An electric core module installed in a battery box beam, an assembling method and a battery

Abstract

This invention discloses a battery cell module, assembly method, and battery installed in a crossbeam of a battery housing, relating to the field of batteries. The module includes: a crossbeam with multiple battery cell receiving cavities; a battery cell fixing bracket installed in the crossbeam, the fixing bracket consisting of multiple battery cell bracket receiving cavities, the distance between two adjacent battery cell bracket receiving cavities in the middle of the fixing bracket being greater than the distance between the remaining battery cell bracket receiving cavities; a battery cell being disposed within each battery cell bracket receiving cavity, the battery cell maintaining a clearance fit with the battery cell bracket receiving cavity; the battery cell fixing bracket being disposed within the battery cell receiving cavity of the crossbeam, a preset gap being left between the battery cell fixing bracket and the inner wall of the battery cell receiving cavity, and a battery cell expansion pre-tightening vacuum compression foam being disposed within the preset gap; the battery cell expansion pre-tightening vacuum compression foam applying a pre-tightening force to the battery cell after expansion. This invention solves the problem that existing battery housings cannot cope with the local deformation of the middle of the crossbeam caused by the thermal expansion of the battery cells.

Description

Technical Field

[0001] This invention relates to the field of battery technology, and in particular to a cell module, assembly method, and battery installed in the crossbeam of a battery casing. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the structural design of power batteries continues to evolve towards higher integration and lighter weight, resulting in the existing battery box internal space utilization rate being unable to meet the demand.

[0003] However, some battery pack designs use crossbeams as the main load-bearing structural components, resulting in a large overall volume and a considerable internal space. If prismatic battery cells are housed within the crossbeam's cavity, under the vibrations and unexpected impacts generated during long-term vehicle operation, the cells are highly susceptible to relative displacement within the cavity, affecting the electrical connection stability and overall safety of the battery module. Furthermore, the relatively uniform strength distribution across the crossbeam means that when the prismatic cells experience significant compressive forces due to thermal expansion during charging and discharging, the central area of ​​the crossbeam, being a weak point, is prone to plastic deformation. This weakens the overall structural rigidity of the module and jeopardizes the safe operation of the battery system. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a cell module, assembly method, and battery installed in the crossbeam of a battery housing, which solves the problem that existing battery housings cannot cope with the thermal expansion of the cells, causing localized deformation in the middle of the crossbeam.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: In a first aspect, a battery cell module installed in a crossbeam of a battery housing includes: a crossbeam having multiple battery cell receiving cavities; a battery cell fixing bracket installed in the crossbeam, the battery cell fixing bracket being composed of multiple battery cell bracket receiving cavities, the distance between two adjacent battery cell bracket receiving cavities in the middle of the battery cell fixing bracket being greater than the distance between the remaining battery cell bracket receiving cavities; a battery cell being disposed within each battery cell bracket receiving cavity, the battery cell maintaining a clearance fit with the battery cell bracket receiving cavity; the battery cell fixing bracket being disposed within the battery cell receiving cavity of the crossbeam, a preset gap being left between the battery cell fixing bracket and the inner wall of the battery cell receiving cavity, a battery cell expansion pre-tightening vacuum compression foam being disposed within the preset gap; the battery cell expansion pre-tightening vacuum compression foam applying a pre-tightening force to the battery cell after expansion.

[0006] As a further implementation, a cell connection assembly is also fixedly installed on the crossbeam, and the cell connection assembly is welded to the pole of the cell in the accommodating cavity of the multiple cell supports.

[0007] As a further implementation, the crossbeam is made of aluminum profile and is a hollow cuboid structure with an open top. Multiple partitions are provided in the crossbeam, and the position of the partitions is the gap between the two adjacent cell support cavities.

[0008] As a further implementation, the battery cell fixing bracket is made of plastic material and manufactured by injection molding. The battery cell fixing bracket also includes a connecting plate, the two ends of which are fixedly connected to the top edge of the adjacent battery cell bracket receiving cavity, so that the battery cell fixing bracket forms an integral structure.

[0009] As a further implementation, the preset gap between the cell fixing bracket and the inner wall of the cell receiving cavity is 2mm to 3mm; the gap between the cell fixing bracket and the cell is 0.3±0.05mm.

