Filling assembly, tray, battery pack, and vehicle

Abstract

A filling assembly, a tray, a battery pack, and a vehicle. The filling assembly comprises a framework and at least one foaming layer, the foaming layer covers at least one a part of the outer surface of the framework, and closed-cell foam formed by means of expansion foaming of the foaming layer adheres to the outer surface of the framework.

Description

Filler assembly, tray, battery pack and vehicle

[0001] Cross Reference to Related Applications

[0002] The present application claims priority to the Chinese patent application No. 202421157544.4, filed on May 24, 2024, entitled “Filler assembly, tray, battery pack and vehicle”, the entire content of which is incorporated herein by reference. TECHNICAL FIELD

[0003] The present disclosure relates to the technical field of battery pack, and in particular to a filler assembly, a tray, a battery pack and a vehicle. BACKGROUND

[0004] In the prior art, a battery pack is composed of a frame, a bottom plate and a filler assembly, and the filler assembly is arranged in a cavity inside the frame or the bottom plate. However, the existing filler assembly increases the assembly difficulty of the battery pack manufacturing, and affects the reinforcement effect; when the filler assembly is located at the welding joint of the frame, the high temperature generated at the welding joint will ablate the reinforcement of the glass fiber or carbon fiber reinforced resin composite material.

[0005] DISCLOSURE

[0006] The present disclosure aims to at least solve one of the technical problems existing in the prior art. To this end, one object of the present disclosure is to provide a filler assembly which can improve the mechanical strength of the filler assembly and enhance the heat preservation performance of the filler assembly.

[0007] A second object of the present disclosure is to provide a tray comprising a tray body and the filler assembly described in the above embodiments.

[0008] A third object of the present disclosure is to provide a battery pack comprising the tray described in the above embodiments.

[0009] A fourth object of the present disclosure is to provide a vehicle comprising the battery pack described in the above embodiments.

[0010] The filler assembly according to the first aspect of the present disclosure comprises a framework and at least one foaming layer, wherein the foaming layer covers at least a part of the outer surface of the framework.

[0011] According to the filling assembly provided by the embodiment of the present disclosure, the framework plays a role of supporting and positioning, which facilitates the positioning of the filling assembly, makes the assembly position of the filling assembly more accurate, and improves the structural strength of the filling assembly. At least part of the outer surface of the framework is covered by the foaming layer, and the closed-cell foam formed after the foaming of the foaming layer can be adhered to the outer surface of the framework, which can make the filling assembly have good heat preservation capacity, collision energy absorption capacity, local collision deformation dispersion capacity and NVH performance. Since the foaming layer has a certain expansion range, the framework does not need to have high precision, and the framework can have some defects such as burrs, pits or flash, which can reduce the production and manufacturing difficulty of the filling assembly and reduce the production cost of the filling assembly.

[0012] In some embodiments, the filling assembly comprises a first filling assembly; the framework of the first filling assembly is a plate structure; and the foaming layer of the first filling assembly is two, and the two foaming layers cover two side surfaces in the thickness direction of the framework, respectively.

[0013] In some embodiments, further comprising: at least one first support structure, the first support structure being arranged on the framework, and the first support structure protruding from at least one side surface of the foaming layer away from the framework.

[0014] In some embodiments, the first support structure is a plurality of first support structures, and the plurality of first support structures comprise: at least one first sub-support structure and at least one second sub-support structure, the first sub-support structure being arranged on at least one side surface in the thickness direction of the framework, and the second sub-support structure being arranged on the side surface of the framework, and a part of the second sub-support structure extending to at least one side surface in the thickness direction of the framework.

[0015] In some embodiments, the first sub-support structure is a plurality of first sub-support structures, and the plurality of first sub-support structures are arranged in an array on two side surfaces in the thickness direction of the framework, respectively; and the second sub-support structure is a plurality of second sub-support structures, and the plurality of second sub-support structures are arranged in an interval along the circumference of the framework, and two ends of the second sub-support structure extend to two side surfaces in the thickness direction of the framework, respectively.

[0016] In some embodiments, the first support structure is a cross-shaped structure, a rice-shaped structure, a wave-shaped structure or a polygonal structure.

[0017] In some embodiments, the height of the first support structure protruding from at least one side surface of the foaming layer away from the framework is h, and the h satisfies: 3mm≤h≤5mm.

[0018] In some embodiments, the skeleton is provided with a plurality of through holes, and two of the foaming layers are connected into one body through the plurality of through holes; and / or at least one side surface of the skeleton in the thickness direction is provided with a plurality of protrusions, and the foaming layer covers the outer surfaces of the plurality of protrusions.

[0019] In some embodiments, the first support structure is an integral structure with the skeleton; or the first support structure is bonded or clamped with the skeleton.

[0020] In some embodiments, the edge of the first filling assembly is provided with a plurality of positioning holes, and the plurality of positioning holes are arranged at intervals along the circumference of the first filling assembly.

[0021] In some embodiments, the skeleton and the foaming layer are respectively a plurality of, the plurality of foaming layers respectively cover at least a part of the outer surfaces of the plurality of skeletons, the plurality of skeletons and the plurality of foaming layers respectively constitute a plurality of sub-filling assemblies, and the plurality of sub-filling assemblies are adapted to be detachably connected.

[0022] In some embodiments, one of the plurality of sub-filling assemblies is provided with at least one connecting groove, and another of the plurality of sub-filling assemblies is provided with at least one connecting protrusion, and the connecting protrusion is adapted to be fitted in the connecting groove to achieve the detachable connection of the plurality of sub-filling assemblies.

[0023] In some embodiments, the connecting groove penetrates through the corresponding sub-filling assembly along the thickness direction of the skeleton, and the width of the connecting groove gradually decreases in the direction towards the edge of the corresponding sub-filling assembly; and the shape of the connecting protrusion is adapted to the shape of the connecting groove.

[0024] In some embodiments, the connecting groove and the connecting protrusion are respectively a plurality of, the plurality of connecting grooves are arranged at intervals along the length direction of the corresponding sub-filling assembly, and the plurality of connecting protrusions correspond to the plurality of connecting grooves respectively.

[0025] In some embodiments, the filling assembly comprises a second filling assembly; the skeleton of the second filling assembly is a long strip structure; and the foaming layer of the second filling assembly covers the outer circumferential surface of the skeleton.

[0026] In some embodiments, further comprising: at least one second support structure, which is arranged on the skeleton, and the second support structure protrudes from at least one side surface of the foaming layer away from the skeleton.

[0027] In some embodiments, the second support structure is a plurality of second support structures, the plurality of second support structures comprises at least one third sub-support structure and at least one fourth sub-support structure, the third sub-support structure is arranged at a first corner of the framework, and the fourth sub-support structure is arranged at a second corner of the framework, the second corner being opposite to the first corner.

[0028] In some embodiments, the third sub-support structure is a plurality of third sub-support structures, the plurality of third sub-support structures are arranged at intervals along a length direction of the framework, and two ends of each of the third sub-support structures extend to two surfaces of the framework adjacent to the first corner; and the fourth sub-support structure is a plurality of fourth sub-support structures, the plurality of fourth sub-support structures are arranged at intervals along the length direction of the framework, and two ends of each of the fourth sub-support structures extend to two surfaces of the framework adjacent to the second corner.

[0029] In some embodiments, the plurality of third sub-support structures and the plurality of fourth sub-support structures are arranged at intervals along the length direction of the framework.

[0030] In some embodiments, the framework is provided with at least one first mounting structure.

[0031] In some embodiments, the first mounting structure comprises at least one of a pre-buried nut, a clamping groove, and a hollow column structure.

[0032] In some embodiments, the framework is a hollow structure.

[0033] In some embodiments, further comprising: a thermal insulation layer, the thermal insulation layer being arranged on at least part of a surface of the foaming layer away from the framework.

[0034] In some embodiments, the thermal insulation layer is a mica sheet, aerogel, or a thermal insulation coating.

[0035] In some embodiments, the thermal insulation layer is bonded or sprayed to the at least part of the surface of the foaming layer away from the framework.

[0036] In some embodiments, the foaming layer is secondarily injection molded on the framework; or the foaming layer is bonded or clamped to the framework.

[0037] In some embodiments, the framework is made of nylon or fiber-reinforced resin composite material.

[0038] According to a second aspect of the present disclosure, a tray comprises a tray body and a filling assembly, the filling assembly being the filling assembly according to the first aspect of the present disclosure, and the filling assembly being arranged in the tray body.

[0039] In some embodiments, the tray body comprises a frame and a bottom plate assembly, the frame comprises a plurality of beam structures, the bottom plate assembly comprises a bottom plate and a bottom guard, the bottom plate is arranged at the bottom of the frame, and the bottom guard is arranged below the bottom plate; the filling assembly comprises at least one of a first filling assembly and a second filling assembly, the first filling assembly is arranged between the bottom plate and the bottom guard, and the second filling assembly is arranged in at least one of the plurality of beam structures.

[0040] In some embodiments, a plurality of second mounting structures are arranged on the bottom guard, and the first filling assembly is mounted to the bottom guard through the plurality of second mounting structures.

[0041] In some embodiments, the second mounting structure comprises a plurality of buckles arranged at intervals, one end of the plurality of buckles adjacent to the first filling assembly is provided with a buckle part, the buckle parts of the plurality of buckles are located on the side of the plurality of buckles away from each other, the buckle parts of the plurality of buckles pass through the corresponding positioning holes of the first filling assembly and are adapted to abut against the side surface of the first filling assembly adjacent to the bottom plate.

[0042] In some embodiments, further comprising a plurality of first fasteners, the first fasteners pass through the corresponding positioning holes of the first filling assembly and cooperate with the corresponding second mounting structures.

[0043] In some embodiments, the first fastener is a screw or a rivet.

[0044] In some embodiments, the bottom plate is a heat exchange plate.

[0045] In some embodiments, at least one mounting hole is formed in the at least one of the plurality of beam structures; the tray further comprises at least one second fastener, the second fastener passes through the mounting hole and cooperates with the first mounting structure of the second filling assembly.

[0046] In some embodiments, the plurality of beam structures comprises a cross beam, a longitudinal beam, an intermediate cross beam, a first corner beam and a second corner beam, the cross beam comprises a first cross beam and a second cross beam, the first cross beam and the second cross beam are arranged in a spaced manner, the longitudinal beam comprises a first longitudinal beam and a second longitudinal beam, the first longitudinal beam and the second longitudinal beam are connected between two ends of the first cross beam and the second cross beam respectively, the intermediate cross beam is connected between the first longitudinal beam and the second longitudinal beam, the intermediate cross beam is located between the first cross beam and the second cross beam, the first longitudinal beam and the first cross beam are connected through the first corner beam, the second longitudinal beam and the first cross beam are connected through the second corner beam, and a plurality of the second filling components are arranged in the first cross beam, the second cross beam, the first longitudinal beam, the second longitudinal beam, the intermediate cross beam, the first corner beam and the second corner beam respectively.

