Battery module, battery pack, electrical device, and manufacturing method for battery module

Abstract

The present application provides a battery module, a battery pack, an electrical device, and a manufacturing method for a battery module. The battery module comprises: a battery cell assembly comprising a plurality of battery cells. Each battery cell comprises an electrode terminal. A first member comprises a bottom wall, side walls, a protrusion, a first space, a first opening, and a second opening. The bottom wall and the side walls form a recess. Part of each electrode terminal is located in the recess. The protrusion is connected to the surface of the bottom wall facing away from the battery cell assembly. In the first direction, the first opening penetrates through the bottom wall. In the second direction, the second opening penetrates though a side wall and the protrusion. The first space, the first opening, and the second opening are in communication. A first conductive element penetrates through the first space and the first opening. The first conductive element is connected to the battery cell assembly. A first adhesive blocking member is located on the side of the first conductive member facing the second opening. At least part of a first potting resin is provided in the first space. The first adhesive blocking member is configured to restrict the flow of the first potting resin to the recess. At least part of a second potting resin is provided in the recess.

Description

Battery modules, battery packs, electrical devices, and methods for manufacturing battery modules

[0001] Cross-references to related applications

[0002] This application claims priority to Chinese Patent Application No. 202411686616.9, filed on November 22, 2024, entitled “Battery Module, Battery Pack, Electrical Device and Method of Manufacturing Battery Module”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of batteries, and in particular to a battery module, a battery pack, an electrical device, and a method for manufacturing a battery module. Background Technology

[0004] A battery pack is a device that can continue to be used after the battery cells have been discharged, by recharging to reactivate the active materials. Battery packs are widely used in electrical devices such as mobile phones, laptops, power tools, and vehicles. In the development of battery technology, improving the energy density of battery packs is one of the research directions. Summary of the Invention

[0005] In view of the above problems, this application provides a battery module, a battery pack, an electrical device, and a method for manufacturing a battery module, which is beneficial to improving the energy density of the battery pack.

[0006] This application provides a battery module including a cell assembly, a first component, a first conductive element, a first retaining element, a first potting resin, and a second potting resin. The cell assembly includes a plurality of cells. Each cell includes electrode terminals. The first component and the cell assembly are arranged along a first direction. The first component includes a bottom wall, a side wall connected to the bottom wall, a protrusion, a first space, a first opening, and a second opening. The bottom wall and the side wall form a recess. The recess faces the cell assembly. A portion of each electrode terminal is located in the recess. The protrusion is connected to the surface of the bottom wall facing away from the cell assembly. The protrusion serves as at least a portion of the component forming the first space. Along the first direction, the first opening penetrates the bottom wall. Along a second direction, the second opening penetrates the side wall and the protrusion. The first space, the first opening, and the second opening communicate. The first conductive element passes through the first space and the first opening. The first conductive element is connected to the cell assembly. The first conductive element is configured to transmit power and / or electrical signals of the cell assembly. The first retaining element is located on the side of the first conductive element facing the second opening. At least a portion of the first potting resin is disposed in the first space. A first potting resin bonds the first conductive element and the protrusion. A first sealing element is configured to restrict the flow of the first potting resin into the recess. At least a portion of the second potting resin is disposed in the recess. The second potting resin bonds the electrode terminal and the recess.

[0007] In this embodiment, during the assembly of the first component and the cell assembly, the first conductive element passes through the second opening in a direction substantially opposite to the second direction, and then the first conductive element can enter the first opening and the first space. The method by which the first conductive element enters the protrusion through the second opening reduces the size of the first space and the first opening, allowing for the injection of relatively less first potting resin into the first space and the first opening to seal the gap between the first conductive element and the protrusion. This helps reduce the amount of first potting resin used and improves the energy density of the battery module and the battery pack.

[0008] In one or more of the above optional embodiments, the battery module includes a second blocking element fixed to the protrusion and the sidewall. Viewed along a second direction, the second blocking element covers the second opening and the first blocking element, and the second direction is perpendicular to the first direction. The second blocking element can prevent the second potting resin from flowing out of the second opening, reducing the possibility of the second potting resin overflowing from the second opening.

[0009] In one or more of the above optional embodiments, a portion of the second potting resin is located at the first opening and the second opening, thereby enhancing the sealing of the cell assembly.

[0010] In one or more of the above optional embodiments, a portion of the first potting resin is located in the second opening, and a first sealing element is disposed in the second opening. This reduces deformation of the protrusion and facilitates assembly. The portion of the first potting resin located within the second opening enhances the seal of the second opening.

[0011] In one or more of the above optional embodiments, the battery cell assembly includes a first connecting portion, which serves as the positive or negative electrode of the battery cell assembly; a first conductive member is connected to the first connecting portion, and the first connecting portion includes a first part facing a second opening, the first part being located between a first baffle and the first conductive member, and the first baffle being connected to the first part.

[0012] The way the first baffle is connected to the first part can, on the one hand, protect the first part from impact and compression, and on the other hand, provide support for the first baffle, making it easier to install and fix the first baffle and reducing the difficulty of installation.

[0013] In one or more of the above optional embodiments, the battery cell includes electrode terminals, wherein one electrode terminal of the battery cell serves as a first connection portion, the first connection portion is stacked with a first conductive element along a second direction; and a first adhesive element is bonded to the first portion.

[0014] The first conductive element and the first connecting portion are stacked along the second direction, and the areas of the first conductive element and the first connecting portion in the overlapping region are relatively large. The relatively large connection area between the first connecting portion and the first adhesive blocking element facilitates the bonding of the first adhesive blocking element to the first part. At the same time, the relatively large bonding area helps to improve the connection stability between the first adhesive blocking element and the first part, and reduces the possibility of the first adhesive blocking element and the first part detaching from the connection state and separating.

[0015] In one or more of the above optional embodiments, the first connecting portion includes a second portion connected to the first portion, and along the second direction, the second portion is located between the protrusion and the first conductive member, with the protrusion abutting against the second portion.