[0010] Secondly, the present invention also provides a method for assembling a cell module installed in a crossbeam of a battery casing, comprising the following steps: The crossbeam is welded and fixed to the box; multiple battery cells are respectively placed into the battery cell bracket receiving cavity of the battery cell fixing bracket, and the battery cells and the battery cell bracket receiving cavity are maintained in clearance fit. The battery cell fixing bracket with the battery cell is placed into the battery cell receiving cavity of the crossbeam, and a preset gap is left between the inner wall of the battery cell receiving cavity and the battery cell fixing bracket. Vacuum-compressed foam is filled into the preset gap; the vacuum-compressed foam is expanded to apply a pre-tightening force to the battery cell; The cell connection assembly is fixedly connected to the crossbeam, and the cell connection assembly is welded to the terminal post of the cell.

[0011] As a further implementation, the vacuum-compressed foam is initially in a vacuum-compressed state and encapsulated in a packaging bag, and the vacuum-compressed foam is expanded by tearing the packaging bag.

[0012] As a further implementation, the cell connection assembly is connected to the electrode of the cell by laser welding.

[0013] Thirdly, the present invention also provides a battery, including a cell module installed in the crossbeam of the battery box, and further including a box and a longitudinal beam. The module is disposed in the box, and the crossbeam and the longitudinal beam of the module are arranged perpendicularly. The connection position of the longitudinal beam and the crossbeam corresponds to the position where the distance between two adjacent cell support cavities in the middle of the cell fixing bracket is the largest.

[0014] As a further implementation, the ends of the crossbeams and longitudinal beams are connected to the box body by welding, and the crossbeams and longitudinal beams are also connected by welding.

[0015] The beneficial effects of the present invention are as follows: This invention designs the spacing between two adjacent cell support cavities in the middle of the cell fixing bracket to be larger than the spacing between the remaining cell support cavities. This allows the crossbeam to have thicker or more layered partitions in the middle section where the spacing between adjacent cell support cavities is larger, thereby improving the structural strength of the crossbeam's middle section. During charging and discharging, the cell undergoes thermal expansion, concentrating the compressive force on the crossbeam in the middle. By increasing the strength of the crossbeam's middle section, its strength is matched to the stress, effectively resisting the compressive force generated by the cell's thermal expansion. This prevents deformation of the crossbeam in the stress-concentrated area, ensuring the structural integrity and long-term reliability of the battery module. The design of maintaining a clearance fit between the cell and the cell support cavity ensures stable cell positioning while allowing space for slight thermal expansion of the cell. This avoids excessive constraint causing additional mechanical stress on the cell casing, effectively protecting the cell's structural safety and extending its service life.

[0016] This invention applies a continuous and stable preload force to the square-shell battery cell by filling a pre-defined gap between the fixing bracket and the inner wall of the crossbeam battery cell receiving cavity with vacuum-compressed foam. The foam expands naturally by absorbing air after the packaging bag is torn open, thus applying the preload force to the square-shell battery cell. Compared to traditional mechanical fastening methods, the vacuum-compressed foam preload method only requires filling the gap with foam and then tearing the packaging bag to complete the preload, eliminating the need for additional fastening tools and complex procedures. The preload force of the vacuum-compressed foam is evenly distributed, and after expansion, it applies force evenly along the side of the battery cell, avoiding localized stress concentration that could damage the cell. Simultaneously, the foam can adaptively adjust the compression amount, always maintaining effective preload on the battery cell, preventing displacement under vibration or impact conditions, and improving the cell's fixation effect and service life. Attached Figure Description

[0017] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0018] Figure 1 This is an exploded view of the module of the present invention installed in the crossbeam cavity of the battery box; Figure 2 This is a structural diagram of the battery cell fixing bracket of the present invention; Figure 3 This is a schematic diagram of the module for installing foam according to the present invention; Figure 4 This is a partial top view of the crossbeam of the present invention installed in the box body; Figure 5 This is a structural diagram of the module of the present invention installed in the housing.

[0019] The components are: 1. Crossbeam; 11. Cell housing cavity; 12. Partition plate; 2. Cell fixing bracket; 21. Cell bracket housing cavity; 22. Connecting plate; 3. Cell; 4. Foam; 5. Cell connecting assembly; 6. Box body; 7. Longitudinal beam. Detailed Implementation

[0020] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0021] Example 1 This embodiment provides a cell module installed in the crossbeam of the battery box, which is mainly used in the power battery system of new energy vehicles to fix and support the cell 3, and ensure the stability and safety of the cell during vehicle operation.

