Battery assembly and assembly process

Abstract

The present invention relates to a battery assembly and an assembly process thereof, the battery assembly including a case, cells, an electrical connection side plate, and electrical connection members, the electrical connection side plate being attached to an inner wall of the case, the electrical connection members being attached to the electrical connection side plate so as to be movable with multiple degrees of freedom, the electrical connection members being provided with insertion / removal passages, the cells being inserted / removably mounted in the case, and the cell poles being inserted into the insertion / removal passages. This invention reduces repair costs, improves maintenance efficiency, and absorbs tolerances that exist when forming a battery pack from cells.

Description

[Technical Field]

[0001] This application claims priority to Chinese Patent Application No. 202310255085.7, entitled "Battery Assembly and Assembling Process Thereof," filed with the China Patent Office on March 16, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to the technical field of new energy batteries, and particularly to a battery assembly and its assembly process. [Background technology]

[0003] As the new energy industry flourishes, battery systems are attracting attention, and current single cells will no longer be able to meet energy demands. Therefore, the final product is an assembly (case, pack) made up of all cells. Ease of installation, safety, and repairability are also important factors in manufacturing high-energy density battery packs. The ability to repair or replace damaged cells in a timely manner and reduce repair costs is also part of product evaluation. During the process of forming battery packs from cells, cell dimensional tolerances affect the consistency of the formation, so pre-loading is required in battery packs to improve the cell's cycleability.

[0004] In the prior art, most cells are connected by electrical connection paths formed by welding the terminal posts to the electrical connection members. To accommodate the preload and dimensional tolerance of the cells, it is common to weld a thin cell tab to a metal busbar portion of a non-metallic support, so that when the preload is applied, the tab can bend slightly to achieve a moderate movement.

[0005] In conventional technology, cells are connected by welding. In this case, if a malfunction occurs in a single cell and replacement or repair is required, the welded portion must be machined, resulting in high repair costs, or the machining process may damage other cells. Furthermore, the single cell may not be repairable; in this case, the only option is to replace the entire battery pack, which results in significantly high repair costs. Regarding cell dimensional tolerances and the application of preload, variations in cell dimensions can cause tabs to join together when the cells are assembled into a battery pack, resulting in a short circuit. While the cell tabs are fixed, applying preload causes the cells to approach each other, resulting in slight displacement, which applies tensile force to the cell tabs and can result in cell damage. Summary of the Invention [Problem to be solved by the invention]

[0006] The primary objective of this application is to provide a battery assembly and its assembly process, which aims to solve one or more of the following technical problems in the prior art: Specifically, when cells are connected by welding, if a malfunction occurs in a single cell and replacement or repair is required, the welded portion must be machined, resulting in high repair costs, or the processing may damage other cells. Furthermore, the single cell may not be repairable; in this case, the only option is to replace the entire battery pack, which results in significantly high repair costs. Regarding cell dimensional tolerances and the application of preload, variations in cell dimensions can cause tabs to join together when the cells are assembled into a battery pack, potentially resulting in a short circuit. While the cell tabs are fixed, applying preload can cause the cells to approach each other, resulting in slight displacement, which can apply tensile force to the cell tabs and potentially damage the cells. [Means for solving the problem]

[0007] The primary objective of this application is to provide a battery assembly and its assembly process, which aims to solve one or more of the following technical problems in the prior art: Specifically, when cells are connected by welding, if a malfunction occurs in a single cell and replacement or repair is required, the welded portion must be machined, resulting in high repair costs, or the processing may damage other cells. Furthermore, the single cell may not be repairable; in this case, the only option is to replace the entire battery pack, which results in significantly high repair costs. Regarding cell dimensional tolerances and the application of preload, variations in cell dimensions can cause tabs to join together when the cells are assembled into a battery pack, potentially resulting in a short circuit. While the cell tabs are fixed, applying preload can cause the cells to approach each other, resulting in slight displacement, which can apply tensile force to the cell tabs and potentially damage the cells.

[0008] To achieve the above object of the invention, the present application proposes a battery assembly and an assembling process thereof.

[0009] A first aspect of the present application proposes a battery assembly including a case, a cell, an electrical connection side plate, and an electrical connection member, wherein the electrical connection side plate is attached to an inner wall of the case, the electrical connection member is attached to the electrical connection side plate so as to be movable with multiple degrees of freedom, the electrical connection member is provided with an insertion / removal path, the cell is provided in the case so as to be insertable and removable, and the pole of the cell is inserted into the insertion / removal path.

[0010] Based on the above technical solutions, the present invention can be further improved as follows:

[0011] Furthermore, an assembly sandwich is provided on the electrical connection side plate, and a first through hole communicating with the assembly sandwich is opened in the electrical connection side plate, the electrical connection member includes a limit piece and an insertion / extraction member, the limit piece is assembled within the assembly sandwich so as to be movable with multiple degrees of freedom, the insertion / extraction member is fixed to the limit piece and is provided through the first through hole, and the insertion / extraction path is provided in the insertion / extraction member.

[0012] Furthermore, the side of the limit piece elastically abuts or is clearance-fitted against the sandwich side wall of the assembly sandwich, a buffer gap is maintained between the first circumferential side edge of the limit piece and the corresponding circumferential side wall of the assembly sandwich, and the second circumferential side edge of the limit piece elastically abuts against the corresponding circumferential side wall of the assembly sandwich, and the second circumferential side edge is located on the axial insertion / removal end side of the insertion / removal path.

[0013] Furthermore, the limit piece is provided with a bending support structure, and a bending edge of the bending support structure is elastically abutted or clearance-fitted against the sandwich side wall of the assembled sandwich; A resilient pad is further provided on the circumferential side wall of the assembly sandwich, and a second circumferential side edge of the limit piece abuts against the resilient pad.

