Pouch battery cell module, battery pack, and electric device

Abstract

The application discloses a soft package battery cell module, a battery pack and an electric device. The module comprises a support plate, has a first mounting surface and a second mounting surface arranged oppositely, a plurality of supports are arranged on the first mounting surface and the second mounting surface and are arranged at intervals along the length direction of the support plate, a plurality of first bus bars are arranged on each support, have first connecting portions and second connecting portions arranged at intervals in the thickness direction of the support plate and are staggered in the length direction and are electrically connected to each other, the first bus bars arranged on the first mounting surface are electrically connected to the corresponding first bus bars arranged on the second mounting surface through a conductive connecting structure, a plurality of battery cells are arranged at intervals in the length direction of the support plate, the first bus bars connect two adjacent battery cells in series in the length direction, and the two adjacent battery cells in the thickness direction are connected to the corresponding first bus bars in parallel through the conductive connecting structure. The application improves the space utilization.

Description

Technical Field

[0001] This invention relates to the field of new energy battery technology, and in particular to a soft-pack battery cell module, battery pack, and power-consuming device. Background Technology

[0002] Currently, the assembly process of pouch batteries generally follows the technical path of "Cell → Module → Pack". During cell assembly, the series connection method typically involves stacking multiple pouch cells in the thickness direction and connecting them in series at the tabs on both sides of the stack. This is a relatively common method for constructing pouch battery modules in the industry.

[0003] However, the aforementioned existing group technologies suffer from significant space utilization bottlenecks, specifically in the following two aspects:

[0004] Firstly, there is spatial redundancy in the cell packaging area. Pouch cells have a large packaging area (not the active area of ​​the cell electrode) on the tab extension side (i.e., both ends along the cell's length). In the aforementioned module structure stacked in series along the thickness direction, this packaging area is retained at the module level and cannot be eliminated, resulting in a significant amount of ineffective space being occupied along the length direction outside the cell's effective capacity area.

[0005] Secondly, there is wasted space in the module assembly gaps. During the further assembly of modules into a PACK, due to assembly process and safety insulation spacing requirements, a certain assembly gap must be reserved between adjacent modules. This additional gap further exacerbates the space consumption along the length of the battery cell.

[0006] In summary, in the existing technology, the combined effect of the cell packaging area occupancy and the module assembly gap leads to a sharp decrease in the space utilization rate of the pouch battery system along the length of the cell, which severely restricts the volume utilization efficiency of the battery system and is not conducive to the high energy density requirements of the vehicle or energy storage system. Summary of the Invention

[0007] This invention proposes a soft-pack battery cell module, a battery pack, and an electrical device to solve the above-mentioned problems.

[0008] In a first aspect, embodiments of the present invention disclose a pouch cell module, comprising:

[0009] The support plate has a first mounting surface and a second mounting surface that are disposed opposite to each other.

[0010] Multiple brackets are respectively set on the first mounting surface and the second mounting surface. Each bracket is arranged at intervals along the length of the support plate and divides the corresponding mounting surface into multiple cell accommodating areas.

[0011] Multiple first buses are respectively disposed on each bracket. Each first bus has a first connecting part and a second connecting part that are spaced apart in the thickness direction of the support plate and staggered in the length direction and electrically connected to each other. The first bus on the first mounting surface and the corresponding first bus on the second mounting surface are electrically connected through a conductive connection structure.

[0012] Multiple first cells are arranged along the length direction in the cell receiving area corresponding to the first mounting surface. In two adjacent first cells, the tab of one is connected to the first connection part of the first busbar, and the tab of the other is connected to the second connection part of the same first busbar. The first busbar connects two adjacent first cells in series.

[0013] Multiple second cells are disposed on the second mounting surface and correspond one-to-one with the positions of the first cells. The second cells and their corresponding first cells are connected in parallel through a conductive connection structure, and the tabs of two adjacent second cells are respectively connected to the first connection part and the second connection part of the first busbar between the first cell and the second cell.

[0014] According to this technical solution, the soft-pack battery module provided by the present invention achieves compact series connection of adjacent battery cells in the length direction by distributing the battery cells on the upper and lower sides of a support plate, separating the battery cells with brackets arranged at intervals along the length direction, and connecting the positive and negative tabs of adjacent battery cells respectively with the first and second connecting parts that are spaced apart in the height direction and staggered in the length direction on the same busbar. At the same time, the corresponding busbars on the upper and lower mounting surfaces are electrically connected by a conductive connection structure, so that the corresponding first and second battery cells on the upper and lower sides form parallel connection, and adjacent parallel groups form series connection through the same busbar. Thus, the "parallel first, series later" electrical topology is realized with a compact integrated structure, which effectively shortens the overall size occupied by the battery cells in the length direction, reduces the gap required for module-level assembly, significantly improves the space utilization rate of the soft-pack battery module in the length direction, and is conducive to improving energy density.

[0015] According to another specific embodiment of the present invention, the support plate is a metal plate, the bracket is an insulating bracket, the insulating bracket is disposed on the surface of the metal plate, and the first busbar is isolated from the metal plate.

[0016] According to another specific embodiment of the present invention, the bracket is provided with a through hole for the conductive connection structure to pass through, and the support plate is provided with a corresponding mounting hole for the conductive connection structure to pass through. The first busbar located on the first mounting surface and the first busbar located on the second mounting surface are connected by the conductive connection structure through the through hole and the mounting hole; and / or, the diameter of the through hole is smaller than the diameter of the mounting hole.

[0017] According to another specific embodiment of the present invention, the support plate includes:

[0018] Multiple straight sections are used to support the main body of the first battery cell, and adjacent straight sections are staggered from each other in the thickness direction;

[0019] The bending section connects two adjacent straight sections, and the encapsulation area and electrode of the first cell are set corresponding to the bending section;

[0020] The second battery cell is correspondingly disposed on the side of the flat portion away from the first battery cell, and the packaging area and tab of the second battery cell are disposed opposite to the packaging area and tab of the first battery cell in the thickness direction.

