Battery panel, upper cover assembly, battery module and electric device

Abstract

The embodiment of the utility model provides a kind of battery panel, upper cover subassembly, battery module and electric equipment.Wherein, battery panel includes: panel body, panel body includes connecting region and assembly area, panel body is equipped with opposite first side and second side;Multiple connecting pedestals, each connecting pedestal is located in the first side of connecting region;Multiple embedded connecting pieces, at least part embedded connecting piece is located in connecting pedestal, and the material of embedded connecting piece is conductive material;Wherein, panel body, connecting pedestal and embedded connecting piece are integrally injection molded.The technical scheme of the utility model, omits pre-assembly process, effectively reduces assembly complexity, reduces cost.

Description

Technical Field

[0001] This utility model relates to the field of battery technology, and more specifically, to a battery panel, a top cover assembly, a battery module, and an electrical device. Background Technology

[0002] Currently, in order to meet the requirements of battery charging and discharging and use safety, commercial battery packs are equipped with various types of connectors. In related technologies, the connectors usually need to be pre-assembled onto a panel of the battery pack, and additional connection bases need to be set on the panel. At the same time, the panel is reassembled onto the main body during the battery pack packaging process, which involves multiple assembly steps and makes the process complicated. Utility Model Content

[0003] The present invention aims to at least solve the technical problem of complex assembly processes in the prior art or related technologies.

[0004] In view of this, an embodiment of the first aspect of the present invention provides a battery panel.

[0005] A second aspect of this utility model provides a top cover assembly.

[0006] A third aspect of this utility model provides a battery module.

[0007] An embodiment of the fourth aspect of this utility model provides an electrical device.

[0008] To achieve the above objectives, embodiments of this utility model provide a battery panel, comprising: a panel body, the panel body including a connection area and an assembly area, the panel body having a first side and a second side opposite to each other; a plurality of connection bases, each connection base being disposed on the first side of the connection area; a plurality of embedded connectors, at least some of the embedded connectors being disposed within the connection bases, the embedded connectors being made of a conductive material; wherein, the panel body, the connection bases and the embedded connectors are integrally injection molded.

[0009] The battery panel proposed in this utility model includes a panel body, connecting bases, and embedded connectors. Multiple dispersed connecting bases are directly injection molded onto the panel body, forming a standardized, integrated module. This eliminates the need for pre-assembly, effectively reducing assembly complexity and lowering costs to some extent. Specifically, the panel body is divided into a connecting area and an assembly area, with opposite sides designated as the first and second sides. Multiple connecting bases are positioned in the connecting area, enabling high-voltage electrical connections. The assembly area primarily provides a secure connection to a specific cover of the battery. This clear functional division allows for better location of faults in case of malfunction, thereby improving maintenance efficiency.

[0010] The connection area and assembly area are not planar partitions, but three-dimensional functional modules that work together through structural continuity. The connection area realizes the electrical connection between the inside and outside of the battery, such as current input, current output or protection, while the assembly area realizes mechanical fixation and sealing. It can be understood that the material of the embedded connector is conductive, that is, a conductive material. Under the action of the embedded connector, a conductive channel can be formed, connecting the inside and outside of the battery panel, that is, the first side and the second side. The first side is the outside and can be connected to the external high-voltage plug, while the second side is the inside and can be connected to the internal copper busbar or wire harness.

[0011] It is important to emphasize that in this solution, the panel body and connecting base are injection molded together, and the conductive embedded connectors are also processed together through injection molding. This effectively improves the integration of the resulting battery panel. Multiple connecting bases and the panel body are integrated into a single workpiece, improving assembly efficiency and reducing the risk of misalignment or omissions that may occur when multiple components are installed independently. Of course, since the battery panel is a single, independent structure, compared to solutions where multiple independent bases are assembled onto the panel, the number of sealing positions is reduced, and the number of auxiliary parts such as seals, fasteners, or brackets required is also reduced accordingly.

[0012] In some technical solutions, optionally, the connection base includes: an electrode base, the electrode base protruding from the surface of a first side of the connection area; wherein, the electrode base is provided with a first mounting hole, the first mounting hole passing through the first side of the connection area and the second side of the connection area; wherein, a portion of the embedded connector is disposed in the first mounting hole, and the embedded connector located in the first mounting hole is used to connect the copper busbar.

[0013] In this technical solution, the connecting base can specifically be a protruding electrode base, protruding from the surface of the first side of the connecting area. By making the electrode base protrude, it facilitates user assembly and increases the spatial distance with adjacent connecting bases, thus achieving insulation. It should be added that the electrode base has a through first mounting hole. By partially embedding a connector within the first mounting hole, the external interface on the first side and the internal copper busbar on the second side can be connected under the action of the embedded connector.