[0016] The protrusion and the second part are in contact with each other, which can restrict the flow of the first potting resin from between the protrusion and the second part into the recess. The protrusion acts as a limiting constraint on the second part, making the connection between the second part and the first conductive element stable. In the event of movement of the first conductive element, the movement amplitude of the connection area between the second part and the first conductive element is small, reducing the possibility that the second part will bear a large tensile force due to large movement amplitude of the connection area between the second part and the first conductive element, and reducing the possibility of the second part cracking or detaching from the first conductive element.

[0017] In one or more of the above optional embodiments, the protrusion includes a first wall and a second wall spaced apart along a second direction. Along the first direction, the thickness of the first wall increases. Along the second direction, a second opening penetrates the first wall, and a second portion is located between the first wall and the first conductive element, with the first wall abutting against the second portion.

[0018] The first wall is a non-uniform thickness structure. During the assembly of the first component and the cell assembly, as the connection area between the first conductive element and the second part enters the first space, the first wall is easily deformed by the pushing force of the connection area, facilitating the smooth entry of the connection area into the first space of the protrusion. The thicker area of ​​the first wall abuts against the second part, while the thinner area does not abut against the second part. This reduces the frictional resistance between the first wall and the second part, lowering the possibility of the second part cracking or wrinkling due to excessive frictional force exerted by the first wall. After the first component and the cell assembly are assembled, the first potting resin can fill the gap between the thinner area and the second part.

[0019] In one or more of the above optional embodiments, the first sealing element does not extend beyond the sidewall in the first direction, and does not extend beyond the protrusion in the opposite direction to the first direction; a portion of the second potting resin is disposed in the first opening, the second opening, and the first space.

[0020] The first stop fills the portion of the second opening. Along the first direction, the area of ​​the second opening located on one side of the first stop can be filled with a second potting resin. Along the opposite direction, the area of ​​the second opening located on one side of the first stop can be filled with a first potting resin. The first and second potting resins are respectively disposed on both sides of the first stop. The second stop, the first potting resin, and the second potting resin can each limit the position of the first stop from different directions, reducing the possibility of positional changes in the first stop.

[0021] In one or more of the above optional embodiments, the first conductive element is a conductive sheet, the first conductive element includes a bent portion, the bent portion is located on the side of the bottom wall opposite to the cell assembly, and the bent portion is located outside the first space.

[0022] In one or more of the above alternative embodiments, the first sealing element includes foam or a silicone pad.

[0023] In one or more of the above optional embodiments, the battery module includes an insulating member, the insulating member covering a portion of the outer surface of the first conductive member, and a first potting resin covering a portion of the insulating member located within the first space.

[0024] The portion of the insulating component located in the first space is encapsulated with the first potting resin. The first potting resin and the insulating component can work together to insulate and isolate the portion of the first conductive component located in the first space from other conductive structures, thereby reducing the possibility of a short circuit between the first conductive component and other conductive structures.

[0025] In one or more of the above optional embodiments, the protrusion includes a projection that protrudes along a second direction, and there is a gap between the insulating member and the projection along the second direction, the gap ranging from 1 mm to 4 mm, and the first direction and the second direction are perpendicular to each other.

[0026] The gap between the insulating component and the protrusion allows the first potting resin to enter the gap to bond the insulating component and the protrusion together. The first potting resin seals the gap, reducing the possibility of moisture intrusion due to poor sealing between the insulating component and the protrusion.

[0027] In one or more of the above optional embodiments, the first conductive element is a sheet-like copper busbar, comprising multiple layers of copper sheets stacked together, each layer having a thickness of 0.05 mm to 0.3 mm. This facilitates bending of the first conductive element.

[0028] In one or more of the above optional embodiments, at 25°C, the viscosity of the first potting resin before curing is greater than that of the second potting resin before curing. This facilitates the first potting resin to fill the gap between the first conductive element and the first space, as well as the gap between the first conductive element and the second opening, more quickly. The second potting resin has a higher viscosity, which is beneficial for better filling of the first space, the first opening, and the second opening.

[0029] In one or more of the above optional embodiments, the second adhesive component is bonded to the first adhesive component.

[0030] In one or more of the above optional embodiments, along the second direction, there is a gap between the second baffle and the first baffle, and the gap is less than 1 mm.

[0031] In one or more of the above optional embodiments, the battery module includes a third conductive element connected to the cell assembly, and the third conductive element is configured to transmit signals.

[0032] This application provides a battery pack, which includes a battery module and a housing. The battery module is located inside the housing.

[0033] This application provides an electrical device that includes a battery pack.

[0034] This application provides a method for manufacturing a battery module, which includes:

[0035] Provide battery cell components;

[0036] A first conductive element is provided, and the first conductive element is electrically connected to the cell assembly;

[0037] A first component is provided, and the first component is pushed toward a first conductive element, the first conductive element passing through a second opening and entering a first space and a first opening;

[0038] Along the first direction, the first component is moved toward the cell assembly to a predetermined position;

[0039] A first adhesive barrier is provided, and the first adhesive barrier is disposed on the side of the first conductive element facing the second opening;

[0040] A first potting resin is provided, and the first potting resin is filled into a first space and a second opening. A first baffle restricts the first potting resin from flowing out of the first opening and the second opening.

[0041] After the first potting resin has cured, the cell assembly and the first component are rotated 180° along the first direction;

[0042] A second potting resin is provided, and the recess is filled with the second potting resin;

[0043] After the second potting resin has cured, the cell assembly and the first component are rotated 180° along the first direction. Attached Figure Description

[0044] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0045] Figure 1 is a schematic diagram of the structure of a battery pack provided in an embodiment of this application;

[0046] Figure 2 is an exploded structural diagram of a battery pack provided in an embodiment of this application;

[0047] Figure 3 is a partial structural schematic diagram of a battery module provided in an embodiment of this application;

[0048] Figure 4 is a partially exploded structural diagram of a battery module provided in an embodiment of this application;

[0049] Figure 5 is a partial structural schematic diagram of a battery module provided in an embodiment of this application;

[0050] Figure 6 is a structural schematic diagram of the first component provided in an embodiment of this application;

