Filler, battery pack and electric device

Abstract

An electric device, having a battery pack, wherein the battery pack has a filler; the filler is adapted to be disposed in a filling space between a battery cell assembly of the battery pack and a side wall of a battery tray; and the filler is provided with a clearance portion, which is used for avoiding an electrical connector of the battery pack. In the present disclosure, the filler can achieve the function of being dual purpose, wherein the filler can not only provide a restraining force for the battery cell assembly, but can also avoid the electrical connector by means of the clearance portion, thereby reducing the risk of interference between the filler and the electrical connector, and between the electrical connector and other components of the battery pack; in addition, the space occupied by the filler in the battery pack can be reduced.

Description

Fillers, battery packs and electrical equipment

[0001] Cross-references to related applications

[0002] This disclosure claims priority to Chinese Patent Application No. 202421631121.1, filed on July 9, 2024, entitled "Filling Material, Battery Pack and Electrical Equipment", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to the field of battery technology, and more specifically, to a filler, a battery pack, and an electrical device. Background Technology

[0004] Nowadays, new energy vehicles are usually equipped with multiple different range versions for consumers to choose from. The number of battery cells in the battery packs of different range versions also varies. Usually, the connection points and positions of the battery packs are the same for the same model. Therefore, the battery packs of different range versions can be designed with the same outer frame so that important components such as battery trays, cold plates and sealing covers can be shared.

[0005] In order to assemble the battery cells into the battery tray of the battery pack, there is usually an assembly gap (called a filling space) between the side beams of the battery tray. In related technologies, fillers are placed into the filling space to provide restraint force to the battery cells. However, existing fillers have the problems of occupying a lot of space and easily interfering with electrical connectors. Summary of the Invention

[0006] The purpose of this disclosure is to provide a filler, a battery pack, and an electrical device to solve at least one of the aforementioned technical problems.

[0007] To achieve the above objectives, this disclosure provides a filler adapted to be disposed in the filling space between the cell assembly and the side wall of the battery tray of a battery pack;

[0008] The filler is provided with a clearance portion, which is used to avoid the electrical connectors of the battery pack.

[0009] Optionally, at least one of the opposite ends of the filler is provided with the clearance portion.

[0010] Optionally, the filler is located on one side in the first direction and is adapted to be connected to the battery cell assembly, and the clearance portion is configured as a first clearance channel penetrating the filler along the first direction.

[0011] Optionally, the outer surface portion of the filler in the second direction is recessed to form the first clearance channel, the second direction intersecting the first direction.

[0012] Optionally, the first clearance channel includes a first clearance surface and a second clearance surface; one end of the first clearance surface in the second direction is connected to one end of the second clearance surface in the third direction, the other end of the first clearance surface in the second direction extends to the surface of the filler in the second direction, and the other end of the second clearance surface in the third direction extends to the end wall of the filler in the third direction; wherein the third direction intersects with the plane defined by the first direction and the second direction.

[0013] Optionally, the third direction is perpendicular to the first direction, and the first avoidance surface is perpendicularly connected to the second avoidance surface.

[0014] Optionally, the filler has an abutment plane adapted to be connected to the battery cell assembly.

[0015] Optionally, the filler is provided with a cavity.

[0016] Optionally, the filler has a first side and a second side opposite to each other along a first direction; the first side is adapted to be connected to the cell assembly, and the second side is adapted to be connected to the sidewall of the battery tray; the cavity has an opening extending to the second side and / or the first side.

[0017] Optionally, a partition structure is fixed inside the cavity, the partition structure dividing the cavity into multiple weight-reducing cavities, and the partition structure extends at least partially along the first direction.

[0018] Optionally, the partition structure includes a plurality of arc-shaped portions, the plurality of arc-shaped portions being spaced apart, each arc-shaped portion extending along the first direction, and one end of the arc-shaped portion located in the first direction being connected to the surface of the filler for connection with the battery cell assembly;

[0019] The partition structure further includes a plurality of first stiffeners, which are arranged along a second direction of the filler and are connected between the cavity wall of the cavity and the convex surface of the corresponding arcuate portion; or, the first stiffeners are connected between the convex surfaces of two corresponding arcuate portions, wherein the second direction intersects the first direction; and / or,

[0020] The partition structure further includes a plurality of second stiffeners, which are arranged along a third direction of the filler and connected between the cavity wall and the convex surface of the corresponding arcuate portion; or, the second stiffeners are connected between the convex surfaces of two corresponding arcuate portions, wherein the third direction intersects the first direction; and / or,

[0021] The partition structure also includes a third stiffener, which is arranged at an angle and whose two ends are respectively connected between two corresponding arc-shaped portions.

[0022] Optionally, a portion of the arcuate portions has a cross-sectional shape perpendicular to the first direction that is annular.

[0023] Optionally, the sum of the volumes occupied by the multiple weight-reducing cavities forms a hollowed-out volume, and the hollowed-out volume accounts for 60% to 80% of the total volume of the filler.

