A battery pack

Abstract

The application discloses a battery pack, which comprises a battery box body, a battery box cover body, a battery pack and an integrated busbar, the battery pack comprises a plurality of single batteries, and a protrusion is arranged on a battery target surface of the single battery; the integrated busbar comprises a supporting assembly and an electrical assembly arranged on the supporting assembly, and a hollow hole is arranged at a position corresponding to the protrusion of the supporting assembly; a filling layer is filled between the battery box cover body and the integrated busbar, and the filling layer is bonded to the protrusion through the hollow hole. The application is provided with the protrusion on the battery target surface, and the protrusion is just corresponding to the hollow hole of the integrated busbar after the integrated busbar is assembled. The gap between the integrated busbar and the battery target surface at the hollow hole is reduced, that is, the thickness of the filling material of the key connection point is controlled. The thickness of the filling material can be controlled within a proper range, so that the filling material can be fully and uniformly solidified, and each structure formed through the hollow hole has high mechanical strength.

Description

Technical Field

[0001] This application relates to the field of battery technology, and more specifically, to a battery pack. Background Technology

[0002] With the increasing popularity of electric vehicles and the development of power batteries, users have higher and higher requirements for battery packs. Within a battery pack, the integrated busbar is a crucial core component, directly affecting the pack's safety, energy density, production efficiency, and reliability. It connects the various cells within the battery pack in an orderly manner and integrates real-time monitoring and protection functions.

[0003] The integrated busbar functions include, but are not limited to, electrical connection and signal acquisition. It connects batteries in series (to increase voltage) and in parallel (to increase capacity) through battery connection components to form a battery pack; and it acquires the voltage and temperature signals of each battery in real time through signal acquisition components.

[0004] Current battery packs incorporate filler material between the integrated busbar and the battery box cover to maintain overall structural strength and improve sealing. When the battery box cover is directly integrated into the vehicle chassis, the structural strength and load-bearing capacity requirements are even higher. Therefore, to enhance the load-bearing capacity of the battery box cover, a filler layer is placed between the battery box cover and the battery pack. If the filler layer is too thin, the adhesive strength is insufficient; if it is too thick, the structural strength is insufficient. Because the upper surface of the battery pack has an integrated busbar, the distance from the upper surface of the battery pack to the battery box cover is inconsistent, resulting in insufficient structural strength in some areas of the battery box cover, affecting the overall structural strength of the pack.

[0005] Therefore, how to improve the structural strength of battery packs is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0006] In view of this, the purpose of this application is to provide a battery pack to improve the structural strength of the battery pack.

[0007] To achieve the above objectives, this application provides the following technical solution:

[0008] The first aspect of this application provides a battery pack, including a battery box body, a battery box cover, a battery pack, and an integrated busbar. The battery pack includes multiple individual cells. The battery box body has an opening. The battery pack is disposed inside the battery box body. A protrusion is provided on the target surface of the individual cell. The protrusion target surface is closer to the battery box cover than the target surface of the individual cell. The protrusion target surface is the surface of the protrusion facing the battery box cover. The target surface of the battery is the surface of the individual cell's casing facing the battery box cover.

[0009] The integrated busbar includes a support component and an electrical component disposed on the support component. The electrical component includes a battery connection component, which is electrically connected to the terminal of the individual battery to connect multiple individual batteries in series or in parallel. The projection of the battery connection component on the battery box cover does not coincide with the projection of the protrusion. The support component has a hollow hole at the position corresponding to the protrusion.

[0010] The battery box cover is disposed on the battery box body to close the opening. A filler layer is filled between the battery box cover and the integrated busbar. The filler layer is bonded to the protrusion through the hollow hole.

[0011] The battery pack provided in this application features a perforated support component on the integrated busbar. After filling material is injected above the integrated busbar, the filling material can adhere to the target surface of the individual battery cells through the perforated holes. Compared to adhering only to the support component of the integrated busbar, the connection strength between the filling material and the individual battery cells is significantly higher. The filling layer located between the integrated busbar and the battery box cover allows for connections between the battery box cover and both the integrated busbar and the individual battery cells, improving the connection strength of the filling material within the battery pack and preventing insufficient structural strength due to loose connections of the filling material.

[0012] The filler material passes through the perforated holes, forming a firm attachment above and below the integrated busbar. This is equivalent to forming a rivet structure between the integrated busbar and the target battery surface, achieving mechanical interlocking and improving connection reliability. By setting the perforated holes, this application allows the filler material to connect to both the integrated busbar and the individual battery cells simultaneously, greatly enhancing the rigidity and integrity of the entire battery pack. This effectively resists severe vibrations and impacts generated during vehicle operation and prevents internal components from failing due to loosening.

[0013] This application features protrusions on the surface of the battery target, which, after assembly, correspond precisely to the perforations in the integrated busbar. This effectively adds a limiting post between the battery cover and the integrated busbar, reducing the gap between the integrated busbar and the battery cover at the perforations, thus controlling the thickness of the filler material at this critical connection point. The filler material thickness can be controlled within an ideal, process-verified range, ensuring that the filler material can fully and uniformly cure, forming a high-density microporous foam structure. This results in each structure formed through the perforations possessing high and consistent mechanical strength, thereby guaranteeing the reliability of the connection between the integrated busbar and the battery cover.