[0014] Furthermore, the insertion / removal passage has an axial opening, the axial insertion / removal starting end of the insertion / removal passage is a large end, the axial insertion / removal terminal end of the insertion / removal passage is a small end, and the pole of the cell is inserted axially from the large end of the insertion / removal passage.

[0015] The case further includes a pipe restricting section, a plurality of liquid cooling plates, an inlet liquid cooling pipe, and an outlet liquid cooling pipe, the pipe restricting section being attached to the base plate or top plate of the case, the water inlets and outlets of the plurality of liquid cooling plates being connected to the inlet liquid cooling pipe and the outlet liquid cooling pipe, respectively, the inlet liquid cooling pipe and the outlet liquid cooling pipe being restricted so as to be insertable and removable within the corresponding pipe restricting section, an insertion / removal gap for accommodating cells being maintained between two adjacent liquid cooling plates, and the cells being arranged within the insertion / removal gap.

[0016] Furthermore, a hook path is further provided on the electrical connection side plate, which extends in the same direction as the insertion / removal path, and a hook block is provided on the side edge of the liquid cooling plate, which is inserted into the hook path.

[0017] Furthermore, the pipe restriction portion is provided with a pipe slot arranged perpendicular to the liquid cooling plate, the opening of the pipe slot is arranged toward the insertion / removal path, and the wall of the pipe slot is provided with an escape notch to accommodate the corner of a cell.

[0018] Furthermore, the liquid cooling plate is a flexible liquid cooling plate.

[0019] Furthermore, the base plate of the case is further provided with multiple rows of second through holes, each row of second through holes including at least one second through hole, and an elastic piece is connected to the base plate at each of the second through holes, the elastic piece is arranged corresponding to the second through hole, and the elastic piece is arranged to protrude from one side of the base plate.

[0020] Furthermore, the second through-hole and the elastic piece are formed in the base plate using a press process.

[0021] Furthermore, a pressure plate is further provided within the case, and the pressure plate is pressed against the upper edge of the cell.

[0022] Furthermore, the limit piece is connected by a soft board, and the inserting / extracting member is connected by a hard board.

[0023] A second aspect of the present application proposes an assembly process for the battery assembly, including the following steps:

[0024] (S1) assembling a pipe restriction part to a base plate or a top plate of the case, and fixing an electrical connection side plate to an inner wall of the case; or (S1') a step of fixing an electrical connection side plate to the inner wall of the case and assembling a pipe restriction part to the base plate or top plate of the case; a step (S2) of assembling the liquid cooling plates and the cells in the case, attaching the inlet and outlet liquid cooling pipes to which the plurality of liquid cooling plates are connected within the pipe restriction sections, inserting the cells into the insertion / removal gap between two adjacent liquid cooling plates, and inserting the poles of the cells into the insertion / removal paths of the electrical connection members; or and (S2') assembling the liquid cooling plates and cells in the case, inserting the cells into the insertion / removal paths of the electrical connection members, maintaining liquid cooling plate insertion / removal gaps between adjacent cells, respectively inserting multiple liquid cooling plates into the corresponding liquid cooling plate insertion / removal gaps, and respectively attaching water inlet liquid cooling pipes and water outlet liquid cooling pipes to which the multiple liquid cooling plates are connected within the pipe restriction portions. [Effects of the Invention]

[0025] The present invention employs separate electrical connection side plates and electrical connection members, and movably assembles the electrical connection side plates to allow cell poles to be inserted and removed within the insertion and removal paths. When a single cell breaks down or malfunctions, it can be easily removed for replacement or repair. This reduces repair costs and improves maintenance efficiency. Furthermore, it eliminates potential defects that may occur due to variations in cell dimensions when forming a battery pack from cells, reduces the risk of cell damage, and absorbs tolerances that exist when forming a battery pack from cells. The provision of an assembly sandwich and through holes allows the limit piece to be easily restricted and moved within the assembly sandwich. The subsequent detachable connection between the insertion and removal members and the cell poles facilitates assembly, resulting in a compact and reliable assembly structure. The provision of a buffer gap facilitates movement of the limit piece within the assembly sandwich. The provision of an inlet liquid cooling pipe and an outlet liquid cooling pipe that can be inserted and removed within the pipe restriction section facilitates assembly. The liquid-cooling plate can be hooked onto the electrical connection side plate, facilitating assembly. The provision of escape notches not only avoids the corners of the cells but also limits them to some extent, making the cell assembly structure more stable. The preload force on the cells can be adjusted as needed by changing the amount of water pressure within the liquid-cooling plate. The base plate has multiple rows of through-holes, each equipped with an elastic strip. When placing the cells on the base plate, the elastic force of the elastic strip provides a certain elastic adjustment space for the cell height, making it easy to adjust the height difference between different cells and accommodate cell tolerances. Furthermore, the elastic strips protrude from the base plate, maintaining a certain gap between the cells and the base plate, improving the heat dissipation capacity of the entire battery pack. Unlike adhesives or rubber pads that restrict cell movement, the elastic strip structure does not restrict cell movement, allowing the cells to be easily removed for subsequent replacement or repair.The through-holes and elastic pieces are formed using a stamping process, which is simple and quick to form. The formed elastic pieces have a consistent structure and can provide effective and stable structural support for each cell. Furthermore, the assembly process of the present invention uses an insertion / removal method to form the battery pack from the cells and connect the liquid cooling system, allowing for physical disassembly and replacement of any abnormalities in the cells. This method allows for the reuse of related parts compared to welding. Furthermore, the electrical connection side plates can accommodate the dimensional tolerances of the cells, reducing the risk of the poles breaking under force and the risk of damage to the cells. The tapered structure facilitates the insertion and positioning of the cell poles. [Brief explanation of the drawings]