[0021] According to another specific embodiment of the present invention, the first busbar has an annular frame structure, including a first connecting arm and a second connecting arm arranged opposite to each other along the length direction, and two transition arms connecting the two ends of the first connecting arm and the second connecting arm.

[0022] The first connecting arm constitutes the first connecting part, the second connecting arm constitutes the second connecting part, the second connecting arm is closer to the support plate than the first connecting arm, and the two transition arms connect the first connecting part and the second connecting part into one unit; and / or, the bracket includes a plate-shaped body and a protrusion protruding from the plate-shaped body, the shape of the protrusion is adapted to the shape of the second connecting part, the second connecting part is supported on the protrusion, and the space between the first connecting part and the second connecting part constitutes a clearance gap for the corresponding electrode tab to pass through.

[0023] According to another specific embodiment of the present invention, the length of the first bus in the longitudinal direction is less than the sum of the lengths of the packaging regions of adjacent first cells, so that the packaging regions of two adjacent first cells at least partially overlap in the longitudinal direction; and / or,

[0024] The length of the first busbar in the longitudinal direction is less than the sum of the lengths of the encapsulation areas of the adjacent second cells, so that the encapsulation areas of the two adjacent second cells at least partially overlap in the longitudinal direction.

[0025] According to another specific embodiment of the present invention, the conductive connection structure is a conductive rod, which is fixed to the side of the first busbar facing the support plate.

[0026] According to another specific embodiment of the present invention, the outer periphery of the support plate is covered with an insulating frame, and the insulating frame is provided with clearance openings corresponding to the positions of the tabs of the first battery cell and / or the second battery cell; and / or, it further includes:

[0027] Two second busbars are respectively wrapped around the two ends of the support plate along its length. The corresponding tabs of the first and second battery cells, which are corresponding to the ends of the support plate along its length, are respectively fixedly connected to the second busbars.

[0028] Secondly, the present invention provides a battery pack including a pouch cell module according to any of the above embodiments.

[0029] According to this technical solution, the battery pack provided by the embodiments of the present invention has a higher space utilization rate in the length direction of the module itself, so more or longer cells can be arranged within the limited volume of the battery pack housing, thereby improving the overall capacity and energy density of the battery pack. At the same time, since the module does not need to reserve assembly gaps in the length direction, the internal structure of the housing is more compact, which can shorten the length of the housing or free up more space for other functional components (such as thermal management system, BMS, etc.), thereby reducing the unit energy cost of the battery pack. In addition, the battery pack can realize internal electrical connection by means of the busbar and conductive connection structure integrated inside the module, reducing the number of wiring harnesses and connectors inside the battery pack, simplifying the assembly process, and improving the assembly efficiency.

[0030] Secondly, the present invention provides an electrical device comprising a pouch cell module or battery pack according to any of the above embodiments.

[0031] According to this technical solution, the electrical device provided by the embodiments of the present invention can extend the driving range (for vehicles) or increase the energy storage capacity (for energy storage systems) without increasing the space occupied by the battery pack or the soft-pack cell module because the battery pack or soft-pack cell module has a higher volumetric energy density. At the same time, because the module has a compact structure and fewer parts, the overall weight of the battery pack is reduced and the cost is lowered, which helps to reduce the curb weight and manufacturing cost of the electrical device. In addition, because the internal electrical connection path of the module is short and the number of contact points is small, it is beneficial to reduce the internal resistance and heat generation, improve the safety and cycle life of the battery system, and thus improve the overall reliability and service life of the electrical device. Attached Figure Description

[0032] Figure 1 This is a three-dimensional structural diagram of the soft-pack battery cell module in an embodiment of the present invention;

[0033] Figure 2 This is an embodiment of the present invention. Figure 1 A magnified view of a portion of S1 in the middle;

[0034] Figure 3 This is a schematic diagram from a first perspective of the three-dimensional structure (excluding the battery cell) of the soft-pack battery cell module in an embodiment of the present invention;

[0035] Figure 4 This is a schematic diagram from a second perspective of the three-dimensional structure (excluding the battery cell) of the soft-pack battery cell module in an embodiment of the present invention;

[0036] Figure 5 This is a schematic diagram of the structure of the first busbar in an embodiment of the present invention;

[0037] Figure 6 This is a schematic diagram showing the connection position of the tabs of adjacent first and second battery cells in an embodiment of the present invention.

[0038] Figure 7 This describes the connection relationship between the upper busbar and the lower busbar in an embodiment of the present invention (including the support plate and bracket).

[0039] Figure 8 This describes the connection relationship between the upper busbar and the lower busbar in an embodiment of the present invention (excluding the support plate and bracket).

[0040] Figure 9 This is a schematic diagram of the structure of the first battery cell in an embodiment of the present invention;

[0041] Figure 10 This is an enlarged schematic diagram of the support and the first busbar according to an embodiment of the present invention;

[0042] Figure 11 This is an embodiment of the present invention. Figure 1 A magnified view of a portion of point S2.

[0043] Figure Labels

[0044] Support plate 1; bracket 2; plate-shaped body 21; protrusion 22; groove 221; fixing post 222; through hole 23; first busbar 3; upper busbar 3B; lower busbar 3A; first connecting part 31; second connecting part 32; transition arm 33; conductive connection structure 34; fixing hole 35; first battery cell 4; first tab 41; second tab 42; first encapsulation area 43; second encapsulation area 44; second battery cell 5; third tab 51; fourth tab 52; second busbar 6; insulating frame 7; cover plate 8. Detailed Implementation

[0045] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention is presented in conjunction with preferred embodiments, this does not mean that the features of the invention are limited to these embodiments. On the contrary, the purpose of describing the invention in conjunction with embodiments is to cover other options or modifications that may be derived based on the claims of the present invention. To provide a deep understanding of the invention, many specific details will be included in the following description. The invention may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of the invention, some specific details will be omitted in the description. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0046] It should be noted that in this specification, similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0047] The terms “first”, “second”, etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0048] In the description of this embodiment, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" 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 or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment based on the specific circumstances.

