Battery module and special-shaped battery pack

Abstract

The invention discloses a battery module and a special-shaped battery pack, and belongs to the field of power batteries. The battery module comprises a battery cell stacking body, a tab welding bracket and a flexible low-voltage sampling circuit board; a first mounting structure is arranged on the tab outlet end side of the battery cell stacking body, and the tab welding bracket is assembled on the battery cell stacking body through an adaptive second mounting structure to provide stable support for tab welding; and the flexible low-voltage sampling circuit board is arranged on the outer side of the tab welding bracket, and is provided with a buffer part along the stacking direction of the battery cells. The special-shaped battery pack comprises the battery module and is provided with multiple layers of box bodies, the second layers of box bodies are arranged at intervals to form avoiding spaces, reinforcing beams are connected between the adjacent box bodies, and third layers of box bodies are arranged on the second layers of box bodies on the two sides and matched with reinforcing structures. The problems that a battery module is low in structural strength, poor in assembly adaptability and unstable in electrical connection are solved, the structural integrity and the whole vehicle adaptability are both considered, the deformation resistance and the impact resistance are improved, the installation stability and the signal collection reliability are guaranteed, and the battery module is suitable for new energy vehicles, energy storage and other scenes.

Description

Technical Field

[0001] This invention relates to the field of power batteries, and in particular to a battery module and an irregularly shaped battery pack. Background Technology

[0002] With the rapid development of new energy vehicles and energy storage, the performance and safety of power batteries, as core energy supply components, directly determine the user experience and market competitiveness of end products. Battery modules, as the core component of power battery packs, are composed of multiple stacked individual cells. Their structural design must simultaneously meet multiple core requirements, including structural strength, heat dissipation efficiency, electrical connection stability, and thermal runaway protection.

[0003] In existing technologies, battery module cell stacks are typically assembled using simple binding, bonding, or frame fixing methods. The tab area lacks dedicated support and positioning structures, leading to deformation and poor soldering during tab welding, affecting the reliability of electrical connections. Simultaneously, the stacked cells lack sufficient structural strength along their length, making them susceptible to cell displacement and fatigue fracture at tab connections under complex conditions such as vehicle bumps and vibrations. Furthermore, the flexible low-voltage sampling circuit board (FPC) in battery modules is often rigidly arranged, lacking a buffer design to accommodate assembly tolerances and deformation under operating conditions. During module assembly or long-term use, the FPC is prone to tensile stress due to dimensional deviations and vibration impacts, causing sampling nickel sheets to detach and circuits to break, leading to voltage and temperature acquisition failures. This affects the accuracy of the battery management system (BMS) monitoring of battery status and, in severe cases, may induce safety hazards.

[0004] On the other hand, with the continuous improvement of the energy density of power batteries, the risk of thermal runaway in battery cells has become a key concern in the industry. In the existing battery module structural design, the assembly coordination between the tab support, sampling circuit, and cell stack is insufficient. Some designs suffer from redundant assembly space or lack of protective structures, which not only affects the integration level of the module but may also lead to ineffective heat and gas dissipation during thermal runaway, exacerbating the risk spread. Therefore, there is an urgent need for a battery module structural design that can balance structural strength, assembly adaptability, electrical connection stability, and protective performance to solve the aforementioned technical problems in the existing technology. Summary of the Invention

[0005] The main objective of this invention is to provide a battery module and an irregularly shaped battery pack, aiming to solve the technical problems of low structural strength, poor assembly adaptability, and poor electrical connection stability of existing battery modules.

[0006] To achieve the above-mentioned objective, the first aspect of the present invention provides a battery module comprising: The battery cell stack has multiple first mounting structures on the end side of its output tab; The electrode welding bracket is provided with a second mounting structure adapted to the first mounting structure, wherein the electrode welding bracket is mounted on the cell stack through the cooperation of the second mounting structure and the first mounting structure; A flexible low-voltage sampling circuit board is disposed on the side of the electrode welding bracket away from the cell stack, wherein the flexible low-voltage sampling circuit board is provided with a buffer portion along the stacking direction of the cell stack.

[0007] A second aspect of the present invention provides an irregularly shaped battery pack, including the battery module described above.

[0008] The battery module of the present invention, through the collaborative structural design of the cell stack, the electrode welding bracket and the flexible low-voltage sampling circuit board, addresses the pain points of the prior art with targeted optimization, bringing the following beneficial effects: Improving the reliability and structural stability of electrode welding: The cell stack and electrode welding bracket are precisely matched through the first and second mounting structures to achieve rapid positioning and stable assembly, providing a continuous and reliable support foundation for electrode welding, effectively resisting welding pressure and high temperature impact, reducing defects such as electrode deformation and incomplete welding, ensuring the stability of electrical connection, and avoiding the risk of fatigue fracture at the electrode connection under vehicle driving conditions.

[0009] Optimize the adaptability and durability of the flexible sampling circuit: The buffer part set along the cell stacking direction of the flexible low-voltage sampling circuit board can effectively absorb the tensile stress caused by the assembly tolerance of the cell stack and vibration impact, avoid the sampling nickel sheet falling off and the circuit breaking, ensure the continuity and accuracy of voltage and temperature acquisition, and ensure the battery management system's accurate monitoring of battery status.

[0010] Simplified assembly process and improved integration: Each component is modularly assembled through an adaptable installation structure, eliminating the need for additional bolts, glues and other auxiliary connectors, reducing assembly steps and time costs, and avoiding structural failures caused by aging or loosening of auxiliary components; the overall structure is compact, ensuring multiple functions without taking up too much extra space, which is in line with the development trend of high integration and lightweight power batteries, and is suitable for the application needs of new energy vehicles, energy storage and other scenarios.

[0011] Enhanced structural adaptability and versatility: This design does not require significant modifications to the core structure of the cell stack. Assembly of each component can be achieved simply by adapting the end mounting structure. It is compatible with the cell stacking requirements of different specifications and provides ample space for subsequent assembly with components such as the battery pack housing, thus possessing broad application adaptability. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the internal structure of an irregularly shaped battery pack according to an embodiment of the present invention; Figure 2 This is a top view of the first layer of the irregularly shaped battery pack according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a battery module according to an embodiment of the present invention; Figure 4 This is an exploded structural diagram of a battery module according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the exposed flexible low-voltage sampling circuit board of a battery module according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of a flexible low-voltage sampling circuit board according to an embodiment of the present invention; Figure 7 This is an exploded structural diagram of a battery cell stack according to an embodiment of the present invention; Figure 8 This is a schematic diagram of the structure of a tab welding bracket according to an embodiment of the present invention; Figure 9 This is a schematic diagram of the protective shell and a single battery cell according to an embodiment of the present invention; Figure 10 This is a schematic diagram of the structure of an electrode holder according to an embodiment of the present invention; Figure 11 yes Figure 10 Enlarged structural diagram at point A; Figure 12 This is an exploded view of the bottom of the battery module display according to an embodiment of the present invention; Figure 13 This is a schematic diagram of the structure of the housing of an irregularly shaped battery pack according to an embodiment of the present invention; Figure 14 This is an exploded structural diagram of the casing of an irregularly shaped battery pack according to an embodiment of the present invention; Figure 15 This is a schematic diagram of the structure of a reinforcing member according to an embodiment of the present invention; Figure 16 This is a schematic diagram of the structure of a reinforcing beam according to an embodiment of the present invention; Figure 17 This is a schematic diagram of the structure of a fastener according to an embodiment of the present invention; Figure 18 This is a schematic diagram of the structure of a single-layer side plate according to an embodiment of the present invention; Figure 19 This is a schematic diagram of the structure of the first layer of the box according to an embodiment of the present invention; Figure 20 This is a schematic diagram of the longitudinal beam connection structure according to an embodiment of the present invention; in: 100 - Battery Pack; 110 - First Layer Cabinet; 1101 - Maintenance Window; 1102 - Maintenance Cover; 120 - Second Layer Cabinet; 130 - Third Layer Cabinet; 111 - Crossbeam; 112 - Longitudinal Beam; 113 - Longitudinal Beam Connection Structure; 114 - Mounting Base; 115 - Protrusion; 116 - Support Platform; 117 - First Layer Side Plate; 1171 - Sump; 1172 - First Step; 1173 - Second Step; 1174 - Third Step; 1175 - Lifting Hole; 121 - Second Side Plate; 131 - First Side Plate; 141 - Reinforcing Beam; 1411 - Reinforcing Beam Body; 1412 - Mounting Protrusion; 1413 - Hollowed-out Section; 1414 - Protruding Edge; 142 - Reinforcing Component; 143 - Horizontal Mounting Surface; 144 - Vertical Mounting Surface; 145 - Reinforcing rib; 146 - Fastener; 1461 - Fastener body; 1462 - Recess; 147 - Reinforcing plate; 148 - Vent hole; 149 - Folded edge; 150 - Screw hole; 151 - Threaded rod; 101 - Gap between housings; 200 - Battery module; 210 - End plate; 220 - Tab side plate; 241 - Thermal conductive strip; 251 - Guide plate; 252 - Flow guide hole; 253 - Exhaust plate; 254 - Baffle; 255 - Separator structure; 256 - Exhaust channel; 257 - Ejection structure; 261 - Tab welding bracket; 262 - First hot riveting hole; 263 - Recess; 2611 - Third hot riveting post; 270 - Inlet plate; 300 - Cell stack; 301 - Individual cell submodule; 302 - Insulation cotton; 303 - Phase change heat insulation board; 304 - Insulation board; 310 - Flexible low-voltage sampling circuit board; 311 - Buffer section; 312 - Flexible sampling section; 313 - First extension section; 314 - Second extension section; 315 - First sampling section; 316 - First tear opening; 317 - Third extension section; 318 - Second sampling section; 319 - Second tear opening; 3101 - Nickel sheet; 3102 - Temperature acquisition unit; 3103 - Third hot riveting hole; 320 - Individual cell; 321 - Tab; 322 - Tab air bag; 324 - Protective shell; 3241 - Top shell; 3242 - Side shell; 3243 - Bottom shell; 330 - Tab bracket; 331 - First hot riveting post; 332 - Second hot riveting hole; 333 - plug; 334 - lifting slot; 335 - sealing foam; 336 - second hot riveting post; 340 - liquid cooling plate; 350 - heat insulation plate.

[0013] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0014] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0015] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0016] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0017] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0018] Reference Figures 4 to 9An embodiment of the present invention provides a battery module, including: a cell stack 300, wherein a plurality of first mounting structures are provided on the end side of the tab 321; a tab welding bracket 261, wherein a second mounting structure is provided that is adapted to the first mounting structures, wherein the tab welding bracket 261 is mounted on the cell stack 300 through the cooperation of the second mounting structure and the first mounting structure; and a flexible low-voltage sampling circuit board 310, which is disposed on the side of the tab welding bracket 261 away from the cell stack 300, wherein the flexible low-voltage sampling circuit board 310 is provided with a buffer portion 311 along the stacking direction of the cell stack 300.

[0019] The cell stack 300 is a core energy storage unit formed by stacking multiple individual cell sub-modules 301 according to a preset rule. The end of the tab 321 is the protruding end area of ​​the tab 321 used for welding connection. The first mounting structure is a connection adapter structure set on this end side for precise assembly with the tab welding bracket 261. The tab welding bracket 261 is a support component adapted to the cell stack 300. The second mounting structure is precisely matched with the first mounting structure in shape, size, and position. Through their cooperation, the tab welding bracket 261 can be stably installed on the cell stack 300, providing reliable support for the welding of the tab 321. The flexible low-voltage sampling circuit board 310 is a component used to collect cell voltage and temperature signals. The buffer part 311 is an elastic structure set along the stacking direction of the cell stack 300 to absorb assembly tolerances and deformation under operating conditions. During assembly, the cell stack 300 is first stacked to ensure the first mounting structure is accurately positioned. Then, the second mounting structure of the tab welding bracket 261 is aligned with the first mounting structure and fixed. Finally, the flexible low-voltage sampling circuit board 310 is installed on the side of the tab welding bracket 261 away from the cell stack 300 to ensure that the buffer part 311 is arranged along the stacking direction.