[0014] In some technical solutions, the embedded connector may optionally include an electrically connected connector and a first nut, the connector being disposed in a first mounting hole and the first nut being disposed on a second side of the electrode base.

[0015] In this technical solution, regarding the electrode base, the embedded connector within the electrode base includes a connector and a first nut, wherein the connector and the first nut are electrically connected. The connector is located within a first mounting hole, and the first nut is located on the second side of the electrode base. The joint action of the connector and the first nut establishes a conductive path from the first side to the second side. Specifically, the connector is mainly used to connect external power supply wires, while the first nut is used to connect the internal copper busbar connected to the battery cell. Through their combined action, external charging and discharging of the internal battery can be achieved.

[0016] In some technical solutions, the electrode base may optionally include a positive electrode connection base and a negative electrode connection base that are spaced apart.

[0017] In this technical solution, the electrode bases are divided into two types: positive electrode connection bases and negative electrode connection bases. These are spaced apart within the connection area and arranged separately to avoid direct contact. The positive electrode connection base serves as the supporting structure for the positive electrical connection in the battery pack, connecting the positive copper busbar or wire. The negative electrode connection base serves as the supporting structure for the negative electrical connection in the battery pack, connecting the negative copper busbar or wire.

[0018] In some technical solutions, the connecting base may optionally include: a disconnecting switch base, a surface protruding from a first side of the connecting area, and a second mounting hole provided in the disconnecting switch base, wherein a portion of the embedded connector is disposed in the second mounting hole, and the embedded connector located in the second mounting hole is used to connect the disconnecting plug.

[0019] In this technical solution, the disconnect switch base is located on the first side of the connection area, protruding from the surface of the panel body, specifically from the surface of the first side of the connection area, facilitating mating with the disconnect plug. A second mounting hole is provided on the disconnect switch base for installing and fixing electrical connectors. The embedded connector located within the second mounting hole is used to connect the disconnect plug, realizing the electrical connection of the disconnect switch. The disconnect switch base protrudes from the first side, providing mechanical support and a connection interface for the disconnect switch. The protruding design facilitates operation and insertion / removal of the disconnect plug. The second mounting hole provides the installation position for the embedded connector; its diameter ensures the positioning and fixation of the embedded connector. The embedded connector serves as an electrical connection terminal, connecting to the conductive end of the disconnect plug.

[0020] In summary, this solution achieves a reliable connection between the disconnector and the external circuit through the protruding base of the disconnector on the first side and the internal second mounting hole, along with the embedded connector. It offers advantages such as convenient operation, robust connection, and high safety and reliability, making it suitable for applications requiring high isolation and connectivity in high-voltage battery packs or electrical systems.

[0021] In some technical solutions, the embedded connector optionally includes an electrically connected fin and a screw, with the fin disposed in the second mounting hole of the disconnector base and the screw disposed on the second side of the disconnector base.

[0022] In this technical solution, the fin component is set in the second mounting hole of the disconnector base and embedded in the hole wall. It mainly serves as an electrical connector and is directly fixed in the hole by insert injection molding to ensure a stable electrical connection. It should be noted that the fin component is a metal sheet with multiple "fins" or "blades", and its shape is similar to a flat sheet or strip structure. The fin design can increase the contact area and reduce the contact resistance.

[0023] In some technical solutions, optionally, a fuse base is also included, located on the second side of the connection area, and a third mounting hole is provided in the fuse base, with an embedded connector provided in the third mounting hole.

[0024] In this technical solution, the fuse base is installed on the second side of the connection area, opposite to the first side where the aforementioned electrode base and disconnector base are located. The fuse base serves as a platform for installing and connecting the fuse. A third mounting hole is located inside the fuse base for installing an embedded connector. The third mounting hole penetrates or partially penetrates the fuse base, and its dimensions match those of the embedded connector.

[0025] The fuse base provides a stable mounting position for the fuse, ensuring that the fuse is fixed in place. At the same time, the fuse base serves as a carrier for the electrical connection between the fuse and the rest of the battery pack, achieving conductivity through the built-in third mounting hole and embedded connector.

[0026] In some technical solutions, optionally, the assembly area surrounds the connecting area, and the connecting area protrudes from the assembly area; wherein, a plurality of positioning posts are provided on the first side of the assembly area, and each positioning post is provided with an embedded connector for connecting the upper cover.

[0027] In this technical solution, the connection area is located at the center or core of the panel body, and the structure protrudes from the surface of the assembly area. Electrical connection bases, namely electrode bases, disconnector bases, fuse bases, etc., are centrally arranged to achieve the integration of electrical modules.

[0028] The connection area protrudes from the assembly area, making the electrical connection parts (connection base, embedded connector) higher than the surrounding assembly area, which facilitates the contact and connection of electrical interfaces. The protruding structure is beneficial for the protection and positioning of electrical connectors.

