Busbar assembly and battery pack

Abstract

The invention discloses a busbar assembly and a battery pack, and belongs to the technical field of batteries, and the busbar assembly comprises at least one output bar; the at least one electric connecting piece is detachably connected with the output bar through a connecting piece; the output row is installed on the support, the support is provided with a limiting part so that the connecting piece can penetrate through the limiting part to be connected with the output row and the electric connecting piece, the limiting part is configured to be arranged in a protruding mode towards a box body of the battery pack, and at least part of the limiting part is located below the connecting piece. Therefore, the distance between the bracket and the box body of the battery pack is reduced, and the connecting piece is prevented from falling off through a gap between the box body and the bracket.

Description

Technical Field

[0001] This application relates to the field of battery technology, and in particular to a busbar assembly and a battery pack. Background Technology

[0002] In related technologies, battery packs include individual battery cells. Each individual battery cell has output connection bars at both its positive and negative terminals. These output connection bars are connected to electronic components such as the BMS and / or BDU inside the battery pack via copper busbars. The copper busbars are then connected to the output connection bars by bolt fastening. Due to creepage distance and clearance requirements, a certain gap is maintained between the output connection bars and the battery pack housing to meet electrical insulation requirements. During the bolt fastening process, bolts can fall out through the gap between the output connection bars and the housing, affecting production cycle time and even causing quality problems. Currently, manual or visual identification of hole positions is used to determine if bolts have fallen out, but there are still no effective measures to address bolt falls or situations where bolts are blindly fastened. Summary of the Invention

[0003] This application provides a bus assembly and a battery pack to at least partially solve the above-mentioned technical problems.

[0004] To achieve the above objectives, according to a first aspect of this application, a bus assembly for a battery pack is provided, comprising: At least one output row; At least one electrical connector is detachably connected to the output port via a connector; A bracket is provided, on which the output port is mounted. The bracket has a limiting portion for the connector to pass through the limiting portion to connect the output port and the electrical connector. The limiting portion is configured to protrude towards the battery pack housing, and at least a portion of the limiting portion is located below the connector. By providing a limiting portion on the bracket, and ensuring that the limiting portion protrudes towards the battery pack housing, the distance between the bracket and the battery pack housing is reduced. Furthermore, the fact that at least a portion of the limiting portion is located below the connector effectively prevents the connector from falling into the gap between the bracket and the housing when it passes through the limiting portion to connect the output port and the electrical connector.

[0005] Optionally, the bracket includes a first sidewall and a second sidewall disposed opposite to each other along a first direction, and at least one of the first sidewall and the second sidewall is provided with the limiting portion.

[0006] Optionally, the bracket further includes a first fixing seat protruding relative to one of the first sidewall and the second sidewall, the sidewall of the first fixing seat having a first boss portion, the limiting portion including the first boss portion, the first boss portion having a first through hole for the connector to pass through; And / or, the bracket further includes a second fixing seat that protrudes relative to the other of the first and second sidewalls, the sidewall of the second fixing seat having a second boss portion, the limiting portion including the second boss portion, the second boss portion having a second through hole for the connector to pass through.

[0007] Optionally, the height of the first boss protruding from the side wall of the first fixing seat is h1, where h1 ranges from 1mm to 5mm; and / or, the height of the second boss protruding from the side wall of the second fixing seat is h2, where h2 ranges from 1mm to 5mm.

[0008] Optionally, the distance between the first boss or the second boss and the housing is set to be less than the length of the connector or less than the diameter of the connector.

[0009] Optionally, the distance between the first boss or the second boss and the housing of the battery pack is 1.0mm to 2.0mm.

[0010] Optionally, at least one of the output bars includes a positive output bar and a negative output bar; one of the positive output bar and the negative output bar includes a first main body and a first fixing part connected to each other, wherein the first fixing part is bent upward relative to the first main body; and or, the included angle between the first main body and the first fixing part is greater than 0° and less than or equal to 90°.

[0011] Optionally, the bracket further includes a bottom wall that is bent and connected to the first side wall and / or the second side wall, the bottom wall having a positive output bar fixing groove to accommodate the first main body; and / or, the bracket further includes a first fixing seat that protrudes relative to one of the first side wall and the second side wall, the first boss being disposed on the outside of the first fixing seat, and the first fixing part abutting against the inside of the first fixing seat.

[0012] Optionally, the distance between the first fixing part and the battery pack housing is h, which is greater than the sum of the height h1 of the first boss protruding from the side wall of the first fixing seat and the distance between the first boss and the battery pack housing; or the distance between the first fixing part and the battery pack housing is set to be greater than or equal to 6.0 mm.

[0013] Optionally, the first main body includes a first welding area, which is welded to the terminal post of the battery cell of the battery pack. The wall thickness of the first welding area is d1, and the wall thickness of the first fixing part is d2, where d1 < d2.

[0014] Optionally, (d2-d1) / d2 = 0.3~0.5.

[0015] Optionally, at least one of the output bars includes a positive output bar and a negative output bar; the other of the positive output bar and the negative output bar includes a second main body and a second fixing part that are bent and connected. The second fixing part includes a first bending segment, a second bending segment and a third bending segment that are bent and connected in sequence, wherein the first bending segment bends downward relative to the second main body and the third bending segment bends upward relative to the second bending segment.

[0016] Optionally, the bracket further includes a bottom wall bent and connected to the first side wall and / or the second side wall, the bottom wall having a negative output bar fixing groove, the negative output bar fixing groove being configured to receive the second main body portion; and / or, the second boss portion being disposed on the outside of the second fixing seat, the second fixing seat having a receiving cavity, the receiving cavity being configured to receive at least a portion of the second fixing portion.

[0017] Optionally, the distance between the second fixing part and the battery pack housing is h, where h is greater than the sum of the height of the second protrusion relative to the side wall of the second fixing seat and the distance between the second protrusion and the battery pack housing; or, the distance between the second fixing part and the battery pack housing is set to be greater than or equal to 6.0 mm.

