting equipment spends more time at the actual first turning trajectory 420 than the designed value. In order to solve the above problem, this disclosure uses the designed trajectory program to run without glue and analyzes it using stopwatches or slow-motion video, etc., to accurately calculate each trajectory, especially to accurately collect the actual running time at each first turning trajectory 420 position, and compare it with the designed value of each glue-applying trajectory.

[0111] The difference between the actual running time and the design time of each trajectory has two manifestations: Specifically, there is a deviation between the actual running time and the design time of the first main trajectory 410. Usually, the linear speed of the robotic arm is as high as several meters per second. The design running speed of a single first main trajectory 410 will not exceed the speed limit of the robotic arm. Therefore, by adjusting the trajectory setting time in the robotic arm's running program, calculating the corresponding actual running time, and iterating and verifying repeatedly, it is possible to finally make the actual running time of each first main trajectory 410 consistent with the design potting time calculated by the glue volume.

[0112] In addition, regarding the position of the first turning trajectory 420, there is a minimum value for the actual turning time of this local area. This minimum value is related to the weight of the robotic arm and the drive motor, and is usually in the range of 0.4s to 1s. It is usually significantly longer than the designed turning time. In order to solve the problem that the actual turning time of this local area at the position of the first turning trajectory 420 is longer than the designed turning time, this disclosure calculates the actual trajectory running time of each position of the first turning trajectory 420 and takes its average value. Based on the actual running time of each first turning trajectory 420, the glue-filling trajectory parameters on the upper surface of each column or row of battery units 210 are recalibrated. In this disclosure, when performing glue-filling operation along the second preset trajectory 4, the part of the actual running time of each first turning trajectory 420 that is longer than the designed time is divided into two equal parts and subtracted from the time of the adjacent first main trajectory 410. At the same time, the length of the first main trajectory 410 is shortened accordingly by the length corresponding to the time subtraction.

[0113] Furthermore, in actual operation, the inertia of the adhesive after leaving the robotic arm must be considered. This inertia will promote the spread of the adhesive along the thickness direction of the battery cell 210. This effect can be summarized through flow field simulation or DOE verification of the battery module 2. This effect data is superimposed on the theoretical turning position trajectory parameters after the above calculation correction to obtain the second preset trajectory 4 above the battery module 2, which can ensure that the foamed adhesive is evenly spread on the upper surface of the battery module 2. After multiple rounds of simulation optimization and superposition test verification, under the parameters of conventional potting equipment, designing the first main trajectory 410 above the battery module 2 at the turning point and optimizing it inward along the thickness direction of the battery cell 210 by a certain distance, that is, optimizing it to the value D' of the first preset distance and the second preset distance mentioned above, and D'≥D*1 / 2 and D'≤3D, can solve the problem of adhesive accumulation at the edge of the battery module 2 and uneven distribution of adhesive.

[0114] In some implementations, reference Figure 4 and Figure 5 As shown, the pre-filled structure 910 is located within the first cavity 121, and the post-filled structure 920 includes a second post-filled structure 922 located within the third cavity 123 and above the pre-filled structure 910. The process of filling the receiving cavity 120 with expanding foam 9 in multiple stages to form the pre-filled structure 910 formed by at least one filling of expanding foam 9 and the post-filled structure 920 formed by at least one filling of expanding foam 9 further includes: filling the first cavity 121 and the third cavity 123 along a third preset trajectory to form the second post-filled structure 922. Thus, through the above-mentioned process along the second preset trajectory 4... Filling the second cavity 122 with expanding foam 9 to form the first post-filling structure 921, and filling the first cavity 121 and the third cavity 123 with expanding foam 9 along the third preset trajectory to form the second post-filling structure 922, can achieve saturated filling of the area above and around the battery assembly 2. This helps to ensure that the battery assembly 2 is stably connected to the cover 3 through the post-filling structure 920 formed by the first post-filling structure 921 and the second post-filling structure 922. This effectively improves the overall structural strength of the battery pack and is conducive to the structural design of the entire pack, thus promoting the structuralization process of the battery pack.

[0115] The bonding area between the post-filling structure 920 and the cover 3 accounts for more than 90% of the inner wall surface of the cover 3, and the bonding strength of the post-filling structure 920 is greater than 0.7MPa, so as to ensure that the battery assembly 2 is stably connected to the cover 3 through the post-filling structure 920.

[0116] Additionally, it should be noted that, in order to reduce the abnormal flow of adhesive to other areas, in some implementations, such as... Figure 4As shown, the battery pack may also include a first sealing structure 5, which is used to separate the first cavity 121, the second cavity 122 and the third cavity 123, thereby reducing the abnormal flow of adhesive between the first cavity 121, the second cavity 122 and the third cavity 123 before it expands and solidifies, ensuring uniform distribution of adhesive and improving the potting effect.