[0014] Because the expansion force of the filler material is relatively large, if left uncontrolled, excessively thick filler material expanding within a confined space may compress delicate components such as those on the integrated busbar, leading to deformation, poor soldering, or damage. The protrusions in this application limit the expansion space, avoiding this risk. Furthermore, by creating protrusions on the target surface of the battery, this application can also reduce the overall amount of filler material used, achieving weight reduction and lower costs. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application 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 application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a partial structural diagram of the battery pack disclosed in an embodiment of this application;

[0017] Figure 2 This is a schematic diagram of the battery pack and integrated busbar disclosed in an embodiment of this application;

[0018] Figure 3 In order to be in Figure 2 A schematic diagram of the structure after removing the first hot-pressing film;

[0019] Figure 4 This is a front view of a single battery cell disclosed in an embodiment of this application;

[0020] Figure 5 This is a top view of a single battery cell disclosed in an embodiment of this application;

[0021] Figure 6 This is a schematic diagram of the integrated busbar structure disclosed in an embodiment of this application.

[0022] The meanings of the various reference numerals in the figure are as follows:

[0023] 100 - Integrated busbar; 110 - Support assembly; 111 - First hot-pressing film; 112 - Second hot-pressing film;

[0024] 120 - Battery connection assembly; 121 - Electrical connector; 130 - Signal acquisition assembly; 131 - Signal acquisition component; 1311 - Voltage acquisition unit; 1312 - Temperature acquisition unit; 1313 - Cantilever; 101 - Hole; 102 - Acquisition hole

[0025] 200 - Single cell; 210 - Battery cover; 211 - Protrusion; 220 - Terminal post;

[0026] 300 - Battery box body. Detailed Implementation

[0027] This application discloses a battery pack to improve the structural strength of the battery pack.

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0029] Those skilled in the art will understand that a battery pack generally includes a battery housing, which is usually a closed or semi-closed structure made of materials such as metal or plastic. It is the physical carrier of the battery pack, and its design and manufacturing must meet the safety, reliability and functionality requirements of the battery pack in different usage scenarios.

[0030] The battery enclosure provides installation space for the battery pack, BMS (Battery Management System), cooling system, electrical connection components, etc., and through reasonable structural design, it fixes these components in the battery enclosure to ensure that they maintain a relatively stable position during battery pack operation and avoid damage to components or loosening of connections due to vibration, impact and other factors.

[0031] A battery box generally includes a battery box body and a battery box cover. The battery box body includes a base plate and side plates that are connected to and surround the base plate. The battery box cover is connected to the side plates and has a battery cover plate that is opposite to the base plate. The battery box cover and the battery box body together enclose a receiving chamber.

[0032] The battery casing can be cast from materials such as steel plates and aluminum alloys, or lightweight materials such as glass fiber reinforced composite materials and carbon fiber reinforced composite materials. The shape of the battery casing can be cylindrical, cuboid, cube, etc.

[0033] The battery housing consists of a battery compartment and an electrical compartment. The core function of the battery compartment is to provide installation space for the battery packs, while the electrical compartment is where the various battery packs within the battery compartment are connected in series and parallel. Through the connection and arrangement of busbars within the electrical compartment, different battery packs can be connected according to design requirements to form a circuit system that meets the vehicle's power needs, while also controlling and managing the battery charging and discharging process.

[0034] The battery compartment and electrical compartment are separated by a partition, which can be made of the same material as the main body of the battery box. The battery compartment can be divided into multiple independent and sealed sub-battery compartments by a partition beam; alternatively, only one battery compartment may be provided. The partition and partition beam can be designed to be perpendicular or arranged at other angles. The partition and partition beam can be glued to the inside of the battery box body or welded to it. The electrical compartment is the compartment within the battery box used to house electrical components, such as the BMS (Battery Management System) and BDU (Battery Disconnect Unit).

[0035] The partitions and beams can be the horizontal and vertical beams inside the battery box, which serve to separate and enhance the strength of the battery box. The materials can be high-temperature resistant materials such as aluminum alloy, stainless steel, and iron.

[0036] A battery pack consists of multiple individual cells, which can be connected in series or parallel. An individual cell generally includes a battery casing and a battery cell housed within the casing. The battery casing typically includes a casing body and a cover plate, and is used to encapsulate the battery cell and electrolyte components. The casing body can come in various shapes and sizes, such as cuboid, cylindrical, or hexagonal prism. The shape of the casing body is determined based on the specific shape and size of the battery cell. The casing body can be made of various materials, including but not limited to copper, iron, aluminum, stainless steel, and aluminum alloys.

[0037] A battery cover is a component that closes onto the opening of the casing to isolate the storage space from the external environment. The shape of the battery cover can be adapted to fit the shape of the casing. The battery cover can be made of a material with a certain degree of hardness and strength (such as aluminum alloy).

[0038] The battery casing is the outer protective structure of a single battery cell, serving to house and protect internal components (such as the battery cell). The main functions of the battery casing are to prevent harmful substances such as moisture and oxygen from entering the interior, avoiding damage to the battery cell, protecting the internal battery cell and other components from external physical impacts and chemical corrosion, and ensuring the safety and stability of the battery cell.

[0039] A battery cell is the smallest charging and discharging unit. A battery cell is formed by winding or stacking a positive electrode, a negative electrode, and a separator between them. Typically, a terminal assembly is located on the battery cover. The terminal assembly is a crucial component connecting the individual battery cell to an external circuit. It transfers the electrical energy generated by the cell to the external circuit and simultaneously draws electrical energy from the external circuit into the cell for charging, acting as a bridge for current conduction.

[0040] A battery terminal assembly typically includes a positive terminal assembly and a negative terminal assembly. When two individual batteries are connected in series, the electrical connectors need to electrically connect the positive terminal assembly of one individual battery and the negative terminal assembly of the other individual battery. When two individual batteries are connected in parallel, the electrical connectors need to electrically connect the terminal assemblies of the same polarity of both individual batteries. A battery cell has a positive tab and a negative tab. The positive tab is electrically connected to the positive terminal assembly of the battery casing, and the negative tab is electrically connected to the negative terminal assembly of the battery casing.