[0022] like Figures 1-3 As shown, the module includes a crossbeam 1, which is made of aluminum profile through an extrusion molding process. The overall structure of the crossbeam 1 is a hollow cuboid structure with an open top. The hollow structure design effectively reduces the weight of the crossbeam 1 while ensuring structural strength, and allows for the placement of more battery cells, thereby increasing the vehicle's driving range. The crossbeam 1 contains multiple battery cell receiving cavities 11. In this embodiment, the length of the crossbeam 1 is approximately 958 mm, the width is approximately 42.5 mm, and the number of battery cell receiving cavities 11 is four. Each battery cell receiving cavity 11 has a length of approximately 190 mm and a width of approximately 38.5 mm.

[0023] The crossbeam 1 has multiple partitions 12 inside, which separate adjacent cell housing cavities 11 and enhance the structural strength of the crossbeam 1. The position of the partitions 12 corresponds to the gap between two adjacent cell support housing cavities 21. In the middle position of the crossbeam 1, that is, between the second and third cell housing cavities 11, there are partitions 12 with greater thickness or more layers.

[0024] Specifically, the thickness of the partitions 12 at both ends of the crossbeam 1 is approximately 0.5 times the thickness of the partition 12 at the middle position, or a double-layer partition structure can be adopted. This design is because the middle position of the crossbeam 1 experiences the greatest stress, and the thermal expansion generated by the battery cell 3 during operation exerts the most significant compressive force on this position. Therefore, it is necessary to increase the thickness or number of layers of the partitions 12 to improve the structural strength at this position and prevent the crossbeam 1 from deforming under stress.

[0025] A cell fixing bracket 2 is installed in the crossbeam 1. The cell fixing bracket 2 is made of plastic material, which must have good mechanical strength, heat resistance, and insulation properties. The cell fixing bracket 2 is manufactured in one piece using an injection molding process, which has high production efficiency and can ensure the dimensional accuracy and consistency of the product.

[0026] The cell fixing bracket 2 consists of multiple cell bracket receiving cavities 21. In this embodiment, there are four cell bracket receiving cavities 21, corresponding to the number of cell receiving cavities 11 in the crossbeam 1. Each cell bracket receiving cavity 21 has a length of approximately 188 mm and a width of approximately 33.5 mm. The size design of the cell bracket receiving cavity 21 allows the cell 3 to maintain a clearance fit with the cell bracket receiving cavity 21. Specifically, the clearance between the cell fixing bracket 2 and the cell 3 is 0.3 ± 0.05 mm. This clearance fit ensures the stable fixing of the cell 3 within the cell bracket receiving cavity 21 while allowing for slight thermal expansion of the cell 3 during charging and discharging, thus avoiding mechanical stress damage to the cell 3 due to excessive constraint.

[0027] The distance between two adjacent cell support cavities 21 in the middle of the cell fixing bracket 2 is greater than the distance between the other cell support cavities 21.

[0028] Specifically, in this embodiment, the distance between the first and second cell support accommodating cavities 21 is approximately 4 mm, the distance between the third and fourth cell support accommodating cavities 21 is also approximately 4 mm, and the distance between the second and third cell support accommodating cavities 21 is approximately 8 mm to 10 mm. This design allows the crossbeam 1 to have thicker or more layered partitions 12 at the location where the distance between adjacent cell support accommodating cavities 21 is relatively large, i.e., at the middle position, thereby improving the strength of the crossbeam 1 at that location and preventing the cell 3 from affecting the shape of the crossbeam 1 during the heating process.

[0029] The cell fixing bracket 2 also includes a connecting plate 22, the two ends of which are fixedly connected to the top edges of adjacent cell bracket receiving cavities 21. The connecting plate 22 serves to connect the various cell bracket receiving cavities 21 and enhance the overall rigidity of the cell fixing bracket 2. Through the connection plate 22, the cell fixing bracket 2 forms an integrated structure, which can better withstand and disperse the mechanical and thermal stresses generated by the cell 3. At the middle position of the cell fixing bracket 2, i.e., between the second and third cell bracket receiving cavities 21, the width of the connecting plate 22 can be appropriately increased to accommodate the increased spacing at this position and further enhance the structural strength.

