Battery device and power utilization device

Abstract

The utility model provides a battery device and a power utilization device, a foam composite material of the battery device comprises a foam base material and a surface film layer, the foam base material is provided with a first surface and a second surface which are oppositely arranged along the thickness direction of the foam base material, and at least one of the first surface and the second surface is provided with the surface film layer. And the surface film layer and the foam base material contain the same self-adhesive material. Compared with the foam base material, the surface film layer arranged on the surface of the foam base material has better wear resistance and can fix the two mutually separated parts of the foam base material, so that the durability of the foam base material is improved by arranging the surface film layer on the surface of the foam base material.

Description

Technical Field

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

[0002] Battery devices have advantages such as high specific energy and high power density, and are widely used in electronic devices and transportation vehicles, such as mobile phones, laptops, electric vehicles, electric cars, electric airplanes, electric ships and power tools.

[0003] Battery devices typically require the use of foam materials to seal the casing or to insulate electrical connections (such as copper or aluminum bars). Improving the durability of foam composite materials is receiving increasing attention from those skilled in the art. Utility Model Content

[0004] In view of the above problems, this application provides a battery device and an electrical device, wherein the foam in the battery device has good durability.

[0005] In a first aspect, this application provides a battery device comprising a foam composite material, the foam composite material comprising a foam substrate and a surface film layer. The foam substrate has a first surface and a second surface disposed opposite to each other along the thickness direction of the foam substrate. The surface film layer covers at least one of the first surface and the second surface. The surface film layer and the foam substrate contain the same self-adhesive material. The thickness of the surface film layer is set to D, where 5 μm ≤ D ≤ 100 μm. In the above structure, since the foam substrate and the surface film layer disposed on its surface contain the same self-adhesive material, the surface film layer and the foam substrate can be tightly bonded, achieving good adhesion. Because the foam substrate is a porous material, the density of the surface film layer is higher than that of the foam substrate, the wear resistance of the surface film layer is higher than that of the foam substrate, and due to the film-like structure of the surface film layer, the probability of damage under shear force is also lower than that of the foam substrate. Therefore, by covering the surface of a foam substrate with a surface film, a protective function can be achieved. On one hand, covering at least part of the foam substrate reduces the risk of debris generation due to wear. On the other hand, the surface film, through its connection with the foam substrate, helps to hold the separated parts of the foam substrate relatively still in the event of shear failure, thus maintaining the structural integrity of the foam composite material and ensuring its proper function. In summary, applying a surface film to the surface of a foam substrate improves its durability.

[0006] According to some embodiments of the battery device provided in this application, the foam substrate is a silicone foam and the surface film layer is a silicone film layer. Since silicon materials have excellent wear resistance, flexibility, and insulation properties, by making the foam substrate a silicone foam and the surface film layer a silicone film layer, the wear resistance, flexibility, and insulation properties of the foam composite material can all be improved.

[0007] According to some embodiments of the battery device provided in this application, both the material of the foam substrate and the material of the surface film layer comprise polyurethane; or, both the material of the foam substrate and the material of the surface film layer comprise polyethylene. Since polyurethane is a self-adhesive material, by including polyurethane in both the material of the foam substrate and the material of the surface film layer, a tight bond is achieved between the surface film layer and the foam substrate, resulting in good adhesion. Similarly, since polyethylene is a self-adhesive material, by including polyethylene in both the material of the foam substrate and the material of the surface film layer, a tight bond is achieved between the surface film layer and the foam substrate, resulting in good adhesion.

[0008] According to some embodiments of the present application, the thickness of the foam substrate is set to E, where 5mm≤E≤10mm. This not only ensures that the foam substrate has sufficient thickness for compression to provide a good seal, but also prevents material waste due to excessive thickness of the foam substrate.

[0009] According to some embodiments of the present application, the battery device further includes a side surface connected between the first surface and the second surface, and a surface film layer covers at least a portion of the side surface, thereby providing more comprehensive protection for the foam substrate.

[0010] According to some embodiments of this application, the battery device further includes a battery cell assembly, a first housing portion and a second housing portion. The first housing portion and the second housing portion are connected and together form an accommodating space. The battery cell assembly is located in the accommodating space. A foam composite material is sandwiched between the first housing portion and the second housing portion to seal the connection between the first housing portion and the second housing portion. The foam composite material can reliably seal the connection gap between the first housing portion and the second housing portion, which is beneficial to the reliability of the seal between the first housing portion and the second housing portion and helps to improve the reliability of the battery device.