[0117] Furthermore, in some implementations, such as Figure 4 As shown, the battery pack may also include a second sealing structure 6, which is used to divide at least a portion of the first cavity 121 and / or at least a portion of the third cavity 123 into a plurality of sub-filling cavities 124, so as to further improve the uniformity of the distribution of the adhesive in the first cavity 121 and the third cavity 123, improve the consistency of the foamed adhesive 9 after foaming, and improve the repeatability of industrial production.

[0118] This disclosure does not specifically limit the specific structure of the first sealing structure 5 and the second sealing structure 6. For example, they can be foam or rubber blocks, etc. The purpose is to separate the first cavity 121, the second cavity 122, and the third cavity 123, and to divide the first cavity 121 and the third cavity 123 into multiple sub-filling cavities. In addition, this disclosure does not specifically limit the specific number of the first sealing structure 5 and the second sealing structure 6, which are constructed as, for example, adhesive-blocking foam or adhesive-blocking rubber blocks. Those skilled in the art can adaptively design the specific number of adhesive-blocking foam or adhesive-blocking rubber blocks according to actual application needs.

[0119] In some embodiments, the aforementioned third preset trajectory can be a ring-shaped trajectory extending circumferentially around the battery assembly 2, enabling the potting operation at the first cavity 121 above the third cavity 123 and the remaining unfilled expanding foam 9 above the pre-filled structure 910. This ring-shaped trajectory can include, but is not limited to, a circular trajectory, a rectangular trajectory, an elliptical trajectory, or any irregular circumferentially closed trajectory.

[0120] Furthermore, the above-mentioned potting method for the battery pack further includes: after filling the second cavity 122 with expanding foam 9 along the second preset trajectory 4, filling the first cavity 121 and the third cavity 123 with expanding foam 9 along the third preset trajectory. It should be noted that the expansion speed of the expanding foam 9 is greatly affected by temperature; the higher the temperature, the faster the expansion speed. In this embodiment, since the area where the second cavity 122 is located is along... Figure 4The expansion area in the X and Y directions is relatively large. After the expansion foam 9 is filled into the second cavity 122, the expansion area of ​​the expansion foam 9 is also relatively large, resulting in a larger heat dissipation area in contact with the air. In addition, the gap between the battery assembly 2 and the cover 3 is reduced, and the amount of expansion foam 9 between the battery assembly 2 and the cover 3 is also less, resulting in less heat accumulation. Compared with the second cavity 122, the area where the first cavity 121 and the third cavity 123 are located along the X and Y directions is larger. Figure 4 The X and Y directions have small unfolded areas but large overall volume. After filling the first cavity 121 and the third cavity 123 with expanding foam 9, a large amount of expanding foam 9 accumulates in the first cavity 121 and the third cavity 123, which is not conducive to the heat dissipation of the expanding foam 9 and will make the internal temperature of the expanding foam 9 high. Therefore, the expanding foam 9 in the first cavity 121 and the third cavity 123 has a shorter expansion time than the expanding foam 9 in the second cavity 122. Thus, this disclosure can fill the second cavity 122 with expanding foam 9 first, and then fill the first cavity 121 and the third cavity 123 with expanding foam 9. This can make the expansion start time of the expanding foam 9 in the second cavity 122, the first cavity 121 and the third cavity 123 close or the same after filling the first cavity 121 and the third cavity 123 with expanding foam 9, thus ensuring the stability of the potting process.

[0121] Before filling the second cavity 122 with expanding foam along the second preset trajectory 4, the process may include: conducting a trial run of the dispensing equipment along the second preset trajectory 4 and the third preset trajectory. For example, the movement speed of the second preset trajectory 4, the third preset trajectory, and the dispensing equipment outlet can be adjusted. During the trial run, the dispensing equipment does not dispense any adhesive. After ensuring that the trajectory parameters and movement speed are correct, the secondary potting operation can be carried out formally. This helps to control the potting equipment to perform the potting operation on the second cavity 122, the third cavity 123, and the first cavity 121 above the pre-filled structure 910 with the remaining unfilled expanding foam 9 according to the predetermined second preset trajectory 4 and the third preset trajectory and the movement speed of the dispensing equipment outlet.

[0122] Additionally, in some embodiments, the potting method for the battery pack may include: after the foam 9 forming the pre-potting structure 910 has expanded to its maximum volume, filling the first cavity 121 and the third cavity 123 with the foam 9 along a third preset trajectory. For example, the field operator may start filling the first cavity 121 and the third cavity 123 with the foam 9 forming the pre-potting structure 910 after it has expanded to its maximum volume, and before the top surface of the pre-potting structure 910 is surface dry (where surface dry can be understood as the adhesive surface of the foam 9 reaching the stage of surface drying, and not surface dry means that the adhesive surface of the foam 9 is not completely dry and has stickiness), to ensure that the bonding interface between the pre-potting structure 910 and the post-potting structure 920 has a high bonding strength.

