Battery pack assembly and battery pack manufacturing method
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-02-09
- Publication Date
- 2026-08-13
Smart Images
Figure CN2026078027_13082026_PF_FP_ABST
Abstract
Description
A battery pack assembly and a method for manufacturing the battery pack.
[0001] This application claims priority to two Chinese patent applications filed on February 10, 2025, with application number CN202510146121.5 entitled "A Battery Pack Assembly and a Method for Manufacturing a Battery Pack" and filed on February 12, 2025, with application number CN202510156086.5 entitled "A Battery Pack Assembly and a Method for Manufacturing a Battery Pack", the entire contents of which are incorporated herein by reference. Technical Field
[0002] This application relates to the field of battery technology, and in particular to a battery pack assembly and a method for manufacturing a battery pack. Background Technology
[0003] With the technological advancements in the new energy industry, the development of electric vehicles is receiving increasing attention. As the power source for electric vehicles, battery packs are evolving from traditional modular solutions to large-module solutions, and even to module-free CTP (Cell to Pack) solutions. Currently, the mainstream CTP solution involves stacking the cells outside the casing, clamping them to the designed dimensions using tooling fixtures, and then placing the assembled cells inside the casing and securing them with adhesives. This eliminates the need for a separate casing to package the cells and form a battery module. While ensuring cell safety, CTP technology reduces internal cables and structural components, thereby improving both the volumetric energy density and gravimetric energy density of the entire battery pack.
[0004] However, the mounting methods in existing CTP solutions place high demands on tooling and equipment. Because battery pack sizes vary across different projects, tooling and fixtures are not interchangeable, leading to increased costs, and the integration efficiency of the battery packs needs further improvement.
[0005] Therefore, there is an urgent need to provide a method for manufacturing battery pack components or battery packs that can save manufacturing costs and improve the integration efficiency of battery packs. Summary of the Invention
[0006] This application provides a battery pack assembly and a method for manufacturing a battery pack, which can eliminate the crossbeams and longitudinal beams in traditional CTP battery packs, making the battery module arrangement more compact, thereby solving the problems of high cost and low integration efficiency and improving the energy density of the battery pack.
[0007] In a first aspect, this application provides a battery pack assembly, comprising: a housing having a bottom plate and a surrounding plate enclosing the bottom plate, the bottom plate and the surrounding plate forming a first cavity; a fixed bending plate disposed within the first cavity and arranged parallel to the length direction of the bottom plate to form a plurality of receiving longitudinal cavities, the fixed bending plate including a fixing part and a first bending part connected to the top end of the fixing part, the first bending part forming an angle with the fixing part, and two fixed bending plates arranged back-to-back between two adjacent receiving longitudinal cavities; and a plurality of battery cells arranged sequentially and accommodated within the receiving longitudinal cavities, the first bending part extending toward the battery cell direction to hold the battery cells within the receiving longitudinal cavities.
[0008] In one possible design, the fixing part includes a partition part and a second bending part, the second bending part is connected to the bottom end of the partition part and extends toward the direction of the battery cell; the first bending part, the partition part and the second bending part form a second cavity, and when the battery cell is accommodated in the accommodating cavity, part of the battery cell is stuck in the second cavity.
[0009] In one possible design, the fixed bending plate further includes a third bending portion, which is connected to the first bending portion and forms an angle with the first bending portion.
[0010] In one possible design, a buffer structure is also provided between the separator section and the battery cell, and the buffer structure is fixed on the separator section.
[0011] In one possible design, a pressure block structure is also included, which includes an insertion part and a pressure shoulder. The pressure shoulder is perpendicular to the insertion part. The insertion part is inserted between two fixed bending plates between two adjacent receiving cavities. The pressure shoulder extends toward the battery cell and its two ends abut against a third bending part, respectively.
[0012] In one possible design, the end of the insertion part is set as a chamfered structure; the length of the insertion part is less than or equal to the height of the battery cell; in another possible design, the extension distance of the first bending part toward the battery cell is the first distance, and the distance between the two fixed bending plates between two adjacent receiving cavities is the second distance, which is greater than the first distance.
[0013] In one possible design, a protective sheet is also included, with the two sides of the battery cell facing the fixed bending plate being the first and second sides of the battery cell, respectively, and the protective sheet is fixed to the first and second sides of the battery cell.
[0014] Secondly, this application provides a battery pack assembly, including: a plurality of battery cells, the upper surface of which has a terminal post, and the upper surface of the terminal post on both sides of which forms the shoulder of the battery cell; a housing, the housing including a base plate and a vertical beam disposed along the length of the base plate, the base plate and the vertical beam forming a plurality of receiving cavities, the plurality of battery cells being arranged sequentially and housed in the receiving cavities; and a pressing block structure disposed on both sides of the battery cells, the pressing block structure including a second fixing part and a pressing shoulder, the second fixing part being used to fix it to the housing, and the pressing shoulder extending toward the battery cell and pressing against the shoulder of the battery cell.
[0015] In one possible design, the height of the vertical beam is lower than the height of the battery cell. The height of the vertical beam is the distance from the bottom surface of the vertical beam to the top surface of the vertical beam, and the height of the battery cell is the distance from the bottom surface of the battery cell to the shoulder. The second fixing part is set as a groove structure, and the groove structure is fixed to the top of the vertical beam.
[0016] The above-described solution, by incorporating a groove structure at the top of the vertical beam, allows for a more stable fixation of the pressure block structure, thereby better securing the battery cell within the accommodating cavity. In one possible design, the depth of the groove structure is equal to the height difference between the vertical beam and the battery cell; a predetermined distance exists between the pressure shoulder and the electrode post.