[0026] [Figure 1] 1 is a perspective view showing an exploded structure of a battery assembly according to the present invention; [Figure 2] 1 is a schematic diagram showing a structure in which a cell according to the present invention is inserted into an insertion member. [Figure 3] FIG. 3 is a schematic diagram showing an enlarged structure of part A in FIG. 2. [Figure 4] 2 is a schematic diagram showing the structure in which the cell according to the present invention is inserted into the insertion member. FIG. [Figure 5] 5 is a schematic diagram showing an enlarged structure of part B in FIG. 4. FIG. [Figure 6] 3 is a schematic diagram showing a structure in which a cell according to the present invention is inserted into an insertion member. [Figure 7] 7 is a schematic diagram showing an enlarged structure of part C in FIG. 6. FIG. [Figure 8] 1 is a perspective view showing a structure of a plurality of liquid cooling plates according to the present invention; [Figure 9] 1 is a schematic diagram showing the fitting structure of the liquid cooling plate and the cell according to the present invention. FIG. [Figure 10] 2 is a schematic diagram showing the fitting structure of the liquid cooling plate and the cell according to the present invention. FIG. [Figure 11] 1 is an exploded perspective view showing a structure in which an electrical connection side plate and an electrical connection member according to the present invention are fitted together; [Figure 12] 12 is a schematic diagram showing an enlarged structure of part D in FIG. 11. FIG. [Figure 13] 1 is a side view showing a fitting structure between an electrical connection side plate and an electrical connection member according to the present invention; [Figure 14] 1 is a perspective view showing the structure of an electrical connection member according to the present invention. [Figure 15] FIG. 2 is a schematic diagram showing a part of the structure of the case according to the present invention. [Figure 16] FIG. 10 is a perspective view showing a structure in which a pipe restricting portion is attached inside a case in the present invention. [Figure 17] 10 is a perspective view showing a structure in which a connecting side plate is attached to a side plate of a case in the present invention. FIG. [Figure 18] FIG. 10 is a perspective view showing a structure in which a sampling plate is attached to an electrical connection side plate in the present invention. [Figure 19] 1 is a perspective view showing a structure in which a liquid cooling plate is attached inside a case according to the present invention; [Figure 20] FIG. 2 is a perspective view showing a structure in which a separator is attached in the present invention. [Figure 21] FIG. 1 is a perspective view showing a structure in which cells are attached in the present invention. [Figure 22] FIG. 10 is a perspective view showing a structure in which a pressure plate is attached in the present invention. [Figure 23] FIG. 1 is a perspective view showing a structure in which a top plate and an end plate are attached in the present invention. [Figure 24] 1 is a perspective view showing the structure of a battery assembly according to the present invention. [Figure 25] 1 is a schematic diagram showing the structure of a base plate of a case according to the present invention. [Figure 26] FIG. 26 is a schematic diagram showing an enlarged structure of part A in FIG. 25. [Figure 27] 1 is a schematic diagram showing the fitting structure of a cell and a base plate according to the present invention. FIG. [Figure 28] 28 is a schematic diagram showing an enlarged structure of part B in FIG. 27. FIG. [Figure 29]2 is a schematic diagram showing the structure of the base plate of the case according to the present invention. [Figure 30] FIG. 30 is a schematic diagram showing an enlarged structure of part C in FIG. 29. [Figure 31] 2 is a schematic diagram showing the fitting structure of the cell and the base plate according to the present invention. FIG. [Figure 32] 32 is a schematic diagram showing an enlarged structure of part D in FIG. 31. FIG. [Figure 33] FIG. 2 is a perspective view showing an exploded structure of a case according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0027] The principles and features of the present invention will be explained below with reference to the accompanying drawings. However, the examples given are merely for the purpose of illustrating the present invention and are not intended to limit the scope of the present invention.

[0028] As shown in Figures 1 to 33, the battery assembly of this embodiment includes a case, a cell 200, an electrical connection side plate 104, and an electrical connection member, the electrical connection side plate 104 is attached to the inner wall of the case, the electrical connection member is assembled to the electrical connection side plate 104 so as to be movable with multiple degrees of freedom, an insertion / removal path is provided in the electrical connection member, the cell 200 is provided in the case so as to be insertable and removable, and the pole 201 of the cell 200 is inserted into the insertion / removal path.

[0029] Here, the electrical connection side plate 104 of this embodiment can be made of any insulating material having a certain degree of toughness.

[0030] The electrical connection member is attached to the electrical connection side plate 104 so as to be movable with multiple degrees of freedom. Specifically, the electrical connection member can be restricted on the electrical connection side plate 104 and movable within a certain range. Taking the six degrees of freedom (each coordinate axis has two degrees of freedom) shown by the XYZ coordinate axes in FIG. 1 as an example, the electrical connection member may be movable in any two or more degrees of freedom directions relative to the electrical connection side plate 104.

[0031] As shown in Figures 11 to 14, in this embodiment, an assembly sandwich 105 is provided on the electrical connection side plate 104, and a first through hole 106 communicating with the assembly sandwich 105 is opened in the electrical connection side plate 104. The electrical connection member includes a limit piece 107 and an insertion / extraction member 108. The limit piece 107 is assembled within the assembly sandwich 105 so as to be movable with multiple degrees of freedom and is gap-fitted with the inner wall of the assembly sandwich 105 (this gap is extremely small, so that the movement of the limit piece 107 can be ensured and the cell pole cannot be pulled too much). The insertion / extraction member 108 is fixed to the limit piece 107 and is provided through the first through hole 106, and the insertion / extraction path is provided in the insertion / extraction member 108. By providing the assembly sandwich and the first through hole, the limit piece can be easily restricted within the assembly sandwich and can be moved within the assembly sandwich, and then the insertable / removable connection between the insertable member and the cell pole makes assembly easy, and the assembled structure is compact and reliable.

