Battery module, battery pack, and electric device

Abstract

The application provides a battery module, a battery pack and a power utilization device. The battery module comprises a battery pack, a limiting assembly, a constraint and a plurality of fillers. The battery pack comprises a plurality of battery cells arranged along a first direction. The limiting assembly comprises a first limiting member and a second limiting member arranged at two ends of the battery pack along the first direction respectively. The constraint is arranged around the limiting assembly and the battery pack and is locked. The constraint and the limiting assembly jointly limit the size of the battery pack along the first direction to a preset size. The plurality of fillers have different sizes along the first direction. The fillers are arranged between two adjacent battery cells and are used to keep the pole columns of the two adjacent battery cells at a preset interval along the first direction when the size of the battery pack along the first direction is kept at the preset size. The application can adapt to battery cells with different thicknesses by replacing fillers with different sizes, thereby ensuring the consistency of the positions of the pole columns of the battery cells and facilitating the assembly of a battery cell connecting assembly.

Description

Technical Field

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

[0002] Energy storage battery packs are widely used in industrial and commercial energy storage, residential energy storage and electric vehicles. Existing technologies typically focus on the structural, connection and thermal management design around specific cell specifications.

[0003] However, existing battery packs often require readjustment of the overall structure and supporting connections and heat dissipation components when the cell thickness changes, which increases the development cycle and manufacturing cost. Although some solutions can expand the range of adaptability, they are complex in structure and are prone to insufficient positioning stability and thermal uniformity in long-term use, and the flexibility of production switching is limited.

[0004] Therefore, how to balance structural compatibility, thermal management stability, and production adaptability under different cell specifications has become an urgent technical problem to be solved. Summary of the Invention

[0005] This application provides a battery module, battery pack, and electrical device, which can maintain a preset spacing between the terminals of battery cells of different thicknesses by fixing the total length of the battery pack and using replaceable fillers, thereby achieving structural compatibility and stable assembly.

[0006] In a first aspect, embodiments of this application provide a battery module, including:

[0007] The battery pack includes a plurality of battery cells arranged along a first direction;

[0008] The limiting assembly includes a first limiting member and a second limiting member respectively disposed at both ends of the battery pack along a first direction;

[0009] A constraint member is wrapped around the outer periphery of the limiting component and the battery pack and locked in place. The constraint member and the limiting component together limit the size of the battery pack along the first direction to a preset size.

[0010] Multiple fillers, each with a different size in the first direction, are disposed between two adjacent cells to maintain a preset distance between the terminals of the two adjacent cells in the first direction when the battery pack maintains a preset size in the first direction.

[0011] In one possible embodiment, along the first direction, the filler includes a laminated insulation layer and a buffer layer, wherein the insulation layer and the buffer layer are bonded together.

[0012] In one possible embodiment, along a first direction, the battery pack includes a first cell and a second cell arranged adjacent to each other, with a gap between the first cell and the second cell, and a heat insulation layer and a buffer layer disposed in the gap;

[0013] The heat insulation layer faces the first battery cell, and the buffer layer faces the second battery cell.

[0014] In one possible embodiment, when cells with multiple thickness dimensions are arranged along a first direction, gaps with multiple spacing dimensions are formed.

[0015] The buffer layer includes multiple thickness dimensions, and each thickness dimension of the buffer layer is adapted to the gap of each spacing dimension.

[0016] In one possible embodiment, the heat insulation layer is connected to the first battery cell via a first adhesive layer, and the buffer layer is connected to the second battery cell via a second adhesive layer.

[0017] In one possible embodiment, both the first limiting member and the second limiting member are plate-shaped structures, with the two ends of the plate-shaped structures extending to the circumferential outer side of the battery pack along the first direction, and the constraint member surrounding the portion of the plate-shaped structure located on the outer side of the battery pack.

[0018] In one possible embodiment, the constraint is a strip locking member, which is wrapped around the periphery of the limiting component and the battery pack in a circumferential direction, and applies a radial locking force to the battery pack by locking the beginning and end ends.

[0019] In one possible embodiment, a cooling plate is also included, on which each cell and each filler are disposed;

[0020] A thermally conductive connection layer is provided between the surface of each battery cell facing the cooling plate and the cooling plate. Each battery cell is bonded and fixed to the cooling plate through the thermally conductive connection layer and conducts heat.

[0021] In one possible embodiment, a support beam is also included, disposed at one end of the cooling plate near the limiting component, the support beam extending along a first direction and supporting the bottom of the first limiting member and the second limiting member;

[0022] The support beam has a stepped structure to block the heat conduction path between the limiting component and the support beam.

[0023] In one possible embodiment, the battery pack further includes a cell connection assembly mounted on the battery pack; the cell connection assembly has multiple connection holes, each connection hole being connected to a corresponding terminal of each cell.

[0024] In one possible embodiment, a first thermal blocking layer is provided between the first limiting member and the battery cell, and a second thermal blocking layer is provided between the second limiting member and the battery cell; used to block heat transfer between the battery cell and the limiting component.

[0025] Secondly, embodiments of this application provide a battery pack including at least one of the battery modules provided above.

[0026] Thirdly, embodiments of this application provide an electrical device, including the battery module or battery pack provided above.

[0027] This application provides a battery module, battery pack, and electrical device. By setting limiting components at both ends of the battery pack along a first direction, and using constraint members wrapped around and locked around the limiting components and the outer periphery of the battery pack, the dimensions of the battery pack along the first direction are limited to a preset size. This can maintain the stability of the overall shape and assembly boundary of the battery pack under different cell specifications. Furthermore, by setting multiple fillers of different sizes in the first direction between adjacent cells, the terminals of adjacent cells can maintain a preset distance along the first direction while the dimensions of the battery pack along the first direction are maintained at the preset size. This facilitates the adaptation and connection of related components, reduces the structural adjustment requirements caused by changes in cell thickness, and improves the structural compatibility, thermal management stability, and production adaptability of the battery module. Attached Figure Description

[0028] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0029] Figure 1 This is a schematic diagram of the structure of an embodiment of this application;

[0030] Figure 2 for Figure 1 A side view diagram;

[0031] Figure 3 This is a schematic diagram of the structure of the filler in an embodiment of this application;

[0032] Figure 4 This is a schematic diagram of the supporting beam in an embodiment of this application;

[0033] Figure 5 This is a layout diagram of the battery pack according to an embodiment of this application;

[0034] Figure 6 This is a schematic diagram showing the alignment of the welding holes of the battery cell connection assembly with the hole layout of the battery cell in an embodiment of this application.

[0035] Figure 7 This is a usage state diagram of an embodiment of this application.

[0036] Explanation of reference numerals in the attached figures:

[0037] 100. Battery pack; 110. Battery cell; 120. First battery cell; 130. Second battery cell; 200. Limiting assembly; 210. First limiting member; 211. First heat-blocking layer; 220. Second limiting member; 221. Second heat-blocking layer; 300. Constraint member; 400. Filler; 410. Heat insulation layer; 420. Buffer layer; 430. First adhesive layer; 440. Second adhesive layer; 500. Cooling plate; 600. Support beam; 700. Stepped structure; 800. Battery cell connection assembly; 810. Connection hole.

[0038] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In the absence of conflict, the following embodiments and features can be combined with each other.

[0040] Battery module technology is mainly used in energy storage battery packs and their assembly structures, and is commonly found in industrial and commercial energy storage, residential energy storage, electric vehicles, and other devices that require integrated cell power supply. These systems typically consist of multiple cells arranged in a predetermined direction to form a battery pack, which is then integrated with limiting, connecting, and heat dissipation components.

[0041] In practical applications, different projects often select battery cells of different thicknesses. In addition to supporting the installation of battery cells, battery modules also involve cell spacing control, terminal alignment, overall size constraints, and subsequent battery pack-level assembly adaptation. The versatility of the module structure directly affects the overall development efficiency and manufacturing cost.

[0042] Existing battery modules are mostly custom-designed according to specific cell specifications. They typically arrange the cells using a fixed-size support frame, end clamping structure, and pre-set spacers, and then use external binding components or a casing to press the battery pack together, ensuring that the terminals of adjacent cells maintain their corresponding connection positions. This type of solution can complete assembly when the target cell specifications are fixed, but the matching relationship between the total module length, cell spacing, and terminal positions is usually predetermined.

[0043] When the thickness of the battery cell changes, the original module's spacing structure, end limiting structure, and peripheral constraint relationship are prone to mismatch, and the spacing between adjacent battery cell terminals changes accordingly, making it difficult to continue using connecting components and assembly tooling. If the frame is redesigned, an adjustment mechanism is added, or the entire module structure is replaced to adapt to different battery cells, the structural complexity and manufacturing cost will increase significantly, and the assembly chain will also become longer.

[0044] Meanwhile, under long-term compression, the adjustment structure is prone to positioning deviation or insufficient compression consistency, which reduces the stability of cell arrangement and affects subsequent battery pack-level connection and thermal management layout. During production switchover, it is also necessary to adjust a variety of components, making it difficult to balance specification compatibility and mass production efficiency.

[0045] To overcome the shortcomings of existing technologies, this application proposes a battery module, a battery pack, and an electrical device. The overall dimension of the battery module along a first direction is fixed, and the dimensional differences caused by different specifications of battery cells are transferred to the filling area between adjacent cells. Even when the cell thickness varies, a uniform module shape and terminal spacing relationship can still be maintained. Limiting members are provided at both ends, and locking constraint members are provided on the outer periphery. The limiting members and constraint members together define the preset dimensions of the battery pack. Multiple filling members with different dimensions in the first direction are arranged between adjacent cells to compensate for the spacing changes caused by different cell specifications.

[0046] Based on this, the battery pack formed by multiple cells arranged along the first direction in the energy storage battery pack can continue to adapt to the original connection and integration architecture, maintain stable pole positions and assembly benchmarks at the module level, reduce overall structural adjustments caused by changes in cell specifications, and alleviate the problems of long development cycles, cumbersome manufacturing switching and insufficient module versatility.

[0047] The present invention will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can have a clearer and more detailed understanding of the present invention.

[0048] Figure 1 This is a schematic diagram of the structure of an embodiment of this application; Figure 2 for Figure 1 A side view diagram; Figure 3 This is a schematic diagram of the structure of the filler in an embodiment of this application; Figure 4 This is a schematic diagram of the supporting beam in an embodiment of this application; Figure 5 This is a layout diagram of the battery pack according to an embodiment of this application; Figure 6 This is a schematic diagram showing the alignment of the welding holes of the battery cell connection assembly with the hole layout of the battery cell in an embodiment of this application. Figure 7 This is a usage state diagram of an embodiment of this application.

[0049] See Figure 1 , Figure 2 , Figure 3, Figure 4 , Figure 5 and Figure 6 This application discloses a battery module including a battery pack 100, a limiting component 200, a constraint member 300, and a plurality of fillers 400. The battery pack 100 includes a plurality of cells 110 arranged along a first direction. The limiting component 200 includes a first limiting member 210 and a second limiting member 220 respectively disposed at both ends of the battery pack 100 along the first direction. The constraint member 300 is wrapped around the limiting component 200 and the outer periphery of the battery pack 100 and locked. The constraint member 300 and the limiting component 200 together limit the size of the battery pack 100 along the first direction to a preset size. Each filler 400 has a different size in the first direction. The filler 400 is disposed between two adjacent cells 110 and is used to maintain a preset distance between the terminals of two adjacent cells 110 along the first direction when the size of the battery pack 100 along the first direction is maintained at the preset size.