[0024] Optionally, the area of ​​the outer contour of the cross-section of the filler perpendicular to the first direction is the initial cross-sectional area, and the area of ​​the cross-section of the filler perpendicular to the first direction is the remaining cross-sectional area, wherein the remaining cross-sectional area accounts for 20% to 40% of the initial cross-sectional area.

[0025] Optionally, the filler is a one-piece molded part.

[0026] Optionally, the filler is made of an insulating material.

[0027] According to a second aspect of this disclosure, a battery pack is provided, including a battery tray, a cell assembly, an electrical connector, and the aforementioned filler.

[0028] The battery tray has a receiving cavity, and the battery cell assembly and the filler are both arranged in the receiving cavity. The filling space is formed between the battery cell assembly and the side wall of the battery tray.

[0029] The electrical connector passes through the clearance portion.

[0030] Optionally, there are multiple battery cell groups, each battery cell group has the filling member disposed on at least one side in the first direction, the clearance portion extends along the first direction, and the multiple battery cell groups are arranged at intervals along a third direction, the third direction intersecting the first direction; the electrical connector includes two first segments and a second segment connecting the two first segments, one of the first segments is located in the clearance portion of one of the two adjacent filling members in the third direction, and the other first segment is located in the clearance portion of the other of the two adjacent filling members in the third direction.

[0031] Optionally, the battery tray includes a base plate, side beams, and partition beams. The side beams are fixed to the edge of the base plate to define a mounting cavity. The partition beams are disposed within the mounting cavity to divide the mounting cavity into multiple receiving cavities. A second clearance channel is provided on the partition beams, and a second section passes through the second clearance channel.

[0032] Optionally, the second clearance channel is a notch provided at the end of the separator beam located in the first direction.

[0033] Optionally, the filling space is formed between the sidewall constructed from the large surface of the battery cell in the battery cell assembly and the sidewall of the battery tray.

[0034] According to a third aspect of this disclosure, an electrical device is provided, including a device body and the aforementioned battery pack, the battery pack being installed in the device body and adapted to supply power to the device body.

[0035] Through the above technical solution, the filler, once placed within the filling space, can abut against the battery cell, providing restraint force for the battery cell assembly. Simultaneously, the presence of clearance portions on the filler reduces its volume and the space it occupies within the battery pack. Furthermore, the existence of these clearance portions allows some electrical connectors to be located there, thus reducing the risk of interference between the filler and electrical connectors, as well as the risk of interference between electrical connectors and other components of the battery pack.

[0036] Other features and advantages of this disclosure will be described in detail in the following detailed description section. Attached Figure Description

[0037] The accompanying drawings are provided to further illustrate the present disclosure and form part of the specification. They are used together with the following detailed description to explain the present disclosure, but do not constitute a limitation thereof. In the drawings:

[0038] Figure 1 is a three-dimensional structural diagram of a filler provided in an exemplary embodiment of this disclosure;

[0039] Figure 2 is a schematic diagram of the end face of one end of the filler connected to the battery cell assembly according to an exemplary embodiment of the present disclosure;

[0040] Figure 3 is a schematic diagram of the installation structure of the battery cell pack in the battery tray according to an exemplary embodiment of the present disclosure;

[0041] Figure 4 is a schematic diagram of the mounting structure of the battery cell assembly and filler in the battery tray according to an exemplary embodiment of the present disclosure;

[0042] Figure 5 is a schematic diagram of the installation structure of the cell assembly, filler and electrical connector in the battery tray according to an exemplary embodiment of the present disclosure;

[0043] Figure 6 is an exploded view of a battery pack provided in an exemplary embodiment of this disclosure.

[0044] Figure 7 is a schematic structural block diagram of an electrical device provided in an exemplary embodiment of this disclosure. Embodiments of the present invention

[0045] The specific embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure.

[0046] In the description of this disclosure, it should be understood that the terms "upper," "lower," "left," and "right," etc., indicating orientation or positional relationships, are defined based on the drawing orientation (as shown in Figure 2) and are only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or a specific orientation construction and operation. Therefore, they should not be construed as limitations on this disclosure. In addition, the terms "inner" and "outer" refer to the inner and outer contours of the corresponding structures. Furthermore, the terms "first," "second," etc., are only used to distinguish one element from another and do not have sequentiality or importance. For example, the first direction X, the second direction Z, and the third direction Y are only used to distinguish one element from another and do not have sequentiality or importance.

[0047] In the description of this disclosure, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "connect," "link," and "install" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0048] As mentioned above, the filler used in the relevant technologies has the problems of taking up a lot of space and being prone to interference with electrical connectors.