[0123] Of course, it should be noted that on-site operators can also continue to fill the first cavity 121 and the third cavity 123 with the foam 9 after the foam 9 in the pre-filled structure 910 has expanded to its maximum volume and the top surface of the pre-filled structure 910 is surface dry (where surface dry can be understood as the bonding surface of the foam 9 has reached the stage of surface drying, and not surface dry means that the bonding surface of the foam 9 is not completely dry and has stickiness) along the third preset trajectory. This disclosure does not specifically limit such deformation mode, and those skilled in the art can design it adaptively according to actual application needs.

[0124] In some embodiments, an adhesive may be added at the bonding interface between the pre-filled structure 910 and the post-filled structure 920 to improve the bonding strength at the bonding interface between the pre-filled structure 910 and the post-filled structure 920.

[0125] Additionally, it should be noted that after the foam 9 forming the pre-filled structure 910 expands to its maximum volume, the operator can immediately fill the second cavity 122 with the foam 9 along the second preset trajectory 4 to form the first post-filled structure 921. Alternatively, the operator can adaptably perform a filling operation, for example, in the second cavity 122 between the battery assembly 2 and the cover 3, before the foam 9 of the pre-filled structure 910 expands to its maximum volume to form the first post-filled structure 921 (described in detail below). At this time, the foam 9 in the first cavity 121 continues to expand. After the filling operation in the second cavity 122 is completed, the foam 9 in the first cavity 121 expands to its maximum volume, and the cavity 120 can continue to be filled with foam to form the second post-filled structure 922 (described in detail below). This helps to save the production time of the entire battery pack on site and improve production efficiency.

[0126] In addition, it should be noted that after the glue filling operation is completed in the second cavity 122, the third cavity 123 and the first cavity 121 above the pre-filled structure 910 where there is still no foam filling, it is usually required that the cover-closing operation be completed before the foam 9 starts to expand, or at the latest before the foam 9 starts to expand and contacts the inner wall of the cover 3, the pressure-holding fixture of the cover 3 be placed, and the sealing bolts at the connection between the cover 3 and the shell 1 be installed and tightened, etc., of the battery pack assembly process. In this way, the above-mentioned battery pack glue filling operation is completed.

[0127] This disclosure exemplarily describes a potting method for a battery pack in one embodiment.

[0128] The dispensing equipment was tested along the first preset trajectory, during which the dispensing equipment did not dispense glue.

[0129] Before the cover 3 is closed, foam 9 is filled into the two first cavities 121 along the first preset trajectory so that the foam 9 can form a pre-filled structure 910 through free expansion.

[0130] The glue dispensing equipment was tested along the second preset trajectory 4 and the third preset trajectory, during which the glue dispensing equipment did not dispense glue.

[0131] Foaming adhesive 9 is filled into the second cavity 122 along the second preset trajectory 4 to form a first post-filling structure 921. The second preset trajectory 4 is determined according to the arrangement of the battery cells 210 of the battery assembly 2. The second preset trajectory 4 includes a first main trajectory 410 and a first turning trajectory 420. Multiple first main trajectories 410 extend along the thickness direction of the battery cell 210 and are arranged side-by-side along the length direction of the battery cell 210. Adjacent first main trajectories 410 are connected by the first turning trajectory 420, so that the second preset trajectory 4 forms a serpentine trajectory. The first main trajectories 410 have relative... The battery assembly 2 has a first sidewall 230 adjacent to the first end 411 and a second sidewall 240 adjacent to the second end 412 along the thickness direction. There is a first preset distance between the first end 411 and the first sidewall 230, and a second preset distance between the second end 412 and the second sidewall 240. The values ​​of the first preset distance and the second preset distance are determined based on the difference between the actual running time of the dispensing port of the dispensing equipment at the first turning trajectory 420 and the set running time. The values ​​of the first preset distance and the second preset distance are calibrated based on flow field simulation and / or experimental design.

[0132] After the expanding foam 9 is filled into the second cavity 122 along the second preset trajectory 4, after the expanding foam 9 forming the pre-filled structure 910 has expanded to its maximum volume and before the top surface of the pre-filled structure 910 has dried, the expanding foam 9 is filled into the first cavity 121 and the third cavity 123 along the third preset trajectory to form the second post-filled structure 922.

[0133] Install the cover 3 and use the existing pressure-holding fixture to hold the pressure so that after the foam 9 has started to expand, the battery assembly 2 is connected to the cover 3 through the post-filling structure 920. Furthermore, the pre-filling structure 910 and the cover 3 are also filled and connected through the post-filling structure 920.