[0011] According to some embodiments of the present application, the first surface of the foam substrate faces the first housing portion, and a surface film layer is provided on the first surface. The second surface of the foam substrate is not provided with a surface film layer, so that the surface film layer can be located on the side of the foam composite material that is subjected to force (the side where the first housing portion is located). The side of the foam composite material subjected to force is provided with a surface film layer, while the side that is not subjected to force is not provided with a surface film layer. This allows the foam composite material to withstand the force brought by the first housing portion while saving materials and reducing costs.

[0012] According to some embodiments of the present application, the battery device has a second surface bonded to the second housing portion, which allows the second surface of the foam substrate in the foam composite material to be bonded and fixed to the second housing portion during installation, thereby improving the ease of installation.

[0013] According to some embodiments of this application, the battery device includes a battery cell assembly and a connector. The connector is electrically connected to the battery cell assembly, and the surface of the connector is covered with the foam composite material. By providing the foam composite material on the outside of the connector, the highly durable foam composite material can protect the connector. The foam composite material is not easily broken under impact and vibration conditions, still has good cushioning performance, and can also provide good insulation protection for the connector.

[0014] According to some embodiments of the present application, the battery device has a surface film layer on the first surface of the foam substrate and a second surface bonded to the connector. This not only allows the surface film layer to be disposed on the side of the foam composite material that is easily subjected to external forces, thereby improving the ability of the foam composite material to withstand external impacts, but also saves materials and reduces costs. At the same time, it also makes it convenient to connect the foam composite material to the connector.

[0015] Secondly, this application provides an electrical device that includes a battery device provided by any of the above-mentioned technical solutions, the battery device being used to store and provide electrical energy.

[0016] The technical solutions provided by the embodiments of this disclosure have at least the following beneficial effects:

[0017] This application provides a battery device comprising a foam composite material, which includes a foam substrate and a surface film. The foam substrate has a first surface and a second surface disposed opposite to each other along its thickness direction. The surface film covers at least one of the first and second surfaces. The surface film and the foam substrate contain the same self-adhesive material. The thickness of the surface film is set to D, where 5 μm ≤ D ≤ 100 μm. In this structure, because the foam substrate and the surface film disposed on its surface contain the same self-adhesive material, the surface film and the foam substrate can be tightly bonded, achieving good adhesion. Since the foam substrate is a porous material, the surface film has higher density and wear resistance than the foam substrate. Furthermore, due to the film-like structure of the surface film, the probability of breakage under shear force is lower than that of the foam substrate. Therefore, by covering the surface of a foam substrate with a surface film, a protective function can be achieved. On one hand, covering at least part of the foam substrate reduces the risk of debris generation due to wear. On the other hand, the surface film, through its connection with the foam substrate, helps to hold the separated parts of the foam substrate relatively still in the event of shear failure, thus maintaining the structural integrity of the foam composite material and ensuring its proper function. In summary, applying a surface film to the surface of a foam substrate improves its durability.

[0018] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0019] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings.

[0020] Figure 1 These are schematic diagrams of the vehicle structure provided in some embodiments of this application;

[0021] Figure 2 This is a exploded view of a battery device provided in some embodiments of this application;

[0022] Figure 3 This is a cross-sectional view of the foam composite material provided in the first embodiment of this application;

[0023] Figure 4This is a cross-sectional view of the foam composite material provided in the second embodiment of this application;

[0024] Figure 5 This is a cross-sectional view of the foam composite material provided in the third embodiment of this application;

[0025] Figure 6 This is a cross-sectional view of the foam composite material provided in the fourth embodiment of this application;

[0026] Figure 7 for Figure 2 Enlarged view at point F;

[0027] Figure 8 This is a schematic diagram of the structure of the connector provided in some embodiments of this application;

[0028] Figure 9 for Figure 8 Sectional view at point GG.

[0029] In the attached diagram:

[0030] 1. Vehicle; 2. Battery unit; 3. Controller; 4. Motor; 5. Housing; 5a. First housing section; 5b. Second housing section; 5c. Reception space; 7. Battery cell; 8. Foam composite material; 81. Foam substrate; 811. First surface; 812. Second surface; 813. Side; 82. Surface film layer; 9. Connector; 10. Battery cell assembly. Detailed Implementation

[0031] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0032] It should be noted that, unless otherwise stated, the technical or scientific terms used in the embodiments of this application should have the ordinary meaning understood by those skilled in the art to which the embodiments of this application pertain.

[0033] In the description of the embodiments of this application, the technical terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0034] Furthermore, technical terms such as "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. In the description of the embodiments of this application, "a plurality of" means two or more (including two), unless otherwise explicitly defined.

