Potting method for battery packs, battery packs and electrical devices

Abstract

This disclosure relates to a potting method for a battery pack, a battery pack, and an electrical device. The potting method for a battery pack includes the steps of filling a housing cavity with foam adhesive in multiple steps before attaching the cover to form a pre-potted structure formed by filling the foam adhesive at least once and a post-potted structure formed by filling the foam adhesive at least once, wherein the battery assembly is connected to the cover by the post-potted structure. [Effects] The above-described technology allows the potting method for battery packs provided in this disclosure to solve the problem in related technologies in which poor engagement between the cover and the battery pack case is likely to occur after the potting work of the battery pack. This effectively improves the overall structural strength of the battery pack and is advantageous for the overall structural design of the battery pack.

Description

Technical Field

[0001] The present disclosure relates to the technical field of battery packs, and particularly to a potting method for battery packs, battery packs, and electrical devices.

Background Art

[0002] In the related art, after the potting operation of a battery pack, poor engagement between the cover and the case of the battery pack is likely to occur.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The object of the present disclosure is to solve the problems in the related art that poor engagement between the cover and the case of the battery pack is likely to occur after the potting operation of the battery pack, and to provide a potting method for battery packs, battery packs, and electrical devices that can improve the feasibility of the potting design and the stability of the process of the entire battery pack.

Means for Solving the Problems

[0004] To achieve the above object, a first aspect of the present disclosure is a potting method for a battery pack, wherein the battery pack includes a case, a battery assembly, and a cover, the case has a receiving cavity with an opening, the battery assembly is located in the receiving cavity, the cover seals the opening, and the potting method for the battery pack includes, before attaching the cover, filling the receiving cavity with a foaming adhesive in multiple portions to form a pre-potting structure formed by filling the foaming adhesive at least once and a post-potting structure formed by filling the foaming adhesive at least once, and connecting the battery assembly to the cover by the post-potting structure. A potting method for a battery pack is provided.

[0005] In the above embodiment, the step of filling the housing cavity with the foam adhesive in multiple steps to form the pre-potting structure formed by filling the foam adhesive at least once and the post-potting structure formed by filling the foam adhesive at least once may include the step of filling at least a portion of the space between the battery assembly and the side wall of the housing cavity with the foam adhesive to form the pre-potting structure.

[0006] Furthermore, in the above embodiment, the battery assembly has a battery unit, the housing cavity has a first cavity located at least one end of the battery assembly along a first direction, and the pre-potting structure may be located at least partially within the first cavity.

[0007] Furthermore, in the above embodiment, the housing cavity has a third cavity located at at least one end of the battery assembly along the second direction, and the volume of the first cavity may be greater than the volume of the third cavity.

[0008] Furthermore, in the above embodiment, in the height direction of the battery pack, the highest point of the upper surface of the pre-potting structure may be located below the highest end of the battery unit, or the highest point of the upper surface of the pre-potting structure may be at the same height as the highest end of the battery unit.

[0009] Furthermore, in the above embodiment, the distance in the height direction between the lowest point on the upper surface of the pre-potting structure and the highest end of the battery unit is h, and the size of the battery unit in the height direction is H, and h ≤ H * 1 / 2.

[0010] Furthermore, in the above embodiment, the size of the housing cavity in the height direction of the battery pack is H', and the height of the highest or lowest point of the upper surface of the pre-potting structure relative to the inner bottom surface of the housing cavity is L, and L ≥ H' * 1 / 3.

[0011] Furthermore, in the above embodiment, the size of the battery unit of the battery assembly in the height direction of the battery pack is H, and H'*1 / 2 <L<Hであってもよい。

[0012] Furthermore, in the above embodiment, the size of the battery unit of the battery assembly in the height direction of the battery pack is H, and H ≥ H' * 2 / 3.

[0013] Furthermore, in the above embodiment, the distance in the height direction between the highest and lowest points on the upper surface of the pre-potting structure may be smaller than a predetermined distance.

[0014] Furthermore, in the above embodiment, the preset distance may be 15 mm.

[0015] Furthermore, in the above embodiment, the step of filling the space between the battery assembly and the side wall of the housing cavity with the foam adhesive to form the pre-potted structure may include the step of filling the space with the foam adhesive along a first predetermined trajectory.

[0016] Furthermore, in the above embodiment, the battery pack may further have a second blocking structure that divides at least a portion of the space into a plurality of sub-filled cavities.

[0017] Furthermore, in the above embodiment, the plurality of sub-filling cavities may be arranged at intervals along the first predetermined trajectory.

[0018] Furthermore, in the above embodiment, the pre-potting structure may be formed by the free rise of the foam adhesive.

[0019] Furthermore, in the above embodiment, the housing cavity has a second cavity located between the battery assembly and the cover, and between adjacent battery units in the battery assembly, and the post-potting structure has a first post-potting structure located within the second cavity, and the step of filling the housing cavity with the foam adhesive in multiple steps to form the pre-potting structure formed by filling with the foam adhesive at least once, and the post-potting structure formed by filling with the foam adhesive at least once, may include the step of filling the second cavity with the foam adhesive along a second predetermined trajectory to form the first post-potting structure.

[0020] Furthermore, the above embodiment may further include the step of determining the second preset trajectory based on the arrangement of the battery units in the battery assembly.

[0021] Furthermore, in the above embodiment, the battery assembly has a plurality of sets of the battery units arranged in a line along the length direction of the battery unit, each set of the battery units has a plurality of the battery units arranged in a line along the thickness direction of the battery unit, the second preset trajectory includes a first main trajectory and a first turning trajectory, the plurality of first main trajectories all extend in the thickness direction of the battery unit and are arranged in a line along the length direction of the battery unit, and the second preset trajectory may be formed as a meandering trajectory by connecting two adjacent first main trajectories by a first turning trajectory.

[0022] Furthermore, in the above embodiment, there is a first gap between two adjacent battery units spaced apart in the longitudinal direction, the first gap forms part of the second cavity, the first gap extends along the thickness direction, and at least one of the first principal trajectories may pass through the first gap.

[0023] In addition, in the above aspect, a pole and a surface area adjacent to the pole are provided on the upper surface of the battery unit, and at least one of the first main trajectories may pass through the pole and at least one of the first main trajectories may pass through the surface area.

[0024] In addition, in the above aspect, the battery assembly has a bus bar assembly located above the battery unit, there is a second gap between the bus bar assembly and the cover, and there is a third gap between the bus bar assembly and the battery unit. The bus bar assembly has an adhesive injection port that communicates the second gap and the third gap, and at least one of the first main trajectories may pass through the adhesive injection port.

[0025] In addition, in the above aspect, the first main trajectory has opposite first and second ends, and the battery assembly has a first side wall adjacent to the first end and a second side wall adjacent to the second end along the thickness direction. There may be a first preset distance between the first end and the first side wall, and a second preset distance between the second end and the second side wall.

[0026] In addition, in the above aspect, it may further include a step of determining the values of the first preset distance and the second preset distance based on the difference between the actual operating time of the adhesive outlet of the adhesive filling device in the first turning trajectory and the set operating time.

[0027] In addition, in the above aspect, the thickness of the battery unit is D, the values of the first preset distance and the second preset distance are D', and D'≥D*1 / 2 and D'≤3D.

[0028] In addition, in the above aspect, the accommodation cavity has a first cavity located at at least one end of the battery assembly along a first direction, the accommodation cavity has a third cavity located at at least one end of the battery assembly along a second direction, the pre-potting structure is located within the first cavity, the post-potting structure has a second post-potting structure located within the third cavity and above the pre-potting structure, and the step of filling the accommodation cavity with the foam adhesive in multiple portions to form the pre-potting structure formed by filling the foam adhesive at least once and the post-potting structure formed by filling the foam adhesive at least once may include the step of filling the first cavity and the third cavity with the foam adhesive along a third preset trajectory to form the second post-potting structure.

[0029] In addition, in the above aspect, the third preset trajectory may be an annular trajectory extending in the circumferential direction of the battery assembly.

[0030] In addition, in the above aspect, after filling the second cavity with the foam adhesive along the second preset trajectory, the step of filling the first cavity and the third cavity with the foam adhesive along the third preset trajectory may further be included.

[0031] In addition, in the above aspect, after the foam adhesive forming the pre-potting structure bulges to the maximum volume, the step of starting to fill the first cavity and the third cavity with the foam adhesive along the third preset trajectory may further be included.

[0032] In addition, in the above aspect, after the foam adhesive forming the pre-potting structure bulges to the maximum volume and before the upper surface of the pre-potting structure dries, the step of starting to fill the first cavity and the third cavity with the foam adhesive along the third preset trajectory may be included.

[0033] A second aspect of this disclosure provides a battery pack that uses the potting method provided in the first aspect.

[0034] A third aspect of the present disclosure provides a battery pack comprising: a case having a housing cavity having an opening; a battery assembly located within the housing cavity; a cover sealing the opening; a pre-potting structure formed of foam adhesive and located within the housing cavity; and a post-potting structure formed of foam adhesive and located within the housing cavity, wherein the battery assembly is connected to the cover by the post-potting structure.

[0035] In the above embodiment, the projection of the post-potting structure in the height direction of the battery pack may cover the pre-potting structure.

[0036] Furthermore, in the above embodiment, the pre-potting structure and the post-potting structure may be bonded together.

[0037] Furthermore, in the above embodiment, the adhesive strength at the interface between the pre-potting structure and the post-potting structure is E, and the adhesive strength between the post-potting structure and the cover is F, and E > F.

[0038] Furthermore, in the above embodiment, the pull-out / shear strength of the interface between the pre-potting structure and the post-potting structure is A, and if there is no interface in the potting structure formed by the foam adhesive, the pull-out / shear strength of the potting structure is B, and A > 0.5B is also possible.

[0039] Furthermore, in the above embodiment, the battery assembly has a battery unit, the housing cavity has a first cavity located at least one end of the battery assembly along a first direction, and the pre-potting structure may be located at least partially within the first cavity.

[0040] Furthermore, in the above embodiment, in the height direction of the battery pack, the highest point of the upper surface of the pre-potting structure may be located below the highest end of the battery unit, or the highest point of the upper surface of the pre-potting structure may be at the same height as the highest end of the battery unit.

[0041] Furthermore, in the above embodiment, the distance in the height direction between the lowest point on the upper surface of the pre-potting structure and the highest end of the battery unit is h, and the size of the battery unit in the height direction is H, and h ≤ H * 1 / 2.

[0042] Furthermore, in the above embodiment, the size of the housing cavity in the height direction of the battery pack is H', and the height of the highest or lowest point of the upper surface of the pre-potting structure relative to the inner bottom surface of the housing cavity is L, and L ≥ H' * 1 / 3.

[0043] Furthermore, in the above embodiment, the size of the battery unit of the battery assembly in the height direction of the battery pack is H, and H'*1 / 2 <L<Hであってもよい。

[0044] Furthermore, in the above embodiment, the size of the battery unit of the battery assembly in the height direction of the battery pack is H, and H ≥ H' * 2 / 3.