[0020] This embodiment achieves rapid positioning and stable connection between the tab welding bracket 261 and the cell stack 300 through the adaptation of the first and second mounting structures, avoiding the bracket misalignment problem in traditional assembly, providing solid support for the welding of the tab 321, and reducing the risk of welding deformation and poor connection. The buffer part 311 design of the flexible low-voltage sampling circuit board 310 effectively absorbs the tensile stress generated by assembly tolerances and vibration impacts, preventing the sampling nickel sheet 3101 from falling off or the circuit from breaking, ensuring the stability of voltage and temperature acquisition. The overall structure requires no additional auxiliary fixing process, simplifying the assembly process and adapting to the design requirements of high integration and high reliability of power batteries.

[0021] In one embodiment, the buffer portion 311 is formed by bending the flexible low-voltage sampling circuit board 310.

[0022] Reference Figure 6The buffer section 311 is an elastic structure formed by bending the flexible low-voltage sampling circuit board 310 itself. The bending shape can be designed according to actual needs (such as S-shaped, wavy, etc.), and the elastic buffering function is achieved by utilizing the material properties of the flexible circuit board. This design does not require additional elastic components, and the buffering capacity is formed directly by modifying the structure of the circuit board itself, ensuring that the buffer section 311 and the flexible low-voltage sampling circuit board 310 are integrated, reducing the number of components. During assembly, the flexible low-voltage sampling circuit board 310 is bent at a preset position along the stacking direction of the cell stack 300 to form the buffer section 311, and then the circuit board is installed on the tab welding bracket 261.

[0023] The buffer section 311 is formed by bending the flexible low-voltage sampling circuit board 310 itself, eliminating the need for additional components, simplifying the structural design, and reducing costs and assembly complexity. The integrated structure avoids the risk of loose connections from additional buffer components, improves the reliability of the buffering function, and more efficiently absorbs assembly tolerances and vibration shocks, ensuring the long-term stable operation of the flexible low-voltage sampling circuit board 310 and further enhancing the electrical performance reliability of the battery module.

[0024] In one embodiment, the flexible low-voltage sampling circuit board 310 extends a flexible sampling portion 312 along its width direction; the flexible sampling portion 312 includes a first extension portion 313, a second extension portion 314 and a first sampling portion 315, and the free ends of the first extension portion 313 and the second extension portion 314 are respectively connected to the first sampling portion 315.

[0025] The flexible sampling section 312 is a sampling structure extending from the flexible low-voltage sampling circuit board 310 along its width direction, used to contact the tab 321 to collect signals. The first extension 313 and the second extension 314 are connecting extensions of the flexible sampling section 312, with their free ends connected to the first sampling section 315, forming a symmetrical or asymmetrical support structure. The first sampling section 315 is the sampling area that directly contacts the tab 321. It achieves signal acquisition by connecting to the tab 321 via a nickel plate 3101, and a temperature acquisition unit 3102 can be set on one or more nickel plates 3101 to collect temperature data. During assembly, ensure that the flexible sampling section 312 extends along the width direction of the flexible low-voltage sampling circuit board 310, that the free ends of the first extension 313 and the second extension 314 are reliably connected to the first sampling section 315, and that the nickel plate 3101 of the first sampling section 315 is precisely aligned with the tab 321.

[0026] The structural design of the flexible sampling section 312 allows the first sampling section 315 to stably contact the tab 321, improving the stability of the sampling signal. The dual-support structure of the first extension section 313 and the second extension section 314 enhances the fatigue resistance of the flexible sampling section 312, preventing breakage during long-term use. The temperature acquisition unit 3102 enables synchronous acquisition of voltage and temperature signals, providing the battery management system with more comprehensive cell status data and improving the monitoring accuracy and safety of the battery module.

[0027] Furthermore, the first extension 313 is bent and has data traces.

[0028] The bent (S-shaped) design of the first extension 313 refers to its continuous bending structure along its length, which enhances the structure's elasticity and buffering capacity. Data traces are conductive lines located inside the first extension 313, used to transmit the electrical signals collected by the first sampling unit 315 to the main circuit of the flexible low-voltage sampling circuit board 310. The integrated design of the S-shaped structure and data traces ensures signal transmission while giving the first extension 313 good deformation capability. During assembly, ensure that the S-shaped bending direction of the first extension 313 is consistent with the direction of force to prevent damage or short circuits to the data traces.

[0029] The S-shaped first extension 313 has excellent buffering performance, effectively absorbing the stress caused by vibration and assembly tolerances, and preventing data traces from breaking due to pulling. The data traces are integrated into the first extension 313, simplifying the structural layout, reducing wear and short-circuit risks caused by exposed lines, improving the stability and reliability of signal transmission, and ensuring the long-term effective operation of the flexible low-voltage sampling circuit board 310.

[0030] Furthermore, the second extension 314 is provided with a first tear opening 316.

[0031] The first tear opening 316 is a structural weak point located on the second extension 314. It is elongated or discontinuous in design, and there are no data traces in this opening area. The second extension 314 is an auxiliary support structure for the flexible sampling unit 312. In the absence of breakage, it works with the first extension 313 to improve the stability of the sampling unit. When there is severe shaking, stress concentrates at the first tear opening 316, causing it to break along the opening. However, the S-shaped bend design of the first extension 313 has a buffering effect and will not break, ensuring that the data traces are not affected. During assembly, the first tear opening 316 must be located in a non-critical stress area of ​​the second extension 314 to ensure that it does not break under normal operating conditions.

[0032] The design of the first tear opening 316 enhances the structural stability of the sampling section under normal operating conditions. Under extreme conditions such as severe shaking, it can break along the opening to release stress and prevent overall damage to the flexible sampling section 312. Since there are no data traces in the opening area, breakage will not affect normal signal acquisition. At the same time, the buffering effect of the first extension 313 further ensures the continuity of data transmission and improves the impact resistance and service life of the flexible low-voltage sampling circuit board 310.

[0033] In one embodiment, the flexible low-voltage sampling circuit board 310 is provided with a third extension 317 and a second sampling section 318 at both ends along its length; the free end of the third extension 317 is connected to the second sampling section 318; wherein, a second tear opening 319 is provided at the partial connection between the third extension 317 and the flexible low-voltage sampling circuit board 310.

[0034] The third extension 317 is a connection structure extending one end of the flexible low-voltage sampling circuit board 310 along its length. The second sampling part 318 is a component used to collect signals from the end cells. The free end of the third extension 317 is connected to the second sampling part 318 to form an end sampling channel. The second tear opening 319 is a structural weak point located at the partial connection between the third extension 317 and the flexible low-voltage sampling circuit board 310. The opening is only partially provided; it improves the stability of the sampling part when there is no breakage, and breaks along the opening during severe shaking. The part without the opening remains connected to ensure normal signal acquisition. During assembly, it is necessary to ensure a reliable connection between the third extension 317 and the second sampling part 318, and the position of the second tear opening 319 should avoid the data trace area.

[0035] This embodiment achieves effective acquisition of end cell signals through the cooperation of the third extension 317 and the second sampling section 318, expanding the sampling coverage. The partial design of the second tear opening 319 takes into account both structural stability under normal operating conditions and stress relief function under extreme operating conditions, avoiding sampling failure due to overall breakage, ensuring the continuity and reliability of signal acquisition of the flexible low-voltage sampling circuit board 310, and adapting to complex operating conditions.

[0036] In one embodiment, the cell stack 300 includes a plurality of individually stacked cell sub-modules 301; the first mounting structure is disposed at the output tab end of the individual cell sub-module 301.

[0037] Reference Figure 7The individual cell submodule 301 is the basic unit constituting the cell stack 300. Each individual cell submodule 301 includes an individual cell 320 and supporting protective and support structures. Multiple individual cell submodules 301 are stacked sequentially from left to right with their long sides facing down and their sides upright, forming a complete cell stack 300. The first mounting structure, as a connecting adapter, is located at the output tab end of each individual cell submodule 301. This end is aligned with the output tab 321 end of the cell stack 300, ensuring that multiple first mounting structures are orderly distributed at the output tab 321 end of the cell stack 300. During assembly, the first mounting structure of each individual cell submodule 301 is first installed in place, and then multiple individual cell submodules 301 are stacked sequentially to form the cell stack 300, so that each first mounting structure forms a unified assembly reference surface.

[0038] The cell stack 300 is divided into multiple individual cell sub-modules 301 for stacking, which facilitates the processing, testing, and replacement of individual modules and reduces the overall production error rate. The first mounting structure is set at the tab end of each individual cell sub-module 301, so that the connection point between the tab welding bracket 261 and the cell stack 300 covers each individual cell sub-module 301, improving the uniformity and stability of the connection, avoiding the problem of insufficient local connection strength, thereby enhancing the structural stability of the entire battery module and adapting to the strength requirements of multi-cell stacking scenarios.

[0039] Further, the single cell submodule 301 includes: a single cell 320; a protective shell 324, which wraps around the outside of the single cell 320; and a tab bracket 330, which is disposed on the protective shell 324 along the direction of the tab 321 of the single cell 320; wherein, the first mounting structure is disposed on the tab bracket 330.

[0040] Reference Figures 9-11 The individual battery cell 320 is the core component for energy storage and output. The protective shell 324 is a protective structure that wraps around the individual battery cell 320, providing physical protection to reduce the impact of external shocks and vibrations, while also improving the structural strength of the individual battery cell submodule 301. The tab bracket 330 is a support component extending along the direction of the tab 321 of the individual battery cell 320, and is fixedly mounted on the protective shell 324, forming an integrated structure with the protective shell 324. After the tab 321 extends out, it can rest against the tab bracket 330 for initial support. The first mounting structure is set on the tab bracket 330, and its position is adapted to the welding area of ​​the tab 321, ensuring that the tab welding bracket 261 can accurately correspond to the welding position of the tab 321 after installation. During assembly, the protective shell 324 is first wrapped around the individual battery cell 320, and then the tab bracket 330 is installed on the protective shell 324, ensuring the accurate positioning of the first mounting structure, and finally the assembly of the individual battery cell submodule 301 is completed.

[0041] The protective shell 324 effectively enhances the protection performance of the individual battery cell 320 and the structural strength of the individual battery cell sub-module 301, extending the battery module's lifespan. The tab bracket 330 provides initial support for the tab 321, forming a double support structure with the tab welding bracket 261, further improving the stability of the tab 321. By placing the first mounting structure on the tab bracket 330, the mounting structure and the tab 321 support structure are integrated, optimizing the structural layout of the individual battery cell sub-module 301, avoiding space occupation and structural redundancy caused by additional mounting structures, and adapting to the high energy density design requirements of power batteries.

[0042] In one embodiment, the first mounting structure is a first hot riveting post 331; the second mounting structure is a first hot riveting hole 262.

