A power battery pack

Abstract

The utility model discloses a kind of power battery packs, comprising: battery pack box cover, jumper copper bar, integrated busbar and battery cell module are sequentially arranged from top to bottom, first force component is equipped between battery pack box cover and jumper copper bar, the gravity of battery pack box cover is passed to jumper copper bar by first force component;Second force component is equipped between jumper copper bar and integrated busbar, the gravity of jumper copper bar is passed to integrated busbar by second force component;Third force component is equipped between integrated busbar and battery cell module, the gravity of integrated busbar is passed to battery cell module by third force component.This power battery pack is from battery pack box cover, jumper copper bar, integrated busbar to battery cell module, each structure between all be equipped with for realizing support force component, realize from battery pack box cover, jumper copper bar, integrated busbar to battery cell module Integrated force design, can help to improve the reliability and stability of each structure of power battery pack, simultaneously also make each structure realize close cooperation.

Description

Technical Field

[0001] This utility model relates to the field of power battery pack technology, and in particular to a power battery pack. Background Technology

[0002] The rapid development of the new energy vehicle industry and its related power battery industry has led to a continuous increase in the demand for energy density in power battery packs. Among these trends, lightweight power battery packs and large-module or even module-less solutions are emerging industry trends, which are also driving the development of integrated busbars towards lighter weight and greater integration.

[0003] The poor load-bearing mechanism between the various parts or components of the power battery pack from top to bottom (such as the battery pack cover, integrated busbar, and cell module) has a certain impact on the structural reliability of the various parts or components of the power battery pack and the tight cooperation between them, which can affect the structural reliability of the power battery pack. Utility Model Content

[0004] In view of this, the present invention provides a power battery pack that can help improve the reliability and stability of each structure of the power battery pack, and at the same time enable the various structures to cooperate closely to ensure the reliability of the power battery pack structure.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A power battery pack includes: a battery pack cover, a crossover copper busbar, an integrated busbar, and a battery cell module arranged sequentially from top to bottom. A first load-bearing component is provided between the battery pack cover and the crossover copper busbar, and the weight of the battery pack cover is transferred to the crossover copper busbar through the first load-bearing component.

[0007] A second load-bearing component is provided between the bridging copper busbar and the integrated busbar, and the gravity of the bridging copper busbar is transmitted to the integrated busbar through the second load-bearing component;

[0008] A third load-bearing component is provided between the integrated busbar and the battery cell module, and the gravity of the integrated busbar is transmitted to the battery cell module through the third load-bearing component.

[0009] Preferably, the first load-bearing component includes a first load-bearing buffer component;

[0010] The first load-bearing buffer component is disposed on the inner wall of the battery pack cover and is used to overlap the top of the crossover copper busbar.

[0011] Preferably, the first load-bearing cushioning component includes a first foam.

[0012] Preferably, the second load-bearing component includes a second load-bearing buffer component;

[0013] The second load-bearing buffer component is disposed on the top of the integrated busbar and is used to support the bottom of the crossover copper busbar.

[0014] Preferably, the second load-bearing cushioning component includes a second foam.

[0015] Preferably, the portion of the integrated busbar used for mounting the second foam is recessed downwards to form a groove;

[0016] The second foam is installed in the groove of the integrated busbar, and its top protrudes from the integrated busbar.

[0017] Preferably, the integrated busbar includes: an insulating top cover plate, a vacuum-formed bracket, and an aluminum busbar;

[0018] The insulating top cover is installed on the top of the blister bracket; wherein, the edge of the insulating top cover is bent downward to form an overlapping edge, and is used to overlap the edge of the top of the blister bracket, and the middle part is provided with the groove, and is used to overlap the middle part of the top of the blister bracket;

[0019] The aluminum strip is disposed on the vacuum forming bracket and located below the insulating upper cover plate.

[0020] Preferably, the third load-bearing component includes a load-bearing overlapping component;

[0021] The load-bearing overlapping component is disposed at the bottom of the integrated busbar and is used to form a gap fit with the top of the cell module. Under the gravity of the battery pack cover, the bridging copper busbar and the integrated busbar, it can overlap the top of the cell module.