[0051] Figure 7 is a structural schematic diagram of the first component provided in an embodiment of this application;

[0052] Figure 8 is a schematic diagram of the structure of a battery cell provided in an embodiment of this application;

[0053] Figure 9 is a schematic diagram of the structure of an inverted battery pack provided in an embodiment of this application;

[0054] Figure 10 is a partial cross-sectional view of a battery module provided in an embodiment of this application;

[0055] Figure 11 is an enlarged schematic diagram of point W in Figure 10;

[0056] Figure 12 is a partial cross-sectional view of a battery module provided in an embodiment of this application;

[0057] Figure 13 is a partial cross-sectional view of a battery module provided in an embodiment of this application;

[0058] Figure 14 is an enlarged view of point P in Figure 13;

[0059] Figure 15 is a structural schematic diagram of the first component provided in an embodiment of this application;

[0060] Figure 16 is an enlarged view of point M in Figure 15;

[0061] Figure 17 is a partial cross-sectional view of a battery module provided in an embodiment of this application;

[0062] Figure 18 is a schematic diagram of the structure of the first conductive element provided in an embodiment of this application;

[0063] Figure 19 is a schematic flowchart of a battery module manufacturing method according to an embodiment of this application;

[0064] Figure 20 is a schematic diagram of the assembly process of the battery cell assembly and the first component provided in an embodiment of this application;

[0065] Figure 21 is a schematic diagram of the assembly process of the battery cell assembly and the first component provided in another embodiment of this application.

[0066] Explanation of reference numerals in the attached drawings: 10, Battery pack; 10a, Battery module; 11, Housing; 1011, Front wall; 1012, Rear wall; 1013, Right wall; 1014, Left wall; 1015, Lower wall; 1016, Top wall; 12, Filling hole; 20, Cell assembly; 201, First connecting part; 2011, First section; 2012, Second section; 202, Sampling piece; 2001, First cell group; 2002, Second cell group; 21, Cell; 211, Housing; 212, Electrode terminal; 30, First component; 301, Bottom wall; 3011, First opening; 302, Side wall; 302a, First side wall; 302b, Second side wall; 302c, Third side wall; 302d, Fourth... Sidewall; 31, Recess; 32, Protrusion; 32a, First space; 321, First wall; 322, Second wall; 323, Protrusion; 33, Second opening; 34, Enclosure; 40, First conductive element; 401, Bending part; 41, Connecting section; 42, Lead-out section; 50, First sealing element; 60, Second sealing element; 70, First potting resin; 80, Second potting resin; 90, Insulator; 100, Heat sink; 101, Drainage hole; 110, First circuit board; 120, Second circuit board; 121, Connector; 130, Second conductive element; 140, Third conductive element; 150, Third potting resin; X, First direction; Y, Second direction; Z, Third direction. Detailed Implementation

[0067] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0068] It should be noted that, unless otherwise stated, the technical or scientific terms used in the embodiments of this application should have the ordinary meaning understood by those skilled in the art to which the embodiments of this application pertain.

[0069] In the description of the embodiments of this application, the technical terms "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0070] Furthermore, technical terms such as "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. In the description of the embodiments of this application, "a plurality of" means two or more, unless otherwise explicitly defined.

[0071] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0072] Referring to Figures 1 to 7, the battery pack 10 mentioned in the embodiments of this application refers to a module including a battery module 10a. The battery pack 10 includes a housing 11 and a battery module 10a disposed within the housing 11.

[0073] This application provides a battery module 10a, which includes a cell assembly 20 and a first component 30. The cell assembly 20 includes a plurality of cells 21, each cell 21 including an electrode terminal 212. The first component 30 and the cell assembly 20 are arranged along a first direction X. The first component 30 includes a bottom wall 301 and a side wall 302 connected to the bottom wall 301. The bottom wall 301 and the side wall 302 form a recess 31. The recess 31 faces the cell assembly 20. A portion of each electrode terminal 212 is located within the recess 31.

[0074] In some implementations, the first member 30 includes a protrusion 32, a first opening 3011, and a second opening 33. The protrusion 32 is connected to the surface of the bottom wall 301 facing away from the cell assembly 20. The first opening 3011 extends through the bottom wall 301 along a first direction X. The second opening 33 extends through the side wall 302 and the protrusion 32 along a second direction Y. In some implementations, referring to FIG6, the side wall 302 surrounds the edge connected to the bottom wall 301.

[0075] In some possible implementations, as shown in Figures 6 and 7, the sidewall 302 includes a first sidewall 302a and a second sidewall 302b disposed opposite each other along a second direction Y, and a third sidewall 302c and a fourth sidewall 302d disposed opposite each other along a third direction Z. The first direction X, the second direction Y, and the third direction Z are all perpendicular to each other. The second opening 33 penetrates the first sidewall 302a and the protrusion 32.

[0076] In some possible implementations, the first member 30 includes a first space 32a, with the protrusion 32 serving as at least a partial member forming the first space 32a. Referring to FIG6, the protrusion 32 is connected to the edge of the first opening 3011, forming the first space 32a. In other embodiments, the protrusion 32 and a portion of the bottom wall 301 form the first space 32a. The first opening 3011, the first space 32a, and the second opening 33 are in communication.

[0077] In some possible implementations, the battery module 10a includes a first conductive element 40 connected to the cell assembly 20. The first conductive element 40 passes through and exits a first space 32a and a first opening 3011. The first conductive element 40 is configured to transmit power and / or electrical signals from the cell assembly 20.

[0078] In some possible implementations, the battery module 10a includes a first deflector 50 and a first potting resin 70. The first deflector 50 is located on the side of the first conductive member 40 facing the second opening 33. At least a portion of the first potting resin 70 is disposed in the first space 32a. The first potting resin 70 bonds the first conductive member 40 and the protrusion 32. The first deflector 50 is configured to restrict the flow of the first potting resin 70 into the recess 31.

[0079] In some possible implementations, the battery module 10a includes a second potting resin 80. The second potting resin 80 is at least partially disposed in the recess 31. The second potting resin 80 bonds the electrode terminal 212 and the recess 31.