[0043] Reference Figures 9-11 The first hot riveting post 331 is a columnar protrusion structure set on the tab bracket 330. Its material is the same as the tab bracket 330, possessing good thermoplasticity and capable of plastic deformation under hot riveting conditions. The first hot riveting hole 262 is a through-hole structure opened on the tab welding bracket 261. The hole diameter precisely matches the diameter of the first hot riveting post 331, ensuring that the first hot riveting post 331 can be smoothly inserted into the first hot riveting hole 262. During assembly, the first hot riveting hole 262 of the tab welding bracket 261 is aligned with the first hot riveting post 331 on the tab bracket 330 and inserted, so that the tab welding bracket 261 fits against the surface of the tab bracket 330. Subsequently, the top of the first hot riveting post 331 is heated and pressurized using hot riveting equipment, causing the top of the first hot riveting post 331 to plastically deform and press against the tab welding bracket 261, achieving a stable connection between the two.

[0044] The hot riveting method, employing the first hot riveting post 331 and the first hot riveting hole 262, eliminates the need for additional bolts, glue, or other auxiliary connectors, simplifying the assembly process and reducing assembly costs and time. The fixed structure formed by the hot riveting connection possesses excellent structural strength and vibration resistance, effectively avoiding the problems of loosening easily in traditional bolt connections and aging and failure in glue connections, ensuring the long-term stable installation of the electrode tab welding bracket 261. Furthermore, the hot riveting process is simple to operate, highly efficient, and suitable for the needs of large-scale power battery production. The resulting structure is compact, does not occupy additional space, and meets the requirements of high-integration design.

[0045] Furthermore, the first hot riveting post 331 is respectively disposed at both ends of the tab bracket 330 along the length direction.

[0046] The length direction of the tab support 330 is perpendicular to the tab 321 of the single cell 320, that is, the direction in which the two narrow surfaces of the single cell 320 are connected (refer to...). Figure 9The first hot-riveting post 331, as the core connecting structure, is symmetrically arranged at both ends of the tab bracket 330, and mates with the corresponding first hot-riveting hole 262 on the tab welding bracket 261. During assembly, ensure that the two first hot-riveting posts 331 are symmetrically distributed on the tab bracket 330, insert them into the corresponding first hot-riveting holes 262, and fix them synchronously through a hot-riveting process, so that the fit between the tab welding bracket 261 and the tab bracket 330 is more uniform.

[0047] The first hot-riveting posts 331 are set at both ends of the tab bracket 330 along its length. Precise installation of the tab welding bracket 261 is achieved through two-point positioning, effectively preventing the tab welding bracket 261 from shifting or twisting during assembly or use. The hot-riveting connection points at both ends form a symmetrical force-bearing structure, improving the fatigue resistance of the connection. When the battery module is subjected to vibration, impact, or other conditions, the stress can be effectively distributed, avoiding overload failure of a single connection point, thereby enhancing the structural reliability and service life of the entire battery module.

[0048] In one embodiment, the first hot riveting hole 262 is a semi-circular hole with an opening on one side, and is disposed on the side of the electrode welding bracket 261.

[0049] Reference Figure 7 and Figure 8 The first hot riveting hole 262 is designed as a semi-circular hole with an opening on one side, facing the side of the tab welding bracket 261. This facilitates insertion of the first hot riveting hole 262 into the first hot riveting post 331 from the side of the tab welding bracket 261 during assembly, without the need for precise alignment and axial insertion. The diameter of the semi-circular hole matches the diameter of the first hot riveting post 331, ensuring that the first hot riveting post 331 fits tightly against the inner wall of the semi-circular hole after engagement, forming a stable pre-fixed structure. During assembly, the tab welding bracket 261 is first inserted into the first hot riveting post 331 from the side through the semi-circular hole to complete the pre-fixation. Then, the top of the first hot riveting post 331 is plastically deformed through the hot riveting process to achieve final fixation.

[0050] The semi-circular hole design with an opening on one side simplifies the assembly process between the electrode welding bracket 261 and the first hot-riveting post 331, reduces the alignment accuracy requirements, and improves assembly efficiency, especially suitable for scenarios with limited installation space after stacking multiple cells. The snap-fit ​​pre-fixing method eliminates the need for additional auxiliary fixing tools during assembly, further reducing production costs. At the same time, the tight fit between the semi-circular hole and the first hot-riveting post 331 ensures stability during the pre-fixing stage, preventing displacement of the electrode welding bracket 261 before hot riveting, ensuring the accuracy of subsequent hot riveting processes, and thus improving the overall assembly quality.

[0051] In one embodiment, the protective shell 324 includes: a side shell 3242 corresponding to the large surface of the corresponding single cell 320; a top shell 3241 corresponding to the top narrow surface of the corresponding single cell 320 and connected to the top end of the side shell 3242, wherein the width of the top shell 3241 is less than half the width of the top narrow surface to form a clearance structure; and a bottom shell 3243 corresponding to the bottom narrow surface of the corresponding single cell 320 and connected to the bottom end of the side shell 3242; wherein the side shell 3242, the top shell 3241, and the bottom shell 3243 form the protective shell 324 with three sides.

[0052] Reference Figure 9 The side shell 3242 is a plate-like structure corresponding to the large surface (largest side area) of the individual battery cell 320, used to protect the side area of ​​the individual battery cell 320. The upper shell 3241 corresponds to the top surface of the individual battery cell 320, and its top end is fixedly connected to the top end of the side shell 3242 (e.g., integrally formed). The clearance structure consists of through holes or notches on the upper shell 3241 corresponding to the shape and position of the explosion-proof weak area of ​​the individual battery cell 320, ensuring that the explosion-proof weak area can function properly. The lower shell 3243 corresponds to the bottom surface of the individual battery cell 320, and its bottom end is connected to the bottom end of the side shell 3242, serving as bottom protection and support. The three-sided protective shell 324, while providing protection for the main areas of the individual battery cell 320, also has a reserved side for the protruding tab 321, facilitating the arrangement and welding of the tab 321. During assembly, the side shell 3242, the top shell 3241 and the bottom shell 3243 are assembled to form a three-sided protective shell 324, which is then wrapped around the outside of the individual battery cell 320 to ensure that the avoidance structure is aligned with the explosion-proof weak area.

[0053] The three-sided protective shell 324 simplifies the structural design and reduces material usage while ensuring protective effectiveness, achieving lightweight design that aligns with the trend of lightweight power batteries. The clearance structure on the upper shell 3241 ensures the normal function of the vulnerable areas of the individual battery cell 320, avoiding safety hazards caused by the encapsulation of the protective shell 324 and improving the safety performance of the battery module. The combined structure of the side shells 3242, upper shell 3241, and lower shell 3243 facilitates the processing and assembly of the protective shell 324, while effectively dispersing external impact forces, providing all-around buffer protection for the individual battery cell 320 and extending the service life of the battery module.

[0054] In one embodiment, a second hot-riveting post 336 is provided on the tab bracket 330 along the thickness direction of the single cell 320; a second hot-riveting hole 332 is provided on the side shell 3242; the tab bracket 330 and the protective shell 324 are hot-riveted together by the second hot-riveting post 336 and the second hot-riveting hole 332.

[0055] Reference Figures 9-11 The second hot-riveting post 336 is a columnar protrusion structure set on the tab bracket 330, extending along the thickness direction of the single cell 320, and is made of a material with good thermoplasticity. The second hot-riveting hole 332 is a through-hole structure opened on the side shell 3242, its position precisely corresponding to the second hot-riveting post 336, and its diameter matching the diameter of the second hot-riveting post 336. During assembly, the tab bracket 330 is fitted to the preset installation position of the side shell 3242, so that the second hot-riveting post 336 on the tab bracket 330 is inserted into the second hot-riveting hole 332 of the side shell 3242. Then, the exposed end of the second hot-riveting post 336 is heated and pressurized by a hot riveting device, causing the second hot-riveting post 336 to undergo plastic deformation and press against the side shell 3242, realizing a stable connection between the tab bracket 330 and the protective shell 324, forming an integrated single cell sub-module 301 structure.

[0056] The hot riveting method using the second hot riveting post 336 and the second hot riveting hole 332 achieves a reliable connection between the tab bracket 330 and the protective shell 324. This connection structure possesses excellent strength and stability, avoiding the loosening issues common with traditional connection methods. The hot riveting process eliminates the need for additional connectors, simplifying the assembly process, reducing costs, and resulting in a compact structure that doesn't occupy extra space, meeting high integration design requirements. The integrated structure of the tab bracket 330 and the protective shell 324 enhances the overall structural strength of the single-cell sub-module 301, making the support of the tab 321 more stable. This provides a solid foundation for subsequent welding of the tab 321 and installation of the tab welding bracket 261, thereby improving the structural reliability of the entire battery module.

[0057] In one embodiment, the tab holder 330 is provided with a plug 333 on one side and a socket on the other side along the stacking direction of the cell stack 300; wherein adjacent tab holders 330 are connected based on the plug 333 and the socket.

[0058] Reference Figures 9-11 The plug 333 is a protruding structure on one side of the tab bracket 330 along the stacking direction of the cell stack 300, and the socket is a recessed structure on the other side. The shape and size of the plug 333 and the socket are precisely matched for the insertion and positioning of adjacent tab brackets 330. During assembly, in the process of stacking multiple individual cell sub-modules 301, the plug 333 of the previous tab bracket 330 is inserted into the socket of the next tab bracket 330. The insertion and mating achieves the positioning of adjacent tab brackets 330, thereby ensuring the stacking accuracy of the entire cell stack 300.

[0059] The adjacent tab brackets 330 achieve precise positioning during the stacking process of the individual cell sub-modules 301 through the plug-in connection of the plug 333 and the socket. This avoids positional deviation of the first mounting structure caused by stacking offset, ensuring the installation accuracy of the subsequent tab welding brackets 261. The plug-in structure enhances the connection strength between adjacent individual cell sub-modules 301, making the overall structure of the cell stack 300 more stable, improving the battery module's resistance to deformation under vibration and impact conditions, and further optimizing the structural reliability of the battery module.

[0060] In one embodiment, the tab support 330 is provided with a lifting groove 334 on the top and / or bottom of the side wall away from the single cell 320.

[0061] Reference Figure 3 , Figure 5 , Figure 7 and Figures 9-11 The lifting slot 334 is a recessed structure formed on the top and / or bottom of the side wall of the tab bracket 330 away from the individual battery cell 320. Its size is adapted to the gripping parts of the lifting fixture and is used for the turnover and box assembly after the module is assembled. The number of lifting slots 334 can be set according to the length of the tab bracket 330 and the load-bearing requirements to ensure that the gripping fixture can grip securely. After the module is assembled, the gripping fixture uses these lifting slots 334 to grip the module assembly, turnover it to the box and complete the box assembly.

[0062] The design of the lifting slot 334 provides convenient gripping points for module turnover and box assembly, eliminating the need for additional lifting structures and simplifying the production process. The multi-point gripping design makes the gripping tooling more refined and lightweight, reducing tooling design and usage costs. Simultaneously, the lifting slot 334 is located on the top side wall of the tab bracket 330, without affecting the assembly and function of other components, ensuring the compactness and integrity of the module structure and improving production assembly efficiency.

[0063] In one embodiment, the single-cell battery module 301 further includes sealing foam 335; wherein, the main body of the tab support 330 is located on one side of the tab air bag 322, and the sealing foam 335 is attached to the other side of the tab air bag 322.

[0064] Reference Figure 9The sealing foam 335 is an elastic cushioning component that is adhered to the other side of the tab air bag 322 with adhesive backing. Together with the main body of the tab bracket 330, it forms a clamping and protective structure for the tab air bag 322. The tab air bag 322 is an important component of the individual battery cell 320 and requires space for expansion. The elastic properties of the sealing foam 335 prevent the sealing adhesive from restricting the expansion of the tab air bag 322 after curing when filling the tab end with sealing adhesive. During assembly, first install the tab bracket 330 on the protective shell 324, ensuring that its main body is located on one side of the tab air bag 322. Then, adhere the sealing foam 335 to the other side of the tab air bag 322 with adhesive backing, ensuring a firm bond and without obstructing the expansion area of ​​the tab air bag 322.