[0032] Specifically, in this embodiment, the limit piece 107 can be connected using a soft board, and the insertion / extraction member 108 can be connected using a hard board. This means that the structural strength of the insertion / extraction member 108 is greater than that of the limit piece 107, and the toughness of the limit piece 107 is greater than that of the insertion / extraction member, thereby facilitating insertion and extraction of the cell poles into the insertion / extraction passages of the insertion / extraction member, and facilitating clearance fit of the limit piece 107 within the assembly sandwich 105. Also, while FIG. 11 shows a single-parallel-multiple-series connection, a multi-parallel-multiple-series connection may be designed as needed. Furthermore, the shape and connection method of the cell poles and the insertion / extraction passages of the insertion / extraction member in this embodiment can be any shape. For example, the cell poles can be rectangular, cylindrical, elliptical, or other shapes.

[0033] 11 and 13 , in this embodiment, the side of the limit piece 107 elastically abuts against the sandwich side wall of the assembled sandwich 105, a buffer gap 109 is maintained between a first circumferential side edge of the limit piece 107 and the corresponding circumferential side wall of the assembled sandwich 105, and a second circumferential side edge of the limit piece 107 elastically abuts against the corresponding circumferential side wall of the assembled sandwich 105, the second circumferential side edge being located on the axial insertion / removal end side of the insertion / removal path. The provision of the buffer gap facilitates movement of the limit piece in the assembled sandwich, eliminates formation defects that may occur due to variations in cell dimensions when forming a battery pack from cells, reduces the risk of cell damage, and absorbs tolerances that exist when forming a battery pack from cells.

[0034] As shown in FIG. 14, the limit piece 107 of this embodiment is provided with a bending support structure 119, and the bending edge of the bending support structure 119 elastically abuts or has a clearance fit against the sandwich side wall of the assembled sandwich 105 (this clearance is very small, so that the movement of the limit piece 107 can be ensured and the poles of the cell cannot be pulled too much).

[0035] As shown in Figures 12 and 13, in this embodiment, a resilient pad 110 is further provided on the circumferential side wall of the assembly sandwich 105, and a second circumferential side edge of the limit piece 107 abuts against the resilient pad 110.

[0036] 2 to 7, the insertion / extraction passage of this embodiment is provided with an axial opening, the axial insertion / extraction start end of the insertion / extraction passage is a large end 111, and the axial insertion / extraction end of the insertion / extraction passage is a small end 112, and the terminal post 201 of the cell 200 is inserted axially from the large end 111 of the insertion / extraction passage. The adoption of a tapered structure makes it easy to insert the terminal post of the cell and to restrict its position.

[0037] 8, 16, 17, 18, and 19, the battery assembly of this embodiment further includes a pipe restricting section 300, multiple liquid cooling plates 301, a water inlet liquid cooling pipe 302, and a water outlet liquid cooling pipe 303. The pipe restricting section 300 is attached to the base plate 100 or top plate 102 of the case. The water inlets and outlets of the multiple liquid cooling plates 301 are connected to the water inlet liquid cooling pipe 302 and the water outlet liquid cooling pipe 303, respectively. The water inlet liquid cooling pipe 302 and the water outlet liquid cooling pipe 303 are restricted so that they can be inserted and removed within the corresponding pipe restricting section 300. An insertion and removal gap is maintained between two adjacent liquid cooling plates 301 to accommodate a cell 200, and the cell 200 is located within this insertion and removal gap. The insertion and removal of the water inlet liquid cooling pipe and the water outlet liquid cooling pipe within the pipe restricting section facilitates assembly.

[0038] 8 to 11, the electrical connection side plate 104 of this embodiment is further provided with a hook path 113, which extends in the same direction as the insertion / removal path, and a hook block 305 is provided on the side edge of the liquid cooling plate 301, which is inserted so as to fit into the hook path 113. The liquid cooling plate can be hooked onto the electrical connection side plate, which makes assembly easier.

[0039] The electrical connection side plate 104 of this embodiment can be formed as a single piece or in separate pieces. This embodiment provides a preferred structural form, in which the electrical connection side plate 104 includes a plastic base plate 117 and a plastic cover plate 118. As shown in Figures 11 to 13, the plastic base plate 117 has a protrusion at its center, and the plastic cover plate 118 has a recess at its center. When the plastic base plate 117 and the plastic cover plate 118 are butted together, the protrusion is inserted into the recess and a gap is maintained, thereby forming the assembly sandwich 105. Then, a limit piece 107 of the electrical connection member is loosely fitted into the assembly sandwich 105 to restrict it. Here, a plurality of first through holes 106 are further formed in the recess of the plastic cover plate 118 for passing insertable members therethrough. Next, a hollow insertion post is provided on the side of the plastic cover plate 118 away from the plastic base plate 117, and the hooking path 113 is formed within the hollow insertion post, and the hooking path 113 is located above the first through-hole 106. Then, a resilient pad 110 is provided at the bottom of the recess. Here, the limit piece 107 abuts against the resilient pad 110, and the buffer gap 109 is held between the upper end of the limit piece 107 and the upper part of the recess. The cell is inserted from top to bottom along the Y-axis. Due to the fitting tolerance between the cell post and the insertion / extraction path, there may be a difference in height between the top and bottom when the battery pack is formed from the cell. The resilient piece 12 on the base plate of the case, the resilient pad 110 on the plastic cover plate, and the buffer gap of the assembly sandwich 105 can all absorb the height tolerance. When the cell is pressed down so that the poles and insertion / removal passages fit tightly, the elastic pieces on the base plate and the elastic pads 110 on the plastic cover plate are deformed by the force, and when the pressing force is removed, they can rebound to a certain extent, without affecting the tight connection between the poles of the cell and the electrical connection members.The limit pieces can move moderately along the X, Y, and Z directions within the assembly sandwich. If there is variation in the position and dimension of the two sides of the cell poles, the electrical connection members can move in the X, Y, and Z directions to absorb the tolerances. When the liquid cooling plate expands and presses against the cells, it provides a preload force to form the battery pack from the cells and also allows the cells to better bond together to dissipate heat during operation. The generated preload force causes a large vertical displacement of the cells, which can be absorbed by compressive deformation of the bending support structure of the electrical connection members.