[0134] According to a second aspect of this disclosure, a battery pack is provided that employs the potting method provided in the first aspect above. This method solves the problem in the related art where poor fit between the cover and the battery pack housing easily occurs after the battery pack potting operation, thereby improving the feasibility and process stability of the overall battery pack potting design. Furthermore, this battery pack also possesses all the beneficial effects of the potting method for battery packs provided in the first aspect above, which will not be elaborated further here.

[0135] According to a third aspect of this disclosure, a battery pack is provided, the battery pack including a housing 1, a battery assembly 2, a cover 3, a pre-filled structure 910, and a post-filled structure 920. The housing 1 includes a receiving cavity 120 having an opening 110; the battery assembly 2 is located in the receiving cavity 120; the cover 3 closes the opening 110; the pre-filled structure 910 is formed of expanding foam 9 and is located in the receiving cavity 120; the post-filled structure 920 is formed of expanding foam 9 and is located in the receiving cavity 120, and the battery assembly 2 is connected to the cover 3 through the post-filled structure 920.

[0136] Through the above-mentioned technical solution, namely the battery pack provided in the third aspect of this disclosure, the battery pack forms a pre-filled structure 910 and a post-filled structure 920 by filling the receiving cavity 120 with foam 9 in stages, and the battery component 2 is stably connected to the cover 3 through the post-filled structure 920. This effectively improves the overall structural strength of the battery pack and is conducive to the overall structural design of the pack. It also helps to improve the insulation performance of the pack and the consistency of thermal management and thermal safety. It can reduce the problem of poor fastening between the cover and the battery pack shell after the battery pack is filled, which is common in related technologies, and improves the feasibility and process stability of the overall battery pack filling design.

[0137] In addition, since this disclosure fills the battery pack cavity 120 with expanding foam 9 in stages, it can achieve saturated filling of various gap areas in the battery pack, improve the filling effect, and help improve the overall structural strength of the battery pack.

[0138] Furthermore, it should be noted that the cover 3 of the aforementioned battery pack can also be constructed as part of the vehicle floor to achieve an integrated design between the cover 3 of the battery pack and the vehicle floor.

[0139] In some embodiments, the projection of the post-filling structure 920 in the height direction of the battery pack can cover the pre-filling structure 910, so that the battery assembly 2 can be bonded to the housing 1 through the pre-filling structure 910, the battery assembly 2 can be bonded to the cover 3 through the post-filling structure 920, and the pre-filling structure 910 and the post-filling structure 920 can be bonded together through the bonding surface of the foam 9 after it has been freely expanded. Alternatively, an adhesive can be added between the pre-filling structure 910 and the post-filling structure 920 to ensure higher connection reliability. This disclosure does not specifically limit this.

[0140] Furthermore, in some embodiments, the adhesive strength at the interface between the pre-filled structure 910 and the post-filled structure 920 is E, and the adhesive strength between the post-filled structure 920 and the cover 3 is F, where E > F. Thus, since the adhesive area between the post-filled structure 920 and the cover 3 is much larger than the adhesive interface area between the pre-filled structure 910 and the post-filled structure 920, stress concentration is more likely to occur at the adhesive interface between the pre-filled structure 910 and the post-filled structure 920 compared to the connection between the post-filled structure 920 and the cover 3. Therefore, this disclosure ensures that the adhesive strength E at the interface between the pre-filled structure 910 and the post-filled structure 920 is greater than the adhesive strength F between the post-filled structure 920 and the cover 3, thereby mitigating the adverse effects of stress concentration. Furthermore, the bonding strength E at the interface between the pre-filled structure 910 and the post-filled structure 920 is greater than the bonding strength F between the post-filled structure 920 and the cover 3. This also ensures that even if the cover 3 and the potting compound detach, the housing 1, battery assembly 2, pre-filled structure 910, post-filled structure 920, and bus assembly 220 remain a single integrated structure, effectively guaranteeing the structural stability and safety of the battery pack.

[0141] Furthermore, in some embodiments, the pull-out / shear strength at the interface between the pre-filled structure 910 and the post-filled structure 920 is A, and the pull-out / shear strength of the potting structure when the potting structure formed by the foam 9 has no interface is B, where A > 0.5B, so as to ensure that the bonding interface between the pre-filled structure 910 and the post-filled structure 920 has a high bonding strength.

[0142] Additionally, in some implementations, references Figure 4 and Figure 5 As shown, the battery assembly 2 may include a battery cell 210, and the receiving cavity 120 has a first direction (see reference). Figure 4The first cavity 121 (located at least at one end of the battery assembly 2 in the left-right direction of the middle drawing) has a pre-filled structure located at least partially within the first cavity 121 to achieve the purpose of pre-filling. This can effectively reduce the volume of the remaining space area in the battery pack that needs to be filled with foam 9, effectively shorten the filling time required for the amount of glue in the filling structure 920 after filling, and reduce the problem of poor fastening of the cover 3.