[0050] In this embodiment, the battery pack 100 includes a plurality of battery cells 110 arranged along a first direction. Each battery cell 110 is the core energy storage unit of the energy storage battery module, used to store and release electrical energy. The plurality of battery cells 110 are arranged sequentially along the first direction, with adjacent cells 110 spaced apart by filler members 400. Each battery cell 110 has a terminal post at its top, which is used to electrically connect to a battery cell connection assembly (e.g., a flexible circuit board type battery cell connection assembly or a wire harness type battery cell connection assembly) to achieve series or parallel connection between the plurality of battery cells 110.

[0051] In one possible implementation, the battery pack 100 includes four sub-cell packs, each equipped with a limit component 200 and a constraint component 300, and the sub-cell packs are electrically connected to each other. Each sub-cell pack is a 1P26S battery pack (i.e., a battery pack with 1 parallel and 26 series connections). The four 1P26S battery packs are connected in series to form a 1P104S battery system (i.e., a battery system with 1 parallel and 104 series connections), with a rated voltage of approximately 332.8V (based on 3.2V cells), suitable for applications such as energy storage systems. This modular structure facilitates production and assembly; each sub-cell pack can be assembled and tested separately, and finally connected in series to form a complete battery system.

[0052] The limiting component 200 includes a first limiting member 210 and a second limiting member 220 respectively disposed at both ends of the battery pack 100 along a first direction.

[0053] The first limiting member 210 is disposed at one end (e.g., the front end) of the battery pack 100 along the first direction, and the second limiting member 220 is disposed at the other end (e.g., the rear end) of the battery pack 100 along the first direction. The first limiting member 210 and the second limiting member 220 limit the battery pack 100 from both ends, respectively, and cooperate with the constraint member 300 to jointly limit the size of the battery pack 100 along the first direction to a preset size.

[0054] In one possible implementation, both the first limiting member 210 and the second limiting member 220 are plate-like structures, such as aluminum end plates. The plate-like structures extend to the circumferential outer sides of the battery pack 100 at both ends along a first direction, so that the constraint member 300 is disposed around the portion of the plate-like structure located outside the battery pack 100. The first limiting member 210 and the second limiting member 220 also serve to uniformly transmit the locking force applied by the constraint member 300 to the ends of the battery pack 100, ensuring uniform force distribution on the battery pack 100.

[0055] The constraint member 300 is disposed around the outer periphery of the limiting component 200 and the battery pack 100 and locked in place. The constraint member 300 and the limiting component 200 together limit the size of the battery pack 100 along the first direction to a preset size.

[0056] In one possible implementation, the constraint member 300 is a strip-shaped locking member, such as a steel strip. The constraint member 300 is wound around the outer periphery of the first limiting member 210, the second limiting member 220, and the battery pack 100 in a circumferential direction, and applies a radial locking force to the battery pack 100 by locking its two ends. Through the locking action of the constraint member 300, the first limiting member 210 and the second limiting member 220 are pressed against the two ends of the battery pack 100, thereby fixing the size of the battery pack 100 in the first direction to a preset size.

[0057] The filler 400 is disposed between two adjacent cells 110 and is used to maintain a preset distance between the terminals of the two adjacent cells 110 along the first direction when the size of the battery pack 100 along the first direction is maintained at a preset size.

[0058] Each filler 400 has a different dimension in the first direction. Specifically, the filler 400 has various thickness specifications, and the filler 400 of different thickness specifications is adapted to the different gaps formed by the arrangement of battery cells 110 of different thicknesses. When the thickness of the battery cells 110 assembled in the battery pack 100 changes, the gap size between adjacent battery cells 110 changes accordingly. At this time, a filler 400 of the corresponding size is selected to fill the gap between adjacent battery cells 110, so that the battery pack 100 maintains the preset size in the first direction, and at the same time fixes the position of each battery cell 110 in the battery pack 100.

[0059] For example, the inner surfaces of the first limiting member 210 and the second limiting member 220 abut against the end faces of the cells 110 at both ends of the battery pack 100. After the constraint member 300 is locked, the first limiting member 210 and the second limiting member 220 are pressed against both ends of the battery pack 100, thereby limiting the battery pack 100 along the first direction.

[0060] The constraint member 300 surrounds the outside of the first limiting member 210 and the second limiting member 220, and also surrounds the outer periphery of the battery pack 100. The first and last ends of the constraint member 300 are locked by a locking mechanism (such as welding, bolting, etc.), so that the constraint member 300 applies a radial locking force to the limiting assembly 200 and the battery pack 100. Through the locking action of the constraint member 300, the first limiting member 210 and the second limiting member 220 are fixed to both ends of the battery pack 100, limiting the size of the battery pack 100 along the first direction to a preset size.

[0061] There is a gap between two adjacent cells 110, and the filler 400 fills the gap. One side surface of the filler 400 along the first direction is attached to the end face of one of the two adjacent cells 110, and the other side surface of the filler 400 along the first direction is attached to the end face of the other of the two adjacent cells 110.

[0062] Furthermore, the constraint member 300 and the limiting component 200 cooperate with each other to limit the size of the battery pack 100 along the first direction to a preset size, and the preset size does not change due to the thickness of the cell 110.

[0063] The filler 400 is disposed between two adjacent cells 110. By selecting fillers 400 of different sizes, the different gaps formed by cells 110 of different thicknesses can be adapted, so that the battery pack 100 can be compatible with cells 110 of different thicknesses without changing the total length.

[0064] Since the total length of the battery pack 100 is fixed and each filler 400 is adapted to the corresponding gap, the position of each cell 110 in the battery pack 100 is fixed, and the terminals of two adjacent cells 110 maintain a preset distance along the first direction.

[0065] Since the terminals of the battery cell 110 maintain a preset spacing along the first direction, the connection holes of the battery cell connection assembly and the terminals always remain matched, so there is no need to redesign the battery cell connection assembly and the limiting assembly 200 and other supporting structures due to changes in the specifications of the battery cell 110.

[0066] During operation, multiple battery cells 110 are first arranged sequentially along the first direction. The filler 400 located between adjacent battery cells 110 is matched and configured according to the thickness of the selected battery cell 110, so that the gaps between adjacent cells are compensated to the corresponding dimensions at the initial stage of assembly. Subsequently, the first limiting member 210 and the second limiting member 220 respectively position the ends of the battery pack 100 from both ends. The constraint member 300 is then wrapped around the outer periphery of the battery pack 100 and the limiting component 200 and locked, so that the end limiting, outer periphery covering and intermediate filling together form an overall limitation on the dimension of the battery pack 100 in the first direction. Since the size of the filler 400 is adjusted according to the specifications of the battery cell 110, the preset spacing between adjacent terminals can be maintained without changing the module shape reference when the battery cell body switches between different specifications, thereby keeping the terminal position, assembly interface and subsequent connection reference of the module consistent.

[0067] Meanwhile, the constraint member 300, in its locked state, provides continuous locking constraint to the battery pack 100. This, combined with the end-position limiters, suppresses the relative displacement of the cells 110 under operational vibration or handling conditions, ensuring the stable positioning of the filler member 400 and maintaining its spacing compensation function. This allows the battery module to maintain a uniform overall size and terminal alignment even when using cells of different thicknesses, reducing repetitive adjustments to the module shape, connection positions, and assembly tooling for different cell specifications. It should be understood that the above example is for illustrative purposes only and is not limiting.

[0068] Based on the foregoing embodiments, further see... Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 Along the first direction, the filler 400 includes a heat insulation layer 410 and a buffer layer 420 stacked together, with the heat insulation layer 410 and the buffer layer 420 bonded together.

[0069] In this embodiment, the heat insulation layer 410 is disposed on one side of the filler 400 along the first direction to block heat transfer between two adjacent cells 110, prevent the heat of a single cell 110 from being conducted to the adjacent cell 110, thereby avoiding the spread of thermal runaway.

[0070] In one possible implementation, the thermal insulation layer 410 is any one of an aerogel layer, an aerogel felt layer, or a nanoporous thermal insulation plate layer. Aerogel is a material with extremely high porosity and extremely low thermal conductivity, which can effectively block heat conduction between adjacent cells 110. Preferably, the thermal insulation layer 410 has a dimension of 0.5 mm along the first direction. The 0.5 mm thick aerogel layer ensures excellent thermal insulation performance while occupying a small space, which is beneficial to improving the energy density of the battery module.

[0071] The heat insulation layer 410 also has an insulation function, which can prevent short circuits between adjacent cells 110.

[0072] A buffer layer 420 is disposed on one side surface of the heat insulation layer 410 along the first direction, and is stacked and bonded to the heat insulation layer 410. The buffer layer 420 is used to absorb the expansion stress generated by the battery cell 110 during charging and discharging, and to provide elastic preload for the battery cell 110.

[0073] In one possible implementation, the buffer layer 420 is any one of an MPP foam layer, a silicone foam layer, or an EPDM foam layer. MPP foam (microporous polypropylene foam) has excellent elastic recovery properties and resistance to compression fatigue, and can maintain stable resilience during long-term use, continuously providing preload to the cell 110 and preventing the cell 110 from loosening in the battery pack 100.

[0074] The buffer layer 420 also serves as the main thickness adjustment layer for the filler 400. Since the insulation layer 410 typically has a fixed thickness (e.g., 0.5 mm), the overall thickness variation of the filler 400 is primarily achieved through variations in the thickness of the buffer layer 420. The filler 400 has various thickness specifications (e.g., the outer frame dimension along the first direction is 2.0 mm, 2.5 mm, or 3.0 mm), and different thickness specifications of the filler 400 are adapted to the different gaps formed by the arrangement of battery cells 110 of different thicknesses. By replacing the buffer layer 420 with different thicknesses, filler 400s of different thicknesses can be formed without redesigning the structure of the insulation layer 410, resulting in flexible production and lower costs.

[0075] For example, the heat insulation layer 410 and the buffer layer 420 are stacked along the first direction and fixed by adhesive bonding. Specifically, one side surface of the heat insulation layer 410 along the first direction is attached to one side surface of the buffer layer 420 along the first direction, and an adhesive layer (e.g., backing adhesive) is provided between them to fix the heat insulation layer 410 and the buffer layer 420 together as one unit.

[0076] The bonding between the heat insulation layer 410 and the buffer layer 420 is a surface contact bonding, with a large bonding area and a firm connection, which can prevent the heat insulation layer 410 and the buffer layer 420 from separating during use.

[0077] Furthermore, the laminated composite structure of the insulation layer 410 and the buffer layer 420 has multiple synergistic effects:

[0078] Functional division and synergy: the heat insulation layer 410 focuses on heat insulation and insulation, the buffer layer 420 focuses on buffering and thickness adjustment. The functional boundaries of each layer are clear, and the material selection does not restrict each other. The optimal material can be selected for each to achieve the best performance.