[0029] The positioning posts serve as mechanical connection points, assisting in the positioning and fixing of the upper cover, ensuring precise alignment between the upper cover and the panel body, avoiding misalignment and sealing failure. The distribution of multiple positioning posts evenly distributes mechanical stress, thereby improving connection strength.

[0030] A second aspect of this application provides a top cover assembly, comprising: a top cover body; and a battery panel of any of the above embodiments, detachably connected to the top cover body.

[0031] The top cover assembly provided in this application includes a detachably connected top cover body and a battery panel. The battery panel and the top cover body are connected by mechanical fasteners (such as bolts or screws). The specific connection method relies on the positioning posts and their embedded connectors (such as injection-molded nuts) in the battery panel assembly area, which cooperate with the corresponding threaded holes or bolts on the top cover body.

[0032] Since the top cover assembly includes any of the aforementioned battery panels, it has the beneficial effects of any of the aforementioned battery panels, which will not be elaborated further here.

[0033] A third aspect of this application provides a battery module, comprising: a housing, wherein at least one battery cell is disposed within the housing; and the aforementioned top cover assembly, which is detachably connected to the housing.

[0034] The battery module provided in this application includes a housing and a top cover assembly. The housing serves as the main structure of the battery module, housing and protecting the internal battery cells and related electrical components, providing mechanical support, structural stability, and certain protective functions such as dustproof, waterproof, and impact resistance. The battery cells are installed inside the housing, fixed securely to prevent vibration and collision, and are electrically connected through the battery panel and connecting base.

[0035] The battery cell is electrically connected and managed through the electrode base, disconnect switch base, fuse base, etc. in the battery panel.

[0036] Since the battery module includes the aforementioned top cover assembly, it has the same beneficial effects as the aforementioned top cover assembly, which will not be elaborated further here.

[0037] The fourth aspect of this application provides an electrical device, including the aforementioned battery module.

[0038] The electrical equipment provided in this application includes a battery module. Since the electrical equipment includes any of the aforementioned battery modules, it has the beneficial effects of the aforementioned battery modules, which will not be elaborated here.

[0039] Among them, electrical equipment refers to the entire equipment including battery modules, such as electric vehicles, power tools, and energy storage devices.

[0040] Additional aspects and advantages of this invention will become apparent in the description that follows, or may be learned by practice of this invention. Attached Figure Description

[0041] Figure 1 A schematic diagram of the structure of a battery panel according to an embodiment of the present invention is shown;

[0042] Figure 2 A schematic diagram of the structure of a battery panel according to an embodiment of the present invention is shown;

[0043] Figure 3 A schematic diagram of the structure of a battery panel according to an embodiment of the present invention is shown;

[0044] Figure 4 A schematic diagram of the structure of the top cover assembly according to an embodiment of the present invention is shown;

[0045] Figure 5 A schematic diagram of the structure of a battery module according to an embodiment of the present invention is shown.

[0046] in, Figures 1 to 5 The correspondence between the reference numerals and component names in the attached drawings is as follows:

[0047] 100: Battery panel; 102: Panel body; 1022: Connection area; 1024: Assembly area; 104: Connection base; 1042: First mounting hole; 106: Embedded connector; 108: Electrode base; 1082: Positive electrode connection base; 1084: Negative electrode connection base; 1102: Connector; 1104: First nut; 112: Disconnect switch base; 1122: Second mounting hole; 1142: Fin component; 1144: Screw component; 116: Fuse base; 1162: Third mounting hole; 118: Positioning post; 120: Limiting plate;

[0048] 200: Top cover assembly; 202: Top cover body;

[0049] 300: Battery module; 302: Housing; 3022: Battery cell. Detailed Implementation

[0050] To better understand the above-mentioned objectives, features, and advantages of the embodiments of this utility model, the embodiments of this utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0051] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, embodiments of the present invention may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0052] The following reference Figures 1 to 5 Some embodiments according to the present invention are described.

[0053] like Figure 1 , Figure 2 and Figure 3 As shown, this embodiment provides a battery panel 100, including a panel body 102, connecting bases 104, and embedded connectors 106. Multiple dispersed connecting bases 104 are directly injection molded onto the panel body 102, forming a standardized integrated module. This eliminates the pre-assembly process, effectively reducing assembly complexity and lowering costs to some extent. Specifically, the panel body 102 is divided into a connecting area 1022 and an assembly area 1024, with opposite sides designated as the first and second sides. Multiple connecting bases 104 are positioned on the connecting area 1022. The connecting area 1022 enables high-voltage electrical connections via the connecting bases 104, while the assembly area 1024 primarily achieves a stable connection with a specific cover of the battery. This clear functional division allows for better location identification of faults, thereby improving maintenance efficiency.