[0065] The sealing foam 335 effectively prevents the sealing adhesive from restricting the breathing and expansion space of the tab air bag 322 after curing, ensuring the normal operation of the individual battery cell 320. Simultaneously, the sealing foam 335, together with the tab bracket 330, protects the tab air bag 322, reducing the risk of damage from external impacts, improving the structural integrity and safety of the individual battery cell submodule 301, and thus extending the battery module's lifespan.

[0066] In one embodiment, the electrode welding bracket 261 is provided with a recess 263 or a through groove in the area where the electrode 321 is welded.

[0067] Reference Figure 7 and Figure 8 The recessed portion 263 is a groove-shaped structure recessed into the inner side of the electrode welding bracket 261, and the through slot is a hollow structure penetrating the electrode welding bracket 261. Both are adapted to the shape and size of the welding area of ​​the electrode 321, and are used to reserve space for welding operations and accelerate heat dissipation. When the electrode 321 is placed on the electrode welding bracket 261, the welding area corresponds to the recessed portion 263 or the through slot, which does not affect the supporting stability of the electrode 321, allows the welding tool to smoothly contact the welding point, and avoids the accumulation of welding heat on the electrode welding bracket 261, resulting in local high temperature.

[0068] The recessed portion 263 or the through groove provides ample operating space for welding the tab 321, facilitating precise alignment of welding tools and welding operations, thus improving the operability of the welding process. Simultaneously, this structural design accelerates heat dissipation in the welding area, preventing heat accumulation that could lead to thermal deformation of the tab 321 or the tab welding bracket 261, reducing the occurrence of defects such as welding spalls, and improving welding quality and reliability. Furthermore, while ensuring the structural strength of the tab welding bracket 261, the amount of material used is reduced, achieving a lightweight design that meets the design requirements of lightweight and low-cost power batteries.

[0069] In one embodiment, the tab welding bracket 261 is provided with a third hot riveting post 2611 on the side opposite to the cell stack 300; the flexible low-voltage sampling circuit board 310 is provided with a third hot riveting hole 3103; the flexible low-voltage sampling circuit board 310 and the tab welding bracket 261 are hot riveted together by the third hot riveting post 2611 and the third hot riveting hole 3103.

[0070] Reference Figures 5-8 The third hot-riveting post 2611 is a columnar protrusion structure located on the side of the tab welding bracket 261 facing away from the cell stack 300, and is made of a material with good thermoplasticity. The third hot-riveting hole 3103 is a through-hole structure opened on the flexible low-voltage sampling circuit board 310, and its position corresponds precisely to the third hot-riveting post 2611, with a suitable hole diameter. During assembly, the third hot-riveting hole 3103 of the flexible low-voltage sampling circuit board 310 is aligned with the third hot-riveting post 2611 of the tab welding bracket 261 and inserted, so that the circuit board fits against the surface of the tab welding bracket 261. Then, the top of the third hot-riveting post 2611 is heated and pressurized by a hot riveting device, causing it to plastically deform and press the circuit board tightly, achieving a stable connection between the two.

[0071] A reliable connection between the flexible low-voltage sampling circuit board 310 and the tab welding bracket 261 is achieved by using a hot-riveting fixing method with a third hot-riveting post 2611 and a third hot-riveting hole 3103. The connection structure has good vibration resistance and avoids the loosening problem of traditional connection methods. The hot-riveting process eliminates the need for additional connectors, simplifies the assembly process, reduces costs, and results in a compact structure that does not occupy extra space, meeting the requirements of high integration design. At the same time, the hot-riveting connection ensures the relative fixation between the circuit board and the tab welding bracket 261, preventing displacement of the sampling nickel sheet 3101 due to vibration and ensuring the stability of signal acquisition.

[0072] Reference Figure 3 and Figure 4 In one embodiment, the battery module further includes: a module housing with a top-opening cavity, wherein the narrow sides of a plurality of individual battery cell sub-modules 301 face the bottom wall of the module housing and are stacked parallel to each other inside the module housing, wherein an explosion-proof weak zone is provided at the end of each individual battery cell 320 away from the bottom wall of the module housing; a flow guide plate 251, which covers the top opening of the module housing, is provided with a flow guide hole 252 corresponding to the explosion-proof weak zone, and a gas-blocking partition structure 255 is provided between the individual battery cell 320 and the flow guide plate 251 to form an independent exhaust channel 256 between each individual battery cell 320.

[0073] The module box is a cavity structure that carries the individual battery cell sub-module 301. The top opening is designed to provide space for the installation of the guide plate 251 and the construction of the exhaust channel 256. The bottom wall is a liquid cooling plate 340 for heat dissipation. The individual battery cell sub-modules 301 are stacked perpendicular to the bottom wall of the module box and in parallel to ensure space utilization and heat dissipation efficiency. The explosion-proof weak area at the end of the individual battery cell 320 away from the bottom wall is used to release high-temperature gases in case of thermal runaway. Specifically, the explosion-proof weak area refers to the area where the two large surfaces, two tab surfaces, and bottom narrow surface of the battery cell are reinforced and protected by structural adhesive, protective shell, etc., while the top narrow surface is not reinforced and protected. When the individual battery cell 320 experiences thermal runaway, because this area is not reinforced and protected, high-temperature gases are released in this area. The guide plate 251 is typically a steel plate, a plate-shaped component that covers the top opening of the module box. The guide holes 252 correspond one-to-one with the explosion-proof weak points of each individual battery cell 320. The partition structure 255 is a sealing structure set between the individual battery cell 320 and the guide plate 251, used to block the gas flow in the exhaust areas of adjacent battery cells, forming an independent exhaust channel 256. During assembly, multiple individual battery cell sub-modules 301 are first stacked vertically and parallel inside the module box, and then the guide plate 251 is covered on the top opening of the module box, ensuring that the guide holes 252 are aligned with the explosion-proof weak points, and the partition structure 255 blocks the gas flow between adjacent battery cells.

[0074] This embodiment achieves the construction of a dedicated independent exhaust channel 256 for each battery cell through the collaborative design of the module box, the cell stack 300, and the guide plate 251, avoiding the gas turbulence problem caused by traditional integrated exhaust. The alignment of the guide hole 252 with the explosion-proof weak area ensures the rapid exhaust of thermal runaway gas, and the baffle structure 255 blocks the gas exchange between adjacent cells, structurally preventing high-temperature gas from carrying heat and impacting undamaged cells, providing a basic guarantee for single-cell failure isolation and improving the safety and reliability of the battery module.

[0075] Furthermore, the battery module also includes: an exhaust plate 253, disposed on the side of the guide plate 251 away from the cell stack 300, and provided with an ejection structure 257 corresponding to each of the guide holes 252.

[0076] The exhaust plate 253 is typically a steel plate, a plate-shaped component located on the side of the guide plate 251 away from the cell stack 300, and is usually fixed by adhesive bonding (see reference). Figure 3 , Figure 4The ejection structure 257 is a structure whose surface corresponds one-to-one with the guide hole 252, used to constrain the direction and range of exhaust. The exhaust plate 253 cooperates with the guide plate 251 to form a complete exhaust path of "explosion-proof weak area → guide hole 252 → ejection structure 257". The ejection structure 257 can prevent high-temperature gas from directly diffusing to non-designated areas outside the module, while strengthening the sealing of each independent exhaust channel 256 to prevent gas from flowing between the guide plate 251 and the exhaust plate 253. During assembly, the exhaust plate 253 is fixed above the guide plate 251 to ensure that the ejection structure 257 and the guide hole 252 are precisely aligned.

[0077] The combination of the exhaust plate 253 and the guide plate 251 extends and optimizes the function of the independent exhaust channel 256. The ejection structure 257 can directionally guide the thermal runaway gas, reducing the impact of gas discharge on the surrounding components of the module and the thermal radiation. At the same time, the exhaust plate 253 improves the structural integrity of the top of the module, enhancing the module's impact resistance while ensuring smooth exhaust, and further improving the overall safety and stability of the battery module.

[0078] In one embodiment, the ejection structure 257 includes a baffle 254; the baffle 254 is flush with the exhaust plate 253, one end of which is connected to the exhaust plate 253, and the other end is disconnected from the exhaust plate 253.

[0079] Reference Figure 3 and Figure 4 The baffle 254 is the core component of the ejection structure 257. It is made of high-temperature resistant metal (such as aluminum alloy) and is flush with the exhaust plate 253 to ensure a flat top structure of the module and avoid protruding parts occupying extra space or affecting surrounding assembly. Only one end of the baffle 254 is fixedly connected to the exhaust plate 253, while the other ends are disconnected. When the corresponding single cell 320 experiences thermal runaway, the strong air pressure will bend the baffle 254 outward along the fixed end to form an open ejection port, ensuring smooth gas discharge. At the same time, the unopened baffle 254 can prevent hot air or ash from entering the corresponding independent exhaust channel 256.

[0080] The ejection structure 257 features a simple design, preventing the disorderly diffusion of high-temperature gases without adding complex components. The connection between the baffle 254 and the exhaust plate 253 balances structural strength and exhaust efficiency, capable of withstanding the impact force during gas discharge without causing internal pressure buildup due to structural enclosure. The directional ejection design reduces the impact of high-temperature gases on surrounding components, further optimizing the single-cell failure isolation effect and improving the module's reliability in thermal runaway scenarios.

[0081] In one embodiment, the partition structure 255 is a structural adhesive strip (not shown in the figure) provided between the protective shell 324 and the guide plate 251, wherein the protective shell 324 is provided with an avoidance structure to avoid the explosion-proof weak zone.

[0082] Structural adhesive strips are elastic components with good sealing and adhesion properties, and are disposed between the contact surfaces of the protective shell 324 and the guide plate 251 (see reference). Figure 4 , Figure 9 The partition structure 255 serves to block gas flow between the exhaust channels 256 of adjacent cells, while also enhancing the connection stability between the protective shell 324 and the guide plate 251. The clearance structure consists of through holes or notches on the protective shell 324, used to avoid the explosion-proof weak points of the individual cell 320, ensuring that the explosion-proof weak points can be activated normally in the event of thermal runaway, allowing gas to smoothly enter the guide hole 252. During assembly, a structural adhesive strip is placed between the contact surfaces of the protective shell 324 and the guide plate 251 to ensure that the clearance structure is aligned with the explosion-proof weak points. In this embodiment, the individual cell 320 is a pouch cell, and the explosion-proof weak point is a heat-sealed structure on a narrow surface, i.e., insulating tape adhered to the heat-sealed structure. The upper shell 3241 of the protective shell 324 only covers a portion of the narrow surface, thus forming the clearance structure.

[0083] The structural adhesive strip, acting as a partition structure 255, achieves the dual functions of sealing and structural reinforcement. While ensuring the effectiveness of the independent exhaust channel 256, it also improves the overall structural compactness of the module. The avoidance structure design ensures unobstructed exhaust paths, avoids functional conflicts between the protective shell 324 and the explosion-proof weak areas and guide holes 252, further optimizes the module's safety protection logic, and improves exhaust efficiency and isolation effect in the event of thermal runaway.

[0084] In one embodiment, the single-cell battery module 301 further includes insulation cotton 302 and phase change heat insulation plate 303; wherein the insulation cotton 302, the single-cell battery 320 which is wrapped around the protective shell 324, and the phase change heat insulation plate 303 are stacked in sequence.