[0040] 17 to 19, the pipe restricting portion 300 of this embodiment is provided with a pipe slot 306 that is arranged perpendicular to the liquid cooling plate 301, the opening of the pipe slot 306 is arranged toward the insertion / removal path, and an avoidance notch 307 is opened in the wall of the pipe slot 306 to accommodate the corner 202 of the cell 200. By providing the avoidance notch, the corner of the cell can be avoided and the corner of the cell can be limited to a certain extent, making the cell assembly structure more stable.

[0041] As a preferred solution for this embodiment, the liquid cooling plate 301 in this embodiment is a flexible liquid cooling plate, as shown in Figures 9 and 10. When a flexible liquid cooling plate is used, the flexible liquid cooling plate expands when filled with liquid refrigerant, and the larger surface area can better fit to the surface of the cells, thereby applying a preload to the cells and improving the cooling efficiency.

[0042] To further enhance the cell height adjustability, as shown in FIGS. 25 to 33 , the base plate 100 of the case of this embodiment further includes multiple rows of second through-holes 11, each row including at least one second through-hole 11. Each second through-hole 11 is connected to the base plate 100 at each second through-hole 11, and the elastic pieces 12 are positioned corresponding to the second through-hole 11 and protrude from one side of the base plate 100. By providing multiple rows of second through-holes in the base plate and providing an elastic piece in each through-hole, when placing cells on the base plate, the elastic force of the elastic piece provides a certain elastic adjustment space for the cell height, making it easy to adjust the height differences between different cells and accommodate tolerances between cells. Furthermore, by providing the elastic pieces protruding from the base plate and maintaining a certain gap between the cells and the base plate, the heat dissipation capacity of the entire battery pack is improved. Unlike adhesives or rubber pads that restrict cell movement, the elastic strip construction does not restrict cell movement and allows the cell to be easily removed if subsequent replacement or repair is required.

[0043] Specifically, each row of through-holes 11 may include only one through-hole 11 or multiple through-holes 11, and the number of through-holes 11 in each row may be the same or different. Generally, the number of through-holes 11 in each row may be the same to stably support each cell in the same way. The base plate 100 may be a flat structure or a U-shaped structure, and the through-holes 11 are provided on the flat structure or on the bottom wall of the U-shaped structure.

[0044] The elastic piece 12 in this embodiment is welded or glued to the base plate 100, or fixedly connected thereto by a connecting member, or integrally connected thereto. The elastic piece can be connected to the base plate in any fixing manner.

[0045] As shown in Fig. 25, in a preferred solution of this embodiment, the elastic piece 12 is connected to the inner wall corresponding to the through hole 11. The inner wall of the area where the through hole 11 is located is provided with an elastic piece, which may be welded to the inner wall of the through hole or integrally connected to the inner wall of the through hole, thereby not occupying space on the side of the base plate and making the structural design more reasonable.

[0046] As a preferred solution in this embodiment, an elastic piece 12 is integrally connected to the inner wall of each of the through holes 11. As in the door opening and closing mechanism, the elastic piece is integrally connected to the inner wall of the through hole, which reduces the need for other additional processes and allows the through holes and the elastic piece to be formed directly by cutting or pressing.

[0047] 25 and 26, the elastic piece 12 has a structure that is curved toward the inside of the base plate 100, and the structure can have any shape. By curving the center of the elastic piece toward one side of the base plate, the cell can be supported by the elastic piece, making the contact between the elastic piece and the cell more stable, and when the elastic piece is pressurized, the through-hole can provide a certain pressure-containing space for the elastic piece.

[0048] As shown in FIG. 26, the portion of the elastic piece 12 near its free end 13 preferably has an arc-shaped structure 14 or a flat structure 16. Here, the arc-shaped structure 14 may be a circular arc-shaped structure, an elliptical arc-shaped structure, or another irregular arc-shaped structure. When the elastic piece employs the arc-shaped structure 14, the elastic support effect is improved. When the elastic piece employs a flat structure, a higher cell support effect can be provided. The elastic piece 12 may be made of any elastic material, such as metal, hard plastic, or a metal-plastic composite structure, metal-rubber composite structure, or plastic-rubber composite structure.

[0049] As shown in Figure 25, in a more preferred solution of this embodiment, the through holes 11 in two adjacent rows are staggered. This avoids stress concentration on the base plate, and the staggered arrangement of the through holes allows all of the elastic pieces of the through holes in each row to support the cells. Here, the through holes 11 in two adjacent rows may be staggered by every other through hole 11 (i.e., one through hole 11 corresponds exactly to the spacing between two through holes 11 in the adjacent rows), or by every two through holes 11, which makes the distribution of the through holes 11 on the base plate more uniform.

[0050] 25 and 26, the shape of the elastic piece 12 preferably matches the shape of the through-hole 11. Since the elastic piece 12 and the through-hole 11 can be formed by cutting or pressing, the size and shape of the elastic piece 12 should generally be the same as the size and shape of the through-hole 11. For other needs (e.g., heat dissipation), the dimensions of the elastic piece 12 can also be set smaller so that the elastic piece can be pressed into the through-hole when subjected to excessive pressure.