[0054] The connection area 1022 and the assembly area 1024 are not planar partitions, but three-dimensional functional modules that work together through structural continuity. The connection area 1022 realizes the electrical connection between the inside and outside of the battery, such as current input, current output or protection, while the assembly area 1024 realizes mechanical fixation and sealing. It can be understood that the material of the embedded connector 106 is conductive, that is, a conductive material. Under the action of the embedded connector 106, a conductive channel can be formed, connecting the inside and outside of the battery panel 100, that is, the first side and the second side. The first side is the outside and can be connected to the external high-voltage plug, while the second side is the inside and can be connected to the internal copper busbar or wire harness.

[0055] It is important to emphasize that in this solution, the panel body 102 and the connecting base 104 are injection molded together, and the conductive embedded connector 106 is also processed together with them by injection molding. This effectively improves the integration of the formed battery panel 100. Multiple connecting bases 104 and the panel body 102 are combined into one workpiece, improving assembly efficiency and reducing the risk of misalignment and omissions that may occur when multiple parts are installed independently. Of course, since the battery panel 100 is a single, independent structure, compared to solutions where multiple independent bases are assembled onto the panel, the number of sealing positions is reduced, and the number of auxiliary parts such as seals, fasteners, or brackets required is also reduced accordingly.

[0056] Furthermore, the embedded connector 106 is made of copper and can be integrally injection molded with the panel body 102 and the connecting base 104 through an insert injection molding process.

[0057] Among them, the panel body 102, as a whole, needs to be stable in the working environment. The material can be engineering plastic to ensure that it does not degrade in the humid and hot environment of the battery pack.

[0058] It is understandable that by integrally injection molding the panel body 102, multiple connecting bases 104, and embedded connectors 106, a high degree of modularity and integration of electrical connectors within the battery pack is achieved. The integration of multiple electrical connecting bases 104 and embedded connectors 106 into a single panel body 102 eliminates the need for dispersed installation and multiple alignment steps, reducing assembly steps and processes.

[0059] The embedded connector 106 is molded from a highly conductive material to ensure low resistance and high stability of the electrical connection. The tight fit between the connecting base 104 and the embedded connector 106 ensures long-term reliability of mechanical strength and electrical contact.

[0060] The connecting base 104 is centrally arranged on the first side of the connecting area 1022 of the panel. The assembly area 1024 is separated from the connecting area 1022, which rationally allocates space and facilitates interface with other components. The panel body 102 is rationally designed to ensure overall size control and facilitate integration into the battery pack.

[0061] One-piece injection molding reduces the number of parts and assembly steps, lowers material procurement and inventory management costs, reduces labor costs and assembly time, and improves production efficiency.

[0062] Furthermore, the panel body 102 is made of plastic, such as PPO or PA66, to ensure the panel's insulation and mechanical strength. The connection area 1022 is a dedicated area on the panel body 102, used to house multiple connection bases 104 for centralized management of electrical connection interfaces. Specifically located on the first side of the panel body 102, it facilitates docking with electrical components or copper busbars within the battery pack. The centralized design of the connection area 1022 facilitates unified management and maintenance of high-voltage electrical interfaces, and also ensures the orderly arrangement of the connection bases 104, enabling quick plugging and unplugging and inspection.

[0063] like Figure 1 As shown, in some embodiments, optionally, the connecting base 104 can be a protruding electrode base 108, specifically protruding from the surface of the first side of the connecting area 1022. By making the electrode base 108 protrude, it facilitates user assembly and increases the spatial distance with adjacent connecting bases 104, thus achieving insulation. It should be added that the electrode base 108 has a through first mounting hole 1042. By partially embedding the connector 106 within the first mounting hole 1042, the external interface on the first side and the internal copper busbar on the second side can be connected under the action of the embedded connector 106.

[0064] It is understood that this solution provides a protruding electrode base 108 within the connection area 1022, and a through first mounting hole 1042 within the base, forming a structure with both conductive connection and mechanical fixing functions. The partially embedded connector 106 is embedded within the first mounting hole 1042, ensuring the stability and convenience of the electrical connection.

[0065] The embedded connector 106 is tightly engaged with the electrode base 108 through the first mounting hole 1042, ensuring low impedance and a secure connection in the conductive path. The electrode base 108 protrudes from the first side of the connection area 1022, providing mechanical support and positioning reference, facilitating docking with copper busbars or other electrical components. The through-hole 1042 achieves spatial integration of conductivity and fixation, reducing additional parts and assembly steps.

[0066] like Figure 1 and Figure 3 As shown, in some embodiments, optionally, for the electrode base 108, the embedded connector 106 disposed within the electrode base 108 includes a connector 1102 and a first nut 1104, wherein the connector 1102 and the first nut 1104 are conductive. The connector 1102 is disposed within the first mounting hole 1042, and the first nut 1104 is disposed on the second side of the electrode base 108. Under the combined action of the connector 1102 and the first nut 1104, a conductive path can be established from the first side to the second side. Specifically, the connector 1102 is mainly used to connect external power supply wires, and the first nut 1104 is used to connect the internal copper busbar connected to the battery cell 3022. Under the action of both, external charging and discharging of the internal battery can be realized.