[0030] A battery cell 3 is housed within the cell support cavity 21. The battery cell 3 is a lithium-ion battery cell, encapsulated in a square aluminum shell, possessing high energy density and good heat dissipation performance. Positive and negative terminals 31 are located at the top of the battery cell 3. These terminals 31 are made of aluminum alloy, with the positive and negative terminals located at opposite ends of the top of the battery cell 3.

[0031] When the battery cell 3 is placed into the battery cell holder cavity 21, a gap of 0.3 ± 0.05 mm is maintained between the battery cell 3 and the inner wall of the battery cell holder cavity 21. This gap fit is achieved by precisely controlling the dimensions of the battery cell holder cavity 21 and the battery cell 3.

[0032] Specifically, the length of the cell holder cavity 21 is approximately 0.6 mm longer than the length of the cell 3, and the width is approximately 0.6 mm wider than the width of the cell 3. During actual assembly, the operator vertically inserts the cell 3 into the cell holder cavity 21. Under gravity, the cell 3 naturally falls to the bottom of the cell holder cavity 21, contacting the bottom surface of the cavity. A preset gap is maintained between the side of the cell 3 and the side wall of the cell holder cavity 21.

[0033] The cell fixing bracket 2 is installed inside the cell receiving cavity 11 of the crossbeam 1.

[0034] Specifically, the cell fixing bracket 2 containing the cell 3 is inserted into the crossbeam 1 through the upper opening of the crossbeam 1, so that each cell bracket receiving cavity 21 is aligned with the corresponding cell receiving cavity 11. A preset gap is left between the cell fixing bracket 2 and the inner wall of the cell receiving cavity 11 of the crossbeam 1, which is 2.5mm in this embodiment. This gap size is set by comprehensively considering manufacturing tolerances, assembly convenience, and the thickness requirements of subsequent filling materials.

[0035] The width of the cell receiving cavity 11 of the crossbeam 1 is 38.5mm, and the outer width of the cell fixing bracket 2 is 33.5mm. The difference between the two is 5mm. Since the cell fixing bracket 2 is placed in the center of the cell receiving cavity 11, the gap between the two sides of the cell fixing bracket 2 and the inner wall of the cell receiving cavity 11 is 2.5mm.

[0036] A pre-compressed vacuum foam 4 for battery cell expansion is installed within the preset gap. The pre-compressed vacuum foam 4 is made of polyurethane foam, which has good elasticity, cushioning properties, and durability. The pre-compressed vacuum foam 4 is initially in a vacuum-compressed state and is encapsulated within an aluminum-plastic composite film packaging bag. Vacuum compression reduces the thickness of the foam 4 to approximately 1mm, facilitating its filling within the 2.5mm preset gap. The packaging bag is sealed using a vacuum heat-sealing process, ensuring the foam 4 remains compressed for an extended period.

[0037] During assembly, the operator fills the pre-compressed vacuum-pressed foam 4, which is in a vacuum-compressed state, into the preset gap between the battery cell fixing bracket 2 and the inner wall of the battery cell receiving cavity 11. Because the foam 4 is compressed and has a small thickness, it can easily fill the 2.5mm gap. The length of the foam 4 matches the length of the battery cell receiving cavity 11. One piece of foam 4 is filled into each of the preset gaps on both sides of the battery cell fixing bracket 2.

[0038] After filling, the operator tears open the packaging bag, exposing the pre-tightened vacuum compression foam 4 to the air. The foam 4 quickly absorbs air and expands, reaching a thickness of approximately 3mm to 3.5mm. Because the preset gap is only 2.5mm, the expanded foam 4 is compressed to a certain extent, thus applying inward pressure to the battery cell fixing bracket 2. Since there is only about 0.3mm of gap between the battery cell 3 and the battery cell fixing bracket 2, this pressure is transmitted to the battery cell 3 through the battery cell fixing bracket 2, applying a pre-tightening force to the battery cell 3.

[0039] By applying a preload, the position of the battery cell 3 can be effectively fixed, preventing displacement due to vibration during vehicle operation, without causing excessive mechanical stress that could affect its performance and lifespan. The elastic properties of the foam 4 ensure that this preload can be applied to the battery cell 3 continuously and stably. When the battery cell 3 undergoes thermal expansion during charging and discharging, the foam 4 can adapt to the dimensional changes of the battery cell 3, continuing to maintain the preload and preventing gaps between the battery cell 3 and the fixing bracket 2, which would reduce the fixing effect.