[0022] Preferably, the load-bearing overlapping component includes: a plurality of protruding feet;

[0023] Multiple protrusions are respectively disposed at the bottom of the integrated busbar, and are used to form a gap fit with the shoulders of the pairs of cells in the battery module. Under the gravity of the battery pack cover, the bridging copper busbar and the integrated busbar, they can all overlap the shoulders of the corresponding pairs of cells in the battery module.

[0024] Preferably, the gap between the protruding foot and the shoulder of each pair of cells in the corresponding group of the cell module is equal to or less than 0.5 mm.

[0025] As can be seen from the above technical solution, the power battery pack provided by this utility model has load-bearing components for support between each structure, from the battery pack cover, the crossover copper busbar, the integrated busbar to the cell module. This achieves an integrated load-bearing design from the battery pack cover, the crossover copper busbar, the integrated busbar to the cell module, which helps to improve the reliability and stability of each structure of the power battery pack. At the same time, it enables each structure to cooperate closely and ensures the reliability of the power battery pack structure. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the structure of the power battery pack provided in an embodiment of the present utility model;

[0028] Figure 2 An exploded view of the power battery pack provided in an embodiment of this utility model;

[0029] Figure 3 This is an assembly diagram of the integrated busbar and battery cell module provided in an embodiment of the present utility model;

[0030] Figure 4 This is an assembly diagram of the blister pack, aluminum busbar, and battery module provided in an embodiment of the present utility model;

[0031] Figure 5 A schematic diagram of the assembly of the cell module in the battery pack housing provided in this embodiment of the utility model;

[0032] Figure 6 This is a schematic diagram of the integrated busbar structure provided in an embodiment of the present utility model;

[0033] Figure 7 A front view of the integrated busbar structure provided in an embodiment of this utility model;

[0034] Figure 8 for Figure 7 A magnified view of a portion of the image, C;

[0035] Figure 9 A schematic diagram of the assembly of the second foam on the insulating top cover plate for an embodiment of this utility model;

[0036] Figure 10 A front view of the second foam assembled on the insulating top cover plate according to an embodiment of this utility model;

[0037] Figure 11 for Figure 3 A magnified view of a portion of the image;

[0038] Figure 12 for Figure 4 Enlarged view of part B;

[0039] Figure 13 This is an assembly side view of the blister pack and the battery module provided in an embodiment of the present invention;

[0040] Figure 14 for Figure 13 A magnified view of part D;

[0041] Figure 15 A schematic diagram of the assembly of the aluminum strip in the vacuum forming bracket provided in an embodiment of this utility model;

[0042] Figure 16 for Figure 15 A magnified view of a portion of the image, E.

[0043] Among them, 1 is the power battery pack, 101 is the battery pack cover, 102 is the bridging copper busbar, 103 is the second foam, 104 is the integrated busbar, 1041 is the insulating top cover plate, 10411 is the overlapping edge, 10412 is the groove, 1042 is the blister bracket, 1043 is the aluminum busbar, 1044 is the low-voltage signal connector, 1045 is the first snap-fit ​​hole, 1046 is the hot riveting post, 1047 is the protrusion, 105 is the cell module, 1051 is the cell, 1052 is the shoulder, and 106 is the battery pack housing. Detailed Implementation

[0044] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0045] The power battery pack provided in this embodiment of the utility model, such as Figure 1 and Figure 2 As shown, it includes: a battery pack cover 101, a bridging copper busbar 102, an integrated busbar 104 and a battery cell module 105 arranged sequentially from top to bottom. A first load-bearing component is provided between the battery pack cover 101 and the bridging copper busbar 102. The weight of the battery pack cover 101 is transmitted to the bridging copper busbar 102 through the first load-bearing component.

[0046] A second load-bearing component is provided between the bridging copper busbar 102 and the integrated busbar 104, and the gravity of the bridging copper busbar 102 is transferred to the integrated busbar 104 through the second load-bearing component;

[0047] A third load-bearing component is provided between the integrated busbar 104 and the battery cell module 105, and the gravity of the integrated busbar 104 is transmitted to the battery cell module 105 through the third load-bearing component.