[0079] Thickness adjustment coordination: By fixing the thickness of the heat insulation layer 410, the overall thickness of the filler 400 can be changed by adjusting the thickness of the buffer layer 420, forming a variety of thickness specifications to adapt to the different gaps formed by the battery cells 110 of different thicknesses, so that the battery pack 100 is compatible with a variety of battery cell specifications while keeping the total length unchanged.

[0080] Synergistic effect of heat insulation and buffering: The heat insulation layer 410 and the buffer layer 420 are filled together in the gap between adjacent cells 110. While blocking heat transfer, they absorb expansion stress and prevent the cells 110 from being damaged by mutual compression due to thermal expansion, thereby improving the safety and reliability of the battery module.

[0081] In one possible implementation, the filler 400 is a frame structure (e.g., a U-shaped frame structure) surrounding the side of the battery cell 110. The outer periphery of the frame structure is adapted to the circumferential outer wall profile of the battery cell 110, and the frame structure is fitted onto the circumferential outer wall of the battery cell 110. An annular contact surface is formed between the inner wall of the frame structure and the circumferential outer wall of the battery cell 110 to increase the contact area between the filler 400 and the battery cell 110 and improve positioning stability.

[0082] The central area of ​​the frame structure is hollowed out to form a hollow section, through which the filler 400 passes. When the filler 400 is placed between two adjacent battery cells 110, the hollow section and the end faces of the two adjacent battery cells 110 enclose a venting space. When a battery cell 110 experiences an abnormality (such as thermal runaway), the generated gas can enter this venting space and be discharged along the hollow section, preventing gas accumulation that could lead to an increase in internal pressure and cause an explosion in the battery cell 110.

[0083] The frame structure includes multiple side walls that are connected end to end and form a ring. Adjacent side walls are connected by a circular arc to avoid stress concentration.

[0084] Based on the foregoing embodiments, further see... Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 Along the first direction, the battery pack 100 includes a first cell 120 and a second cell 130 disposed adjacent to each other, with a gap between the first cell 120 and the second cell 130, and a heat insulation layer 410 and a buffer layer 420 disposed in the gap; the heat insulation layer 410 is disposed toward the first cell 120, and the buffer layer 420 is disposed toward the second cell 130.

[0085] In this embodiment, the first cell 120 and the second cell 130 are two adjacent cells 110 arranged along the first direction in the battery pack 100. The first cell 120 is disposed on one side of the second cell 130 along the first direction, and there is a gap between them of a certain size. The size of the gap depends on the thickness of the first cell 120 and the second cell 130 and the total length of the battery pack 100 along the first direction.

[0086] In the battery pack 100, a filler 400 is provided between adjacent cells 110. For ease of description, any two adjacent cells 110 are referred to as the first cell 120 and the second cell 130, respectively. The first cell 120 and the second cell 130 have the same structure, both being square cells 110 with terminals on their end faces for electrical connection with the cell connection assembly.

[0087] A gap exists between the first cell 120 and the second cell 130, and a filler 400 is disposed in the gap. The dimension of the gap along the first direction is determined by the thickness of the first cell 120 along the first direction, the thickness of the second cell 130 along the first direction, and the total length of the battery pack 100 along the first direction.

[0088] Since the total length of the battery pack 100 is limited to a preset size by the constraint member 300 and the limiting component 200, the gap size between adjacent battery cells 110 will change accordingly when the thickness of the battery cell 110 changes. Specifically, when the thickness of the battery cell 110 increases, the gap size between adjacent battery cells 110 decreases; when the thickness of the battery cell 110 decreases, the gap size between adjacent battery cells 110 increases. This application maintains the preset size of the battery pack 100 along the first direction by filling the gap with fillers 400 of different thicknesses.

[0089] The heat insulation layer 410, acting as the primary heat insulation barrier, is positioned close to the first battery cell 120, effectively blocking heat transfer from the first battery cell 120 to the second battery cell 130 along the shortest path. The buffer layer 420, acting as a secondary heat insulation barrier, is positioned between the heat insulation layer 410 and the second battery cell 130, forming a second line of heat insulation. Together, they constitute a double heat insulation structure, significantly improving the heat blocking effect between adjacent battery cells 110.

[0090] The buffer layer 420 is positioned towards the second battery cell 130 and provides elastic preload to the second battery cell 130 after the constraint member 300 is locked. The heat insulation layer 410, due to its small thickness, mainly serves as heat insulation and positioning. It has high compressive strength and can provide support when the buffer layer 420 is under pressure, preventing the buffer layer 420 from being over-compressed and causing heat insulation failure.

[0091] The thickness of the heat insulation layer 410 is fixed (e.g., 0.5 mm), while the thickness of the buffer layer 420 can be adjusted as needed. The heat insulation layer 410 is positioned facing the first battery cell 120, maintaining a fixed positional relationship between them. The buffer layer 420 is positioned facing the second battery cell 130, positioned closer to the side of the gap where dimensional changes need to be compensated. By replacing the buffer layer 420 with different thicknesses, the overall thickness of the filler 400 can be adjusted to accommodate battery cells 110 of varying thicknesses. The structure is simple and adjustment is convenient.

[0092] In one possible implementation, see Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 When the cells 110 with multiple thicknesses are arranged along the first direction, they form gaps with multiple spacing dimensions; the buffer layer 420 includes multiple thicknesses, and each thickness of the buffer layer 420 is adapted to the gap with each spacing dimension.

[0093] In this embodiment, the battery cells 110 in the battery pack 100 can be selected with different thickness specifications according to different application requirements. For example, in an energy storage system, square battery cells 110 with thicknesses of 50mm, 52mm, 54mm, etc., can be selected according to capacity requirements.

[0094] When multiple battery cells 110 with the same thickness are arranged along a first direction, the gap between adjacent battery cells 110 is a first spacing; when multiple battery cells 110 with a different thickness are arranged along the first direction, the gap between adjacent battery cells 110 is a second spacing. Since the total length of the battery pack 100 is limited to a preset size by the constraint member 300 and the limiting component 200, the gap between adjacent battery cells 110 changes with the thickness of the battery cells 110 after the battery cells 110 with different thicknesses are arranged.

[0095] Specifically, assume that the battery pack 100 includes N cells 110 along the first direction, the total length of the battery pack 100 is L (preset dimension), and the thickness of each cell 110 is... , 、…、tN, the gap between adjacent cells 110 is , Given g(N-1), then: .

[0096] When the thickness t of the battery cell 110 increases, the corresponding gap g needs to be reduced to keep L constant; when the thickness t of the battery cell 110 decreases, the corresponding gap g needs to be increased to keep L constant.

[0097] Because the battery cell 110 has multiple thickness dimensions, multiple gaps of different spacing dimensions are formed between adjacent battery cells 110. For example, when the thickness of the battery cell 110 is 50mm, the gap between adjacent battery cells 110 is 3.0mm; when the thickness of the battery cell 110 is 52mm, the gap between adjacent battery cells 110 is 2.5mm; and when the thickness of the battery cell 110 is 54mm, the gap between adjacent battery cells 110 is 2.0mm.

[0098] The spacing of the gap determines the size of the space that the filler 400 needs to fill. The thickness of the filler 400 must match the spacing of the gap to ensure that the battery pack 100 maintains its preset size along the first direction.

[0099] The buffer layer 420 is the main thickness adjustment layer of the filler 400. The buffer layer 420 includes multiple thickness dimensions, and each thickness dimension of the buffer layer 420 is adapted to the gap of each spacing dimension. Specifically, the thickness dimension of the buffer layer 420 corresponds to the gap dimension between adjacent cells 110: when the gap dimension is large, a thicker buffer layer 420 is selected; when the gap dimension is small, a thinner buffer layer 420 is selected.

[0100] In one possible implementation, the outer frame of the filler 400 has a dimension along the first direction of any one of 2.0mm, 2.5mm, or 3.0mm. Since the thickness of the heat insulation layer 410 is fixed at 0.5mm, the thickness of the buffer layer 420 is correspondingly 1.5mm, 2.0mm, or 2.5mm. When the gap between adjacent cells 110 is 3.0mm, the total thickness of the filler 400 is selected to be 3.0mm (0.5mm for the heat insulation layer 410 + 2.5mm for the buffer layer 420); when the gap is 2.5mm, the total thickness of the filler 400 is selected to be 2.5mm (0.5mm for the heat insulation layer 410 + 2.0mm for the buffer layer 420); when the gap is 2.0mm, the total thickness of the filler 400 is selected to be 2.0mm (0.5mm for the heat insulation layer 410 + 1.5mm for the buffer layer 420).

[0101] The thickness adjustment function of the buffer layer 420, combined with the fixed thickness of the heat insulation layer 410, allows the filler 400 to achieve various thickness specifications by replacing the buffer layer 420 with different thicknesses without changing the structure and material of the heat insulation layer 410, thus adapting to battery cells 110 of different thicknesses.

[0102] Furthermore, there is a one-to-one correspondence between the thickness of the battery cell 110 and the thickness of the buffer layer 420. When the thickness of the battery cell 110 increases, the thickness of the buffer layer 420 decreases; when the thickness of the battery cell 110 decreases, the thickness of the buffer layer 420 increases. That is, the thickness of the battery cell 110 and the thickness of the buffer layer 420 are negatively correlated, and the sum of their dimensions remains constant under the condition that the total length of the battery pack 100 is fixed (in a gap unit between two adjacent battery cells 110, the thickness of the battery cell 110 + the thickness of the buffer layer 420 + the thickness of the heat insulation layer 410 = a constant value).

[0103] Taking specific values ​​as an example, assuming the battery pack 100 includes N cells 110, the total length of the battery pack 100 is L, and the thickness of the heat insulation layer 410 is fixed at h (e.g., 0.5 mm), then for any two adjacent cells 110, the gap unit is: (Constant value).

[0104] Where t is the thickness of the battery cell 110, d is the thickness of the buffer layer 420, and h is the thickness of the heat insulation layer 410 (a fixed value). When the thickness t of the battery cell 110 changes, the thickness d of the buffer layer 420 changes accordingly to keep t+d+h a constant value C.

[0105] Therefore, the total length L of the battery pack 100 is approximately N×C (ignoring the thickness of the end plates, etc.), which is independent of the specific thickness of the cell 110 and always maintains the preset size.

[0106] Based on the above analysis, when the system is started and enters the assembly or working state, the cells 110 of different thicknesses, arranged along the first direction, will naturally form multiple gaps with different spacing sizes. At this time, the corresponding specifications can be selected from the preset multi-thickness heat insulation layers according to the gap size, and they can be adapted to the corresponding gaps and work together with the buffer layer 420 to complete the filling. Under the action of the continuous clamping force provided by the external constraint 300, each heat insulation layer 410 maintains a stable thickness and rebound support within the compression range. On the one hand, it blocks the heat conduction path between adjacent cells 110 and suppresses the lateral diffusion of heat inside the battery pack 100. On the other hand, it maintains the stability of the relative position of adjacent cells 110 and the spacing between the terminals, so that the battery pack 100 can maintain a uniform module shape and assembly benchmark when switching between different cell specifications. This reduces the need for structural redesign caused by changes in cell thickness and improves the versatility, assembly efficiency, and thermal safety of the battery module. It should be understood that the above example is only for demonstration and is not limiting.

[0107] In one possible implementation, the heat insulation layer 410 is connected to the first battery cell 120 via the first adhesive layer 430, and the buffer layer 420 is connected to the second battery cell 130 via the second adhesive layer 440.