[0049] In view of this, as shown in Figures 1 to 6, this disclosure provides a filler 100 in a first aspect, which is adapted to be disposed within a filling space 203 between the cell group 300 and the side wall of the battery tray 200 of the battery pack 10. The filler 100 is provided with a clearance portion 110 for clearance of an electrical connector 400 of the battery pack 10. The electrical connector 400 may be a connector that connects adjacent cell groups 300 in series, and / or, the electrical connector 400 may be a connector that electrically connects the cell group 300 to the power distribution structure of the battery pack 10. That is, the electrical connector 400 may be a connector that connects adjacent cell groups 300 in series, a connector that electrically connects the cell group 300 to the power distribution structure of the battery pack 10, or a connector that connects other components; this disclosure does not limit this.

[0050] Through the above scheme, the filler 100, after being placed within the filling space 203, can abut against the battery cell, providing restraint for the battery cell assembly 300. Simultaneously, the presence of the clearance portion 110 on the filler 100 reduces its volume and the space it occupies within the battery pack 10. Furthermore, the existence of the clearance portion 110 allows some of the electrical connectors 400 to be located at the clearance portion 110, thus reducing the risk of interference between the filler 100 and the electrical connectors 400, as well as the risk of interference between the electrical connectors 400 and other components of the battery pack 10. For example, without the clearance portion 110, some of the electrical connectors 400 would need to be placed above the filler, potentially causing the electrical connectors 400 to be higher than the height of the battery cell assembly 300, thus preventing the battery cover 500 of the battery pack 10 from sealing properly with the battery tray 200. However, with the clearance portion 110, the electrical connectors 400 will not be higher than the height of the battery cell assembly 300. Thus, in this disclosure, the filler 100 can serve a dual purpose: it can provide restraint to the cell assembly 300 and also avoid the electrical connector 400 through the avoidance part 110, thereby reducing the risk of interference between the filler 100 and the electrical connector 400, as well as between the electrical connector 400 and other components of the battery pack 10. At the same time, it can reduce the space occupied by the filler 100 in the battery pack 10.

[0051] It should be noted that the aforementioned electrical connector 400 may be a connecting bar, a metal connecting piece, a wire harness, or other electrical connector, and this disclosure does not specifically limit its application. The power distribution structure of the battery pack 10 may be a high-voltage distribution box, etc., and this disclosure does not specifically limit its application.

[0052] In some alternative embodiments, as shown in FIG1, at least one of the opposite ends of the filler 100 is provided with a clearance portion 110. For example, as shown in FIG1 to FIG5, at least one of the opposite ends of the filler 100 in the third direction Y is provided with a clearance portion 110.

[0053] When a clearance portion 110 is provided at one of the two opposite ends of the filler 100, the installation direction of the filler 100 can be adjusted according to the position of the electrical connector 400 within the battery pack 10 during installation, so that the clearance portion 110 on the filler 100 can avoid the electrical connector 400. Of course, when clearance portions 110 are provided at both opposite ends of the filler 100, it is not necessary to adjust the installation direction of the filler 100, so that the filler 100 has a foolproof function when engaging with the electrical connector 400.

[0054] In some alternative embodiments, the filler 100 is located on one side in the first direction X and is adapted to be connected to the cell assembly 300, and the clearance portion 110 is configured as a first clearance channel 120 passing through the filler 100 in the first direction X.

[0055] The clearance portion 110 is configured as a first clearance channel 120 that penetrates the filler 100, which facilitates the arrangement of the electrical connectors 400 and also allows the clearance portion 110 to avoid more electrical connectors 400.

[0056] It should be noted that the first clearance channel 120 can be set at any position of the filler 100. For example, it can be located at the top, middle and bottom in the height direction of the filler 100 (as shown in the second direction Z of Figure 1). This disclosure does not make specific limitations in this regard.

[0057] Furthermore, it is understood that the first clearance channel 120 can be located inside the filler 100 or on the outer surface of the filler 100, that is, the first clearance channel 120 can be formed by a partial recess on the outer surface of the filler 100.

[0058] In some alternative embodiments, as shown in Figures 1 and 2, the outer surface portion of the filler 100 in the second direction Z is recessed to form a first clearance channel 120, the second direction Z intersecting the first direction X.

[0059] By setting the first clearance channel 120 on the outer surface of the filler 100, it is convenient to process the first clearance channel 120, and it is also easier to place part of the structure of the electrical connector 400 in the first clearance channel 120, so as to achieve clearance of the clearance part 110 to the electrical connector 400.

[0060] It is understood that the second direction Z here can be the up-down or left-right direction when the filler 100 is in the installed state (see Figures 1 and 2), and this disclosure does not limit it in this way. In other words, the first clearance channel 120 can be located on the upper or lower surface of the filler 100 as shown in Figure 2, or it can be located on the left or right surface of the filler 100 as shown in Figure 2.

[0061] In some embodiments, as shown in Figures 1 and 2, the first clearance channel 120 can be located on the upper surface of the filler 100. In other words, a portion of the upper surface of the filler 100 is recessed downwards. The first clearance channel 120, constructed by recessing the upper surface of the filler 100 downwards, faces an upward opening. Therefore, after the filler 100 is installed in the filling space 203, it is even more convenient to place a portion of the structure of the electrical connector 400 in the first clearance channel 120.