[0040] A cell connection assembly 5 is also fixedly installed on the crossbeam 1. The main function of the cell connection assembly 5 is to realize the series or parallel connection between multiple cells 3 and to output the electrical energy of the cells 3 to the battery management system. The cell connection assembly 5 includes a conductive bus, an insulating support, and connection terminals.

[0041] One end of the conductive busbar is connected to the positive terminal of a battery cell 3, and the other end is connected to the negative terminal of an adjacent battery cell 3, thus achieving a series connection between the battery cells 3. The battery cell connection assembly 5 is fixed to the top of the crossbeam 1 by bolts. The top of the crossbeam 1 is pre-set with threaded holes, and the insulating bracket of the battery cell connection assembly 5 is provided with corresponding mounting holes. The insulating bracket is fixed to the crossbeam 1 by bolts. The insulating bracket is made of high-strength engineering plastics such as PBT or nylon, which serves to support the conductive busbar and achieve electrical insulation, preventing short circuits between the conductive busbar and the crossbeam 1.

[0042] The conductive busbar and the terminal post 31 of the battery cell 3 are connected by laser welding. Laser welding has advantages such as low heat input, fast welding speed, and high weld quality, making it particularly suitable for welding battery modules. Specifically, during the welding process, the copper layer side of the conductive busbar is aligned with the terminal post, and the laser beam irradiates the contact point between the copper layer and the terminal post, causing them to melt and form a weld. After welding, a strong metallurgical bond is formed at the weld, which can meet the requirements of high-current charging and discharging.

[0043] In this embodiment, four battery cells 3 are connected in series through three conductive busbars to form a battery module.

[0044] The crossbeam 1 is connected to the housing 6 by welding. The housing 6 is manufactured by stamping aluminum alloy sheet. During the welding process, the end of the crossbeam 1 is aligned with the inner wall of the housing 6, and welding is performed using cold metal transfer welding equipment. After welding, a strong connection is formed between the crossbeam 1 and the housing 6, and the weld strength is sufficient to meet the various mechanical loads that the battery module can withstand during vehicle operation.

[0045] Example 2 This embodiment provides a method for assembling a cell module installed in a crossbeam of a battery box, including the following steps: The housing 6 is made of aluminum alloy sheet through stamping, bending and other processes to form a rectangular container structure. The bottom and four side walls of the housing 6 are closed structures, while the top is an open structure, which facilitates the subsequent installation of battery modules.

[0046] The crossbeam 1 is manufactured from aluminum profiles through an extrusion molding process. The length of the extruded crossbeam 1 is cut according to the actual dimensions of the box 6. An aluminum cutting saw is used to cut the crossbeam 1 to the appropriate length, ensuring the cut surface is smooth and burr-free. After cutting, the ends of the crossbeam 1 are deburred and cleaned.

[0047] Place the crossbeam 1 inside the housing 6, with both ends of the crossbeam 1 contacting the inner walls on both sides of the housing 6. Use positioning clamps to fix the crossbeam 1 in the predetermined position, with the distance between the crossbeam 1 and the inner walls on both sides of the housing 6 being equal, and the crossbeam 1 being parallel to the length direction of the housing 6.

[0048] The beam 1 and the box 6 are welded using cold metal transfer welding equipment. Before welding, the welding area needs to be cleaned to remove impurities such as oil and oxide film; argon gas is used as a protective gas during the welding process; after welding, a strong connection is formed between the beam 1 and the box 6.

[0049] The battery cell mounting bracket 2 is manufactured using injection molding. After injection molding, post-processing processes such as gate removal and deburring are required. The dimensional accuracy and surface quality of the battery cell mounting bracket 2 are checked to ensure that the dimensions of the battery cell bracket receiving cavity 21 meet the design requirements.

[0050] Place the battery cell 3 vertically into the battery cell holder cavity 21 of the battery cell fixing bracket 2. During operation, pay attention to the orientation of the battery cell 3, ensuring that the positive and negative terminals 31 of the battery cell 3 are facing upwards and that their positions match the design requirements. Under the influence of gravity, the battery cell 3 will naturally fall to the bottom of the battery cell holder cavity 21, with the bottom surface of the battery cell 3 contacting the bottom surface of the battery cell holder cavity 21.