[0045] Furthermore, in the above embodiment, the distance to which the upper surface of the pre-potting structure is pulled out in the height direction may be less than a predetermined distance.

[0046] Furthermore, in the above embodiment, the preset distance may be 15 mm.

[0047] Furthermore, in the above embodiment, the housing cavity may have a second cavity located between the battery assembly and the cover, and between adjacent battery units in the battery assembly, and a third cavity located at at least one end of the battery assembly along the second direction, and the post-potting structure may have a first post-potting structure located within the second cavity, and a second post-potting structure located within the third cavity and above the pre-potting structure.

[0048] Furthermore, in the above embodiment, the densities of the first post-potting structure, the second post-potting structure, and the pre-potting structure may be successively reduced.

[0049] Furthermore, in the above embodiment, the second post-potting structure has a first structure located within the third cavity and a second structure located above the pre-potting structure, and the densities of the first post-potting structure, the first structure, the second structure, and the pre-potting structure may decrease in order.

[0050] Furthermore, in the above embodiment, the battery pack may further have a first barrier structure for partitioning the first cavity, the second cavity, and the third cavity.

[0051] Furthermore, in the above embodiment, the battery pack may further have a second barrier structure for partitioning at least a portion of the first cavity and / or at least a portion of the third cavity into a plurality of sub-filling cavities.

[0052] A fourth aspect of this disclosure provides an electrical device comprising a battery pack provided according to the second aspect or a battery pack provided according to the third aspect.

[0053] In the above embodiment, the electrical device may be a vehicle. [Effects of the Invention]

[0054] According to the above-mentioned technical proposal, i.e., the potting method for a battery pack provided by this disclosure, the potting method for a battery pack includes the step of filling the housing cavity with foam adhesive in multiple stages before attaching the cover, thereby forming a pre-potting structure formed by filling the foam adhesive at least once and a post-potting structure formed by filling the foam adhesive at least once, thereby ensuring that the battery assembly is stably connected to the cover by the post-potting structure, effectively improving the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack, helps to improve the insulation performance of the entire battery pack, and the consistency of thermal management and thermal safety, reduces the problem in related technologies in that poor engagement between the cover and the battery pack case is likely to occur after the potting work of the battery pack, and improves the feasibility of the potting design of the entire battery pack and the stability of the process.

[0055] Other features and advantages of this disclosure are described in detail in the following sections on specific embodiments. [Brief explanation of the drawing]

[0056] The drawings are for further understanding of this disclosure, form part of the specification, and are used to illustrate this disclosure together with the following specific embodiments, and do not limit this disclosure. [Figure 1] This is a schematic exploded view of the battery pack provided by the exemplary embodiments of the present disclosure. [Figure 2] This is a schematic exploded view of a battery pack with the cover removed, as provided in an exemplary embodiment of the present disclosure. [Figure 3] This is a partially enlarged schematic diagram of location A in Figure 2. [Figure 4] This is a top view of a battery pack with the cover removed, as provided in an exemplary embodiment of the present disclosure, showing the shielding structure. [Figure 5] Figure 4 is a schematic cross-sectional view of position BB. [Figure 6]This is a top view of a battery pack with the cover removed, provided in an exemplary embodiment of the present disclosure, showing a second preset trajectory. [Figure 7] This is a top view of the battery pack with the cover removed, as provided in an exemplary embodiment of the present disclosure, showing a fourth preset trajectory. [Figure 8] This is a schematic diagram of a part of the structure of a battery assembly provided in a second embodiment of the present disclosure. [Figure 9] This is a schematic diagram of a part of the structure of a battery assembly provided in a third embodiment of this disclosure. [Figure 10] This is a schematic diagram of a part of the structure of a battery assembly provided in a fourth embodiment of the present disclosure. [Modes for carrying out the invention]

[0057] The following describes specific embodiments of this disclosure in detail with reference to the drawings. The specific embodiments described herein are for illustrative purposes only and do not limit the scope of this disclosure.

[0058] Furthermore, in this disclosure, any operations to acquire signals, information, or data will be carried out in accordance with the relevant data protection laws and policies of the country in which they are located, and with permission granted by the owner of the corresponding device.

[0059] For the sake of clarity, this disclosure defines three coordinate systems, namely the XYZ coordinate system, for the battery pack. Referring to Figure 1, the Y direction corresponds to the width direction of the battery pack, and may refer to the second direction or the up-down direction in Figure 4. The X direction corresponds to the length direction of the battery pack, and may refer to the first direction or the left-right direction in Figure 4. The Z direction corresponds to the height direction of the battery pack, and may refer to the direction perpendicular to the plane of the paper in Figure 4 or the up-down direction in Figure 5. Unless otherwise stated, directional terms such as "up" and "down" used generally refer to the top and bottom of the battery pack in its space when it is in use. "Inside" and "outside" refer to the inside and outside of the contour of the part or structure itself. Also, terms such as "first" and "second" used are used to distinguish one element from another and do not have any order or importance. Furthermore, in the description of the drawings, the same reference numerals in different drawings represent the same element.

[0060] The inventor's research revealed that while related technologies use a single-full potting method to pot the battery pack with adhesive, the potting time for the foamed adhesive inside the battery pack is usually shorter than the sum of the potting time, cover installation time, and fastening time for the single-full potting method, due to the large total potting volume within the battery pack. In other words, when the battery pack cover is being installed, the foamed adhesive may have already begun to expand and may have expanded to its maximum volume, posing a risk of expansion outside the battery pack's housing cavity. As a result, when field workers install the battery pack cover, problems such as poor engagement between the cover and the battery pack case are likely to occur.

[0061] Based on this, a potting method for a battery pack is provided according to a first aspect of the present disclosure. Referring to the contents shown in Figures 1 to 7, the battery pack comprises a case 1, a battery assembly 2, and a cover 3. The case 1 has a housing cavity 120 having an opening 110, the battery assembly 2 is located inside the housing cavity 120, and the cover 3 seals the opening 110. The potting method for the battery pack involves filling the housing cavity 120 with foam adhesive 9 in multiple portions before attaching the cover 3. This creates a pre-potting structure 910 formed by filling the foam adhesive 9 at least once, and a post-potting structure 920 formed by filling the foam adhesive 9 at least once. The battery assembly 2 is then connected to the cover 3 by the post-potting structure 920.

[0062] According to the above-mentioned technical proposal, namely the potting method for a battery pack provided by this disclosure, the potting method for a battery pack includes the step of filling the housing cavity 120 with foam adhesive 9 multiple times before attaching the cover 3 to form a pre-potting structure 910 formed by filling with foam adhesive 9 at least once, and a post-potting structure 920 formed by filling with foam adhesive 9 at least once. This ensures that the battery assembly 2 is stably connected to the cover 3 by the post-potting structure 920, effectively improving the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack, helps to improve the insulation performance of the entire battery pack, and the consistency of thermal management and thermal safety, reduces the problem in related technologies in that poor engagement between the cover and the battery pack case is likely to occur after the potting work of the battery pack, and can improve the feasibility of the potting design of the entire battery pack and the stability of the process.

[0063] Furthermore, in related technologies, the single full potting method has a large volume of foam adhesive required for filling the cavity of the battery pack. As a result, the time it takes for the foam adhesive to rise inside the battery pack is usually shorter than the total time for potting, cover installation, and fastening of the fasteners in single full potting, making it prone to problems with poor engagement between the battery pack and the cover. In other words, in related technologies, the single full potting method usually involves at least the tasks of filling the adhesive, installing the cover, and tightening the fasteners. However, because the volume of the area of ​​the battery pack that requires filling the foam adhesive is large, the total time for one adhesive filling usually accounts for a large proportion of the total time for filling the adhesive, installing the cover, and tightening the fasteners. Thus, when field workers install the cover, the foam adhesive may have already begun to rise and may have risen to its maximum volume. There is also a risk of it rising outside the cavity of the battery pack, making it prone to problems with poor engagement between the cover and the battery pack case.

[0064] To solve the above problems, this disclosure makes it possible to pre-fill a portion of the space within the housing cavity 120 of the battery pack with foam adhesive 9 by using a potting method in which foam adhesive 9 is filled into the housing cavity 120 of the battery pack in multiple stages, thereby forming, for example, the pre-potted structure 910. Since pre-potting involves filling a portion of the space within the battery pack with foam adhesive 9, and subsequent adhesive filling work is also required, the adhesive filling time for pre-potting in the multi-stage potting method of this disclosure is designed to be considered independently compared to the single-stage full potting method in related technologies. In other words, in related technologies, the total time of potting time, cover mounting time, and fastening time of the fasteners in the single-stage full potting method corresponds in this disclosure to the total time of adhesive filling time used to fill the amount of adhesive required for the post-potting structure 920 (which may be understood as the final adhesive filling work before attaching the cover), cover mounting time, and fastener tightening time in the multi-stage potting method. Normally, the time required to attach the cover and tighten the fasteners is constant. However, by employing a technique that involves potting in multiple stages, the time required for adhesive filling is significantly reduced, and the risk of poor engagement between cover 3 and case 1 due to premature foaming of the adhesive is greatly reduced.

[0065] In summary, the present disclosure allows for partial pre-potting of a portion of the entire battery pack in multiple potting stages, thereby reducing the volume of the area within the battery pack's housing cavity 120 that needs to be filled with foam adhesive 9 when the next potting stage (filling the required amount of adhesive for the post-potting structure 920) is performed. Thus, when the next potting stage (which may be understood as the final adhesive filling stage before attaching the cover) is performed, the volume of the area within the battery pack's housing cavity 120 that needs to be filled with foam adhesive 9 is significantly reduced, effectively shortening the adhesive filling time required for the next potting stage. As a result, the total time used for filling the required amount of adhesive for the post-potting structure 920 (the final adhesive filling stage before attaching the cover), the cover attachment time, and the fastening time of the fasteners in the multi-stage potting method of the present disclosure is significantly shorter than the total time for potting, cover attachment, and fastener tightening in the single-stage full-potting method of related technology, with the adhesive filling time being significantly reduced in particular. As a result, when the cover is installed on-site, the foam adhesive 9 for forming the post-potting structure 920 has not yet risen, or has just begun to rise, so the problem of poor fit of the cover does not occur. Furthermore, after the cover 3 is installed, the foam adhesive 9 can be bonded to the inner surface of the cover 3 with high strength after it has finished rising, ensuring that the battery assembly 2 is stably connected to the cover 3 via the foam adhesive. This effectively improves the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack and helps to improve the insulation performance of the entire battery pack and the consistency of thermal management and thermal safety.