[0143] It should be noted that the battery assembly 2 can be placed in the receiving cavity 120 of the housing 1, for example, upright or inverted. Figure 4 The illustration exemplarily shows that after the battery assembly 2 and the housing 1 are assembled, the receiving cavity 120 can be formed with two first cavities 121 located at opposite ends of the battery assembly 2 along a first direction, i.e., as shown in the example. Figure 4 The diagram shows a front cavity 7 on the left and a rear cavity 10 on the right. The receiving cavity 120 also forms two third cavities 123 located at opposite ends of the battery assembly 2 along a second direction, i.e., as shown... Figure 4 As shown, the slit area on the side of the battery assembly 2 has a larger volume of space requiring foam filling in the two first cavities 121 (e.g., the front cavity 7 and the rear cavity 10) compared to the two third cavities 123 (e.g., the slit area on the side of the battery assembly 2). Therefore, pre-filling the two larger spaces requiring foam filling in the front cavity 7 and the rear cavity 10 can effectively reduce the remaining volume of space requiring foam filling in the battery pack. This effectively shortens the filling time required for the amount of glue needed for the encapsulation structure 920 after filling, reduces the problem of poor cover 3 fastening, improves the feasibility and process stability of the overall battery pack encapsulation design, effectively improves the overall structural strength of the battery pack, and is beneficial to the overall structural design of the pack.

[0144] Furthermore, considering that during the pre-filling operation in the two first cavities 121, the expanding foam 9 is typically a fluid liquid before it expands, and is in a liquid state when injected into the first cavity 121. Therefore, in order to reduce abnormal flow of the expanding foam 9 to other areas (e.g., the second cavity 122 between the battery assembly 2 and the cover 3), in some embodiments, in the height direction of the battery pack (which can be referred to as perpendicular to...), Figure 4 Direction or reference of the drawing Figure 5 In the vertical direction of the drawing, the highest point of the top surface of the pre-filled structure 910 is located below the top of the battery cell 210, or the highest point of the top surface of the pre-filled structure 910 is flush with the top of the battery cell 210, which reduces the problem of abnormal flow of adhesive to other areas, ensures uniform distribution of adhesive, and improves the potting effect.

[0145] Furthermore, considering that in order to better achieve multi-stage potting and shorten the potting time for, for example, the final potting, in some embodiments, the lowest point of the top surface of the pre-potting structure 910 is aligned with the top of the battery cell 210 in the height direction of the battery pack (refer to perpendicular to). Figure 4 Direction or reference of the drawing Figure 5 The distance in the vertical direction of the drawing can be h, and the distance of the battery unit 210 in the height direction of the battery pack (which can be referenced to the direction perpendicular to the height of the battery pack) can be h. Figure 4 Direction or reference of the drawing Figure 5 The dimension in the vertical direction of the drawing can be H, h≤H*1 / 2. By controlling the position of the lowest point of the top surface of the pre-filled structure, it is possible to achieve multi-stage filling, thereby shortening the filling time for the last filling, improving the feasibility and process stability of the battery pack filling design, effectively improving the structural strength of the battery pack and facilitating the structural design of the entire pack.

[0146] In addition, in some embodiments, the dimension of the receiving cavity 120 in the height direction of the battery pack can be H', and the height of the highest or lowest point of the top surface of the pre-filled structure 910 relative to the inner bottom surface of the receiving cavity 120 is L, where L≥H'*1 / 3. In this way, after the pre-filling operation, the volume of the remaining space area in the battery pack that needs to be filled with foam 9 can be effectively reduced, so as to effectively shorten the filling time required for the amount of glue in the filling structure 920 after filling.

[0147] For example, in some embodiments, since the dimension of the battery cell 210 of the battery assembly 2 in the height direction of the battery pack is H, it is possible to make H'*1 / 2 < L < H to facilitate on-site potting operations and effectively shorten the potting time required for the amount of adhesive needed for the potting structure 920 after filling. Furthermore, for the structural and lightweight design of the entire battery pack, in some embodiments, when the dimension of the battery cell 210 of the battery assembly 2 in the height direction of the battery pack is H, it is possible to make H ≥ H'*2 / 3 to facilitate the structural and lightweight design of the entire battery pack.