[0041] Currently, battery packs typically utilize signal acquisition components to detect battery voltage and / or temperature. In a battery pack, these signal acquisition components are not merely simple wires, but highly integrated sensors and signal transmission systems. Their primary function is to monitor the voltage and / or temperature of individual battery cells in real time and accurately, transmitting this crucial data to the battery management system.

[0042] Because there are many electrical connectors used to connect individual cells in series and parallel, as well as signal acquisition components for detecting battery voltage and / or temperature information, integrated busbars are currently commonly used to integrate the various electrical connectors and signal acquisition components into a single unit for installation, thereby improving installation efficiency.

[0043] Current battery packs use foam or other filler materials between the integrated busbar and the battery compartment cover to maintain the battery compartment's airtightness. However, the foam adhering to the integrated busbar has poor bonding strength and is prone to loosening, thus affecting the sealing effect.

[0044] Based on this, embodiments of this application disclose a battery pack, such as... Figures 1-3 As shown, the battery pack includes a battery box body 300, a battery box cover, a battery pack, and an integrated busbar 100. The battery pack includes multiple individual cells 200, and the battery box body 300 has an opening, with the battery pack disposed within the battery box body 300.

[0045] like Figure 4 As shown, a protrusion 211 is provided on the target surface of the battery cell 200. The protrusion target surface of the protrusion 211 is closer to the battery box cover than the target surface of the battery cell 200. The protrusion target surface is the surface of the protrusion 211 facing the battery box cover, and the battery target surface is the surface of the battery casing of the battery cell 200 facing the battery box cover.

[0046] The single battery cell 200 includes a battery cover 210. A protrusion 211 can be disposed on the battery cover 210, and the surface of the battery cover 210 facing the battery case cover is the target surface of the battery. It should be noted that the protrusion 211 can also be disposed on the end face of the battery casing opposite to the battery cover 210. For ease of understanding, this article uses the example of the protrusion 211 being disposed on the battery cover 210.

[0047] It should be noted that the specific structures of the battery box body 300, battery box cover, individual battery 200 and integrated busbar 100 can be referred to the previous description, and will not be repeated here.

[0048] The integrated busbar 100 includes a support assembly 110 and an electrical assembly disposed on the support assembly 110. The electrical assembly includes a battery connection assembly 120, which is electrically connected to the terminal post 220 of a single battery 200 to connect multiple single batteries 200 in series or in parallel. The projection of the battery connection assembly 120 on the battery box cover does not coincide with the projection of the protrusion 211.

[0049] The support assembly 110 is used to support the electrical components. Each battery pack can be equipped with an integrated busbar 100, which integrates electrical components such as series / parallel connection devices for the individual cells 200 of the battery pack and signal acquisition devices for detecting temperature and / or voltage information onto a support assembly 110, facilitating connection to the battery pack.

[0050] The support component 110 has a perforated hole 101 at the position corresponding to the protrusion 211. The battery box cover is disposed on the battery box body to close the opening. A filler layer is filled between the battery box cover and the integrated busbar 100. The filler layer is bonded to the protrusion 211 through the perforated hole 101. Those skilled in the art will understand that the filler material of the filler layer can be expanding foam.

[0051] The battery pack disclosed in this application, by having a perforated hole 101 in the support component 110 of the integrated busbar 100, and injecting expanding foam (i.e., a filler material forming a filling layer; other filler materials can also be used to form the filling layer, but expanding foam is used as an example here) above the integrated busbar 100, can be bonded to the battery cover 210 (i.e., the target surface of the battery) of the individual battery 200 through the perforated hole 101. Compared to bonding only to the support component 110 of the integrated busbar 100, the connection strength between the expanding foam and the individual battery 200 is higher. The filling layer located between the integrated busbar 100 and the battery box cover can realize the connection between the battery box cover and the integrated busbar 100 and the individual battery 200 respectively, improving the strength of the sealing connection of the expanding foam in the battery pack and avoiding the problem of insufficient structural strength due to loosening of the expanding foam connection position.

[0052] The expanding foam passes through the perforated hole 101, forming a firm adhesion both above and below the integrated busbar 100. This is equivalent to forming a rivet structure between the integrated busbar 100 and the battery cover 210, achieving mechanical interlocking and improving the reliability of the connection. By setting the perforated hole 101, this application allows the expanding foam to connect to both the integrated busbar 100 and the individual battery cells 200 simultaneously, greatly enhancing the rigidity and integrity of the entire battery pack. This effectively resists severe vibrations and impacts generated during vehicle operation and prevents internal components from failing due to loosening.

[0053] In this embodiment, a protrusion 211 is provided on the battery cover 210. After the integrated busbar 100 is assembled, the protrusion 211 corresponds precisely to the perforation 101 of the integrated busbar 100. This is equivalent to adding a limiting post between the battery cover 210 and the integrated busbar 100, reducing the gap between the integrated busbar 100 and the battery cover 210 at the perforation 101, thus controlling the thickness of the foam at this critical connection point. The foam thickness can be controlled within an ideal, process-verified range, ensuring that the foam can fully and uniformly cure, forming a high-density microporous foam structure. This results in each structure formed through the perforation 101 having high and consistent mechanical strength, thereby ensuring the reliability of the connection between the integrated busbar 100 and the battery cover 210.