[0049] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0050] Firstly, reference Figure 1 , Figure 2 , Figure 3 , Figure 4 As shown, an embodiment of the present invention discloses a soft-pack battery module, comprising: a support plate 1, multiple brackets 2, multiple first busbars 3, multiple first battery cells 4, and multiple second battery cells 5. Figure 6 As shown in the figure, the support plate 1 has a first mounting surface and a second mounting surface that are arranged opposite to each other; a plurality of brackets 2 are respectively fixedly connected to the first mounting surface and the second mounting surface, and each bracket 2 is along the length direction of the support plate 1 ( Figure 1 The cells are arranged at intervals (in the middle a direction), dividing the corresponding mounting surface into multiple cell accommodating areas; multiple first busbars 3 are respectively disposed on each bracket 2, for connecting adjacent first cells 4 and second cells 5 in series, such as... Figure 5 As shown, each first busbar 3 has a thickness direction of the support plate 1 ( Figure 4 The first connecting portion 31 and the second connecting portion 32 are arranged at intervals along the middle (H direction) and staggered in the length direction and electrically connected to each other; combined Figure 6 ( Figure 6 The middle arrow indicates the fixed position of the first electrode tab 41 and the second electrode tab 42. The arrow points to the connection position of the first electrode tab 41 and the second electrode tab 42. The dotted line indicates that the first electrode tab 41 passes under the first connecting part 31 to reach the second connecting part 32. Figure 7 as well as Figure 8As shown, a first busbar 3 (upper busbar 3B) disposed on the first mounting surface and a corresponding first busbar 3 (lower busbar 3A) disposed on the second mounting surface are electrically connected by a conductive connection structure 34; a plurality of first cells 4 are arranged along the length direction in the corresponding cell receiving areas of the first mounting surface. In two adjacent first cells 4, the tab of one (such as the second tab 42) is connected to the first connecting part 31 of the first busbar 3, and the tab of the other (such as the first tab 41) is connected to the second connecting part 32 of the same first busbar 3. The first busbar 3 connects two adjacent first cells 4 in series; a plurality of second cells 5 are disposed on the second mounting surface and correspond one-to-one with the positions of the first cells 4. The second cells 5 and the corresponding first cells 4 are connected in parallel by a conductive connection structure 34, and the tabs of two adjacent second cells 5 are respectively connected to the first connecting part 31 and the second connecting part 32 of the first busbar 3 between the first cells 4 and the second cells 5.

[0051] Through the above-described method, the soft-pack battery module provided by the present invention achieves compact series connection of adjacent battery cells in the length direction by distributing the battery cells on the upper and lower sides of the support plate 1, separating the battery cells with brackets 2 arranged at intervals along the length direction, and connecting the positive and negative tabs of adjacent battery cells respectively with the first connecting part 31 and the second connecting part 32 that are spaced apart in the height direction and staggered in the length direction on the same busbar. At the same time, the corresponding busbars on the upper and lower mounting surfaces are electrically connected by the conductive connection structure 34, so that the corresponding first battery cell 4 and second battery cell 5 are connected in parallel, and adjacent parallel groups are connected in series through the same busbar. Thus, the electrical topology of "parallel first and then series or series first and then parallel" is realized with a compact integrated structure, which effectively shortens the overall size occupied by the battery cells in the length direction, reduces the gap required for module-level assembly, significantly improves the space utilization rate of the soft-pack battery module in the length direction, and is conducive to improving energy density.

[0052] It should be noted that the "first connecting portion 31 and second connecting portion 32 arranged at intervals in the thickness direction and staggered in the length direction" described in this embodiment means that the first connecting portion 31 and the second connecting portion 32 are not located at the same height, that is, the first connecting portion 31 and the second connecting portion 32 are arranged vertically and are spaced apart in the height direction, and when the first connecting portion 31 and the second connecting portion 32 are on the same horizontal plane (the surface in the length direction), they do not overlap at all. With this structure, the first connecting portion 31 and the second connecting portion 32 are arranged at intervals in the thickness direction and staggered in the length direction (that is, the projections of the first connecting portion 31 and the second connecting portion 32 arranged vertically and on the same horizontal plane do not overlap at all), so that the tabs of two adjacent cells connected to the first connecting portion 31 and the second connecting portion 32 respectively form a three-dimensional misalignment in space, neither on the same height layer nor in the same length section. The spacing along the thickness direction provides space for layered wiring between the two tabs of adjacent cells (those adjacent in the length direction), ensuring that the two tabs do not interfere with each other in the thickness direction. The staggered arrangement along the length direction provides the packaging areas of adjacent cells with the capacity to embed into each other's length space: when one cell's tab is connected to the first connection part, and the tab of an adjacent cell is connected to a second connection part staggered in the length direction, the packaging areas of the two cells naturally form an interleaved distribution along the length direction, following the positions of their respective tabs. The packaging areas no longer need to be aligned and accumulated one by one along the length direction, but can partially extend into the length range originally occupied by the other, thus eliminating the ineffective occupation of the packaging area in the length direction. The synergistic effect of these two dimensions allows the adjacent cells to achieve the most compact layout in three-dimensional space, realizing the series connection of multiple cells without increasing the module thickness and length, significantly improving the volumetric packing ratio of the pouch battery module.