[0051] Check the gap between cell 3 and cell support cavity 21. Use a feeler gauge to measure the gap between the side of cell 3 and the side wall of cell support cavity 21, ensuring the gap is 0.3±0.05mm. If the gap does not meet the requirements, check the dimensions of cell 3 and cell support cavity 21 and make adjustments.

[0052] The four battery cells 3 are respectively placed into the four battery cell holder cavities 21 of the battery cell fixing bracket 2. After assembly, the four battery cells 3 in the battery cell fixing bracket 2 are arranged in a straight line, and the battery cells 3 are connected to each other as a whole by the connecting plate 22 of the battery cell fixing bracket 2.

[0053] Place the battery cell fixing bracket 2 containing the battery cell 3 into the battery cell receiving cavity 11 of the crossbeam 1. During operation, hold both ends of the battery cell fixing bracket 2 with both hands and vertically insert the battery cell fixing bracket 2 from the upper opening of the crossbeam 1. During the descent of the battery cell fixing bracket 2, it is necessary to maintain the relative position of the battery cell fixing bracket 2 and the crossbeam 1 so that each battery cell bracket receiving cavity 21 is aligned with the corresponding battery cell receiving cavity 11.

[0054] After the cell fixing bracket 2 is fully inserted into the crossbeam 1, the bottom of the cell fixing bracket 2 contacts the bottom of the crossbeam 1. At this time, a preset gap is left between the cell fixing bracket 2 and the inner wall of the cell receiving cavity 11.

[0055] Use vernier calipers to measure the gap between the outer wall of the cell fixing bracket 2 and the inner wall of the cell receiving cavity 11, ensuring the gap is 2.5 ± 0.2 mm. Measurements should be taken at multiple locations on the cell fixing bracket 2, including both ends and the middle, to ensure the gap between the entire cell fixing bracket 2 and the cell receiving cavity 11 is uniform. If the gap does not meet the requirements, the position of the cell fixing bracket 2 needs to be adjusted, or the dimensions of the crossbeam 1 and the cell fixing bracket 2 need to be checked.

[0056] Prepare the pre-tightened vacuum compression foam 4 for the battery cell expansion. The foam 4 is in a vacuum-compressed state before filling and is encapsulated in an aluminum-plastic composite film packaging bag. Fill the pre-set gap between the battery cell fixing bracket 2 and the inner wall of the battery cell receiving cavity 11 with the vacuum compression foam 4. During operation, insert the packaging bag into the gap from one end and push it along the length of the gap until the packaging bag is completely inside. Because the foam 4 is in a compressed state and has a small thickness, it can be easily filled into the 2.5mm gap.

[0057] Fill each side gap of the cell fixing bracket 2 with a strip of foam 4. When filling, pay attention to the position of the foam 4 to ensure that the foam 4 is evenly distributed along the entire length of the gap without gaps or overlaps.

[0058] After filling, tear open the packaging bag to expose the pre-tightened vacuum-compressed foam 4 to the air. To tear the packaging bag, use a knife or scissors to make a small cut at one end, then tear it open by hand. Immediately after tearing, pull the torn portion of the packaging bag out of the gap.

[0059] When foam 4 is exposed to air, it quickly absorbs air and begins to expand. Due to the preset gap of only 2.5mm, the expanded foam 4 will be compressed to a certain extent. After being compressed, foam 4 generates elastic restoring force, which applies inward pressure to the cell fixing bracket 2. This pressure is transmitted to the cell 3 through the cell fixing bracket 2, applying a preload force to the cell 3.

[0060] Prepare the cell connection assembly 5, including a conductive busbar, an insulating bracket, bolts, and nuts. Place the insulating bracket of the cell connection assembly 5 on the top of the crossbeam 1, aligning the mounting holes on the insulating bracket with the threaded holes on the top of the crossbeam 1. Pass the bolts through the mounting holes of the insulating bracket and screw them into the threaded holes of the crossbeam 1 to securely fix the insulating bracket to the crossbeam 1.

[0061] Install the conductive busbar on the insulating support. Each end of the conductive busbar corresponds to a terminal of one of the two adjacent cells 3. Adjust the position of the conductive busbar so that the copper layer side of the busbar is aligned with the terminal and maintains good contact.