[0066] Furthermore, in the potting method in which the foam adhesive 9 is filled into the housing cavity 120 in multiple stages, the total number of stages is not specifically limited. Therefore, this disclosure will explain below as an example of filling the housing cavity 120 with the foam adhesive 9 in two stages. Specifically, the pre-potting structure 910 is formed by filling the housing cavity 120 with the foam adhesive 9 in the first stage, and the post-potting structure 920 is formed by filling the housing cavity 120 with the foam adhesive 9 in the second stage. This ensures that the adhesive interface between the pre-potting structure 910 and the post-potting structure 920 has high adhesive strength, thereby effectively improving the structural strength of the entire battery pack. Of course, this disclosure is not limited thereto. For example, in some other embodiments, the total number of stages may be three or four, and this disclosure does not specifically limit the number of times the foam adhesive 9 is filled to form the corresponding number of pre-potting structures 910 and the number of times the foam adhesive 9 is filled to form the corresponding number of post-potting structures 920. Those skilled in the art can adjust the number of applications as appropriate based on the total number of applications, provided that the adhesive interface between the pre-potting structure 910 and the pre-potting structure 910, or between the pre-potting structure 910 and the post-potting structure 920, or between the post-potting structure 920 and the post-potting structure 920, all have high adhesive strength, thereby achieving the objective of improving the overall structure of the battery pack.

[0067] Furthermore, this disclosure enables saturated potting filling of each gap area within the battery pack by filling the battery pack housing cavity 120 with foam adhesive 9 in multiple stages, thereby improving the potting effect and contributing to an improvement in the overall structural strength of the battery pack.

[0068] In one embodiment, referring to Figures 4 and 5, the step of filling the housing cavity 120 with foam adhesive 9 in multiple stages to form a pre-potting structure 910 formed by filling the foam adhesive 9 at least once and a post-potting structure 920 formed by filling the foam adhesive 9 at least once includes the step of filling the space between the battery assembly 2 and the side wall of the housing cavity 120 with foam adhesive 9 to form the pre-potting structure 910. Thus, by pre-filling the space between the battery assembly 2 and the side wall of the housing cavity 120 with foam adhesive 9, the present disclosure can effectively reduce the volume of the remaining space area in the battery pack that needs to be filled with foam adhesive 9, thereby effectively shortening the potting time used for the amount of adhesive required to fill the post-potting structure 920, reducing the problem of poor engagement of the cover 3, improving the feasibility and process stability of the overall potting design of the battery pack, effectively improving the overall structural strength of the battery pack, and is advantageous for the overall structural design of the battery pack.

[0069] Exemplary, as shown in Figures 4 and 5, the battery assembly 2 may have a battery unit 210, and the housing cavity 120 has a first cavity 121 located at at least one end of the battery assembly 2 along a first direction (referring to the left-right direction in the plane of the paper of Figure 4), and at least a portion of the pre-potting structure 910 is located within the first cavity 121 to achieve the purpose of pre-potting, effectively reducing the volume of the remaining space area in the battery pack that needs to be filled with foam adhesive 9, effectively shortening the adhesive filling time used to fill the required amount of adhesive in the post-potting structure 920, and reducing the problem of poor engagement of the cover 3.

[0070] Furthermore, in one embodiment, referring to Figure 4, the housing cavity 120 may have a third cavity 123 located at at least one end of the battery assembly 2 along a second direction (referring to the up and down direction of the paper in Figure 4), and the volume of the first cavity 121 is larger than the volume of the third cavity 123. In this way, by pre-filling the relatively large first cavity 121 with adhesive, the volume of the remaining space area in the battery pack that needs to be filled with foam adhesive 9 can be effectively reduced, achieving the objective of effectively shortening the adhesive filling time used to fill the amount of adhesive required for the post-potting structure 920, and reducing the problem of poor engagement of the cover 3.

[0071] The battery assembly 2 may be arranged in a manner such as upright or inverted within the housing cavity 120 of the case 1. Illustratively, Figure 4 illustrates that after the assembly of the battery assembly 2 and the case 1 is complete, the housing cavity 120 may have two first cavities 121 located at opposing ends of the battery assembly 2 along a first direction, namely the vehicle front end cavity 7 on the left side and the vehicle rear end cavity 10 on the right side as shown in Figure 4. Simultaneously, the housing cavity 120 may also have two third cavities 123 located at opposing ends of the battery assembly 2 along a second direction, namely the slit areas located on the sides of the battery assembly 2 as shown in Figure 4. The volume of the space area in the two first cavities 121 (e.g., the vehicle front end cavity 7 and the vehicle rear end cavity 10) that needs to be filled with foam adhesive is greater than the volume of the space area in the two third cavities 123 (e.g., the slit areas on the sides of the battery assembly 2) that needs to be filled with foam adhesive. Therefore, by pre-filling the foam adhesive 9 into two relatively large spatial areas that need to be filled with foam adhesive 9, namely the front end cavity 7 and the rear end cavity 10 of the vehicle, the volume of the remaining spatial areas in the battery pack that need to be filled with foam adhesive 9 can be effectively reduced. This achieves the objective of effectively shortening the adhesive filling time used to fill the amount of adhesive required for the post-potting structure 920, thereby reducing the problem of poor engagement of the cover 3, improving the feasibility and process stability of the overall potting design of the battery pack, effectively improving the overall structural strength of the battery pack, and thus being advantageous for the overall structural design of the battery pack.

[0072] Furthermore, when pre-filling the two first cavities 121 with adhesive, since the foamed adhesive 9 is typically a liquid, fluid adhesive liquid from the time it is injected into the first cavities 121 until it rises, in some embodiments, to reduce the possibility of the adhesive liquid abnormally flowing to other areas (e.g., the second cavity 122 between the battery assembly 2 and the cover 3), the highest point of the top surface of the pre-potting structure 910 is located below the highest end of the battery unit 210 in the height direction of the battery pack (referring to the direction perpendicular to the plane of the paper in Figure 4), or the highest point of the top surface of the pre-potting structure 910 is aligned with the highest end of the battery unit 210, thereby reducing the problem of the adhesive liquid abnormally flowing to other areas, ensuring a uniform distribution of the adhesive liquid, and improving the potting effect. Here, the highest end of the battery unit 210 may be understood as the upper wall surface of the battery cell shell in the height direction of the battery pack. As shown in Figure 5, the distance between the highest end / top wall of the battery unit 210 and the inner wall of the housing cavity 120 is H (or may be understood as the height H of the battery unit 210 as described below).

[0073] Furthermore, in order to better realize multi-stage potting, and for example to achieve the objective of shortening the adhesive filling time used for the final adhesive filling, in one embodiment, the distance between the lowest point of the upper surface of the pre-potting structure 910 and the highest end of the battery unit 210 in the height direction of the battery pack (see the direction perpendicular to the plane of the paper in Figure 4 or the up and down direction in Figure 5) may be h, and the size of the battery unit 210 in the height direction of the battery pack (see the direction perpendicular to the plane of the paper in Figure 4 or the up and down direction in Figure 5) may be H, where h ≤ H * 1 / 2. In this way, by controlling the position of the lowest point of the upper surface of the pre-potting structure, it is possible to realize multi-stage potting and achieve the objective of shortening the adhesive filling time used for the final adhesive filling, thereby improving the feasibility of the potting design of the entire battery pack and the stability of the process, effectively improving the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack.

[0074] Also, in some embodiments, the size of the accommodation cavity 120 in the height direction of the battery pack is H', the height of the highest or lowest point of the upper surface of the pre-potting structure 910 with respect to the inner bottom surface of the accommodation cavity 120 is L, and L≥H'*1 / 3 may be satisfied. Thus, after the pre-potting operation, the volume of the remaining space area in the battery pack that needs to be filled with the foaming adhesive 9 can be effectively reduced, thereby achieving the purpose of effectively shortening the filling time of the adhesive used to fill the post-potting structure 920.

[0075] Exemplarily, in some embodiments, since the size of the battery unit 210 of the battery assembly 2 in the height direction of the battery pack is H, by setting H'*1 / 2 < L < H, the adhesive filling operation at the site can be facilitated, and at the same time, the adhesive filling time used to fill the amount of adhesive required for the post-potting structure 920 can be effectively shortened. Also, for the overall structure and lightweight design of the battery pack, in some embodiments, when the size of the battery unit 210 of the battery assembly 2 in the height direction of the battery pack is set to H, by setting H≥H'*2 / 3, the overall structure and lightweight design of the battery pack can be facilitated.

[0076] Furthermore, considering the fluidity of the adhesive liquid, if there are relatively large depressions on the upper surface of the pre-potting structure 910 when filling the adhesive liquid on top of the pre-potting structure 910, the adhesive liquid will flow into the depressions, causing the adhesive liquid to accumulate and resulting in poor uniform distribution of the adhesive liquid. On the other hand, when a foamed adhesive 9 is used as the adhesive liquid, after the foamed adhesive 9 rises up to form a portion of the post-potting structure 920, the unevenness of the upper surface of the portion of the post-potting structure 920 becomes even larger, and as a result, the bonding area between the post-potting structure 920 and the cover 3 becomes smaller. Therefore, in the embodiments provided by this disclosure, the height distance between the highest and lowest points on the upper surface of the pre-potting structure 910 can be made smaller than a preset distance. Exemplarily, the preset distance can be 10 mm or 15 mm, which allows the flatness of the upper surface of the pre-potting structure 910 to meet the requirements, reduces the flow of the adhesive liquid when filling the upper surface of the pre-potting structure 910, and improves the uniform distribution of the adhesive liquid. As a result, after the adhesive liquid rises to form a portion of the post-potting structure 920, the bonding area between the portion of the post-potting structure 920 and the cover 3 is increased, ensuring that the bonding interface between the pre-potting structure 910 and the post-potting structure 920 has high bonding strength, thereby improving the overall structural strength of the battery pack.

[0077] In one embodiment, the step of filling at least a portion of the space between the battery assembly 2 and the side wall of the housing cavity 120 with foam adhesive 9 to form a pre-potting structure 910 includes the step of filling at least a portion of the space with foam adhesive 9 along a first preset trajectory. Thus, the pre-potting structure 910 is formed by, for example, controlling the adhesive outlet of an adhesive filling device to fill the adhesive along the first preset trajectory, thereby facilitating the work.

[0078] Herein, this disclosure does not limit the specific trajectory path of the first preset trajectory, and those skilled in the art can design it appropriately according to the needs of the actual application. For example, the pre-potting structure 910 is formed by controlling the robot arm of the adhesive filling device to fill the housing cavity 120 with adhesive along the first preset trajectory, which is a straight line trajectory. That is, as shown in Figure 4, the adhesive outlet of the adhesive filling device can perform pre-potting work on the spatial areas of the two first cavities 121 (e.g., the vehicle front end cavity 7 and the vehicle rear end cavity 10) that need to be filled with foamed adhesive 9, along a straight line trajectory (for example, from top to bottom or bottom to top on the page of Figure 4), and by performing pre-potting work along a straight line trajectory, the problem of uneven distribution of the filled adhesive liquid can be solved and the potting effect can be improved.