[0080] Please refer to Figure 2, which is an exploded structural diagram of the battery pack, where the first potting resin 70 and the second potting resin 80 are simplified schematic diagrams.

[0081] In this embodiment of the application, referring to Figures 4 and 8, the battery cell assembly 20 may include a plurality of battery cells 21 arranged side by side. The plurality of battery cells 21 are arranged along a second direction Y. The battery cell 21 includes a housing 211 and electrode terminals 212. During the manufacturing process of the battery pack 10, resin is poured into the battery module 10a to form a second potting resin 80. The second potting resin 80 insulates and isolates the electrode terminals 212 from other conductive structural components. Exemplarily, the battery cell 21 may be a pouch cell 21. The housing 211 of the battery cell 21 may be an aluminum-plastic film. The battery cell 21 includes two electrode terminals 212. One electrode terminal 212 serves as the positive terminal, and the other electrode terminal 212 serves as the negative terminal.

[0082] In this embodiment of the application, the connection between the first opening 3011, the first space 32a and the second opening 33 means that they are interconnected when the first potting resin 70 and the second potting resin 80 are not provided.

[0083] During the assembly of the first component 30 and the cell assembly 20, the first conductive element 40 passes through the second opening 33 in a direction generally opposite to the second direction Y, and then the first conductive element 40 can enter the first opening 3011 and the first space 32a. The way the first conductive element 40 enters the protrusion 32 through the second opening 33 can reduce the size of the first space 32a and the first opening 3011. A relatively small amount of first potting resin 70 can be poured into the first space 32a and the first opening 3011 to seal the gap between the first conductive element 40 and the protrusion 32, which is beneficial to reducing the amount of first potting resin 70 used and improving the energy density of the battery module 10a and the battery pack 10.

[0084] When the first potting resin 70 is poured into the first space 32a, the uncured first potting resin 70 is fluid. The first potting resin 70 can flow along the gap between the first conductive member 40 and the protrusion 32. During the flow, the fluidity of the first potting resin 70 may deteriorate and it may cure. The first sealant 50 can restrict the flow of the first potting resin 70 out of the first space 32a, reducing the possibility that the first potting resin 70 flows into the recess 31 of the first member 30.

[0085] Referring to Figure 9, after the first potting resin 70 has cured, the cell assembly 20 and the first component 30 are flipped 180° to an inverted state, so that the recess 31 of the first component 30 faces upward, and the second potting resin 80 is poured into the recess 31. When the second potting resin 80 is poured into the recess 31, the cured first potting resin 70 restricts the flow of the second potting resin 80 from the first space 32a. After the second potting resin 80 has cured, the cell assembly 20 and the first component 30 are flipped 180°. The first sealing member 50 and the first potting resin 70 can prevent the second potting resin 80 from flowing into and out of the first space 32a.

[0086] In some examples, the first potting resin 70 may include, but is not limited to, silicone adhesive. The second potting resin 80 may include, but is not limited to, polyurethane adhesive.

[0087] In some feasible ways, the first baffle 50 includes, but is not limited to, foam or silicone pads. The foam or silicone pads can be compressed to better fill the gaps.

[0088] In some feasible ways, portions of the second potting resin 80 are located at the first opening 3011 and the second opening 33, and the first potting resin 70 and the second potting resin 80 are bonded together to enhance the sealing of the cell assembly 20.

[0089] In some possible implementations, the battery module 10a includes a second baffle 60, which is fixed to the outside of the protrusion 32 and the sidewall 302. Referring to FIG. 5, viewed along the second direction Y, the second baffle 60 covers the second opening 33 and the first baffle 50. A first potting resin 70 is disposed within the first space 32a and the second opening 33. The first potting resin 70 bonds the first conductive element 40 and the protrusion 32. The second baffle 60 is configured to restrict the flow of the first potting resin 70 into the recess 31. The second baffle 60 is configured to restrict the flow of the second potting resin 80 from the second opening 33, reducing the possibility of the second potting resin 80 overflowing from the second opening 33. At least a portion of the second potting resin 80 is disposed within the recess 31 and the second opening 33.

[0090] In some feasible embodiments, the second baffle 60 is bonded to the first baffle 50. In other embodiments, there is a gap between the second baffle 60 and the first baffle 50 along the second direction Y, the gap being less than 1 mm. When the first potting resin 70 is poured, the gap is relatively small, allowing the first potting resin 70 to cure faster and reducing the flow of uncured first potting resin 70 into the recess 31.

[0091] The second adhesive element 60 is an insulating sheet. The material of the second adhesive element 60 may include, but is not limited to, polycarbonate. The second adhesive element 60 is bonded to the protrusion 32 and the sidewall 302. For example, the second adhesive element 60 can be bonded to the protrusion 32 and the sidewall 302 by double-sided tape or glue.

[0092] In some feasible implementations, as shown in Figures 10, 11, and 12, the first sealing element 50 is disposed within the second opening 33. This reduces deformation of the protrusion 32 and facilitates assembly. A portion of the first potting resin 70 is located within the second opening 33, enhancing the seal of the second opening 33.

[0093] In some feasible ways, the second sealing element 60 can be removed after the second potting resin 80 has cured.

[0094] In some possible implementations, referring to Figures 4 and 12, the cell assembly 20 includes a first connection portion 201. The first connection portion 201 serves as either the positive or negative electrode of the cell assembly 20. A first conductive member 40 is connected to the first connection portion 201. The first connection portion 201 includes a first portion 2011 facing a second opening 33. Along the second direction Y, the first portion 2011 is located between a first retaining member 50 and the first conductive member 40. The first retaining member 50 is connected to the first portion 2011.

[0095] The battery cell assembly 20 can be discharged or charged through the first connection portion 201 and the first conductive element 40. Alternatively, the battery cell assembly 20 can interact with external devices through the first connection portion 201 and the first conductive element 40. Without the first and second blocking elements 50 and 60, the first portion 2011 can be observed through the second opening 33 when viewed along the second direction Y.