[0067] It should be added that the connector 1102 is usually made of metal, such as copper or copper alloy, and its shape is adapted to the inner diameter of the first mounting hole 1042. Specifically, it can be in the form of a pin or a contact terminal to ensure tight contact with the copper busbar or wire. By embedding the connector 1102 into the first mounting hole 1042, the electrical path is ensured to be continuous and the impedance is low.

[0068] The first nut 1104 on the inner side is mainly used to connect the copper busbar inside the battery, ensuring a reliable connection and low impedance conduction between the copper busbar and the electrode base 108, making it easier for internal electrical wiring and maintenance, and ensuring the stability of the internal electrical system of the battery pack.

[0069] The first mounting hole 1042 penetrates the electrode base 108, the connector 1102 is embedded in the first mounting hole 1042, and the first nut 1104 is located at the other end of the first mounting hole 1042.

[0070] like Figure 1As shown, in some embodiments, the electrode base 108 is optionally divided into two types: a positive electrode connection base 1082 and a negative electrode connection base 1084. These are spaced apart within the connection area 1022 and arranged separately to avoid direct contact. The positive electrode connection base 1082 serves as the supporting structure for the positive electrical connection in the battery pack, connecting the positive copper busbar or wire. The negative electrode connection base 1084 serves as the supporting structure for the negative electrical connection in the battery pack, connecting the negative copper busbar or wire.

[0071] Physical separation prevents direct contact between positive and negative terminals, thus avoiding the risk of short circuits. The spacing design, combined with insulating materials, enhances the safety performance of the battery pack. Clear spatial division ensures the electrical safety and stability of the positive and negative connections, preventing short circuit risks caused by vibration or assembly errors.

[0072] like Figure 1 As shown, in some embodiments, optionally, the disconnector base 112 is located on the first side of the connection area 1022, protruding from the surface of the panel body 102, specifically protruding from the surface of the first side of the connection area 1022, to facilitate docking with the disconnector plug. A second mounting hole 1122 is provided on the disconnector base 112 for installing and fixing electrical connectors. The embedded connector 106 located within the second mounting hole 1122 is used to connect the disconnector plug, realizing the electrical connection of the disconnector switch. The disconnector base 112 protrudes from the first side, providing mechanical support and a connection interface for the disconnector switch. The protruding design facilitates operation and insertion / removal of the disconnector plug. The second mounting hole 1122 provides the installation position for the embedded connector 106, and the hole diameter ensures the positioning and fixation of the embedded connector 106. The embedded connector 106 serves as an electrical connection terminal, connecting to the conductive end of the disconnector plug.

[0073] In summary, this solution, through the protruding disconnector base 112 on the first side and the internal second mounting hole 1122, in conjunction with the embedded connector 106, achieves a reliable connection between the disconnector and the external circuit. It offers advantages such as convenient operation, robust connection, and high safety and reliability, making it suitable for applications requiring high isolation and connectivity in high-voltage battery packs or electrical systems.

[0074] like Figure 1 and Figure 2 As shown, in some embodiments, optionally, the fin member 1142 is disposed in the second mounting hole 1122 of the disconnector base 112 and embedded in the hole wall. It mainly serves as an electrical connector and is directly fixed in the hole by insert injection molding to ensure a stable electrical connection. It should be noted that the fin member 1142 is a metal sheet with multiple "fins" or "blades", and its shape is similar to a flat sheet or strip structure. The fin design can increase the contact area and reduce the contact resistance.

[0075] The fin 1142 acts as an electrical conductor, connecting the isolation plug or external wires to ensure efficient current transmission.

[0076] The screw 1144 is located on the second side of the disconnector base 112, that is, the back or internal space of the base. It is connected to the fin 1142 via the screw 1144, or used as a fastener to fix the wires / copper busbars.

[0077] Furthermore, the screw component 1144 is typically a metal bolt, screw, or stud. The copper busbar is located inside the battery and connected to the other end of the screw component 1144. The copper busbar is screwed into the threaded portion of the screw by bolts or screws. After the screw is tightened, the copper busbar is locked onto the screw component 1144, forming a strong conductive connection.

[0078] In summary, one end of the screw 1144 is connected to the finned component 1142 inside the disconnector base 112, and the other end is directly connected to the copper busbar inside the battery. As a mechanical connector, the screw 1144 firmly connects the internal copper busbar to the finned component 1142, ensuring conductivity and mechanical strength. The threaded fastening achieves stable clamping between the copper busbar and the finned component 1142, preventing loosening.