[0085] Reference Figure 7The insulation cotton 302 is a heat insulation component used to reduce heat exchange between the individual battery cell 320 and the surrounding environment, maintaining a stable cell temperature under normal operating conditions. The phase change insulation plate 303 is a component that utilizes the characteristics of phase change materials to absorb heat when the temperature of the individual battery cell 320 rises, especially inhibiting a rapid temperature rise in the early stages of thermal runaway, and further blocking heat transfer in conjunction with the protective shell 324. The individual battery cell sub-module 301 is composed of the insulation cotton 302, the individual battery cell 320 wrapped with the protective shell 324, and the phase change insulation plate 303 stacked sequentially. Multiple stacked sub-units are continuously stacked to form a complete battery cell stack 300. During assembly, the insulation cotton 302, the individual battery cell 320 with the protective shell 324, and the phase change insulation plate 303 are stacked sequentially to form the individual battery cell sub-module 301, and then multiple individual battery cell sub-modules 301 are stacked to form the battery cell stack 300.

[0086] The synergistic effect of the thermal insulation cotton 302 and the phase change heat insulation board 303 constructs a dual thermal protection system of active heat absorption and passive heat insulation, ensuring the temperature stability of the battery cells under normal operating conditions and slowing down the rate of heat spread in thermal runaway scenarios. Combined with the independent exhaust channel 256, it forms a synergistic protection of heat insulation and exhaust, further enhancing the safety performance of the module. At the same time, the modular stacking design makes the assembly of the battery cell stack 300 more convenient, facilitating later maintenance and replacement.

[0087] In one embodiment, the battery module further includes two insulation plates 304 disposed at both ends of the cell stack 300.

[0088] The insulation board 304 is a plate-shaped component made of high-efficiency thermal insulation materials such as aerogel and high-strength insulation cotton. Its dimensions are adapted to the end face dimensions of the battery cell stack 300, and it is used to completely cover both end faces of the battery cell stack 300 (see reference). Figure 7 Two insulation plates 304 are respectively installed at both ends of the cell stack 300 (along the stacking direction of the individual cells 320) to block heat transfer between the cell stack 300 and the module box end plate, preventing heat from diffusing from the ends of the cell stack 300 to the outside of the module or being transferred in the opposite direction, while reducing the impact of the external ambient temperature on the cell stack 300. An inlet plate 270 is also provided on the outside of the insulation plates 304 to guide the cell stack 300 into the module box. During assembly, the two insulation plates 304 are first installed at both ends of the cell stack 300, and then the cell stack 300 is guided into the module box through the inlet plate 270.

[0089] The insulation plates 304 at both ends of the cell stack 300 complete the module's thermal protection system, forming a comprehensive thermal insulation structure that integrates cell insulation and end insulation, effectively reducing the disordered heat transfer within the module. The insulation plates 304 also provide a certain degree of cushioning, reducing collision damage between the cell stack 300 and the end plates under vibration and impact conditions, thus combining thermal protection and structural protection functions. The guide plate 270 enhances the ease of assembly of the cell stack 300 into the enclosure, further optimizing the module's assembly efficiency and environmental adaptability.

[0090] Reference Figure 3 , Figure 4 and Figure 12 In one embodiment, the module box includes: a liquid cooling plate 340; end plates (generally longitudinal beams 112 as described below, or plate-like structures can be specially designed), located at both ends of the cell stack 300 along a stacking direction perpendicular to the individual cells 320, for clamping the cell stack 300; and tab side plates 220, disposed on the outside of the tab welding bracket 261; wherein the module box is formed by the liquid cooling plate 340 as the bottom wall, the two end plates, and the two tab side plates 220 as the side walls.

[0091] The liquid cooling plate 340 serves as a heat dissipation component on the bottom wall of the module box, dissipating the heat generated by the individual battery cells 320 during operation and maintaining the cell temperature within a reasonable range. The end plates are plate-shaped components positioned at both ends of the battery cell stack 300 perpendicular to the stacking direction of the individual battery cells 320. They are secured with bolts or other fasteners to clamp and fix the battery cell stack 300, preventing loosening. The tab side plates 220 are plate-shaped components located outside the tab welding bracket 261, protecting the welding area of ​​the tabs 321 and ensuring electrical safety. The cavity formed by the liquid cooling plate 340, end plates, and tab side plates 220 provides a stable installation space for components such as the battery cell stack 300 and the flow guide plate 251. During assembly, the liquid cooling plate 340 is first placed as the bottom wall, then the two end plates and two tab side plates 220 are assembled as side walls to form the module box. Finally, the battery cell stack 300 is installed inside the module box and secured with the end plates.

[0092] The enclosed design of the module box integrates structural load-bearing, heat dissipation, and electrical protection. The liquid cooling plate 340 addresses the heat dissipation requirements of the cell stack 300, the end plates ensure the stacking stability of the cell stack 300, and the tab side plate 220 provides protection for the welding area of ​​the tab 321. The coordinated operation of all components makes the module box structure compact and space-efficient, avoiding the space waste caused by traditional separate designs. At the same time, it improves the overall structural strength and assembly efficiency of the module, meeting the design requirements of high integration and high reliability of power batteries.

[0093] Furthermore, the tab side plate 220 features a hollow design. This hollow design ensures electrical safety clearances and creepage requirements within a minimal space. Simultaneously, the hollow design allows structural adhesive to enter the module housing during the potting process, resulting in a more secure connection between the cell stack 300 and the module housing.

[0094] In one embodiment, a heat insulation plate 350 is provided on the bottom surface of the liquid cooling plate 340.

[0095] The heat insulation plate 350 is a plate-shaped component made of high-temperature resistant and heat-insulating materials such as mica board and silicone foam composite board. Its dimensions are identical to the bottom surface dimensions of the liquid cooling plate 340, and it is used to completely cover the bottom surface of the liquid cooling plate 340. The heat insulation plate 350 is located on the bottom surface of the liquid cooling plate 340 (the side furthest from the cell stack 300). Its main function is to block heat exchange between the liquid cooling plate 340 and the external environment of the module, preventing the liquid cooling plate 340 from transferring heat to the outside during heat dissipation, or from the external high-temperature environment transferring heat to the liquid cooling plate 340, ensuring that the heat dissipation efficiency of the liquid cooling plate 340 is not affected by the external environment. During assembly, the heat insulation plate 350 is fixedly installed on the bottom surface of the liquid cooling plate 340, ensuring complete coverage and secure fixation.

[0096] The heat insulation plate 350 on the bottom surface of the liquid cooling plate 340 optimizes the module's heat dissipation system, reduces ineffective heat transfer, and makes the heat dissipation efficiency of the liquid cooling plate 340 more concentrated, further improving the accuracy of temperature control of the individual battery cells 320. At the same time, the heat insulation plate 350 can also provide a certain degree of protection for the liquid cooling plate 340, avoiding damage to the liquid cooling plate 340 from external impacts, corrosion, etc., extending the service life of the liquid cooling plate 340, and indirectly improving the overall reliability of the battery module.

[0097] In one embodiment, the space between the tab side plate 220 and the cell stack 300 is filled with sealing adhesive.

[0098] Sealing adhesive, such as high-temperature resistant structural adhesive, is used to fill the gap between the tab side plate 220 and the cell stack 300 to form a sealing layer. If the gap between the tab side plate 220 and the cell stack 300 is not sealed, it may become a channel for heat transfer or gas leakage. In the event of thermal runaway, high-temperature gas may diffuse through this gap to the tab 321 area, causing a short circuit or damage to the tab 321. During assembly, sealing adhesive is filled into the gap between the tab side plate 220 and the cell stack 300 to ensure complete filling and the formation of a reliable sealing layer.

[0099] The sealing adhesive achieves a dual function of sealing and reinforcing between the tab side plate 220 and the cell stack 300. It effectively blocks heat transfer from the gap to the tab 321 area, avoiding the risk of short circuits in tab 321 caused by high-temperature gas carrying conductive dust, thus ensuring electrical safety. Simultaneously, the sealing adhesive enhances the overall structural integrity of the module, improves its stability under vibration and impact conditions, and further optimizes the module's safety protection system.

[0100] In one embodiment, a thermally conductive adhesive strip 241 is provided between the battery cell stack 300 and the liquid cooling plate 340.

[0101] Reference Figure 12 The thermally conductive adhesive strip 241 is a strip-shaped component made of a flexible material with high thermal conductivity. Its thickness is determined according to the design gap between the battery cell stack 300 and the liquid cooling plate 340. The thermally conductive adhesive strip 241 is disposed between the bottom surface of the battery cell stack 300 (i.e., the lower shell 3243) and the upper surface of the liquid cooling plate 340, so that the heat generated by the individual battery cell 320 during operation can be transferred to the liquid cooling plate 340 more efficiently, improving heat dissipation efficiency. During assembly, the thermally conductive adhesive strip 241 is tightly attached between the battery cell stack 300 and the liquid cooling plate 340 to ensure complete coverage of the contact area and filling of tiny gaps.

[0102] The thermally conductive adhesive strip 241 effectively reduces the contact thermal resistance between the cell stack 300 and the liquid cooling plate 340, improves heat transfer efficiency, and ensures that the temperature of the individual cell 320 can be dissipated in time, preventing heat from accumulating at the bottom of the cell. At the same time, the flexible nature of the thermally conductive adhesive strip 241 can buffer the vibration and impact between the cell stack 300 and the liquid cooling plate 340, reducing component damage caused by hard contact, thus balancing heat dissipation performance and structural protection, and improving the operational stability of the module.

[0103] Furthermore, thermally conductive adhesive is also filled between the battery cell stack 300 and the liquid cooling plate 340.

[0104] Thermally conductive adhesive is a gel-like material with high thermal conductivity, such as thermally conductive silicone. After the thermally conductive adhesive strip 241 is installed, it is filled into the remaining gap between the battery cell stack 300 and the liquid cooling plate 340. The thermally conductive adhesive strip 241 first serves a positioning function, ensuring that the installation height of the battery cell stack 300 in the module box meets the design requirements. Simultaneously, its own rigidity supports the battery cell stack 300, preventing displacement during the filling of the thermally conductive adhesive. After filling, the thermally conductive adhesive forms a continuous thermally conductive layer with the thermally conductive adhesive strip 241, completely covering the contact surface between the battery cell stack 300 and the liquid cooling plate 340, further reducing contact thermal resistance and improving the uniformity of heat dissipation. During assembly, the thermally conductive adhesive strip 241 is installed first to position the battery cell stack 300, and then the remaining gap is filled with thermally conductive adhesive, ensuring uniform filling without air bubbles.

[0105] The combined design of the thermally conductive strip 241 and the thermally conductive adhesive achieves a synergistic function of positioning and efficient heat dissipation. The thermally conductive strip 241 ensures installation accuracy and structural stability, while the thermally conductive adhesive provides comprehensive thermal coverage of the contact surface, significantly improving heat dissipation efficiency and uniformity, and preventing overheating issues in individual battery cells 320 caused by poor local heat dissipation. Simultaneously, the filling with thermally conductive adhesive enhances the connection between the battery cell stack 300 and the liquid cooling plate 340, improves the module's vibration resistance, and further optimizes the overall performance of the module.

[0106] Reference Figure 1 The present invention also provides an irregularly shaped battery pack 100, which includes the battery module 200 described in any of the above embodiments.