[0047] In some embodiments, the second filling component comprises a corner filling component, the corner filling component comprises a first corner filling component, one end of the first corner filling component is fitted in the longitudinal beam, and the other end of the first corner filling component is fitted in the second cross beam.

[0048] In some embodiments, the corner filling component further comprises a second corner filling component, one end of the second corner filling component is fitted in the longitudinal beam or the first cross beam, and the other end of the second corner filling component is fitted in the first corner beam or the second corner beam.

[0049] In some embodiments, the corner filling component and the second filling component in the adjacent cross beam or longitudinal beam are connected through at least one connecting structure.

[0050] In some embodiments, the connecting structure comprises a connecting hole and a connecting shaft, the connecting hole is formed on one of the corner filling component and the second filling component in the adjacent cross beam or longitudinal beam, the connecting shaft is on the other of the corner filling component and the second filling component in the adjacent cross beam or longitudinal beam, and the connecting shaft is fitted in the connecting hole.

[0051] In some embodiments, the plurality of beam structures further comprises a plurality of mounting beams and a plurality of lifting lugs, the plurality of mounting beams are arranged on sides of the first longitudinal beam and the second longitudinal beam away from each other respectively, the plurality of lifting lugs are arranged on sides of the first cross beam and the second cross beam away from each other respectively, and the second filling components are arranged in the plurality of mounting beams and the plurality of lifting lugs respectively.

[0052] In some embodiments, the at least one of the plurality of beam structures is formed with a plurality of cavities, and at least one of the plurality of cavities is provided with the second filling assembly.

[0053] According to the third aspect of the battery pack of the present disclosure, the tray is according to the second aspect of the present disclosure.

[0054] According to the fourth aspect of the vehicle of the present disclosure, the battery pack is according to the third aspect of the present disclosure.

[0055] Additional aspects and advantages of the present disclosure will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0056] The above and / or additional aspects and advantages of the present disclosure will become apparent and be readily appreciated from the following description, including the appended drawings.

[0057] FIG. 1 is a schematic view of a battery pack according to an embodiment of the present disclosure;

[0058] FIG. 2 is an exploded schematic view of a battery pack according to an embodiment of the present disclosure;

[0059] FIG. 3 is an exploded schematic view of a tray according to an embodiment of the present disclosure;

[0060] FIG. 4 is a cross-sectional schematic view of a frame according to an embodiment of the present disclosure;

[0061] FIG. 5 is an enlarged schematic view of the P region in FIG. 4;

[0062] FIG. 6 is an enlarged schematic view of the Q region in FIG. 4;

[0063] FIG. 7 is a schematic view of a first filling assembly according to an embodiment of the present disclosure;

[0064] FIG. 8 is an enlarged schematic view of the R region in FIG. 7;

[0065] FIG. 9 is a cross-sectional schematic view of a first support structure according to an embodiment of the present disclosure;

[0066] FIG. 10 is a partial cross-sectional schematic view of a first filling assembly according to an embodiment of the present disclosure;

[0067] FIG. 11 is a cross-sectional schematic view of a through hole according to an embodiment of the present disclosure;

[0068] FIG. 12 is a cross-sectional schematic view of a protrusion according to an embodiment of the present disclosure;

[0069] FIG. 13 is a schematic view of a sub-filling assembly according to an embodiment of the present disclosure;

[0070] FIG. 14 is an exploded schematic view of a sub-filling assembly according to an embodiment of the present disclosure;

[0071] FIG. 15 is a schematic view of a first filling assembly and a bottom fender according to an embodiment of the present disclosure;

[0072] FIG. 16 is an enlarged schematic view of an S region in FIG. 15;

[0073] FIG. 17 is a schematic view of a positioning hole and a second mounting structure according to an embodiment of the present disclosure;

[0074] FIG. 18 is an assembly schematic view of the second mounting structure and the first filling assembly according to an embodiment of the present disclosure;

[0075] FIG. 19 is a schematic view of the second mounting structure and a first fastener according to an embodiment of the present disclosure;

[0076] FIG. 20 is an exploded schematic view of a frame and a second filling assembly according to an embodiment of the present disclosure;

[0077] FIG. 21 is a schematic view of the frame according to an embodiment of the present disclosure;

[0078] FIG. 22 is an exploded schematic view of the frame according to an embodiment of the present disclosure;

[0079] FIG. 23 is a cross-sectional schematic view of the frame according to an embodiment of the present disclosure;

[0080] FIG. 24 is a schematic view of the second filling assembly according to an embodiment of the present disclosure;

[0081] FIG. 25 is an assembly schematic view of a first corner filling assembly according to an embodiment of the present disclosure;

[0082] FIG. 26 is a cross-sectional schematic view of the first corner filling assembly according to an embodiment of the present disclosure;

[0083] FIG. 27 is an assembly schematic view of a second corner filling assembly according to an embodiment of the present disclosure;

[0084] FIG. 28 is a cross-sectional schematic view of the second corner filling assembly according to an embodiment of the present disclosure;

[0085] FIG. 29 is a schematic view of the second corner filling assembly according to an embodiment of the present disclosure;

[0086] FIG. 30 is a schematic view of a connection structure according to an embodiment of the present disclosure.

[0087] FIG. 31 is a schematic view of a vehicle according to an embodiment of the present disclosure.

[0088] 100, filling assembly; 13, cavity; 10, skeleton; 11, foaming layer; 20, first filling assembly; 21, first support structure; 211, first sub-support structure; 212, second sub-support structure; 22, through hole; 23, protrusion; 24, positioning hole; 25, sub-filling assembly; 251, first sub-filling assembly; 252, second sub-filling assembly; 253, third sub-filling assembly; 254, connecting protrusion; 255, connecting groove; 30, second filling assembly; 31, second support structure; 311, third sub-support structure; 312, fourth sub-support structure; 32, first corner; 33, second corner; 34, first mounting structure; 35, first corner filling assembly; 36, second corner filling assembly; 361, first sub-corner filling assembly; 362, second sub-corner filling assembly; 37, connecting structure; 371, connecting hole; 372, connecting shaft; 38, corner filling assembly; 381, thermal insulation layer; 200, tray; 40, tray body; 50, frame; 51, beam structure; 511, second fastener; 52, mounting hole; 53, cross beam; 531, first cross beam; 532, second cross beam; 54, longitudinal beam; 541, first longitudinal beam; 542, second longitudinal beam; 55, middle cross beam; 56, first corner beam; 57, second corner beam; 58, mounting beam; 59, lifting lug; 60, bottom plate assembly; 61, bottom plate; 62, bottom guard plate; 63, second mounting structure; 631, buckle; 632, buckle part; 633, connecting part; 64, first fastener; 300, battery pack; 70, upper cover; 71, battery module; 400, vehicle; A, first direction; B, second direction; C, third direction. DETAILED DESCRIPTION

[0089] Embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. The embodiments described below with reference to FIGS. 1-30 are exemplary, and a filling assembly 100 according to embodiments of the present disclosure is described below with reference to FIGS. 1-30, including a skeleton 10 and at least one foaming layer 11.

[0090] Specifically, as shown in FIGS. 1-6, the foaming layer 11 covers at least a portion of the outer surface of the skeleton 10.

[0091] In combination with FIGS. 1-6, the foaming layer 11 is expandable and foamed under specific high-temperature baking conditions. After foaming, the foaming layer 11 forms a closed-cell foam, has good thermal insulation performance, and has strong adhesion to the surface of metal and non-metal materials. The foaming layer 11 is covered on the outer surface of the skeleton 10 and formed as a whole with the skeleton 10.

[0092] According to the filling assembly 100 provided by the embodiment of the present disclosure, the framework 10 plays a role of supporting and positioning, facilitates positioning of the filling assembly 100, makes the assembly position of the filling assembly 100 more accurate, and can also improve the structural strength of the filling assembly 100. At least a part of the outer surface of the framework 10 is covered by the foaming layer 11, and the closed-cell foam formed after the foaming layer 11 is expanded and foamed can be adhered to the outer surface of the framework 10, so that the filling assembly 100 has good heat preservation capacity, collision energy absorption capacity, local collision deformation dispersion capacity and NVH performance. Since the foaming layer 11 has a certain expansion range, the framework 10 does not need to have high precision, and the framework 10 is allowed to have some defects such as burrs, pits or flash, which can also reduce the production and manufacturing difficulty of the filling assembly 100 and reduce the production cost of the filling assembly 100.

[0093] According to some embodiments of the present disclosure, as shown in FIGS. 5-7, the filling assembly 100 comprises a first filling assembly 20, the framework 10 of the first filling assembly 20 is a plate structure, the foaming layer 11 of the first filling assembly 20 is two, and the two foaming layers 11 cover the two side surfaces in the thickness direction of the framework 10 respectively, and the two side surfaces of the framework 10 in the thickness direction are covered with the foaming layers 11 with equal thickness. In this way, the framework 10 with a plate structure can serve as the structural main body of the filling assembly 100, and can enhance the structural strength and stability of the first filling assembly 20 and bear the foaming layer 11, and the two foaming layers 11 covering the two side surfaces of the framework 10 in the thickness direction can make the two foaming layers 11 cover the framework 10 more comprehensively after foaming, which can improve the heat preservation performance and impact resistance of the first filling assembly 20.

[0094] According to some embodiments of the present disclosure, as shown in FIGS. 7-9, the filling assembly 100 further comprises at least one first support structure 21, the first support structure 21 is arranged on the framework 10, and the first support structure 21 protrudes from at least one side surface of the foaming layer 11 away from the framework 10. The first support structure 21 protrudes from the two side surfaces of the framework 10 in the thickness direction toward the direction away from the center of the framework 10, and the height of the part of the first support structure 21 protruding from the two side surfaces of the framework 10 in the thickness direction is equal, that is, the first support structure 21 is symmetrically distributed along the thickness direction of the framework 10. Along the thickness direction of the framework 10, the height of the first support structure 21 relative to the surface of the framework 10 is greater than the thickness of the foaming layer 11, that is, the first support structure 21 protrudes from the foaming layer 11.

[0095] Thus, the first support structure 21 is arranged to facilitate assembly of the first filling assembly 20, the first support structure 21 protruding from the foamed layer 11 is arranged to facilitate positioning of the first filling assembly 20 in the thickness direction, the first filling assembly 20 is adapted to be assembled in a closed or semi-closed space, the first support structure 21 is adapted to be in contact with the inner wall of the assembly space of the first filling assembly 20, and the first support structure 21 is arranged to enable the skeleton 10 to be located in the middle of the assembly space after assembly. The first support structure 21 protruding from at least one side surface of the foamed layer 11 away from the skeleton 10 can leave a swelling gap for the foaming and swelling of the foamed layer 11, thereby improving the reliability of the first filling assembly 20.

[0096] According to some embodiments of the present disclosure, as shown in FIGS. 7-9, the first support structure 21 is in plurality, and the plurality of first support structures 21 comprises at least one first sub-support structure 211 and at least one second sub-support structure 212, the first sub-support structure 211 is arranged on at least one side surface of the skeleton 10 in the thickness direction, and the second sub-support structure 212 is arranged on the side surface of the skeleton 10, and a portion of the second sub-support structure 212 extends to at least one side surface of the skeleton 10 in the thickness direction.