[0054] Because of the significant expansion force of expanding foam, if left uncontrolled, excessively thick expanding foam in a confined space may compress delicate components such as those on the integrated busbar 100, leading to deformation, poor soldering, or damage. The protrusion 211 in this application limits the expansion space, avoiding this risk. Furthermore, by providing the protrusion 211 on the battery cover 210, this application can also reduce the overall amount of expanding foam used, achieving weight reduction and lower costs.

[0055] In one specific embodiment of this application, the height difference between the raised target surface and the target surface of the battery connection assembly 120 is 0mm to 8mm, and the target surface of the battery connection assembly 120 is the surface close to the battery box cover. It should be noted that when the battery box cover is arranged facing upwards, the raised target surface is the upper surface of the protrusion 211, and the target surface of the battery connection assembly 120 is the upper surface of the battery connection assembly 120. That is, in this embodiment, the upper surface of the protrusion 211 is flush with, lower than or higher than the upper surface of the battery connection assembly 120.

[0056] For example, the height difference between the target surface and the target surface of the battery connection assembly 120 is 0mm, 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, etc. This embodiment does not limit the specific value of the above height difference. Those skilled in the art can select the specific value of the above height difference within the range of 0mm to 8mm based on their needs.

[0057] In one specific embodiment of this application, the minimum distance between the protrusion 211 on the single cell 200 and the battery connection assembly 120 electrically connected to the terminal post 220 of the single cell 200 is 2mm to 30mm. Assuming that the two terminals 220 of the single cell 200 are arranged along a first direction, the minimum distance between the protrusion 211 and the battery connection assembly 120 is the distance along the first direction.

[0058] For example, the minimum spacing between the protrusion 211 on the single cell 200 and the battery connection assembly 120 electrically connected to the terminal post 220 of the single cell 200 can be 2mm, 5mm, 8mm, 10mm, 13mm, 15mm, 17mm, 20mm, 22mm, 25mm, 28mm, 30mm, etc. This embodiment does not limit the specific value of the above minimum spacing; those skilled in the art can select a specific value of the above minimum spacing within the range of 2mm to 30mm based on requirements. This setting can avoid the problem of easy interference between the two due to the above minimum spacing being too small, and can also avoid the problem of poor structural strength due to the above minimum spacing being too large.

[0059] like Figure 5 As shown, the single cell 200 has two terminals 220 with opposite polarities, which are arranged along a first direction. Along a second direction, the minimum distance between the protrusion 211 on the single cell 200 and the side of the single cell 200 (i.e., the side of the single cell 200 arranged along the second direction) is Lmm, where Lmm≤20mm. The second direction is perpendicular to the first direction and parallel to the target surface of the battery.

[0060] Assuming the first direction is the length direction of the single cell 200, the second direction is the thickness direction of the single cell, and the third direction is the height direction of the single cell, then the minimum distance between the protrusion 211 on the single cell 200 and the side of the single cell 200 is the distance between the protrusion 211 and the adjacent side of the single cell 200 in the thickness direction.

[0061] For example, Lmm can be 0mm, 2mm, 4mm, 6mm, 8mm, 10mm, 12mm, 14mm, 16mm, 18mm, 20mm, etc. This embodiment does not limit the specific value of Lmm, and those skilled in the art can choose a specific value of Lmm within 20mm based on their needs.

[0062] In one specific embodiment of this application, at least one side of the raised target surface has a gap with the adjacent side of the perforated hole 101, and the width of the gap is 2mm to 10mm. For example, Lmm can be 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, etc. This embodiment does not limit the specific value of the gap width; those skilled in the art can select a specific value of the gap width within the range of 2mm to 10mm based on requirements. This setting can avoid the problem of easy clogging of the expanding foam due to an excessively small gap, and can also avoid the problem of affecting the structural strength due to an excessively large gap.

[0063] For ease of understanding, the projected area of ​​the protrusion 211 on the battery cover 210 is defined as the first area, and the projected area of ​​the perforated hole 101 on the battery cover 210 is defined as the second area. The projections of the protrusion 211 and the perforated hole 101 on the battery cover 210 refer to the projections on the large surface of the battery cover 210, that is, the projections on the side surface of the battery cover 210 facing the integrated busbar 100.

[0064] In this embodiment, the first area is less than or equal to the second area. That is, in this embodiment, the area of ​​the pattern formed by the outer contour of the protrusion 211 is less than or equal to the area of ​​the perforation 101. This allows the expanding foam passing through the perforation 101 to not only adhere to the surface of the protrusion 211 facing the integrated busbar 100, but also to wrap around the outer surface of the protrusion 211, resulting in a stronger connection between the expanding foam and the protrusion 211.

[0065] Of course, those skilled in the art will understand that the first area can also be designed to be larger than the second area, that is, the area of ​​the graphic formed by the outer contour of the protrusion 211 is larger than the area of ​​the cutout hole 101. This ensures that the expanding foam passing through the cutout hole 101 can only adhere to the surface of the protrusion 211 facing the integrated busbar 100, ensuring that the expanding foam does not spread outward and avoids damage to surrounding components.

[0066] In this embodiment, the protrusion 211 has a uniform cross-sectional structure in the direction from away from the target surface of the battery (taking the battery cover 210 as an example) to near the target surface of the battery. The projection shape of the protrusion 211 on the battery cover 210 can be rectangular, circular, parallelogram, elliptical, etc. Of course, the protrusion 211 can also be a non-uniform cross-sectional structure, that is, in the direction from away from the battery cover 210 to near the battery cover 210, the protrusion 211 includes at least two protrusions, and the cross-sectional area of ​​each protrusion is different, and the cross-sectional area of ​​the protrusion is parallel to the cross-sectional area of ​​the battery cover 210. In the direction from away from the battery cover 210 to near the battery cover 210, the cross-sectional area of ​​the protrusion can be designed to gradually increase. That is, the cross-sectional area of ​​the protrusion closer to the integrated busbar 100 is smaller, and the cross-sectional area of ​​the protrusion closer to the battery cover 210 is larger. This embodiment does not limit the structural shape of the protrusion 211. Those skilled in the art can choose according to technical requirements, or design it based on the shape of the battery cover 210. For example, when the battery cover 210 is circular, the protrusion 211 is also designed to be circular; when the battery cover 210 is rectangular, the protrusion 211 is also designed to be rectangular.