[0053] The first tab 41 and the second tab 42 in this embodiment of the invention are not described for convenience only; their specific functions as positive or negative tabs can be determined based on the actual parallel or series circuit connection. Furthermore, the first battery cell 4 and the second battery cell 5 are installed in the same way. This embodiment mainly uses the first battery cell 4 located on the first mounting surface as an example for explanation. Based on the same principle, the specific installation structure of the second battery cell 5 can be obtained, such as... Figure 6In the diagram, the support plate 1 serves as the dividing line between the first battery cell 4 and the second battery cell 5. The diagram shows the positional relationship between the third tab (not shown in the diagram, the third tab extends from the third encapsulation area 51 and extends to the second connection portion 32 of the lower busbar 3A, the third tab is connected to the side of the first connection portion 31 away from the support plate 1) and the fourth tab (not shown in the diagram, the fourth tab extends from the fourth encapsulation area 52 and connects to the first connection portion 31 of the lower busbar 3A) on the second mounting surface and the lower busbar 3A. This relationship is the same as the positional relationship between the first tab 41 and the second tab 42 of the first battery cell 4 on the first mounting surface and the upper busbar 3B (the upper busbar 3B and the lower busbar 3A are centrally symmetrical). This embodiment will not elaborate further on this relationship.

[0054] In this embodiment, for ease of description of the battery cells at different locations, the battery cells are divided into a first battery cell 4 and a second battery cell 5. In reality, both the first battery cell 4 and the second battery cell 5 are as follows: Figure 9 The cell structure shown.

[0055] In the above embodiment, the support plate 1 is a metal plate, and the bracket 2 is an insulating bracket 2. The insulating bracket 2 is disposed on the surface of the metal plate to isolate the first busbar 3 from the metal plate.

[0056] In this way, the support plate 1, made of metal, ensures the overall structural strength and rigidity of the module, providing reliable support for the battery cell and effectively resisting vibration and expansion forces. The bracket 2, made of insulating material and placed on the surface of the metal plate, isolates the busbar from the metal plate, preventing short circuits between the busbar and the conductive metal plate. This ensures electrical safety while maintaining structural strength, eliminating the need for additional insulating gaskets or insulating coatings, and simplifying the structure and assembly process. In some embodiments, the support plate 1 can also be an insulating plate, and the bracket 2 can be a protruding structure on the insulating plate. The support plate 1 and the bracket 2 can be an integral structure or separate structures.

[0057] In the above embodiments, continue to refer to Figure 3 The bracket 2 has a through hole 23 for the conductive connection structure 34 to pass through, and the support plate 1 has a corresponding mounting hole (not shown in the figure) for the conductive connection structure 34 to pass through. The first busbar 3 located on the first mounting surface and the first busbar 3 located on the second mounting surface are connected by the conductive connection structure 34 through the through hole 23 and the mounting hole.

[0058] In the above manner, the first busbar 3 located on the first mounting surface and the first busbar 3 located on the second mounting surface are electrically connected through the through hole 23 on the bracket 2 and the mounting hole on the support plate 1 via the conductive connection structure 34, thereby establishing a parallel electrical path between the upper and lower battery cells in the thickness direction; at the same time, the through hole 23 and the mounting hole provide a precise positioning and installation channel for the conductive connection structure 34, ensuring the alignment accuracy and connection reliability between the upper and lower first busbars 3, eliminating the need to wind additional connecting wires around the support plate 1, making the internal structure of the module more compact.

[0059] Furthermore, the diameter of the through hole 23 is smaller than the diameter of the mounting hole. In actual assembly, the conductive connection structure 34 (such as a conductive rod) needs to pass through both the bracket 2 and the support plate 1. If the diameter of the through hole 23 is greater than or equal to the diameter of the mounting hole, the metal edge of the support plate 1 at the mounting hole may be exposed inside the through hole 23, and there is a risk of short circuit between the conductive connection structure 34 and the support plate 1.

[0060] The diameter of the through hole 23 is smaller than that of the mounting hole, so that when the conductive connection structure 34 passes through, the edge of the support plate 1 at the mounting hole is completely covered by the material of the bracket 2 and is not exposed in the through hole 23. This reduces or eliminates the risk of accidental contact or short circuit between the conductive connection structure 34 and the support plate 1, significantly improving the electrical insulation safety of the module. At the same time, there is no need to add an additional insulating sleeve in the mounting hole, further simplifying the structure and assembly process.

[0061] Furthermore, this design is particularly effective when the support plate 1 is made of metal. However, even if the support plate 1 is made of non-metallic material, this aperture difference design can still provide safety protection such as increasing the creepage distance and preventing contact with foreign objects.

[0062] In the above embodiments, continue to refer to Figure 5 The first busbar 3 has an annular frame structure, including a first connecting arm and a second connecting arm arranged opposite each other along the length direction, and two transition arms 33 connecting the two ends of the first connecting arm and the second connecting arm; the first connecting arm constitutes the first connecting part 31, the second connecting arm constitutes the second connecting part 32, the second connecting arm is closer to the support plate 1 than the first connecting arm, and the two transition arms 33 connect the first connecting part 31 and the second connecting part 32 into one unit.

[0063] In the above manner, the first busbar 3 has an annular frame structure. The first connecting arm and the second connecting arm are connected as one unit through the transition arms 33 at both ends, so that the first connecting part 31 and the second connecting part 32 form a closed conductive circuit. The first connecting part 31 and the second connecting part 32 are respectively used to connect the tabs of two adjacent cells. The current can flow in through one connecting arm, through the transition arm 33, and out through the other connecting arm, realizing the series connection between adjacent cells. At the same time, the annular frame structure makes the busbar occupy a compact size in the length direction of the support plate 1, which is conducive to reducing the spacing between the tabs of adjacent cells and improving the space utilization rate. Moreover, the integrated structure reduces the number of welding points or connection points, reducing the connection internal resistance and the risk of failure.

[0064] Specifically, the first connecting arm and the second connecting arm are two opposite long sides, forming the first connecting part 31 and the second connecting part 32 respectively; the two transition arms 33 are two opposite short sides, connecting the ends of the two long sides on the same side to form a closed loop of the current path.