[0097] The skeleton 10 has a length direction and a width direction. In some embodiments, the skeleton 10 is provided with a plurality of first sub-support structures 211 on both side surfaces in the thickness direction, and the plurality of first sub-support structures 211 on both side surfaces of the skeleton 10 are opposite to each other in the thickness direction, and the plurality of first sub-support structures 211 protrude from both side surfaces of the skeleton 10 in the thickness direction. The skeleton 10 is provided with a plurality of second sub-support structures 212, the plurality of second sub-support structures 212 are arranged around the four sides of the skeleton 10 in the circumferential direction of the skeleton 10, and the plurality of second sub-support structures 212 protrude from the four peripheral edges of the skeleton 10.

[0098] Thus, the first sub-support structure 211 is arranged to facilitate positioning of the first filling assembly 20 in the thickness direction, the second sub-support structure 212 is arranged to facilitate positioning of the first filling assembly 20 in the length direction and the width direction of the skeleton 10, and the first sub-support structure 211 and the second sub-support structure 212 are adapted to be in contact with the inner wall of the assembly space of the first filling assembly 20, so as to maintain a predetermined distance between the outer surface of the first filling assembly 20 and the inner wall of the assembly space.

[0099] According to some embodiments of the present disclosure, as shown in FIGS. 7-9, the first sub-support structure 211 is in plurality, and the plurality of first sub-support structures 211 are arranged in an array on both side surfaces of the skeleton 10 in the thickness direction; the second sub-support structure 212 is in plurality, and the plurality of second sub-support structures 212 are arranged in an array in the circumferential direction of the skeleton 10, and both ends of the second sub-support structure 212 extend to both side surfaces of the skeleton 10 in the thickness direction.

[0100] The plurality of first sub-support structures 211 are arranged on both sides of the skeleton 10 in the length and width directions of the skeleton 10. The plurality of second sub-support structures 212 are arranged on the four edges of the skeleton 10, and the second sub-support structures 212 extend in the thickness direction of the skeleton 10. In some embodiments, the two ends of the second sub-support structure 212 are connected to the ends of the first support structure 21.

[0101] Therefore, the arrangement of the plurality of first sub-support structures 211 and the plurality of second sub-support structures 212 can make the positioning effect of the first support structure 21 on the first filling assembly 20 more comprehensive and sufficient, and achieve accurate positioning when the first filling assembly 20 is assembled.

[0102] According to some embodiments of the present disclosure, as shown in FIG. 7, the first support structure 21 is a cross-shaped structure, a rice-shaped structure, a wave-shaped structure, or a polygonal structure. After the filling assembly 100 is assembled, the anticorrosive treatment solution can flow freely between the outer surface of the filling assembly 100 in the thickness direction and the inner wall of the assembly space, and the plurality of first support structures 21 are not connected to form a closed structure, so as to avoid affecting the free flow of the anticorrosive treatment solution on the surface of the filling assembly 100. Therefore, the first support structure 21 being a cross-shaped structure, a rice-shaped structure, a wave-shaped structure, or a polygonal structure can increase the surface area of the first support structure 21, so as to improve the reliability of the first support structure 21 when the filling assembly 100 is assembled, and improve the accuracy of the positioning effect of the first support structure 21 on the filling assembly 100.

[0103] According to some embodiments of the present disclosure, as shown in FIG. 5, the height of the first support structure 21 protruding from at least one side surface of the foamed layer 11 away from the skeleton 10 is h, wherein h satisfies: 3mm≤h≤5mm.

[0104] That is, in the thickness direction of the skeleton 10, the distance between the end of the first support structure 21 away from the center of the skeleton 10 and the side surface of the foamed layer 11 away from the skeleton 10 is h, that is, the distance between the foamed layer 11 and the inner wall of the assembly space after the filling assembly 100 is assembled is h. If the height of the first support structure 21 protruding from at least one side surface of the foamed layer 11 away from the skeleton 10 is h<3mm, the distance between the foamed layer 11 and the inner wall of the assembly space is too small, which can cause the flow of the anticorrosive treatment solution to be blocked. If the height of the first support structure 21 protruding from at least one side surface of the foamed layer 11 away from the skeleton 10 is h>5mm, the distance between the foamed layer 11 and the inner wall of the assembly space is too large, which causes space waste and is not conducive to reducing the production cost of the filling assembly 100. For example, h=4mm.

[0105] Thus, limiting the height of the side surface of the first support structure 21 protruding from the framework 10 to the side of the at least one foamed layer 11 can ensure that the free flow of the anti-corrosion treatment solution is not affected, and can also leave a certain space for the foaming and expansion of the foamed layer 11.

[0106] According to some embodiments of the present disclosure, as shown in FIGS. 10-12, a plurality of through holes 22 are formed on the framework 10, and the two foamed layers 11 are connected into one body through the plurality of through holes 22. The through holes 22 are arranged on the framework 10 in the thickness direction of the framework 10, and the plurality of through holes 22 are arranged on the framework 10 in the width direction and the length direction of the framework 10. The foamed layer 11 is attached to the two side surfaces of the framework 10 in the thickness direction, and the two foamed layers 11 on the two side surfaces of the framework 10 in the thickness direction are solidified into one body through the through holes 22 so as not to be easily detached.

[0107] Alternatively, a plurality of protrusions 23 are arranged on at least one side surface of the framework 10 in the thickness direction, and the foamed layer 11 covers the outer surfaces of the plurality of protrusions 23. The protrusions 23 are formed by protruding a part of at least one side surface of the framework 10 in the thickness direction from the surface of the framework 10 in a direction away from the center of the framework 10, and the plurality of protrusions 23 are arranged on the surface of the framework 10 in the width direction and the length direction of the framework 10, and the foamed layer 11 is attached to the plurality of protrusions 23. Alternatively, the framework 10 is formed with both the plurality of through holes 22 and the plurality of protrusions 23.

[0108] Thus, the arrangement of the plurality of through holes 22 can make the foamed layer 11 more stably attached to the surface of the framework 10, the arrangement of the protrusions 23 can increase the contact area between the foamed layer 11 and the surface of the framework 10 to increase the adhesion of the foamed layer 11, and the arrangement of the through holes 22 and the protrusions 23 are both used to enhance the connection strength between the foamed layer 11 and the framework 10 to improve the reliability of the filling assembly 100 as a whole.

[0109] According to some embodiments of the present disclosure, the first support structure 21 and the framework 10 are an integral structure. The integral structure of the first support structure 21 and the framework 10 facilitates the batch production of the first support structure 21 and the framework 10, and simplifies the assembly steps between the first support structure 21 and the framework 10. Alternatively, the first support structure 21 and the framework 10 are bonded or clamped, which can simplify the structure of the framework 10, reduce the production difficulty of the framework 10, and thus reduce the production cost of the framework 10.

[0110] According to some embodiments of the present disclosure, as shown in FIGS. 15-19, the edge of the first filling assembly 20 is formed with a plurality of positioning holes 24, which are arranged along the circumference of the first filling assembly 20. The positioning holes 24 are arranged through the first filling assembly 20 along the thickness direction of the framework 10 and are arranged at the four edges of the first filling assembly 20. The positioning holes 24 are used to cooperate with fasteners, and the fasteners are arranged in the positioning holes 24 to achieve the assembly of the first filling assembly 20. Thus, the arrangement of the positioning holes 24 is used for the installation and positioning of the first filling assembly 20 during the assembly process, and the arrangement of the plurality of positioning holes 24 can improve the positioning accuracy and assembly firmness of the first filling assembly 20. The first filling assembly 20 is suitable for use in the battery pack 300, the plurality of positioning holes 24 are arranged along the circumference of the first filling assembly 20, and the positioning holes 24 are arranged at the four edges of the first filling assembly 20, which can make the positioning holes 24 avoid the projection area of the battery module 71, so that when the position bears an impact, the fasteners matched in the positioning holes 24 become a protruding structure invading and damaging the battery cells inside the battery module 71.

[0111] According to some embodiments of the present disclosure, as shown in FIGS. 13 and 14, the framework 10 and the foaming layer 11 are respectively a plurality of, the plurality of foaming layers 11 respectively cover at least a part of the outer surface of the plurality of frameworks 10, and the plurality of frameworks 10 and the plurality of foaming layers 11 respectively constitute a plurality of sub-filling assemblies 25, and the plurality of sub-filling assemblies 25 are suitable for being detachably connected.

[0112] For example, along the length direction of the framework 10, the first filling assembly 20 is divided into a plurality of sub-filling assemblies 25, and adjacent filling assemblies 100 are detachably connected between the mutually adjacent sides along the length direction. The volume of the sub-filling assembly 25 is small, and the sub-filling assembly 25 can also be arranged in regions. For example, when the filling assembly 100 is applied in the battery pack 300, the sub-filling assembly 25 can be arranged in the area that needs to be protected to improve the protection of the battery pack 300 by the filling assembly 100 and to enhance the practicability and functionality of the filling assembly 100. Thus, when the size of the filling assembly 100 is large, the filling assembly 100 is formed by a plurality of sub-filling assemblies 25 with smaller sizes, which can reduce the production difficulty of the filling assembly 100, facilitate the mass production of the filling assembly 100, and be conducive to reducing the production cost of the filling assembly 100.

[0113] According to some embodiments of the present disclosure, as shown in FIGS. 13 and 14, at least one connecting groove 255 is formed on one of the plurality of sub-filling assemblies 25, and at least one connecting protrusion 254 is arranged on another of the plurality of sub-filling assemblies 25, and the connecting protrusion 254 is suitable for being matched in the connecting groove 255 to achieve the detachable connection of the plurality of sub-filling assemblies 25.

[0114] The plurality of sub-filling components 25 form a first sub-filling component 251, and the plurality of sub-filling components 25 include: the first sub-filling component 251, at least one second sub-filling component 252, and a third sub-filling component 253. The first sub-filling component 251 and the third sub-filling component 253 are respectively arranged on two sides of the at least one second sub-filling component 252 along the length direction of the skeleton 10. The first sub-filling component 251 is formed with a plurality of connecting grooves 255 on one side edge adjacent to the second sub-filling component 252 along the length direction of the skeleton 10, and the plurality of connecting grooves 255 are arranged at intervals along the width direction of the skeleton 10. The third sub-filling component 253 is formed with a plurality of connecting protrusions 254 on one side edge adjacent to the second sub-filling component 252 along the length direction of the skeleton 10, and the plurality of connecting protrusions 254 are arranged at intervals along the width direction of the skeleton 10. The second sub-filling component 252 is formed with a plurality of connecting protrusions 254 on one side edge adjacent to the first sub-filling component 251 along the length direction of the skeleton 10, and the second sub-filling component 252 is formed with a plurality of connecting grooves 255 on the other side edge adjacent to the third sub-filling component 253 along the length direction of the skeleton 10.