[0079] Furthermore, in one embodiment, referring to Figure 4, the battery pack may further have a second blocking structure 6, which is used to divide at least a portion of the space into a plurality of sub-filling cavities 124, the plurality of sub-filling cavities 124 being spaced apart in a first predetermined trajectory, which is advantageous for improving the uniformity of the adhesive liquid distribution in each sub-filling cavity 124, ensuring uniformity of the height after the foam adhesive 9 filled by pre-potting rises, and ensuring that the adhesive interface between the pre-potting structure 910 and the post-potting structure 920 has high adhesive strength.

[0080] Furthermore, the pre-potting structure 910 is formed by the free rise of the foamed adhesive 9 (for example, the foamed adhesive 9 automatically rises to its maximum volume and hardens in an open space, thereby forming the pre-potting structure 910). In this way, the free rise method provides higher adhesive strength at the adhesive interface formed by working with the foamed adhesive 9 in multiple stages, compared to a method that uses the upper die of the mold to control its position, and facilitates continuous production on site. This is because controlling the rise height of the foamed adhesive 9 using the method that uses the upper die of the mold to control its position has the disadvantage of requiring demolding, which necessitates hardening the foamed adhesive 9 to a certain strength before demolding, requiring several hours of hardening time, making it unsuitable for continuous production. In addition, to facilitate the demolding process, it is necessary to place a demolding agent between the foamed adhesive 9 and the mold, resulting in lower interfacial adhesive strength of the foamed adhesive formed after demolding compared to the interfacial adhesive strength of the free rise method.

[0081] Furthermore, in some embodiments, the process may further include a step of test-operating the adhesive filling device along a first preset trajectory before filling at least a portion of the space with foam adhesive 9 along the first preset trajectory. For example, the first preset trajectory, the moving speed of the adhesive outlet of the adhesive filling device, etc., can be adjusted. Also, the adhesive filling device does not need to discharge adhesive during the test operation. In this way, after ensuring that the trajectory parameters and moving speed, etc., are correct, the formal pre-potting operation can be performed, which helps the adhesive filling device to perform the adhesive filling operation in the first cavity 121 according to a predetermined first preset trajectory and the moving speed of the adhesive outlet of the adhesive filling device.

[0082] In one embodiment, referring to Figures 4 and 5, the housing cavity 120 may have a second cavity 122 located between the battery assembly 2 and the cover 3, and between adjacent battery units 210 within the battery assembly 2. The post-potting structure 920 has a first post-potting structure 921 in the second cavity 122, and the steps of filling the housing cavity 120 with foam adhesive 9 in multiple stages to form a pre-potting structure 910 formed by filling the foam adhesive 9 at least once and a post-potting structure 920 formed by filling the foam adhesive 9 at least once include the step of filling the second cavity 122 with foam adhesive 9 along a second preset trajectory 4 to form the first post-potting structure 921. Thus, the first post-potting structure 921 can be realized by, for example, controlling the adhesive outlet of an adhesive filling device to fill the adhesive along the second preset trajectory 4, making the work easier.

[0083] Here, Figure 3 illustrates the arrangement of multiple battery units 210 in the battery assembly 2, namely, the battery assembly 2 has multiple sets of battery units 210 arranged side by side along the length direction of the battery unit 210, each set of battery units 210 has multiple battery units 210 arranged side by side along the thickness direction of the battery unit 210, the length direction of each battery unit 210 is parallel to the first direction, the thickness direction of the battery unit 210 is parallel to the second direction, and the height direction of the battery unit 210 is parallel to the height direction of the battery pack. In this embodiment, the battery unit 210 is a battery monomer, also called a battery cell, and is the minimum discharge power source in the battery pack, and includes a positive electrode and a negative electrode separator membrane, a battery cell shell, etc.

[0084] Of course, the specific embodiment of the battery assembly 2 described above is illustrative, and in some other embodiment, the battery units 210 of the battery assembly 2 may be arranged as shown in Figure 8, that is, the battery assembly 2 may have multiple sets of battery units 210 arranged in a line along the length direction of the battery unit 210, each set of battery units 210 having multiple battery units 210 arranged in a line along the height direction of the battery unit 210, and multiple sets of battery units 210 stacked along the height direction of the battery pack. Here, the length direction of each battery unit 210 is parallel to the first direction, the thickness direction of the battery unit 210 is parallel to the height direction of the battery pack, and the height direction of the battery unit 210 is parallel to the second direction. In this embodiment, the battery unit 210 is a battery monomer, also called a battery cell, and is the minimum discharge power source in the battery pack, and includes a positive electrode and a negative electrode separator membrane, a battery cell shell, etc.

[0085] Alternatively, in some other embodiment, the battery assembly 2 may have a plurality of battery units 210 arranged side by side along the first and / or second directions. Referring to Figure 9, each of the battery units 210 is configured as a blade battery monomer. Or, referring to Figure 10, each of the battery units 210 is configured as a battery module 280, each of which comprises a casing and a plurality of battery monomers installed within the casing, the battery monomers also called battery cells, which are the minimum discharge power sources in the battery pack and include positive and negative electrode separators, battery cell shells, etc. This disclosure does not specifically limit the above variations, and those skilled in the art can appropriately configure the specific arrangement of the battery assembly 2 according to the needs of the actual application.

[0086] In one embodiment, the potting method for a battery pack further includes the step of determining a second preset trajectory 4 based on the arrangement of the battery units 210 of the battery assembly 2, the arrangement of the battery units 210 of the battery assembly 2 shown in Figure 3 is described exemplarily, and the details are as follows.

[0087] For example, the adhesive filling operation can be performed along a second preset trajectory 4 shown in Figure 6. Exemplarily, as shown in Figure 6, the second preset trajectory 4 may include a first main trajectory 410 and a first turning trajectory 420. Each of the multiple first main trajectories 410 extends along the thickness direction of the battery unit 210 and is arranged in a line along the length direction of the battery unit 210, and two adjacent first main trajectories 410 are connected by a first turning trajectory 420, so that the second preset trajectory 4 becomes a meandering trajectory.

[0088] Therefore, the specific arrangement of the second preset trajectory 4 is determined in accordance with the arrangement method of the battery units 210 of the battery assembly 2, and the adhesive outlet of the adhesive filling device is controlled to perform the adhesive filling operation along the second preset trajectory 4. Specifically, as shown in Figures 3 to 6, there is a first gap 250 between two adjacent battery units 210 spaced apart in the longitudinal direction, the first gap 250 forms a part of the second cavity 122, and the first gap 250 extends along the thickness direction. In addition, a pole 211 and a surface area 212 adjacent to the pole 211 are installed on the upper surface of the battery unit 210, the battery assembly 2 has a busbar assembly 220 located above the battery unit 210, there is a second gap 260 between the busbar assembly 220 and the cover 3, there is a third gap 270 between the busbar assembly 220 and the battery unit 210, and the busbar assembly 220 has an adhesive injection port 221 that communicates with the second gap 260 and the third gap 270. Therefore, in order to saturate the second cavity 122 formed in the first gap 250, pole 211 and surface area 212 adjacent to pole 211, second gap 260 and third gap 270, etc., at least one first main trajectory 410 passes through the first gap 250, at least one first main trajectory 410 passes through the surface area 212, at least one first main trajectory 410 passes through pole 211, and at least one first main trajectory 410 passes through the adhesive injection port 221, thereby achieving the objective of saturating the second cavity 122 with adhesive.

[0089] In an interchangeable embodiment, to distinguish the movement trajectories in Figure 6 and Figure 7, the second preset trajectory 4 can be shown as the fourth preset trajectory 8 in Figure 7, and when filling the second cavity 122 with foam adhesive 9, the adhesive outlet of the adhesive filling device can be controlled to perform the adhesive filling operation along the fourth preset trajectory 8 shown in Figure 7, the second main trajectory 810 of the fourth preset trajectory 8 extends along the length direction of the battery unit 210 and is arranged side by side along the thickness direction of the battery unit 210 (referring to the top and bottom direction of the paper in Figure 4), and two adjacent second main trajectories 810 are connected by a second turning trajectory 820.

[0090] Furthermore, depending on the arrangement of the battery unit 210 in the battery assembly 2, that is, as shown in Figures 3 and 4, when controlling the adhesive outlet of the adhesive filling device to perform the adhesive filling operation along the fourth preset trajectory 8 shown in Figure 7, the second main trajectory 810 sequentially passes through the pole 211, surface area 212, first gap 250, and adhesive inlet 221, etc., and the size of the gap areas formed by different structures differs. In the step of controlling the adhesive outlet of the adhesive filling device to perform the adhesive filling operation along the fourth preset trajectory 8, problems are likely to occur where some areas are not saturated with adhesive and other areas are filled with too much adhesive. Moreover, in order to achieve saturated filling of each sub-area, it is necessary to control the adhesive outlet of the adhesive filling device to operate along a single second main trajectory 810 and continuously adjust the operating speed and the amount of adhesive discharged, which significantly increases the difficulty of designing the adhesive filling process and / or adhesive filling trajectory.

[0091] When controlling the adhesive outlet of the adhesive filling device to perform the adhesive filling operation along the second preset trajectory 4 shown in Figure 6, the single trajectory of the first main trajectory 410 passes through multiple poles 211, or multiple surface areas 212, or multiple first gaps 250, or multiple adhesive inlets 221, all arranged in a row along the thickness direction of the battery unit 210. In this way, adhesive can be saturated in the gap areas of identical structures arranged in a row. Furthermore, because they are all identical structures, overall repeatability is improved, and thus, controlling the operating speed of the adhesive outlet of the adhesive filling device and the amount of adhesive discharged along a single first main trajectory 410 is simpler and requires no adjustment, reducing the difficulty of operating the adhesive filling device and the difficulty of designing the adhesive filling process and / or adhesive filling trajectory. Therefore, this disclosure ensures that the adhesive outlet of the adhesive filling device performs the adhesive filling operation along the second preset trajectory 4 in accordance with the arrangement of the battery unit 210 of the battery assembly 2, and because the overall reproducibility of surface features in the same structural area through which a single trajectory of the first main trajectory 410 passes is better, saturated filling in the second cavity 122 can be achieved, effective potting in narrow gaps can be achieved and the potting effect can be improved.

[0092] Furthermore, the total adhesive filling time for filling the second cavity 122 with foam adhesive 9 along the second preset trajectory 4 is divided into specific single adhesive filling trajectories and times in each row or column of the battery assembly 2 of the second preset trajectory 4. That is, depending on the actual needs, the multiple first main trajectories 410 of the second preset trajectory 4 may be designed to have equal lengths and equal potting times, or they may be designed to have unequal lengths and potting times, and the adhesive filling trajectories may be straight lines or arcs. Similarly, the lengths and times of the multiple first turning trajectories 420 of the second preset trajectory 4 may also be adjusted according to the needs, generally between 0.1 and 0.5 s, with the determining factors being the adhesive filling flow rate at the adhesive outlet of the adhesive filling device and the flow diffusion capacity of the adhesive in the actual viscosity state, thereby achieving saturated filling in the second cavity 122, effective potting into the narrow gap, and improving the potting effect.