[0062] The conductor busbar and the electrode post of cell 3 were welded using laser welding equipment. After welding, the weld was rapidly cooled and solidified. The appearance quality of the weld was then inspected to ensure that the weld surface was smooth and free of defects such as cracks and porosity.

[0063] Following the aforementioned welding operation, all conductive busbars and terminals are welded sequentially. In this embodiment, the four cells 3 are connected in series through three conductive busbars, thus requiring the completion of six welding points.

[0064] After welding is completed, the electrical performance of the entire battery module is tested.

[0065] Example 3 This embodiment provides a battery, including the module described in Embodiment 1, and also including a housing 6 and a longitudinal beam 7.

[0066] like Figures 4-5As shown, the container 6 is manufactured from aluminum alloy sheet through processes such as stamping, bending, and welding. The overall structure of the container 6 is a rectangular container, with a closed bottom and four side walls, and an open top. The bottom and side walls of the container 6 are integrally formed by bending, and the four corners are connected by welding, and the surface is polished smooth after welding.

[0067] The bottom of the housing 6 is equipped with multiple reinforcing ribs made of aluminum alloy profiles, which are fixed to the inner side of the bottom of the housing 6 by welding. The reinforcing ribs are distributed in a cross pattern, which can effectively improve the rigidity and strength of the bottom of the housing 6 and prevent the housing 6 from deforming when bearing the weight of the battery module.

[0068] The longitudinal beam 7 is made of aluminum alloy profile through extrusion molding process. The cross-sectional shape of the longitudinal beam 7 is I-shaped, which has high bending stiffness and torsional stiffness.

[0069] In this embodiment, two longitudinal beams 7 are provided inside the housing 6. The two longitudinal beams 7 are arranged coaxially and are perpendicular to the length direction of the housing 6. The two ends of the longitudinal beams 7 contact the inner walls on both sides of the housing 6 and are connected by welding. The welding adopts cold metal transfer welding technology, and the welding parameters are the same as those of the crossbeam 1 and the housing 6.

[0070] The connection position between the longitudinal beam 7 and the transverse beam 1 is a key design feature of this embodiment. The connection position between the longitudinal beam 7 and the transverse beam 1 corresponds to the position where the distance between the two adjacent cell support receiving cavities 21 in the middle of the cell fixing bracket 2 is the largest.

[0071] The distance between the second and third cell support cavities 21 in the middle of the cell fixing bracket 2 is greater than the distance at other locations. The connection position between the longitudinal beam 7 and the crossbeam 1 corresponds exactly to this position with the largest distance. This position corresponds to the position with the greatest thickness or the most layers of the partition 12 in the middle of the crossbeam 1. The crossbeam 1 has the highest strength at this position, which can better bear the load transmitted by the longitudinal beam 7 and improve the stability of the crossbeam 1. At the same time, this position is far from the cell 3, so the heat generated when the longitudinal beam 7 and the crossbeam 1 are welded has the least impact on the cell 3, which can effectively protect the cell 3 from damage caused by welding heat.

[0072] The longitudinal beam 7 and the transverse beam 1 are connected by welding. During welding, the bottom flange of the longitudinal beam 7 is brought into contact with the top of the transverse beam 1, and welding is performed using cold metal transfer welding equipment. After welding, a strong connection is formed between the longitudinal beam 7 and the transverse beam 1. After welding, the weld quality is inspected to ensure that there are no defects such as cracks, porosity, or slag inclusions.

[0073] The top of the enclosure 6 is equipped with a cover plate made of aluminum alloy sheet. The cover plate is connected to the top edge of the enclosure 6 by bolts, and a sealing strip is provided between the cover plate and the enclosure 6 to ensure the airtightness of the enclosure 6 and prevent water, dust and other substances from entering the interior of the enclosure 6.

[0074] The cover plate has a mounting location for the Battery Management System (BMS), which is fixed to the cover plate with bolts. The BMS is connected to the cell connection assembly 5 via wires to monitor and manage parameters such as battery voltage, current, and temperature in real time, ensuring the safe operation of the battery.

[0075] The cover plate also features high-voltage and low-voltage interfaces. The high-voltage interface connects the battery to the vehicle's high-voltage electrical system, supplying power from the battery to electrical equipment such as motors. The low-voltage interface connects the battery to the vehicle's low-voltage electrical system, providing power to control systems such as the BMS (Battery Management System).