[0048] It should be noted that the first load-bearing component can be set on the inner wall of the battery pack cover 101 or the top of the crossover copper busbar 102, so that the battery pack cover 101 is connected to the top of the crossover copper busbar 102 through the first load-bearing component, and the crossover copper busbar 102 supports the battery pack cover 101 through the first load-bearing component, so that the weight of the battery pack cover 101 is transferred to the crossover copper busbar 102.

[0049] The second load-bearing component can be set at the bottom of the bridging copper busbar 102 or the top of the integrated busbar 104, so that the bridging copper busbar 102 is connected to the top of the integrated busbar 104 through the second load-bearing component, and the integrated busbar 104 supports the bridging copper busbar 102 through the second load-bearing component, so that the weight of the battery pack cover 101 and the bridging copper busbar 102 is transferred to the integrated busbar 104.

[0050] The third load-bearing component can be located at the bottom of the integrated busbar 104 or the top of the cell module 105, allowing the integrated busbar 104 to connect to the top of the cell module 105 via the third load-bearing component. This also allows the cell module 105 to support the integrated busbar 104 via the third load-bearing component, thus transferring the weight of the battery pack cover 101, the connecting copper busbar 102, and the integrated busbar 104 to the cell module 105. This design ensures that each structure of the power battery pack has a load-bearing structure, thereby improving the reliability of each structure and making the fit between them tighter. The aforementioned load-bearing component can be a flexible or rigid load-bearing component. Furthermore, if... Figure 3 As shown, the power battery pack also includes a battery pack housing 106, with the cell module 105 assembled inside the battery pack housing 106, and the battery pack cover 101 can be assembled into the battery pack housing 106. In other words, the weight of the battery pack cover 101, the bridging copper busbar 102, and the integrated busbar 104 is actually transferred to the cell module 105 and the battery pack housing 106 through the third load-bearing component.

[0051] The integrated busbar (Cells Contact System, CCS) is a core component in the power battery pack used for cell connection and signal acquisition. It mainly consists of aluminum / copper busbars, signal acquisition components, and structural parts. The aluminum / copper busbars are used for circuit connections between cells and between cell modules and output terminals. The signal acquisition components are responsible for providing information to the Battery Management System (BMS). The system (BMS) collects and outputs temperature and voltage information of the battery cells; structural components generally include plastic brackets / base plates, reinforcing plates, etc., which are responsible for the overall structural support of the integrated busbar and the insulation protection of aluminum / copper busbars and other metal parts; compared with traditional wire harness busbars, integrated busbars have advantages such as large space utilization, high component integration and assembly efficiency; the current trend in integrated busbar design is integration and lightweighting, but lightweight design may result in poor strength and load-bearing capacity of the integrated busbar itself. This solution provides load-bearing components between the integrated busbar and the adjacent structures above and below (bridging copper busbar 102 and battery cell module 105), which can improve the load-bearing capacity of the integrated busbar structure and reduce its own structural risks while ensuring that the integrated busbar is as lightweight as possible;

[0052] In other words, the power battery pack, from the battery pack cover 101, the bridging copper busbar 102, the integrated busbar 104 to the cell module 105, is equipped with load-bearing components for support between each structure, achieving an integrated load-bearing design from the battery pack cover 101, the bridging copper busbar 102, the integrated busbar 104 to the cell module 105.

[0053] This allows the weight of the upper structure to be transferred to the lower structure, which helps to improve the reliability and stability of each structure in the power battery pack. It also makes the fit between the various structures tighter, ensuring the reliability of the power battery pack structure. In other words, the above-mentioned load-bearing method can improve the reliability of each structure above the cell module 105, while achieving a tight fit between the structures.

[0054] In summary, the load-bearing design between the various structures of the power battery pack enables the transfer of the self-weight and other forces between the structures to the cell module 105 and the housing, improving the reliability of the integrated busbar and its upper structure design. At the same time, it fully considers the structural strength level and good fit requirements of each structure, and achieves a rational load-bearing design and stress transfer for similar battery packs while ensuring design, manufacturing and assembly costs, thereby improving the reliability of the battery pack's related structures.