[0035] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0036] In the description of the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0037] Currently, judging from market trends, the application of battery devices is becoming increasingly widespread. Battery devices are not only used in energy storage power systems such as hydropower, thermal power, wind power, and solar power plants, but also widely used in electric vehicles such as electric bicycles, electric motorcycles, and electric cars, as well as in aerospace and other fields.

[0038] The battery device mentioned in the embodiments of this application refers to a single physical module comprising one or more battery cell assemblies to provide higher voltage and capacity. A battery cell assembly may include multiple battery cells, which are connected in series, parallel, or mixed connections via a busbar.

[0039] As an example, a battery cell assembly can be a battery module, which is formed by arranging and fixing multiple battery cells together to form an independent module. As another example, a battery module can be formed by bundling multiple battery cells together with cable ties.

[0040] A battery cell can be a rechargeable battery cell, which refers to a battery cell that can be recharged after being discharged to activate the active materials and continue to be used.

[0041] Battery cells can be lithium-ion cells, sodium-ion cells, sodium-lithium-ion cells, lithium metal cells, sodium metal cells, lithium-sulfur cells, magnesium-ion cells, nickel-metal hydride cells, nickel-cadmium cells, lead-acid cells, etc.

[0042] In some embodiments, a battery cell assembly is typically formed by arranging multiple battery cells.

[0043] As an example, a battery cell assembly can be a battery module, which is formed by arranging and fixing multiple battery cells together to form an independent module. As another example, a battery module can be formed by bundling multiple battery cells together with cable ties.

[0044] In some embodiments, the battery device may be a battery pack, which includes a housing and one or more individual battery cell assemblies housed within the housing.

[0045] As an example, the battery cell assembly can be a battery module, which can be housed in a housing by fixing the battery module in the housing.

[0046] As an example, battery cell assemblies can also be housed in a housing by directly fixing multiple battery cells to the housing.

[0047] As an example, the enclosure may include a top cover, a frame, and a bottom plate. The top cover and bottom plate are connected to the frame, creating an enclosed space inside the enclosure to house the individual battery cells.

[0048] In some embodiments, the housing may be part of the vehicle's chassis structure. For example, a portion of the housing may be at least a part of the vehicle's floor, or a portion of the housing may be at least a part of the vehicle's crossbeams and longitudinal beams.

[0049] In some embodiments, the battery device can be used in an energy storage device. Energy storage devices include energy storage containers, energy storage cabinets, etc.

[0050] In existing battery devices, foam is typically used to provide sealing, cushioning, and insulation. During use, foam may be worn down, producing debris. On one hand, wear can impair the foam's function, such as reducing its sealing or insulation performance. On the other hand, debris may fall onto individual battery cells, causing malfunctions, such as increasing internal resistance. Foam may also break under shear forces, preventing it from functioning properly.

[0051] To improve the durability of foam in a battery device, this application provides a battery device comprising a battery cell, a foam composite material, a first housing portion, and a second housing portion. The foam composite material includes a foam substrate and a surface film layer. The foam substrate has a first surface and a second surface disposed opposite to each other along its thickness direction. At least one of the first and second surfaces is provided with the surface film layer. The surface film layer and the foam substrate contain the same self-adhesive material. The first housing portion and the second housing portion are connected and together form an accommodating space. The battery cell is located in the accommodating space. The foam composite material is sandwiched between the first housing portion and the second housing portion to seal the connection gap between the first housing portion and the second housing portion. In the above structure, because the foam substrate and the surface film layer disposed on its surface contain the same self-adhesive material, the surface film layer and the foam substrate can be tightly bonded, achieving good adhesion. Because foam substrates are porous materials, the surface film layer exhibits higher density and wear resistance compared to the foam substrate itself. Furthermore, due to its membrane-like structure, the surface film layer is less likely to break under shear forces. Therefore, by covering the surface of the foam substrate with a surface film layer, a protective function can be achieved. Firstly, by covering at least part of the foam substrate's surface, the risk of debris formation due to wear is reduced. Secondly, through the connection between the surface film layer and the foam substrate, in the event of breakage due to shear forces, the surface film layer relatively fixes the separated parts of the foam substrate, preserving the structural integrity of the foam composite material and ensuring its proper function. In summary, applying a surface film layer to the surface of the foam substrate improves its durability.

[0052] The battery device described in the embodiments of this application is applicable to electrical devices that use battery devices.