[0107] The irregularly shaped battery pack 100 is an energy storage device integrating multiple battery modules 200. These modules are connected in a preset series-parallel configuration to form an energy output unit that meets actual power consumption needs. The battery pack 100 also includes a multi-layered load-bearing enclosure, a heat dissipation structure, a battery management system (BMS), and a cover covering the top of the enclosure. The battery modules 200 are connected to the bottom plate of the enclosure by applying thermally conductive adhesive. Thermally conductive silicone pads (or rigid strips) ensure the thickness of the adhesive layer at the bottom, guaranteeing the heat dissipation efficiency and installation stability of the battery modules 200. During assembly, multiple battery modules 200 are installed in the enclosure according to a preset layout, completing the series-parallel connection. The heat dissipation structure, battery management system, and cover are then installed to form the complete irregularly shaped battery pack 100.

[0108] The irregularly shaped battery pack 100 adopts the aforementioned battery module 200, inheriting the advantages of the battery module 200, such as stable structure, reliable welding, efficient assembly, and strong safety protection, effectively improving the overall reliability and service life of the battery pack 100. The standardized design of multiple battery modules 200 facilitates the assembly, maintenance, and replacement of the battery pack 100, reducing its production and maintenance costs. The high integration and lightweight design of the battery module 200 helps to improve the energy density of the battery pack 100, adapting to the application needs of different scenarios such as new energy vehicles and energy storage systems. At the same time, the excellent heat dissipation and structural stability design reduces safety hazards and improves the safety of use.

[0109] Reference Figure 13 and Figure 14In one embodiment, the irregularly shaped battery pack includes a first housing 110 and a second housing 120 that carry the battery module 200; the second housing 120 includes a plurality of units, which are spaced apart on the first housing 110 so that a clearance space is formed between adjacent second housings 120; a reinforcing beam 141 is connected between adjacent second housings 120, and the end of the reinforcing beam 141 away from the first housing 110 is lower than the top surface of the second housing 120.

[0110] The first-layer housing 110 is the basic load-bearing component of the irregularly shaped battery pack 100, used to support the upper structure and adapt to the vehicle's installation area. High-strength aluminum alloy can be used to balance load-bearing capacity and lightweight requirements. The second-layer housing 120 is the carrier for installing the battery modules 200. The number can be flexibly adjusted according to the distribution of the heavy-duty truck's main beam and the total capacity requirements of the battery pack 100 (e.g., 2-4 units). The clearance space between adjacent second-layer housings 120 matches the width and height of the main beam to ensure that the housings do not interfere with the main beam during installation. The reinforcing beam 141 is a plate-like structure made of the same material as the first-layer housing 110. Both ends are fixed to the side walls of the adjacent second-layer housing 120 by bolts. Its top surface is lower than the top surface of the second-layer housing 120 to ensure that the clearance space function is not affected, while simultaneously connecting the discrete second-layer housings 120 into a whole. During assembly, multiple second-layer boxes 120 are first installed on the first-layer box 110 at intervals, then reinforcing beams 141 are connected between adjacent second-layer boxes 120, and finally the battery module 200 is installed into each second-layer box 120.

[0111] Reference Figure 16 The aforementioned reinforcing beam 141 includes a reinforcing beam body 1411, with protruding edges 1413 at both ends along its length. Through holes are provided on the protruding edges 1413 to facilitate the passage of screws or similar devices to securely connect the reinforcing beam body 14111 to the second-layer housing 120. Furthermore, the reinforcing beam body 1411 has a hollowed-out portion to reduce its weight and material usage. Mounting protrusions 1412 are also provided on both sides of the reinforcing beam body 1411 for fixing the reinforcing member 142 described below. Specifically, the mounting protrusions 1412 are fixedly connected to the horizontal mounting surface 143 of the reinforcing member 142.

[0112] This embodiment solves the compatibility problem between the irregularly shaped battery pack 100 and the heavy-duty truck beam by creating a clearance space through the spaced arrangement of the second-layer housing 120, thus meeting the overall vehicle layout requirements. The reinforcing beam 141 compensates for the structural discontinuity caused by the spaced distribution of the second-layer housing 120, enhances the overall load-bearing capacity of the second-layer housing 120, avoids stress concentration in the gap area due to bumps and impacts during vehicle operation, ensures the installation stability of the battery module 200, reduces the risk of structural damage, and does not affect the normal function of the clearance space.

[0113] In one embodiment, the irregularly shaped battery pack further includes a third housing 130 that carries the battery module 200; the third housing 130 includes two, which are respectively disposed on the second housing 120 located on both sides.

[0114] The third-layer housing 130 is also used to install the battery module 200. It consists of two housings, one on each side of the second-layer housing 120. This is because the central section of the heavy-duty truck beam typically integrates key components such as suspension and transmission, leaving insufficient space for the third-layer housing 130 structure. The bottom surface of the third-layer housing 130 fits snugly against the top surface of the second-layer housing 120, and the connection is detachable via bolts, facilitating future maintenance and replacement of the battery module 200. Its dimensions are compatible with the second-layer housing 120, ensuring the coordination of the multi-layer structure. During assembly, the two third-layer housings 130 are fixed to the second-layer housings 120 on each side, and then the battery module 200 is installed into the third-layer housing 130.

[0115] Adding two third-layer housings 130 increases the installation capacity of the battery pack 100 without occupying additional space in the vehicle, meeting the long-range requirements of heavy-duty trucks and other commercial vehicles. The third-layer housings 130 are only located on the two second-layer housings 120 on either side, avoiding interference with key components in the middle of the frame. This balances capacity increase with vehicle compatibility, and the symmetrical distribution structure ensures more even stress distribution across the multiple housings, improving the structural stability of the battery pack 100. It should be noted that the first-layer housing 110, second-layer housing 120, and third-layer housing 130 are provided with inter-housing gaps 101, forming exhaust channels.

[0116] In one embodiment, a reinforcing member 142 is provided on one side of each of the two third-layer boxes 130; the side of the reinforcing member 142 is fixed to the side of the third-layer box 130 and the side of the second-layer box 120 below the third-layer box 130.

[0117] Reference Figures 13-15 The reinforcing member 142 is a plate-like structure made of high-strength steel or aluminum alloy. The number of reinforcing members 142 is the same as that of the third-layer housing 130 (i.e., two), and they are respectively attached to the inner side walls of the two opposing third-layer housings 130. The sides (vertically) of the reinforcing members 142 are fixed to the inner side walls of the third-layer housing 130 and the inner side wall of the lower second-layer housing 120 by welding or bolts. The height of the reinforcing member 142 is approximately the same as the height of the third-layer housing 130, meaning that the reinforcing member 142 is in close contact with the third-layer housing 130 over a large area, ensuring that the load can be effectively transferred to the second-layer housing 120. During assembly, the reinforcing members 142 are attached to the connection between the third-layer housing 130 and the second-layer housing 120 and fixed with fasteners.

[0118] The reinforcing member 142 establishes a lateral rigid connection between the third-layer housing 130 and the second-layer housing 120. This transfers the lateral impact and vibration loads experienced by the third-layer housing 130 during vehicle operation to the second-layer housing 120, preventing the third-layer housing 130 from swaying or loosening due to independent force. This connection method enhances the overall synergy of the multi-layer housing, making the third-layer housing 130 and the second-layer housing 120 form a stable force-bearing unit, improving the housing's resistance to deformation, and further ensuring the installation stability of the battery module 200.

[0119] In one embodiment, the bottom surface of the reinforcing member 142 is fixed to the reinforcing beam 141.

[0120] Reference Figure 15 The reinforcing member 142 includes a vertical mounting surface 144 and a horizontal mounting surface 143. The horizontal mounting surface 143 extends outward at a 90-degree angle from the bottom of the vertical mounting surface 144. A perforation is provided on the side (vertical mounting surface 144), and a reinforcing rib 145, which gradually widens from top to bottom, is provided between the side and the bottom surface. The bottom surface of the horizontal mounting surface 143 is abutted against the top surface of the mounting protrusion 1412 of the reinforcing beam 141 and fixed with bolts, thus connecting the reinforcing member 142 simultaneously to the third-layer housing 130, the second-layer housing 120, and the reinforcing beam 141. During assembly, the side surface of the reinforcing member 142 is first fixed to the third-layer housing 130 and the second-layer housing 120, and then its bottom surface is fixed to the reinforcing beam 141, forming a complete force transmission structure.

[0121] The bottom surface of the reinforcing member 142 is fixed to the reinforcing beam 141, forming a closed loop of force transmission: "third-layer box 130 - reinforcing member 142 - second-layer box 120 - reinforcing beam 141", which significantly improves the overall rigidity of the multi-layer box. The hollow design achieves lightweighting, meeting the weight reduction requirements of new energy vehicle components. The gradually widened reinforcing ribs 145 further optimize the stress performance of the reinforcing member 142 and extend its service life. At the same time, the integrated structure reduces connection nodes and lowers the risk of loosening.

[0122] In one embodiment, the first side plates 131 of the two third-layer boxes 130 are provided with through holes along the height direction; the second side plate 121 of the second-layer box 120 corresponding to the first side plate 131 is provided with screw holes 150 corresponding to the through holes; the first side plate 131 and the second side plate 121 are connected by screws 151 based on the through holes and screw holes 150.

[0123] The first side panel 131 is the side wall of the third layer box 130 along the distribution direction of the second layer box 120. The through holes are circular light holes, and 3-5 through holes are provided on each side of the first side panel 131 and are evenly distributed along the length direction (see reference). Figure 10 , Figure 11The second side plate 121 is the side wall of the second layer box 120 corresponding to the first side plate 131. The screw holes 150 are internally threaded holes, and their number and position perfectly match the through holes. The screw 151 is a high-strength bolt, longer than the height of the third layer box 130. After passing through the through holes, it is threaded into the screw holes 150, and after tightening, the third layer box 130 and the second layer box 120 fit tightly together. During assembly, the screw 151 is passed through the through holes of the first side plate 131 and tightened into the screw holes 150 of the second side plate 121 for fixation.

[0124] The first side plate 131 and the second side plate 121 are connected by screws 151, providing rigid constraints along the height direction for the third-layer housing 130 and the second-layer housing 120. This effectively resists the tendency of the two to separate when the vehicle is bumpy, enhancing the connection's firmness. Multiple evenly distributed screws 151 ensure more even load distribution, preventing excessive local stress that could lead to side plate deformation or thread damage. Simultaneously, the bolted connection facilitates disassembly, providing convenience for future maintenance and replacement of the battery module 200.

[0125] In one embodiment, the first layer box 110, the second layer box 120 and the third layer box 130 are connected by fasteners 146 at both ends along the length of the box.

[0126] Reference Figure 14 and Figure 17 The length direction of the box body is along the distribution direction of the second layer box body 120, and the two ends of the length direction of the box body are the opposite sides of the two third layer box bodies 30. The fastener 146 includes a fastener body 1461, which is provided with a recess 1462. The fastener body 1461 is a long strip plate structure, and the material is the same as that of the reinforcing member 142. The design of the recess 1462 can reduce the weight and material of the fastener body 61. There are 2-3 fasteners 146 on each side of the box body, which are parallel to each other. Their height covers the total height of the first layer box body 110, the second layer box body 120, and the third layer box body 130. They are fixed to the side walls of the three layers of boxes by bolts to ensure that the fasteners 146 are tightly fitted to each layer of boxes to form a longitudinal connection. During assembly, fastener 146 is attached to the outer wall of the three-layer box, and the first layer box 110, the second layer box 120 and the third layer box 130 are fixed in sequence by fasteners.

[0127] The fasteners 146 connect the first-layer housing 110, the second-layer housing 120, and the third-layer housing 130 as a whole on the outside, strengthening the longitudinal rigidity of the multi-layer housing and preventing relative displacement of each layer of housing due to independent vibration during vehicle operation. The multiple parallel fasteners 146 can distribute the load, improve the overall impact resistance, and further optimize the overall stability of the housing without affecting the function of the inner clearance space.