[0108] In this embodiment, the first adhesive layer 430 is disposed between the heat insulation layer 410 and the first battery cell 120, and is used to bond and fix the heat insulation layer 410 and the first battery cell 120.

[0109] The first adhesive layer 430 is an adhesive material layer disposed on the surface of the heat insulation layer 410 facing the first battery cell 120. In one possible implementation, the first adhesive layer 430 is a backing adhesive layer (double-sided adhesive layer), with one side surface adhered and fixed to the heat insulation layer 410, and the other side surface adhered and fixed to the end face of the first battery cell 120. The backing adhesive layer has advantages such as high bonding strength, convenient operation, and short curing time, making it suitable for mass automated production.

[0110] In another possible implementation, the first adhesive layer 430 is a thermally conductive structural adhesive layer, which has both adhesive and thermal conductivity functions.

[0111] The first adhesive layer 430 covers the entire or most of the surface of the heat insulation layer 410 facing the first battery cell 120 to ensure that the bonding area between the heat insulation layer 410 and the first battery cell 120 is large enough and the bonding strength is high enough. Preferably, the dimension of the first adhesive layer 430 along the first direction is 0.05mm-0.2mm, which ensures the bonding strength without excessively increasing the overall thickness of the filler 400.

[0112] The functions of the first adhesive layer 430 include:

[0113] Fixed connection: The heat insulation layer 410 is bonded to the first battery cell 120 as a whole to prevent relative displacement between the heat insulation layer 410 and the first battery cell 120 during use.

[0114] Positioning function: During the assembly process, the pre-positioning function of the adhesive layer accurately positions the filler 400 on the end face of the first cell 120, which facilitates subsequent assembly.

[0115] Sealing function: The adhesive layer fills the tiny gap between the heat insulation layer 410 and the end face of the first battery cell 120 to form a seal and prevent dust, moisture and other substances from entering the gap between the battery cells 110.

[0116] The second adhesive layer 440 is disposed between the buffer layer 420 and the second battery cell 130, and is used to bond and fix the buffer layer 420 and the second battery cell 130.

[0117] The second adhesive layer 440 is an adhesive material layer disposed on the surface of the buffer layer 420 facing the second battery cell 130. In one possible implementation, the second adhesive layer 440 is a backing adhesive layer (double-sided adhesive layer), with one side surface adhered and fixed to the buffer layer 420 and the other side surface adhered and fixed to the end face of the second battery cell 130.

[0118] The second adhesive layer 440 covers the entire or most of the surface of the buffer layer 420 facing the second cell 130 to ensure that the bonding area between the buffer layer 420 and the second cell 130 is large enough and the bonding strength is high enough.

[0119] The function of the second adhesive layer 440 includes:

[0120] Fixed connection: The buffer layer 420 and the second battery cell 130 are bonded together to prevent relative displacement between the buffer layer 420 and the second battery cell 130 during use.

[0121] Preload transmission: After the buffer layer 420 is locked by the constraint 300, it is in a compressed state. Its rebound force is transmitted to the end face of the second cell 130 through the second adhesive layer 440, providing a stable preload for the second cell 130.

[0122] Positioning function: During the assembly process, the pre-positioning function of the adhesive layer accurately positions the filler 400 at the end face of the second cell 130.

[0123] Furthermore, the first adhesive layer 430 is disposed between the heat insulation layer 410 and the first battery cell 120, and the second adhesive layer 440 is disposed between the buffer layer 420 and the second battery cell 130. Because the heat insulation layer 410 and the buffer layer 420 have different material properties (the heat insulation layer 410 is a rigid material such as aerogel, and the buffer layer 420 is an elastic material such as MPP foam), the first adhesive layer 430 and the second adhesive layer 440 can differ in material selection and placement.

[0124] In one possible implementation, the first adhesive layer 430 is made of an adhesive with good adhesion to aerogel materials, and the second adhesive layer 440 is made of an adhesive with good adhesion to MPP foam materials, to ensure maximum bonding strength for each. In another possible implementation, the first adhesive layer 430 and the second adhesive layer 440 use the same adhesive material to simplify production and material management.

[0125] The first adhesive layer 430 fixes the heat insulation layer 410 to the first battery cell 120, and the second adhesive layer 440 fixes the buffer layer 420 to the second battery cell 130. Together, they fix the filler 400 to the adjacent battery cell 110 as a whole. After the constraint member 300 is locked, the preload of the filler 400 is transmitted to the adjacent battery cell 110 through the two adhesive layers, so as to achieve a uniform distribution of the preload.

[0126] The first adhesive layer 430 accurately positions the heat insulation layer 410 on the end face of the first battery cell 120, ensuring a tight fit between the heat insulation layer 410 and the end face of the first battery cell 120, eliminating air gaps, and maximizing the heat insulation effect.

[0127] The second adhesive layer 440 accurately positions the buffer layer 420 on the end face of the second battery cell 130, ensuring a tight fit between the buffer layer 420 and the end face of the second battery cell 130, so that the elastic rebound force of the buffer layer 420 can be accurately transmitted to the second battery cell 130.

[0128] The double-sided adhesive structure makes the filler 400 an independent pre-bonded component, which can bond the heat insulation layer 410 to the first battery cell 120 and the buffer layer 420 to the second battery cell 130 before assembly, and then directly assemble them during final assembly, simplifying the assembly process and improving assembly efficiency.

[0129] In one possible implementation, see Figure 1 , Figure 2 , Figure 5 , Figure 6 The first limiting member 210 and the second limiting member 220 are both plate-shaped structures. The two ends of the plate-shaped structures extend to the outer circumferential direction of the battery pack 100, and the constraint member 300 is wrapped around the portion of the plate-shaped structure located on the outer side of the battery pack 100.

[0130] In this embodiment, the first limiting member 210 is disposed at one end of the battery pack 100 along the first direction, and the second limiting member 220 is disposed at the other end of the battery pack 100 along the first direction.

[0131] Both the first limiting member 210 and the second limiting member 220 are plate-like structures. A plate-like structure refers to a flat structure whose thickness is much smaller than its length and width, such as a plate-like end plate. In one possible implementation, the first limiting member 210 and the second limiting member 220 are aluminum end plates, which have high structural strength and good thermal conductivity, while being lightweight, which is beneficial to the weight reduction of the battery module.

[0132] The plate-like structure has two main surfaces along the first direction: an inner surface facing the battery pack 100 and an outer surface facing away from the battery pack 100. The inner surface abuts against the end face of the cell 110 at the end of the battery pack 100 to limit the battery pack 100; the outer surface faces the outside of the battery pack 100 to withstand the locking force of the constraint member 300.

[0133] The dimensions of the plate-like structure along the second and third directions are larger than the dimensions of the battery pack 100 along the second and third directions, so that the plate-like structure forms an "extension" on the circumferential outer side of the battery pack 100. The extension of the plate-like structure is used for the constraint member 300 to be wound around, and is the direct point of application of the locking force of the constraint member 300.

[0134] The main functions of the first limiting member 210 and the second limiting member 220 include:

[0135] Limiting function: Limits the battery pack 100 from both ends to prevent the battery cell 110 from coming out along the first direction.

[0136] Force transmission function: The locking force of the constraint member 300 is transmitted from the extension of the plate structure to the end of the battery pack 100, so that the battery pack 100 is pressed along the first direction.

[0137] Protection function: As a protective structure at the end of the battery pack 100, it protects the end cells 110 from external impacts.

[0138] Pressure equalization function: The locking force of the constraint 300 is evenly distributed to the entire end face of the battery pack 100 to prevent excessive local stress from causing deformation of the cell 110.

[0139] The plate-like structure extends from both ends (i.e., the edge regions of the plate-like structure) along the first direction to the circumferential outer side of the battery pack 100, forming an "extension" located on the outer side of the battery pack 100. The extension direction of the extension is perpendicular to the first direction (i.e., extending outward along the second direction and / or a third direction).

[0140] The extension length along the second or third direction is greater than the width of the constraint member 300, so that the constraint member 300 can completely wrap around the outer surface of the extension. The outer surface of the extension fits against the inner surface of the constraint member 300, forming a surface contact fit.

[0141] The extension is located on the circumferential outer side of the battery pack 100. Therefore, when the constraint member 300 is wrapped around the extension, the constraint member 300 is located on the outer periphery of the battery pack 100 and does not directly contact the battery cell 110 of the battery pack 100.

[0142] The portion of the plate-like structure extending to the outside of the battery pack 100 can have several possible forms:

[0143] Continuous extension: The plate-like structure extends continuously in the circumferential direction to form an annular mounting surface surrounding the battery pack 100.

[0144] Discrete extension: The plate-like structure forms multiple discrete extended lugs at specific locations (e.g., the location corresponding to constraint 300).

[0145] Bending extension: The plate-like structure has bending portions at both ends along the first direction, and the bending portions extend outward along the second or third direction.

[0146] Based on the foregoing embodiments, further see... Figure 1 , Figure 2 , Figure 4 , Figure 5 , Figure 6The constraint member 300 is a strip-shaped locking member. The strip-shaped locking member is wrapped around the outer periphery of the limiting component 200 and the battery pack 100 in the surrounding direction, and the strip-shaped locking member applies a radial locking force to the battery pack 100 by locking the beginning and end ends.

[0147] In this embodiment, the strip-shaped locking member is a specific implementation of the constraint member 300. The strip-shaped locking member is a long strip-shaped structure with a predetermined width and thickness, and a length much greater than the width and thickness.

[0148] In one possible implementation, the strip locking element is a steel strip. The steel strip has high tensile strength, enabling it to withstand significant tension after locking without plastic deformation, ensuring long-term maintenance of the locking force. The steel strip also possesses good flexibility, allowing it to bend along the circumferential direction and conform to the outer peripheral surfaces of the limiting component 200 and the battery pack 100.

[0149] The width of the strip locking member determines the contact area with the limiting component 200 and the battery pack 100. In one possible implementation, the width of the strip locking member is 20mm-40mm, which ensures sufficient contact area while facilitating winding and locking operations.

[0150] The thickness of the strip locking element determines its tensile strength and stiffness. In one possible implementation, the thickness of the strip locking element is 0.5mm-1.5mm, providing sufficient tensile strength while maintaining appropriate flexibility.

[0151] The strip locking member has a head end and a tail end. The head end and the tail end can be locked by a locking mechanism (such as welding, bolt connection, snap connection, etc.) so that the strip locking member forms a closed loop around the periphery of the limiting component 200 and the battery pack 100.

[0152] The number of strip-shaped locking elements is multiple, and each strip-shaped locking element is arranged at intervals along a third direction (a direction perpendicular to the first and second directions). In one possible implementation, the number of strip-shaped locking elements is four, arranged at equal intervals along the third direction, and respectively disposed at different positions of the battery pack 100 along the third direction, so that the battery pack 100 is subjected to a uniform radial locking force at each position along the third direction.

[0153] The surrounding direction refers to the direction around the periphery of the limiting component 200 and the battery pack 100, that is, along the circumference of the battery pack 100. The strip locking member is wrapped around the periphery of the limiting component 200 and the battery pack 100 along the surrounding direction, that is, the strip locking member wraps around the circumference of the battery pack 100 once, forming a ring structure around the periphery of the battery pack 100.