[0148] In addition, considering the fluidity of the adhesive, if there is a large depression on the top surface of the pre-filled structure 910 when filling the adhesive above the pre-filled structure 910, the adhesive will flow into the depression, causing the adhesive to accumulate and resulting in poor uniform distribution of the adhesive. When the adhesive is foaming adhesive 9, after the foaming adhesive 9 expands to form part of the post-filled structure 920, the top surface of this part of the post-filled structure 920 will be more uneven, thereby reducing the bonding area between the post-filled structure 920 and the cover 3. Therefore, in the embodiments provided in this disclosure, the distance between the highest and lowest points of the top surface of the pre-filled structure 910 in the height direction can be less than a preset distance. For example, the preset distance can be 10mm or 15mm. This allows the flatness of the top surface of the pre-filled structure 910 to meet the requirements, thereby reducing the flow of adhesive when filling the top surface of the pre-filled structure 910 and improving the uniform distribution of adhesive. This allows the adhesive to expand and form a portion of the post-filled structure 920, increasing the bonding area between the portion of the post-filled structure 920 and the cover 3, ensuring a high bonding strength at the bonding interface between the pre-filled structure 910 and the post-filled structure 920, and improving the overall structural strength of the battery pack.

[0149] Additionally, in some implementations, references Figure 4 and Figure 5 As shown, the receiving cavity 120 may include a second cavity 122 located between the battery assembly 2 and the cover 3 and between adjacent battery cells 210 in the battery assembly 2, and a third cavity 123 located at at least one end of the battery cell 210 along the second direction. The post-filling structure 920 includes a first post-filling structure 921 located in the second cavity 122, and a second post-filling structure 922 located in the third cavity 123 and above the pre-filling structure 910. In this way, the first post-filling structure 921 and the second post-filling structure 922 can achieve saturated filling of the area above and around the battery assembly 2 (the first cavity 121 above the third cavity 123 and the pre-filling structure 910 where the remaining unfilled foam 9 is located). This helps to ensure that the battery assembly 2 is stably connected to the cover 3 by the post-filling structure 920 formed by the first post-filling structure 921 and the second post-filling structure 922, effectively improving the overall structural strength of the battery pack and facilitating the overall structural design of the pack.

[0150] Furthermore, in some embodiments, the densities of the first post-filling structure 921, the second post-filling structure 922, and the pre-filling structure 910 decrease sequentially. For example, such as... Figure 4 and Figure 5As shown, the second post-filling structure 922 includes a first structure 9221 located within the third cavity 123 and a second structure 9222 above the pre-filling structure 910. The densities of the first post-filling structure 921, the first structure 9221, the second structure 9222, and the pre-filling structure 910 decrease sequentially, which effectively improves the overall structural strength of the battery pack and facilitates the overall structural design of the pack. It also helps to improve the insulation performance of the pack and enhance the consistency of thermal management and thermal safety.

[0151] In some implementations, such as Figure 4 As shown, the battery pack may also include a first sealing structure 5, which is used to separate the first cavity 121, the second cavity 122 and the third cavity 123, thereby reducing the abnormal flow of adhesive between the first cavity 121, the second cavity 122 and the third cavity 123 before it expands and solidifies, ensuring uniform distribution of adhesive and improving the potting effect.

[0152] In addition, in some implementations, such as Figure 4 As shown, the battery pack may also include a second sealing structure 6, which is used to divide at least a portion of the first cavity 121 and / or at least a portion of the third cavity 123 into a plurality of sub-filling cavities 124, so as to further improve the uniformity of the distribution of the adhesive in the first cavity 121 and the third cavity 123, improve the consistency of the foamed adhesive 9 after foaming, and improve the repeatability of industrial production.

[0153] Furthermore, the battery pack provided in the third aspect of this disclosure does not specifically limit the structure of the first sealing structure 5 and the second sealing structure 6. For example, they can be adhesive-blocking foam or adhesive-blocking rubber blocks, etc. The purpose is to separate the first cavity 121, the second cavity 122, and the third cavity 123, and to divide the first cavity 121 and the third cavity 123 into multiple sub-filling cavities. In addition, the battery pack provided in the third aspect of this disclosure does not specifically limit the number of the first sealing structure 5 and the second sealing structure 6, which are constructed as, for example, adhesive-blocking foam or adhesive-blocking rubber blocks. Those skilled in the art can adaptively design the specific number of adhesive-blocking foam or adhesive-blocking rubber blocks according to actual application requirements.

[0154] According to a fourth aspect of this disclosure, an electrical appliance is provided, comprising the battery pack provided in the second aspect or the battery pack provided in the third aspect. This electrical appliance possesses all the beneficial effects of the battery pack provided in the second aspect or the battery pack provided in the third aspect, which will not be elaborated further herein.

[0155] In some exemplary application scenarios, the aforementioned electrical equipment can be a vehicle, wherein the vehicle can be a new energy vehicle, which can be a pure electric vehicle, a hybrid electric vehicle, or a range-extended electric vehicle, etc., and this disclosure does not make any specific limitations in this regard.

[0156] Of course, in other application scenarios, the above-mentioned electrical equipment can also be used for vehicles that need to be powered by battery packs, such as in the field of energy storage, aerospace or water transportation.