[0079] The finned element 1142 is embedded in the second mounting hole 1122 of the disconnector base 112, connected to one end of the screw element 1144, and the other part is connected to the external disconnector plug. The finned element 1142 serves as an electrical conduction medium, transferring the current from the internal copper busbar through the screw element 1144 to the finned element 1142, and then to the external disconnector plug, thus achieving circuit connection and disconnection. Furthermore, the finned element 1142 provides a large surface area through its fin structure, which helps dissipate the heat generated by the passing current, reducing local temperature and improving system safety and stability.

[0080] The internal battery copper busbar is mechanically and electrically connected to the finned component 1142 via a screw component 1144. Current flows from the copper busbar to the screw, and then through the screw component 1144 to the finned component 1142. The finned component 1142 not only serves as a conductive terminal but also dissipates heat through its heat dissipation fin structure while conducting current to the external isolation plug, achieving efficient and safe electrical isolation and connection. The isolation plug, through its connection with the finned component 1142, enables the circuit to be opened or closed, completing the electrical management of the battery pack.

[0081] It is understandable that the screw component 1144 acts as a connecting bridge, with one end connected to the internal copper busbar and the other end connected to the fin component 1142. The fin component 1142 not only performs the function of electrical connection to the isolation plug, but also undertakes the task of heat dissipation. This design takes into account electrical performance, mechanical stability and thermal management, and is suitable for the high safety and reliability requirements of high-voltage battery packs.

[0082] like Figure 3As shown, in one embodiment, a limiting plate 120 is provided on the second side of the assembly area 1024. By avoiding the connection area 1022, the space for the structure to make electrical connections in the connection area 1022 is guaranteed. At the same time, the limiting plate 120 can also be used to position the copper busbar during the installation process.

[0083] In some embodiments, optionally, the fuse base 116 is mounted on the second side of the connection area 1022, opposite to the first side where the aforementioned electrode base 108 and disconnector base 112 are located. The fuse base 116 serves as a mounting and connection platform for the fuse. A third mounting hole 1162 is provided inside the fuse base 116 for mounting the embedded connector 106. The third mounting hole 1162 penetrates or partially penetrates the fuse base 116, and its size matches that of the embedded connector 106.

[0084] The fuse base 116 provides a stable mounting position for the fuse, ensuring that the fuse is fixed and does not loosen. At the same time, the fuse base 116 serves as a carrier for the electrical connection between the fuse and the rest of the battery pack, and achieves conductivity through the built-in third mounting hole 1162 and the embedded connector 106.

[0085] The fuse base 116 is located on the second side of the connection area 1022, forming a spatial separation with the electrode base 108 and the disconnect switch base 112 to avoid interference. The connector 106 is embedded in the third mounting hole 1162 to connect the electrical terminals of the fuse. The fuse is connected to the battery pack electrical system through the embedded connector 106 to realize the overcurrent protection function.

[0086] In summary, the fuse base 116, as an important structure for the electrical protection of the battery pack, is located on the second side of the connection area 1022. It has a third mounting hole 1162 and an embedded connector 106 to ensure the reliable installation and electrical connection of the fuse. This achieves an effective combination of protection function and structural integration, improving the overall safety and assembly efficiency of the battery pack.

[0087] Based on any of the above embodiments, the connection area 1022 is located at the center or core of the panel body 102, and its structure protrudes from the surface of the assembly area 1024. Electrical connection bases 104, namely electrode bases 108, disconnector bases 112, fuse bases 116, etc., are centrally arranged to realize the integration of electrical modules.

[0088] The assembly area 1024 surrounds the periphery of the connection area 1022, is flat or slightly lower than the protrusion height of the connection area 1022, and serves as a functional area for the mechanical connection between the panel body 102 and the battery pack cover 202.

[0089] Positioning posts 118 are located on the first side of the assembly area 1024, which is also the side of the panel body 102 facing the upper cover 202. Embedded connectors 106 are embedded in each positioning post 118 and are used to cooperate with bolts or fasteners on the upper cover 202 to achieve mechanical connection. Among them, the embedded connectors 106 are injection-molded nuts or metal inserts.

[0090] Furthermore, multiple positioning posts 118 are evenly distributed to form support points for fixing and positioning the upper cover 202.

[0091] The assembly area 1024 surrounds the connection area 1022, forming the outer structure of the panel body 102. It provides mechanical support and assembly interface, protects the electrical structure of the connection area 1022, avoids external mechanical impact from directly acting on the connection area 1022, facilitates the arrangement of sealing elements such as sealing rings and gaskets, and improves the airtightness of the battery pack.

[0092] The connection area 1022 protrudes from the assembly area 1024, making the electrical connection part (connection base 104, embedded connector 106) higher than the surrounding assembly area 1024, which facilitates the contact and connection of the electrical interface. The protruding structure is beneficial for the protection and positioning of the electrical connector.