[0076] A coolant inlet is located on the side wall of the housing 6, and this inlet connects to the vehicle's thermal management system. Coolant enters the housing 6 through this inlet, flows through the cooling channels at the bottom of the housing 6, carrying away the heat generated by the battery cells 3 during operation, and then flows out of the housing 6 through another inlet. This circulating coolant effectively controls the battery temperature, ensuring that the battery operates within a suitable temperature range, thus improving battery performance and lifespan.

[0077] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A battery cell module installed in a battery case beam, characterized by, include: A crossbeam is provided with multiple cell receiving cavities. A cell fixing bracket is installed in the crossbeam, and the cell fixing bracket is composed of multiple cell support receiving cavities. The distance between two adjacent cell support receiving cavities in the middle of the cell fixing bracket is greater than the distance between the remaining cell support receiving cavities. A cell is disposed in each cell support receiving cavity, and the cell maintains a clearance fit with the cell support receiving cavity. The cell fixing bracket is disposed in the cell receiving cavity of the crossbeam, and a preset gap is left between the cell fixing bracket and the inner wall of the cell receiving cavity. A cell expansion pre-tightening vacuum compression foam is disposed in the preset gap. The cell expansion pre-tightening vacuum compression foam applies a pre-tightening force to the cell after expansion.

2. The battery cell module mounted in the cross beam of the battery case according to claim 1, wherein, A cell connection assembly is also fixedly installed on the crossbeam, and the cell connection assembly is welded to the electrode post of the cell in the cavity of the multiple cell support.

3. The battery cell module mounted in the cross beam of the battery case according to claim 1, wherein, The crossbeam is made of aluminum profile and is a hollow cuboid structure with an open top. Multiple partitions are provided in the crossbeam, and the position of the partitions is the gap between the two adjacent cell support cavities.

4. The battery cell module mounted in the cross beam of the battery case according to claim 1, wherein, The battery cell fixing bracket is made of plastic material and manufactured by injection molding. The battery cell fixing bracket also includes a connecting plate. The two ends of the connecting plate are respectively fixedly connected to the top edge of the adjacent battery cell bracket receiving cavity, so that the battery cell fixing bracket forms an integral structure.

5. The battery cell module mounted in the cross beam of the battery case according to claim 1, wherein, The preset gap between the cell fixing bracket and the inner wall of the cell receiving cavity is 2mm to 3mm; the gap between the cell fixing bracket and the cell is 0.3±0.05mm.

6. The method of claim 1-5, wherein, Includes the following steps: The crossbeam is welded and fixed to the box; multiple battery cells are respectively placed into the battery cell bracket receiving cavity of the battery cell fixing bracket, and the battery cells and the battery cell bracket receiving cavity are maintained in clearance fit. The battery cell fixing bracket with the battery cell is placed into the battery cell receiving cavity of the crossbeam, and a preset gap is left between the inner wall of the battery cell receiving cavity and the battery cell fixing bracket. Vacuum-compressed foam is filled into the preset gap; the vacuum-compressed foam is expanded to apply a pre-tightening force to the battery cell; The cell connection assembly is fixedly connected to the crossbeam, and the cell connection assembly is welded to the terminal post of the cell.

7. The method of claim 6, wherein, The vacuum-compressed foam is initially in a vacuum-compressed state and encapsulated in a packaging bag. The vacuum-compressed foam expands by tearing the packaging bag.

8. The assembly method of a cell module installed in a crossbeam of a battery box according to claim 6, characterized in that, The cell connection assembly is connected to the electrode of the cell by laser welding.

9. A battery, characterized in that, The battery cell module, as described in any one of claims 1-5, is installed in the crossbeam of a battery housing and further includes a housing and a longitudinal beam. The module is disposed in the housing, and the crossbeam and longitudinal beam of the module are arranged perpendicularly. The connection position between the longitudinal beam and the crossbeam corresponds to the position where the distance between two adjacent battery cell support cavities in the middle of the battery cell fixing bracket is the largest.

10. The battery according to claim 9, characterized in that, The ends of the crossbeams and longitudinal beams are connected to the box body by welding, and the crossbeams and longitudinal beams are also connected to each other by welding.

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