[0055] In this scheme, the first load-bearing component includes a first load-bearing buffer component;

[0056] The first load-bearing buffer component is disposed on the inner wall of the battery pack cover 101 and is used to overlap the top of the bridging copper busbar 102. In this way, the battery pack cover 101 can be buffered and overlapped on the top of the bridging copper busbar 102, providing a buffer support for the battery pack cover 101 and avoiding rigid support for the battery pack cover 101; wherein, the first load-bearing buffer component is the flexible load-bearing component mentioned above.

[0057] Specifically, the first load-bearing buffer component includes a first foam. That is, the battery pack cover 101 is cushioned and overlapped on the top of the bridging copper busbar 102 by the first foam, which can provide better cushioning and support for the battery pack cover 101; wherein, the first foam and the bridging copper busbar 102 are vertically aligned, the shape of the first foam can be adapted to the shape of the top of the bridging copper busbar 102, and it can be a long strip of foam; of course, the first foam can also be set on the top of the bridging copper busbar 102, and this solution can also use a rubber component as the first load-bearing buffer component.

[0058] Furthermore, the second load-bearing component includes a second load-bearing buffer component;

[0059] The second load-bearing buffer component is disposed on the top of the integrated busbar 104 and is used to support the bottom of the bridging copper busbar 102. In this way, the bridging copper busbar 102 can be buffered and overlapped on the top of the integrated busbar 104, providing buffer support for the bridging copper busbar 102 and avoiding rigid support for the bridging copper busbar 102; wherein, the second load-bearing buffer component is also the flexible load-bearing component described above.

[0060] Furthermore, such as Figure 2 or Figure 9 As shown, the second load-bearing buffer component includes a second foam 103. That is, the bridging copper busbar 102 is buffered and overlapped on top of the integrated busbar 104 by the second foam 103, providing better buffering and support for the bridging copper busbar 102. The bridging copper busbar 102 and the second foam 103 are vertically aligned. The shape of the second foam can be adapted to the shape of the bottom of the bridging copper busbar 102, and it can be a long strip of foam spanning the top of the integrated busbar 104 in the X direction. The size of the second foam 103 is not less than the projected area of ​​the bridging copper busbar 102 on the integrated busbar 104. The deformation of the second foam, calculated based on the weight of the bridging copper busbar 102 and the foam compression force, should not be less than 30%, thus ensuring sufficient force distribution and uniform force distribution for the second foam 103 and the components below. Alternatively, the second foam can be placed at the bottom of the bridging copper busbar 102, and this solution can also use a rubber component as the second load-bearing buffer component.

[0061] In other words, the power battery pack, from the battery pack cover 101 and the bridging copper busbar 102 to the integrated busbar 104, uses foam for load-bearing design between each structure or component, allowing the weight of the battery pack cover 101 and the bridging copper busbar 102 to be transferred to the integrated busbar 104. Specifically, the load-bearing design between the battery pack cover 101 and the integrated busbar 104 is achieved through the bridging copper busbar 102 above the integrated busbar 104 and the foam above and below it; specifically, support is achieved by covering the bridging copper busbar 102 with foam both above and below it. The overlapping design allows the weight of the bridging copper busbar 102 to be evenly transferred to the integrated busbar 104 without adding additional fixing points. In other words, the bridging copper busbar 102 itself is a component for high-voltage connection between modules, and its own weight is evenly distributed on the integrated busbar 104 through the long strip of foam set below it, without the need for additional fixing points. On the other hand, the foam above the bridging copper busbar 102 can support the battery pack cover 101, thereby improving the structural stability and reliability of the battery pack cover 101 and the bridging copper busbar 102.

[0062] In addition, such as Figure 2 As shown, the number of cell modules 105 in this power battery pack can be two, and the number of integrated busbars 104 can also be two, corresponding one-to-one with the two cell modules 105. The number of bridging copper busbars 102 can also be two, with the two bridging copper busbars 102 spanning the tops of the two cell modules 105 respectively. The number of first foam can also be two, corresponding one-to-one with the tops of the two bridging copper busbars 102. The number of second foams 103 can be four, with two second foams 103 disposed on the top of one integrated busbar 104, corresponding one-to-one with a portion of the bottom of the two bridging copper busbars 102, and the other two second foams 103 disposed on the top of another integrated busbar 104, corresponding one-to-one with another portion of the bottom of the two bridging copper busbars 102.