[0154] The strip-shaped locking member is wound around the extensions of the first limiting member 210 and the second limiting member 220 and the outer periphery of the battery cell 110 of the battery pack 100 in a circumferential direction. After the winding is completed, the strip-shaped locking member surrounds the entire outer periphery of the battery module, enclosing the limiting component 200 and the battery pack 100 inside it.

[0155] Radial locking force refers to the radial (i.e., from the outer periphery to the center) pressure applied to the internal structure after the strip locking member is locked. When the two ends of the strip locking member are locked, the circumference of the strip locking member shortens, generating a centripetal contraction force. This centripetal contraction force acts on the outer peripheral surfaces of the limiting assembly 200 and the battery pack 100, forming a radial locking force.

[0156] The magnitude of the radial locking force is directly proportional to the tension of the strip locking element and inversely proportional to its width. In one possible implementation, the magnitude of the radial locking force is controlled by the degree of locking of the strip locking element (i.e., the tension at both ends). The greater the degree of locking of the strip locking element, the greater the radial locking force; conversely, the smaller the radial locking force.

[0157] The mechanism of radial locking force in battery pack 100 is as follows:

[0158] After the band locking member is locked, radial pressure is applied to the extensions of the first limiting member 210 and the second limiting member 220.

[0159] The radial pressure is converted into axial pressure acting on the end of the battery pack 100 along the first direction by the plate-like structure of the first limiting member 210 and the second limiting member 220.

[0160] Axial pressure presses the first limiting member 210 and the second limiting member 220 against both ends of the battery pack 100, thereby limiting the size of the battery pack 100 along the first direction to a preset size.

[0161] The radial locking force can be likened to the "bucket hoop effect": just as an iron hoop tightens the barrel boards to form a wooden barrel, the strip locking component uses radial locking force to clamp the limiting component 200 and the battery pack 100 into a whole module.

[0162] The two ends of the strip locking member are locked by a locking mechanism, so that the strip locking member forms a closed loop around the periphery of the limiting component 200 and the battery pack 100.

[0163] The locking mechanism is used to securely connect the first and second ends of a strip-shaped locking element and maintain its tension. There are various types of locking mechanisms:

[0164] Welding: The first and last ends of the strip-shaped locking component are fixed by welding to form a permanent connection. Welded connections have high strength and reliability, making them suitable for mass production.

[0165] Bolted connection: The first and second ends of the band-shaped locking element are fixed with bolts to form a detachable connection. Bolted connections are easy to maintain and disassemble, but are more expensive.

[0166] Snap-fit ​​connection: The first and last ends of the strip locking component are locked together using a snap-fit ​​structure to form a detachable connection. Snap-fit ​​connections are easy to operate and suitable for quick assembly.

[0167] After the locking mechanism is tightened, the circumference of the strip locking member is fixed, and the radial locking force is maintained. During the long-term use of the battery pack 100, the tension of the strip locking member should remain stable and should not loosen due to material creep or vibration.

[0168] The locking principle of the strip locking member can be summarized as "radial contraction and axial compression": the strip locking member applies radial locking force to the battery pack 100 by wrapping around it. This radial locking force is converted into axial pressure through the plate-like structure of the limiting component 200, thereby pressing the battery pack 100 into a preset size along the first direction.

[0169] Furthermore, in an implementation with multiple strip-shaped locking elements, the strip-shaped locking elements are arranged at intervals along a third direction. The multiple strip-shaped locking elements cooperate with each other to jointly apply a radial locking force to the battery pack 100.

[0170] The strip-shaped locking elements are arranged at equal intervals along a third direction, ensuring that the battery pack 100 is subjected to a uniform radial locking force at all positions along the third direction. If the strip-shaped locking elements are only located at specific positions of the battery pack 100 (e.g., the middle position), the two ends of the battery pack 100 may loosen due to insufficient locking force. By arranging multiple strip-shaped locking elements at intervals along the third direction, it can be ensured that all positions of the entire battery pack 100 are fully locked along the third direction.

[0171] The tightening degree of each strip locking component should be consistent to ensure a uniform distribution of radial locking force. During assembly, the consistency of the tightening degree can be ensured by controlling the tension of each strip locking component.

[0172] Based on the foregoing embodiments, further see... Figure 4 , Figure 5 , Figure 6 It also includes a cooling plate 500, and each battery cell 110 and each filler 400 are disposed on the cooling plate 500; a thermally conductive connection layer is provided between the surface of each battery cell 110 facing the cooling plate 500 and the cooling plate 500, and each battery cell 110 is bonded and fixed to the cooling plate 500 through the thermally conductive connection layer and conducts heat.

[0173] In this embodiment, the cooling plate 500 is a plate-shaped structure disposed below the battery pack 100, used to support each cell 110 and the filler 400, and to dissipate heat from the cell 110.

[0174] The cooling plate 500 is disposed below the battery pack 100 along a second direction (a vertical direction perpendicular to the first direction). The bottom surface of each battery cell 110 and the bottom surface of the filler 400 are disposed on the upper surface of the cooling plate 500.

[0175] In one possible implementation, the cooling plate 500 is a stamped and brazed structure. A stamped and brazed structure refers to a structure where the flow channel plate and cover plate are formed by a stamping process, and then welded together by a brazing process. The stamped and brazed structure has the following advantages:

[0176] Flexible flow channel design: Various flow channel patterns can be formed on the plate through stamping process to adapt to different heat dissipation requirements.

[0177] Good sealing performance: The plate and cover are welded together by brazing, which ensures good sealing performance and eliminates the risk of leakage.

[0178] High strength: Brazed joints have high strength and can withstand high coolant pressure.

[0179] Low cost: The stamping and brazing processes are mature and suitable for mass production.

[0180] The cooling plate 500 has internal coolant channels through which coolant (such as water or ethylene glycol aqueous solution) flows. The coolant channels extend along the interior of the cooling plate 500, covering the bottom area of ​​each battery cell 110, ensuring that each battery cell 110 can be effectively cooled.

[0181] The cooling plate 500 also serves as the structural base plate of the battery pack 100, providing rigid support for the battery pack 100. In one possible implementation, the cooling plate 500 is an aluminum alloy plate, which has high structural strength and good thermal conductivity.

[0182] The cooling plate 500 is also equipped with a coolant inlet and a coolant outlet, which are connected to the two ends of the coolant flow channel, respectively. The coolant enters the cooling plate 500 through the coolant inlet, absorbs heat through the coolant flow channel, and then flows out through the coolant outlet, carrying away the heat.

[0183] A thermally conductive bonding layer is disposed between the surface of each battery cell 110 facing the cooling plate 500 (i.e. the bottom surface of the battery cell 110) and the cooling plate 500, for bonding and fixing each battery cell 110 to the cooling plate 500 and conducting heat.

[0184] A thermally conductive bonding layer is disposed between the bottom surface of the battery cell 110 and the upper surface of the cooling plate 500 along the second direction. One side surface of the thermally conductive bonding layer along the second direction is adhered and fixed to the bottom surface of the battery cell 110, and the other side surface of the thermally conductive bonding layer along the second direction is adhered and fixed to the upper surface of the cooling plate 500.

[0185] In one possible implementation, the thermally conductive bonding layer is a thermally conductive structural adhesive layer. The thermally conductive structural adhesive is a functional adhesive that combines adhesive and thermal conductivity properties. It efficiently conducts the heat generated by the battery cell 110 to the cooling plate 500, while simultaneously firmly bonding the battery cell 110 to the cooling plate 500.

[0186] In another possible implementation, the thermally conductive bonding layer is an AB adhesive layer. AB adhesive is a two-component adhesive, formed by mixing component A (resin) and component B (curing agent) in a certain proportion and then curing. AB adhesive has advantages such as high bonding strength, fast curing speed, and simple operation, making it suitable for mass automated production.

[0187] The thickness of the thermally conductive bonding layer has a significant impact on thermal conductivity and adhesive strength. In one possible implementation, the thickness of the thermally conductive bonding layer is 0.8mm-1mm. Within this thickness range, the thermally conductive bonding layer can provide sufficient adhesive strength while ensuring good thermal conductivity. If the thickness of the thermally conductive bonding layer is too thin, the adhesive strength will be insufficient, and the cell 110 may loosen during long-term use; if the thickness of the thermally conductive bonding layer is too thick, the thermal resistance will increase, the thermal conductivity will decrease, and the temperature of the cell 110 may rise.

[0188] The thermally conductive bonding layer covers all or most of the bottom surface of the battery cell 110 to ensure that the thermally conductive area and the bonding area are sufficiently large. In one possible implementation, the thermally conductive bonding layer covers ≥90% of the bottom surface area of ​​the battery cell 110.

[0189] The thermally conductive bonding layer serves both thermal conductivity and adhesive bonding functions, achieving "two uses in one". Compared to solutions that use separate thermally conductive pads and adhesive layers, the structure of this application is more compact, the heat conduction path is shorter, and the adhesive strength is higher.

[0190] Furthermore, each battery cell 110 is connected to the cooling plate 500 through a thermally conductive connection layer. Specifically, a thermally conductive connection layer is provided between the bottom surface of each battery cell 110 and the upper surface of the cooling plate 500, and each battery cell 110 is bonded and fixed to the cooling plate 500 through its respective thermally conductive connection layer.

[0191] The thermally conductive connection layer between each battery cell 110 and the cooling plate 500 can be continuous (i.e., multiple battery cells 110 share a large thermally conductive connection layer) or discrete (i.e., each battery cell 110 has its own thermally conductive connection layer). In one possible implementation, each battery cell 110 has an independent thermally conductive connection layer to facilitate the replacement and maintenance of individual battery cells 110.

[0192] Each filler 400 is also disposed on the cooling plate 500. Specifically, the bottom surface of the filler 400 is in contact with or nearly in contact with the upper surface of the cooling plate 500.

[0193] A thermally conductive connection layer may or may not be provided between the filler 400 and the cooling plate 500. In one possible implementation, no thermally conductive connection layer is provided between the filler 400 and the cooling plate 500, and the filler 400 is directly disposed on the upper surface of the cooling plate 500. Since the main function of the filler 400 is heat insulation and buffering, rather than heat conduction, the absence of a thermally conductive connection layer will not affect the heat dissipation performance of the battery module.

[0194] The cooling plate 500 serves both as a rigid support for the structural base plate of the battery pack 100 and as a heat dissipation component to remove heat from the battery cell 110, thus achieving a dual function and unifying structural and functional components.

[0195] The thermally conductive bonding layer serves as both a heat conduction path and an adhesive path. Heat is conducted from the battery cell 110 to the cooling plate 500 through the thermally conductive bonding layer, while the adhesive force fixes the battery cell 110 to the cooling plate 500 through the thermally conductive bonding layer. The two paths overlap in space, shortening the heat transfer path.

[0196] The cooling plate 500 is located at the bottom of the battery pack 100, providing bottom support while achieving bottom heat dissipation. This makes the bottom surface of the cell 110 both a mounting surface and a heat dissipation surface, resulting in high space utilization.