[0018] Optionally, the second main body includes a second welding area, the wall thickness of the second welding area is d3, and the wall thickness of the second fixing part is d4, where d3 < d4.

[0019] Alternatively, (d4-d3) / d4 = 0.3~0.5.

[0020] Optionally, the bracket further includes a third sidewall and a fourth sidewall disposed opposite to each other along a second direction, the third sidewall or the fourth sidewall being connected between the first sidewall and the second sidewall; the busbar assembly further includes a plurality of connecting bars, each connecting bar being adapted to connect two adjacent battery cells of the battery pack, each connecting bar including an arch bridge portion located between the two battery cells, the third sidewall and the fourth sidewall being provided with a plurality of notches, each notch being provided with a latching portion, each latching portion abutting against the arch bridge portion to limit the displacement of the connecting bar along a third direction.

[0021] Optionally, the bracket is provided with a plurality of connecting row fixing slots, and the bracket includes a plurality of partition walls arranged at intervals along the first direction. Each partition wall is disposed between two adjacent connecting row fixing slots. The plurality of partition walls include a first partition wall and a second partition wall located on opposite sides of the same connecting row fixing slot. The first partition wall is provided with at least one first positioning piece, and the second partition wall is provided with at least one second positioning piece. The first positioning piece and the second positioning piece are respectively located on both sides of the same connecting row to limit the displacement of the connecting row along the first direction. The first direction and the third direction are intersected.

[0022] According to a second aspect of this application, a battery pack is provided, comprising: a housing; a plurality of battery cells disposed within the housing; and a bus assembly as described above, the bus assembly being electrically connected to the plurality of battery cells.

[0023] In the bus assembly of this application embodiment, a limiting part is provided on the bracket, the limiting part protruding towards the battery pack housing, so as to reduce the distance between the bracket and the battery pack housing, and at least part of the limiting part is located below the connector, so that when the connector passes through the limiting part to connect the output bus and the electrical connector, the connector can be effectively prevented from falling into the gap between the bracket and the housing.

[0024] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0026] Figure 1 This is a schematic diagram of the overall structure of the box provided in an exemplary embodiment of this disclosure; Figure 2 This is a three-dimensional structural diagram of the bus assembly provided in an exemplary embodiment of this disclosure; Figure 3 yes Figure 2 A magnified view of part A; Figure 4 yes Figure 2 A magnified view of section B; Figure 5This is a perspective view of the bus assembly provided in the exemplary embodiments of this disclosure connected to the positive and negative electrical connectors. Figure 6 This is a three-dimensional structural view of the bus assembly provided in the exemplary embodiments of this disclosure, connected to the positive and negative electrical connectors; Figure 7 This is a perspective structural diagram of the support for the bus assembly provided in an exemplary embodiment of this disclosure; Figure 8 This is a three-dimensional structural diagram of the positive output bus of the bus assembly provided in the exemplary embodiments of this disclosure; Figure 9 This is a three-dimensional structural diagram of the negative output bus of the bus assembly provided in an exemplary embodiment of this disclosure.

[0027] Explanation of reference numerals in the attached figures: 1. Enclosure; 11. Mounting holes; 2. Busbar assembly; 3. Bracket; 311. First boss; 312. Second boss; 313. First through hole; 314. Second through hole; 321. First side wall; 322. Second side wall; 323. Third side wall; 324. Fourth side wall; 325. Bottom wall; 331. Positive output bar fixing slot; 332. Negative output bar fixing slot; 333. Connecting bar fixing slot; 341. First fixing seat; 342. Second fixing seat; 343. Receiving cavity; 351. First partition wall; 352. Second partition wall; 361. First positioning piece; 362. Second positioning piece; 37. Buckle; 38. Pressure relief hole; 39. Notch; 4. Connecting row; 41. Arch bridge section; 5. Positive output bar; 51. First main body; 52. First fixing part; 53. First fixing hole; 54. First welding area; 55. First non-welding area; 6. Negative output bar; 61. Second main body; 62. Second fixing part; 621. First bending section; 622. Second bending section; 623. Third bending section; 63. Second fixing hole; 64. Second welding area; 65. Second non-welding area; 71. Positive electrical connector; 72. Negative electrical connector; 8. Connectors. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0029] In related technologies, battery packs include individual battery cells. Each individual battery cell has output connection bars at both its positive and negative terminals. These output connection bars are connected to electronic components such as the BMS and / or BDU inside the battery pack via copper busbars. The copper busbars are then connected to the output connection bars by bolt fastening. Due to creepage distance and clearance requirements, a certain gap is maintained between the output connection bars and the battery pack housing to meet electrical insulation requirements. During the bolt fastening process, bolts can fall out through the gap between the output connection bars and the housing, affecting production cycle time and even causing quality problems. Currently, manual or visual identification of hole positions is used to determine if bolts have fallen out, but there are still no effective measures to address bolt falls or situations where bolts are blindly fastened.

[0030] In view of this, this application provides a battery pack. The battery pack disclosed in the embodiments of this application can be used in electrical devices that use the battery pack as a power source or in various energy storage systems that use the battery pack as an energy storage element. Electrical devices can be, but are not limited to, mobile phones, tablets, laptops, electric toys, power tools, electric vehicles, electric cars, ships, spacecraft, etc. Electric toys can include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc. Spacecraft can include airplanes, rockets, space shuttles, and spacecraft, etc. Taking a vehicle as an example, the vehicle can be a gasoline-powered car, a natural gas-powered car, or a new energy vehicle. New energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles, etc. The battery pack is installed inside the vehicle and can be located at the bottom, front, or rear of the vehicle. The battery pack can not only serve as the operating power source for the vehicle but also as the driving power source, replacing or partially replacing gasoline or natural gas to provide driving power for the vehicle. The individual battery cells in the battery pack can also be used to power the vehicle; for example, the individual battery cells can serve as the operating power source for the vehicle. The vehicle may also include a controller and a motor, with the controller controlling the battery pack to power the motor, for example, for the vehicle's power needs during starting, navigation, and driving.