[0062] Regarding the specific structure of the first clearance channel 120, as shown in FIG1, in some optional embodiments, the clearance portion 110 includes a first clearance surface 111 and a second clearance surface 112; the first clearance surface 111 is connected to one end in the second direction Z (as shown in FIG2, the lower end in the drawing direction) and the second clearance surface 112 is connected to one end in the third direction X (as shown in FIG2, the left or right end in the drawing direction); the other end of the first clearance surface 111 in the second direction Z extends to the surface of the filler 100 in the second direction Z; the other end of the second clearance surface 112 in the third direction X extends to the end wall of the filler 100 in the third direction Y; the third direction X intersects the plane defined by the first direction X and the second direction Z. For example, referring to FIG2, the upper end of the first clearance surface 111 extends upward to the upper surface of the filler 100, and the other end of the second clearance surface 112 in the left-right direction extends to the left or right end wall of the filler 100. This configuration allows the first clearance channel 120 of the clearance section 110 to have openings in both the intersecting second direction Z and the third direction Y, thus making it easier to place the electrical connector 400.

[0063] In the disclosed diagram, the third direction Y intersects both the first direction X and the second direction Z. The third direction Y intersects (e.g., perpendicularly) the plane defined by the first direction X and the second direction Z. The first direction X, the second direction Z, and the third direction Y are relative. For example, in the drawing shown in Figure 2, when the first direction X is a direction perpendicular to the drawing, the second direction Z can be the up-down direction of the drawing (the up-down direction of the filler 100), and the third direction Y can be the left-right direction of the drawing (the left-right direction of the filler 100).

[0064] The first avoidance surface 111 and the second avoidance surface 112 can have any suitable angle. In some optional embodiments, the third direction Y is perpendicular to the first direction X, and the first avoidance surface 111 and the second avoidance surface 112 are perpendicularly connected.

[0065] The second clearance surface 112 is positioned along a third direction Y, and this third direction Y is perpendicular to the first direction. This allows the second clearance surface 112 to be positioned horizontally. The horizontally positioned second clearance surface 112 provides more stable support for the electrical connector 400. The vertically connected first clearance surface 111 and second clearance surface 112 allow the first clearance surface 111 to be in a vertical state, making it more convenient to remove or discharge the electrical connector 400.

[0066] In order to provide better restraint for the battery cell assembly 300, as shown in Figures 1 and 2, in some alternative embodiments, the filler 100 has an abutment surface 101 adapted to be connected to the battery cell assembly 300.

[0067] The end of the filler 100 connected to the cell assembly 300 is configured as an abutment plane 101, so that the filler 100 can make surface contact with the cell assembly 300, thereby having a larger abutment area and providing better restraint.

[0068] The tilt angle of the abutting plane 101 can be set according to the tilt angle of the side of the battery pack 300 that abuts the abutting plane 101. This disclosure does not specifically limit this. In some optional embodiments, after the filler 100 is installed in the filling space 203, the abutting plane 101 is parallel to the vertical plane, that is, the abutting plane 101 is perpendicular to the second clearance surface 112, and the tilt angle of the abutting plane 101 is 0.

[0069] It can be understood that in the filler 100 shown in Figure 1, the end of the filler 100 connected to the cell assembly 300 can be the end in the first direction X shown in the figure.

[0070] It should be noted that the shape of the side of the filler 100 that connects to the side wall of the battery tray 200 can be adapted to the shape of the side wall of the battery tray 200, so that the side of the filler 100 that connects to the side wall of the battery tray 200 has a larger contact area with the corresponding side wall of the battery tray 200. When the side wall of the battery tray 200 is flat, the filler 100 has a connecting plane 102 suitable for connecting to the side wall of the battery tray 200.

[0071] Optionally, the connecting plane 102 is parallel to the abutting plane 101.

[0072] In some alternative embodiments, as shown in FIG1, a cavity 130 is provided within the filler 100. Providing the cavity 130 can reduce the weight of the filler 100, thereby reducing the weight of the battery pack 10 after the filler 100 is installed inside the battery pack 10.

[0073] In some alternative embodiments, the filler 100 has a first side and a second side opposite to each other along a first direction X; the first side is adapted to be connected to the cell assembly 300, the second side is adapted to be connected to the sidewall of the tray, and the cavity 130 has an opening extending to the second side and / or the first side, that is, the opening of the cavity 130 may extend only to the first side, or only to the second side, or to both the first side and the second side respectively (the cavity 130 may have openings on both sides in the first direction X).

[0074] The cavity 130 has an opening extending to the second side and / or the first side, thereby enabling the cavity 130 to be formed through the opening and making the machining of the cavity 130 easier. For example, the cavity 130 and the opening can be formed by drilling or boring at the second end of the filler 100.