[0067] The single cell 200 has a current output terminal, which is typically a terminal post 220. The terminal post 220 is located on the battery cover plate 210 and protrudes from the battery cover plate 210. When the electrical connectors on the integrated busbar 100 are welded to the terminal post 220, the terminal post 220 supports the integrated busbar 100, resulting in a larger gap between the support component 110 of the integrated busbar 100 and the battery cover plate 210 of the single cell 200. The protrusion 211 is provided at the position corresponding to the hollow hole 101 on the battery cover plate 210, which can reduce the above gap and reduce the thickness of the foam adhesive bonded to the battery cover plate 210.

[0068] In one specific embodiment of this application, the surface of the protrusion 211 away from the battery cover 210 is defined as the protrusion target surface (i.e., the surface of the protrusion 211 facing the battery box cover is the protrusion target surface), and the surface of the terminal post 220 away from the battery cover 210 is defined as the terminal post target surface (i.e., the surface of the terminal post 220 facing the battery box cover is the terminal post target surface). The protrusion target surface and the terminal post target surface can be designed to be coplanar, which allows the terminal post 220 and the protrusion 211 to protrude from the battery cover 210 at the same height. Alternatively, the protrusion target surface can be designed to be farther from the battery cover 210 than the terminal post target surface, which allows the height of the protrusion 211 protruding from the battery cover 210 to be greater than the height of the terminal post 220 protruding from the battery cover 210.

[0069] In this embodiment, the height relationship between the protrusion 211 and the terminal post 220 protruding from the battery cover 210 is not limited. The greater the height of the protrusion 211, the smaller the thickness of the filling layer on the protrusion 211; the smaller the height of the protrusion 211, the greater the thickness of the filling layer on the protrusion 211. Those skilled in the art can design the height of the protrusion 211 based on the thickness requirements of the filling layer.

[0070] Furthermore, the battery cover 210 (i.e., the target surface of the battery) is provided with two terminals 220 (typically one is the positive terminal and the other is the negative terminal), and a protrusion 211 is located between the two terminals 220. Specifically, the protrusion 211 is located in the middle of the two terminals 220, that is, the center of the protrusion 211 coincides with the center of the line connecting the two terminals 220. Of course, the position of the protrusion 211 can also be biased towards one of the terminals 220; this embodiment does not limit the specific position of the protrusion 211.

[0071] The battery cover 210 can have only one protrusion 211, so the number of corresponding perforations 101 for the support assembly 110 and the battery cover 210 of each individual battery cell 200 is also one. With this configuration, after the foam adhesive cures, it will form an integral adhesive column that runs through the support assembly 110 and connects the battery box cover and the battery cover. This adhesive column can effectively transfer stress, providing the battery pack with strong local compressive strength and overall rigidity, especially playing a crucial supporting role when dealing with external impacts or cell expansion. When injecting the foam adhesive, the adhesive is injected through a relatively large perforation 101, resulting in a relatively simple and direct flow path, which helps reduce the risk of air bubble retention. The fewer the openings and the simpler the shape on the support assembly 110, the lower the mold and process costs.

[0072] The battery cover 210 can also be provided with multiple protrusions 211, so the number of corresponding perforations 101 for the support assembly 110 and the battery cover 210 of each individual battery 200 is also multiple. Multiple perforations 101 mean that multiple parallel heat flow paths are established (when the foam is thermally conductive foam), making the contact points between the foam and the battery cover 210 more widely distributed. This can significantly improve heat dissipation uniformity, reduce the temperature difference on the battery surface, and help extend battery life and maintain consistent performance. Multiple smaller foam pillars share the load, which can more evenly distribute stress and constraint force, avoid excessive stress at a single point, and have better compatibility with battery expansion and deformation.

[0073] When multiple protrusions 211 are provided on the battery cover 210, the structure of each protrusion 211 can be designed to be identical. Of course, the shape and size of the multiple perforated holes 101 corresponding to the battery cover of the single battery cell 200 can also be designed to be identical. Those skilled in the art can also design the structure of the multiple protrusions 211 on the battery cover 210 to be identical based on design requirements, or design the shape of the multiple protrusions 211 to be identical but the size to be different. For example, taking three protrusions 211 as an example, the middle protrusion 211 can be circular, and the two side protrusions 211 can be rectangular, etc.

[0074] In one specific embodiment of this application, the battery cover 210 includes a first cover body and a second cover body arranged in a stacked manner, with the second cover body positioned closer to the integrated busbar 100 than the first cover body. The first cover body is made of metal to ensure that the battery cover 210 has high strength. The second cover body is an insulating component, which ensures that the outer side of the battery cover 210 is insulated, preventing contact with the battery housing and thus avoiding the battery housing becoming energized.

[0075] To ensure the strength of the protrusion 211, the protrusion 211 can be provided on the first cover plate body, and the second cover plate body is provided with a cover plate through hole for the protrusion 211 to extend out, so that the protrusion 211 can be exposed on the second cover plate body, ensuring that the foam adhesive can be bonded to the protrusion 211. The protrusion 211 and the first cover plate body can be an integral structure.