[0031] like Figure 1 , Figure 2 and Figure 5 As shown, the battery pack mentioned in the embodiments of this application includes a housing 1, at least one battery cell assembly, a bus assembly 2, and electronic components.

[0032] The housing 1 may include a separate upper housing and a lower housing, which together enclose a battery cavity and an electrical cavity. The battery cavity is configured to house at least one battery cell assembly. The electrical cavity is configured to house electronic components. Figure 1 The housing 1 shown only shows the lower housing. When the battery pack is used in a vehicle, the housing can be part of the vehicle's chassis structure. For example, a portion of the housing can be at least part of the vehicle's floor, or a portion of the housing can be at least part of the vehicle's crossbeams and longitudinal beams.

[0033] One or more battery cell assemblies are used to provide voltage and capacity. A battery cell assembly may include multiple battery cells, which are connected in series, parallel, or mixed connections via a busbar assembly. A battery cell can be a rechargeable battery, meaning a battery cell that can be recharged after discharge to reactivate its active materials and continue to be used. Battery cells can be lithium-ion batteries, sodium-ion batteries, sodium-lithium-ion batteries, lithium metal batteries, sodium metal batteries, lithium-sulfur batteries, magnesium-ion batteries, nickel-metal hydride batteries, nickel-cadmium batteries, lead-acid batteries, etc., but this application does not limit the specific type of battery cell.

[0034] As an example, a battery cell assembly is formed by arranging multiple battery cells, which are directly fixed within a housing. As yet another example, a battery cell assembly can be a battery module, which is formed by arranging and fixing multiple battery cells into a single module. A battery module can be formed by bundling multiple battery cells together with cable ties. The battery cell assembly can be housed within a housing by fixing the battery module within the housing.

[0035] The electronic components in a battery include one or more of BMS, BDU, and PDU.

[0036] BMS, short for Battery Management System, is electrically connected at both ends to the positive and negative output terminals of at least one battery cell assembly via a positive connector 71 and a negative connector 72, respectively. The BMS monitors the voltage, current, and temperature of at least one battery cell assembly and provides safety protection and control for normal charging and discharging. The BMS also provides estimates of the remaining capacity and lifespan of at least one battery cell assembly.

[0037] BDU, short for Battery Disconnect Unit, is an electrical connection at both ends of a battery cell to the positive and negative output terminals of at least one battery cell assembly via a positive connector 71 and a negative connector 72, respectively. The BDU is configured as an electrical integrated box consisting of multiple high-voltage relays (contactors), fuses, a pre-charge circuit, and current sensors, thus providing the battery pack with the functions of main positive / main negative relays, fast-charge relays, a pre-charge circuit, fuses / circuit breakers, and current sensors.

[0038] A PDU (Power Distribution Unit) is a high-voltage power distribution unit. Its two ends are electrically connected to the positive and negative output terminals of at least one battery cell assembly via a positive connector 71 and a negative connector 72, respectively. The PDU provides power distribution and management in the high-voltage system of electrical equipment, offering functions such as charge / discharge control, high-voltage component power-on control, circuit overload and short-circuit protection, high-voltage sampling, and low-voltage control, thereby protecting and monitoring the operation of the high-voltage system.

[0039] Busbar assembly 2 includes a support 3, multiple connecting bars 4, a positive output bar 5, and a negative output bar 6. The battery cell assembly includes multiple battery cells arranged along a first direction. There can be one or more battery cell assemblies, for example, multiple battery cell assemblies arranged sequentially along a second direction. The busbar assembly is located on one side of the battery cell assembly along a third direction, where the first direction can be the thickness direction of the battery cell, the second direction can be the length direction of the battery cell, and the third direction can be the height direction of the battery cell. Taking a square battery cell as an example, each battery cell has a positive and a negative terminal on its top surface. Multiple battery cells correspondingly form two rows of terminals. The multiple connecting bars 4 are arranged in two rows, where each row of connecting bars corresponds to one row of terminals of multiple battery cells, and each connecting bar 4 is configured to connect the positive and negative terminals of two adjacent battery cells.

[0040] like Figure 2 and Figure 6 As shown, the bracket 3 has multiple connecting bar fixing slots 333 corresponding to multiple connecting bars 4. The multiple connecting bar fixing slots 333 are configured in two sets for fixing multiple connecting bars 4. Each connecting bar fixing slot 333 has a through hole in its groove wall to facilitate sufficient contact surface between each connecting bar 4 and the positive or negative terminal of the corresponding battery cell.

[0041] like Figure 2 and Figure 7As shown, the bracket 3 is provided with multiple pressure relief holes 38, which are located between two sets of connecting row fixing grooves 333. Each pressure relief hole 38 corresponds to the explosion-proof valve of a battery cell, so that the high-pressure gas discharged through the explosion-proof valve of the battery cell can continue to be discharged through the pressure relief hole.

[0042] The positive output bus 5 is configured to connect the positive terminal of the battery cell assembly to the positive electrical connector 71, which can be a copper busbar. The negative output bus 6 is configured to connect the negative terminal of the battery cell assembly to the negative electrical connector 72, which can be a copper busbar. Both the positive and negative output buses can be made of copper, aluminum, or a copper-aluminum composite busbar.

[0043] like Figure 2 and Figure 6 As shown, the bracket 3 includes a first sidewall 321 and a second sidewall 322 opposite to each other along a first direction, and a bottom wall 325 bent and connected to the first sidewall 321 and the second sidewall 322. Multiple connecting row fixing grooves 333 in each group of connecting row fixing grooves 333 are spaced apart on the bottom wall 325 along the first direction. The first direction is as follows: Figure 2 The x-direction is shown.