[0065] In the above embodiments, such as Figure 3 , Figure 4 As shown, the bracket 2 includes a plate-shaped body 21 and a protrusion 22 protruding from the plate-shaped body 21. The shape of the protrusion 22 is adapted to the shape of the second connecting part 32. The second connecting part 32 is supported on the protrusion 22. The space between the first connecting part 31 and the second connecting part 32 forms a clearance gap for the corresponding electrode tab to pass through.

[0066] In the above manner, the support 2 includes a plate-shaped body 21 and a protrusion 22 protruding from the plate-shaped body 21. The shape of the protrusion 22 is adapted to the shape of the second connecting part 32. The second connecting part 32 is supported on the protrusion 22, so that the lower second connecting part 32 obtains reliable mechanical support, avoiding deformation or breakage of the second connecting part 32 due to suspension during electrode connection or vibration. The space between the first connecting part 31 and the second connecting part 32 forms a clearance gap for the corresponding electrode to pass through, so that the electrode connected to the first connecting part 31 in the adjacent cell can pass through the clearance gap without interfering with the second connecting part 32, ensuring accurate alignment and reliable connection between the electrode and the corresponding connecting part.

[0067] In this embodiment, the bracket 2 not only serves as insulation and isolation but also provides support for the lower connection portion (second connection portion 32) of the busbar through a local protrusion, solving the suspension problem caused by the staggered arrangement. The shape of the protrusion 22 is preferably adapted to the shape of the second connection portion 32 (for example, if the second connecting arm is strip-shaped, the protrusion 22 is also a corresponding strip-shaped boss; furthermore, if the length of the protrusion 22 is greater than the lower connection portion of the busbar, the surface of the protrusion 22 is recessed inward to form a groove 221 to accommodate the second connection portion 32, and the inner wall of the groove 221 limits the second connection portion 32), thereby increasing the support area and reducing contact stress. The height of the clearance gap is determined by the height difference between the first connection portion 31 and the second connection portion 32, and this height difference should be greater than the thickness of the tab to ensure that the tab can pass smoothly without being squeezed or scratched. Furthermore, the protrusion 22 and the bracket 2 can be an integrally molded structure (such as injection molding), eliminating the need for additional parts and reducing manufacturing costs and assembly difficulty.

[0068] In some embodiments, when the number of first busbars 3 on the first mounting surface is not less than two, the tabs at both ends of the first battery cell 4 are respectively fixedly connected to the first connecting portion 31 of the corresponding first busbar 3, or the tabs at both ends of the first battery cell 4 are respectively fixedly connected to the second connecting portion 32 of the corresponding first busbar 3. That is, the tabs at both ends of the same first battery cell 4 are fixed at the same height on the first busbar 3, so that the first battery cell 4 is mounted on the mounting surface of the support plate 1 in a horizontal posture in its length direction. The tabs do not need to be bent up and down before connection and can be directly extended to the connecting portion of the corresponding height for fixation, reducing the tab forming process, reducing the processing difficulty and cost, and avoiding the damage or fatigue risks that bending operations may cause to the tabs.

[0069] The tabs are kept straight during connection, and there is no residual stress or springback force caused by bending at the connection point. The connection is stable after welding or riveting and is not prone to loosening or cracking due to vibration or thermal expansion and contraction, thus improving the long-term reliability of the electrical connection.

[0070] After the battery cell is placed horizontally on the mounting surface, the tabs at both ends naturally align with the connection parts at the same height. There is no need to adjust the position in the height direction during the assembly process, which simplifies the alignment operation and improves assembly efficiency and consistency.

[0071] The arrangement of the tabs at both ends of the same cell at the same height ensures that the tab connection layers on both sides of the support plate 1 are in the same plane. This is beneficial for the unified layout and orderly routing of the first busbar 3 on the support plate 1, and also provides a clear spatial division for the staggered arrangement of adjacent cells in the height direction, avoiding structural disorder or space waste caused by inconsistent heights at both ends of the same cell.

[0072] This feature also applies to the second battery cell 5. When the second battery cell 5 is disposed on the second mounting surface, the tabs at both ends of the same second battery cell 5 are respectively fixedly connected to the first connecting part 31 of the corresponding busbar, or respectively fixedly connected to the second connecting part 32 of the corresponding first busbar 3. That is, the fixed height of the tabs at both ends of the second battery cell 5 on the first busbar 3 is also the same, so that all battery cells located on the upper and lower mounting surfaces can be installed horizontally and straight without any bending or twisting of the tabs, further improving the standardization and consistency of module assembly.

[0073] In some embodiments, the tabs of the first or second battery cell can be fixed to the corresponding connecting parts without bending by designing the support plate 1 to bend. Specifically, as shown in the figure... Figure 6 As shown, the support plate 1 includes a bent portion 11 and a plurality of straight portions 12. The straight portions 12 are used to support the main body of the first battery cell 4. Two adjacent straight portions 12 are staggered from each other in the thickness direction. The bent portion 11 is connected between two adjacent straight portions 12. The encapsulation area and the electrode of the first battery cell 4 are disposed corresponding to the bent portion 11. The second battery cell 5 is disposed on the side of the straight portion 12 away from the first battery cell 4, and the encapsulation area and the electrode of the second battery cell 5 are disposed opposite to the encapsulation area and the electrode of the first battery cell 4 in the thickness direction.

[0074] When the straight section 12 includes three or more, the support plate 1 has a wave-like structure, including wave crests and wave troughs arranged alternately along the length direction. The wave crests and wave troughs respectively constitute the straight section, and adjacent wave crests and wave troughs are connected by bending sections.

[0075] In the above embodiment, the length of the first busbar 3 in the longitudinal direction is less than the sum of the lengths of the encapsulation areas (including the first encapsulation area 43 and the second encapsulation area 44) of the adjacent first cells 4, so that the encapsulation areas of the two adjacent first cells 4 at least partially overlap in the longitudinal direction. Since the positions of the first cells 4 and the second cells 5 are arranged in a one-to-one correspondence, the length of the first busbar 3 in the longitudinal direction is less than the sum of the lengths of the encapsulation areas of the adjacent second cells 5, so that the encapsulation areas of the two adjacent second cells 5 at least partially overlap in the longitudinal direction.