[0075] It can be understood that the first side of the filler 100 can be the side where the abutting plane 101 is located, and the second side of the filler 100 can be the side where the connecting plane 102 is located.

[0076] In some optional embodiments, as shown in FIG1, a partition structure 140 is fixed within the cavity 130. The partition structure 140 divides the cavity 130 into multiple weight-reducing cavities 131, and the partition structure 140 extends at least partially along the first direction X. With this design, the partition structure 140 within the cavity 130 can provide support for the cavity 130 of the filler 100, thereby improving the deformation resistance of the filler 100 and preventing the surface of the filler 100 from concave and deforming into the cavity 130 under external force.

[0077] It should be noted that the partition structure 140 can be fixed within the cavity 130 in two ways: either it can be integrally formed with the filler 100, meaning that after creating a weight-reducing cavity 131 on the filler 100, the cavity wall of the weight-reducing cavity 131 constitutes the partition structure 140; or the partition structure 140 can be fixed to the filler 100 by a fixing structure. For example, after creating a cavity 130 on the filler 100, the partition structure 140 is placed in the cavity 130 and fixed to the filler 100 by a fixing structure. The fixing structure here includes, but is not limited to, any form of fixing structure such as bonding, snap-fitting, or welding.

[0078] The specific structure of the partition structure 140 can be any structure, and this disclosure does not impose any specific limitations.

[0079] In some optional embodiments, as shown in FIG1, the partition structure 140 includes a plurality of arc-shaped portions 143, which are spaced apart. Each arc-shaped portion 143 extends along a first direction X. One end of the arc-shaped portion 143 located in the first direction X is connected to the surface of the filler 100 for connection with the cell assembly 300. The partition structure 140 may also include a plurality of first stiffeners 141, which are arranged along a second direction X of the filler 100 (such as the height direction of the filler 100). The first stiffeners 141 are connected between the cavity wall of the cavity 130 and the convex surface of the corresponding arc-shaped portion 143, or the first stiffeners 141 are connected between the convex surfaces of two corresponding arc-shaped portions 143. The first stiffener 141 is arranged along the second direction X of the filler 100, and at least one end of the first stiffener 141 is connected to the convex surface of the corresponding arc-shaped portion 143. When the filler 100 is subjected to an inward compressive force at any end in the second direction X, the compressive force is transmitted to the convex surface of the arc-shaped portion 143. Since the convex surface of the arc-shaped portion 143 forms an arch structure, it has a greater compressive strength. Therefore, the filler 100 has a stronger compressive strength in the second direction X (such as the height direction of the filler 100).

[0080] As shown in Figure 1, the partition structure 140 also includes a plurality of second stiffeners 142. The second stiffeners 142 are arranged along the third direction Y of the filler 100 (such as the length direction of the filler 100), and the second stiffeners 142 are connected between the cavity wall of the cavity 130 and the convex surface of the corresponding arc-shaped portion 143, or the second stiffeners 142 are connected between the convex surfaces of two corresponding arc-shaped portions 143.

[0081] The second stiffener 142 is arranged along the third direction Y of the filler 100, and one straight end of the second stiffener 142 is connected to the convex surface of the corresponding arc-shaped portion 143. When the filler 100 is subjected to an inward compressive force at any end in the third direction Y, the compressive force is transmitted to the convex surface of the arc-shaped portion 143, so that the filler 100 has a stronger compressive strength in the third direction Y (the length direction of the filler 100).

[0082] It can be understood that in the filler 100 shown in Figure 1, the width direction of the filler 100 can be the first direction X shown in the figure.

[0083] In some alternative embodiments, as shown in FIG1, the partition structure 140 further includes a third stiffener 144, which is arranged at an angle and whose two ends are respectively connected between two corresponding arcuate portions 143.

[0084] A third stiffener 144 is provided at an angle, and the two ends of the third stiffener 144 are respectively connected between two corresponding arc-shaped parts 143, so that the filler 100 has a stronger compressive strength when subjected to compressive force in the inclined direction.

[0085] In some alternative embodiments, a portion of the arcuate portions 143 of the plurality of arcuate portions 143 has an annular shape in the cross-section perpendicular to the first direction X.

[0086] The cross-sectional shape of the arc-shaped portion 143 is annular, so the first stiffener 141, the second stiffener 142 and the third stiffener 144 can be connected to any position on the outer wall of the arc-shaped portion 143 with annular cross-sectional shape. All of these can achieve a connection with the convex surface of the arc-shaped portion 143, and the arc-shaped portion 143 can be used to improve the compressive strength in the corresponding direction.

[0087] It is understood that in other embodiments of this disclosure, the partition structure 140 may not have the arc-shaped portion 143 shown in FIG1. ​​For example, in this embodiment, the partition structure 140 may only have horizontal stiffeners and / or vertical stiffeners, or only include cross-shaped stiffeners.