[0096] The first blocking component 50 is connected to the first part 2011. On the one hand, the first blocking component 50 can protect the first part 2011 and reduce the possibility of the first part 2011 being hit or squeezed. On the other hand, the first connecting part 201 and the first conductive component 40 can provide support for the first blocking component 50, which facilitates the installation and fixing of the first blocking component 50 and reduces the difficulty of the installation operation of the first blocking component 50.

[0097] In some examples, the first conductive element 40 and the first connection portion 201 are welded, for example, by laser welding.

[0098] In some examples, the first conductive element 40 and the first connection portion 201 are connected via a sampling piece 202. Exemplarily, the first conductive element 40, the first connection portion 201, and the sampling piece 202 are welded together.

[0099] In some examples, as shown in Figures 4, 8, and 12, the battery cell 21 includes electrode terminals 212. One electrode terminal 212 of the battery cell 21 serves as a first connection portion 201. A first conductive element 40 and the first connection portion 201 are stacked along a second direction Y. A first adhesive barrier 50 is bonded to the first portion 2011.

[0100] For example, the first adhesive barrier 50 and the first portion 2011 can be bonded together with double-sided tape or glue.

[0101] Multiple cells 21 in the cell assembly 20 can be electrically connected to each other via their respective electrode terminals 212, for example, in series or in parallel. The electrode terminal 212 of one cell 21 is configured to be connected to the first conductive element 40, and the electrode terminal 212 of the cell 21 can serve as the positive or negative electrode of the cell assembly 20.

[0102] The first conductive element 40 and the first connecting portion 201 are stacked along the second direction Y, and the areas of the first conductive element 40 and the first connecting portion 201 in the overlapping region are relatively large. The connection area between the first connecting portion 201 and the first adhesive blocking element 50 is relatively large, which facilitates the bonding of the first adhesive blocking element 50 to the first portion 2011. At the same time, the relatively large bonding area helps to improve the connection stability between the first adhesive blocking element 50 and the first portion 2011 and reduces the possibility of the first adhesive blocking element 50 and the first portion 2011 detaching from the connection state and separating.

[0103] In some examples, as shown in Figures 13 and 14, the first connection portion 201 includes a second portion 2012 connected to the first portion 2011. Along the second direction Y, the second portion 2012 is located between the protrusion 32 and the first conductive member 40, with the protrusion 32 abutting against the second portion 2012.

[0104] The protrusion 32 and the second portion 2012 are in contact with each other, which can restrict the flow of the first potting resin 70 from between the protrusion 32 and the second portion 2012 into the recess 31. The protrusion 32 acts as a limiting constraint on the second portion 2012, making the connection between the second portion 2012 and the first conductive element 40 stable. In the event of movement of the first conductive element 40, the movement amplitude of the connection area between the second portion 2012 and the first conductive element 40 is small, reducing the possibility that the second portion 2012 will bear a large tensile force due to large movement of the connection area between the second portion 2012 and the first conductive element 40, and reducing the possibility of the second portion 2012 cracking or detaching from the first conductive element 40.

[0105] In some examples, referring to Figures 12, 14, 15, and 16, the protrusion 32 includes a first wall 321 and a second wall 322 spaced apart along a second direction Y. The thickness of the first wall 321 increases along the first direction X. A second opening 33 penetrates the first wall 321 along the second direction Y. A second portion 2012 is located between the first wall 321 and the first conductive element 40. The first wall 321 abuts against the second portion 2012.

[0106] The first wall 321 is a non-uniform thickness structure. During the assembly of the first component 30 and the battery cell assembly 20, as the connecting area of ​​the first conductive element 40 and the second part 2012 enters the first space 32a, the first wall 321 is easily deformed by the pushing force of the connecting area, facilitating the smooth entry of the connecting area into the first space 32a. The thicker area of ​​the first wall 321 abuts against the second part 2012, while the thinner area does not abut against the second part 2012. This reduces the frictional resistance between the first wall 321 and the second part 2012, lowering the possibility of the second part 2012 cracking or wrinkling due to excessive frictional force exerted by the first wall 321. After the first component 30 and the battery cell assembly 20 are assembled, the first potting resin 70 can fill the gap between the thinner area and the second part 2012.

[0107] In some possible implementations, referring to Figure 12, the first sealing element 50 does not extend beyond the sidewall 302 along the first direction X. In the direction opposite to the first direction X, the first sealing element 50 does not extend beyond the protrusion 32. A portion of the second potting resin 80 is provided in the first opening 3011, the second opening 33, and the first space 32a.

[0108] The first blocking element 50 fills a portion of the second opening 33. Along the first direction X, the area below the first blocking element 50 can be filled with a second potting resin 80. Along the opposite direction X, the area above the second opening 33 can be filled with a first potting resin 70. The first potting resin 70 and the second potting resin 80 are respectively disposed on both sides of the first blocking element 50. The second blocking element 60, the first potting resin 70, and the second potting resin 80 can respectively limit the position of the first blocking element 50 from different directions, reducing the possibility of positional changes in the first blocking element 50.

[0109] In some examples, as shown in Figures 12 and 14, the second baffle 60 is not lower than the sidewall 302 along the first direction X. When the second potting resin 80 is poured in the inverted position, the second baffle 60 can prevent the second potting resin 80 from flowing out of the second opening 33 area, reducing the possibility of resin leakage at the sidewall 302.

[0110] Along a direction opposite to the first direction X, the second sealing element 60 is not lower than the protrusion 32. When the cell assembly 20 is in an upright state and the first potting resin 70 is being poured, the second sealing element 60 can restrict the first potting resin 70 from flowing out of the second opening 33, reducing the possibility of resin leakage at the protrusion 32.

[0111] In some examples, at 25°C, the viscosity of the first potting resin 70 before curing is greater than that of the second potting resin 80 before curing. This is beneficial for the first potting resin 70 to fill the gap between the first conductive element 40 and the first space 32a, as well as the gap between the first conductive element 40 and the second opening 33. The second potting resin 80 has a higher viscosity, which is beneficial for better filling of the first space 32a, the first opening 3011, and the second opening 33. For example, at 25°C, the viscosity of the first potting resin 70 before curing is in the range of 35000±5000 mPa·s.