[0115] Thus, the first sub-filling component 251, the second sub-filling component 252, and the third sub-filling component 253 form the first filling component 20 through the matching connection between the connecting protrusions 254 and the connecting grooves 255. The arrangement of the connecting grooves 255 and the connecting protrusions 254 can improve the connection reliability between the first sub-filling component 251, the second sub-filling component 252, and the third sub-filling component 253, and can simplify the assembly difficulty of the sub-filling component 25, thereby facilitating the reduction of the assembly cost of the sub-filling component 25.

[0116] According to some embodiments of the present disclosure, as shown in FIGS. 13 and 14, the connecting grooves 255 penetrate through the corresponding sub-filling component 25 along the thickness direction of the skeleton 10, and the width of the connecting grooves 255 gradually decreases in the direction towards the edge of the corresponding sub-filling component 25; the shape of the connecting protrusions 254 is matched with the shape of the connecting grooves 255.

[0117] The connecting grooves 255 are formed by recessing a part of one side edge of the sub-filling component 25 along the length direction of the skeleton 10 towards the center of the sub-filling component 25, and the connecting protrusions 254 are formed by protruding a part of one side edge of the sub-filling component 25 along the length direction of the skeleton 10 away from the center of the sub-filling component 25. In some embodiments, the connecting grooves 255 and the connecting protrusions 254 are in a trapezoidal structure, and the short side of the trapezoidal structure coincides with the edge of the sub-filling component 25.

[0118] Thus, the structure of the connecting groove 255 and the connecting protrusion 254 is matched to facilitate the assembly between the sub-filling assemblies 25, and the gradually reduced width of the connecting groove 255 in the direction towards the edge of the corresponding sub-filling assembly 25 can enable the connecting groove 255 to limit the connecting protrusion 254 in the length direction and the width direction of the framework 10, thereby enhancing the stability of the assembly between the connecting protrusion 254 and the connecting groove 255.

[0119] According to some embodiments of the present disclosure, as shown in FIGS. 13 and 14, the connecting groove 255 and the connecting protrusion 254 are respectively in plurality, the plurality of connecting grooves 255 are arranged in the length direction of the corresponding sub-filling assembly 25, and the plurality of connecting protrusions 254 correspond to the plurality of connecting grooves 255 respectively. The length direction of the sub-filling assembly 25 is the same as the width direction of the framework 10. The plurality of connecting grooves 255 and the plurality of connecting protrusions 254 are arranged on the corresponding edges of the sub-filling assembly 25 in the length direction of the sub-filling assembly 25, and the plurality of connecting protrusions 254 correspond to the plurality of connecting grooves 255 respectively. Thus, the arrangement of the plurality of connecting grooves 255 and the plurality of connecting protrusions 254 can further improve the reliability of the assembly between the sub-filling assemblies 25, and the correspondence between the plurality of connecting protrusions 254 and the plurality of connecting grooves 255 can ensure the accuracy of the assembly between the sub-filling assemblies 25.

[0120] According to some embodiments of the present disclosure, as shown in FIG. 24, the filling assembly 100 comprises a second filling assembly 30; the framework 10 of the second filling assembly 30 is in a long strip structure; and the foaming layer 11 of the second filling assembly 30 covers the outer circumferential surface of the framework 10.

[0121] The framework 10 of the second filling assembly 30 has a length direction, a width direction and a height direction. The framework 10 of the second filling assembly 30 extends in the length direction, and comprises two side walls opposite in the width direction and two side walls opposite in the height direction, and is formed as a hollow long strip structure. The foaming layer 11 of the second filling assembly 30 covers the outer circumferential surface of the framework 10 in the circumferential direction of the framework 10 of the second filling assembly. The material, performance and manufacturing process of the framework 10 and the foaming layer 11 of the second filling assembly 30 are consistent with those of the framework 10 and the foaming layer 11 of the first filling assembly 20.

[0122] Thus, the framework 10 of the second filling assembly 30 serves to support and carry the foaming layer 11, and the second filling assembly 30 is suitable for being assembled in a long strip closed or semi-closed space structure to improve the structural strength of the structure, enhance the extrusion resistance, torsion resistance and bending resistance of the structure, and enhance the overall performance of the structure.

[0123] According to some embodiments of the present disclosure, as shown in FIGS. 21-24, the second filling assembly 30 further comprises at least one second supporting structure 31, which is arranged on the framework 10 and protrudes from the side surface of the at least one foaming layer 11 away from the framework 10.

[0124] When the second supporting structure 31 is arranged on the outer surface of the side wall of the framework 10 along the width direction, the second supporting structure 31 protrudes from the outer surface of the side wall of the framework 10 along the width direction of the framework 10 towards the direction away from the center of the framework 10. When the second supporting structure 31 is arranged on the outer surface of the side wall of the framework 10 along the height direction, the second supporting structure 31 protrudes from the outer surface of the side wall of the framework 10 along the height direction of the framework 10 towards the direction away from the center of the framework 10. The height of the second supporting structure 31 relative to the outer surface of the framework 10 is greater than the thickness of the foaming layer 11, that is, the second supporting structure 31 protrudes from the foaming layer 11. The height of the second supporting structure 31 protruding from the side surface of the at least one foaming layer 11 away from the framework 10 is h, wherein h satisfies 3mm≤h≤5mm.

[0125] Therefore, the arrangement of the second supporting structure 31 facilitates the assembly of the second filling assembly 30, and the second supporting structure 31 can realize the positioning effect of the second filling assembly 30 in the width direction and the height direction of the framework 10 of the second filling assembly 30. The second supporting structure 31 is adapted to contact and stop the inner part of the assembly space of the second filling assembly 30, and the arrangement of the second supporting structure 31 can make the framework 10 of the second supporting structure 31 be located at the middle position of the assembly space after assembly. The arrangement of the second supporting structure 31 protruding from the side surface of the at least one foaming layer 11 away from the framework 10 can keep a predetermined distance between the outer surface of the second filling assembly 30 and the inner wall of the assembly space, and can leave space for the expansion of the foaming layer 11 and the flow of the corrosion-resistant treatment solution.

[0126] According to some embodiments of the present disclosure, as shown in FIG. 22, the second supporting structure 31 is a plurality of second supporting structures 31, which comprises at least one third sub-supporting structure 311 and at least one fourth sub-supporting structure 312, the third sub-supporting structure 311 is arranged at the first corner 32 of the framework 10, and the fourth sub-supporting structure 312 is arranged at the second corner 33 of the framework 10, the second corner 33 is opposite to the first corner 32.

[0127] The junctions of the adjacent side walls of the skeleton 10 of the second filling assembly 30 form corners, and a first corner 32 and a second corner 33 are oppositely arranged along the diagonals of the skeleton 10. The third sub-support structure 311 and the fourth sub-support structure 312 each include a first end and a second end, the first end extends along the width direction of the skeleton 10, and the first ends of the third sub-support structure 311 and the fourth sub-support structure 312 are respectively arranged on the outer surfaces of the two side walls of the skeleton 10 that are opposite in the height direction. The second end extends along the height direction of the skeleton 10, and the second ends of the third sub-support structure 311 and the fourth sub-support structure 312 are respectively arranged on the outer surfaces of the two side walls of the skeleton 10 that are opposite in the width direction.

[0128] Therefore, the third sub-support structure 311 and the fourth sub-support structure 312 are arranged at the first corner 32 and the second corner 33 of the skeleton 10 to achieve the positioning effect of the second filling assembly 30 in the width direction and the height direction of the skeleton 10 of the second filling assembly 30, and the third sub-support structure 311 and the fourth sub-support structure 312 are in contact with the corners of the inner walls of the space where the second filling assembly 30 is assembled, so that the outer surface of the second filling assembly 30 and the inner walls of the assembly space maintain a predetermined distance.

[0129] According to some embodiments of the present disclosure, as shown in FIGS. 22-24, the third sub-support structure 311 is a plurality of third sub-support structures 311, and the plurality of third sub-support structures 311 are arranged at intervals along the length direction of the skeleton 10, and the two ends of the third sub-support structure 311 extend to the two surfaces of the skeleton 10 adjacent to the first corner 32; the fourth sub-support structure 312 is a plurality of fourth sub-support structures 312, and the plurality of fourth sub-support structures 312 are arranged at intervals along the length direction of the skeleton 10, and the two ends of the fourth sub-support structure 312 extend to the two surfaces of the skeleton 10 adjacent to the second corner 33.

[0130] The plurality of third sub-support structures 311 are arranged at intervals along the length direction of the skeleton 10 at the first corner 32 of the skeleton 10, and the fourth sub-support structure 312 is arranged at intervals along the length direction of the skeleton 10 at the second corner 33 of the skeleton 10. The first end and one end of the second end of the third sub-support structure 311 are connected to form an L-shaped structure arranged at the first corner 32, and the first end and one end of the second end of the fourth sub-support structure 312 are connected to form an L-shaped structure arranged at the second corner 33. Therefore, the arrangement of the plurality of third sub-support structures 311 and the plurality of fourth sub-support structures 312 can make the positioning effect of the second support structure 31 on the second filling assembly 30 more comprehensive and sufficient, and achieve accurate positioning when the second filling assembly 30 is assembled.

[0131] According to some embodiments of the present disclosure, as shown in FIG. 24, the plurality of third sub-supporting structures 311 and the plurality of fourth sub-supporting structures 312 are arranged staggered along the length direction of the framework 10. That is, along the height direction of the framework 10, the projections of the plurality of third sub-supporting structures 311 and the plurality of fourth sub-supporting structures 312 are staggered in sequence. In this way, while reducing the number of third sub-supporting structures 311 and fourth sub-supporting structures 312, the positioning effect of the third sub-supporting structures 311 and the fourth sub-supporting structures 312 on the second filling assembly 30 can be ensured, and the production cost of the second filling assembly 30 can be reduced.

[0132] According to some embodiments of the present disclosure, as shown in FIGS. 22 and 24, the framework 10 is provided with at least one first mounting structure 34. In some embodiments, the framework 10 is provided with a plurality of first mounting structures 34, which are arranged on the outer surfaces of the side walls on opposite sides of the framework 10 along the width direction, and are arranged spaced apart along the length direction of the framework 10. In this way, the first mounting structure 34 is used to fix and install the second filling assembly 30 in the assembly space, and fix the second filling assembly 30 at a predetermined position, and the arrangement of the plurality of first mounting structures 34 can make the assembly of the second filling assembly 30 more stable and reliable.

[0133] According to some embodiments of the present disclosure, as shown in FIG. 24, the first mounting structure 34 includes at least one of a pre-buried nut, a clamping groove, and a hollow column structure. The pre-buried nut, the clamping groove, and the hollow column structure all have the characteristics of simple processing, simple assembly, low production cost, and high connection strength. In this way, the first mounting structure 34 including one of the pre-buried nut, the clamping groove, and the hollow column structure is conducive to reducing the assembly difficulty and production cost of the second filling assembly 30, enhancing the practicability of the second filling assembly 30, and facilitating the application of the second filling assembly 30.