[0044] like Figure 2 , Figure 6 and Figure 7 As shown, a positive output row fixing groove 331 and a negative output row fixing groove 332 are also provided on the bottom wall 325 of the bracket 3. The positive output row fixing groove 331 is configured to fix at least a portion of the positive output row 5, and the negative output row fixing groove 332 is configured to fix at least a portion of the negative output row 6. The positive output row fixing groove 331 is located close to the first side wall 321, and the negative output row fixing groove 332 is located close to the second side wall 322.

[0045] Among them, such as Figures 2 to 4 As shown, the bracket 3 also has a limiting part, which is configured to protrude towards the housing 1, and at least a portion of the limiting part is located below the connector 8. The connector 8 passes through the limiting part to connect the positive output port 5 and the positive electrical connector 71, or the connector 8 passes through the limiting part to connect the negative output port 6 and the negative electrical connector 72. Because the limiting part is configured to protrude towards the housing 1, the gap between the limiting part of the bracket 3 and the housing 1 can be effectively reduced, and since at least a portion of the limiting part is located below the connector 8, the connector 8 is effectively prevented from falling into the gap between the bracket 3 and the housing 1.

[0046] In some embodiments, at least one of the first sidewall 321 and the second sidewall 322 of the bracket 3 is provided with the aforementioned limiting portion, so that the limiting portion provided on the first sidewall 321 or the second sidewall 322 can block the connector 8 fixed on the first sidewall 321 or the second sidewall 322, thereby preventing the connector 8 from falling into the gap between the bracket 3 and the housing 1.

[0047] Among them, such as Figures 2 to 4 As shown, a first boss 311 is provided on the first side wall 321 of the bracket 3. The first boss 311 protrudes towards the housing 1. The limiting part includes the first boss 311, which has a first through hole 313. The first through hole 313 is configured for the connector 8 to pass through. The positive output row 5 has a first fixing hole 53, and the positive electrical connector 71 has a third fixing hole (not shown in the figure). The connector 8 is configured to first pass through the mounting hole 11 of the housing 1, then through the first through hole 313 on the first boss 311, and then sequentially through the first fixing hole 53 of the positive output row 5 and the third fixing hole of the positive electrical connector 71 to connect the positive output row 5 and the positive electrical connector 71. It should be noted that the connector 8 can also first pass through the third fixing hole on the positive electrical connector 71 and then through the first fixing hole 53 of the positive output row 5. As an example, the connector 8 includes a bolt. Since the first protrusion 311 is configured to protrude towards the housing 1, the first protrusion 311 is configured to reduce the gap between the bracket 3 and the housing 1, thereby preventing the connector 8 from falling through the gap between the bracket 3 and the housing 1 during the process of locking the positive output bar 5 and the positive electrical connector 71.

[0048] Continue to refer to Figures 2 to 4 A second protrusion 312 is provided on the second side wall 322 of the bracket 3, protruding towards the housing 1. The limiting part includes the second protrusion 312, which has a second through hole 314. The negative output row 6 is located in the second fixing hole 63, and the negative electrical connector 72 has a fourth fixing hole (not shown in the figure). The connector 8 is configured to first pass through the mounting hole 11 of the housing 1, then through the second through hole 314 on the second protrusion 312, and then sequentially through the second fixing hole 63 of the negative output row 6 and the fourth fixing hole of the negative electrical connector 72 to connect the negative output row 6 and the negative electrical connector 72. It should be noted that the connector 8 can also first pass through the fourth fixing hole on the negative electrical connector 72 and then through the second fixing hole 63 of the negative output row 6. As an example, the connector 8 includes a bolt. Since the second protrusion 312 is configured to protrude towards the housing 1, the second protrusion 312 is configured to reduce the gap between the bracket 3 and the housing 1, thereby preventing the connector 8 from falling through the gap between the bracket 3 and the housing 1 during the process of locking the negative output bar 6 and the negative electrical connector 72.

[0049] In some embodiments, such as Figure 2 and Figure 3 As shown, a first fixing seat 341 protrudes from the first sidewall 321 of the bracket 3, and a first boss 311 is disposed on the first fixing seat 341. The height of the first boss 311 protruding from the sidewall of the first fixing seat 341 is h1, and the range of h1 is 1.0mm to 5.0mm. It is understood that the electrical insulation distance, i.e., the creepage distance, between the positive output line 5 and the housing 1 is usually set to 6.0mm to 7.0mm. By setting the height of the first boss 311 protruding from the sidewall of the first fixing seat 341 to 1.0mm to 5.0mm, the installation gap between the positive output line 5 and the bracket 3 can be reserved, while the gap between the bracket 3 and the housing 1 can be effectively shortened, thereby preventing the connector 8 from falling through the gap between the bracket 3 and the housing 1. Understandably, if the height of the first protrusion 311 protruding from the side wall of the first fixing seat 341 is less than 1.0 mm, the gap between the first protrusion 311 of the bracket 3 and the housing 1 will be too large, which may cause the connector 8 to fall through the gap between the first protrusion 311 and the housing 1. If the height of the first protrusion 311 protruding from the side wall of the first fixing seat 341 is greater than 5.0 mm, while maintaining the installation gap between the bracket 3 and the housing 1, the bracket 3 will occupy a large amount of internal space in the housing 1, which is not conducive to improving the energy density of the battery pack. In a specific embodiment, the height of the first protrusion 311 protruding from the first side wall 321 is 1.0 mm, 1.5 mm, 2.0 mm, 2.3 mm, 2.5 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, or any two of the above values ​​or a range between any two of the above values.