[0076] The expanding foam, passing through the perforation 101 and bonded to the protrusion 211, will inevitably spread and expand outwards along the protrusion 211. This expansion can damage nearby components. In some applications, to control the spread of the expanding foam, the battery pack disclosed in this embodiment may further include adhesive-blocking strips. These strips are positioned between the battery pack and the integrated busbar 100, with adhesive-blocking strips on both sides of the protrusion 211 along the length of the battery cover 210. This arrangement ensures that the expanding foam, as it spreads from the protrusion 211 outwards through the perforation 101, is blocked by the adhesive-blocking strips, thus confining the expanding foam between the two strips.

[0077] In this embodiment, the arrangement direction of the two terminals parallel to the single cell 200 is defined as the first direction, and the direction perpendicular to the first direction is defined as the second direction. The adhesive strip extends along the second direction and traverses the entire battery pack. In a battery pack, multiple adhesive strips are arranged at intervals along the second direction, so that adhesive strips are provided on both sides of each protrusion 211.

[0078] like Figure 2 and Figure 3As shown in a specific embodiment of this application, the electrical components include a battery connection assembly 120 and a signal acquisition assembly 130. The battery connection assembly 120 includes a plurality of electrical connectors 121 for connecting individual battery cells 200 in series or in parallel, thereby enabling the series or parallel connection of individual battery cells 200 in the corresponding battery pack.

[0079] The signal acquisition component 130 includes at least one signal acquisition element 131, which is used to acquire the voltage and / or temperature signals of the individual battery cell 200. The appropriate acquisition element is configured according to the voltage and temperature information required for acquisition.

[0080] like Figure 6 As shown, the support component 110 includes a first hot-pressing film 111 and a second hot-pressing film 112 stacked together. A battery connection component 120 and a signal acquisition component 130 are pressed between the first hot-pressing film 111 and the second hot-pressing film 112. That is, the battery connection component 120 and the signal acquisition component 130 are disposed between the first hot-pressing film 111 and the second hot-pressing film 112, and are connected together through a hot-pressing process, thus pressing the battery connection component 120 and the signal acquisition component 130 together between the first hot-pressing film 111 and the second hot-pressing film 112. It should be noted that, under the action of the hot-pressing process, the portions between the first hot-pressing film 111 and the second hot-pressing film 112 where the battery connection component 120 and the signal acquisition component 130 are not disposed are bonded together to form a single unit.

[0081] The integrated busbar 100 disclosed in this application uses a support component 110 as a connection and support component for the battery connection component 120 and the signal acquisition component 130, so that each battery connection component 120 and the signal acquisition component 130 can form a whole, which facilitates installation in the battery pack.

[0082] The support assembly 110 includes a first hot-pressed film 111 and a second hot-pressed film 112 stacked together. The battery connection assembly 120 and the signal acquisition assembly 130 are sandwiched between the first hot-pressed film 111 and the second hot-pressed film 112, which are hot-pressed together. The hot-pressed film itself is relatively thin and tightly wraps around the battery connection assembly 120 and the signal acquisition assembly 130, occupying almost no space in the height direction of the battery pack. This allows more individual batteries to be placed in the same volume, increasing the energy density of the battery pack. The support assembly 110 is also lighter, replacing the relatively heavy plastic frame and effectively reducing the overall weight of the battery pack.

[0083] In existing technology, the battery connection assembly 120 and the signal acquisition assembly 130 are fixed in the slots of a plastic frame, which is a mechanical connection. Under long-term vibration, there is a risk of loosening. However, in this embodiment, after hot pressing, the support assembly 110, with its first hot pressing film 111 and second hot pressing film 112, is firmly combined with the battery connection assembly 120 and the signal acquisition assembly 130 to form a robust integral structure. This integral structure can better withstand the stress caused by vibration, impact, and cell expansion.

[0084] In existing technologies, the assembly process typically involves inserting the battery connection component 120 and signal acquisition component 130 one by one into the slots of the plastic frame, which requires more steps, makes automation more difficult, and may result in slightly lower production efficiency. However, in this embodiment, the process is highly standardized. The battery connection component 120 and signal acquisition component 130 can be pre-placed in a mold and formed by heating and pressing in a single operation using a hot press. The entire process is highly automated, with a fast production cycle, good consistency, and minimal human intervention.

[0085] The filling layer located between the support assembly 110 and the battery box cover enables the battery box cover to connect to the support assembly 110, individual cells, and electrical connectors 121 (electrical connectors 121 typically need to be welded to the current output terminal of the individual cells; therefore, the welding area of ​​electrical connectors 121 needs to be exposed outside the support assembly 110. In other words, the first hot-press film 111 and the second hot-press film 112 are both provided with clearance holes at positions corresponding to the welding area of ​​electrical connectors 121, so that electrical connectors 121 can be welded to the current output terminal. The non-welded area of ​​electrical connectors 121 can be wrapped inside by the first hot-press film 111 and the second hot-press film 112). This improves the reliability of the foam seal connection within the battery pack and avoids problems such as reduced sealing or even sealing failure due to loosening of the foam connection position.

[0086] The heat-pressed film of the support assembly 110 adjacent to the individual cell 200 is the second heat-pressed film 112, and the heat-pressed film away from the individual cell 200 is the first heat-pressed film 111. When the battery pack is placed normally, that is, when the battery box cover is facing upward, the first heat-pressed film 111 is the upper film and the second heat-pressed film 112 is the lower film.