[0076] In the above manner, the length of the first busbar 3 in the longitudinal direction is less than the sum of the lengths of the encapsulation areas of the adjacent first cells 4, so that the encapsulation areas of the two adjacent first cells 4 overlap at least partially in the longitudinal direction, thereby eliminating the invalid space occupied by the encapsulation areas being accumulated one by one in the longitudinal direction in the traditional solution; at the same time, since the positions of the first cells 4 and the second cells 5 are set in a one-to-one correspondence and are connected in parallel with each other, the same relationship applies to the second cells 5, so that the encapsulation areas of the upper and lower cells overlap in the longitudinal direction, further reducing the overall size occupied by the cells in the longitudinal direction and significantly improving the space utilization rate of the module in the longitudinal direction.

[0077] In the above embodiment, the conductive connection structure 34 is a conductive rod, which is fixed to the side of the first busbar 3 facing the support plate 1.

[0078] In the above manner, the conductive connection structure 34 is a conductive rod, which is fixed to the side of the busbar facing the support plate 1, so that the busbars on the upper and lower mounting surfaces can be reliably connected through the conductive rod. As an independent conductive element, the length of the conductive rod can be adapted according to the thickness of the support plate 1, which is convenient for flexible adjustment according to the support plate 1 of different thicknesses. At the same time, the conductive rod is fixed on the busbar and installed together with the busbar during assembly, which simplifies the assembly process and improves the assembly efficiency.

[0079] Specifically, the conductive rod can take various forms, preferably a cylindrical or square rod. One end is fixed to the busbar on the first mounting surface, and the other end passes through corresponding holes on the bracket 2 and the support plate 1 and is fixed to the corresponding busbar on the second mounting surface. The conductive rod can be fixed to the busbar by welding (such as resistance welding or laser welding), riveting, or threaded connection, ensuring that the contact resistance is sufficiently low to guarantee the reliability of the parallel path. In some embodiments, the conductive rod can be an integral extension of the first busbar 3 (i.e., a protruding post stamped from the body of the first busbar 3 towards the support plate 1), or it can be a separate part connected by subsequent processes. Furthermore, the number and position of the conductive rods can be flexibly adjusted according to the magnitude of the parallel current and the arrangement of the tabs. For example, multiple conductive rods can be provided on each busbar to enhance the current carrying capacity of the parallel path.

[0080] In this embodiment, such as Figure 10As shown, the first busbar 3 is rectangular. Two conductive rods are provided at each end of one long side of the rectangle, and two fixing holes 35 are provided at each end of the other long side of the rectangle. The two fixing holes 35 are located at both ends of the extension direction of the second connecting part 32. Correspondingly, the length of the protrusion 22 is greater than the length of the second connecting part 32. The protrusion 22 has a groove 221 corresponding to the position of the second connecting part 32 and two fixing posts 222 that engage with the two fixing holes 35. The two fixing posts 222 are located at both ends of the groove 221. The fixing holes 35 and the fixing posts 222 cooperate to fix the first busbar 3 on the bracket 2, simplifying the fixing method of the first busbar 3 and improving the stability of the first busbar 3.

[0081] In the above embodiments, such as Figure 3 , Figure 11 As shown, the soft-pack battery module also includes two second busbars 6, which cover the two ends of the support plate 1 in the length direction, respectively. The corresponding tabs of the first battery cell 4 and the second battery cell 5 corresponding to the ends of the support plate 1 in the length direction are fixedly connected to the second busbars 6.

[0082] In the above manner, two second busbars 6 are respectively covered at both ends of the support plate 1 along its length. The corresponding tabs of the first battery cell 4 and the second battery cell 5, which are corresponding to the ends of the support plate 1 along its length, are respectively fixedly connected to the second busbars 6, so that the second busbars 6 constitute the positive output terminal and the negative output terminal of the module, which facilitates the electrical connection between the module and external circuits or other modules. At the same time, the second busbars 6, which cover the ends of the support plate 1, also serve as end insulation protection and structural reinforcement, further improving the structural strength and electrical safety of the module ends.

[0083] It should be noted that the two second busbars 6 described in this embodiment are only relative to one pouch cell module, that is, each pouch cell module has a second busbar 6 at both ends in the length direction.

[0084] Specifically, the second busbar 6 includes a third connecting portion and a fourth connecting portion covering the upper and lower surfaces of the support plate 1, as well as a transition connecting portion connecting the third connecting portion and the fourth connecting portion. The second busbar 6 has a simple structure, is easy to process and manufacture, and helps to save costs.

[0085] In the above embodiment, the outer periphery of the support plate 1 is covered with an insulating frame 7, and the insulating frame 7 is provided with clearance openings corresponding to the positions of the tabs of the first battery cell 4 and / or the second battery cell 5.

[0086] In this way, the outer periphery of the support plate 1 is covered with an insulating frame 7, which provides insulation protection for the four edges of the support plate 1, preventing short circuits or leakage between the edges of the support plate 1 and the battery cell, thus improving the overall electrical safety of the module. The insulating frame 7 has a clearance opening corresponding to the position of the battery cell tab, which facilitates the fixing of the second busbar 6 to the clearance opening of the insulating frame 7. It also allows the battery cell tab to be fixed to the second busbar 6 without bending, taking into account both insulation protection and electrical connection requirements, and simplifying the structure.

[0087] Specifically, the insulating frame 7 is preferably made of plastic or rubber and is fixed to the perimeter of the support plate 1 by injection molding, overlay, or snap-fit. When the support plate 1 is a metal plate, the insulating frame 7 covers the burrs or sharp edges of the support plate 1 to prevent them from cutting the battery cell or damaging the wiring harness. The position and size of the clearance opening must correspond to the position and size of the battery cell tab to ensure that the tab can pass through freely without interfering with the insulating frame 7. The insulating frame 7 can also serve as an external structural component of the module, providing the module with a certain degree of impact and compression protection.