[0088] In some alternative embodiments, the sum of the volumes occupied by the multiple weight-reducing cavities 131 forms the hollowed-out volume, which accounts for 60% to 80% of the overall volume of the filler 100. This configuration allows the filler 100 to achieve a larger hollowed-out volume while ensuring strength and deformation, thereby making the filler 100 lighter.

[0089] It should be noted that the hollowed-out volume accounts for 60% to 80% of the overall volume of the filler 100, which can be obtained by simulating the force of the cell expansion on the filler 100 through topology simulation.

[0090] In some optional embodiments, the area of ​​the outer contour of the cross-section of the filler 100 perpendicular to the first direction X is the initial cross-sectional area, and the area of ​​the cross-section of the filler 100 perpendicular to the first direction X is the remaining cross-sectional area, with the remaining cross-sectional area accounting for 20% to 40% of the initial cross-sectional area. This configuration allows the filler 100 to achieve a larger hollowed-out volume while ensuring strength and deformation, thereby making the filler 100 lighter.

[0091] In some alternative embodiments, the filler 100 is a one-piece molded part. That is, the partition structure 140 and the filler 100 are integrally molded.

[0092] The filler 100 can be made of any material, and this disclosure does not impose any specific limitations. In some optional embodiments, the filler 100 is made of an insulating material. Using an insulating material as the filler 100 allows the filler 100 to be directly bonded to the cell assembly 300, eliminating the need for additional insulation treatment between the filler 100 and the cell assembly 300, thus improving the assembly efficiency of the battery pack 10. Furthermore, since the filler 100 is entirely made of an insulating material, insulation failure will not occur, thereby reducing the risk of high-voltage arcing in the battery pack 10.

[0093] Optionally, the insulation material is made of one-piece autoclaved foamed MPPO block.

[0094] Based on the aforementioned filler 100, as shown in Figures 3 to 6, this disclosure also provides a battery pack 10 in a second aspect. The battery pack 10 includes a battery tray 200, a cell assembly 300, an electrical connector 400, and the aforementioned filler 100. The battery tray 200 has a receiving cavity 201, in which the cell assembly 300 and the filler 100 are both arranged. A filling space 203 is formed between the cell assembly 300 and the side wall of the battery tray 200. The electrical connector 400 passes through the clearance portion 110.

[0095] After the filler 100 and the cell assembly 300 are installed in the battery pack 10, the filler 100 can use the clearance portion 110 to avoid the electrical connector 400, so that the electrical connector 400 passes through the clearance portion 110 to connect the adjacent cell assembly 300, and / or, so that the electrical connector 400 passes through the clearance portion 110 to connect the cell assembly 300 and the power distribution junction of the battery pack 10, or so that the electrical connector 400 can pass through the clearance portion 110 to connect other components.

[0096] It should be noted that, in some optional embodiments, the portion of the space within the receiving cavity 201 used to house the battery cell assembly 300 is a pre-defined battery cell receiving space 202. The battery cell assembly 300 is installed in the battery cell receiving space 202 to achieve installation of the battery cell assembly 300 within the receiving cavity 201. A power distribution space 204 is also formed between the battery cell assembly 300 and the side wall of the battery tray 200. The power distribution space 204 is used to house connectors or power distribution components between multiple batteries in the battery cell assembly 300. It can be understood that both the battery cell receiving space 202 and the power distribution space 204 are components of the receiving cavity 201.

[0097] In some alternative embodiments, as shown in FIG6, the battery pack 10 further includes a battery cover 500, which is detachably and sealingly connected to the battery tray 200, and the battery cover 500 covers the receiving cavity 201 so that the interior of the battery pack 10 forms a relatively sealed structure through the battery cover 500 and the battery tray 200.

[0098] In some alternative embodiments, structural adhesive 600 is provided on the end face of the filler 100 in the height direction, and the filler 100 and the battery cover 500 are bonded and fixed by the structural adhesive 600.

[0099] In some optional embodiments, as shown in FIG5, there are multiple battery cell groups 300, which are arranged at intervals along a third direction. Each battery cell group 300 has a filler 100 on at least one side in the first direction, and a clearance portion 110 extends along the first direction. The electrical connector 400 includes two first segments 410 and a second segment 420 connecting the two first segments 410. One of the two first segments 410 is located in the clearance portion 110 of one of the two adjacent fillers 100 in the third direction, and the other first segment 410 is located in the clearance portion 110 of the other of the two adjacent fillers 100 in the third direction.

[0100] The fillers 100 of two adjacent cell groups 300 are also adjacent on the same side. The two first segments 410 of the electrical connector 400 are used to connect the two adjacent cell groups 300 respectively. The two first segments 410 are located on the clearance portion 110 of the two adjacent fillers 100 and are connected by the second segment 420. In this way, the electrical connector 400 is generally arranged in a U-shape. Part of the electrical connector 400 is located in the filling space 203. This reduces the risk of interference between the electrical connector 400 and other components of the battery pack 10.