[0051] In a preferred solution of this embodiment, the base plate 100 uses a press process to form the through holes 11 and elastic pieces 12. The press process is used to form the through holes and elastic pieces, which is a simple process, fast to form, and the formed elastic pieces have a consistent structure, providing effective and stable structural support for each cell. Pressing is a forming method that uses a press or mold to apply external force to plate material, strip material, tube material, or shaped material, causing plastic deformation or separation, thereby obtaining a workpiece (pressed part) with a desired shape and dimensions.

[0052] 29, the case of this embodiment includes a top plate 102, a base plate 100, end plates 116, and side plates 101. As shown in FIGS. 25 and 29, the top plate 102, base plate 100, end plates 116, and side plates 101 of this embodiment may be detachably connected to one another, or the base plate 100 and the two side plates 101 may be integrally formed. That is, after the base plate 100, left side plate, and right side plate are formed by bending a single plate, the separator 103 and the end plate 116 are fixed to the base plate 100, left side plate, and right side plate so as to maintain a gap between the separator 103 and the end plate 116 for assembling electrical components. After the entire battery pack is assembled, the top plate 102 is attached. Because an elastic piece is designed on the bottom or top of the case, the elastic piece structure on the bottom of the case can provide the same effect as an adhesive / soft rubber pad with a small contact area.

[0053] 27 and 28, the cell 200 is mounted in the case, and the non-pole side 31 of the circumferential side wall of the cell 200 corresponds to one row of through-holes 15 and abuts against the elastic pieces 12 in this row of through-holes 15. Here, the pole side of the cell 200 may be disposed opposite the non-pole side 31 or may be disposed adjacent to the non-pole side 31. FIG. 28 is a schematic diagram showing that the non-pole side 31 of the cell 200 abuts against the elastic piece 12, and one cell 200 of the entire battery pack may abut against the elastic piece 12, or all cells 200 may abut against the elastic piece 12.

[0054] Furthermore, the opening direction of the elastic pieces 12 relative to the arrangement direction of the cells 200 can be at any angle. The opening direction of the elastic pieces 12 shown in Figures 29 and 32 is perpendicular to the major surface of the cell 200. Of course, in addition to the opening direction of the elastic pieces 12 shown in Figures 15 and 32 (the direction indicated by arrow A in Figure 32), the opening direction of the elastic pieces 12 can be set parallel to the major surface of the cell 200 or can be set at any angle. In all of these cases, the elastic support effect for the cell can be exerted. Furthermore, the opening directions of all the elastic pieces 12 can be the same or different, without affecting the elastic support effect for the cell. To facilitate press processing, the opening directions of the elastic pieces 12 are generally set in the same direction. That is, the opening directions of all the elastic pieces 12 in Figure 1 are facing in the same direction.

[0055] 22 and 23, a pressure plate 114 is further provided in the case of this embodiment, and the pressure plate 114 is crimped to the upper edge of the cell 200. Here, crimped edges 121 are provided on both sides of the pressure plate 114, and the crimped edges 121 can wrap around the upper side edges of the cell, and the crimped edges 121 are further provided with escape holes 120 to avoid the processed protruding edges of the cell.

[0056] This embodiment employs separate electrical connection side plates and electrical connection members, and the electrical connection members are movably attached to the electrical connection side plates, allowing the cell posts to be inserted and removed into the insertion and removal paths. When a single cell breaks down or develops a defect, it can be removed for replacement or repair. This reduces repair costs and improves maintenance efficiency. Furthermore, it eliminates defects that can occur when forming a battery pack from cells due to variations in cell dimensions, reduces the risk of cell damage, and absorbs tolerances that exist when forming a battery pack from cells. This embodiment connects the cells to form a battery pack using a physical insertion and removal method. When connecting a cell, the cell is securely connected by pressing down with an appropriate force, and when replacing it, it is replaced using a similar physical disassembly method. This method allows related parts to be reused compared to welding. Furthermore, the electrical connection assembly has six degrees of freedom to accommodate the dimensional tolerances of the cells, and the electrical connection members adopt a combination method of softball and hardboard connection, i.e., they provide the strength necessary to connect the cell poles to form a battery pack, and also buffer the force applied to the poles when preload is applied to the cells, thereby reducing the risk of the poles being broken under the force and the risk of the cells being damaged. This embodiment also provides an assembly process for the battery assembly, which, as shown in Figures 15 to 24, includes the following steps.

[0057] S1: Assemble the pipe restricting portion 300 to the base plate 100 or top plate 102 of the case, and fix the electrical connection side plate 104 to the inner wall of the case. Or, S1': The electrical connection side plate 104 is fixed to the inner wall of the case, and the pipe restricting portion 300 is assembled to the base plate 100 or the top plate 102 of the case.

[0058] S2: Assemble the assembled liquid cooling plates 301 and cells 200 in the case, install the water inlet liquid cooling pipes 302 and water outlet liquid cooling pipes 303 to which the multiple liquid cooling plates 301 are connected in the pipe restricting section 300, insert the cells 200 into the insertion / removal gap between two adjacent liquid cooling plates 301, and insert the poles 201 of the cells 200 into the insertion / removal paths of the electrical connection members (at this time, the liquid cooling plates 301 are in a flat state when not filled with water, and the gap between the liquid cooling plates 301 is large). When the cells are inserted, they do not adhere to the liquid cooling plate, and if the liquid cooling plate is filled with water, the liquid cooling plate 301 will expand and adhere to the cells, and the cells will be pressed due to the positional restrictions between the cells and the case. After all the liquid cooling plates have been installed, a separator 103 is installed on one side of the cell arrangement direction. The separator 103 not only serves to restrict the over-expansion of the cells and the liquid cooling system and restrict their position, but can also be used to hang electrical components such as BMUs. S2': Assemble the liquid cooling plate 301 and the cell 200 in the case, insert the cell 200 into the insertion / removal path of the electrical connection member, maintain a liquid cooling plate insertion / removal gap between adjacent cells 200, insert multiple liquid cooling plates 301 into the corresponding liquid cooling plate insertion / removal gaps, and install the water inlet liquid cooling pipe 302 and water outlet liquid cooling pipe 303 to which the multiple liquid cooling plates 301 are connected within the pipe restriction section 300, respectively.