[0087] Since the signal acquisition component 130 typically transmits signals through the main body of an FPC (Flexible Printed Circuit), and the FPC main body is a flexible structure with thin internal wiring, it is easily broken due to bending, leading to an open circuit. In this embodiment, the first heat-pressing film 111 is a transparent heat-pressing film. When connecting the integrated busbar 100 to the battery pack, operators or testing equipment can quickly check the installation status of the signal acquisition component 130 through the first heat-pressing film 111 without needing to use a multimeter to measure continuity point by point. By designing the first heat-pressing film 111 as a transparent heat-pressing film, some obvious physical defects can be immediately detected, such as: FPC breakage (clear cracks or complete breakage); severe wrinkles and bends (excessive bending of the FPC during installation, which may damage the internal circuitry); component misalignment / poor soldering (facilitating inspection of whether the signal acquisition component 131 is installed in the correct position and whether there are obvious abnormalities in the solder joints); foreign matter residue (facilitating inspection of whether conductive foreign matter such as metal shavings has fallen on the FPC, avoiding potential short circuit risks).

[0088] Furthermore, the second hot-press film 112 can also be a transparent hot-press film. This arrangement ensures that the areas of the support assembly 110 not obstructed by the battery connection assembly 120 and the signal acquisition assembly 130 are transparent, allowing observation of the individual battery cells in these areas.

[0089] After the integrated busbar 100 is installed inside the battery pack, key components of individual cells, such as battery covers, sealing pins, and explosion-proof valves (if located on the battery cover), can be directly inspected visually or via machine vision for scratches, dents, contamination, or manufacturing defects. Furthermore, during the after-sales phase, early signs of bulging, deformation, or leakage in individual cells can be directly observed without disassembling any components, achieving non-destructive testing. The laser welding quality between the current output terminal and the electrical connector 121 can also be clearly observed, including the location of the weld points, the uniformity and continuity of the weld spots, and the presence of defects such as incomplete welds or burn-through.

[0090] In one specific embodiment of this application, the signal acquisition unit 131 may include a voltage signal sampling unit, which includes a voltage acquisition section 1311 connected to the electrical connector 121. The voltage acquisition section 1311 is generally a nickel sheet, which can be soldered onto the electrical connector 121 to export the voltage signal of the single cell 200 connected to the electrical connector 121 and transmit it to the battery management system through the FPC body.

[0091] Specifically, the voltage signal sampling device may include a first FPC main body, on which a cantilever portion 1313 is provided, and a voltage acquisition portion 1311 is connected to the cantilever portion 1313. Multiple cantilever portions 1313 may be spaced apart along the extending direction of the first FPC main body, so that the voltage signals of multiple individual batteries 200 can be transmitted through one first FPC main body. That is, multiple voltage acquisition portions 1311 are spaced apart along the extending direction of the first FPC main body. The first FPC main body integrates wiring harnesses that are respectively connected to each voltage acquisition portion 1311.

[0092] Multiple voltage signal sampling devices can be set, depending on the number of rows of individual cells in the battery pack. The more rows of individual cells there are (for example, each voltage signal sampling device is responsible for collecting the voltage signals of two adjacent rows of individual cells; the specific arrangement is not limited in this application), the more voltage signal sampling devices are required. Typically, each electrical connector 121 needs to be connected to a corresponding voltage acquisition unit 1311.

[0093] In one specific embodiment of this application, the signal acquisition device 131 further includes a temperature information sampling device, which includes a temperature acquisition unit 1312. The temperature acquisition unit 1312 can be a thermistor, typically packaged in a form similar to a metal film resistor, a small ceramic capacitor, or a surface-mount solder element; these are generally referred to as thermistors. Some thermistors have resistance values ​​that decrease with increasing temperature, such as NTC (Negative Temperature Coefficient) thermistors. The thermistor element may also have a sealant around its periphery and may be provided with a protective structure such as an elastic and / or rigid metal support. Besides being an NTC, the temperature acquisition unit 1312 can also be other temperature measuring devices capable of detecting the temperature of a single battery cell; this embodiment does not limit the specific type of the temperature acquisition unit 1312.

[0094] The support assembly 110 has a sampling hole 102 at the position corresponding to the temperature sampling unit 1312, so that the temperature sampling unit 1312 can be attached to the battery cover of the single cell 200 through the sampling hole 102. That is, the sampling side of the temperature sampling unit 1312 is not blocked by the support assembly 110, and can be directly attached to the battery cover of the single cell to collect the temperature of the battery cover.

[0095] Accordingly, the temperature information sampling element includes a second FPC main body, and the temperature acquisition unit 1312 is connected to the second FPC main body. Multiple second FPC main bodies can be spaced apart along the extending direction of the second FPC main body to measure the temperature of multiple individual cells. In this embodiment, the temperature signals of multiple individual cells 200 can be transmitted through one second FPC main body. The second FPC main body integrates wiring harnesses that are respectively connected to each temperature acquisition unit 1312.

[0096] It should be noted that a battery pack may only need to detect the temperature of some of its individual cells; therefore, the number of temperature acquisition units 1312 will be significantly less than the number of voltage acquisition units 1311. Those skilled in the art can select which individual cells' temperatures should be detected for a battery pack based on technical requirements; this embodiment does not impose any limitations.

[0097] Furthermore, the first FPC main body and the second FPC main body are integrated into the same FPC main body. That is, both the voltage acquisition unit 1311 and the temperature acquisition unit 1312 can be provided on one FPC main body. Since the number of temperature acquisition units 1312 is relatively small, both the temperature acquisition unit 1312 and the voltage acquisition unit 1311 can be provided on one FPC main body to reduce the number of FPC main bodies.

[0098] As illustrated in this application, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of expressly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements. An element defined by the phrase "comprising an..." does not exclude the presence of other identical elements in the process, method, product, or apparatus that includes the element.