[0063] Furthermore, such as Figure 6 As shown, the portion of the integrated busbar 104 used for mounting the second foam 103 is recessed downward to form a groove 10412;

[0064] like Figure 9 and Figure 10As shown, the second foam 103 is installed in the groove 10412 of the integrated busbar 104, and its top protrudes from the integrated busbar 104. This design allows a portion of the second foam 103 to be embedded in the top of the integrated busbar 104, which fully utilizes the height space of the integrated busbar 104, thereby improving the space utilization rate in the height direction of the battery pack and facilitating the rapid installation of the second foam 103. The groove 10412 is equivalent to a conformal mounting groove for the second foam 103, its shape matching the shape of the second foam 103, and it can be a long, narrow groove. Furthermore, it must ensure that there is no direct contact between the second foam 103, the bridging copper busbar 102, and the integrated busbar 104 after compression. Additionally, as... Figure 9 As shown, each integrated busbar 104 has two grooves 10412, which correspond one-to-one with the two corresponding second foams 103.

[0065] In this plan, such as Figure 6 As shown, the integrated busbar 104 includes: an insulating upper cover plate 1041, a vacuum-formed bracket 1042, and an aluminum busbar 1043;

[0066] An insulating top cover 1041 is installed on top of the vacuum forming bracket 1042; wherein, as Figure 11 As shown, the edge of the insulating top cover plate 1041 is bent downward to form an overlapping edge 10411, which is used to overlap the edge of the top of the blister bracket 1042. The middle part is provided with a groove 10412, which is used to overlap the middle part of the top of the blister bracket 1042.

[0067] like Figure 12 As shown, aluminum busbar 1043 is disposed on the blister bracket 1042 and located below the insulating upper cover plate 1041.

[0068] It should be noted that, as Figure 11 As shown, both sides of the insulating top cover 1041 (such as the left and right sides) are bent downwards to form overlapping edges 10411, which are used to overlap and fit with the corresponding sides of the top of the vacuum forming bracket 1042. Figure 6As shown, the middle portion of the insulating top cover plate 1041 is provided with the aforementioned groove 10412, which is used to overlap with the middle portion of the top of the blister bracket 1042. In this way, the middle portion and both side edges of the insulating top cover plate 1041 overlap with the corresponding positions on the top of the blister bracket 1042, resulting in multiple overlaps between the insulating top cover plate 1041 and the top of the blister bracket 1042. This increases the load-bearing area of ​​the blister bracket 1042, reduces stress concentration and the risk of deformation of the insulating top cover plate 1041, and also helps to improve the assembly stability of the insulating top cover plate 1041. Of course, the design depth of the groove of the insulating top cover plate 1041 should meet the height difference and processing tolerance between the insulating top cover plate 1041 and the blister bracket 1042, ensuring that the insulating top cover plate 1041 directly overlaps with the blister bracket 1042 through the groove structure.

[0069] In addition, such as Figure 6 and Figure 11 As shown, the insulating top cover 1041 has multiple first snap-fit ​​holes 1045 on both sides of its aforementioned side edges, and the corresponding second snap-fit ​​holes are also provided on both sides of the top of the blister bracket 1042. The multiple first snap-fit ​​holes 1045 on the same side correspond one-to-one with the multiple second snap-fit ​​holes, and are all fastened by snaps (such as airplane clips), thus allowing the insulating top cover 1041 and the blister bracket 1042 to first overlap and then snap together. More specifically, the insulating top cover 1041 can adopt an integrated design, which facilitates reducing the difficulty and cost of design, processing, and assembly, and also plays a certain role in improving the utilization rate of the internal space of the enclosure and the feasibility of assembly. In addition, the aluminum strip 1043 can be assembled to the blister bracket 1042 in the original manner and is located below the insulating top cover 1041; wherein, as shown... Figure 12 As shown, the vacuum forming bracket 1042 is hot-riveted to the aluminum busbar 1043 (connected aluminum busbar) by the hot riveting post 1046 set thereon, and is fixed by welding to the electrode between the connected aluminum busbar and the battery cell 1051; of course, the top of the integrated busbar 104 mentioned above is the top of the insulating top cover plate 1041.