[0088] Furthermore, the height of the insulating frame 7 is at least flush with the surface of the first cell 4 and / or the second cell 5 facing away from the support plate 1.

[0089] In this way, the height of the insulating frame 7 is at least flush with the surface of the battery cell away from the support plate 1, so that the insulating frame 7 can provide enclosure protection for the side and part of the outer surface of the battery cell, preventing external objects from colliding with the battery cell from the side, and also preventing short circuits between adjacent modules or between modules and the housing due to exposed battery cells.

[0090] In this embodiment, "at least flush" means that the height of the insulating frame 7 can be either equal to the height of the outer surface of the battery cell (flush) or higher than the outer surface of the battery cell (protruding), depending on actual needs. When the insulating frame 7 is higher than the surface of the battery cell, a receiving cavity can be further formed on the module surface to accommodate functional components such as the cover plate 8, buffer pad, or heat insulation layer. The height of the insulating frame 7 must also take into account the limitation of the total height of the module to avoid affecting the installation of the module in the battery pack box due to excessive height. In addition, a positioning step or snap-fit ​​structure can be provided on the upper edge of the insulating frame 7 to position and fix the cover plate 8, so that a stable fit is formed between the cover plate 8 and the insulating frame 7.

[0091] In the above embodiments, the first busbar 3 includes 2 to 20 units. The number of first busbars 3 can be flexibly selected from 2 to 20 units according to actual application needs, so that the module can be adapted to support plates 1 of different lengths and different numbers of battery cells, thereby meeting the diverse needs of different vehicle models or energy storage scenarios for module length and capacity.

[0092] In this embodiment, the number of first busbars 3 corresponds to the number of groups of cells connected in series (i.e., the number of connection points between adjacent cells in a block), and also determines the total number of cells in the module to a certain extent. For example, three cells connected in series require two busbars, and five cells connected in series require four busbars. This range of numbers can be reasonably configured according to the actual size of the support plate 1 and the thickness of the cells, ensuring that the design flexibility is not reduced due to too few numbers, nor that the internal structural complexity of the module or the accumulation of assembly errors is increased due to too many numbers. Preferably, the specific number of first busbars 3 can be determined according to the voltage and capacity requirements of the power device for the module.

[0093] In the above embodiments, it also includes: a plurality of cover plates 8, connected to the side of the first battery cell or the second battery cell away from the support plate 1.

[0094] In this embodiment, the cover plate 8 is placed on the side of the battery cell away from the support plate 1 to provide physical protection for the battery cell and prevent external objects from directly contacting the surface of the battery cell and causing damage. At the same time, the cover plate 8 can also apply a certain clamping force to the battery cell to limit the expansion and deformation of the battery cell during use, thereby improving the cycle life and safety of the battery cell. Multiple cover plates 8 are respectively set on top of different battery cells or different battery cell groups, which facilitates individual disassembly and maintenance.

[0095] Specifically, the cover plate 8 can be made of insulating material (such as plastic) or metal material (such as aluminum alloy). If it is made of metal, an insulating layer must be provided on the side facing the battery cell. The cover plate 8 can be fixed to the bracket 2 or the insulating frame 7 by bolts, clips, or adhesive. The arrangement of multiple cover plates 8 means that each cover plate 8 corresponds to one battery cell. When a battery cell malfunctions and needs to be repaired or replaced, only the corresponding cover plate 8 needs to be removed, without disassembling the entire module, thus improving maintainability. The cover plate 8 can also serve as a heat sink (e.g., using thermally conductive material) or a heat insulation plate (e.g., with a heat insulation layer), and its function can be designed according to thermal management requirements. In addition, raised reinforcing ribs can be provided on the surface of the cover plate 8 to improve its structural strength and bending resistance.

[0096] Secondly, embodiments of the present invention provide a battery pack including the soft-pack cell module of any of the above embodiments.

[0097] Through the above methods, the battery pack provided by the embodiments of the present invention has a higher space utilization rate in the length direction of the module itself. Therefore, more or longer cells can be arranged within the limited volume of the battery pack housing, thereby improving the overall capacity and energy density of the battery pack. At the same time, since the module does not need to reserve assembly gaps in the length direction, the internal structure of the housing is more compact, which can shorten the length of the housing or free up more space for other functional components (such as thermal management system, BMS, etc.), thereby reducing the unit energy cost of the battery pack. In addition, the battery pack can realize internal electrical connection by means of the busbar and conductive connection structure 34 integrated inside the module, reducing the number of wiring harnesses and connectors inside the battery pack, simplifying the assembly process, and improving the assembly efficiency.

[0098] Furthermore, multiple pouch cell modules are stacked in the height direction to improve the energy density of the battery pack. Multiple pouch cell modules can be connected in series on both sides. Additionally, adjacent pouch cell modules in the height direction can be separated by cover plates 8. The cover plates 8 can be set according to the height of the mounting surface of the support plate 1. For example, in this embodiment, the cell accommodating areas at both ends of the support plate 1 in the length direction are lower than the cell accommodating area in the middle of the support plate 1. The pouch cell module includes three first cells located on the first mounting surface and three second cells located on the second mounting surface. The first cells 4 located at both ends of the first mounting surface are correspondingly provided with cover plates 8, and the second cells 5 located in the middle of the second mounting surface are correspondingly provided with cover plates 8, such that the cover plates 8 are positioned in the thickness direction of the module. By creating an alternating layer rather than placing all cells at the same height, the excessively high cover plate 8 in the middle is avoided due to the need to set cover plates 8 for all cells, thus effectively controlling the overall thickness of the module. At the same time, when multiple soft-pack cell modules are stacked along the thickness direction, adjacent soft-pack cell modules can be physically isolated by cover plates 8 that are set relatively oppositely and staggered in height. The cover plate 8 acts as an insulating partition between adjacent modules, eliminating the need for additional isolation plates or insulating plates. While ensuring electrical insulation and mechanical isolation between stacked modules, the number of components is reduced, further improving the space utilization and assembly efficiency of the battery pack in the thickness direction.