[0134] According to some embodiments of the present disclosure, as shown in FIG. 24, the framework 10 is a hollow structure. The framework 10 of the second filling assembly 30 is a hollow frame 50 structure, and at least part of the side wall on one side of the framework 10 along the width direction is a hollow structure. The framework 10 includes a plurality of first hollow structures arranged spaced apart along the length direction of the framework 10 on the side wall on one side of the framework 10 along the width direction. In this way, the hollow structure of the framework 10 can effectively reduce the mass of the framework 10, realize lightweight design of the framework 10, and also reduce the material of the framework 10. The foaming layer 11 can also be arranged in a local area to reduce the production cost, thereby realizing lightweight design of the second filling assembly 30 and reducing the production cost of the second filling assembly 30.

[0135] According to some embodiments of the present disclosure, as shown in FIG. 23, the framework 10 further includes a heat insulation layer 381 arranged on at least part of the surface of the foaming layer 11 away from the framework 10.

[0136] The connection between the second filling assembly 30 and other components during the assembly process is usually connected by welding process. High temperature generated during welding may cause ablation damage to the second filling assembly 30. The heat insulation layer 381 arranged on at least part of the surface of the foaming layer 11 away from the framework 10 can effectively block the local transient temperature above 2000K generated during welding and conduct heat, so that the temperature of the surface of the second filling assembly 30 is lower than the melting point of the framework 10 and the foaming layer 11, thereby forming a protective effect on the second filling assembly 30 to prolong the service life of the second filling assembly 30.

[0137] According to some embodiments of the present disclosure, the heat insulation layer 381 is a mica sheet, aerogel or heat insulation coating. The mica sheet has high insulation strength and large resistance, low dielectric loss and arc resistance, corona resistance and other excellent dielectric properties, and is hard in texture, high in mechanical strength, resistant to high temperature and rapid temperature change, and has good physical and chemical properties such as acid and alkali resistance. Aerogel has the properties of high temperature resistance, low radiant heat conduction, good thermal stability, and the preparation method of aerogel is simple, controllable, light in weight and low in production cost. The heat insulation coating has the characteristics of heat insulation, waterproof, rust prevention, corrosion prevention, short construction period and quick effect. Therefore, the heat insulation layer 381 being a mica sheet, aerogel or heat insulation coating can ensure the heat insulation effect of the heat insulation layer 381, enhance the protective effect of the heat insulation layer 381 on the second filling assembly 30, improve the reliability of the heat insulation layer 381, and reduce the production cost of the heat insulation layer 381.

[0138] According to some embodiments of the present disclosure, the heat insulation layer 381 is bonded or sprayed on at least part of the surface of the foaming layer 11 away from the framework 10. The foaming layer 11 needs to be foamed and expanded in a continuous high temperature environment, and when the second filling assembly 30 is in a continuous high temperature environment, the bonding or spraying of the heat insulation layer 381 on at least part of the surface of the foaming layer 11 away from the framework 10 will not affect the overall temperature rise of the second filling assembly 30. The foaming layer 11 covered with the heat insulation layer 381 can still normally foam and expand to fill the gap between the framework 10 and the assembly space, and will not affect the local reinforcing performance of the second filling assembly 30. Therefore, the bonding or spraying of the heat insulation layer 381 on at least part of the surface of the foaming layer 11 away from the framework 10 will not affect the foaming and expansion process of the foaming layer 11 in the second filling member, and can ensure that the heat preservation capacity, collision energy absorption capacity and local collision deformation dispersion capacity of the second filling member are not affected.

[0139] According to some embodiments of the present disclosure, as shown in FIG. 24, the foaming layer 11 is overmolded on the skeleton 10. Through the overmolding process, the foaming layer 11 and the skeleton 10 can be formed as a whole structure. The overmolding of the foaming layer 11 on the skeleton 10 can improve the connection strength between the foaming layer 11 and the skeleton 10, improve the durability of the filling assembly 100, and the overmolding process has high automation degree, which can realize automatic production and improve the production efficiency of the filling assembly 100.

[0140] Alternatively, the foaming layer 11 is bonded or clamped to the skeleton 10. The foaming layer 11 is fixedly connected to the skeleton 10 by bonding or clamping. The bonding or clamping assembly method is simple, which can simplify the assembly steps between the skeleton 10 and the foaming layer 11, and reduce the assembly cost of the filling assembly 100.

[0141] According to some embodiments of the present disclosure, the material of the skeleton 10 is nylon or fiber reinforced resin composite material. The mechanical strength of nylon is high, which has high strength and good toughness. The performance of nylon is still stable in high temperature environment, and it is easy to process and shape, which is suitable for various manufacturing occasions. The fiber reinforced resin composite material has high strength, high modulus, light weight, good durability and molding performance, etc. It can withstand high pressure and high load, has excellent impact resistance, is not easy to deform, and has lighter weight, which is easy to process and can meet various application requirements. The skeleton 10 can be manufactured by processes such as molding, extrusion and machining.

[0142] Therefore, the material of the skeleton 10 is nylon or fiber reinforced resin composite material, which can effectively enhance the structural strength of the skeleton 10, improve the impact resistance of the skeleton 10, reduce the processing difficulty of the skeleton 10, improve the overall performance of the skeleton 10, make the skeleton 10 have the characteristics of resisting high temperature above 200℃, high strength and high rigidity, and further improve the overall performance of the filling assembly 100, prolong the service life of the filling assembly 100.

[0143] The material of the foaming layer 11 is epoxy glue, polyurethane or butyl rubber, etc., and a certain foaming additive is mixed, which can expand and foam under certain high temperature baking conditions, and the expansion ratio is between 100%-3000%. The epoxy glue has excellent physical and mechanical properties, electrical insulation properties, chemical corrosion resistance, heat resistance and bonding properties. The polyurethane has excellent mechanical properties, good chemical corrosion resistance, good heat insulation performance, good shock resistance, and excellent oil resistance and aging resistance. The butyl rubber has excellent airtightness, good heat resistance and aging resistance, good electrical insulation and damping properties. In some embodiments, the foaming layer 11 is realized by injecting a filling agent, which has a certain expansion rate and forms a closed-cell foam structure after curing.

[0144] According to the tray 200 of the second aspect of the present disclosure, as shown in FIG. 3, the tray 200 comprises a tray body 40 and a filling assembly 100, the filling assembly 100 is the filling assembly 100 according to the first aspect of the present disclosure, and the filling assembly 100 is arranged in the tray body 40. The tray body 40 defines an assembly space for the filling assembly 100, and the filling assembly 100 is assembled in the assembly space.

[0145] According to the tray 200 of the present disclosure, the filling assembly 100 is arranged in the tray body 40, which can make the tray body 40 have good heat preservation capacity, collision energy absorption capacity, local collision deformation dispersion capacity and NVH performance, enhance the heat preservation performance and mechanical performance of the tray body 40, and improve the overall extrusion deformation resistance, torsional strength, bending stiffness and fatigue strength of the tray 200 at the connection position of the tray 200.

[0146] According to some embodiments of the present disclosure, as shown in FIGS. 3, 20 and 22, the tray body 40 comprises a frame 50 and a bottom plate assembly 60, the frame 50 comprises a plurality of beam structures 51, the bottom plate assembly 60 comprises a bottom plate 61 and a bottom guard plate 62, the bottom plate 61 is arranged at the bottom of the frame 50, and the bottom guard plate 62 is arranged below the bottom plate 61; the filling assembly 100 comprises at least one of the first filling assembly 20 and the second filling assembly 30, the first filling assembly 20 is arranged between the bottom plate 61 and the bottom guard plate 62, and the second filling assembly 30 is arranged in at least one of the plurality of beam structures 51.

[0147] The bottom plate 61 and the bottom guard plate 62 have a certain interval, the outer periphery of the bottom plate 61 and the bottom guard plate 62 are connected, and the space defined between the bottom plate 61 and the bottom guard plate 62 is the assembly space of the first filling assembly 20. The first filling assembly 20 is located at the central position between the bottom plate 61 and the bottom guard plate 62, the upper end surface of the first support structure 21 in the thickness direction of the skeleton 10 abuts against the side surface of the bottom plate 61 adjacent to the bottom guard plate 62, and the lower end surface of the first support structure 21 in the thickness direction of the skeleton 10 abuts against the side surface of the bottom guard plate 62 adjacent to the bottom plate 61. The two foamed layers 11 are arranged between the skeleton 10 of the first filling assembly 20 and the bottom plate 61 and between the skeleton 10 of the first filling assembly 20 and the bottom guard plate 62, respectively, and the foamed layers 11 can fill the space between the bottom plate 61 and the bottom guard plate 62 after foaming and expansion.

[0148] The beam structure 51 can be a plurality of profile members with closed or semi-closed cavity sections, and the plurality of beam structures 51 are connected to each other to form the frame 50. The space defined in the beam structure 51 is the assembly space of the second filling assembly 30, and the second filling assembly 30 is located at the central position of the beam structure 51. The second support structure 31 is abutted against the inner wall surface of the beam structure 51 away from the side surface of the skeleton 10 of the second filling assembly 30. The foaming layer 11 is arranged between the skeleton 10 of the second filling assembly 30 and the inner wall surface of the beam structure 51, and the foaming layer 11 can fill the gap between the skeleton 10 of the second filling assembly 30 and the inner wall surface of the beam structure 51 after expansion.

[0149] Therefore, the frame 50 is arranged around the outer periphery of the bottom plate assembly 60, and the frame 50 and the bottom plate assembly 60 jointly define a space for mounting the battery module 71. When the battery module 71 is assembled in the tray 200, the bottom of the battery module 71 is in contact with the bottom plate 61. The tray body 40 serves as a carrier for the battery module 71, the bottom plate 61 can provide a stable carrying and mounting position function for the battery module 71, and the bottom guard plate 62 can provide a protection function for the battery module 71 at the bottom. The structure design of the bottom plate 61, the first filling assembly 20, and the bottom guard plate 62 can enhance the heat preservation performance and impact resistance of the bottom of the tray 200. The plurality of beam structures 51 are sequentially connected to form a closed frame 50 space, which cooperates with the bottom plate assembly 60 to provide a containing space for the battery module 71. The frame 50 can provide a protection function for the battery module 71 around the battery module 71, enhance the structural strength of the tray 200 around the tray 200, and the second filling assembly 30 arranged in the frame 50 can improve the overall heat preservation performance and impact resistance of the tray 200, and improve the overall reliability of the tray 200.

[0150] According to some embodiments of the present disclosure, as shown in FIGS. 15-19, the bottom guard plate 62 is provided with a plurality of second mounting structures 63, and the first filling assembly 20 is mounted on the bottom guard plate 62 through the plurality of second mounting structures 63. The plurality of second mounting structures 63 and the plurality of positioning holes 24 on the first filling assembly 20 are one-to-one corresponding along the thickness direction of the skeleton 10 of the first filling assembly 20. The second mounting structure 63 is adapted to cooperate with the positioning hole 24, and the second mounting structure 63 is fitted in the positioning hole 24 to fix the first filling assembly 20 on the bottom guard plate 62. Therefore, the first filling assembly 20 is mounted on the bottom guard plate 62 through the cooperation between the second mounting structure 63 and the positioning hole 24, and the second mounting structure 63 can limit the first filling assembly 20 to improve the assembly reliability and stability of the first filling assembly 20.