[0093] Furthermore, as shown in Figure 6, the first main trajectories 410 of each row of the second preset trajectory 4 correspondingly pass through poles 211, surface areas 212, first gaps 250, and adhesive inlet 221, etc. However, because the gap area sizes formed by the surface features of different structural areas differ, the lengths of the first main trajectories 410 in each row are designed to be the same. However, the potting times of the first main trajectories 410 in each row differ, and the specific potting time is determined by the volume of foam adhesive that needs to be filled into the gap area formed by the surface features of the corresponding structural area through which the corresponding first main trajectory 410 passes. Exemplarily, for example, in this disclosure, among the multiple first main trajectories 410, the potting time of the trajectory passing through the adhesive inlet 221 and the first gap 250 is the longest, thereby enabling saturation filling of the third gap 270 and the first gap 250. On the other hand, the length and operating time of multiple first turning trajectories 420 on the surface of each row of battery units 210 may be specifically designed according to the amount of filling required in the local area, but considering the dimensions of the entire row of battery units 210, the top surface state of each row of battery units 210 is approximately the same, so the design of multiple first turning trajectories 420 may be the same.

[0094] Herein, the specific structure of the busbar assembly 220 is not limited in this disclosure. For example, any CCS (Cells Contact System) integrated busbar structure known in the art can be adopted, which may include, for example, a plastic bracket, a Busbar metal busbar, an FPC / NTC sampling component, etc. However, this disclosure is not limited, and those skilled in the art can design it appropriately according to their actual needs. By encasing and protecting weaker components of the busbar assembly 220, such as the NTC temperature sensor and sampling weld points, with foam adhesive 9, saturation filling of all gap areas between the busbar assembly 220 and the battery unit 210 can be achieved. Furthermore, the foam adhesive 9 can make contact with the inside of the cover 3 over a sufficient area to form structural strength and realize the structural design of the entire battery pack.

[0095] Furthermore, in the actual potting process, when controlling the adhesive outlet of the adhesive filling device to perform adhesive filling along the second preset trajectory 4, the surface of the busbar assembly 220 is uneven, and the corresponding space below the busbar assembly 220 is different. Therefore, the width of the single-trajectory potting adhesive spreading on the surface of the busbar assembly 220 is limited. According to actual measurement results of single-trajectory potting with different adhesive filling flow rates of the adhesive filling device, the width of the busbar assembly 220 covered by a single trajectory is only 1 / 6 to 1 / 3 of the length of the upper surface of the corresponding battery unit 210 (see the left-right direction of the paper in Figure 4). In other words, in order to ensure that the entire upper surface of the busbar assembly 220 is covered with adhesive liquid, the number of designed turns on each row of battery units 210 is 2 to 5, and the total number of turns for the battery assembly 2 reaches several tens of times. The precise calculation of the adhesive filling trajectory time is concentrated in multiple first main trajectories 410. Therefore, the time of multiple first turning trajectories 420 is usually designed to be as short as possible to mitigate the adverse effects of extra turning on the potting of the entire battery pack. Depending on the setting accuracy of the adhesive filling device's program, the turning time is usually designed to be 0.1 to 0.2 seconds. However, during the actual execution of adhesive filling, due to the weight and motion inertia of the robot arm of the adhesive filling device, each turning actually involves two changes of direction and two accelerations and decelerations. The actual operating time of the robot arm during turning is much longer than 0.2 seconds, closer to 0.4 to 1 second. Furthermore, the number of turns on the top surface of the entire battery assembly 2 is high, resulting in a significantly larger actual amount of adhesive filling than the designed amount. The excess adhesive liquid concentrates at both ends of the multiple first main trajectories 410, and this abnormal accumulation of adhesive liquid causes the battery pack cover 3 to not engage securely.

[0096] To solve the problem of the adhesive liquid concentrating at both ends of the multiple first main trajectories 410, in one embodiment, referring to Figure 6, the first main trajectory 410 has opposing first end 411 and second end 412, and the battery assembly 2 has a first side wall 230 adjacent to the first end 411 along the thickness direction and a second side wall 240 adjacent to the second end 412, and there is a first preset distance between the first end 411 and the first side wall 230, and a second preset distance between the second end 412 and the second side wall 240, and the values ​​of the first preset distance and the second preset distance are determined based on the difference between the actual operating time of the adhesive outlet of the adhesive filling device in the first turning trajectory 420 and the set operating time. For example, the thickness of the battery unit 210 is D, the values ​​of the first preset distance and the second preset distance are D', D'≧D*1 / 2 and D'≦3D. Thus, the first main trajectory 410 above the battery assembly 2 is optimized inward by a certain distance along the thickness direction of the battery unit 210 at the turning position, that is, optimized to the values ​​D' of the first preset distance and the second preset distance, such that D'≧D*1 / 2 and D'≦3D. In this way, the inertia along the thickness direction of the battery unit 210 when the foamed adhesive 9 is ejected from the adhesive outlet of the adhesive filling device causes the adhesive liquid of the foamed adhesive 9 to spread uniformly over the battery assembly 2. This solves the problem where the actual operating time when the adhesive filling device turns along the second preset trajectory 4 is clearly longer than the set time, increasing the operating time on the trajectory at the turning, causing the adhesive liquid to increase abnormally and accumulate at both ends of the multiple first main trajectories 410.

[0097] Furthermore, after determining the values ​​of the first and second preset distances, the potting method for the battery pack further includes the step of correcting the values ​​of the first and second preset distances based on flow field simulation and / or experimental design, and verifying the feasibility of the first and second preset distances.

[0098] According to the above description, the actual amount of adhesive filled is clearly greater than the designed amount of adhesive, and excess adhesive liquid accumulates at both ends of multiple first main trajectories 410. This abnormal accumulation of adhesive liquid causes the battery pack cover to not engage securely. The cause of this is that the time the robot arm of the adhesive filling device spends on the actual first turning trajectory 420 is longer than the design value. To solve the above problem, this disclosure employs a method of running the device without discharging adhesive using the designed trajectory program, and accurately calculates each trajectory using analysis means such as a stopwatch or slow-motion video playback. In particular, it accurately collects the actual operating time at each first turning trajectory 420 position and compares it with the design value for filling each trajectory with adhesive.

[0099] The difference between the actual operating time and the design time for each trajectory can be expressed in two ways. Specifically, there is a deviation between the actual operating time and the design time for the first main trajectory 410. Typically, the linear velocity of the robot arm reaches several meters / second, and the design operating speed of a single first main trajectory 410 does not exceed the upper limit speed of the robot arm. Therefore, by adjusting the trajectory setting time in the robot arm's motion program, calculating the corresponding actual operating time, and repeatedly verifying it, it is ultimately possible to match the actual operating time for each first main trajectory 410 with the design potting time calculated based on the amount of adhesive.

[0100] Furthermore, for each position of the first turning trajectory 420, there is a minimum value for the actual operating turning time in the partial area, and this minimum value is related to the weight of the robot arm itself and the drive motor, and is usually in the range of 0.4s to 1s, which is clearly longer than the designed turning time. To solve the problem that the actual operating turning time in the partial area, which is the first turning trajectory 420 position, is longer than the designed turning time, the present disclosure accurately calculates the actual trajectory operating time at each position of the first turning trajectory 420 and takes its average value, and then corrects the adhesive filling trajectory parameters on the top surface of the battery unit 210 in each column or row based on the actual operating time at each first turning trajectory 420. In this disclosure, when performing adhesive filling work along the second preset trajectory 4, the present disclosure bisects the portion of the actual operating time at each first turning trajectory 420 that is longer than the design time, and subtracts each of these from the time of the adjacent first main trajectory 410, while simultaneously shortening the length of the first main trajectory 410 by the length corresponding to the subtracted time.

[0101] When actually performing the work, the inertia of the adhesive liquid after it leaves the robot arm must be considered. This inertia promotes the spread of the adhesive liquid along the thickness direction of the battery unit 210. The effect of this part can be summarized by flow field simulation or adhesive filling DOE verification of the battery assembly 2. By superimposing this effect data onto the above-calculated and corrected theoretical turning position trajectory parameters, a second preset trajectory 4 above the final battery assembly 2 is obtained, ensuring uniform spread of the foamed adhesive liquid on the upper surface of the battery assembly 2. Furthermore, through optimization by multiple simulations and test verification, the first main trajectory 410 above the battery assembly 2 is optimized to move inward by a certain distance along the thickness direction of the battery unit 210 at the turning point, i.e., optimized to the value D' of the first preset distance and the second preset distance, so that D'≧D*1 / 2 and D'≦3D, under normal adhesive filling device parameters. As a result, the problem of adhesive accumulation on the edges of the battery assembly 2 and uneven distribution of the adhesive liquid can be solved.

[0102] In one embodiment, referring to Figures 4 and 5, the pre-potting structure 910 is located within the first cavity 121, and the post-potting structure 920 includes a second post-potting structure 922 located within the third cavity 123 and above the pre-potting structure 910. The step of filling the housing cavity 120 with foam adhesive 9 in multiple stages to form the pre-potting structure 910, which is formed by filling the foam adhesive 9 at least once, and the post-potting structure 920, which is formed by filling the foam adhesive 9 at least once, further includes the step of filling the first cavity 121 and the third cavity 123 with foam adhesive 9 along a third predetermined trajectory to form the second post-potting structure 922. In this way, by filling the second cavity 122 with foam adhesive 9 along the second preset trajectory 4 to form the first post-potting structure 921, and by filling the first cavity 121 and the third cavity 123 with foam adhesive 9 along the third preset trajectory to form the second post-potting structure 922, saturation potting filling of the area above and around the battery assembly 2 can be achieved. The battery assembly 2 is then stably connected to the cover 3 via the post-potting structure 920 formed by the first post-potting structure 921 and the second post-potting structure 922, effectively improving the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack and promotes the structuring process of the battery pack.

[0103] Here, the adhesive area between the post-potting structure 920 and the cover 3 occupies more than 90% of the inner wall surface of the cover 3, and the adhesive strength of the post-potting structure 920 is ensured to be higher than 0.7 MPa, thereby ensuring that the battery assembly 2 is stably connected to the cover 3 by the post-potting structure 920.

[0104] Furthermore, in some embodiments, the battery pack may further have a first blocking structure 5, as shown in Figure 4, to reduce abnormal flow of the adhesive liquid to other areas. The first blocking structure 5 is used to partition the first cavity 121, the second cavity 122, and the third cavity 123, reducing abnormal flow between the first cavity 121, the second cavity 122, and the third cavity 123 before the adhesive liquid rises and hardens, ensuring a uniform distribution of the adhesive liquid and improving the potting effect.

[0105] Furthermore, in some embodiments, as shown in Figure 4, the battery pack may further include a second blocking structure 6, which is used to partition at least a portion of the first cavity 121 and / or at least a portion of the third cavity 123 into a plurality of sub-filling cavities 124. This further improves the uniformity of the distribution of the adhesive liquid in the first cavity 121 and the third cavity 123, thereby improving consistency after foaming of the adhesive 9 and the reproducibility of industrial production.