[0101] In some alternative embodiments, the battery tray 200 includes a base plate 210, a side beam 220, and a partition beam 230. The side beam 220 is fixed to the edge of the base plate 210 to define a mounting cavity, and the partition beam is disposed within the mounting cavity to divide the mounting cavity into multiple receiving cavities 201. A second clearance channel 231 is provided on the partition beam 230, and a second segment 420 passes through the second clearance channel 231.

[0102] When a partition beam 230 is provided inside the battery pack 10, a second clearance channel 231 is opened on the partition beam 230, allowing the second segment 420 to pass through the second clearance channel 231, while the two first segments 410 are respectively located in the receiving cavities 201 on both sides of the partition beam 230. In this way, the electrically connected second segment 420 is prevented from interfering with other components of the battery pack 10 at the partition beam 230.

[0103] It should be noted that the second clearance channel 231 can be located at the top, middle or bottom of the partition beam 230, and this disclosure does not specifically limit this. Optionally, the height of the second clearance channel 231 is approximately the same as the height of the first clearance channel 120, so as to facilitate the electrical connector 400 to pass through the first clearance channel 120 and the second clearance channel 231 to connect to adjacent battery cell groups 300.

[0104] In some alternative embodiments, the second clearance channel 231 is a notch located at the end of the partition beam 230 in the first direction X. The notch-shaped second clearance channel 231 can form an opening at the top of the partition beam 230 to facilitate the insertion of the electrical connector 400 into the second clearance channel 231 through the notch.

[0105] In some alternative embodiments, a filling space 203 is formed between the sidewall of the large surface of the battery cell in the cell assembly 300 and the sidewall of the battery tray 200. After the filler 100 is placed in the filling space 203, the filler 100 can come into contact with the large surface of the battery cell, thereby giving the filler 100 and the battery cell a larger contact area and further preventing the battery cell from expanding and deforming.

[0106] Based on the aforementioned battery pack 10, as shown in FIG7, this disclosure further provides an electrical device 100 in a third aspect, the electrical device 100 including a device body 101 and an upper battery pack 10, the battery pack 10 being installed on the device body 101 and adapted to supply power to the device body 101.

[0107] Here, electrical equipment 100 can be vehicles, mobile phones, portable devices, laptops, ships, spacecraft, electric toys, and power tools, etc. Vehicles can be gasoline-powered cars, natural gas-powered cars, or new energy vehicles. New energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles, etc. Spacecraft include airplanes, rockets, space shuttles, and spacecraft, etc. Electric toys include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc. Power tools include metal cutting power tools, grinding power tools, assembly power tools, and railway power tools, such as electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete vibrators, and electric planers, etc. This disclosure does not limit these. The preferred embodiments of this disclosure have been described in detail above with reference to the accompanying drawings. However, this disclosure is not limited to the specific details of the above embodiments. Within the scope of the technical concept of this disclosure, various simple modifications can be made to the technical solutions of this disclosure, and these simple modifications all fall within the protection scope of this disclosure.

[0108] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, this disclosure will not describe the various possible combinations separately.

[0109] Furthermore, various different embodiments of this disclosure can be combined in any way, as long as they do not violate the spirit of this disclosure, they should also be regarded as the content disclosed in this disclosure.

Claims

1. A filler (100), characterized in that, The filler (100) is adapted to be disposed in the filling space (203) between the cell group (300) and the side wall of the battery tray (200) of the battery pack (10); The filler (100) is provided with a clearance part (110) for avoiding the electrical connector (400) of the battery pack (10).

2. The filler (100) according to claim 1, characterized in that, The avoidance portion (110) is provided at least one of the opposite ends of the filler (100).

3. The filler (100) according to claim 1 or 2, characterized in that, The filler (100) is located on one side in the first direction and is adapted to be connected to the battery cell assembly (300); The clearance portion (110) is configured as a first clearance channel (120) that penetrates the filler (100) along the first direction.

4. The filler (100) according to claim 3, characterized in that, The outer surface portion of the filler (100) in the second direction is recessed to form the first clearance channel (120), the second direction intersecting the first direction.

5. The filler (100) according to claim 4, characterized in that, The first clearance channel (120) includes a first clearance surface (111) and a second clearance surface (112); The first clearance surface (111) is connected at one end in the second direction to the second clearance surface (112) at one end in the third direction; The first clearance surface (111) extends from the other end of the second direction to the surface of the filler (100) located in the second direction; The second clearance surface (112) extends from the other end of the third direction to the end wall of the filler (100) located in the third direction; The third direction intersects the plane defined by the first direction and the second direction.

6. The filler (100) according to claim 5, characterized in that, The third direction is perpendicular to the first direction, and the first avoidance surface (111) is perpendicularly connected to the second avoidance surface (112).

7. The filler (100) according to any one of claims 1-6, characterized in that, The filler (100) has an abutment surface (101) suitable for connection with the battery cell assembly (300).