[0070] In other words, in the integrated busbar 104, the insulating top cover plate 1041 and the vacuum forming bracket 1042 are not only overlapped but also snapped together. The first snap hole 1045 of the insulating top cover plate 1041 can be a large hole, and the second snap hole of the vacuum forming bracket 1042 can be a small hole. This eliminates the processing tolerance of the integrally designed insulating top cover plate 1041. Moreover, the simple connection of the snaps improves the tightness of the insulating top cover plate 1041 and the vacuum forming bracket 1042, ensuring the transfer of the weight above to the vacuum forming bracket 1042 and the support of the vacuum forming bracket 1042 for the insulating top cover plate 1041 and the copper busbar structure above it, thereby improving the structural reliability.

[0071] Specifically, the third load-bearing component includes a load-bearing lap joint component;

[0072] The load-bearing overlapping component is located at the bottom of the integrated busbar 104 and is used to form a clearance fit with the top of the cell module 105. Under the gravity of the battery pack cover 101, the bridging copper busbar 102 and the integrated busbar 104, it can overlap the top of the cell module 105. In other words, the load-bearing overlapping component is located at the bottom of the integrated busbar 104 and has a certain gap with the top of the cell module 105. Under the gravity of the battery pack cover 101, the bridging copper busbar 102 and the integrated busbar 104, it can deform downwards and overlap with the top of the cell module 105. This allows the gravity of the battery pack cover 101, the bridging copper busbar 102 and the integrated busbar 104 to be transferred to the cell module 105 through overlapping. This allows the cell module 105 to support the battery pack cover 101, the bridging copper busbar 102 and the integrated busbar 104 through the load-bearing overlapping component, thereby improving the stability and reliability of the above structure. The bottom of the integrated busbar 104 is the bottom of the vacuum forming bracket 1042.

[0073] Furthermore, such as Figure 15 and Figure 16 As shown, the load-bearing overlapping component includes: multiple protrusions 1047;

[0074] Multiple protrusions 1047 are respectively disposed at the bottom of the integrated busbar 104, and are used to form a gap fit with the shoulders of the multiple groups of two cells 1051 of the cell module 105. Under the gravity of the battery pack cover 101, the bridging copper busbar 102 and the integrated busbar 104, they can all be connected to the shoulders of the corresponding groups of two cells 1051 of the cell module 105.

[0075] It should be noted that, as Figure 16 As shown, multiple protruding feet 1047 are respectively disposed at the bottom of the vacuum forming bracket 1042, and are used to form a clearance fit between the shoulders of multiple groups of two cells 1051 in each row of cells 1051 of the cell module 105; wherein, the length of the protruding feet 1047 is consistent with the width of the aluminum busbar 1043 in the Y direction; as shown Figure 5 As shown, the battery cell module 105 may have three rows of battery cells 1051, each row of battery cells 1051 having multiple battery cells 1051 arranged side by side, and in each row of battery cells 1051, as shown... Figure 13 and Figure 14As shown, the shoulder of each pair of adjacent battery cells 1051 corresponds to a protrusion 1047 at the bottom of the blister bracket 1042, forming a clearance fit. Under the weight of the battery pack cover 101, the bridging copper busbar 102, and the integrated busbar 104, the protrusion 1047 can deform downwards and overlap the shoulders of the corresponding two battery cells 1051. This allows the bottom of the integrated busbar 104 to overlap the top of the battery cell module 105 more evenly through multiple protrusions 1047, thus making the weight of the battery pack cover 101, the bridging copper busbar 102, and the integrated busbar 104 more evenly distributed to the battery cell module 105. Moreover, the overlap occurs at the shoulders of every pair of battery cells 1051 in the battery cell module 105, which allows for full utilization of the height space of the battery cell module 105, thereby facilitating further improvement in the space utilization rate in the height direction of the battery pack. Of course, the multiple protrusions 1047 are the rigid load-bearing components mentioned above.