[0053] Electrical devices can include vehicles, mobile phones, portable devices, laptops, ships, spacecraft, electric toys, and power tools, among others. Vehicles can be gasoline-powered cars, natural gas-powered cars, or new energy vehicles; new energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles, etc. Spacecraft include airplanes, rockets, space shuttles, and spacecraft, etc. Electric toys include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc. Power tools include metal cutting power tools, grinding power tools, assembly power tools, and railway power tools, such as electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete vibrators, and electric planers, etc.

[0054] For ease of explanation, the following embodiments will be described using a vehicle as an example of an electrical device according to an embodiment of this application.

[0055] Figure 1 The diagram shows the structural features of a vehicle provided in some embodiments of this application.

[0056] like Figure 1 As shown, a battery device 2 is installed inside the vehicle 1. The battery device 2 can be located at the bottom, front, or rear of the vehicle 1. The battery device 2 can be used to power the vehicle 1; for example, the battery device 2 can serve as the operating power source for the vehicle 1.

[0057] The vehicle 1 may also include a controller 3 and a motor 4. The controller 3 is used to control the battery device 2 to supply power to the motor 4, for example, for the power needs of the vehicle 1 during starting, navigation and driving.

[0058] In some embodiments of this application, the battery device 2 can not only serve as the operating power source for the vehicle 1, but also as the driving power source for the vehicle 1, replacing or partially replacing fuel or natural gas to provide driving power for the vehicle 1.

[0059] Figure 2 This is a exploded view of a battery device provided in some embodiments of this application. For example... Figure 2 As shown, the battery device 2 includes a housing 5 and battery cells 7, with the battery cells 7 housed within the housing 5. The battery cell 7 can be the smallest unit that makes up a battery.

[0060] The housing 5 is used to house the battery cell 7, and the housing 5 can have various structures. In some embodiments, the housing 5 may include a first housing portion 5a and a second housing portion 5b, which overlap each other, and together define a housing space 5c for housing the battery cell 7. The second housing portion 5b may be a hollow structure with one end open, and the first housing portion 5a may be a plate-like structure, with the first housing portion 5a covering the open side of the second housing portion 5b to form a housing 5 with the housing space 5c; alternatively, both the first housing portion 5a and the second housing portion 5b may be hollow structures with one side open, with the open side of the first housing portion 5a covering the open side of the second housing portion 5b to form a housing 5 with the housing space 5c. Of course, the first housing portion 5a and the second housing portion 5b can be various shapes, such as cylinders, cuboids, etc.

[0061] To improve the sealing performance after the first housing part 5a and the second housing part 5b are connected, a sealing element, such as sealant or sealing ring, can also be provided between the first housing part 5a and the second housing part 5b.

[0062] In the battery device 2, there can be one or more battery cells 7. If there are multiple battery cells 7, they can be connected in series, in parallel, or in a mixed manner. A mixed connection means that multiple battery cells 7 are connected in both series and parallel. Multiple battery cells 7 can be directly connected in series, in parallel, or in a mixed manner, and then the whole assembly of multiple battery cells 7 is housed in the housing 5. Alternatively, multiple battery cells 7 can first be connected in series, in parallel, or in a mixed manner to form a battery module, and then multiple battery modules can be connected in series, in parallel, or in a mixed manner to form a whole assembly, which is then housed in the housing 5.

[0063] Some embodiments of this application provide a battery device 2, which includes a foam composite material 8, see reference. Figure 3 and Figure 4 The foam composite material 8 includes a foam substrate 81 and a surface film layer 82. The foam substrate 81 has a first surface 811 and a second surface 812 disposed opposite to each other along the thickness direction of the foam substrate 81. The surface film layer 82 covers at least one of the first surface 811 and the second surface 812. The surface film layer 82 and the foam substrate 81 contain the same self-adhesive material. The thickness of the surface film layer 82 is set to D, where 5μm≤D≤100μm.

[0064] Foam substrate 81 can refer to the main structural part of the foam composite material 8, which is made of foam. Since foam is a lightweight porous material, it usually has a certain degree of elasticity and cushioning, which gives the foam composite material 8 a certain degree of elasticity and cushioning.

[0065] The surface film layer 82 refers to the film layer structure covering the surface of the foam substrate 81.

[0066] A surface film layer 82 is provided on at least one of the first surface 811 and the second surface 812. This can mean that the surface film layer 82 is provided on the first surface 811, but not on the second surface 812; it can also mean that the surface film layer 82 is provided on the second surface 812, but not on the first surface 811; or it can mean that both the first surface 811 and the second surface 812 are provided with a surface film layer 82. By providing a surface film layer 82 on at least one of the first surface 811 and the second surface 812, when the foam composite material 8 comes into contact with an external device, the surface film layer 82 can directly contact the external device. Generally, the surface film layer 82 has better wear resistance than the foam substrate 81, which helps to reduce the risk of the foam substrate 81 generating debris due to wear.