8. The filler (100) according to any one of claims 1-7, characterized in that, The filler (100) has a cavity (130).

9. The filler (100) according to claim 8, characterized in that, The filler (100) has a first side and a second side opposite to each other along a first direction; The first side is adapted to be connected to the cell assembly (300), and the second side is adapted to be connected to the side wall of the battery tray (200); The cavity (130) has an opening extending to the second side and / or the first side.

10. The filler (100) according to claim 9, characterized in that, A partition structure (140) is fixed inside the cavity (130). The partition structure (140) divides the cavity (130) into multiple weight-reducing cavities (131). The partition structure (140) extends at least partially along the first direction.

11. The filler (100) according to claim 10, characterized in that, The partition structure (140) includes a plurality of arc-shaped portions (143). The plurality of said arc-shaped portions (143) are spaced apart, and each said arc-shaped portion (143) extends along the first direction; The arc-shaped portion (143) is connected at one end in the first direction to the surface of the filler (100) for connection with the battery cell assembly (300); The partition structure (140) also includes a plurality of first stiffeners (141). The first stiffener (141) is arranged along the second direction of the filler (100), and the first stiffener (141) is connected between the cavity wall of the cavity (130) and the convex surface of the corresponding arcuate portion (143), or the first stiffener (141) is connected between the convex surfaces of two corresponding arcuate portions (143), the second direction intersecting the first direction; and / or, The partition structure (140) further includes a plurality of second stiffeners (142), which are arranged along a third direction of the filler (100), and the second stiffeners (142) are connected between the cavity wall of the cavity (130) and the convex surface of the corresponding arcuate portion (143), or the second stiffeners (142) are connected between the convex surfaces of two corresponding arcuate portions (143), wherein the third direction intersects with the first direction; and / or, The partition structure (140) further includes a third stiffener (144), which is arranged at an angle and whose two ends are respectively connected between two corresponding arc-shaped parts (143).

12. The filler (100) according to claim 11, characterized in that, A portion of the arcuate portions (143) has a cross-sectional shape that is annular perpendicular to the first direction.

13. The filler (100) according to any one of claims 10-12, characterized in that, The sum of the volumes occupied by the multiple weight-reducing cavities (131) forms the hollowed-out volume, which accounts for 60% to 80% of the total volume of the filler (100).

14. The filler (100) according to any one of claims 10-13, characterized in that, The area of ​​the outer contour of the cross section of the filler (100) perpendicular to the first direction is the initial cross-sectional area, and the area of ​​the cross section of the filler (100) perpendicular to the first direction is the remaining cross-sectional area. The remaining cross-sectional area accounts for 20% to 40% of the initial cross-sectional area.

15. The filler (100) according to any one of claims 10-14, characterized in that, The filler (100) is a one-piece molded part.

16. The filler (100) according to any one of claims 1-15, characterized in that, The filler (100) is made of insulating material.

17. A battery pack (10), characterized in that, It includes a battery tray (200), a battery cell assembly (300), an electrical connector (400), and a filler (100) as described in any one of claims 1-16. The battery tray (200) has a receiving cavity (201), and the battery cell assembly (300) and the filler (100) are both arranged in the receiving cavity (201); The filling space (203) is formed between the cell assembly (300) and the side wall of the battery tray (200). The electrical connector (400) passes through the clearance portion (110).

18. The battery pack (10) according to claim 17, characterized in that, The number of the battery cell packs (300) is multiple; Each of the battery cells (300) has the filler (100) disposed on at least one side in the first direction; The avoidance portion (110) extends along the first direction; The plurality of said battery cell packs (300) are arranged at intervals along a third direction, which intersects with the first direction; The electrical connector (400) includes two first segments (410) and a second segment (420) connecting the two first segments (410). One of the first segments (410) is located within the clearance portion (110) of one of the two adjacent fillers (100) in the third direction, and the other of the first segments (410) is located within the clearance portion (110) of the other of the two adjacent fillers (100) in the third direction.

19. The battery pack (10) according to claim 18, characterized in that, The battery tray (200) includes a base plate (210), a side beam (220) and a partition beam (230), wherein the side beam (220) is fixed to the edge of the base plate (210) to define a mounting cavity; The partition beam (230) is disposed in the mounting cavity to divide the mounting cavity into a plurality of the receiving cavities (201). The partition beam (230) has a second clearance passage (231), and the second section (420) passes through the second clearance passage (231).

20. The battery pack (10) according to claim 19, characterized in that, The second clearance passage (231) is a notch provided at the end of the partition beam (230) in the first direction.

21. The battery pack (10) according to any one of claims 17-20, characterized in that, The filling space (203) is formed between the sidewall of the battery cell assembly (300) constructed from the large surface of the battery cell and the sidewall of the battery tray (200).

22. An electrical appliance (100), characterized in that, The device includes a main body (101) and a battery pack (10) according to any one of claims 17-21, the battery pack (10) being mounted on the main body (101) and adapted to supply power to the main body (101).

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