[0128] In one embodiment, the first layer box 110, the second layer box 120 and the third layer box 130 are connected by a reinforcing plate 147 at both ends in the width direction of the box.

[0129] The width direction of the enclosure is perpendicular to the distribution direction of the second-layer enclosure 20, and the two ends of the width direction are perpendicular to the distribution direction of the second-layer enclosure 20 on both sides. The reinforcing plate 147 is a rectangular plate structure made of high-strength alloy and is installed on the left and right sides of the enclosure along the distribution direction of the second-layer enclosure 120. The height of the reinforcing plate 147 is consistent with the total height of the three-layer enclosure, and its width is adapted to the side wall dimensions of each layer. It is fixed to the outer side walls of the first-layer enclosure 110, the second-layer enclosure 120, and the third-layer enclosure 130 respectively by welding or bolting. The connection area must be completely fitted to avoid gaps that could lead to uneven stress. During assembly, the reinforcing plate 147 is placed over the side connection points of the three-layer enclosure and fixed using fasteners or welding.

[0130] The reinforcing plate 147 provides overall constraint to the first-layer box 110, the second-layer box 120, and the third-layer box 130 from both sides of the box, significantly improving the lateral load-bearing capacity and torsional resistance of the box, effectively resisting the torque generated when the vehicle turns or experiences lateral impact. The planar structure of the reinforcing plate 147 can disperse local stress, preventing damage to the side walls of each box layer due to concentrated stress, further ensuring the structural integrity of the box and improving the overall reliability of the battery pack 100.

[0131] Furthermore, the bottom end of the reinforcing plate 147 is provided with a folded edge 149, which is fixedly connected to the bottom plate of the first layer box 110.

[0132] The folded edge 149 is a horizontal structure formed by bending the bottom end of the reinforcing plate 147 90 degrees outwards towards the outside of the housing. Its length is the same as that of the reinforcing plate 147 to ensure sufficient connection area. The folded edge 149 is fixed to the bottom plate surface of the first-layer housing 110 by bolts, forming an additional connection node of "reinforcing plate 147 - folded edge 149 - bottom plate of first-layer housing 110", enhancing the connection strength between the reinforcing plate 147 and the first-layer housing 110. During assembly, the reinforcing plate 147 is first fixed to the side wall of the three-layer housing, and then the folded edge 149 is fixed to the bottom plate of the first-layer housing 110.

[0133] The folded edge 149 increases the connection area between the reinforcing plate 147 and the first-layer housing 110, allowing the load on the reinforcing plate 147 to be more evenly distributed to the bottom plate of the first-layer housing 110. This prevents damage to the connection node between the bottom end of the reinforcing plate 147 and the side wall of the first-layer housing 110 due to stress concentration. The folded edge 149 provides bottom support for the reinforcing plate 147, improving its stability and further optimizing the overall load-bearing performance of the housing.

[0134] In one embodiment, an exhaust hole 148 is provided on the reinforcing plate 147 in the area where the second layer box 120 and the third layer box 130 intersect.

[0135] The vent holes 148 are circular, rectangular, or elliptical holes, located on the reinforcing plate 147 in the area corresponding to the connection between the second-layer housing 120 and the third-layer housing 130. There are 2-4 vent holes evenly distributed throughout. The size of the vent holes 148 must meet the venting requirements of the battery module 200 in the event of thermal runaway, while avoiding excessive size that could affect the structural strength of the reinforcing plate 147. The edges of the holes must be chamfered to prevent sharp edges from scratching cables or operators. During assembly, the vent holes 148 are opened at the predetermined positions on the reinforcing plate 147, and then the reinforcing plate 147 is installed to the side of the housing, ensuring that the vent holes 148 are connected to the internal space of the housing and are not obstructed by other components.

[0136] The vent 148 provides an effective venting channel for the battery module 200 (especially the modules inside the second and third layer housings 120 and 130) in the event of thermal runaway, preventing safety accidents such as explosions caused by excessive pressure inside the housing and improving the thermal safety performance of the battery pack 100. The vent 148 is located at the intersection of the two housing layers, allowing for targeted discharge of high-temperature gases accumulated in this area without affecting the overall load-bearing capacity of the reinforcing plate 147, achieving a balance between safety performance and structural strength, and further improving the thermal runaway protection system of the battery pack 100.

[0137] In one embodiment, in the width direction of the housing, a hoisting hole 1175 is provided on a layer of side plates 117 on both sides of the first layer housing 110.

[0138] Reference Figure 18 , Figure 19 The first-layer side panel 117 consists of the left and right side walls of the first-layer box 110 along the distribution direction of the second-layer box 120. The lifting holes 1175 are circular through holes, located in the upper area of ​​the first-layer side panel 117. Multiple holes are set on each side of the first-layer side panel 117 and symmetrically distributed to ensure balanced force distribution on the box during lifting. The diameter of the lifting holes 1175 must be compatible with the size of the lifting equipment, and the hole walls must be reinforced (e.g., by adding metal bushings) to prevent deformation of the hole walls due to excessive force during lifting. During assembly, the lifting holes 1175 are pre-set at designated positions on the first-layer side panel 117 to ensure symmetrical positioning and precise diameter.

[0139] The installation of the lifting holes 1175 provides convenient lifting points for the installation and removal of the irregularly shaped battery pack 100, eliminating the need for additional lifting structures and simplifying the vehicle assembly process. The symmetrically distributed lifting holes 1175 ensure the stability of the battery pack during lifting, preventing tilting that could lead to displacement or damage to the battery module 200. The reinforced hole walls extend the service life of the lifting holes 1175, ensuring long-term lifting safety and improving the ease of assembly of the battery pack 100.

[0140] Furthermore, the top of the first-layer side panel 117 includes three steps; wherein, the first step 1172 is the lowest step, close to the inner side of the first-layer box 110, and is used to support the second-layer box 120; the third step 1174 is the highest step, away from the outer side of the first-layer box 110, and is used to set the lifting hole 1175; the second step 1173 is located between the first step 1172 and the third step 1174, and is used to place the sealing strip of the box cover.

[0141] Reference Figure 18 The three-tiered steps at the top of the first-layer side panel 117 are a single-piece molded structure. The height difference between the steps is set according to functional requirements: the top surface of the first-tier step 1172 is flush with the bottom surface of the second-layer box 120 to support the second-layer box 120, and its width must ensure sufficient load-bearing area; the top surface of the third-tier step 1174 is higher than that of the second-tier step 1173, and the lifting hole 1175 is located on the third-tier step 1174 to ensure that the hook does not interfere with other structures during lifting, and the third-tier step 1174 has an inward protrusion, and the lifting hole 1175 is located on the protrusion to improve strength; the top surface of the second-tier step 1173 is flat and is used to place the rubber box cover sealing strip, and its width is adapted to the size of the sealing strip. During assembly, ensure that the dimensions of the three-tiered steps are adapted to the corresponding parts, and that the sealing strip is placed stably on the second-tier step 1173.

[0142] The integrated design of the three-tiered steps allows the first-layer side panel 117 to simultaneously support the second-layer enclosure 120, install the lifting hole 1175, and place the sealing strip, eliminating the need for additional independent structures, thus simplifying the enclosure structure and reducing manufacturing costs. The clear division of labor among the tiers ensures stable load-bearing, convenient lifting, and reliable sealing of the enclosure cover, enhancing the enclosure's integration and performance while balancing structural practicality and ease of assembly.

[0143] In one embodiment, a crossbeam 111 is provided inside the first layer box 110, and a support platform 116 is provided on the crossbeam 111 for supporting the second layer box 120.

[0144] Reference Figure 2 and Figure 19The crossbeam 111 is a long strip structure, made of the same material as the first-layer box 110, and is installed inside the first-layer box 110 along a direction perpendicular to the distribution of the second-layer box 120. The support platform 116 is a block structure made of high-strength alloy, with multiple platforms evenly distributed along the length of the crossbeam 111. It is fixed to the top surface of the crossbeam 111 with bolts. The top surface of the support platform 116 is at the same height and flush with the top surface of the first step 1172 of the first-layer side plate 117, ensuring that the second-layer box 120 remains level after placement. During assembly, the crossbeam 111 is first fixed inside the first-layer box 110, and then the support platforms 116 are evenly installed on the crossbeam 111 and adjusted until their top surfaces are flush.

[0145] The combination of the crossbeam 111 and the support platform 116 provides additional bottom support for the second-layer box 120, preventing uneven stress caused by the second-layer box 120 relying solely on a single side plate 117 for support. Multiple evenly distributed support platforms 116 can distribute the weight of the second-layer box 120, reducing local stress on the crossbeam 111. The bolted connection of the support platforms 116 facilitates position adjustment according to the dimensions of the second-layer box 120, improving the box's versatility and structural stability.

[0146] In one embodiment, in the width direction of the box body, a groove 1171 is provided on the inner side of a layer of side plates 117 on both sides of the first layer box body 110, and a longitudinal beam connecting structure 113 is fixedly installed in the groove 1171.

[0147] Reference Figure 18 , Figure 19 and Figure 20 The recessed groove 1171 is a rectangular groove formed by a recess on the inner side of the first-layer side plate 117 (near the interior of the first-layer box 110). Its depth and width are adapted to the dimensions of the mounting base 114 of the longitudinal beam connecting structure 113, ensuring that the longitudinal beam connecting structure 113 does not protrude from the inner surface of the first-layer side plate 117 after installation. The longitudinal beam connecting structure 113 is a metal structural component, fixed in the recessed groove 1171 by welding or bolts, and is used to connect the first-layer box 110 and the longitudinal beam 112. Two recessed grooves 1171 and corresponding longitudinal beam connecting structures 113 are provided on each side plate 117. During assembly, the longitudinal beam connecting structure 113 is fixedly installed in the recessed groove 1171, ensuring that the installation is firm and does not protrude.

[0148] The recessed groove 1171 allows the longitudinal beam connecting structure 113 to be embedded within the first-layer side plate 117, preventing it from occupying the internal space of the first-layer housing 110 and ensuring the installation area of ​​the battery module 200. The embedded installation makes the connection between the longitudinal beam connecting structure 113 and the first-layer side plate 117 tighter, improving connection strength and ensuring the fixed reliability of the first-layer housing 110 and the longitudinal beam 112. This prevents the housing from shifting during vehicle operation and enhances the overall structural stability of the battery pack 100.

[0149] In one embodiment, the longitudinal beam connection structure 113 includes a mounting base 114 adapted to the shape and depth of the sink 1171, and a protrusion 115 integrally formed with the mounting base 114, the protrusion 115 being used to fix the longitudinal beam 112.

[0150] Reference Figure 20 The mounting base 114 is a plate-like structure whose shape (rectangular) and depth perfectly match the recess 1171, ensuring that it is flush with the inner surface of the first-layer side plate 117 after installation. The protrusion 115 is a structure that protrudes from the mounting base 114 away from the first-layer side plate 117. Its shape can be rectangular or trapezoidal depending on the connection requirements of the longitudinal beam 112. The protrusion 115 has bolt holes for fixing to the longitudinal beam 112 with bolts. The mounting base 114 and the protrusion 115 are integrally formed and made of high-strength steel to ensure structural integrity and load-bearing capacity. During assembly, the mounting base 114 is fixed inside the recess 1171 and connected and fixed to the longitudinal beam 112 through the bolt holes of the protrusion 115.

[0151] The matching design of the mounting base 114 and the recess 1171 ensures the stable installation of the longitudinal beam connection structure 113, avoiding protrusion and occupation of internal space. The one-piece molded protrusion 115 simplifies the connection process with the longitudinal beam 112 and improves the strength of the connection node. It can effectively transfer the load between the box and the longitudinal beam 112, ensure the installation stability of the box during vehicle operation, reduce the risk of loosening, and further optimize the structural load-bearing performance of the battery pack 100.