[0112] In some possible implementations, as shown in Figures 10, 11, and 12, the battery module 10a includes an insulating member 90. The insulating member 90 covers a portion of the outer surface of the first conductive member 40. A first potting resin 70 covers the portion of the insulating member 90 located within the first space 32a. Optionally, the insulating member 90 includes a heat-shrinkable film.

[0113] The first potting resin 70 covers the portion of the insulating member 90 located within the first space 32a. The first potting resin 70 and the insulating member 90 can work together to insulate and isolate the portion of the first conductive member 40 located within the first space 32a from other conductive structures, thereby reducing the possibility of a short circuit between the first conductive member 40 and other conductive structures.

[0114] Referring to Figures 12, 17, and 18, the first conductive element 40 includes a connecting section 41 and a lead-out section 42. The connecting section 41 has a relatively large width, while the lead-out section 42 has a relatively small width. The connecting section 41 is connected to the electrode terminal 212. No insulating element 90 is provided on the connecting section 41. A portion of the lead-out section 42 is provided with an insulating element 90. No insulating element 90 is provided at the end of the lead-out section 42. The end of the lead-out section 42 is configured to connect to other devices. The insulating element 90 can insulate and isolate the first conductive element 40 from other conductive structures, reducing the possibility of a short circuit between the first conductive element 40 and other conductive structures.

[0115] When the first component 30 and the cell assembly 20 are assembled, the lead-out section 42 of the first conductive element 40 passes through the second opening 33 and enters the first space 32a and the first opening 3011. Then, the first component 30 is pushed approximately along the first direction X, and the connecting section 41 of the first conductive element 40 enters the first opening 3011 and the first space 32a.

[0116] In some possible implementations, referring to Figures 11 and 12, the protrusion 32 includes a protrusion 323. The protrusion 323 protrudes along a second direction Y. Along the second direction Y, there is a gap H between the insulating member 90 and the protrusion 323. The gap H ranges from 1 mm to 4 mm. The first direction X is perpendicular to the second direction Y.

[0117] The space H between the insulating member 90 and the protrusion 323 allows the first potting resin 70 to enter the space H to bond the insulating member 90 and the protrusion 32. The first potting resin 70 seals the space H, reducing the possibility of moisture intrusion due to poor sealing between the insulating member 90 and the protrusion 32.

[0118] In some examples, the protrusion 32 includes a first wall 321 and a second wall 322 spaced apart along a second direction Y. A second opening 33 extends through the first wall 321 along the second direction Y. The second wall 322 is provided with a protrusion 323.

[0119] In some possible implementations, as shown in Figures 12 and 18, the first conductive element 40 is a conductive sheet. The first conductive element 40 includes a bent portion 401. The bent portion 401 is located on the side of the bottom wall 301 facing away from the cell assembly 20, and the bent portion 401 is located outside the protrusion 32. The portion of the first conductive element 40 located inside the protrusion 32 can be in an upright state.

[0120] Before the battery cell assembly 20 is assembled with the first component 30, the first conductive element 40 can be bent into shape. In the embodiments of this application, when the first component 30 and the battery cell assembly 20 are assembled, the first conductive element 40 can enter the first space 32a and the first opening 3011 of the protrusion 32 through the second opening 33.

[0121] In this embodiment, the first component 30 and the battery cell assembly 20 can be assembled first, and then after the first component 30 and the battery cell assembly 20 are assembled, the first potting resin 70 is injected to seal the gap between the protrusion 32 and the first conductive element 40.

[0122] In some examples, the first conductive element 40 is a sheet-like copper busbar, comprising multiple layers of copper sheets. These multiple copper sheets are stacked, with each layer having a thickness of 0.05 mm to 0.3 mm, facilitating bending of the first conductive element 40. For example, the thickness of the copper sheet can be 0.1 mm. Twenty copper sheets are stacked to form the first conductive element 40, resulting in a thickness of 2 mm. Alternatively, the thickness of the copper sheet can be 0.5 mm. Ten copper sheets are stacked to form the first conductive element 40, resulting in a thickness of 5 mm.

[0123] In some examples, referring to Figure 13, the battery module 10a includes a second conductive element 130. One of the first conductive element 40 and the second conductive element 130 is connected to the positive terminal of the cell assembly 20, and the other of the first conductive element 40 and the second conductive element 130 is connected to the negative terminal of the cell assembly 20. The connection method between the second conductive element and the first component 30 is substantially the same as the connection method between the first conductive element 40 and the first component 30.

[0124] In some examples, the first conductive element 40 and the second conductive element 130 may have the same structure.

[0125] In some possible implementations, referring to Figure 9, the battery pack 10 has a filling hole 12 configured for resin filling. Resin can be filled into the battery pack 10 through the filling hole 12. When filling the resin, referring to Figure 9, the battery pack 10 is first placed upside down, with the first component 30 located below the cell assembly 20. The resin filled into the battery pack 10 can flow into the recess 31 of the first component 30 under the influence of gravity.

[0126] In some examples, referring to Figure 2, the battery pack 10 includes a housing 11 and a battery module 10a. The battery module 10a is located inside the housing 11.

[0127] In some examples, referring to Figure 2, the housing 11 includes a front wall 1011 and a rear wall 1012 oppositely arranged, a right wall 1013 and a left wall 1014 oppositely arranged, and a lower wall 1015 and a top wall 1016 oppositely arranged.

[0128] In some examples, referring to Figures 3 and 9, the battery module 10a includes a heat sink 100. The cell assembly 20 includes a first cell group 2001 and a second cell group 2002 spaced apart along a third direction Z. A first direction X and a second direction Y are perpendicular to the third direction Z. Along the third direction Z, the heat sink 100 is located between the first cell group 2001 and the second cell group 2002. The heat sink 100 has a flow guide hole 101, and the front wall 1011 has a filling hole 12. The flow guide hole 101 and the filling hole 12 are configured to fill a second potting resin 80 into the recess 31. In other embodiments, the filling hole 12 may be provided on the rear wall 1012.