[0151] According to some embodiments of the present disclosure, as shown in FIGS. 15-17, the second mounting structure 63 comprises a plurality of buckles 631 arranged at intervals, one end of the plurality of buckles 631 is provided with a buckle portion 632, the buckle portions 632 of the plurality of buckles 631 are located on the side of the plurality of buckles 631 away from each other, and the buckle portions 632 of the plurality of buckles 631 pass through the corresponding positioning holes 24 of the first filling assembly 20 and are adapted to abut against the side surface of the first filling assembly 20 adjacent to the bottom plate 61.

[0152] The second mounting structure 63 comprises buckles 631 and connecting portions 633, one end of the buckle 631 is connected with the connecting portion 633, the other end of the buckle 631 extends along the thickness direction of the framework 10 towards the side where the framework 10 is located, the buckle portion 632 of the buckle 631 is arranged at the other end of the buckle 631, the buckle portion 632 protrudes from the outer surface of the buckle 631 towards the direction away from the center of the second mounting structure 63, the plurality of buckles 631 are arranged at intervals, and the buckle 631 can be deformed towards the center of the second mounting structure 63 to facilitate the assembly of the second mounting structure 63. The connecting portion 633 of the second mounting structure 63 is fixed on the bottom guard plate 62, and the other end of the buckle 631 passes through the positioning hole 24 of the first filling piece to fix the first filling piece.

[0153] Therefore, the plurality of buckles 631 arranged at intervals can deform towards the center of the second mounting structure 63 when the second mounting structure 63 is assembled into the positioning hole 24, and restore to the original state after the buckle portion 632 passes through the positioning hole 24, so as to facilitate the assembly of the second mounting structure 63, and also facilitate the abutment of the buckle portion 632 of the buckle 631 against the side surface of the first filling assembly 20 adjacent to the bottom plate 61, so that the second mounting structure 63 limits the first filling assembly 20 along the thickness direction of the framework 10.

[0154] According to some embodiments of the present disclosure, as shown in FIGS. 18 and 19, further comprising: a plurality of first fasteners 64 passing through the corresponding positioning holes 24 of the first filling assembly 20 and cooperating with the corresponding second mounting structures 63. Therefore, the plurality of first fasteners 64 pass through the positioning holes 24 and cooperate with the second mounting structures 63 to fix the first filling assembly 20 on the bottom guard plate 62.

[0155] According to some embodiments of the present disclosure, as shown in FIG. 19, the first fastener 64 is a screw or a rivet. Both the screw and the rivet have the advantages of simple structure, convenient disassembly and assembly, high connection strength, low production cost and small connection deformation. Therefore, the first fastener 64 being a screw or a rivet can effectively reduce the assembly cost and difficulty of the first filling assembly 20, and improve the connection strength between the first filling assembly 20 and the bottom guard plate 62, and enhance the assembly reliability and stability of the first filling assembly 20.

[0156] According to some embodiments of the present disclosure, as shown in FIGS. 2 and 3, the bottom plate 61 is a heat exchange plate. The bottom plate 61 is adapted to carry the battery module 71, and the bottom plate 61 being a heat exchange plate can exchange heat with the battery module 71. In this way, the bottom plate 61 being a heat exchange plate can adjust the temperature of the battery module 71, prevent a large amount of heat from gathering in a small space, and keep the temperature of the battery module 71 within a suitable temperature range at all times, thereby maintaining the optimal working state of the battery module 71, preventing the battery module 71 from overheating and causing rapid aging, and prolonging the service life of the battery module 71.

[0157] According to some embodiments of the present disclosure, as shown in FIG. 22, at least one of the plurality of beam structures 51 is formed with at least one mounting hole 52; the tray 200 further comprises: at least one second fastener 511, the second fastener 511 passing through the mounting hole 52 and cooperating with the first mounting structure 34 of the second filling assembly 30. The mounting hole 52 penetrates the side wall of the beam structure 51, a plurality of mounting holes 52 are arranged along the length direction of the skeleton 10 of the second filling assembly 30, the mounting hole 52 corresponds to the first mounting structure 34 of the second filling assembly 30 one by one, and the second fastener 511 is arranged in the mounting hole 52 and cooperates with the first mounting structure 34. In this way, the mounting hole 52 is arranged for the installation and positioning of the second filling assembly 30 during assembly, the plurality of mounting holes 52 can improve the positioning accuracy and assembly firmness of the second filling assembly 30, the second fastener 511 passes through the mounting hole 52 and cooperates with the first mounting structure 34 of the second filling assembly 30 to fix and install the second filling assembly 30 in the beam structure 51, and the second filling assembly 30 is assembled at the preset position in the beam structure 51, thereby ensuring the assembly reliability and stability of the second filling assembly 30.

[0158] According to some embodiments of the present disclosure, as shown in FIG. 20, the plurality of beam structures 51 comprises: a cross beam 53, a longitudinal beam 54, an intermediate cross beam 55, a first corner beam 56, and a second corner beam 57, the cross beam 53 comprises a first cross beam 531 and a second cross beam 532, the first cross beam 531 and the second cross beam 532 are arranged in a spaced manner; the longitudinal beam 54 comprises a first longitudinal beam 541 and a second longitudinal beam 542, the first longitudinal beam 541 and the second longitudinal beam 542 are respectively connected between the two ends of the first cross beam 531 and the second cross beam 532; the intermediate cross beam 55 is connected between the first longitudinal beam 541 and the second longitudinal beam 542, and the intermediate cross beam 55 is located between the first cross beam 531 and the second cross beam 532; the first longitudinal beam 541 and the first cross beam 531 are connected through the first corner beam 56, and the second longitudinal beam 542 and the first cross beam 531 are connected through the second corner beam 57; the second filling assembly 30 is a plurality of, and the plurality of second filling assemblies 30 are respectively arranged in the first cross beam 531, the second cross beam 532, the first longitudinal beam 541, the second longitudinal beam 542, the intermediate cross beam 55, the first corner beam 56, and the second corner beam 57.

[0159] The tray body 40 comprises a first direction A, a second direction B and a third direction C. The cross beam 53 and the middle cross beam 55 extend along the first direction A, the first cross beam 531, the middle cross beam 55 and the second cross beam 532 are arranged at intervals along the second direction B, and the middle cross beam 55 is arranged between the first cross beam 531 and the second cross beam 532 along the second direction B. The longitudinal beam 54 extends along the second direction B, and the first longitudinal beam 541 and the second longitudinal beam 542 are arranged at intervals along the first direction A. One end of the middle cross beam 55 along the first direction A is connected to the middle of the first longitudinal beam 541 along the second direction B, and the other end of the middle cross beam 55 along the first direction A is connected to the middle of the second longitudinal beam 542 along the second direction B. The first corner beam 56 and the second corner beam 57 are respectively connected to the two ends of the first cross beam 531 along the first direction A, one end of the first corner beam 56 is connected to one end of the first cross beam 531 along the first direction A, and the other end of the first corner beam 56 is connected to one end of the first longitudinal beam 541 along the second direction B adjacent to the first cross beam 531. One end of the second corner beam 57 is connected to the other end of the first cross beam 531 along the first direction A, and the other end of the second corner beam 57 is connected to one end of the second longitudinal beam 542 along the second direction B adjacent to the first cross beam 531. The second filling assembly 30 is arranged in each of the plurality of beam structures 51. One end of the second cross beam 532 along the first direction A is connected to the other end of the first longitudinal beam 541 along the second direction B, and the other end of the second cross beam 532 along the first direction A is connected to the other end of the second longitudinal beam 542 along the second direction B.

[0160] The beam structure 51 can be processed by extrusion, rolling and machining processes, and the material of the beam structure 51 is high-strength steel or aluminum alloy, and the connection process between the plurality of beam structures 51 can be welding, riveting, gluing or a combination of the above processes.

[0161] Thus, the first cross beam 531, the second cross beam 532, the first longitudinal beam 541, the second longitudinal beam 542, the first corner beam 56 and the second corner beam 57 are sequentially connected to form a closed frame 50 structure, the middle cross beam 55 is used for reinforcing the middle structure of the frame 50, and the plurality of second filling assemblies 30 arranged in the first cross beam 531, the second cross beam 532, the first longitudinal beam 541, the second longitudinal beam 542, the middle cross beam 55, the first corner beam 56 and the second corner beam 57 can effectively enhance the structural strength of the beam structure 51, improve the mechanical properties of the tray 200 frame 50, improve the extrusion deformation resistance and bending and torsional strength of the beam structure 51, and optimize the overall performance of the tray 200.

[0162] According to some embodiments of the present disclosure, as shown in FIGS. 20, 25 and 26, the second filling assembly 30 comprises a corner filling assembly 38, which comprises: a first corner filling assembly 35, one end of which is fitted in the longitudinal beam 54, and the other end of which is fitted in the second cross beam 532.

[0163] One end of the first corner filling assembly 35 extends along the first direction A, and the other end of the first corner filling assembly 35 extends along the second direction B, i.e., the first corner 32 assembly has an L-shaped structure. The corner filling assembly 38 comprises two first corner filling assemblies 35, wherein one end of one first corner filling assembly 35 is fitted in one end of the second cross beam 532 along the first direction A, and the other end of the first corner filling assembly 35 is fitted in the other end of the first longitudinal beam 541 along the second direction B; one end of the other first corner filling assembly 35 is fitted in the other end of the second cross beam 532 along the first direction A, and the other end of the first corner filling assembly 35 is fitted in the other end of the second longitudinal beam 542 along the second direction B. In this way, the first corner filling assembly 35 can improve the fatigue strength of the connection between the second cross beam 532 and the first longitudinal beam 541 and the second longitudinal beam 542, and enhance the mechanical strength of the connection between the second cross beam 532 and the first longitudinal beam 541 and the second longitudinal beam 542.

[0164] According to some embodiments of the present disclosure, as shown in FIGS. 20, 27-29, the corner filling assembly 38 further comprises: a second corner filling assembly 36, one end of which is fitted in the longitudinal beam 54 or the first cross beam 531, and the other end of which is fitted in the first corner beam 56 or the second corner beam 57.

[0165] The second corner filling assembly 36 comprises a first sub-corner filling assembly 361 and a second sub-corner filling assembly 362. One end of the first sub-corner filling assembly 361 extends along the first direction A, and the other end of the first sub-corner filling assembly 361 extends obliquely. One end of the second sub-corner filling assembly 362 extends along the second direction B, and the other end of the second sub-corner filling assembly 362 extends obliquely. The corner filling assembly 38 comprises two second corner filling assemblies 36, wherein one end of the first sub-corner filling assembly 361 in one second corner filling assembly 36 is fitted in one end of the first transverse beam 531 along the first direction A, and the other end is fitted in the first corner beam 56. One end of the second sub-corner filling assembly 362 in the second corner filling assembly 36 is fitted in one end of the first longitudinal beam 541 along the second direction B, and the other end is fitted in the first corner beam 56. The other end of the first sub-corner filling assembly 361 in the other second corner filling assembly 36 is fitted in the other end of the first transverse beam 531 along the first direction A, and the other end is fitted in the second corner beam 57. One end of the second sub-corner filling assembly 362 in the second corner filling assembly 36 is fitted in one end of the second longitudinal beam 542 along the second direction B, and the other end is fitted in the second corner beam 57.