[0050] In some embodiments, the gap between the first protrusion 311 of the bracket 3 and the housing 1 is set to be less than the length of the connector 8 or the diameter of the connector 8, thereby effectively preventing the connector 8 from falling through the gap between the first protrusion 311 and the housing 1 during the installation process, or preventing the connector 8 from falling through the gap between the first protrusion 311 and the housing 1 after it has come loose.

[0051] In some embodiments, such as Figure 2 and Figure 4As shown, a second fixing seat 342 protrudes from the second side wall 322 of the bracket 3, and a second boss portion 312 is disposed on the second fixing seat 342. The height of the second boss portion 312 protruding from the side wall of the second fixing seat 342 is h2, and the range of h2 is 1.0mm~5.0mm. It can be understood that the electrical insulation distance, i.e., the creepage distance, between the negative output row 6 and the housing 1 is usually set to 6.0mm~7.0mm. By setting the height of the second boss portion 312 protruding from the side wall of the second fixing seat 342 to 1.0mm~5.0mm, while reserving the installation gap between the negative output row 6 and the bracket 3, the gap between the second boss portion 312 of the second fixing seat 342 of the bracket 3 and the housing 1 can be effectively shortened, thereby preventing the connector 8 from falling off through the gap between the second boss portion 312 of the bracket 3 and the housing 1. Understandably, if the height of the second protrusion 312 protruding from the side wall of the second fixing seat 342 is less than 1.0 mm, the gap between the second protrusion 312 of the second fixing seat 342 of the bracket 3 and the housing 1 will be too large, which may cause the connector 8 to fall through the gap between the second protrusion 312 and the housing 1. If the height of the second protrusion 312 protruding from the side wall of the second fixing seat 342 is greater than 5.0 mm, while maintaining the installation gap between the bracket 3 and the housing 1, the bracket 3 will occupy a large amount of internal space in the housing 1, which is not conducive to improving the energy density of the battery pack. In a specific embodiment, the height of the second protrusion 312 protruding from the side wall of the second fixing seat 342 is 1.0 mm, 1.5 mm, 2.0 mm, 2.3 mm, 2.5 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, or any two of the above values ​​or a range between any two of the above values.

[0052] In some embodiments, the gap between the second protrusion 312 of the bracket 3 and the housing 1 is set to be less than the length of the connector 8 or the diameter of the connector 8, thereby effectively preventing the connector 8 from falling through the gap between the second protrusion 312 and the housing 1 during the installation process, or preventing the connector 8 from falling through the gap between the second protrusion 312 and the housing 1 after it has come loose.

[0053] In some embodiments, such as Figure 2 , Figure 3 and Figure 8As shown, the positive output busbar 5 includes a first main body 51 and a first fixing part 52. The first fixing part 52 is bent upward relative to the first main body 51. The first main body 51 is disposed in the positive output busbar fixing groove 331 on the bottom wall 325 of the bracket 3. The first fixing part 52 abuts against the inner side of the first fixing seat 341 of the bracket 3. By bending the first fixing part 52 upward, it is convenient for the first fixing part 52 of the positive output busbar 5 to be connected to the positive electrical connector 71 located on the busbar assembly 2 through the connector 8. Furthermore, when the battery cell assembly is subjected to electrical performance testing, the first fixing part 52 of the positive output busbar 5 needs to be electrically connected to the high-voltage electrical connector. By bending the first fixing part 52 upward, it is convenient for the first fixing part 52 of the positive output busbar 5 to be connected to the high-voltage electrical connector through bolts.

[0054] The included angle between the first main body portion 51 and the first fixing portion 52 is greater than 0° and less than or equal to 90°. That is, the first fixing portion 52 is bent upward relative to the first main body portion 51 so that the first fixing portion 52 of the positive output bus 5 can be connected to the positive electrical connector 71 located on the bus assembly 2 through the connector 8.

[0055] In some embodiments, the distance between the first fixing part 52 of the positive output bar 5 and the housing 1 is greater than or equal to 6.0 mm. For example, the distance between the first fixing part 52 of the positive output bar 5 and the housing 1 is 6.0 mm to 7.0 mm, ensuring sufficient electrical insulation clearance between them to prevent high-voltage breakdown and arcing of the air medium between them. It is understood that if the distance between the first fixing part 52 of the positive output bar 5 and the housing 1 is greater than 7.0 mm, it would result in wasted internal space in the housing 1. In specific embodiments, the distance between the first fixing part 52 of the positive output bar 5 and the housing 1 can be 6.0 mm, 6.1 mm, 6.3 mm, 6.5 mm, 6.7 mm, 6.9 mm, 7.0 mm, or any two of these values, or a range between any two of these values.

[0056] In some embodiments, the distance between the first fixing part 52 of the positive output row 5 and the housing 1 is h, which is greater than the sum of the height h1 of the first protrusion part 311 of the bracket 3 protruding relative to the side wall of the first fixing seat 341 and the distance between the first protrusion part 311 and the housing 1, so that the first fixing part 52 of the positive output row 5 is located inside the first protrusion part 311.

[0057] In some embodiments, continue to refer to Figure 8The first main body 51 of the positive output row 5 includes a first welding area 54 and a first non-welding area 55, wherein the wall thickness of the first welding area 54 is d1, the wall thickness of the first non-welding area 55 is the same as the wall thickness of the first fixing part 52, and the wall thickness of the first fixing part 52 is set to d2, wherein d1 < d2.