[0129] In some feasible ways, the battery module 10a can be set up upside down as shown in FIG9, and then the second potting resin 80 can be poured through the gap between the recess 31 and the cell assembly 20.

[0130] In some possible implementations, referring to Figures 2, 4, and 12, the battery module 10a includes a first circuit board 110. The electrode terminals 212 of each battery cell 21 are connected to the first circuit board 110. The first circuit board 110 is located within a recess 31. A second potting resin 80 covers the first circuit board 110.

[0131] The second potting resin 80 can provide insulation for the first circuit board 110, allowing the first circuit board 110 to be isolated from other conductive components, thereby reducing the possibility of the first circuit board 110 failing due to electrical connection with other conductive components.

[0132] In some examples, the first circuit board 110 may be a printed circuit board (PCB).

[0133] In some possible implementations, referring to Figure 2, the battery pack 10 includes a second circuit board 120. The second circuit board 120 is a battery management circuit board. A first conductive element 40 is connected to the second circuit board 120. Data signals can be exchanged between the first circuit board 110 and the second circuit board 120.

[0134] In some possible implementations, the second circuit board 120 includes a connector 121 configured to connect to an electrical device.

[0135] In some possible implementations, referring to Figures 2 and 3, the battery module 10a includes a third conductive element 140. The third conductive element 140 is connected to the first circuit board 110 and the second circuit board 120, and is configured to transmit signals. The third conductive element 140 includes a wiring harness, and in Figure 2, it is shown in an unbent state. In other embodiments, the third conductive element 140 may be in a bent state.

[0136] The first component 30 includes a retaining portion 34. A third conductive element 140 passes through the retaining portion 34 and is led out. A third potting resin 150 is filled between the third conductive element 140 and the retaining portion 34. The third potting resin 150 seals the gap between the third conductive element 140 and the retaining portion 34.

[0137] After the first potting resin 70 and the third potting resin 150 have cured, the battery cell assembly 20 and the first component 30 are flipped 180° to an inverted state, so that the recess 31 of the first component 30 faces upward, and the second potting resin 80 is poured into the recess 31 and the first component 30. During the pouring of the second potting resin 80 into the recess 31, the cured first potting resin 70 and the third potting resin 150 restrict the second potting resin 80 from flowing out of the first space 32a. After the second potting resin 80 has cured, the battery cell assembly 20 and the first component 30 are flipped 180°.

[0138] According to some embodiments of this application, this application also provides an electrical device, including a battery module 10a of any of the above-described solutions, and the battery module 10a is used to provide electrical energy to the electrical device. The electrical device may be, but is not limited to, electronic devices, drones, backup power supplies, electric vehicles, electric motorcycles, electric-assisted bicycles, power tools, large household energy storage modules, etc.

[0139] Referring to Figure 19, this application embodiment provides a method for manufacturing a battery module 10a, which includes:

[0140] Provide 20 battery cell assemblies;

[0141] A first conductive element 40 is provided, and the first conductive element 40 is connected to the cell assembly 20;

[0142] A first component 30 is provided, and the first component 30 is pushed toward a first conductive element 40. The first conductive element 40 passes through a second opening 33 and enters a first space 32a and a first opening 3011.

[0143] Along the first direction X, the first component 30 is moved toward the cell assembly 20 to a predetermined position;

[0144] A first adhesive barrier 50 is provided, and the first adhesive barrier 50 is provided on the side of the first conductive member 40 facing the second opening 33;

[0145] A first potting resin 70 is provided, and a flowable first potting resin 70 is poured into a first space 32a and a second opening 33. A first baffle 50 restricts the first potting resin 70 from flowing out of the first opening 3011 and the second opening 33.

[0146] After the first potting resin 70 has cured, the cell assembly 20 and the first component 30 are rotated 180° along the first direction X.

[0147] A second potting resin 80 is provided, and a flowable second potting resin 80 is injected into the recess 31;

[0148] After the second potting resin 80 has cured, the cell assembly 20 and the first component 30 are rotated 180° along the first direction X.

[0149] In some possible implementations, referring to Figure 20, the first component 30 is placed in a first tilted state. The first component 30 is pushed toward the first conductive member 40, which passes through the second opening 33 and enters the first space 32a. The first component 30 is then flipped from the first tilted state to a second tilted state, with the first conductive member 40 passing through the second opening 33 and entering the first opening 3011. The first component 30 is then placed in a flat position and moved toward the cell assembly 20 in a predetermined position along the first direction X. The installation of the first component 30 is then complete.

[0150] Placing the first component 30 in a first tilted state before pushing it helps reduce the installation and operation difficulty of the first component 30, and improves assembly convenience and assembly efficiency.

[0151] In some examples, as shown in Figure 19, the first conductive element 40 is a copper busbar. Before the cell assembly 20 is assembled with the first component 30, the first conductive element 40 can be bent into shape. During assembly of the first component 30 and the cell assembly 20, a portion of the first conductive element 40 is folded away from the cell assembly 20. After the first component 30 is installed, a portion of the first conductive element 40 is folded back towards the cell assembly 20.

[0152] In some possible implementations, referring to Figure 21, the first component 30 is placed in a flat position. The first component 30 is pushed toward the first conductive element 40 in a direction opposite to the second direction Y, the first conductive element 40 passing through the second opening 33 and entering the first space 32a and the first opening 3011. Then, the first component 30 is moved toward the cell assembly 20 in a predetermined position along the first direction X. The installation of the first component 30 is complete.

[0153] In some possible implementations, prior to the step of providing the first potting resin 70, a second baffle 60 is provided, fixed to the outside of the protrusion 32 and the sidewall 302, and the second baffle 60 covers the second opening 33 and the first baffle 50. The first baffle 50 and the second baffle 60 can restrict the outflow of the first potting resin 70 from the first opening 3011 and the second opening 33. The second baffle 60 can restrict the outflow of the second potting resin 80 from the second opening 33.

[0154] In some feasible embodiments, a third potting resin 150 is injected between the third conductive element 140 and the enclosure portion 34 prior to the step of providing the second potting resin 80.