[0166] Thus, the second corner filling assembly 36 can improve the fatigue strength of the connection between the first transverse beam 531, the first longitudinal beam 541, the second longitudinal beam 542, the first corner beam 56 and the second corner beam 57, and enhance the mechanical strength of the connection between the first transverse beam 531, the first longitudinal beam 541, the second longitudinal beam 542, the first corner beam 56 and the second corner beam 57.

[0167] According to some embodiments of the present disclosure, as shown in FIG. 30, the corner filling assembly 38 is connected to the second filling assembly 30 in the adjacent transverse beam 53 or longitudinal beam 54 through at least one connecting structure 37. The connecting structure 37 is arranged at the end of the corner filling assembly 38 and the filling assembly 100 arranged in the transverse beam 53 or longitudinal beam 54. Taking the first corner beam 56 and the first transverse beam 531 as an example, one end of the first sub-corner filling assembly 361 in the second corner filling assembly 36 located in the first corner beam 56 is in contact with the end of the second filling assembly 30 in the first transverse beam 531 adjacent to the first corner beam 56, and the connecting structure 37 is arranged between the two ends of the two filling assemblies 100 to connect the two filling assemblies 100 into one. Thus, the arrangement of the connecting structure 37 is used to connect the corner filling assembly 38 and the filling assembly 100 in the adjacent transverse beam 53 or longitudinal beam 54 into one when the corner beam is combined with the transverse beam 53 or longitudinal beam 54, which is more conducive to enhancing the mechanical strength of the frame 50 at the corner.

[0168] According to some embodiments of the present disclosure, as shown in FIG. 30, the connecting structure 37 comprises: a connecting hole 371 formed on one of the corner filling assembly 38 and the second filling assembly 30 in the adjacent beam 53 or 54; and a connecting shaft 372 on the other of the corner filling assembly 38 and the second filling assembly 30 in the adjacent beam 53 or 54, the connecting shaft 372 being fitted in the connecting hole 371.

[0169] Taking the first corner beam 56 and the first beam 531 as an example, the connecting hole 371 is formed on one end of the first sub-corner filling assembly 361 in the second corner filling assembly 36 in the first corner beam 56, the connecting hole 371 being recessed from a part of the end face towards the inside of the first sub-corner filling assembly 361, the connecting shaft 372 is formed on one end of the second filling assembly 30 in the first beam 531, the connecting shaft 372 being protruded from a part of the end face towards one side of the first sub-corner filling assembly 361, and the connecting shaft 372 on one end of the second filling assembly 30 in the first beam 531 is fitted in the connecting hole 371 on one end of the first sub-corner filling assembly 361.

[0170] Thus, the connecting hole 371 and the connecting shaft 372 can realize the connection between the corner filling assembly 38 and the second filling assembly 30 in the adjacent beam 53 or 54, so that the two filling assemblies 100 can be connected and integrated with each other, thereby strengthening the structural strength of the frame 50.

[0171] According to some embodiments of the present disclosure, as shown in FIG. 20, the plurality of beam structures 51 further comprises: a plurality of mounting beams 58 respectively arranged on the sides of the first longitudinal beam 541 and the second longitudinal beam 542 away from each other; and a plurality of lifting lugs 59 respectively arranged on the sides of the first beam 531 and the second beam 532 away from each other; and the plurality of mounting beams 58 and the plurality of lifting lugs 59 are respectively provided with the second filling assembly 30.

[0172] The plurality of mounting beams 58 comprises a first mounting beam and a second mounting beam, the mounting beam 58 extending along the second direction B, the first mounting beam being connected to the side of the first longitudinal beam 541 away from the second longitudinal beam 542 along the first direction A, and the second mounting beam being connected to the side of the second longitudinal beam 542 away from the first longitudinal beam 541 along the first direction A. The plurality of lifting lugs 59 are respectively arranged on the sides of the first beam 531 and the second beam 532 away from each other along the second direction B, and the plurality of lifting lugs 59 are arranged on the first beam 531 or the second beam 532 along the first direction A.

[0173] Therefore, the plurality of mounting beams 58 and the plurality of lifting lugs 59 are arranged for the connection of the tray 200 and the external system, facilitating the assembly of the tray 200, and the second filling assembly 30 arranged in the plurality of mounting beams 58 and the plurality of lifting lugs 59 can enhance the structural strength of the plurality of mounting beams 58 and the plurality of lifting lugs 59, and improve the stability of the connection of the tray 200 and the external system.

[0174] According to some embodiments of the present disclosure, as shown in FIG. 20, at least one of the plurality of beam structures 51 is formed with a plurality of cavities 13, and at least one of the plurality of cavities 13 is provided with a second filling assembly 30. In some embodiments, two cavities 13 are formed in the plurality of beam structures 51, and the two cavities 13 are arranged at intervals along the third direction C, and the two cavities 13 are each provided with a second filling assembly 30. Therefore, the structural strength of the beam structure 51 can be further improved, the mechanical properties of the beam structure 51 can be improved, and the extrusion deformation resistance of the beam structure 51 can be enhanced.

[0175] The manufacturing process of the tray 200 is as follows:

[0176] First, the frame 50, the bottom plate assembly 60, the mounting beam 58, the lifting lug 59, and other single-piece components of the tray 200 are processed, and at the same time, the skeleton 10 of the filling assembly 100 is processed. The foaming layer 11 is wrapped on the skeleton 10 of the filling assembly 100, and the filling assembly 100 is processed. The filling assembly 100 is assembled in the frame 50, the bottom plate assembly 60, the mounting beam 58, the lifting lug 59, and other profile components, and the assembled filling assembly 100 is integrated into the tray 200. The mounting parts of the filling assembly 100 in different structures need to be connected, and then the welding process is performed. Then, the tray 200 after welding is placed in a surface treatment solution, and the surface treatment solution flows in the gap between the skeleton 10 and the inner walls of the frame 50, the bottom plate assembly 60, the mounting beam 58, and the lifting lug 59. After the treatment is completed, the tray 200 is taken out and the internal solution is drained. The tray 200 after the surface treatment process is placed in a high-temperature oven for baking, and the baking conditions meet the foaming conditions of the foaming layer 11 in the filling assembly 100. After the foaming layer 11 is foamed and expanded, it becomes a closed-cell foam, and the gap between the skeleton 10 and the inner walls of the frame 50, the bottom plate assembly 60, the mounting beam 58, and the lifting lug 59 is completely filled. Finally, the tray 200 is offline, the tray 200 is partially treated, and the quality of the tray 200 is inspected. In some embodiments, part of the tray 200 does not need to be subjected to the surface treatment process, and some profile components of the tray 200 are made of single-plate rolled closed-section profiles. In the case of not affecting the profile rolling process, the mounting process of the frame 50, the bottom plate assembly 60, the mounting beam 58, and the lifting lug 59 can be performed in the processing process.

[0177] According to the battery pack 300 of the third aspect of the embodiments of the present disclosure, the tray 200 of the second aspect of the embodiments of the present disclosure is used.

[0178] In combination with FIGS. 1-3, the battery pack 300 includes the tray 200, the upper cover 70, and the battery module 71 installed in the closed space formed by the upper cover 70 and the battery tray 200.

[0179] According to the battery pack 300 of the embodiments of the present disclosure, by using the tray 200 described in the above embodiments, the tray 200 can provide good heat preservation and impact protection for the battery pack 300, enhance the protection of the battery module 71 by the tray 200, improve the overall mechanical strength of the battery pack 300, improve the safety of the battery pack 300, and prolong the service life of the battery pack 300.

[0180] According to the vehicle 400 of the fourth aspect of the embodiments of the present disclosure, as shown in FIG. 31, the battery pack 300 of the third aspect of the embodiments of the present disclosure is used.

[0181] According to the vehicle 400 of the embodiments of the present disclosure, by using the battery pack 300 described in the above embodiments, the service life of the battery pack 300 can be prolonged, and thus the service life of the vehicle is prolonged, the comprehensive performance and safety performance of the vehicle are improved, and the after-sales cost of the vehicle is reduced.

[0182] In the description of the present disclosure, it should be understood that the orientation or positional relationship indicated by the terms “center”, “longitudinal”, “transverse”, “length”, “width”, “thickness”, “upper”, “lower”, “front”, “rear”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inner”, “outer”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential” and the like are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present disclosure and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present disclosure.

[0183] In the description of the present disclosure, “first feature” and “second feature” can include one or more features. In the description of the present disclosure, the meaning of “a plurality of” is two or more. In the description of the present disclosure, the “above” or “below” of the first feature to the second feature can include that the first and second features are in direct contact, or can include that the first and second features are not in direct contact but are in contact through another feature between them. In the description of the present disclosure, the “above”, “over” and “on” of the first feature to the second feature include that the first feature is directly above and obliquely above the second feature, or only means that the first feature is higher than the second feature in horizontal height.

[0184] In the description of the disclosure, references to "one embodiment", "some embodiments", "an example embodiment", "an example", "a specific example", or "some examples" means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the disclosure. The illustrative appearances of the above-described terms in various places in the specification are not necessarily intended to refer to the same embodiment or example.

Claims

1. A filling assembly (100), characterized in that, Comprising: a skeleton (10); at least one foamed layer (11) covering at least a part of the outer surface of the skeleton (10).

2. The filling assembly (100) according to claim 1, characterized in that The filling assembly (100) comprises a first filling assembly (20); The skeleton (10) of the first filling assembly (20) is a plate structure; The foamed layer (11) of the first filling assembly (20) is two, and the two foamed layers (11) cover the two side surfaces in the thickness direction of the skeleton (10) respectively.

3. The filling assembly (100) according to claim 2, characterized in that Further comprising further comprising: At least one first support structure (21) is provided on the skeleton (10), and the first support structure (21) protrudes from at least one side surface of the foamed layer (11) away from the skeleton (10).

4. The filling assembly (100) according to claim 3, characterized in that The first support structure (21) is a plurality of, and the plurality of first support structures (21) comprises: At least one first sub-support structure (211) is provided on at least one side surface in the thickness direction of the skeleton (10); At least one second sub-support structure (212) is provided on the side surface of the skeleton (10), and a part of the second sub-support structure (212) extends to at least one side surface in the thickness direction of the skeleton (10).

5. The filling assembly (100) according to claim 4, characterized in that The first sub-support structure (211) is a plurality of, and the plurality of first sub-support structures (211) are arranged in an array on the two side surfaces in the thickness direction of the skeleton (10) respectively; The second sub-support structure (212) is a plurality of, and the plurality of second sub-support structures (212) are arranged at intervals along the circumference of the skeleton (10), and the two ends of the second sub-support structure (212) extend to the two side surfaces in the thickness direction of the skeleton (10) respectively.