[0076] In addition, such as Figure 15 and Figure 16 As shown, the multiple protrusions 1047 corresponding to each row of cells 1051 can be arranged in a staggered manner; for example, as Figure 16 As shown, in the first row of cells 1051 of the cell module 105, the protrusions 1047 corresponding to the shoulders of the first cell 1051 and the second cell 1051, the protrusions 1047 corresponding to the shoulders of the second cell 1051 and the third cell 1051, and the protrusions 1047 corresponding to the shoulders of the third cell 1051 and the fourth cell 1051 can be staggered. The remaining protrusions 1047 of the cell 1051 in this row are also staggered.

[0077] In other words, the load-bearing overlapping component is a plurality of protrusions 1047 set at the bottom of the blister bracket 1042. The protrusions 1047 are equivalent to the overlapping structure at the bottom of the blister bracket 1042, and form a gap fit with the shoulders of the corresponding pairs of battery cells 1051. Under gravity, the protrusions 1047 of the blister bracket 1042 can overlap with the shoulders of the pairs of battery cells 1051, forming support for the upper structure at the shoulders of the pairs of battery cells 1051, thereby helping to improve the stability and reliability of the overall load-bearing structure. Of course, the load-bearing method between the various structures of this power battery pack is simple, which also helps to improve the production efficiency of power battery pack assembly.

[0078] Furthermore, such as Figure 14As shown, the gap between the protruding foot 1047 and the shoulder of the corresponding pair of battery cells 1051 in the battery cell module 105 is equal to or less than 0.5mm. Specifically, the distance between the lowest point of the protruding foot 1047 and the shoulder of the corresponding pair of battery cells 1051 is designed to be no greater than 0.5mm. This design ensures that under the weight of the upper component, the protruding foot 1047 of the thermoforming bracket 1042 can deform downwards and overlap the shoulder of the corresponding pair of battery cells 1051, thus allowing the battery cell module 105 to bear the weight of the upper component. Of course, this gap design also considers the processing tolerance of the thermoforming bracket 1042, preventing the thermoforming bracket 1042 from being lifted by the battery cells 1051, which would cause stress on the riveting points and solder joints.

[0079] In other words, the power battery pack provided by this solution involves the load-bearing design between the battery pack cover and the insulating top cover of the integrated busbar, the connection design between the insulating top cover of the integrated busbar and the vacuum forming bracket, and the load-bearing design between the vacuum forming bracket of the integrated busbar and the cell module body.

[0080] The load-bearing design between the battery pack cover and the insulating top cover of the integrated busbar is achieved through a copper busbar bridging the top cover and the foam above and below it. The bridging copper busbar itself serves as a component for high-voltage connection between modules, and its own weight is evenly distributed on the insulating top cover through the long strip of foam below it, eliminating the need for additional fixing points. To achieve this, the insulating top cover can be designed as an integrated cover covering the entire module, with conformal grooves designed at the positions corresponding to the foam. This fully utilizes the height space while setting an overlapping structure between the insulating top cover and the blister bracket along the entire X-axis in the middle of the module, transferring the weight of the copper busbar to the blister bracket. The copper busbar and the battery pack cover are connected by spaced foam, providing additional support for the cover. Due to the number of cell rows and series connection requirements in the cell module 105, the bridging copper busbar 102 located above two cell modules 105 can serve as a high-voltage electrical connection for these cell modules 105.

[0081] The connection design between the insulating cover plate of the integrated busbar and the vacuum forming bracket is achieved through the groove of the insulating cover plate and the overlap and snap-fit ​​between the edge and the vacuum forming bracket: the overlap design in the middle section and edge of the module can increase the load-bearing area of ​​the vacuum forming bracket and reduce stress concentration and the risk of cover plate deformation; the insulating cover plate and the vacuum forming bracket are connected by interference holes and snap-fit, which can reduce the difficulty of processing and assembly and improve the fastening ability of component connection;

[0082] The load-bearing design between the integrated busbar's vacuum forming bracket and the battery cell module body is achieved through the protruding feet at the bottom of the vacuum forming bracket and the gap fit between it and the upper shell of the battery cell. Under the gravity of the upper components, the deformation of the protruding feet of the vacuum forming bracket can eliminate the gap of <0.5mm between it and the upper shell of the battery cell, overlapping the shoulders of two adjacent battery cells to achieve force transmission and support of the battery cells for the upper structure. Considering the connection method between the battery cells and the lower housing and their own strength, the above-mentioned load-bearing method can significantly improve the structural reliability of each component above the module, achieve a tight fit between components, and the connection method is simple, which helps to improve assembly production efficiency.