[0093] The positioning post 118 serves as a mechanical connection point, assisting in the positioning and fixing of the upper cover 202, ensuring the precise alignment of the upper cover 202 with the panel body 102, avoiding misalignment and sealing failure. The distribution of multiple positioning posts 118 evenly distributes mechanical stress and enhances connection strength.

[0094] In summary, this solution effectively achieves the mechanical connection and positioning of the battery pack panel body 102 and the upper cover 202 by setting the assembly area 1024 as the outer structure surrounding the connection area 1022 and designing multiple positioning posts 118 with embedded connectors 106 on the first side of the assembly area 1024. The protruding design of the connection area 1022 improves the reliability and convenience of the electrical connection, while the positioning posts 118 and embedded connectors 106 of the assembly area 1024 ensure the stability of the overall structure and the convenience of maintenance. The overall design takes into account electrical performance, mechanical strength, assembly efficiency, and subsequent maintenance needs, making it suitable for practical applications of high-performance battery pack systems.

[0095] In addition, a sealing ring can be provided within the connection area 1022 to achieve a sealed connection of the battery panel 100.

[0096] like Figure 4As shown, another embodiment of this application provides a top cover assembly 200, including a detachably connected top cover body 202 and a battery panel 100, wherein the battery panel 100 and the top cover body 202 are connected by mechanical fasteners (such as bolts or screws). Specifically, the connection method relies on the positioning post 118 in the assembly area 1024 of the battery panel 100 and its embedded connector (such as injection nut), which cooperates with the corresponding threaded hole or bolt on the top cover body 202.

[0097] Since the top cover assembly 200 includes any of the aforementioned battery panels 100, it has the beneficial effects of any of the aforementioned battery panels 100, which will not be elaborated here.

[0098] like Figure 5 As shown, another embodiment of this application provides a battery module 300, including a housing 302 and a top cover assembly 200. The housing 302 serves as the main structure of the battery module 300, housing and protecting the internal battery cells 3022 and related electrical components, providing mechanical support, structural stability, and certain protective functions such as dustproof, waterproof, and impact resistance. The battery cells 3022 are installed inside the housing 302, fixed securely to prevent vibration and collision, and are electrically connected through the battery panel 100 and the connecting base 104.

[0099] The battery cell 3022 is electrically connected and managed through the electrode base 108, the disconnect switch base 112, the fuse base 116, etc. in the battery panel 100.

[0100] Since the battery module 300 includes the aforementioned cover assembly 200, it has the beneficial effects of the aforementioned cover assembly 200, which will not be elaborated here.

[0101] Another embodiment of this application provides an electrical device including a battery module 300. Since the electrical device includes any of the above-mentioned battery modules 300, it has the beneficial effects of the above-mentioned battery modules 300, which will not be repeated here.

[0102] Among them, electrical equipment refers to the entire equipment including battery module 300, such as electric vehicles, power tools, energy storage devices, etc.

[0103] In a specific embodiment, the structural design scheme of mounting external electrical modules on the front panel in related technologies has the following problems: complex assembly process and low structural reliability. Based on system functional requirements, the battery pack needs to integrate multiple electrical units such as fuses, high-voltage power connectors, and manual service disconnect (MSD). Traditional processes use a modular pre-assembly structure, where each electrical component is first assembled onto an independent mounting cover, and then the entire assembly is reassembled onto the battery pack body. This multi-stage assembly process not only increases process complexity but also causes contact impedance accumulation due to the stacked connections of connectors, leading to decreased system structural stability, potential safety risks, and high processing costs. In current designs, each independent functional unit requires a dedicated mounting base, supplemented by connecting components to form a modular unit, resulting in high material costs. Traditional electrical mounting covers have multiple holes for assembling electrical components, posing a risk of airtightness failure. This embodiment proposes an integrated modular structure design for electrical components. This structure uses injection molding to integrate all electrical component bases, such as positive / negative connector bases, MSD bases, and fuse bases, into a single electrical mounting panel. This integrated electrical mounting panel integrates positive / negative connection sockets, MSD disconnect switches, fuses, etc. It eliminates the pre-assembly process, effectively reducing assembly complexity, lowering costs to some extent, and improving airtight reliability.

[0104] The integrated electrical modular structure includes: an integrated electrical mounting panel (i.e., panel body 102), a battery negative terminal connection base (i.e., negative terminal connection base 1084), a battery positive terminal connection base (i.e., positive terminal connection base 1082), a disconnect switch connection base (i.e., disconnect switch base 112), a fuse mounting base (fuse base 116), a copper busbar mounting limit plate 120, a step, a bolt mounting positioning post 118, and an injection-molded insert (i.e., embedded connector 106).