[0067] Because the surface film layer 82 has a higher density than the foam substrate 81, and because the film-like structure of the surface film layer 82 is not easily damaged by vibration and impact, the probability of the surface film layer 82 breaking under shear force is also lower than that of the foam substrate 81. When the foam substrate 81 breaks, the undamaged surface film layer 82 can stably connect the broken foam substrate 81 pieces together, giving the foam composite material 8 good durability.

[0068] Self-adhesive materials are materials that can adhere to other objects without the need for additional adhesives. Self-adhesive materials of the same type have strong affinity and bonding forces due to their similar molecular structures. When two surfaces of the same self-adhesive material come into contact, the molecules attract each other and bond tightly, achieving good adhesion without the need for additional adhesives or special treatment.

[0069] By including the same self-adhesive material in the surface film layer 82 and the foam substrate 81, the surface film layer 82 and the foam substrate 81 can be bonded tightly, and good adhesion can be achieved without the need for adhesive.

[0070] By setting the thickness D of the surface film layer 82 to a range of D≥5μm, the thickness of the surface film layer 82 is not too small, which helps to improve the wear resistance and shear resistance of the surface film layer 82 and reduce the risk of damage to the surface film layer 82. By setting the thickness D of the surface film layer 82 to a range of D≤100μm, the thickness of the surface film layer 82 is not too large, which helps to reduce the thickness of the foam composite material 8, thereby reducing the space occupied by the foam composite material 8 in the box and also helps to save materials.

[0071] The thickness D of the surface film layer 82 can be set to a range of 10μm≤D≤60μm. For example, the thickness D of the surface film layer 82 can be set to 10μm, 15μm, 20μm, 25μm, 30μm, 35μm, 40μm, 45μm, 50μm, 55μm or 60μm, so that the surface film layer 82 is not only less prone to damage, but also reduces the space occupied in the box and helps to save materials.

[0072] In the above structure, since the foam substrate 81 and the surface film layer 82 disposed on its surface contain the same self-adhesive material, the surface film layer 82 and the foam substrate 81 can be tightly bonded together, achieving good adhesion. Because the foam substrate 81 is a porous material, the surface film layer 82 has higher density and wear resistance than the foam substrate 81. Furthermore, due to the film-like structure of the surface film layer 82, the probability of damage under shear force is lower than that of the foam substrate 81. Therefore, by covering the surface of the foam substrate 81 with a surface film layer 82, the foam substrate 81 can be protected. On the one hand, by covering at least part of the surface of the foam substrate 81, the risk of debris generated by the foam substrate 81 due to wear is reduced. On the other hand, through the connection between the surface film layer 82 and the foam substrate 81, in the event of breakage due to shear force, the two separated parts of the foam substrate 81 are relatively fixed by the surface film layer 82, thus maintaining the structural integrity of the foam composite material 8 as much as possible, so as to ensure its normal function. In summary, by setting a surface film layer 82 on the surface of the foam substrate 81, the durability of the foam substrate 81 is improved.

[0073] In some embodiments, the foam substrate 81 is a silicone foam and the surface film layer 82 is a silicone film layer.

[0074] Silicone-containing foam is a lightweight, porous, and flexible elastic foam material made from silicone rubber as the base material through chemical or physical foaming processes. The silicone-containing film layer is a thin film layer formed from silicone polymers (such as silicone rubber or silicone gel) with silicon as the core element. Because silicone materials are self-adhesive, by setting the foam substrate 81 as silicone-containing foam and the surface film layer 82 as a silicone-containing film layer, such as a silicone film, a tight bond is achieved between the surface film layer 82 and the foam substrate 81, resulting in good adhesion.

[0075] Since silicon materials have good wear resistance, flexibility and insulation properties, by making the foam substrate 81 a silicon-containing foam and the surface film layer 82 a silicon-containing film layer, the wear resistance, flexibility and insulation properties of the foam composite material 8 can be improved.

[0076] In some embodiments, both the foam substrate 81 and the surface film layer 82 comprise polyurethane; or, both the foam substrate 81 and the surface film layer 82 comprise polyethylene.

[0077] The foam substrate 81 is made of polyurethane, meaning it is polyurethane foam. Polyurethane foam is a lightweight, porous, and flexible elastic foam material made from polyurethane elastomers (such as polyurethane rubber) through chemical or physical foaming processes. The surface film layer 82 is also made of polyurethane, meaning it is a polyurethane elastic film layer. This elastic film layer is a thin film layer formed with polyurethane elastomers (such as polyurethane rubber) as its core element. Because polyurethane elastomers are self-adhesive materials, by making the foam substrate 81 polyurethane foam and the surface film layer 82 a polyurethane elastic film layer, a tight bond is achieved between the surface film layer 82 and the foam substrate 81, resulting in good adhesion.