[0106] This disclosure does not specifically limit the specific structures of the first blocking structure 5 and the second blocking structure 6, and they may be, for example, sponges or rubber blocks. The purpose is to separate the first cavity 121, the second cavity 122, and the third cavity 123, and to partition the inside of the first cavity 121 and the third cavity 123 into a plurality of sub-filling cavities. Furthermore, this disclosure does not specifically limit the specific number of the first blocking structure 5 and the second blocking structure 6, which are, for example, the adhesive blocking sponges or adhesive blocking rubber blocks, and a person skilled in the art can design the specific number of adhesive blocking sponges or adhesive blocking rubber blocks according to the actual application needs.

[0107] In one embodiment, the third preset trajectory may be an annular trajectory extending along the circumferential direction of the battery assembly 2. This enables the adhesive filling operation in the third cavity 123 and the remaining first cavity 121 above the pre-potting structure 910 that is not filled with foam adhesive 9. Here, the annular trajectory includes, but is not limited to, a circular trajectory, a rectangular trajectory, an elliptical trajectory or any irregular circumferentially closed trajectory.

[0108] Furthermore, the potting method for the battery pack described above further includes the step of filling the second cavity 122 with foam adhesive 9 along a second preset trajectory 4, and then filling the first cavity 121 and the third cavity 123 with foam adhesive 9 along a third preset trajectory, wherein the rate of expansion of the foam adhesive 9 is greatly affected by temperature, with higher temperatures resulting in a faster expansion rate. In this embodiment, the area where the second cavity 122 is located has a large area that expands along the X and Y directions in Figure 4, so after filling the second cavity 122 with foam adhesive 9, the area of ​​expansion of the foam adhesive 9 is also large, resulting in a large heat dissipation area in contact with air, and the gap between the battery assembly 2 and the cover 3 becomes smaller, the amount of foam adhesive 9 between the battery assembly 2 and the cover 3 becomes smaller, and less heat is accumulated. Compared to the second cavity 122, the area where the first cavity 121 and the third cavity 123 are located has a smaller area along the X and Y directions in Figure 4, but a larger total volume. Therefore, after filling the first cavity 121 and the third cavity 123 with foam adhesive 9, a large amount of foam adhesive 9 accumulates inside the first cavity 121 and the third cavity 123. This is unfavorable for heat dissipation of the foam adhesive 9, and the temperature inside the foam adhesive 9 rises. Consequently, the foam adhesive 9 in the first cavity 121 and the third cavity 123 has a shorter rise time than the foam adhesive 9 in the second cavity 122. Therefore, this disclosure allows for filling the second cavity 122 with foam adhesive 9 before filling the first cavity 121 and the third cavity 123 with foam adhesive 9. As a result, after filling the first cavity 121 and the third cavity 123 with foam adhesive 9, the start times of the foaming of the foam adhesive 9 in the second cavity 122 and the foam adhesive 9 in the first cavity 121 and the third cavity 123 become close or the same, ensuring the stability of the adhesive filling process.

[0109] Here, before filling the second cavity 122 with foam adhesive along the second preset trajectory 4, the procedure may further include a step of test-running the adhesive filling device along the second preset trajectory 4 and the third preset trajectory. For example, the second preset trajectory 4, the third preset trajectory, and the moving speed of the adhesive outlet of the adhesive filling device can be adjusted, and during the test run, the adhesive filling device does not discharge adhesive. In this way, after the trajectory parameters and moving speeds are correctly secured, the second potting operation can be formally performed, and the adhesive filling device can be controlled to perform the adhesive filling operation on the second cavity 122, the third preset trajectory 4, and the first cavity 121 above the pre-potting structure 910, where the remaining foam adhesive 9 has not been filled, according to the predetermined second preset trajectory 4, the third preset trajectory, and the moving speed of the adhesive outlet of the adhesive filling device.

[0110] In some embodiments, the potting method for the battery pack may include a step of beginning to fill the first cavity 121 and the third cavity 123 along a third predetermined trajectory after the foam adhesive 9 forming the pre-potting structure 910 has risen to its maximum volume. Exemplarily, a field worker fills the first cavity 121 and the third cavity 123 along a third predetermined trajectory after the foam adhesive 9 forming the pre-potting structure 910 has risen to its maximum volume and before the top surface of the pre-potting structure 910 has dried (where dried means that the adhesive surface of the foam adhesive 9 has reached the surface-drying stage, and not dried means that the adhesive surface of the foam adhesive 9 has not completely dried and is still sticky), thereby ensuring that the adhesive interface between the pre-potting structure 910 and the post-potting structure 920 has high adhesive strength.

[0111] Of course, on-site workers may continue filling the first cavity 121 and the third cavity 123 along a third predetermined trajectory after the foam adhesive 9 forming the pre-potting structure 910 has risen to its maximum volume and the upper surface of the pre-potting structure 910 has dried (where "dried" means that the bonding surface of the foam adhesive 9 has reached the surface-drying stage, and "not dried" may be understood as the bonding surface of the foam adhesive 9 not being completely dry and being tacky). This disclosure does not specifically limit such modifications, and those skilled in the art can design them as appropriate according to their actual application needs.

[0112] In one embodiment, an adhesive may be added to the adhesive interface between the pre-potting structure 910 and the post-potting structure 920, thereby improving the adhesive strength at the adhesive interface between the pre-potting structure 910 and the post-potting structure 920.

[0113] Furthermore, after the foam adhesive 9 forming the pre-potting structure 910 has risen to its maximum volume, the worker can immediately fill the second cavity 122 with the foam adhesive 9 along the second preset trajectory 4 to form the first post-potting structure 921. Alternatively, for example, before the foam adhesive 9 of the pre-potting structure 910 has risen to its maximum volume, the worker may appropriately fill the second cavity 122 between the battery assembly 2 and the cover 3 with adhesive to form the first post-potting structure 921 (details to be described later). At this time, the foam adhesive 9 located in the first cavity 121 continues to rise. Once the adhesive filling work in the second cavity 122 is completed, the foam adhesive 9 in the first cavity 121 has risen to its maximum volume, and the second post-potting structure 922 (details to be described later) can be formed by continuing to fill the housing cavity 120 with adhesive, which helps to shorten the production time of the entire battery pack at the site and improves production efficiency.

[0114] Furthermore, after completing the adhesive filling work in the first cavity 121, which is not yet filled with the remaining foam adhesive above the second cavity 122, the third cavity 123, and the pre-potting structure 910, it is required to complete the assembly process of the entire pack, including the installation of the cover, the placement of the pressure-holding fixture for the cover 3, and the installation and tightening of the sealing bolts at the connection points between the cover 3 and the case 1, before the foam adhesive 9 bulges, or at the latest before the foam adhesive 9 bulges and contacts the inner wall of the cover 3. In this way, the adhesive filling work for the entire battery pack is completed.

[0115] This disclosure exemplifies a potting method for a battery pack in an embodiment.

[0116] First, the adhesive filling device is test-run along a pre-set trajectory, and during the test run, the adhesive filling device does not discharge adhesive. Before attaching the cover 3, foam adhesive 9 is filled into the two first cavities 121 along a first pre-set trajectory, and the free rise of the foam adhesive 9 forms a pre-potting structure 910. The adhesive filling device is test-run along the second pre-set trajectory 4 and the third pre-set trajectory, and during the test run, the adhesive filling device is not discharged. The first post-potting structure 921 is formed by filling the second cavity 122 with foam adhesive 9 along the second preset trajectory 4, the second preset trajectory 4 is determined based on the arrangement of the battery unit 210 of the battery assembly 2, the second preset trajectory 4 includes a first main trajectory 410 and a first turning trajectory 420, all of which first main trajectories 410 extend along the thickness direction of the battery unit 210 and are arranged side by side along the length direction of the battery unit 210, two adjacent first main trajectories 410 are connected by the first turning trajectory 420, the second preset trajectory 4 is formed as a meandering trajectory, and the first main trajectory 410 has opposing first ends 4 Having an end 11 and a second end 412, the battery assembly 2 has a first side wall 230 adjacent to the first end 411 along the thickness direction and a second side wall 240 adjacent to the second end 412, with a first preset distance between the first end 411 and the first side wall 230 and a second preset distance between the second end 412 and the second side wall 240, the values ​​of the first preset distance and the second preset distance are determined based on the difference between the actual operating time and the set operating time of the adhesive outlet of the adhesive filling device in the first turning trajectory 420, and the values ​​of the first preset distance and the second preset distance are corrected based on flow field simulation and / or experimental design.

[0117] After filling the second cavity 122 with foam adhesive 9 along the second preset trajectory 4, and after the foam adhesive 9 forming the pre-potting structure 910 has risen to its maximum volume and before the upper surface of the pre-potting structure 910 has dried, the second post-potting structure 922 is formed by filling the first cavity 121 and the third cavity 123 along the third preset trajectory. By attaching the cover 3 and maintaining pressure using the existing pressure-holding fixture, the battery assembly 2 is connected to the cover 3 by the post-potting structure 920 after the foam adhesive 9 has finished rising, and the space between the pre-potting structure 910 and the cover 3 is similarly filled and connected by the post-potting structure 920.

[0118] A battery pack is provided according to a second aspect of this disclosure. The battery pack, using the potting method provided in the first aspect, can solve the problem in the related technology of poor engagement between the cover and the battery pack case after the potting of the battery pack, thereby improving the feasibility of the overall potting design of the battery pack and the stability of the process. The battery pack also has all the beneficial effects of the potting method for battery packs provided in the first aspect, which are omitted from this disclosure in detail.

[0119] According to a third aspect of the present disclosure, a battery pack is provided comprising a case 1, a battery assembly 2, a cover 3, a pre-potting structure 910, and a post-potting structure 920, wherein the case 1 has a housing cavity 120 having an opening 110, the battery assembly 2 is located within the housing cavity 120, the cover 3 seals the opening 110, the pre-potting structure 910 is formed of foam adhesive 9 and located within the housing cavity 120, the post-potting structure 920 is formed of foam adhesive 9 and located within the housing cavity 120, and the battery assembly 2 is connected to the cover 3 by the post-potting structure 920.

[0120] According to the above-mentioned technical proposal, i.e., the battery pack provided in the third aspect of this disclosure, the battery pack is formed by filling the housing cavity 120 with foam adhesive 9 in multiple stages to create a pre-potting structure 910 and a post-potting structure 920. The battery assembly 2 is stably connected to the cover 3 by the post-potting structure 920, which effectively improves the overall structural strength of the battery pack, is advantageous for the overall structural design of the battery pack, helps to improve the overall insulation performance of the battery pack, and the consistency of thermal management and thermal safety. It also reduces the problem in related technologies where poor engagement between the cover and the battery pack case is likely to occur after the potting work of the battery pack, and can improve the feasibility of the overall potting design of the battery pack and the stability of the process.

[0121] Furthermore, this disclosure makes it possible to achieve saturated potting filling in each gap area within the battery pack by filling the housing cavity 120 of the battery pack with foam adhesive 9 in multiple stages, which improves the potting effect and is advantageous for improving the overall structural strength of the battery pack.