[0157] The preferred embodiments of the present disclosure have been described in detail above with reference to the accompanying drawings. However, the present disclosure is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present disclosure, various simple modifications can be made to the technical solutions of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.

[0158] It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To reduce unnecessary repetition, this disclosure will not further describe the various possible combinations.

[0159] Furthermore, various different embodiments of this disclosure can be combined in any way, as long as they do not violate the spirit of this disclosure, they should also be regarded as the content disclosed in this disclosure.

Claims

1. A potting method for a battery pack, characterized by, The battery pack comprises a shell, a battery assembly and a cover, the shell comprises a receiving cavity with an opening, the battery assembly is located in the receiving cavity, and the cover seals the opening, and the method comprises: Before the cover is installed, the foaming glue is filled into the receiving cavity in multiple times to form a pre-sealing structure formed by at least one time of filling the foaming glue and a post-sealing structure formed by at least one time of filling the foaming glue, and the battery assembly is connected to the cover through the post-sealing structure.

2. The potting method for a battery pack according to claim 1, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

3. The potting method for a battery pack according to claim 2, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

4. The potting method for a battery pack according to claim 3, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

5. The potting method for a battery pack according to claim 3, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

6. The potting method for a battery pack according to claim 5, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

7. The potting method for a battery pack according to claim 5, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

8. The potting method for a battery pack according to claim 7, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

9. The potting method for a battery pack according to claim 7, wherein The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

10. The potting method for a battery pack according to claim 5, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

11. The potting method for a battery pack according to claim 10, wherein The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

12. The potting method for a battery pack according to any one of claims 2-11, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

13. The potting method for a battery pack according to claim 12, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

14. The potting method for a battery pack according to claim 13, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

15. The potting method for a battery pack according to claim 2, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises:

16. The potting method for a battery pack according to claim 1, characterized by, The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery assembly and the side wall of the receiving cavity in multiple times to form the pre-sealing structure and the post-sealing structure formed by at least one time of filling the foaming glue, and the method comprises: The foaming glue is filled into the at least partial space between the battery The method further comprises: filling the foaming glue into the second cavity along a second preset track to form the first post-potting structure.

17. The potting method for a battery pack according to claim 16, wherein The method further comprises: determining the second preset track according to the arrangement of the battery cells of the battery assembly.

18. The potting method for a battery pack according to claim 17, wherein The battery assembly comprises a plurality of groups of battery cells arranged side by side along the length direction of the battery cells, each group of battery cells comprising a plurality of battery cells arranged side by side along the thickness direction of the battery cells, The second preset track comprises a first main track and a first turning track, a plurality of the first main tracks each extend along the thickness direction of the battery cells and are arranged side by side along the length direction of the battery cells, and the first turning track connects between any two adjacent first main tracks, so that the second preset track forms a serpentine track.

19. The potting method for a battery pack according to claim 18, wherein There is a first gap between any two adjacent battery cells spaced apart along the length direction, the first gap forms part of the second cavity, the first gap extends along the thickness direction, and at least one first main track passes through the first gap.

20. The potting method for a battery pack according to claim 18, wherein The upper surface of the battery cell is provided with a pole and a surface area adjacent to the pole, at least one first main track passes through the pole, and at least one first main track passes through the surface area.

21. The potting method for a battery pack according to claim 18, wherein The battery assembly comprises a busbar assembly located above the battery cells, the busbar assembly has a second gap with the cover, the busbar assembly has a third gap with the battery cells, the busbar assembly has a glue injection port communicating the second gap and the third gap, and at least one first main track passes through the glue injection port.

22. The potting method for a battery pack according to claim 18, wherein The first main track has opposite first and second ends, the battery assembly has a first side wall adjacent to the first end along the thickness direction and a second side wall adjacent to the second end, the first end has a first preset distance from the first side wall, and the second end has a second preset distance from the second side wall.

23. The potting method for a battery pack according to claim 22, wherein The method further comprises: determining the values of the first preset distance and the second preset distance according to the difference between the actual running time of the glue outlet of the glue filling device at the first turning track and the set running time.

24. The potting method for a battery pack according to claim 22, wherein, The thickness of the battery cell is D, the values of the first preset distance and the second preset distance are D', D'≥D*1 / 2, and D'≤3D.

25. The potting method for a battery pack according to claim 16, wherein The accommodating cavity has a first cavity located at at least one end of the battery assembly along a first direction, the accommodating cavity comprises a third cavity located at at least one end of the battery assembly along a second direction, the pre-potting structure is located in the first cavity, and the post-potting structure comprises a second post-potting structure located in the third cavity and above the pre-potting structure; The method further comprises: filling the foaming glue into the second cavity along a second preset track to form the first post-potting structure. filling the foaming glue into the first cavity and the third cavity along the third preset track to form the second post-pouring sealing structure.