[0197] In one possible implementation, a protective sheet is also provided between the surface of the battery cell 110 facing the cooling plate 500 and the thermally conductive bonding layer. The protective sheet covers the surface of the battery cell 110 facing the cooling plate 500 to prevent the insulating film (such as blue film) on the surface of the battery cell 110 from being damaged by friction during handling or assembly.

[0198] The protective sheet is made of insulating material, such as PET film, PI film, or polypropylene film. The protective sheet is disposed between the bottom surface of the battery cell 110 and the thermally conductive connection layer along the second direction, with its upper surface along the second direction attached to the bottom surface of the battery cell 110 and its lower surface along the second direction attached to the thermally conductive connection layer.

[0199] The protective film is pre-attached to the bottom surface of the battery cell 110 before or during the insertion of the battery cell 110 into the casing. When the battery cell 110 is assembled onto the cooling plate 500, the protective film is located between the battery cell 110 and the thermally conductive connection layer, which serves to protect the blue film on the bottom surface of the battery cell 110.

[0200] In one possible implementation, see Figure 4 and Figure 5 It also includes a support beam 600, which is disposed at one end of the cooling plate 500 near the limiting component 200. The support beam 600 extends along the first direction and is supported at the bottom of the first limiting member 210 and the second limiting member 220. The support beam 600 is provided with a stepped structure 700 to block the heat conduction path between the limiting component 200 and the support beam 600.

[0201] In this embodiment, the support beam 600 is a long strip structure disposed on the cooling plate 500, used to support the limiting component 200 and connect the cooling plate 500 and the limiting component 200 into one unit.

[0202] A support beam 600 is disposed at one end of the cooling plate 500 near the limiting component 200, that is, at both ends of the cooling plate 500 along the first direction. Specifically, a first support beam 600 is provided at one end of the cooling plate 500 along the first direction (the end near the first limiting member 210), and a second support beam 600 is provided at the other end of the cooling plate 500 along the first direction (the end near the second limiting member 220). The first support beam 600 and the second support beam 600 are respectively disposed at both ends of the cooling plate 500 along the first direction, and are used to support the first limiting member 210 and the second limiting member 220, respectively.

[0203] The support beam 600 extends along a first direction, which is consistent with the arrangement direction (first direction) of the battery pack 100. The extension length of the support beam 600 along the first direction matches the thickness of the first limiting member 210 and the second limiting member 220 along the first direction, ensuring that the support beam 600 can be fully supported on the bottom of the first limiting member 210 and the second limiting member 220. In one possible implementation, the extension length of the support beam 600 along the first direction is equal to or slightly greater than the thickness of the first limiting member 210 and the second limiting member 220.

[0204] The support beam 600 is supported on the bottom of the first limiting member 210 and the second limiting member 220. Specifically, the upper surface of the support beam 600 is opposite to the bottom surface of the first limiting member 210 and the second limiting member 220, and is in contact with the bottom surface of the first limiting member 210 and the second limiting member 220 through the stepped structure 700.

[0205] In one possible implementation, the support beam 600 and the cooling plate 500 are integrally formed, meaning the support beam 600 is part of the cooling plate 500, and a protruding beam-like structure is formed at the end of the cooling plate 500 by stamping or machining. This integrally formed structure has advantages such as high connection strength, no connection gaps, and simple structure.

[0206] In another possible implementation, the support beam 600 is a separate component, fixed to the upper surface of the cooling plate 500 by welding, bolting, or bonding. This separate component structure facilitates processing and replacement.

[0207] The support beam 600 is made of the same material as the cooling plate 500. In one possible implementation, the support beam 600 is made of aluminum alloy. Aluminum alloy has high structural strength and good thermal conductivity. However, in this application, since the stepped structure 700 blocks the heat conduction path, the high thermal conductivity of the aluminum alloy support beam 600 will not lead to a thermal bridging effect.

[0208] The main functions of the support beam 600 include:

[0209] Support function: Provides bottom support for the first limiting member 210 and the second limiting member 220 to prevent the limiting assembly 200 from shifting downward under the action of gravity.

[0210] Connection function: Connects the limiting component 200 and the cooling plate 500 into one unit, enhancing the overall structural rigidity of the battery module.

[0211] Positioning function: Provides an installation reference for the limit component 200, ensuring that the limit component 200 is accurately positioned on the cooling plate 500.

[0212] Thermal bridge blocking carrier: The heat conduction path between the limiting component 200 and the support beam 600 is blocked by the stepped structure 700.

[0213] The stepped structure 700 is set on the support beam 600 to block the heat conduction path between the limiting component 200 and the support beam 600.

[0214] The stepped structure 700 refers to a non-planar structure set on the upper surface of the support beam 600. By changing the shape of the upper surface of the support beam 600, the contact area between the limiting component 200 and the support beam 600 is reduced, and a heat insulation gap is formed between the limiting component 200 and the support beam 600.

[0215] In one possible implementation, the stepped structure 700 is a boss located on the top surface of the support beam 600. The boss is a local structure that protrudes upward from the upper surface of the support beam 600. The top surface of the boss abuts against the bottom surface of the limiting component 200, forming a local contact area. A thermal insulation gap is formed between the bottom area of ​​the limiting component 200 (excluding the area abutting against the top surface of the boss) and the upper surface of the support beam 600. The thermal insulation gap is filled with air, which has an extremely low thermal conductivity and can effectively block heat conduction.

[0216] The number of bosses can be one or more. When there are multiple bosses, they are arranged at intervals along a first direction or a third direction. In one possible implementation, the bosses are positioned at the middle of the top surface of the support beam 600 along the first direction, so that the bottom of the limiting component 200 contacts the support beam 600 only in the middle area, and a heat insulation gap is formed at both ends, effectively reducing the heat conduction area.

[0217] In another possible implementation, the stepped structure 700 is a groove on the top surface of the support beam 600. The groove is a partial structure that recesses downward from the upper surface of the support beam 600. The bottom of the limiting component 200 abuts against the upper surface area of ​​the support beam 600 outside the groove, and the groove area forms a heat-insulating cavity filled with air to block heat conduction.

[0218] The dimensions of the stepped structure 700 (e.g., the height of the boss and the depth of the groove) determine the contact area and the size of the thermal insulation gap between the limiting component 200 and the support beam 600. In one possible implementation, the height of the boss is 0.5mm-2mm to ensure that a sufficiently large thermal insulation gap is formed between the bottom of the limiting component 200 and the upper surface of the support beam 600 to prevent heat transfer through air convection.

[0219] The stepped structure 700 can also be a corrugated structure, a sawtooth structure or other irregular structure set on the upper surface of the support beam 600, as long as it can reduce the contact area between the limiting component 200 and the support beam 600 and form a heat insulation gap between them.

[0220] The core technology of the stepped structure 700 lies in changing the geometry of the contact interface to transform the original surface contact into a combination of local contact and thermal insulation gap, thereby blocking the heat conduction path to the maximum extent without affecting the support function.

[0221] The principle of the stepped structure 700 blocking the heat conduction path is as follows: by reducing the contact area between the limiting component 200 and the support beam 600, the contact thermal resistance is increased, and at the same time, the heat conduction is further blocked by the air (a medium with low thermal conductivity) in the thermal insulation gap.

[0222] The heat conduction path is: cell 110 → limiting component 200 → stepped structure 700 (contact area) → support beam 600 → cooling plate 500.

[0223] In this path, the stepped structure 700 increases thermal resistance in the following ways:

[0224] Reduced contact area: The contact area between the limiting component 200 and the support beam 600 is reduced from surface contact (large area) to local contact (small area), resulting in increased contact thermal resistance.

[0225] Thermal insulation gap formation: A thermal insulation gap is formed in the non-contact area between the limiting component 200 and the support beam 600. The gap is filled with air, which has an extremely low thermal conductivity, thus blocking the heat conduction path.

[0226] Thermal flow contraction effect: When heat is conducted along the first direction in the limiting component 200, it must first be collected in the contact area of ​​the stepped structure 700, and then conducted to the support beam 600 through the contact area. The thermal flow lines contract in the contact area, which further increases the thermal resistance.

[0227] The effect of the stepped structure 700 on blocking the heat conduction path can be quantified by the thermal resistance formula. The contact thermal resistance R between the limiting component 200 and the support beam 600 is inversely proportional to the contact area A. The stepped structure 700 reduces the contact area from... Reduce to The contact thermal resistance R is determined by Increase to This effectively blocks heat conduction.

[0228] Furthermore, the support beam 600 and the stepped structure 700 work together to achieve the dual functions of support and thermal insulation:

[0229] Synergy between support function and heat blocking function: The support beam 600 provides structural support, while the stepped structure 700 blocks the heat conduction path while providing support. The two achieve functional synergy on the same structure.

[0230] Synergy between structural strength and thermal performance: The stepped structure 700 reduces the contact area while ensuring sufficient support strength and stability through reasonable structural design (such as the width and height of the boss), thus achieving a balance between structural strength and thermal performance.

[0231] Separation of heat conduction path and mechanical path: On the support beam 600, the mechanical force transmission path (limiting component 200 → step structure 700 → support beam 600 → cooling plate 500) and the heat conduction path (limiting component 200 → step structure 700 → support beam 600 → cooling plate 500) overlap in space. However, due to the presence of the step structure 700, the heat conduction path is effectively blocked, while the mechanical force transmission path remains unchanged, thus achieving the separation of the heat path and the force path.

[0232] The aforementioned thermal bridge effect refers to the phenomenon where heat is preferentially conducted along a low-thermal-resistance path in a localized area, resulting in uneven temperature distribution. In a battery module, the presence of the thermal bridge effect leads to an increase in the temperature difference between the two ends and the middle of the battery pack 100 along the first direction.

[0233] The mechanism by which the thermal bridge effect affects the temperature uniformity of the battery pack is as follows:

[0234] In addition to being conducted to the cooling plate 500 through the bottom thermal conductive connection layer, the heat generated by the cells 110 at both ends of the battery pack 100 can also be conducted to the cooling plate 500 through the low thermal resistance path of the limiting component 200 → support beam 600 → cooling plate 500. This results in multiple heat dissipation paths, high heat dissipation efficiency, and lower temperature.

[0235] The battery cell 110 in the middle of the battery pack 100 can only be conducted to the cooling plate 500 through the bottom heat-conducting connection layer. The heat dissipation path is single, the heat dissipation efficiency is relatively low, and the temperature is high.

[0236] The temperature difference between the two ends and the middle of the battery cell 110 increases as the thermal bridge effect intensifies.

[0237] This application uses the stepped structure 700 to block the heat conduction path between the limiting component 200 and the support beam 600, thereby eliminating the low thermal resistance path and making the heat dissipation path of the cells 110 at both ends of the battery pack 100 more consistent with the heat dissipation path of the cell 110 in the middle. This reduces the temperature difference between the two ends and the middle of the battery pack 100 along the first direction and improves thermal uniformity.

[0238] In one possible implementation, see Figure 1 , Figure 4 , Figure 5 , Figure 6 It also includes a cell connection assembly 800, which is mounted on the battery pack 100; the cell connection assembly 800 is provided with a plurality of connection holes 810, and each connection hole 810 is connected to the corresponding terminal of each cell 110.

[0239] In this embodiment, the cell connection assembly 800 is an electrical connection component installed on the battery pack 100, used to electrically connect the terminals of each cell 110 to realize the series or parallel connection between multiple cells 110 to form the required voltage and capacity.