[0099] Thirdly, the present invention provides an electrical device comprising a pouch cell module or battery pack according to any of the above embodiments.

[0100] Through the above methods, the electrical device provided by the embodiments of the present invention can extend the driving range (for vehicles) or increase the energy storage capacity (for energy storage systems) without increasing the space occupied by the battery pack or the soft-pack cell module, because the battery pack or soft-pack cell module has a higher volumetric energy density. At the same time, because the module has a compact structure and fewer parts, the overall weight of the battery pack is reduced and the cost is lowered, which helps to reduce the curb weight and manufacturing cost of the electrical device. In addition, because the internal electrical connection path of the module is short and the contact points are few, it is beneficial to reduce the internal resistance of the connection and heat generation, improve the safety and cycle life of the battery system, and thus improve the overall reliability and service life of the electrical device.

[0101] While the present invention has been illustrated and described with reference to certain preferred embodiments, those skilled in the art should understand that the above description is a further detailed explanation of the invention in conjunction with specific embodiments, and should not be construed as limiting the specific implementation of the invention to these descriptions. Various changes in form and detail can be made by those skilled in the art, including several simple deductions or substitutions, without departing from the spirit and scope of the invention.

Claims

1. A soft-pack battery cell module, characterized in that, include: The support plate has a first mounting surface and a second mounting surface that are disposed opposite to each other. Multiple brackets are respectively disposed on the first mounting surface and the second mounting surface. Each bracket is arranged at intervals along the length direction of the support plate and divides the corresponding mounting surface into multiple cell accommodating areas. Multiple first busbars are respectively disposed on each of the brackets. Each first busbar has a first connecting portion and a second connecting portion that are spaced apart in the thickness direction of the support plate and staggered in the length direction and electrically connected to each other. The first busbar disposed on the first mounting surface and the corresponding first busbar disposed on the second mounting surface are electrically connected through a conductive connection structure. Multiple first cells are arranged along the length direction in the cell receiving areas corresponding to the first mounting surface. In two adjacent first cells, the tab of one is connected to the first connection part of the first busbar, and the tab of the other is connected to the second connection part of the same first busbar. The first busbar connects two adjacent first cells in series. Multiple second cells are disposed on the second mounting surface and correspond one-to-one with the positions of the first cells. The second cells and the corresponding first cells are connected in parallel through the conductive connection structure, and the tabs of two adjacent second cells are respectively connected to the first connection part and the second connection part of the first busbar between the first cells and the second cells.

2. The soft-pack battery module according to claim 1, characterized in that, The support plate is a metal plate, and the bracket is an insulating bracket. The insulating bracket is disposed on the surface of the metal plate to isolate the first busbar from the metal plate.

3. The soft-pack battery module according to claim 1, characterized in that, The bracket has a through hole for the conductive connection structure to pass through, and the support plate has a corresponding mounting hole for the conductive connection structure to pass through. The first busbar located on the first mounting surface and the first busbar located on the second mounting surface are connected by the conductive connection structure through the through hole and the mounting hole; and / or, the diameter of the through hole is smaller than the diameter of the mounting hole.

4. The soft-pack battery module according to claim 1, characterized in that, The support plate includes: Multiple straight sections are provided to support the main body of the first battery cell, and adjacent straight sections are staggered from each other in the thickness direction. A bend is connected between two adjacent straight portions, and the encapsulation area and the tab of the first cell are provided corresponding to the bend. The second battery cell is correspondingly disposed on the side of the flat portion away from the first battery cell, and the packaging area and tab of the second battery cell are disposed opposite to the packaging area and tab of the first battery cell in the thickness direction.

5. The soft-pack battery module according to claim 1, characterized in that, The first busbar has an annular frame structure, including a first connecting arm and a second connecting arm arranged opposite to each other along the length direction, and two transition arms connecting the two ends of the first connecting arm and the second connecting arm; The first connecting arm constitutes the first connecting portion, the second connecting arm constitutes the second connecting portion, the second connecting arm is closer to the support plate relative to the first connecting arm, and the two transition arms connect the first connecting portion and the second connecting portion as a single unit; and / or, The bracket includes a plate-shaped body and a protrusion protruding from the plate-shaped body. The shape of the protrusion is adapted to the shape of the second connecting part. The second connecting part is supported on the protrusion. The space between the first connecting part and the second connecting part forms a clearance gap for the corresponding tab to pass through.

6. The soft-pack battery module according to claim 1, characterized in that, The length of the first busbar in the length direction is less than the sum of the lengths of the packaging areas of the adjacent first cells, so that the packaging areas of two adjacent first cells at least partially overlap in the length direction. And / or, The length of the first busbar in the length direction is less than the sum of the lengths of the packaging areas of the adjacent second cells, so that the packaging areas of the two adjacent second cells at least partially overlap in the length direction.

7. The soft-pack battery module according to claim 1, characterized in that, The conductive connection structure is a conductive rod, which is fixed to the side of the first busbar facing the support plate.

8. The soft-pack battery module according to claim 1, characterized in that, The outer periphery of the support plate is covered with an insulating frame, and the insulating frame is provided with clearance openings corresponding to the positions of the tabs of the first battery cell and / or the second battery cell. And / or, also includes: Two second busbars are respectively covering both ends of the support plate along its length. The corresponding tabs of the first battery cell and the second battery cell, which are corresponding to the ends of the support plate along its length, are respectively fixedly connected to the second busbars.

9. A battery pack, characterized in that, Includes the pouch cell module according to any one of claims 1 to 8.

10. An electrical device, characterized in that, Includes the soft-pack battery cell module according to any one of claims 1 to 8 or the battery pack according to claim 9.

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