[0122] Furthermore, the battery pack cover 3 may be configured as part of the vehicle body floor, thereby achieving an integrated design between the battery pack cover 3 and the vehicle body floor.

[0123] In some embodiments, the projection of the post-potting structure 920 in the height direction of the battery pack can cover the pre-potting structure 910, thereby bonding the battery assembly 2 to the case 1 by the pre-potting structure 910 and the battery assembly 2 to the cover 3 by the post-potting structure 920, and the pre-potting structure 910 and the post-potting structure 920 are bonded by a freely raised bonding surface of foam adhesive 9, or an adhesive may be added between the pre-potting structure 910 and the post-potting structure 920, thereby ensuring high connection reliability, but the disclosure is not limited thereto.

[0124] Furthermore, in one embodiment, the adhesive strength at the interface between the pre-potting structure 910 and the post-potting structure 920 is E, and the adhesive strength between the post-potting structure 920 and the cover 3 is F, where E > F. Thus, because the adhesive area between the post-potting structure 920 and the cover 3 is much larger than the adhesive interface area between the pre-potting structure 910 and the post-potting structure 920, stress tends to concentrate at the adhesive interface between the pre-potting structure 910 and the post-potting structure 920 rather than at the connection point between the post-potting structure 920 and the cover 3. Therefore, this disclosure can improve the unfavorable effects of stress concentration by making the adhesive strength E at the interface between the pre-potting structure 910 and the post-potting structure 920 higher than the adhesive strength F between the post-potting structure 920 and the cover 3. Furthermore, by making the adhesive strength E at the interface between the pre-potting structure 910 and the post-potting structure 920 higher than the adhesive strength F between the post-potting structure 920 and the cover 3, even if the cover 3 peels off from the potting adhesive, the case 1, battery assembly 2, pre-potting structure 910, post-potting structure 920, and busbar assembly 220 remain as a single integrated structure, effectively ensuring the structural stability and safety of the battery pack.

[0125] Furthermore, in one embodiment, the pull-out / shear strength at the interface between the pre-potting structure 910 and the post-potting structure 920 is denoted as A, and the pull-out / shear strength of the potting structure when there is no interface in the potting structure formed by the foam adhesive 9 is denoted as B, where A > 0.5B. This ensures that the adhesive interface between the pre-potting structure 910 and the post-potting structure 920 has high adhesive strength.

[0126] Furthermore, in some embodiments, referring to Figures 4 and 5, the battery assembly 2 may have a battery unit 210, and the housing cavity 120 has a first cavity 121 located at at least one end of the battery assembly 2 along a first direction (refer to the left-right direction of the paper in Figure 4), and the pre-potting structure achieves the purpose of pre-potting by having at least a portion of it located within the first cavity 121, effectively reducing the volume of the remaining space area in the battery pack that needs to be filled with foam adhesive 9, effectively shortening the filling time used to fill the required amount of adhesive in the post-potting structure 920, and reducing the problem of poor engagement of the cover 3.

[0127] The battery assembly 2 may be placed in the housing cavity 120 of the case 1 in a manner such as upright or inverted. Exemplarily, Figure 4 illustrates that after the assembly of the battery assembly 2 and the case 1 is complete, two first cavities 121 may be formed in the housing cavity 120, located at opposing ends of the battery assembly 2 along a first direction: the vehicle front end cavity 7 on the left side and the vehicle rear end cavity 10 on the right side, as shown in Figure 4. Simultaneously, two third cavities 123 may be formed in the housing cavity 120, located at opposing ends of the battery assembly 2 along a second direction: slit areas located on the sides of the battery assembly 2 as shown in Figure 4. Since the volume of the space area that needs to be filled with foam adhesive in the two first cavities 121 (e.g., the vehicle front cavity 7 and the vehicle rear cavity 10) is larger than the volume of the space area that needs to be filled with foam adhesive in the two third cavities 123 (e.g., the slit area on the side of the battery assembly 2), pre-filling the two locations with large volume of space area that need to be filled with foam adhesive 9, namely the vehicle front cavity 7 and the vehicle rear cavity 10, effectively reduces the remaining volume of space area in the battery pack that needs to be filled with foam adhesive 9. This achieves the objective of effectively shortening the filling time used to fill the amount of adhesive required for the post-potting structure 920, reduces the problem of poor engagement of the cover 3, improves the feasibility and process stability of the overall potting design of the battery pack, effectively improves the overall structural strength of the battery pack, and is advantageous for the overall structural design of the battery pack.

[0128] Furthermore, when pre-filling the two first cavities 121 with adhesive, the foamed adhesive 9 is usually a liquid fluid before it is injected into the first cavities 121 and rises up. To reduce the problem of the adhesive fluid abnormally flowing to other areas (for example, the second cavity 122 between the battery assembly 2 and the cover 3), in some embodiments, the highest point of the upper surface of the pre-potting structure 910 is located below the highest end of the battery unit 210, or the highest point of the upper surface of the pre-potting structure 910 is aligned with the highest end of the battery unit 210, in the height direction of the battery pack (see the direction perpendicular to the plane of the paper in Figure 4 or the up and down direction in Figure 5). This reduces the problem of the adhesive fluid abnormally flowing to other areas, ensures a uniform distribution of the adhesive fluid, and improves the potting effect.

[0129] Furthermore, in order to achieve the objective of shortening the adhesive filling time used for the final adhesive filling, for example, by better realizing multi-stage potting, in one embodiment, the distance between the lowest point on the upper surface of the pre-potting structure 910 and the highest end of the battery unit 210 in the height direction of the battery pack (see the direction perpendicular to the plane of the paper in Figure 4 or the up and down direction in Figure 5) is h, and the size of the battery unit 210 in the height direction of the battery pack (see the direction perpendicular to the plane of the paper in Figure 4 or the up and down direction in Figure 5) is H, where h ≤ H * 1 / 2. In this way, by controlling the position of the lowest point on the upper surface of the pre-potting structure, the objective of shortening the adhesive filling time used for the final adhesive filling can be achieved by realizing multi-stage potting, improving the feasibility of the overall potting design of the battery pack and the stability of the process, effectively improving the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack.

[0130] In some embodiments, the size of the accommodation cavity 120 in the height direction of the battery pack is H', the height of the highest or lowest point of the upper surface of the pre-potting structure 910 with respect to the inner bottom surface of the accommodation cavity 120 is L, and L≧H'*1 / 3. In this way, after the pre-potting operation, the volume of the remaining space area in the battery pack that needs to be filled with the foam adhesive 9 can be effectively reduced, and the filling time used to fill the amount of adhesive required for the post-potting structure 920 can be effectively shortened, thus achieving the purpose.

[0131] Exemplarily, in some embodiments, the size of the battery unit 210 of the battery assembly 2 in the height direction of the battery pack is H. By setting H’*1 / 2<L<H, the adhesive filling operation at the site can be facilitated. At the same time, the filling time used to fill the amount of adhesive required for the post-potting structure 920 can be effectively shortened. Also, for the overall structure and lightweight design of the battery pack, in some embodiments, when the size of the battery unit 210 of the battery assembly 2 in the height direction of the battery pack is H, by setting H≧H’*2 / 3, the overall structure and lightweight design of the battery pack can be facilitated.

[0132] Furthermore, considering the fluidity of the adhesive liquid, when filling the pre-potting structure 910 with adhesive liquid, if there is a large depression on the upper surface of the pre-potting structure 910, the adhesive liquid will flow into the depression, causing it to accumulate and resulting in poor uniform distribution of the adhesive liquid. In contrast, if the adhesive liquid is a foamed adhesive 9, after the foamed adhesive 9 rises up and forms a part of the post-potting structure 920, the unevenness of the upper surface of that part of the post-potting structure 920 becomes even larger, and therefore the bonding area between the post-potting structure 920 and the cover 3 becomes smaller. As described above, in the embodiments provided by this disclosure, the height distance between the highest and lowest points on the upper surface of the pre-potting structure 910 may be smaller than a preset distance, and exemplary the preset distance may be 10 mm or 15 mm, thereby ensuring that the flatness of the upper surface of the pre-potting structure 910 meets the requirements, thereby reducing the flow of the adhesive liquid when filling the upper surface of the pre-potting structure 910 and improving the uniform distribution of the adhesive liquid. This increases the bonding area between the post-potting structure 920 and the cover 3 after the adhesive liquid has risen to form a part of the post-potting structure 920, ensuring that the bonding interface between the pre-potting structure 910 and the post-potting structure 920 has high bonding strength, and improving the overall structural strength of the battery pack.

[0133] Furthermore, in some embodiments, referring to Figures 4 and 5, the housing cavity 120 may have a second cavity 122 between the battery assembly 2 and the cover 3, and between adjacent battery units 210 in the battery assembly 2, and a third cavity 123 located at at least one end of the battery unit 210 along the second direction. The post-potting structure 920 may have a first post-potting structure 921 located within the second cavity 122, and a second post-potting structure 922 located within the third cavity 123 and above the pre-potting structure 910. Thus, the first post-potting structure 921 and the second post-potting structure 922 enable saturated potting filling in the area above and around the battery assembly 2 (the third cavity 123 and the remaining part of the first cavity 121 above the pre-potting structure 910, where the foam adhesive 9 is not filled), which helps the battery assembly 2 to be stably connected to the cover 3 via the post-potting structure 920 formed by the first post-potting structure 921 and the second post-potting structure 922, effectively improving the structural strength of the entire battery pack and being advantageous for the overall structural design of the battery pack.

[0134] Furthermore, in some embodiments, the density of the first post-potting structure 921, the second post-potting structure 922, and the pre-potting structure 910 decreases sequentially. Exemplarily, as shown in Figures 4 and 5, the second post-potting structure 922 has a second structure 9222 located above the first structure 9221 and the pre-potting structure 910, which are located within the third cavity 123, and the density of the first post-potting structure 921, the first structure 9221, the second structure 9222, and the pre-potting structure 910 decreases sequentially, effectively improving the structural strength of the entire battery pack, which is advantageous for the overall structural design of the battery pack, and helps to improve the insulation performance of the entire battery pack, as well as the consistency of thermal management and thermal safety.

[0135] In one embodiment, as shown in Figure 4, the battery pack may further have a first blocking structure 5, which is used to partition the first cavity 121, the second cavity 122, and the third cavity 123. This reduces abnormal flow between the first cavity 121, the second cavity 122, and the third cavity 123 before the adhesive liquid rises and hardens, ensuring a uniform distribution of the adhesive liquid and improving the potting effect.

[0136] Furthermore, in some embodiments, as shown in Figure 4, the battery pack may further have a second blocking structure 6, which divides at least a portion of the first cavity 121 and / or at least a portion of the third cavity 123 into a plurality of sub-filling cavities 124, thereby improving the uniformity of the distribution of adhesive liquid within the first cavity 121 and the third cavity 123, and improving consistency after the foaming of the adhesive 9 and reproducibility in industrial production.