[0105] The integrated electrical mounting panel is made of plastic, with optional materials including but not limited to PPO, PP, PA6, PA66, and PBT, and a main wall thickness of 1.5mm to 3.5mm. The battery negative terminal connection base 1084 is integrally injection molded with the electrical mounting panel, and is cylindrical in shape, with optional diameters of 20mm to 30mm and heights of 20mm to 30mm. The battery negative terminal connection base 1084 has an embedded injection-molded nut (i.e., the first nut 1104) for connection to the copper busbar; the nut is generally made of copper, with optional specifications of M6 to M10.

[0106] The battery positive terminal connection base 1082 is integrally injection molded with the electrical mounting panel. It is cylindrical in shape, with selectable diameters of 20mm to 30mm and heights of 20mm to 30mm. The battery positive terminal connection base 1082 has an embedded injection-molded nut for connection to the copper busbar. The nut is typically made of copper and is available in sizes from M6 to M10.

[0107] The disconnector connection base 104 is integrally injection molded with the electrical mounting panel. It is rectangular in shape and compatible with the optional MSD plug. It has embedded copper fins (i.e., fin part 1142) for electrical connection and an embedded injection molded screw (i.e. screw part 1144) for connection with the copper busbar.

[0108] The fuse mounting base is integrally injection molded with the electrical installation panel. Its shape includes, but is not limited to, cylindrical and cuboid shapes. It is used to place the fuse and has an embedded injection-molded copper nut (i.e., the third mounting hole 1162). The nut can be selected from M5 to M10 and is used to connect the fuse to the copper busbar.

[0109] The limiting plate 120 for copper busbar installation has a thickness of 1.5mm to 2.5mm and a height of 5mm to 10mm. It is used for positioning the copper busbar during the installation process.

[0110] The step, with a height of 3mm to 8mm, is where a sealing ring can be attached to meet the airtightness requirements of the battery pack;

[0111] The bolt-mounted positioning post 118 has a height of 1.5mm to 4mm and corresponds to the hole position on the battery pack cover. It is embedded with an injection-molded copper nut, and the nut size can be selected from M3 to M6. It is used to connect with the battery pack cover.

[0112] In this utility model, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "install," "connect," "join," and "fix" should be interpreted broadly. For example, "connect" can be a fixed connection, a detachable connection, or an integral connection; "join" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0113] In the description of this utility model, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", 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 this utility model and simplifying the description, and do not indicate or imply that the device or unit 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 this utility model.

[0114] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0115] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A battery panel, characterized in that, include: A panel body, the panel body including a connection area and an assembly area, the panel body having a first side and a second side opposite to each other; Multiple connecting bases, each of the connecting bases being disposed on a first side of the connecting area; Multiple embedded connectors, at least some of which are disposed within the connecting base, wherein the embedded connectors are made of a conductive material; The panel body, the connecting base, and the embedded connector are integrally injection molded.

2. The battery panel according to claim 1, characterized in that, The connecting base includes: An electrode base that protrudes from the surface of a first side of the connection area; The electrode base is provided with a first mounting hole, which passes through the first side of the connection area and the second side of the connection area. Some of the embedded connectors are disposed in the first mounting hole, and the embedded connectors located in the first mounting hole are used to connect copper busbars.

3. The battery panel according to claim 2, characterized in that, The embedded connector includes an electrically connected connector and a first nut. The connector is disposed in the first mounting hole, and the first nut is disposed on the second side of the electrode base.

4. The battery panel according to claim 2, characterized in that, The electrode base includes a positive electrode connection base and a negative electrode connection base arranged at intervals.

5. The battery panel according to claim 1, characterized in that, The connecting base includes: The disconnect switch base protrudes from the surface of the first side of the connection area, and the disconnect switch base is provided with a second mounting hole. Some of the embedded connectors are disposed within the second mounting hole, and the embedded connectors located within the second mounting hole are used to connect the isolation plug.

6. The battery panel according to claim 5, characterized in that, The embedded connector includes an electrically connected fin and a screw. The fin is disposed in the second mounting hole of the disconnector base, and the screw is disposed on the second side of the disconnector base.

7. The battery panel according to claim 1, characterized in that, Also includes: A fuse base is provided on the second side of the connection area, and a third mounting hole is provided in the fuse base, and the embedded connector is provided in the third mounting hole.

8. The battery panel according to claim 1, characterized in that, The assembly area surrounds the connecting area, and the connecting area protrudes from the assembly area; The first side of the assembly area is provided with multiple positioning posts, and each positioning post is provided with an embedded connector for connecting the upper cover.

9. A top cover assembly, characterized in that, include: Upper cover; The battery panel as described in any one of claims 1 to 8 is detachably connected to the upper cover.

10. A battery module, characterized in that, include: The housing contains at least one battery cell; The top cover assembly as described in claim 9 is detachably connected to the housing.

11. An electrical appliance, characterized in that, include: The battery module as described in claim 10.

Images