6. The filling assembly (100) according to any one of claims 3-5, characterized in that, The first support structure (21) is a cross-shaped structure, a rice-shaped structure, a wave-shaped structure or a polygonal structure.

7. The filling assembly (100) according to any one of claims 3-6, characterized in that, The height of the first support structure (21) protruding from at least one side surface of the foamed layer (11) away from the skeleton (10) is h, wherein the h satisfies: 3mm≤h≤5mm.

8. The filling assembly (100) according to claim 2, characterized in that A plurality of through holes (22) are formed on the skeleton (10), and the two foamed layers (11) are connected into one body through the plurality of through holes (22); and / or A plurality of protrusions (23) are provided on at least one side surface in the thickness direction of the skeleton (10), and the foamed layer (11) covers the outer surface of the plurality of protrusions (23).

9. The filling assembly (100) according to any one of claims 3-8, characterized in that, The first support structure (21) and the skeleton (10) are an integral structure; or The first support structure (21) and the skeleton (10) are bonded or clamped.

10. The filling assembly (100) according to any one of claims 2-9, characterized in that, The edge of the first filling assembly (20) is formed with a plurality of positioning holes (24), and the plurality of positioning holes (24) are arranged at intervals along the circumference of the first filling assembly (20).

11. The filling assembly (100) according to any one of claims 1-10, characterized in that, The skeletons (10) and the foamed layers (11) are respectively multiple, multiple foamed layers (11) cover at least part of the outer surface of multiple skeletons (10) respectively, multiple skeletons (10) and multiple foamed layers (11) respectively constitute multiple sub-filling assemblies (25), multiple sub-filling assemblies (25) are suitable for being detachably connected.

12. The filling assembly (100) according to claim 11, characterized in that At least one connecting groove (255) is formed on one of multiple sub-filling assemblies (25), and at least one connecting protrusion (254) is provided on another of multiple sub-filling assemblies (25), the connecting protrusion (254) is suitable for being fitted in the connecting groove (255) to realize detachable connection of multiple sub-filling assemblies (25).

13. The filling assembly (100) according to claim 12, characterized in that The connecting groove (255) penetrates the corresponding sub-filling assembly (25) along the thickness direction of the skeleton (10), and the width of the connecting groove (255) gradually decreases in the direction towards the edge of the corresponding sub-filling assembly (25); The shape of the connecting protrusion (254) is matched with the shape of the connecting groove (255).

14. The filling assembly (100) according to claim 12 or 13, characterized in that The connecting groove (255) and the connecting protrusion (254) are respectively multiple, multiple connecting grooves (255) are arranged in the length direction of the corresponding sub-filling assembly (25), and multiple connecting protrusions (254) correspond to multiple connecting grooves (255) respectively.

15. The filling assembly (100) according to any one of claims 1-14, characterized in that, The filling assembly (100) comprises a second filling assembly (30); The skeleton (10) of the second filling assembly (30) is a long strip structure; The foamed layer (11) of the second filling assembly (30) covers the outer peripheral surface of the skeleton (10).

16. The filling assembly (100) according to claim 15, characterized in that Further comprising: At least one second support structure (31) is provided on the skeleton (10), and the second support structure (31) protrudes from at least one side surface of the foamed layer (11) away from the skeleton (10).

17. The filling assembly (100) according to claim 16, characterized in that The second support structure (31) is multiple, and multiple second support structures (31) comprise: At least one third sub-support structure (311) is provided at a first corner (32) of the skeleton (10); At least one fourth sub-support structure (312) is provided at a second corner (33) of the skeleton (10), and the second corner (33) is opposite to the first corner (32).

18. The filling assembly (100) according to claim 17, characterized in that The third sub-support structure (311) is multiple, and multiple third sub-support structures (311) are arranged in the length direction of the skeleton (10), and both ends of the third sub-support structure (311) respectively extend to two surfaces of the skeleton (10) adjacent to the first corner (32); The fourth sub-support structure (312) is multiple, and multiple fourth sub-support structures (312) are arranged in the length direction of the skeleton (10), and both ends of the fourth sub-support structure (312) respectively extend to two surfaces of the skeleton (10) adjacent to the second corner (33).

19. The filling assembly (100) according to claim 18, characterized in that A plurality of the third sub-support structures (311) and a plurality of the fourth sub-support structures (312) are arranged in a staggered manner along the length direction of the framework (10).

20. The filling assembly (100) according to any one of claims 15-18, characterized in that, The framework (10) is provided with at least one first mounting structure (34).

21. The filling assembly (100) according to claim 20, characterized in that The first mounting structure (34) comprises at least one of a pre-buried nut, a clamping groove, and a hollow column structure.

22. The filling assembly (100) according to any one of claims 1-21, characterized in that, The framework (10) is a hollow structure.

23. The filling assembly (100) according to any one of claims 1-22, characterized in that, Further comprising: A thermal insulation layer (381) is arranged on at least part of the surface of the foaming layer (11) away from the framework (10).

24. The filling assembly (100) according to claim 23, characterized in that The thermal insulation layer (381) is a mica sheet, aerogel, or a thermal insulation coating.

25. The filling assembly (100) according to claim 23 or 24, characterized in that The thermal insulation layer (381) is bonded or sprayed to the at least part of the surface of the foaming layer (11) away from the framework (10).

26. The filling assembly (100) according to any one of claims 1-25, characterized in that, The foaming layer (11) is overmolded on the framework (10); or The foaming layer (11) is bonded or clamped to the framework (10).

27. The filling assembly (100) according to any one of claims 1-26, characterized by, The material of the framework (10) is nylon or fiber-reinforced resin composite material.

28. A tray (200) characterized by Further comprising: A tray body (40); And A filling assembly (100) according to any one of claims 1-27, the filling assembly (100) is arranged in the tray body (100).

29. The tray (200) according to claim 28, characterized in that The tray body (100) comprises: A frame (50) comprising a plurality of beam structures (51); and A bottom plate assembly (60) comprising a bottom plate (61) arranged at the bottom of the frame (50) and a bottom guard plate (62) arranged below the bottom plate (61); The filling assembly (100) comprises at least one of a first filling assembly (20) arranged between the bottom plate (61) and the bottom guard plate (62) and a second filling assembly (30) arranged in at least one of the plurality of beam structures (51).

30. The tray (200) according to claim 29, characterized in that The bottom guard plate (62) is provided with a plurality of second mounting structures (63), and the first filling assembly (20) is mounted on the bottom guard plate (62) through the plurality of second mounting structures (63).

31. The tray (200) according to claim 30, characterized in that The second mounting structure (63) comprises a plurality of buckles (631) arranged at intervals, one end of the plurality of buckles (631) adjacent to the first filling assembly (20) has a buckle part (632), the buckle parts (632) of the plurality of buckles (631) are located on the side of the plurality of buckles (631) away from each other, the buckle parts (632) of the plurality of buckles (631) pass through the corresponding positioning holes (24) of the first filling assembly (20) and are adapted to abut against the side surface of the first filling assembly (20) adjacent to the bottom plate (61).

32. The tray (200) according to claim 30 or 31, characterized in that Further comprising: A plurality of first fasteners (64) passing through the corresponding positioning holes (24) of the first filling assembly (20) and cooperating with the corresponding second mounting structures (63).

33. The tray (200) according to claim 32, characterized in that The first fastener (64) is a screw or a rivet.

34. The tray (200) according to any one of claims 29-33, characterized in that, The bottom plate (61) is a heat exchange plate.

35. The tray (200) according to any one of claims 29-34, characterized by At least one mounting hole (52) is formed on the at least one of the plurality of beam structures (51). The tray (200) further comprises: At least one second fastener (511) cooperates with the first mounting structure (34) of the second filling assembly (30) through the mounting hole (52).

36. The tray (200) according to any one of claims 29-35, characterized by The plurality of beam structures (51) comprises: A cross beam (53) comprises a first cross beam (531) and a second cross beam (532) which are arranged at intervals; A longitudinal beam (54) comprises a first longitudinal beam (541) and a second longitudinal beam (542) which are connected between the two ends of the first cross beam (531) and the second cross beam (532) respectively; An intermediate cross beam (55) is connected between the first longitudinal beam (541) and the second longitudinal beam (542), and the intermediate cross beam (55) is located between the first cross beam (531) and the second cross beam (532); A first corner beam (56) connects between the first longitudinal beam (541) and the first cross beam (531); and A second corner beam (57) connects between the second longitudinal beam (542) and the first cross beam (531), The second filling assembly (30) is a plurality of second filling assemblies (30) which are respectively arranged in the first cross beam (531), the second cross beam (532), the first longitudinal beam (541), the second longitudinal beam (542), the intermediate cross beam (55), the first corner beam (56) and the second corner beam (57).

37. The tray (200) according to claim 36, characterized in that The second filling assembly (30) comprises a corner filling assembly (38) which comprises: A first corner filling assembly (35) is cooperated in the longitudinal beam (54) at one end, and is cooperated in the second cross beam (532) at the other end.

38. The tray (200) according to claim 37, characterized in that The corner filling assembly (38) further comprises: A second corner filling assembly (36) is cooperated in the longitudinal beam (54) or the first cross beam (531) at one end, and is cooperated in the first corner beam (56) or the second corner beam (57) at the other end.

39. The tray (200) according to claim 38, characterized in that The corner filling assembly (38) is connected with the second filling assembly (30) in the adjacent cross beam (53) or longitudinal beam (54) through at least one connecting structure (37).

40. The tray (200) according to claim 39, characterized in that The connecting structure (37) comprises: A connecting hole (371) is formed on one of the corner filling assembly (38) and the second filling assembly (30) in the adjacent cross beam (53) or longitudinal beam (54); and A connecting hole (371) is formed on one of the corner filling assembly (38) and the second filling assembly (30) in the adjacent cross beam (53) or longitudinal beam (54); and A connecting shaft (372) is fitted in the connecting hole (371) on the corner filling assembly (38) and another one of the second filling assembly (30) in the adjacent beam (53) or longitudinal beam (54).

41. The tray (200) according to any one of claims 36-40, characterized by The plurality of beam structures (51) further comprise: A plurality of mounting beams (58) are respectively arranged on the sides of the first longitudinal beam (541) and the second longitudinal beam (542) away from each other; and A plurality of lifting lugs (59) are respectively arranged on the sides of the first transverse beam (531) and the second transverse beam (532) away from each other, Wherein, the second filling assembly (30) is arranged in the plurality of mounting beams (58) and the plurality of lifting lugs (59) respectively.

42. The tray (200) according to any one of claims 29-41, characterized by The at least one of the plurality of beam structures (51) is formed with a plurality of cavities, and at least one of the plurality of cavities is provided with the second filling assembly (30).

43. A battery pack (300) characterized by, The tray (200) according to any one of claims 28-42.

44. A vehicle characterized by The battery pack (300) according to claim 43. The battery pack (300) according to claim 43.

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