[0059] After the assembly of the cell and liquid cooling plate is completed, the pressure plate is attached. The pressure plate is used to fix the cell and also acts as a protection, preventing displacement due to vibration during transportation of the pack. Finally, the top plate and end plate are attached.

[0060] Here, when attaching the electrical connection side plate, guide posts 115 are provided on the side plates of the case, so holes can be drilled in the electrical connection side plate, the guide posts 115 can be hooked onto the holes, and then the bolts can be tightened to secure the electrical connection side plate. After the electrical connection side plate is attached, a sampling plate 400 can be attached to the electrical connection side plate. The sampling plate 400 can be used to collect the voltage of the electrical connection members and the operating temperature of the cells, and can detect abnormalities during operation in real time and issue an alarm.

[0061] In the assembly process of this embodiment, the pipe restriction and the electrical connection side plate can be assembled in any order without interference. The cells and liquid-cooled plates can also be assembled in any order. The preferred solution of this embodiment adopts step S2, that is, first assemble the liquid-cooled plate, then assemble the cell, so that the liquid-cooled plate and the liquid-cooled pipe are connected as a whole. Therefore, when assembling the whole, the case is inserted first, and then the cell is inserted between the two liquid-cooled plates, which makes the process easier.

[0062] In this assembly process, the battery pack formation from the cells and the connection to the liquid cooling system are all performed using an insertion / removal method, so if a cell malfunctions, it can be physically disassembled and replaced. This method allows related parts to be reused compared to welding. Furthermore, the electrical connection side plates can accommodate the dimensional tolerances of the cells, reducing the risk of the terminal posts breaking under force and the risk of damage to the cells.

[0063] In describing the present invention, it should be understood that the orientations or positional relationships indicated by terms such as "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," "outer," "axial," "circumferential," etc. are orientations or positional relationships shown based on the accompanying drawings, and the purpose thereof is merely to facilitate and simplify the description of the present invention, and does not expressly or imply that the referred-to devices or elements necessarily have a specific orientation, are configured, or are operated in a specific orientation, and should not be understood as limitations of the present invention.

[0064] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or to implicitly designate the number of the indicated technical features. Features qualified as "first" and "second" may thereby expressly or imply the inclusion of at least one of the features. In the description of the present invention, "plurality" means at least two, e.g., two, three, etc., unless otherwise limited.

[0065] In the present invention, unless otherwise clearly defined or limited, the terms "attach," "couple," "connect," "fixed," etc. should be understood in a broad sense, and may refer to, for example, a fixed connection, a detachable connection, or an integral connection, a mechanical connection, an electrical connection, a direct connection, an indirect connection via an intermediate medium, a communication within two elements, or an interactive relationship between two elements. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention according to the specific circumstances.

[0066] In the present invention, unless otherwise clearly defined or limited, a first feature being "above" or "below" a second feature may mean direct contact between the first feature and the second feature, or indirect contact between the first feature and the second feature via an intermediate medium. Furthermore, a first feature being "above," "above," and "on the upper surface" of a second feature may mean that the first feature is directly above or diagonally above the second feature, or may simply mean that the horizontal height of the first feature is higher than that of the second feature. A first feature being "below," "below," and "on the lower surface" of a second feature may mean that the first feature is directly below or diagonally below the second feature, or may simply mean that the horizontal height of the first feature is lower than that of the second feature.

[0067] In the description herein, a description that refers to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples" means that a specific feature, structure, material, or characteristic described based on the embodiment or example is included in at least one embodiment or example of the present invention. In the description herein, exemplary expressions for the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, a person skilled in the art may combine different embodiments or examples and features of different embodiments or examples described herein without mutually contradicting each other.

[0068] While the embodiments of the present invention have been shown and described above, the above embodiments are illustrative and should not be understood as limiting the present invention. It should be understood that those skilled in the art can change, modify, replace, and alter the above embodiments within the scope of the present invention. [Explanation of symbols]

[0069] In the drawings, the components represented by the respective symbols are as follows: 100, base plate; 101, side plate; 102, top plate; 103, separator; 104, electrical connection side plate; 105, assembly sandwich; 106, first through hole; 107, limit piece; 108, insertion / extraction member; 109, buffer gap; 110, elastic pad; 111, large end; 112, small end; 113, hook path; 114, pressure plate; 115, guide post; 116, end plate; 117, plastic base plate; 118, plastic cover Plate; 119, bending support structure; 120, escape hole; 121, crimped edge portion; 200, cell; 201, polar column; 202, corner; 300, pipe restriction portion; 301, liquid cooling plate; 302, water inlet liquid cooling pipe; 303, water outlet liquid cooling pipe; 305, hook block; 306, pipe slot; 307, escape notch; 400, sampling plate; 11, second through hole; 12, elastic piece; 13, free end; 14, arc-shaped structure; 15, one row of through holes; 16, flat structure; 31, non-polar column side