[0058] In this design, the first welding area 54 of the positive output outlet 5 is welded to the terminal post of the battery cell. Therefore, thinning the first welding area 54 helps reduce the laser energy used during welding, thereby preventing damage to the plastic support 3 caused by high-energy lasers. For example, high-energy lasers can melt the support 3. The thicker the wall of the first welding area 54, the higher the laser welding energy. By thinning the first welding area 54 of the first main body 51 of the positive output outlet 5, the laser energy can be reduced while still meeting welding requirements. At the same time, thickening the first non-welding area 55 and the first fixing part 52 of the first main body 51 of the positive output outlet 5 relative to the first welding area 54 can improve the current carrying capacity of the positive output outlet 5. Meanwhile, since the first welding area 54 of the first main body 51 is welded to the terminal post of the battery cell, and the first non-welding area 55 and the first fixing part 52 of the first main body 51 are stress-bearing areas connected to the positive electrode connector 71, the deformation of the positive electrode output row 5 can be effectively improved by thickening the first non-welding area 55 and the first fixing part 52 of the first main body 51.

[0059] In some embodiments, the wall thickness of the first welding area 54 of the first main body 51 is d1, and the wall thickness of the first fixing part 52 is d2, where (d2-d1) / d2 = 0.3~0.5. That is, the ratio of the thinning of the first welding area 54 of the first main body 51 relative to the thinning of the first fixing part 52 is 0.3~0.5. As an example, the wall thickness d1 of the first welding area 54 of the first main body 51 is 1.5mm, and the wall thickness of the first non-welding area 55 of the first main body 51 and the first fixing part 52 is 2.5mm. It is understood that if the ratio of (d2-d1) / d2 is set to less than 0.3, then while the wall thickness d2 of the first fixing part 52 remains unchanged, the wall thickness thinning of the first welding area 54 is reduced, and the high-energy laser used for welding will still damage the bracket 3. If the ratio (d2-d1) / d2 is set to be greater than 0.5, then while the wall thickness d2 of the first fixing part 52 remains unchanged, the wall thickness of the first welding area 54 will be reduced, resulting in a smaller flow capacity of the first welding area 54. In a specific embodiment, the ratio (d2-d1) / d2 can be 0.3, 0.4, 0.5, or any value between any two of the above, or a range between any two of the above values.

[0060] In some embodiments, such as Figure 2 , Figure 4 and Figure 9 As shown, the negative output outlet 6 includes a second main body 61 and a second fixing part 62 connected together. The second fixing part 62 includes a first bending segment 621, a second bending segment 622, and a third bending segment 623 connected in sequence. The first bending segment 621 bends downward relative to the second main body 61, and the third bending segment 623 bends upward relative to the second bending segment 622. By setting the second fixing part 62 of the negative output outlet 6 as a three-segment bending structure, compared with a single-segment bending structure, the three-segment bending structure has better elastic deformation capability. This allows the negative output outlet 6 to have better elastic deformation capability in its length extension direction. Under severe vibration conditions, the negative output outlet 6 can release stress through the three-segment bending structure, avoiding fatigue fracture caused by stress concentration, improving the service life of the negative output outlet 6, and reducing the failure rate of the battery pack. The bending direction of the third bending segment 623 is opposite to that of the first bending segment 621, thereby reducing the space occupied by the negative output outlet 6 in terms of height. Furthermore, the third bending section 623 bends upwards, facilitating the connection between the third bending section 623 of the second fixing part 62 of the negative output row 6 and the negative electrical connector 72 located on the busbar assembly 2 via the connector 8. Simultaneously, during electrical performance testing of the battery cell assembly, the third bending section 623 of the second fixing part 62 of the negative output row 6 needs to be electrically connected to the high-voltage electrical connector. By bending the third bending section 623 of the second fixing part 62 upwards, it is convenient to connect the third bending section 623 of the second fixing part 62 of the negative output row 6 and the high-voltage electrical connector located on the busbar assembly 2 via bolts.

[0061] In some embodiments, such as Figure 2 , Figure 4 , Figure 7 and Figure 9 As shown, the bracket 3 also includes a second fixing seat 342 protruding from the second sidewall 322. The second fixing seat 342 has a receiving cavity 343. The second main body 61 of the negative output row 6 is disposed in the negative output row fixing groove 332 of the bracket 3. At least a portion of the second fixing part 62 is received in the receiving cavity 343 of the second fixing seat 342, wherein the second boss part 312 is located on the sidewall of the second fixing seat 342. By receiving the second fixing part 62 of the negative output row 6 in the receiving cavity 343 of the second fixing seat 342, the second fixing part 62 can be stably supported on the bracket 3. This facilitates the formation of a stable connection between the negative output row 6 and the negative terminal post and negative electrical connector 72 of the battery cell assembly. It also prevents the negative output row 6 from shaking violently due to unstable positioning when the battery pack is under severe vibration, thus avoiding loosening between the negative terminal post 6 and the negative electrical connector 72 of the battery cell assembly.

[0062] In some embodiments, the distance between the second fixing part 62 of the negative output bar 6 and the housing 1 is set to be greater than or equal to 6.0 mm. For example, the distance between the second fixing part 62 of the negative output bar 6 and the housing 1 is 6.0 mm to 7.0 mm, ensuring sufficient electrical insulation clearance between them to prevent high-voltage breakdown and arcing of the air medium between them. It is understood that if the distance between the second fixing part 62 of the negative output bar 6 and the housing 1 is greater than 7.0 mm, it would result in wasted internal space in the housing 1. In specific embodiments, the distance between the second fixing part 62 of the negative output bar 6 and the housing 1 can be 6.0 mm, 6.1 mm, 6.3 mm, 6.5 mm, 6.7 mm, 6.9 mm, 7.0 mm, or any two of the above values, or a range between any two of the above values.

[0063] In some embodiments, the distance between the second fixing part 62 of the negative output row 6 and the housing 1 is h, which is greater than the sum of the height of the second protrusion 312 of the bracket 3 protruding from the side wall of the second fixing seat 342 and the distance between the second protrusion 312 and the housing 1, so that the second fixing part 62 of the negative output row 6 is located inside the second protrusion 312.