[0099] In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0100] 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.

[0101] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. A battery pack, characterized in that, The battery pack includes a battery box body (300), a battery box cover, a battery pack, and an integrated busbar (100). The battery pack includes multiple individual cells (200). The battery box body has an opening. The battery pack is disposed inside the battery box body (300). The target surface of the individual cell (200) is provided with a protrusion (211). The protrusion target surface of the protrusion (211) is closer to the battery box cover than the target surface of the individual cell (200). The protrusion target surface is the surface of the protrusion (211) facing the battery box cover. The target surface of the battery is the surface of the battery casing of the individual cell (200) facing the battery box cover. The integrated busbar (100) includes a support component (110) and an electrical component disposed on the support component (110). The electrical component includes a battery connection component (120). The battery connection component (120) is electrically connected to the terminal post (220) of the individual battery (200) to connect multiple individual batteries (200) in series or in parallel. The projection of the battery connection component (120) on the battery box cover does not coincide with the projection of the protrusion (211). The support component (110) has a hollow hole (101) at the position corresponding to the protrusion (211). The battery box cover is disposed on the battery box body to close the opening. A filling layer is filled between the battery box cover and the integrated busbar (100). The filling layer is bonded to the protrusion (211) through the hollow hole (101).

2. The battery pack as described in claim 1, characterized in that, The height difference between the raised target surface and the target surface of the battery connection assembly (120) is 0mm~8mm, and the target surface of the battery connection assembly (120) is the surface close to the battery box cover.

3. The battery pack as described in claim 1, characterized in that, The minimum distance between the protrusion (211) on the single cell (200) and the battery connection assembly (120) electrically connected to the terminal post (220) of the single cell (200) is 2mm to 30mm.

4. The battery pack as described in claim 1, characterized in that, The single cell (200) is provided with two terminals (220) with opposite polarities, and the two terminals (220) are arranged along a first direction; Along the second direction, the minimum distance between the protrusion (211) on the single cell (200) and the side of the single cell (200) is Lmm, where Lmm≤20mm. The second direction is perpendicular to the first direction and parallel to the target surface of the battery.

5. The battery pack as described in claim 1, characterized in that, At least one side of the protruding target surface has a gap with the adjacent side of the hollow hole (101), and the width of the gap is 2mm to 10mm.

6. The battery pack as described in claim 1, characterized in that, The protrusion (211) has a uniform cross-section structure in the direction from away from the target surface of the battery to near the target surface of the battery.

7. The battery pack as described in claim 6, characterized in that, In the direction from away from the target surface of the battery to near the target surface of the battery, the protrusion (211) includes at least two protrusions, and the cross-sectional area of ​​each protrusion is different, the cross-sectional area of ​​the protrusion being a cross-sectional area parallel to the target surface of the battery.

8. The battery pack as described in claim 7, characterized in that, The cross-sectional area of ​​the protrusion gradually increases from the direction away from the target surface of the battery to the direction closer to the target surface of the battery.

9. The battery pack as claimed in claim 1, characterized in that, The electrode post (220) is disposed on the target surface of the battery, and the surface of the electrode post (220) facing the battery box cover is the target surface of the electrode post; The protruding target surface is coplanar with the electrode target surface, or the protruding target surface is farther away from the battery target surface than the electrode target surface.

10. The battery pack as claimed in claim 9, characterized in that, The battery target surface is provided with two terminals (220), and the protrusion (211) is located between the two terminals (220).

11. The battery pack as claimed in claim 10, characterized in that, The center of the protrusion (211) coincides with the center of the line connecting the two poles (220).

12. The battery pack as claimed in claim 1, characterized in that, One or more of the protrusions (211) are provided on the surface of the battery target.

13. The battery pack as claimed in claim 12, characterized in that, When multiple protrusions (211) are provided on the target surface of the battery, each protrusion (211) has the same structure and is arranged at intervals.

14. The battery pack according to any one of claims 1-13, characterized in that, The support assembly (110) includes a first hot-pressed film (111) and a second hot-pressed film (112) stacked together. The electrical assembly also includes a signal acquisition assembly (130). The battery connection assembly (120) and the signal acquisition assembly are hot-pressed between the first hot-pressed film (111) and the second hot-pressed film (112). The battery connection assembly (120) includes a plurality of electrical connectors (121) for connecting individual battery cells (200) in series or in parallel. The signal acquisition assembly (130) includes at least one signal acquisition element (131) for acquiring the voltage and / or temperature signals of the individual battery cells (200).

15. The battery pack as claimed in claim 14, characterized in that, The signal acquisition device (131) includes: A voltage signal sampling device, the voltage signal sampling device including a voltage acquisition unit (1311) connected to the electrical connector (121). A temperature signal sampling device, the temperature signal sampling device includes a temperature acquisition part (1312), and the support component (110) has an acquisition hole (102) at the position corresponding to the temperature acquisition part (1312) so that the temperature acquisition part (1312) can be attached to the target surface of the battery through the acquisition hole (102).

16. The battery pack as claimed in claim 15, characterized in that, The voltage signal sampling device includes a first FPC main body, on which a cantilever (1313) is provided, and the voltage acquisition unit (1311) is connected to the cantilever (1313). Multiple voltage acquisition units (1311) are connected at intervals along the extension direction of the first FPC main body. And / or, The temperature signal sampling device includes a second FPC main body, and the temperature acquisition unit (1312) is connected to the second FPC main body.

17. The battery pack as claimed in claim 16, characterized in that, The first FPC body and the second FPC body are integrated into the same FPC body.

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