[0078] The foam substrate 81 is made of polyethylene, which can mean that the foam substrate 81 is polyethylene foam. Polyethylene foam is a lightweight, porous, and flexible elastic foam material made from polyethylene elastomers (such as polyethylene rubber) as the substrate through chemical foaming or physical foaming processes. The surface film layer 82 is made of polyethylene, which can mean that the surface film layer 82 is a polyethylene elastic film layer. The polyethylene elastic film layer is a thin film layer formed with polyethylene elastomers (such as polyurethane rubber) as the core element. Since polyethylene elastomers are self-adhesive materials, by making the foam substrate 81 polyethylene foam and the surface film layer 82 a polyethylene elastic film layer, a tight bond is achieved between the surface film layer 82 and the foam substrate 81, resulting in good adhesion.

[0079] In some embodiments, the thickness of the foam substrate 81 is set to E, where 5mm ≤ E ≤ 10mm.

[0080] By setting the thickness E of the foam substrate 81 to a range of E≥5mm, the foam substrate 81 is not too small, and the foam substrate 81 has sufficient thickness for compression to provide a good seal; by setting the thickness E of the foam substrate 81 to a range of E≤10mm, the thickness of the foam substrate 81 is not too large, which helps to save materials.

[0081] For example, when the foam composite material 8 is used as a cushioning element, the thickness of the foam substrate 81 can be designed according to the size of the space to be cushioned, so that the foam composite material 8 can play a good cushioning role.

[0082] In some embodiments, the foam substrate 81 is formed on the first surface 811 and / or the second surface 812 of the surface film layer 82 by a coating foaming process.

[0083] The foam substrate 81 is formed onto the surface of the surface film layer 82 through a coating and foaming process. This can mean that the foam coating and foaming process is performed on the surface of one surface film layer 82, so that the surface of the surface film layer 82 is uniformly covered by the foam substrate 81; or it can mean that the foam coating and foaming process is performed between two relatively spaced surface film layers 82, so that the foam uniformly covers the surfaces of the two relatively spaced surface film layers 82. For example, the foam can be directly coated onto the surface of the surface film layer 82 through a coating roll forming process, followed by foaming, so that the foam substrate 81 and the surface film layer 82 are bonded together as a whole. For example, the foam substrate 81 can also be formed onto the surface of the surface film layer 82 through an extrusion coating and foaming process.

[0084] In some embodiments, the surface film 82 can be formed by uniformly coating the material of the surface film 82 onto the surface of the substrate using a coating process.

[0085] In some embodiments, a surface film layer 82 is provided on both the first surface 811 and the second surface 812.

[0086] By providing surface film layers 82 on both the first surface 811 and the second surface 812, the surface film layers 82 can provide more comprehensive protection for the foam substrate 81 from both sides in the thickness direction, which not only improves the durability of the foam composite material 8, but also improves the sealing performance, waterproof performance and ductility of the foam composite material 8.

[0087] In some embodiments, reference Figure 5 and Figure 6 The foam substrate 81 also includes a side surface 813, which is connected between the first surface 811 and the second surface 812, and the surface film layer 82 covers at least a portion of the side surface 813.

[0088] Side 813 can refer to the surface of foam substrate 81 that connects the first surface 811 and the second surface 812.

[0089] By providing a surface film layer 82 on at least a portion of the side surface 813 of the foam substrate 81, more comprehensive protection can be provided to the foam substrate 81.

[0090] The surface film 82 covering at least a portion of the side 813 can mean that the surface film 82 is covered on a portion of the side 813 while the surface film 82 is not covered on another portion of the side 813; or it can mean that the surface film 82 is covered on the entire side 813.

[0091] For example, the surface film layer 82 covering the side surface 813 is connected to the surface film layer 82 on the first surface 811; or, the surface film layer 82 covering the side surface 813 is connected to the surface film layer 82 on the second surface 812; or, the surface film layer 82 covering the side surface 813 is connected to both the surface film layer 82 on the first surface 811 and the surface film layer 82 on the second surface 812. By connecting the surface film layer 82 covering the side surface 813 to the surface film layers 82 on other surfaces, the film layers on the outer surface of the foam substrate 81 can be connected into a whole, resulting in good overall structural strength.