[0064] In some embodiments, continue to refer to Figure 9 The second main body 61 of the negative output row 6 includes a second welding area 64 and a second non-welding area 65, wherein the wall thickness of the second welding area 64 is d3, the wall thickness of the second non-welding area 65 is the same as the wall thickness of the second fixing part 62, and the wall thickness of the second fixing part 62 is set to d4, wherein d3 < d4.

[0065] In this design, the second welding area 64 of the second main body 61 of the negative electrode output port 6 is welded to the terminal post of the battery cell. Therefore, the thinning of the second welding area 64 helps to reduce the laser energy used in the welding process, thereby avoiding damage to the plastic support 3 caused by high-energy laser. For example, high-energy laser can melt the support 3. The thicker the wall of the second welding area 64, the higher the laser welding energy. By thinning the second welding area 64 of the second main body 61 of the negative electrode output port 6, the laser energy can be reduced while meeting the welding requirements. At the same time, the second non-welding area 65 and the second fixing part 62 of the second main body 61 of the negative electrode output port 6 are thickened relative to the second welding area 64, thereby improving the current carrying capacity of the negative electrode output port 6. Meanwhile, since the second welding area 64 of the second main body 61 is welded to the terminal post of the battery cell, and the second non-welding area 65 and the second fixing part 62 of the second main body 61 are stress-bearing areas connected to the negative electrode connector 72, the deformation of the negative electrode output row 6 can be effectively improved by thickening the second non-welding area 65 and the second fixing part 62 of the second main body 61.

[0066] In some embodiments, continue to refer to Figure 9 The wall thickness of the second welding area 64 of the second main body 61 is d3, and the wall thickness of the second fixing part 62 is d4, with (d4-d3) / d4 = 0.3~0.5. That is, the ratio of the thinning of the second welding area 64 of the second main body 61 relative to the second fixing part 62 is 0.3~0.5. As an example, the wall thickness d3 of the second welding area 64 of the second main body 61 is 1.5mm, and the wall thickness of the second non-welding area 65 of the second main body 61 and the second fixing part 62 is 2.5mm. It is understandable that if the ratio of (d4-d3) / d4 is set to less than 0.3, then under the premise that the wall thickness d4 of the second fixing part 62 remains unchanged, the wall thickness of the second welding area 64 will be reduced, and the high-energy laser used for welding will still damage the bracket 3. If the ratio (d4-d3) / d4 is set to be greater than 0.5, then while the wall thickness d4 of the second fixing part 62 remains unchanged, the wall thickness of the second welding area 64 will be reduced, resulting in a smaller flow capacity of the second welding area 64. In a specific embodiment, the ratio (d4-d3) / d4 can be 0.3, 0.4, 0.5, or any value between any two of the above, or a range between any two of the above values.

[0067] In some embodiments, such as Figure 2 , Figure 6 and Figure 7 As shown, the bracket 3 also includes a third sidewall 323 and a fourth sidewall 324 disposed opposite to each other along a second direction, both the third sidewall 323 and the fourth sidewall 324 being connected between the first sidewall 321 and the second sidewall 322. The second direction is as follows: Figure 2The y-direction is shown. Multiple notches 39 are provided on both the third sidewall 323 and the fourth sidewall 324. Each notch 39 contains a latching part 37, and each latching part 37 abuts against the arched bridge part 41 on each connecting row 4 along the third direction to limit the displacement of the connecting row 4 along the third direction, thereby providing pre-positioning for the connecting row 4 before welding to the terminal post of the battery cell. The arched bridge part 41 of the connecting row 4 is located between two adjacent battery cells, and the third direction is the height direction of the battery cell assembly, as shown. Figure 2 The Z direction is shown.

[0068] In some embodiments, continue to refer to Figure 2 , Figure 6 and Figure 7 The bracket 3 includes multiple partition walls arranged in two rows. Each row of partition walls has multiple partition walls spaced apart along a first direction. Each partition wall is located between two adjacent connecting row fixing slots 333. The multiple partition walls include a first partition wall 351 and a second partition wall 352 located on opposite sides of the same connecting row fixing slot 333. The first partition wall 351 has at least one first positioning piece 361, and the second partition wall 352 has at least one second positioning piece 362. The first positioning piece 361 and the second positioning piece 362 are located on opposite sides of the same connecting row 4 to limit the displacement of the connecting row along the first direction. The first direction is the length direction of the battery cell assembly, such as... Figure 2 The x-direction is shown.

[0069] In the description of this application, 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 technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0070] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0071] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0072] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A busbar assembly (2) for a battery pack, characterized in that, include: At least one output row (5, 6); At least one electrical connector (71, 72) is detachably connected to the output bar (5, 6) via a connector (8); A bracket (3) is provided on which the output rows (5, 6) are mounted. The bracket (3) is provided with at least one limiting part (311, 312) such that the connector (8) passes through the limiting part (311, 312) to connect the output rows (5, 6) and the electrical connector (71, 72). The limiting part (311, 312) is configured to protrude toward the housing (1) of the battery pack, and at least a portion of the limiting part is located below the connector (8).

2. The bus assembly (2) according to claim 1, characterized in that, The bracket (3) includes a first sidewall (321) and a second sidewall (322) disposed opposite to each other along a first direction, and at least one of the first sidewall (321) and the second sidewall (322) is provided with the limiting portion (311, 312).

3. The bus assembly (2) according to claim 2, characterized in that, The bracket further includes a first fixing seat (341) that protrudes from one of the first sidewall (321) and the second sidewall (322). The sidewall of the first fixing seat (341) is provided with a first boss (311). The limiting part (311, 312) includes the first boss (311). The first boss (311) is provided with a first through hole (313) for the connector (8) to pass through. And / or, the bracket (3) further includes a second fixing seat (342) that protrudes from the other of the first sidewall (321) and the second sidewall (322), the sidewall of the second fixing seat (342) having a second boss (312), the limiting part (311, 312) including the second boss (312), the second boss (312) having a second through hole (314) for the connector (8) to pass through.