[0152] Reference Figure 1 and Figure 2 In one embodiment, the first layer box 110 is provided with a maintenance window 1101 at one end of the box in the length direction; the maintenance window 1101 is detachably equipped with a maintenance cover plate 1102.

[0153] In this embodiment, the maintenance window 1101 is located on one end face of the first-layer housing 110 along its length. Its position avoids the installation areas of the second-layer housing 120 and the third-layer housing 130, as well as the critical clearance space for the main beam, ensuring that maintenance operations do not interfere with the upper structure or the vehicle main beam. The maintenance window 1101 adopts a rectangular design, and its size is determined according to the maintenance needs of core components such as battery modules and electrical connection components in the first-layer housing 110. It must meet the space for the operator's hands or commonly used maintenance tools to reach in, while avoiding the window being too large, which would weaken the strength of the housing structure.

[0154] The maintenance cover 1102 and maintenance window 1101 are precisely matched in size, and the material is the same high-strength aluminum alloy as the first-layer box 110, ensuring the material uniformity and lightweight requirements of the overall structure. The maintenance cover 1102 and maintenance window 1101 are connected by detachable bolts. The edge of the cover is provided with a sealing groove, and a rubber sealing strip is embedded in the groove. When the maintenance cover 1102 is tightened by bolts, the sealing strip fits tightly with the edge of the maintenance window 1101, achieving a waterproof and dustproof sealing effect, and ensuring the stability of the working environment of the electrical components in the first-layer box 110.

[0155] In addition, the inner surface of the maintenance cover 1102 can be provided with reinforcing ribs (not marked in the figure) to further enhance the structural strength of the cover itself and prevent the maintenance cover 1102 from deforming due to vibration during vehicle operation; the outer surface of the maintenance cover 1102 can be reserved with wrench operating space to facilitate quick disassembly of bolts during maintenance and improve maintenance efficiency.

[0156] This embodiment, by setting a maintenance window 1101 and a removable maintenance cover 1102, allows for the inspection, maintenance, and replacement of core components within the first-layer battery pack housing 110 without disassembling the entire battery pack housing (including the first-layer housing 110, the second-layer housing 120, the third-layer housing 130, and related structures such as the reinforcing beam 141 and reinforcing member 142). This significantly simplifies the maintenance process and reduces overall vehicle maintenance costs and downtime. The sealed design ensures that the maintenance window 1101 does not affect the overall protective performance of the housing, preventing external moisture and dust from entering the first-layer housing 110 and causing electrical faults. The location of the maintenance window 1101 is cleverly designed to avoid key load-bearing structures (such as the crossbeam 111 and the longitudinal beam connection structure 113) and the fitting area, ensuring maintenance convenience without weakening the structural strength and vehicle compatibility of the housing, further enhancing the practicality and ease of maintenance of the irregularly shaped battery pack housing.

[0157] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A battery module, characterized in that, include: The battery cell stack has multiple first mounting structures on the end side of its output tab; The electrode welding bracket is provided with a second mounting structure adapted to the first mounting structure, wherein the electrode welding bracket is mounted on the cell stack through the cooperation of the second mounting structure and the first mounting structure; A flexible low-voltage sampling circuit board is disposed on the side of the electrode welding bracket away from the cell stack, wherein the flexible low-voltage sampling circuit board is provided with a buffer portion along the stacking direction of the cell stack.

2. The battery module according to claim 1, characterized in that, The buffer section is formed by bending the flexible low-voltage sampling circuit board.

3. The battery module according to claim 1, characterized in that, The flexible low-voltage sampling circuit board has a flexible sampling section extending along its width direction; The flexible sampling section includes a first extension, a second extension, and a first sampling section, with the free ends of the first extension and the second extension respectively connected to the first sampling section.

4. The battery module according to claim 3, characterized in that, The first extension is bent and has data traces.

5. The battery module according to claim 4, characterized in that, The second extension is provided with a first tear opening.

6. The battery module according to claim 1, characterized in that, The flexible low-voltage sampling circuit board is provided with a third extension and a second sampling section at both ends along its length. The free end of the third extension is connected to the second sampling section; wherein, a second tear opening is provided at the partial connection between the third extension and the flexible low-voltage sampling circuit board.

7. The battery module according to any one of claims 1-6, characterized in that, The cell stack comprises multiple individual cell sub-modules stacked sequentially; The first mounting structure is disposed at the output tab end of the single cell sub-module; The single-cell sub-module includes: Single battery cell; A protective casing, which wraps around the outside of the individual battery cell; A tab support is disposed on the protective shell along the direction of the tab exiting the individual battery cell; wherein, the first mounting structure is disposed on the tab support. The sealing foam is attached to the other side of the electrode air bag, with the main body of the electrode bracket located on one side of the electrode air bag. The tab bracket is provided with a plug on one side and a socket on the other side along the stacking direction of the battery cell stack; adjacent tab brackets are connected based on the plug and socket.

8. The battery module according to claim 7, characterized in that, The first mounting structure is a first hot riveting post; the second mounting structure is a first hot riveting hole; The first hot riveting posts are respectively disposed at both ends of the electrode bracket along the length direction; The first hot riveting hole is a semi-circular hole with an opening on one side, and is located on the side of the electrode welding bracket.

9. The battery module according to claim 7, characterized in that, The protective shell includes: The side shell corresponds to the large surface of the corresponding individual battery cell; The top shell corresponds to the top narrow face of the corresponding single cell and is connected to the top of the side shell. The width of the top shell is less than half the width of the top narrow face to form the avoidance structure. The lower shell corresponds to the bottom narrow surface of the corresponding single cell and is connected to the bottom end of the side shell; The side shell, the top shell, and the bottom shell form a protective shell with three sides. A second hot-riveting post is provided on the electrode bracket along the thickness direction of the single cell; a second hot-riveting hole is provided on the side shell; The tab bracket and the protective shell are fixed by hot riveting using the second hot riveting post and the second hot riveting hole.

10. The battery module according to claim 7, characterized in that, The tab support is provided with a lifting groove on the top and / or bottom of the side wall away from the individual battery cell.

11. The battery module according to claim 7, characterized in that, The electrode welding bracket is provided with a recess or through groove in the area corresponding to the electrode welding; The electrode welding bracket is provided with a third hot riveting post on the side opposite to the battery cell stack; the flexible low-voltage sampling circuit board is provided with a third hot riveting hole; The flexible low-voltage sampling circuit board and the electrode welding bracket are fixed by hot riveting through the third hot riveting post and the third hot riveting hole.

12. The battery module according to claim 7, characterized in that, Also includes: The module box has a cavity with an open top. Multiple individual battery cell sub-modules have their narrow faces facing the bottom wall of the module box and are stacked parallel to each other inside the module box. The end of each individual battery cell away from the bottom wall of the module box is provided with an explosion-proof weak zone. A flow guide plate covers the top opening of the module box and is provided with flow guide holes corresponding to the explosion-proof weak areas. A baffle structure that blocks gas flow is provided between the individual battery cells and the flow guide plate so that each individual battery cell forms an independent exhaust channel. An exhaust plate is disposed on the side of the guide plate away from the battery cell stack, and is provided with an ejection structure corresponding to each of the guide holes.

13. The battery module according to claim 12, characterized in that, The ejection structure includes a baffle; The baffle is flush with the exhaust plate, with one end connected to the exhaust plate and the other end disconnected from the exhaust plate.

14. The battery module according to claim 12, characterized in that, The partition structure is a structural adhesive strip provided between the protective shell and the guide plate, wherein the protective shell is provided with a avoidance structure to avoid the explosion-proof weak area; The individual battery cell module also includes thermal insulation cotton and a phase change heat insulation board; The insulation cotton, the individual battery cell wrapped with the protective shell, and the phase change heat insulation plate are stacked in sequence.

15. The battery module according to claim 14, characterized in that, It also includes two insulation plates, which are set at both ends of the cell stack.

16. The battery module according to any one of claims 12-15, characterized in that, The module box includes: Liquid cooling plate; End plates, located at both ends of the cell stack along a stacking direction perpendicular to the individual cells, are used to clamp the cell stack. The electrode tab side plate is located on the outside of the electrode tab welding bracket; The module box is formed by the liquid cooling plate as the bottom wall, the two end plates and the two electrode side plates as the side walls. The bottom surface of the liquid cooling plate is provided with a heat insulation plate; The space between the tab side plate and the cell stack is filled with sealing adhesive; A thermally conductive adhesive strip is provided between the battery cell stack and the liquid cooling plate; The space between the battery cell stack and the liquid cooling plate is filled with thermally conductive adhesive, which is located on the side of the thermally conductive adhesive strip and has the same thickness as the thermally conductive adhesive strip.

17. An irregularly shaped battery pack, characterized in that, The battery module includes any one of claims 1 to 16.

18. The irregularly shaped battery pack according to claim 17, characterized in that, It includes a first-layer housing, a second-layer housing, and a third-layer housing that carry the battery module; The second layer of the box includes multiple units, which are spaced apart on the first layer of the box to create clearance space between adjacent second layer boxes; A reinforcing beam connects adjacent second-layer boxes, with the end of the reinforcing beam furthest from the first-layer box being lower than the top surface of the second-layer box; The third layer of the housing consists of two units, which are respectively installed on the second layer of the housing located on both sides.

19. The irregularly shaped battery pack according to claim 18, characterized in that, Reinforcing members are provided on the opposite sides of the two third-layer boxes; The side of the reinforcing member is fixed to the side of the third layer box and the side of the second layer box below the third layer box; The bottom surface of the reinforcing member is fixed to the reinforcing beam.

20. The irregularly shaped battery pack according to claim 18, characterized in that, The first side panels of the two third-layer boxes are provided with through holes along the height direction; The second layer of the housing has screw holes corresponding to the through holes on the second side plate below the first side plate; The first side plate and the second side plate are connected by screws based on the through holes and screw holes.

21. The irregularly shaped battery pack according to claim 18, characterized in that, At both ends of the length of the box, the first layer box, the second layer box, and the third layer box are connected by fasteners; The first, second, and third layers of the box are connected at both ends of the box in the width direction by reinforcing plates.

22. The irregularly shaped battery pack according to claim 21, characterized in that, The bottom end of the reinforcing plate is provided with a folded edge, which is fixedly connected to the bottom plate of the first layer box body; The reinforcing plate has exhaust holes in the area where the second and third layers of the housing intersect.

23. The irregularly shaped battery pack according to any one of claims 18-22, characterized in that, In the width direction of the box, lifting holes are provided on the side plates on both sides of the first layer of the box; The top of the first-layer side panel includes three steps; The first step is the lowest step, located near the inner side of the first layer of the box, and is used to support the second layer of the box; the third step is the highest step, located away from the outer side of the first layer of the box, and is used to set the lifting hole; the second step is located between the first step and the third step and is used to place the sealing strip of the box cover.

24. The irregularly shaped battery pack according to any one of claims 18-22, characterized in that, The first layer of the box is equipped with a crossbeam, and a support platform is provided on the crossbeam for supporting the second layer of the box.

25. The irregularly shaped battery pack according to any one of claims 18-22, characterized in that, In the width direction of the box body, a groove is provided on the inner side of the first layer of side plates on both sides of the first layer of the box body, and a longitudinal beam connecting structure is fixedly installed in the groove. The longitudinal beam connection structure includes a mounting base adapted to the shape and depth of the sinkhole, and a protrusion integrally formed with the mounting base, the protrusion being used to fix the longitudinal beam.

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