[0155] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and they should all be covered within the scope of the claims and specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A battery module, characterized in that, include: A battery cell assembly, comprising a plurality of battery cells, wherein each battery cell includes electrode terminals; A first component and the battery cell assembly are arranged along a first direction. The first component includes a bottom wall, a side wall connected to the bottom wall, a protrusion, a first space, a first opening, and a second opening. The bottom wall and the side wall form a recess facing the battery cell assembly. A portion of each electrode terminal is located in the recess. The protrusion is connected to the bottom wall surface facing away from the cell assembly, and the protrusion serves as at least a partial component forming the first space; Along the first direction, the first opening penetrates the bottom wall; along the second direction, the second opening penetrates the side wall and the protrusion; the first space, the first opening, and the second opening are connected. A first conductive element passes through the first space and the first opening, the first conductive element is connected to the cell assembly, and the first conductive element is configured to transmit power and / or electrical signals of the cell assembly. The first sealing element is located on the side of the first conductive element facing the second opening; A first potting resin is at least partially disposed in the first space, the first potting resin adheres to the first conductive element and the protrusion, and the first sealant is configured to restrict the flow of the first potting resin to the recess. A second potting resin is at least partially disposed in the recess, and the second potting resin bonds the electrode terminal and the recess.

2. The battery module according to claim 1, characterized in that, The battery module includes a second baffle, which is fixed to the protrusion and the sidewall. Viewed along the second direction, the second sealing element covers the second opening and the first sealing element, and the second direction is perpendicular to the first direction.

3. The battery module according to claim 1 or 2, characterized in that, The portion of the second potting resin is located at the first opening and the second opening.

4. The battery module according to any one of claims 1 to 3, characterized in that, The first potting resin portion is located in the second opening, and the first sealant is disposed in the second opening.

5. The battery module according to any one of claims 1 to 4, characterized in that, The battery cell assembly includes a first connection portion, which serves as the positive or negative electrode of the battery cell assembly. The first conductive element is connected to the first connecting portion, the first connecting portion includes a first part facing the second opening, the first part is located between the first adhesive barrier and the first conductive element, and the first adhesive barrier is connected to the first part.

6. The battery module according to claim 5, characterized in that, The battery cell includes electrode terminals, wherein one of the electrode terminals of the battery cell serves as the first connection portion; along the second direction, the first connection portion and the first conductive element are stacked; The first adhesive barrier is bonded to the first part.

7. The battery module according to claim 6, characterized in that, The first connecting portion includes a second portion connected to the first portion, and along the second direction, the second portion is located between the protrusion and the first conductive member, and the protrusion abuts against the second portion.

8. The battery module according to claim 7, characterized in that, The protrusion includes a first wall and a second wall spaced apart along the second direction, wherein the thickness of the first wall increases along the first direction; Along the second direction, the second opening penetrates the first wall, the second portion is located between the first wall and the first conductive element, and the first wall abuts against the second portion.

9. The battery module according to any one of claims 1 to 8, characterized in that, Along the first direction, the first adhesive barrier does not extend beyond the sidewall; along the direction opposite to the first direction, the first adhesive barrier does not extend beyond the protrusion. The second potting resin portion is disposed in the first opening, the second opening, and the first space.

10. The battery module according to any one of claims 1 to 9, characterized in that, The first conductive element is a conductive sheet, and the first conductive element includes a bent portion, which is located on the side of the bottom wall opposite to the cell assembly, and the bent portion is located outside the first space.

11. The battery module according to any one of claims 1 to 10, characterized in that, The first sealing element includes foam or silicone pad.

12. The battery module according to any one of claims 1 to 11, characterized in that, The battery module includes an insulating component, which covers a portion of the outer surface of the first conductive component, and the first potting resin covers the portion of the insulating component located within the first space.

13. The battery module according to claim 12, characterized in that, The protrusion includes a protruding portion that protrudes along the second direction. Along the second direction, there is a gap between the insulating member and the protruding portion, the gap ranging from 1 mm to 4 mm. The first direction and the second direction are perpendicular to each other.

14. The battery module according to any one of claims 1 to 13, characterized in that, The first conductive element is a sheet-shaped copper busbar, which includes multiple layers of copper sheets stacked together, with each layer having a thickness of 0.05 mm to 0.3 mm.

15. The battery module according to any one of claims 1 to 14, characterized in that, At 25°C, the viscosity of the first potting resin before curing is greater than that of the second potting resin before curing.

16. The battery module according to any one of claims 1 to 15, characterized in that, The battery module includes a second sealing element, which is fixed to the protrusion and the side wall; the second sealing element is bonded to the first sealing element.

17. The battery module according to any one of claims 1 to 16, characterized in that, The battery module includes a second baffle, which is fixed to the protrusion and the sidewall; along the second direction, there is a gap between the second baffle and the first baffle, and the gap is less than 1 mm.

18. The battery module according to any one of claims 1 to 17, characterized in that, The battery module includes a third conductive element connected to the cell assembly, and the third conductive element is configured to transmit signals.

19. A battery pack, characterized in that, It includes a battery module and a housing as described in any one of claims 1 to 18, wherein the battery module is located within the housing.

20. An electrical appliance, characterized in that, Includes the battery pack as described in claim 19.

21. A method for manufacturing a battery module as claimed in any one of claims 1 to 18, characterized in that, include: Provide the battery cell assembly; Provide the first conductive element and connect the first conductive element to the cell assembly; The first component is provided, and the first component is pushed toward the first conductive element, the first conductive element passing through the second opening and entering the first space and the first opening; Along the first direction, the first component is moved toward the cell assembly to a predetermined position; The first adhesive-blocking member is provided, and the first adhesive-blocking member is disposed on the side of the first conductive member facing the second opening; The first potting resin is provided, and a flowable first potting resin is injected into the first space and the second opening, wherein the first baffle restricts the first potting resin from flowing out of the first opening and the second opening; After the first potting resin has cured, the cell assembly and the first component are rotated 180° along the first direction; Provide the second potting resin and inject a flowable second potting resin into the recess; After the second potting resin has cured, the cell assembly and the first component are rotated 180° along the first direction.

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