[0083] In summary, the three designs proposed in this solution fully consider the structural strength level and good fit requirements of each component. While ensuring design, manufacturing and assembly costs, they can achieve rational load-bearing design and stress transmission for similar battery packs, thereby improving the reliability of battery pack components.

[0084] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0085] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A power battery pack, comprising: The battery pack cover (101), the bridging copper busbar (102), the integrated busbar (104) and the cell module (105) are arranged sequentially from top to bottom. The battery pack cover (101) and the bridging copper busbar (102) are provided with a first load-bearing component, and the weight of the battery pack cover (101) is transmitted to the bridging copper busbar (102) through the first load-bearing component. A second load-bearing component is provided between the bridging copper busbar (102) and the integrated busbar (104), and the gravity of the bridging copper busbar (102) is transmitted to the integrated busbar (104) through the second load-bearing component. A third load-bearing component is provided between the integrated busbar (104) and the battery cell module (105), and the gravity of the integrated busbar (104) is transmitted to the battery cell module (105) through the third load-bearing component.

2. The power battery pack according to claim 1, characterized in that, The first load-bearing component includes a first load-bearing buffer component; The first load-bearing buffer assembly is disposed on the inner wall of the battery pack cover (101) and is used to overlap the top of the crossover copper busbar (102).

3. The power battery pack according to claim 2, characterized in that, The first load-bearing buffer component includes a first foam.

4. The power battery pack according to claim 1, characterized in that, The second load-bearing component includes a second load-bearing buffer component; The second load-bearing buffer assembly is disposed on the top of the integrated busbar (104) and is used to support the bottom of the crossover copper busbar (102).

5. The power battery pack according to claim 4, characterized in that, The second load-bearing cushioning component includes a second foam (103).

6. The power battery pack according to claim 5, characterized in that, The integrated busbar (104) for installing the second foam (103) is recessed downward to form a groove (10412). The second foam (103) is installed in the groove (10412) of the integrated busbar (104), and its top protrudes from the integrated busbar (104).

7. The power battery pack according to claim 6, characterized in that, The integrated busbar (104) includes: an insulating top cover plate (1041), a vacuum forming bracket (1042), and an aluminum busbar (1043). The insulating top cover plate (1041) is installed on the top of the blister bracket (1042); wherein, the edge of the insulating top cover plate (1041) is bent downward to form an overlapping edge (10411), and is used to overlap the edge of the top of the blister bracket (1042), and the middle part is provided with the groove (10412), and is used to overlap the middle part of the top of the blister bracket (1042); The aluminum busbar (1043) is disposed on the blister bracket (1042) and located below the insulating upper cover plate (1041).

8. The power battery pack according to claim 1, characterized in that, The third load-bearing component includes a load-bearing overlapping component; The load-bearing overlapping component is disposed at the bottom of the integrated busbar (104) and is used to form a gap fit with the top of the cell module (105). Under the gravity of the battery pack cover (101), the crossover copper busbar (102) and the integrated busbar (104), it can overlap the top of the cell module (105).

9. The power battery pack according to claim 8, characterized in that, The load-bearing lap joint component includes: multiple protrusions (1047). Multiple protrusions (1047) are respectively disposed at the bottom of the integrated busbar (104) and are used to form a gap fit with the shoulders of multiple pairs of cells (1051) of the cell module (105). Under the gravity of the battery pack cover (101), the crossover copper busbar (102) and the integrated busbar (104), they can overlap the shoulders of the corresponding pairs of cells (1051) of the cell module (105).

10. The power battery pack according to claim 9, characterized in that, The gap between the protruding foot (1047) and the corresponding pair of cells (1051) of the cell module (105) is equal to or less than 0.5 mm.

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