[0092] In some embodiments, the surface film layer 82 on the side 813 is an integrally formed structure with at least one of the surface film layer 82 on the first surface 811 and the surface film layer 82 on the second surface 812.

[0093] The surface film layer 82 on the side 813 is integrally formed with at least one of the surface film layer 82 on the first surface 811 and the surface film layer 82 on the second surface 812. This can be achieved by: the first surface 811 having a surface film layer 82, the second surface 812 not having a surface film layer 82, and the surface film layer 82 on the side 813 being formed from the same film layer structure as the surface film layer 82 on the first surface 811; or the second surface 812 having a surface film layer 82, the first surface 811 not having a surface film layer 82, and the surface film layer 82 on the side 813 being formed from the same film layer structure as the surface film layer 82 on the second surface 812; or the second surface 812 having a surface film layer 82, the first surface 811 also having a surface film layer 82, and the surface film layer 82 on the side 813 being formed from the same film layer structure as the surface film layer 82 on the first surface 811 and the surface film layer 82 on the second surface 812.

[0094] In some embodiments, continue to refer to Figure 2 The battery device 2 also includes a battery cell assembly 10, a first housing portion 5a and a second housing portion 5b, the first housing portion 5a and the second housing portion 5b together form an accommodating space 5c, the battery cell assembly 10 is located in the accommodating space 5c, and the foam composite material 8 is sandwiched between the first housing portion 5a and the second housing portion 5b to seal and connect the first housing portion 5a and the second housing portion 5b.

[0095] By sandwiching the foam composite material 8 provided by the aforementioned technical solution between the first housing part 5a and the second housing part 5b, the foam composite material 8 can seal and connect the first housing part 5a and the second housing part 5b, which is beneficial to the reliability of the seal between the first housing part 5a and the second housing part 5b and helps to improve the reliability of the battery device 2.

[0096] In some embodiments, reference Figure 7 The first surface 811 of the foam substrate 81 faces the first housing portion 5a. The first surface 811 is provided with a surface film layer 82. The surface film layer 82 contacts and connects to the first housing portion 5a, and the second surface 812 contacts and connects to the second housing portion 5b.

[0097] The first housing part 5a can be fastened to the upper side of the second housing part 5b. The first housing part 5a is fastened to the second housing part 5b from above and locked to the second housing part 5b, pressing the foam composite material 8 onto the second housing part 5b.

[0098] By aligning the first surface 811 of the foam substrate 81 with the first housing portion 5a and providing a surface film layer 82 on the first surface 811, while not providing a surface film layer 82 on the second surface 812 of the foam substrate 81, the surface film layer 82 is positioned on the stressed side of the foam composite material 8 (the side where the first housing portion 5a is located). This allows the surface film layer 82 to be provided on the stressed side of the foam composite material 8, while the unstressed second surface does not have a surface film layer 82 and directly contacts and connects to the second housing. This enables the foam composite material 8 to withstand the force exerted by the first housing portion 5a while also saving materials and reducing costs.

[0099] In some embodiments, the second surface 812 is bonded to the second housing portion 5b.

[0100] By bonding the second surface 812 of the foam substrate 81 to the second housing portion 5b with adhesive, the second surface 812 of the foam substrate 81 in the foam composite material 8 can be bonded and fixed to the second housing portion 5b during installation, which helps to improve the ease of installation.

[0101] In some embodiments, the battery device 2 further includes a battery cell assembly 10 and a connector 9, the connector 9 being electrically connected to the battery cell assembly 10, as shown in the reference. Figure 8 The surface of connector 9 is covered with foam composite material 8.

[0102] The connector 9 can be a device that connects the battery cell assembly 10 in the battery device 2 to devices such as the high voltage box, so that the battery cell assembly 10 can be charged and discharged smoothly.

[0103] By covering the surface of the connector 9 with foam composite material 8, the highly durable foam composite material 8 can protect the connector 9. The foam composite material 8 is not easy to break under impact and vibration conditions, and still has good cushioning performance, which can provide good insulation protection for the connector 9.

[0104] In some embodiments, reference Figure 9In the foam composite material 8, the first surface 811 of the foam substrate 81 is provided with a surface film layer 82, and the second surface 812 is bonded to the connector 9.

[0105] The surface film layer 82 is not provided on the second surface 812 of the foam substrate 81, but is provided on the first surface 811, and the second surface 812 is bonded to the connector 9. This not only allows the surface film layer 82 to be provided on the side of the foam composite material 8 that is easily subjected to external forces, thus improving the ability of the foam composite material 8 to withstand external impacts, but also saves materials and reduces costs. At the same time, it also makes it convenient to connect the foam composite material 8 to the connector 9.