Claims

1. The device includes a case, a cell (200), an electrical connection side plate (104), and an electrical connection member, the electrical connection side plate (104) is attached to an inner wall of the case, the electrical connection member is assembled to the electrical connection side plate (104) so ​​as to be movable with multiple degrees of freedom, the electrical connection member is provided with an insertion / removal path, the cell (200) is provided in the case so as to be insertable and removable, a terminal post (201) of the cell (200) is inserted into the insertion / removal path, an assembly sandwich (105) is provided in the electrical connection side plate (104), a first through hole (106) communicating with the assembly sandwich (105) is opened in the electrical connection side plate (104), the electrical connection member includes a limit piece (107) and an insertion / removal member (108), the limit piece (107) is provided in the assembly sandwich a first circumferential side edge of the limit piece (107) elastically abuts against or is clearance-fitted with a side wall of the assembled sandwich (105), a buffer gap (109) is maintained between the first circumferential side edge of the limit piece (107) and the corresponding circumferential side wall of the assembled sandwich (105), and a second circumferential side edge of the limit piece (107) elastically abuts against the corresponding circumferential side wall of the assembled sandwich (105), the second circumferential side edge being located on the axial insertion / extraction end side of the insertion / extraction path.

2. The limit piece (107) is provided with a bending support structure (119), and the bending edge of the bending support structure (119) is in elastic abutment or clearance fit with the sandwich side wall of the assembly sandwich (105); 2. The battery assembly according to claim 1, wherein a resilient pad (110) is further provided on a circumferential side wall of the assembly sandwich (105), and a second circumferential side edge of the limit piece (107) abuts against the resilient pad (110).

3. 2. The battery assembly according to claim 1, wherein the insertion / removal passage has an axial opening, the axial insertion / removal starting end of the insertion / removal passage is a large end (111), and the axial insertion / removal ending end of the insertion / removal passage is a small end (112), and the terminal post (201) of the cell (200) is inserted axially from the large end (111) of the insertion / removal passage.

4. 3. The battery assembly according to claim 2, wherein the insertion / removal passage has an axial opening, the axial insertion / removal starting end of the insertion / removal passage is a large end (111), and the axial insertion / removal ending end of the insertion / removal passage is a small end (112), and the terminal post (201) of the cell (200) is inserted axially from the large end (111) of the insertion / removal passage.

5. 2. The battery assembly according to claim 1, further comprising a pipe restricting portion (300), a plurality of liquid cooling plates (301), a water inlet liquid cooling pipe (302), and a water outlet liquid cooling pipe (303), wherein the pipe restricting portion (300) is attached to the base plate (100) or the top plate (102) of the case, the water inlets and water outlets of the plurality of liquid cooling plates (301) are connected to the water inlet liquid cooling pipe (302) and the water outlet liquid cooling pipe (303), respectively, the water inlet liquid cooling pipe (302) and the water outlet liquid cooling pipe (303) are restricted so as to be insertable and removable within the corresponding pipe restricting portion (300), an insertion / removal gap for accommodating the cell (200) is maintained between two adjacent liquid cooling plates (301), and the cell (200) is provided within the insertion / removal gap.

6. 6. The battery assembly of claim 5, wherein the electrical connection side plate (104) is further provided with a hook path (113), the hook path (113) extending in the same direction as the insertion / removal path, and the liquid cooling plate (301) is provided with a hook block (305) on a side edge thereof, the hook block (305) being inserted into the hook path (113).

7. 6. The battery assembly according to claim 5, wherein the pipe restriction portion (300) is provided with a pipe slot (306) arranged perpendicular to the liquid cooling plate (301), the opening of the pipe slot (306) is arranged toward the insertion / extraction path, and an avoidance notch (307) is opened in the wall of the pipe slot (306) to accommodate a corner (202) of the cell (200).

8. The battery assembly of claim 5, wherein the liquid-cooled plate (301) is a flexible liquid-cooled plate.

9. 2. The battery assembly of claim 1, wherein the base plate (100) of the case is further provided with a plurality of rows of second through holes (11), each row of the second through holes (11) including at least one second through hole (11), and the base plate (100) at each of the second through holes (11) is connected to an elastic piece (12), the elastic piece (12) is arranged corresponding to the second through hole (11), and the elastic piece (12) is arranged to protrude from one side of the base plate (100).

10. The battery assembly according to claim 9, wherein the base plate (100) forms the second through-hole (11) and the elastic piece (12) using a press working process.

11. 2. The battery assembly of claim 1, further comprising a pressure plate (114) disposed within the case, the pressure plate (114) being pressed against an upper edge of the cell (200).

12. 2. The battery assembly according to claim 1, wherein the limit piece (107) adopts a connection by a soft board, and the inserting member (108) adopts a connection by a hard board.

13. (S1) assembling the pipe restriction (300) to the base plate (100) or top plate (102) of the case and fixing the electrical connection side plate (104) to the inner wall of the case; or (S1') fixing the electrical connection side plate (104) to the inner wall of the case and assembling the pipe restriction part (300) to the base plate (100) or top plate (102) of the case; a step (S2) of assembling the liquid cooling plate (301) and the cell (200) in the case, attaching the water inlet liquid cooling pipe (302) and the water outlet liquid cooling pipe (303) to which the plurality of liquid cooling plates (301) are connected, respectively, in the pipe limiting portion (300), inserting the cell (200) into the insertion / removal space between two adjacent liquid cooling plates (301), and inserting the pole (201) of the cell (200) into the insertion / removal path of the electrical connection member; or 6. The battery assembly assembly process according to claim 5, further comprising the steps of: assembling the liquid cooling plate (301) and the cells (200) in the case; inserting the cells (200) into the insertion / removal paths of the electrical connection members; maintaining liquid cooling plate insertion / removal gaps between adjacent cells (200); inserting the plurality of liquid cooling plates (301) into the corresponding liquid cooling plate insertion / removal gaps; and attaching the inlet liquid cooling pipe (302) and the outlet liquid cooling pipe (303) to which the plurality of liquid cooling plates (301) are connected, respectively, into the pipe restriction portion (300).

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