[0240] The cell connection assembly 800 is disposed on one side of the battery pack 100 along the second direction (i.e., the side where the terminal of the cell 110 is located, typically the top of the battery pack 100). The cell connection assembly 800 is disposed opposite to the battery pack 100 along the second direction, and the surface (lower surface) of the cell connection assembly 800 facing the battery pack 100 is opposite to the terminal of the cell 110.

[0241] The cell connection assembly 800 includes an insulating carrier and conductive lines disposed on the insulating carrier. The insulating carrier is used to support and fix the conductive lines and provide electrical insulation; the conductive lines are used to realize electrical connection between the terminals of each cell 110.

[0242] In one possible implementation, the cell connection assembly 800 is a flexible circuit board-type cell connection assembly (FPC-CCS). The FPC-type cell connection assembly uses a flexible circuit board as the carrier of the conductive lines, which has the advantages of thinness, light weight, flexibility, and high integration, making it suitable for application scenarios with high space and weight requirements.

[0243] In another possible implementation, the cell connection assembly 800 is a wire harness-type cell connection assembly (wire harness-CCS). The wire harness-type cell connection assembly uses wires as conductive lines, which has the advantages of low cost, high current carrying capacity, and high reliability, making it suitable for applications with high cost requirements.

[0244] Two types of cell connection assemblies 800 can be selectively adapted and installed with the same battery pack 100. Specifically, the terminal welding areas of each cell 110 in the battery pack 100 adopt a uniform layout, ensuring that the connection holes 810 of both the FPC-type and wire harness-type cell connection assemblies are in the same position and can be accurately aligned with the terminals of the cell 110. This design allows the same battery pack 100 to flexibly select different types of cell connection assemblies 800 according to different application requirements without requiring any modifications to the structure of the battery pack 100.

[0245] In one possible implementation, the FPC-type cell connection assembly and the wire harness-type cell connection assembly are each equipped with their own dedicated blister trays. The blister trays are provided with positioning grooves that are adapted to the shape of the corresponding cell connection assembly 800, which are used to accurately position the cell connection assembly 800 during assembly to ensure that the connection hole 810 is accurately aligned with the terminal of the cell 110.

[0246] The connection hole 810 is a through hole or welding hole provided on the cell connection assembly 800, used to connect to the corresponding pole of the cell 110.

[0247] The number of connection holes 810 is the same as the number of cells 110 in the battery pack 100, and each cell 110 has one connection hole 810 corresponding to its terminal. The position of each connection hole 810 corresponds one-to-one with the position of each cell 110's terminal.

[0248] The size of the connection hole 810 matches the size of the electrode post of the battery cell 110, ensuring that the electrode post can pass through the connection hole 810 or fit against the edge of the connection hole 810. In one possible implementation, the diameter of the connection hole 810 is slightly larger than the diameter of the electrode post, so that the electrode post can pass through the connection hole 810 and form a strong electrical connection after welding.

[0249] In one possible implementation, the connection hole 810 is a welding hole. After the pole passes through the connection hole 810, the pole is welded to the edge of the connection hole 810 by welding (e.g., laser welding, resistance welding, etc.) to achieve electrical and mechanical connection.

[0250] The spacing of the connection holes 810 along the first direction is consistent with the preset spacing of the terminals of the adjacent cells 110 along the first direction. This is one of the core features of this application - because the filler 400 keeps the terminals of the adjacent cells 110 at a preset spacing along the first direction, the spacing of the connection holes 810 matches the preset spacing of the terminals, so the cell connection assembly 800 can be accurately installed on the battery pack 100.

[0251] Even when the thickness of the cell 110 changes, because the overall length of the battery pack 100 is fixed and the size of the filler 400 is adjusted accordingly, the position of the terminal of each cell 110 remains unchanged, and the position of the connection hole 810 matches the position of the terminal. Therefore, the same cell connection assembly 800 can be used for battery packs 100 with cells 110 of different thicknesses.

[0252] Furthermore, each connection hole 810 is connected to the corresponding terminal of each battery cell 110. Specifically, the terminal of each battery cell 110 passes through the corresponding connection hole 810 on the battery cell connection assembly 800, and the terminal is fixedly connected to the connection hole 810 by means of welding or other methods.

[0253] The connection between the cell connection assembly 800 and the terminal of the cell 110 is a combination of electrical and mechanical connection. Through this connection, the terminals of each cell 110 are electrically connected through the conductive lines of the cell connection assembly 800, while the cell connection assembly 800 is fixed to the battery pack 100.

[0254] In one possible implementation, after the electrode of the battery cell 110 passes through the connection hole 810, the electrode is welded to the edge of the connection hole 810 by laser welding. Laser welding has the advantages of fast welding speed, small heat-affected zone, and high welding quality, making it suitable for mass automated production.

[0255] The prerequisite for the proper assembly of the cell connection assembly 800 is that the terminal positions of each cell 110 are accurate and consistent. This application ensures the consistency of the terminal positions of the cell 110 through the following mechanism:

[0256] The constraint member 300 and the limiting component 200 limit the size of the battery pack 100 along the first direction to a preset size, so that the total length of the battery pack 100 remains unchanged.

[0257] Filler 400 is disposed between adjacent cells 110. Each filler 400 has a different size in the first direction. Filler 400 of different sizes is adapted to the different gaps formed by cells 110 of different thicknesses.

[0258] With the total length of the battery pack 100 fixed, the sum of the dimensions of each cell 110 and the corresponding filler 400 is a constant value. Therefore, the position of each cell 110 in the battery pack 100 is fixed, and the terminals of adjacent cells 110 maintain a preset distance along the first direction.

[0259] The spacing between the connection holes 810 of the cell connection assembly 800 is consistent with the preset spacing of the pole post, so the positions of the connection holes 810 and the pole post are always matched.

[0260] Both FPC-type and wire harness-type cell connection assemblies can be selectively adapted and installed with the same battery pack 100. Although the two types of cell connection assemblies 800 differ in structure and materials, the layout and spacing of the connection holes 810 are the same, so both can be aligned with the terminals of the same battery pack 100.

[0261] In one possible implementation, both the FPC-type cell connection assembly and the wire harness-type cell connection assembly are equipped with their own dedicated blister trays. The blister trays have positioning grooves that fit the shape of the corresponding cell connection assembly 800. During assembly, the cell connection assembly 800 is placed in the positioning groove of the blister tray, and then the blister tray moves the cell connection assembly 800 above the battery pack 100, achieving accurate positioning of the connection hole 810 and the terminal post. Different types of cell connection assemblies 800 use different blister trays to ensure positioning accuracy.

[0262] Based on the aforementioned embodiments, a first heat-blocking layer 211 is provided between the first limiting member 210 and the battery cell 110, and a second heat-blocking layer 221 is provided between the second limiting member 220 and the battery cell 110; these are used to block heat transfer between the battery cell 110 and the limiting component 200.

[0263] In this embodiment, within the battery module, the thermal bridge effect refers to the phenomenon where heat is preferentially conducted along a low-thermal-resistance path, resulting in uneven temperature distribution. The mechanism of the thermal bridge effect in the battery pack 100 is as follows:

[0264] The first limiting member 210 and the second limiting member 220 are usually made of aluminum, which has a high thermal conductivity.

[0265] The first limiting member 210 and the second limiting member 220 are respectively disposed at both ends of the battery pack 100 along the first direction, and are in direct contact or adjacent to the end face of the end cell 110.

[0266] The bottoms of the first limiting member 210 and the second limiting member 220 are connected to the cooling plate 500 via the support beam 600.

[0267] The heat generated by the end cell 110 can be conducted to the cooling plate 500 through the path of "end face of cell 110 → limiting component 200 → support beam 600 → cooling plate 500".

[0268] This path has low thermal resistance, high heat dissipation efficiency of the end cell 110, and low temperature.

[0269] The middle cell 110 can only dissipate heat through the path of "bottom surface of cell 110 → thermally conductive connection layer → cooling plate 500". The heat dissipation path is long, the thermal resistance is large, and the temperature is high.

[0270] The temperature difference between the end and middle cells 110 increases as the thermal bridge effect intensifies.

[0271] Excessive temperature difference caused by thermal bridge effect will lead to the following problems: The performance and lifespan of cell 110 are sensitive to temperature. Excessive temperature difference will cause different aging rates of each cell 110, affecting the overall lifespan of battery pack 100; Excessive temperature difference may cause some cells 110 to be overcharged or over-discharged, posing a safety hazard; The internal resistance and capacity changes of each cell 110 are inconsistent, affecting the battery management system's accurate estimation of the state of battery pack 100.

[0272] The first heat-blocking layer 211 is disposed between the first limiting member 210 and the battery cell 110, that is, disposed at one end of the battery pack 100 along the first direction, located between the inner surface of the first limiting member 210 and the end face of the end battery cell 110.

[0273] The first heat-blocking layer 211 has one side surface along the first direction attached to the inner surface of the first limiting member 210, and the other side surface along the first direction attached to the end face of the end cell 110.

[0274] The first heat-blocking layer 211 is used to block the heat conduction path between the end cell 110 and the first limiting member 210, and to prevent the heat of the end cell 110 from being conducted to the support beam 600 and the cooling plate 500 through the first limiting member 210.

[0275] In one possible implementation, the first thermally blocking layer 211 includes an aerogel layer. Aerogel is a nanoporous material with extremely high porosity and extremely low thermal conductivity. The thermal insulation performance of aerogel far exceeds that of traditional thermal insulation materials (such as foam plastics, glass fiber, etc.), and it can achieve excellent thermal insulation effects with extremely small thicknesses.

[0276] The aerogel layer has a dimension of 0.5 mm along the first direction. The 0.5 mm thick aerogel layer ensures excellent thermal insulation performance while occupying a very small space and does not affect the energy density of the battery module.

[0277] In one possible implementation, the first thermal blocking layer 211 further includes an insulating layer. The insulating layer is laminated with the aerogel layer to provide electrical insulation and prevent short circuits between the end cell 110 and the first limiting member 210. In one possible implementation, the insulating layer is a PC insulating sheet (polycarbonate insulating sheet), which has high electrical insulation strength and good mechanical strength.

[0278] The insulating layer can be disposed on the surface of the aerogel layer facing the battery cell 110, or on the surface of the aerogel layer facing the first limiting member 210. In one possible implementation, the insulating layer is disposed on the surface of the aerogel layer facing the battery cell 110, and the insulating layer is in direct contact with the end face of the battery cell 110 to provide electrical insulation; the aerogel layer is disposed on the surface of the insulating layer facing the first limiting member 210, and the aerogel layer is in direct contact with the inner surface of the first limiting member 210 to provide thermal insulation.

[0279] The insulating layer and the aerogel layer are bonded together using an adhesive backing. The adhesive backing is a double-sided adhesive layer, with one side bonded to the insulating layer and the other side bonded to the aerogel layer.

[0280] The second heat-blocking layer 221 is disposed between the second limiting member 220 and the battery cell 110, that is, disposed at the other end of the battery pack 100 along the first direction, located between the inner surface of the second limiting member 220 and the end face of the end battery cell 110.