26. The potting method for a battery pack according to claim 25, wherein The third preset track is an annular track extending in the circumferential direction of the battery assembly.

27. The potting method for a battery pack according to claim 25, wherein The method further comprises: filling the foaming glue into the first cavity and the third cavity along the third preset track after filling the foaming glue into the second cavity along the second preset track.

28. The potting method for a battery pack according to claim 25, wherein The method comprises: filling the foaming glue into the first cavity and the third cavity along the third preset track after the foaming glue of the pre-pouring sealing structure expands to the maximum volume.

29. The potting method for a battery pack according to claim 28, wherein, The method comprises: filling the foaming glue into the first cavity and the third cavity along the third preset track after the foaming glue of the pre-pouring sealing structure expands to the maximum volume and before the top surface of the pre-pouring sealing structure is dry to the touch.

30. A battery pack, characterized by The battery pack adopts the pouring method of any one of claims 1-29.

31. A battery pack, characterized by Comprise: a housing comprising a receiving cavity with an opening; a battery assembly located in the receiving cavity; a cover body, the cover body closes the opening; a pre-pouring sealing structure formed by foaming glue and located in the receiving cavity; and a post-pouring sealing structure formed by foaming glue and located in the receiving cavity, the battery assembly is connected to the cover body through the post-pouring sealing structure.

32. The battery pack of claim 31, wherein, The projection of the post-pouring sealing structure in the height direction of the battery pack covers the pre-pouring sealing structure.

33. The battery pack of claim 31, wherein, The pre-pouring sealing structure and the post-pouring sealing structure are bonded.

34. The battery pack of claim 31, wherein, The bonding strength at the interface of the pre-pouring sealing structure and the post-pouring sealing structure is E, the bonding strength between the post-pouring sealing structure and the cover body is F, E>F.

35. The battery pack of claim 31, wherein, The pull-out / shear strength at the interface of the pre-pouring sealing structure and the post-pouring sealing structure is A, the pull-out / shear strength of the pouring structure formed by the foaming glue without interface is B, A>0.5B.

36. The battery pack of any one of claims 31-35, wherein, The battery assembly comprises battery cells, the receiving cavity has a first cavity located at least one end of the battery assembly in a first direction, and the pre-pouring sealing structure is at least partially located in the first cavity.

37. The battery pack of claim 36, wherein, In the height direction of the battery pack, the highest point of the top surface of the pre-pouring sealing structure is below the top end of the battery cell, or the highest point of the top surface of the pre-pouring sealing structure is flush with the top end of the battery cell.

38. The battery pack of claim 37, wherein, The distance between the lowest point of the top surface of the pre-pouring sealing structure and the top end of the battery cell in the height direction is h, and the size of the battery cell in the height direction is H, h≤H*1 / 2.

39. The battery pack of claim 37, wherein, The size of the receiving cavity in the height direction of the battery pack is H', and the height of the highest point or the lowest point of the top surface of the pre-pouring sealing structure corresponding to the inner bottom surface of the receiving cavity is L, L≥H'*1 / 3.

40. The battery pack of claim 39, wherein, The size of the battery cell of the battery assembly in the height direction of the battery pack is H, H'*1 / 2 41. The battery pack of claim 39, wherein, The size of the battery cell of the battery assembly in the height direction of the battery pack is H, H≥H'*2 / 3.

42. The battery pack of claim 37, wherein, The distance between the highest point and the lowest point of the top surface of the pre-pouring sealing structure in the height direction is less than a preset distance.

43. The battery pack of claim 42, wherein, The preset distance is 15 mm.

44. The battery pack of claim 36, wherein, The accommodating cavity comprises a second cavity between the battery assembly and the cover and between adjacent battery cells in the battery assembly, and a third cavity at at least one end of the battery assembly in a second direction, the post-potting structure comprises a first post-potting structure in the second cavity, and a second post-potting structure in the third cavity and above the pre-potting structure.

45. The battery pack of claim 44, wherein, The densities of the first post-potting structure, the second post-potting structure and the pre-potting structure decrease in sequence.

46. The battery pack of claim 45, wherein, The second post-potting structure comprises a first structure in the third cavity and a second structure above the pre-potting structure, and the densities of the first post-potting structure, the first structure, the second structure and the pre-potting structure decrease in sequence.

47. The battery pack of claim 44, wherein, The battery pack further comprises a first blocking structure for separating the first cavity, the second cavity and the third cavity.

48. The battery pack of claim 44, wherein, The battery pack further comprises a second blocking structure for separating at least part of the first cavity and / or at least part of the third cavity into a plurality of sub-potting cavities.

49. An electrical device, comprising: The battery pack of claim 30 or any one of claims 31-48.

50. The powered device of claim 49, wherein, The electrical equipment is a vehicle.

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