[0106] Some embodiments of this application also provide an electrical device that includes the battery device 2 provided in the foregoing technical solutions. The battery device 2 can be used to store and provide electrical energy.

[0107] The electrical device can be any of the aforementioned technical solutions that utilizes the battery device 2.

[0108] Some embodiments of this application provide a battery device 2, which includes a battery cell assembly 10, a foam composite material 8, a first housing portion 5a, and a second housing portion 5b. The foam composite material 8 includes a foam substrate 81 and a surface film layer 82. The foam substrate 81 has a first surface 811 and a second surface 812 disposed opposite to each other along the thickness direction of the foam substrate 81. The surface film layer 82 is disposed on the first surface 811, and the surface film layer 82 is not disposed on the second surface 812. The foam substrate 81 is a silicone foam, the surface film layer is a silicone film layer, and the thickness of the surface film layer 82 is set to D, where 5μm≤D≤100μm. The battery cell assembly 10 is located in the housing space 5c formed by the connection of the first housing part 5a and the second housing part 5b. The foam composite material 8 is sandwiched between the first housing part 5a and the second housing part 5b to seal the connection gap between the first housing part 5a and the second housing part 5b. The surface film layer 82 contacts and connects to the first housing part 5a, and the second surface 812 contacts and connects to the second housing part 5b.

[0109] In the above structure, since the foam substrate 81 and the surface film layer 82 disposed on its surface contain the same self-adhesive material, the surface film layer 82 and the foam substrate 81 can be tightly bonded together, achieving good adhesion. Because the foam substrate 81 is a porous material, the surface film layer 82 has higher density and wear resistance than the foam substrate 81. Furthermore, due to the film-like structure of the surface film layer 82, the probability of damage under shear force is lower than that of the foam substrate 81. Therefore, by covering the surface of the foam substrate 81 with a surface film layer 82, the foam substrate 81 can be protected. On the one hand, by covering at least part of the surface of the foam substrate 81, the risk of debris generated by the foam substrate 81 due to wear is reduced. On the other hand, through the connection between the surface film layer 82 and the foam substrate 81, in the event of breakage due to shear force, the two separated parts of the foam substrate 81 are relatively fixed by the surface film layer 82, thus maintaining the structural integrity of the foam composite material 8 as much as possible, so as to ensure its normal function. In summary, by setting a surface film layer 82 on the surface of the foam substrate 81, the durability of the foam substrate 81 is improved. Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application 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 therein. 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 this application, and they should all be covered within the scope of the claims and specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A battery device, characterized in that, include: A foam composite material includes a foam substrate and a surface film layer. The foam substrate has a first surface and a second surface disposed opposite to each other along the thickness direction of the foam substrate. The surface film layer covers at least one of the first surface and the second surface. The surface film layer and the foam substrate contain the same self-adhesive material. The thickness of the surface film layer is D, where 5 μm ≤ D ≤ 100 μm.

2. The battery device according to claim 1, characterized in that, The foam substrate is a silicone foam, and the surface film is a silicone film.

3. The battery device according to claim 1, characterized in that, Both the foam substrate and the surface film layer are made of polyurethane; or... Both the foam substrate and the surface film layer are made of polyethylene.

4. The battery device according to claim 1, characterized in that, The thickness of the foam substrate is E, where 5mm ≤ E ≤ 10mm.

5. The battery device according to claim 1, characterized in that, The foam substrate also includes a side surface connected between the first surface and the second surface, and the surface film layer covers at least a portion of the side surface.

6. The battery device according to any one of claims 1-5, characterized in that, The battery device includes: Battery cell assembly; A first housing section and a second housing section are connected and together form an accommodating space. The battery cell assembly is located in the accommodating space. The foam composite material is sandwiched between the first housing section and the second housing section to seal and connect the first housing section and the second housing section.

7. The battery device according to claim 6, characterized in that, The first surface of the foam substrate faces the first housing portion, and the first surface is provided with the surface film layer. The surface film layer contacts and connects to the first housing portion, and the second surface contacts and connects to the second housing portion.

8. The battery device according to claim 7, characterized in that, The second surface is bonded to the second housing portion.

9. The battery device according to any one of claims 1-5, characterized in that, The battery device includes: Battery cell assembly; A connector electrically connected to the battery cell assembly, the surface of which is covered with the foam composite material.

10. The battery device according to claim 9, characterized in that, The first surface of the foam substrate is provided with the surface film layer, and the second surface is adhered to the connector.

11. An electrical appliance, characterized in that, Includes the battery device as described in any one of claims 1-10.

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