[0281] The structure of the second heat-blocking layer 221 is the same as that of the first heat-blocking layer 211, and it also includes an aerogel layer and an insulating layer. One side surface of the second heat-blocking layer 221 along the first direction is attached to the inner surface of the second limiting member 220, and the other side surface of the second heat-blocking layer 221 along the first direction is attached to the end face of the end cell 110.

[0282] The second heat-blocking layer 221 is used to block the heat conduction path between the end cell 110 and the second limiting member 220, preventing the heat of the end cell 110 from being conducted to the support beam 600 and the cooling plate 500 through the second limiting member 220.

[0283] The first heat-blocking layer 211 and the second heat-blocking layer 221 are symmetrically disposed at both ends of the battery pack 100. They have the same structure and function, ensuring that the thermal management performance at both ends of the battery pack 100 is consistent.

[0284] Furthermore, the first heat-blocking layer 211 and the second heat-blocking layer 221 simultaneously possess both heat insulation and electrical insulation functions:

[0285] Thermal insulation is achieved through an aerogel layer. The aerogel layer has an extremely low thermal conductivity, effectively blocking heat conduction between the battery cell 110 and the limiting component 200. The heat generated by the end battery cell 110 cannot be conducted to the support beam 600 and the cooling plate 500 through the limiting component 200, but can only be conducted to the cooling plate 500 through the bottom thermally conductive connection layer, which is consistent with the heat dissipation path of the middle battery cell 110.

[0286] Insulation function: Achieved through an insulating layer. The insulating layer (PC insulating sheet) has high electrical insulation strength, preventing short circuits between the battery cell 110 and the limiting component 200. In the battery module, the casing of the battery cell 110 is typically made of aluminum, which has a certain degree of conductivity; the first limiting component 210 and the second limiting component 220 are also made of aluminum. If the battery cell 110 is in direct contact with the limiting component 200, leakage or a short circuit may occur. The insulating layer separates the battery cell 110 from the limiting component 200, ensuring electrical safety.

[0287] The thermal insulation and electrical insulation functions are undertaken by two independent layered structures. Different materials can be used for each layer to optimize their respective performance. The functions are clearly divided and do not interfere with each other.

[0288] In this embodiment, the heat-blocking layers (first heat-blocking layer 211 and second heat-blocking layer 221) cooperate with the stepped structure 700 to jointly block the heat conduction path between the battery cell 110 and the cooling plate 500.

[0289] Thermal blocking layers (first thermal blocking layer 211 and second thermal blocking layer 221): disposed between the battery cell 110 and the limiting component 200 to block the heat conduction path of "battery cell 110 → limiting component 200".

[0290] Step structure 700: It is set between the limiting component 200 and the support beam 600 to block the heat conduction path of "limiting component 200 → support beam 600 → cooling plate 500".

[0291] The combination of the two achieves full-path thermal blockade from the end face of the battery cell 110 to the cooling plate 500, preventing the heat from the end of the battery cell 110 from being conducted to the cooling plate 500 through the limiting component 200 and the support beam 600. The heat dissipation path of the end battery cell 110 is consistent with that of the middle battery cell 110, and the thermal uniformity is significantly improved.

[0292] See Figure 7 This application also proposes a battery pack including at least one of the battery modules provided above.

[0293] As a core component of an energy storage system, the battery pack encapsulates and protects the battery modules and provides electrical and mechanical interfaces for connecting to external devices.

[0294] At least one battery module is used as a standardized unit and combined in series or parallel to provide the required voltage and capacity. The battery module itself has its overall length fixed by the constraint component 300 and the limiting component 200, and is compatible with cells 110 of different thicknesses by the filler component 400, achieving cell specification compatibility and consistent terminal position. Based on this, at least one battery module is integrated into the battery pack housing, and the battery modules are electrically connected to each other and to external devices by connectors such as busbars. The battery modules are protected and sealed by the housing and the top cover, ultimately forming a complete energy storage battery pack product.

[0295] In one possible implementation, the battery pack includes a housing, a top cover, and multiple battery modules. The housing houses the battery modules and provides structural support and bottom protection. The top cover is located at the open end of the housing and closes the housing, providing top protection and sealing. The multiple battery modules are arranged inside the housing along a first or third direction, and the battery modules are connected in series or parallel via busbars.

[0296] In one possible implementation, the battery management unit (BMU) of the battery module corresponding to the top cover is provided with a removable maintenance panel, which facilitates the debugging and maintenance of the BMU without removing the entire top cover.

[0297] In one possible implementation, the bottom of the enclosure is provided with a coolant inlet and outlet, and the cooling plate 500 of each battery module is connected to the coolant inlet and outlet of the enclosure through coolant pipes to form a coolant circulation loop for liquid cooling of each battery module.

[0298] This application also proposes an electrical device, including the battery module or battery pack provided above.

[0299] Using the aforementioned battery modules or battery packs as power supply units for electrical devices, the high cell compatibility, high structural reliability, excellent thermal uniformity, and flexible production adaptability of the battery modules or battery packs provide a stable, safe, and long-lasting power supply for the electrical devices. The battery modules and battery packs provided in this application are applicable to various types of electrical devices, including but not limited to energy storage systems, electric vehicles, backup power supplies for communication base stations, and home energy storage devices.

[0300] Electrical equipment includes the main body of the equipment and battery modules or battery packs mounted on the main body. The battery modules or battery packs are connected to the electrical load of the main body via an electrical interface, are fixedly connected to the main body via a mechanical interface, and communicate with the control system of the main body via a communication interface. As independent power supply units within the electrical equipment, the battery modules or battery packs can be installed and replaced as a whole, facilitating maintenance and upgrades.

[0301] In one possible implementation, the electrical device is an energy storage system. The energy storage system includes an energy storage cabinet, battery modules or battery packs, a power supply converter (PCS), and a battery management system (BMS). The battery modules or battery packs are housed inside the energy storage cabinet and connected to the power supply converter via a DC bus. The power supply converter converts DC power to AC power and connects it to the power grid or load. The battery management system monitors and manages the battery modules or battery packs to ensure the safe operation of the energy storage system.

[0302] In another possible implementation, the electrical device is an electric vehicle. An electric vehicle includes a vehicle body, battery modules or battery packs, a drive motor, and a vehicle controller. The battery modules or battery packs are located in the chassis or underside of the vehicle body and are connected to the drive motor via high-voltage electrical lines. The drive motor converts electrical energy into mechanical energy to propel the vehicle. The vehicle controller manages the battery modules or battery packs through a battery management system, controlling the charging and discharging process and monitoring the battery status.

[0303] In another possible implementation, the power supply serves as a backup power source for the communication base station. The backup power source includes a cabinet, battery modules or battery packs, communication equipment, and a power management system. The battery modules or battery packs are located inside the cabinet and are in a float-charge state when the power grid is functioning normally. When the power grid fails, they provide backup power to the communication equipment, ensuring the continuous operation of the communication base station.

[0304] In another possible implementation, the electrical device is a home energy storage device. This device includes a cabinet, battery modules or packs, an inverter, and an energy management system. The battery modules or packs are housed inside the cabinet and connected to the home power grid via the inverter. They charge and store energy during off-peak hours when electricity prices are low, and discharge to supply power during peak hours or when the grid experiences a power outage, thus achieving peak shaving and valley filling as well as emergency backup power functions.

[0305] It should be noted that the terms "one embodiment," "embodiment," "exemplary embodiment," "some embodiments," etc., mentioned in the specification indicate that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0306] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "a" or "the" can also be understood to convey either singular or plural usage.

[0307] It should be readily understood that the terms “on,” “above,” and “on top of” in this application should be interpreted in the broadest possible sense, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on something” but also “on something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0308] Furthermore, for ease of explanation, spatially relative terms such as "below," "below," "under," "above," and "above" may be used to describe the relationship of one element or feature relative to other elements or features as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation other than those shown in the figures. The device may have other orientations (rotated 90° or in other orientations), and the spatially relative descriptive terms used herein may be interpreted accordingly.

[0309] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A battery module, characterized in that, include: The battery pack includes a plurality of battery cells arranged along a first direction; The limiting assembly includes a first limiting member and a second limiting member respectively disposed at both ends of the battery pack along a first direction; A constraint member is disposed around the outer periphery of the limiting component and the battery pack and locked in place. The constraint member and the limiting component together limit the size of the battery pack along the first direction to a preset size. Multiple fillers, each with a different size in a first direction, are disposed between two adjacent cells to maintain a preset distance between the terminals of two adjacent cells in the first direction when the battery pack maintains the preset size in the first direction.

2. The battery module according to claim 1, characterized in that, Along the first direction, the filler includes a heat insulation layer and a buffer layer stacked together, wherein the heat insulation layer and the buffer layer are bonded together.

3. The battery module according to claim 2, characterized in that, Along the first direction, the battery pack includes a first cell and a second cell arranged adjacent to each other, with a gap between the first cell and the second cell, and the heat insulation layer and the buffer layer disposed in the gap; The heat insulation layer is disposed towards the first battery cell, and the buffer layer is disposed towards the second battery cell.

4. The battery module according to claim 3, characterized in that, When the cells having multiple thickness dimensions are arranged along a first direction, a gap with multiple spacing dimensions is formed; The buffer layer includes multiple thickness dimensions, and each thickness dimension of the buffer layer is adapted to the gap of each spacing dimension.

5. The battery module according to claim 3, characterized in that, The heat insulation layer is connected to the first battery cell through a first adhesive layer, and the buffer layer is connected to the second battery cell through a second adhesive layer.

6. The battery module according to any one of claims 2 to 5, characterized in that, Both the first limiting member and the second limiting member are plate-shaped structures. The two ends of the plate-shaped structure extend to the outer circumferential direction of the battery pack, and the constraint member is wrapped around the portion of the plate-shaped structure located on the outer side of the battery pack.

7. The battery module according to any one of claims 2 to 5, characterized in that, The constraint member is a strip-shaped locking member, which is wrapped around the outer periphery of the limiting component and the battery pack in a circumferential direction, and applies a radial locking force to the battery pack by locking the two ends of the strip-shaped locking member.

8. The battery module according to claim 7, characterized in that, It also includes a cooling plate, on which each of the battery cells and the filler are disposed; A thermally conductive connection layer is provided between the surface of each battery cell facing the cooling plate and the cooling plate. Each battery cell is bonded and fixed to the cooling plate through the thermally conductive connection layer and conducts heat.

9. The battery module according to claim 8, characterized in that, It also includes a support beam disposed at one end of the cooling plate near the limiting component, the support beam extending along a first direction and supporting the bottom of the first limiting member and the second limiting member; The support beam has a stepped structure to block the heat conduction path between the limiting component and the support beam.

10. The battery module according to claim 7, characterized in that, It also includes a cell connection assembly, which is mounted on the battery pack; the cell connection assembly has a plurality of connection holes, each of which is connected to the terminal of each cell.

11. The battery module according to claim 6, characterized in that, A first heat-blocking layer is provided between the first limiting member and the battery cell, and a second heat-blocking layer is provided between the second limiting member and the battery cell; these layers are used to block heat transfer between the battery cell and the limiting member.

12. A battery pack, characterized in that, It includes at least one battery module as described in any one of claims 1 to 11.

13. An electrical appliance, characterized in that, Includes the battery module as described in any one of claims 1 to 11, or the battery pack as described in claim 12.

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