[0137] Furthermore, in the battery pack provided by the third aspect of this disclosure, the specific structures of the first blocking structure 5 and the second blocking structure 6 are not specifically limited, and may be, for example, adhesive blocking sponges or adhesive blocking rubber blocks, as long as they can partition the first cavity 121, the second cavity 122, and the third cavity 123 and achieve the objective of dividing the inside of the first cavity 121 and the third cavity 123 into a plurality of sub-filling cavities. Also, in the battery pack provided by the third aspect of this disclosure, the specific number of arrangements of the first blocking structure 5 and the second blocking structure 6, whose structures are, for example, adhesive blocking sponges or adhesive blocking rubber blocks, is not limited, and a person skilled in the art can appropriately design the specific number of arrangements of adhesive blocking sponges or adhesive blocking rubber blocks according to the actual application needs.

[0138] A fourth aspect of this disclosure provides an electrical device comprising the battery pack provided in the second aspect or the battery pack provided in the third aspect. The electrical device has all the beneficial effects of the battery pack provided in the second aspect or the battery pack provided in the third aspect, and this disclosure omits a further detailed description herein.

[0139] In some exemplary application scenario, the above-mentioned electrical device may be a vehicle, which may be a new energy vehicle, which may be a pure electric vehicle, a hybrid vehicle, or a range-extender electric vehicle, and this disclosure is not specifically limited thereto.

[0140] Of course, in other application scenarios, the above-mentioned electrical devices may be transport equipment that needs to be powered by battery packs, such as in the energy storage field, space flight, or hydrographic transport.

[0141] While preferred embodiments of this disclosure have been described in detail above with reference to the drawings, this disclosure is not limited to the specific details of the above embodiments. Within the scope of the technical idea of ​​this disclosure, various simple modifications can be made to the technical proposals of this disclosure, and all such simple modifications fall within the scope of protection of the present invention.

[0142] Furthermore, each specific technical feature described in the above-described embodiment can be combined in any suitable manner, provided they do not conflict. To avoid unnecessary repetition, this disclosure will not further describe various combinations.

[0143] Furthermore, various different embodiments of this disclosure can be combined in any way, and insofar as they do not contradict the spirit of this disclosure, they should also be considered as part of what is disclosed by this disclosure. [Explanation of symbols]

[0144] 1 case 110 Aperture 120 capacity cavity 121 First Cavity 122 Second Cavity 123 Third Cavity 124 Sub-filled cavities 2 Battery Assembly 210 Battery Unit 211 Paul 212 Surface Area 220 Busbar Assembly 221 Adhesive injection port 230 First side wall 240 Second side wall 250 First Gap 260 Second Gap 270 Third Gap 280 Battery Modules 3 Cover 4. Second pre-set trajectory 410 1st main trajectory 411 1st end 412 2nd end 420 The First Turning Point 5. First Shut-off Structure 6. Second Shut-off Structure 7. Cavity at the front of the vehicle 8. Fourth pre-set trajectory 810 2nd main trajectory 820 The Second Turning Point 9. Foam adhesive 910 Pre-potting structure 920 Post-potting structure 921 First Post-Potting Structure 922 Second Post-Potting Structure 9221 1st structure 9222 2nd structure 10. Rear end cavity of the vehicle

Claims

1. A potting method for battery packs, The battery pack comprises a case, a battery assembly, and a cover, the case having a housing cavity with an opening, the battery assembly being located within the housing cavity, and the cover sealing the opening. The potting method for the aforementioned battery pack is: The step of filling the housing cavity with foam adhesive in multiple stages before attaching the cover includes forming a pre-potting structure formed by filling with the foam adhesive at least once, and a post-potting structure formed by filling with the foam adhesive at least once. A potting method for a battery pack, characterized in that the battery assembly is connected to the cover by the post-potting structure.

2. The step of filling the containment cavity with the foam adhesive in multiple steps to form the pre-potting structure formed by filling the foam adhesive at least once, and the post-potting structure formed by filling the foam adhesive at least once, A potting method for a battery pack according to claim 1, characterized in that it includes the step of filling at least a portion of the space between the battery assembly and the side wall of the housing cavity with the foam adhesive to form the pre-potting structure.

3. The potting method for a battery pack according to claim 2, wherein the battery assembly has a battery unit, the housing cavity has a first cavity located at least one end of the battery assembly along a first direction, and the pre-potting structure is at least partially located within the first cavity.

4. The housing cavity has a third cavity located at at least one end of the battery assembly along the second direction, and the volume of the first cavity is greater than the volume of the third cavity, or The potting method for a battery pack according to claim 3, characterized in that, in the height direction of the battery pack, the highest point of the upper surface of the pre-potting structure is located below the highest end of the battery unit, or the highest point of the upper surface of the pre-potting structure is at the same height as the highest end of the battery unit.

5. The step of filling the space between the battery assembly and the side wall of the housing cavity with the foam adhesive to form the pre-potted structure includes the step of filling the space with the foam adhesive along a first predetermined trajectory, or The potting method for a battery pack according to any one of claims 2 to 4, characterized in that the pre-potting structure is formed by the free rise of the foam adhesive.

6. The housing cavity has a second cavity located between the battery assembly and the cover, and between adjacent battery units in the battery assembly, and the post-potting structure has a first post-potting structure located within the second cavity. The step of filling the containment cavity with the foam adhesive in multiple steps to form the pre-potting structure formed by filling the foam adhesive at least once, and the post-potting structure formed by filling the foam adhesive at least once, The process includes the step of filling the second cavity with the foaming adhesive along a second predetermined trajectory to form the first post-potting structure, The potting method for the aforementioned battery pack is: The potting method for a battery pack according to claim 1, further comprising the step of determining the second preset trajectory based on the arrangement of the battery units of the battery assembly.

7. The battery assembly has a plurality of sets of the battery units arranged side by side along the length direction of the battery unit, and each set of the battery units has a plurality of the battery units arranged side by side along the thickness direction of the battery unit. The potting method for a battery pack according to claim 6, characterized in that the second preset trajectory includes a first main trajectory and a first turning trajectory, the plurality of first main trajectories all extend along the thickness direction of the battery unit and are arranged side by side along the length direction of the battery unit, and two adjacent first main trajectories are connected by a first turning trajectory so that the second preset trajectory is formed as a meandering trajectory.

8. A first gap exists between two adjacent battery units spaced apart in the longitudinal direction, the first gap forms part of the second cavity, the first gap extends along the thickness direction, and at least one of the first principal trajectories passes through the first gap, or The upper surface of the battery unit is provided with a pole and a surface area adjacent to the pole, and at least one of the first main trajectories passes through the pole, and at least one of the first main trajectories passes through the surface area, or The battery assembly has a busbar assembly located above the battery unit, a second gap between the busbar assembly and the cover, a third gap between the busbar assembly and the battery unit, the busbar assembly has an adhesive inlet connecting the second gap and the third gap, and at least one of the first main trajectories passes through the adhesive inlet, or The potting method for a battery pack according to claim 7, characterized in that the first main trajectory has opposing first and second ends, the battery assembly has a first side wall adjacent to the first end and a second side wall adjacent to the second end along the thickness direction, there is a first preset distance between the first end and the first side wall, and there is a second preset distance between the second end and the second side wall.

9. The housing cavity has a first cavity located at least one end of the battery assembly along a first direction, the housing cavity has a third cavity located at least one end of the battery assembly along a second direction, the pre-potting structure is located within the first cavity, and the post-potting structure has a second post-potting structure located within the third cavity and above the pre-potting structure. The step of filling the containment cavity with the foam adhesive in multiple steps to form the pre-potting structure formed by filling the foam adhesive at least once, and the post-potting structure formed by filling the foam adhesive at least once, The third step includes filling the first cavity and the third cavity with the foaming adhesive along a predetermined trajectory to form the second post-potting structure, The potting method for a battery pack according to any one of claims 6 to 8, characterized in that the third pre-set trajectory is an annular trajectory extending in the circumferential direction of the battery assembly.

10. The steps include: filling the second cavity with the foaming adhesive along the second preset trajectory, and then filling the first cavity and the third cavity with the foaming adhesive along the third preset trajectory; After the foaming adhesive forming the pre-potting structure has risen to its maximum volume, the step of starting to fill the first cavity and the third cavity with the foaming adhesive along the third predetermined trajectory, and A potting method for a battery pack according to claim 9, further comprising at least one of the following steps: after the foam adhesive forming the pre-potting structure has risen to its maximum volume, and before the upper surface of the pre-potting structure dries, begin filling the first cavity and the third cavity with the foam adhesive along the third predetermined trajectory.

11. It is a battery pack, A case having an opening and a housing cavity, A battery assembly located within the aforementioned housing cavity, A cover that seals the aforementioned opening, A pre-potting structure formed by foam adhesive and located within the housing cavity, It comprises a post-potting structure formed from the aforementioned foaming adhesive and located within the aforementioned housing cavity, A battery pack characterized in that the battery assembly is connected to the cover by the post-potting structure.

12. The projection of the post-potting structure in the height direction of the battery pack covers the pre-potting structure, or The pre-potting structure and the post-potting structure are bonded together, or The battery pack according to claim 11, characterized in that the adhesive strength at the interface between the pre-potting structure and the post-potting structure is E, the adhesive strength between the post-potting structure and the cover is F, and E > F.

13. The battery assembly has a battery unit, the housing cavity has a first cavity located at least one end of the battery assembly along a first direction, and the pre-potting structure is located at least a portion within the first cavity. In the height direction of the battery pack, the highest point of the upper surface of the pre-potting structure is located below the highest end of the battery unit, or the highest point of the upper surface of the pre-potting structure is at the same height as the highest end of the battery unit, or The height distance between the lowest point on the upper surface of the pre-potting structure and the highest point of the battery unit is h, the size of the battery unit in the height direction is H, and h ≤ H * 1 / 2, or The size of the housing cavity in the height direction of the battery pack is H', and the height of the highest or lowest point of the upper surface of the pre-potting structure relative to the inner bottom surface of the housing cavity is L, where L ≥ H' * 1 / 3, or The size of the battery unit of the battery assembly in the height direction of the battery pack is H, and H' * 1 / 2 < L < H, or The battery pack according to claim 11, characterized in that the size of the battery unit of the battery assembly in the height direction of the battery pack is H, and H ≥ H' * 2 / 3.

14. The housing cavity has a second cavity located between the battery assembly and the cover and between adjacent battery units in the battery assembly, and a third cavity located at at least one end of the battery assembly along a second direction, and the post-potting structure has a first post-potting structure located within the second cavity, and a second post-potting structure located within the third cavity and above the pre-potting structure. The density of the first post-potting structure, the second post-potting structure, and the pre-potting structure decreases sequentially. The battery pack according to claim 13, wherein the second post-potting structure comprises a first structure located within the third cavity and a second structure located above the pre-potting structure, and the density of the first post-potting structure, the first structure, the second structure, and the pre-potting structure decreases sequentially.

15. An electrical device characterized by comprising a battery pack according to any one of claims 11 to 14.

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