4. The bus assembly (2) according to claim 3, characterized in that, The height by which the first boss (311) protrudes relative to the side wall of the first fixed seat (341) is h1, and the range of h1 is 1mm to 5mm. And / or, the height by which the second boss (312) protrudes relative to the side wall of the second fixing seat (342) is h2, and the range of h2 is 1mm to 5mm.

5. The bus assembly (2) according to claim 3, characterized in that, The distance between the first boss (311) or the second boss (312) and the housing (1) of the battery pack is set to be less than the length of the connector (8) or the diameter of the connector (8); Alternatively, the distance between the first boss (311) or the second boss (312) and the housing (1) of the battery pack is 1.0 mm to 2.0 mm.

6. The bus assembly (2) according to claim 3, characterized in that, At least one of the output rows (5, 6) includes a positive output row (5) and a negative output row (6); One of the positive output bar (5) and the negative output bar (6) includes a first main body (51) and a first fixing part (52) connected to each other. The first fixing part (52) is bent upward relative to the first main body part (51); And / or, the included angle between the first main body (51) and the first fixing part (52) is greater than 0° and less than or equal to 90°.

7. The bus assembly (2) according to claim 6, characterized in that, The bracket (3) further includes a bottom wall (325) that is bent and connected to the first side wall (321) and / or the second side wall (322), and the bottom wall (325) is provided with a positive output bar fixing groove (331) to accommodate the first main body (51). And / or, the first boss (311) is disposed on the outside of the first fixing seat (341), and the first fixing part (52) abuts against the inside of the first fixing seat (341).

8. The bus assembly (2) according to claim 6, characterized in that, The distance between the first fixing part (52) and the housing (1) of the battery pack is h, which is greater than the sum of the height h1 of the first boss part (311) protruding relative to the side wall of the first fixing seat (341) and the distance between the first boss part (311) and the housing (1) of the battery pack; or, the distance between the first fixing part (52) and the housing (1) of the battery pack is set to be greater than or equal to 6.0 mm. And / or, the first main body (51) includes a first welding area (54), which is welded to the terminal post of the battery cell of the battery pack. The wall thickness of the first welding area (54) is d1, and the wall thickness of the first fixing part (52) is d2, where d1 < d2.

9. The bus assembly (2) according to claim 8, characterized in that, (d2-d1) / d2=0.3~0.

5.

10. The bus assembly (2) according to claim 3, characterized in that, At least one of the output rows (5, 6) includes a positive output row (5) and a negative output row (6); The other of the positive output bar (5) and the negative output bar (6) includes a second main body (61) and a second fixing part (62) that are bent and connected. The second fixing part (62) includes a first bent segment (621), a second bent segment (622) and a third bent segment (623) that are bent and connected in sequence. The first bent segment (621) is bent downward relative to the second main body (61), and the third bent segment (623) is bent upward relative to the second bent segment (622).

11. The bus assembly (2) according to claim 10, characterized in that, The bracket (3) further includes a bottom wall (325) that is bent and connected to the first side wall (321) and / or the second side wall (322). The bottom wall (325) is provided with a negative output row fixing groove (332). The negative output row (6) fixing groove is configured to receive the second main body (61). And / or, the second boss (312) is disposed on the outside of the second fixing seat (342), the second fixing seat (342) is provided with a receiving cavity (343), the receiving cavity (343) is configured to receive at least a portion of the second fixing part (62).

12. The bus assembly (2) according to claim 10, characterized in that, The distance between the second fixing part (62) and the housing (1) of the battery pack is h, which is greater than the sum of the height of the second boss part (312) protruding from the side wall of the second fixing seat (342) and the distance between the second boss part (312) and the housing (1) of the battery pack; or, the distance between the second fixing part (62) and the housing (1) of the battery pack is set to be greater than or equal to 6.0 mm; And / or, the second main body (61) includes a second welding area (64), the wall thickness of the second welding area (64) is d3, the wall thickness of the second fixing part (62) is d4, and d3 < d4.

13. The bus assembly (2) according to claim 12, characterized in that, (d4-d3) / d4 = 0.3~0.

5.

14. The bus assembly (2) according to any one of claims 1 to 13, characterized in that, The bracket (3) further includes a third sidewall (323) and a fourth sidewall (324) disposed opposite to each other along the second direction, wherein the third sidewall (323) or the fourth sidewall (324) is connected between the first sidewall (321) and the second sidewall (322); The busbar assembly (2) further includes multiple connecting bars (4), each connecting bar (4) being adapted to connect two adjacent battery cells of the battery pack. Each connecting bar (4) includes an arch bridge portion (41) located between two battery cells. The third sidewall (323) and the fourth sidewall (324) are provided with multiple notches (39), each notch (39) having a latching portion (37) inside. Each latching portion (37) abuts against the arch bridge portion (41) to limit the displacement of the connecting bar (4) in the third direction.

15. The bus assembly (2) according to claim 14, characterized in that, The bracket (3) is provided with a plurality of connecting row fixing slots (333). The bracket (3) includes a plurality of partition walls arranged at intervals along a first direction. Each partition wall is disposed between two adjacent connecting row fixing slots (333). The plurality of partition walls include a first partition wall (351) and a second partition wall (352) located on opposite sides of the same connecting row fixing slot (333). The first partition wall (351) is provided with at least one first positioning piece (361), and the second partition wall (352) is provided with at least one second positioning piece (362). The first positioning piece (361) and the second positioning piece (362) are respectively located on both sides of the same connecting row (4) to limit the displacement of the connecting row (4) along the first direction. The first direction and the third direction are intersected.

16. A battery pack, characterized in that, include: Box (1); Multiple battery cells are disposed inside the housing (1); The bus assembly (2) according to any one of claims 1 to 15, wherein the bus assembly (2) is electrically connected to a plurality of the battery cells.

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