[0017] In one possible design, a protective sheet is also included, with the two sides of the battery cell facing the vertical beam being the first side and the second side, respectively, and the protective sheet is fixed to the first side and the second side.
[0018] In one possible design, the protective sheet includes a protective body plate and a first isolation plate. The protective body plate is attached to a first side or a second side of the battery cell, and the first isolation plate is connected to the top of the protective body plate. The first isolation plate includes a first protective sheet attached to a portion of the upper surface of the battery cell.
[0019] In one possible design, the first isolation plate also includes a second protective plate and a third protective plate, with the second protective plate connected to the first protective plate and the third protective plate connected to the second protective plate, forming a protective cavity; the bottom end of the protective main plate is also connected to a second isolation plate, which extends toward the battery cell.
[0020] In one possible design, the distance that the upper surface of the portion of the first protective sheet that is attached to the battery cell extends toward the battery cell is a first distance, and the distance that the shoulder portion extends toward the battery cell is less than the first distance.
[0021] In one possible design, a thermally conductive cushioning pad, made of elastic material, is also included at the bottom of the cavity.
[0022] One possible design also includes end plate structures located at both ends of the cavity, used to isolate the large surface of the battery cell from direct contact with the housing.
[0023] The above description is merely an overview of the technical solutions of the embodiments of this application. In order to better understand the technical means of the embodiments of this application and to implement them in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the embodiments of this application more obvious and understandable, specific implementation methods of this application are described below. Attached Figure Description
[0024] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0025] Figure 1 is a schematic diagram of a battery pack assembly provided in an embodiment of this application.
[0026] Figure 2 is an enlarged view of region A in Figure 1.
[0027] Figure 3 is a schematic diagram of a structure in which a protective sheet is provided on a single battery cell according to an embodiment of this application.
[0028] Figure 4 is a schematic diagram of a pressing block structure provided in an embodiment of this application.
[0029] Figure 5 is a schematic diagram of the battery cell being installed into the receiving cavity according to an embodiment of this application.
[0030] Figure 6 is a schematic diagram of the structure for installing a pressure block after the battery cell is inserted into the longitudinal cavity according to an embodiment of this application.
[0031] Figure 7 is a schematic diagram of the battery pack clamping structure after installation according to an embodiment of this application.
[0032] Figure 8 is a schematic diagram of the structure along section line CC1 in Figure 7.
[0033] Figure 9 is an enlarged view of region B in Figure 8.
[0034] Figure 10 is a schematic diagram of a battery pack assembly provided in an embodiment of this application.
[0035] Figure 11 is a schematic diagram of a pressing block structure provided in an embodiment of this application.
[0036] Figure 12 is a schematic diagram of a structure in which a protective sheet is provided on a single battery cell according to an embodiment of this application.
[0037] Figure 13 is a schematic diagram of a battery cell being installed into a receiving cavity according to an embodiment of this application.
[0038] Figure 14 is a schematic diagram of the structure for installing a pressure block after the battery cell is inserted into the longitudinal cavity according to an embodiment of this application.
[0039] Figure 15 is a schematic diagram of the battery pack clamping structure after installation according to an embodiment of this application.
[0040] Figure 16 is a schematic diagram of the structure along section line AA1 in Figure 15.
[0041] Figure 17 is an enlarged view of region D in Figure 16.
[0042] Explanation of reference numerals in the attached drawings: 100, housing; 101, bottom plate; 102, surrounding plate; 103, plastic end plate; 110, fixed bending plate; 111, partition section; 112, second bending section; 113, first bending section; 114, third bending section; 120, pressure block structure; 121, insertion section; 122, pressure shoulder section; 130, accommodating longitudinal cavity; 200, battery cell; 210, protective sheet; 211, protective main body plate; 212, first protective sheet; 213, second protective sheet; 214, second isolation plate; 220, pad area; 300, buffer structure; area A; section line CC1; area B; first distance L1; second distance L2; 510, Vertical beam; 520, Buffer heat-conducting pad; 530, End plate structure; 310, Second fixing part; 411, First isolation plate; 214, Second isolation plate; AA1, Section line; Region D. Detailed Implementation
[0043] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0044] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein in the specification of the application is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims and drawings of this application are intended to cover non-exclusive inclusion.
[0045] The term "embodiment" as used herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of the phrase "embodiment" in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0046] In this article, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists, A and B exist simultaneously, or B exists. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.
[0047] The directional terms appearing in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of this application. For example, in the description of this application, the terms "center," "longitudinal," "lateral," "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 figures. They are only for the convenience of describing 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 this application.
[0048] Furthermore, the terms "first," "second," etc., in the specification and claims of this application or in the aforementioned drawings are used to distinguish different objects rather than to describe a specific order, and may explicitly or implicitly include one or more of the features.
[0049] In the description of this application, unless otherwise stated, "multiple" means two or more (including two), and similarly, "multiple groups" means two or more (including two groups).
[0050] In the description of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, "connection" or "joining" in mechanical structures can refer to a physical connection, such as a fixed connection, for example, a connection fixed by a partition, such as a connection fixed by screws, bolts, or other partitions; a physical connection can also be a detachable connection, such as a snap-fit or interlocking connection; a physical connection can also be an integral connection, such as a connection formed by welding, bonding, or integral molding. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0051] CTP (Cell to Pack) is a battery integration technology mainly used in the field of new energy vehicles. Its core is to skip the module stage in traditional battery packs and directly integrate the cells into the battery pack.
[0052] In CTP (Cell-to-Pack) solutions of related technologies, cell fixing typically relies on structural adhesives or complex mechanical fixing structures, which makes the design and use of tooling fixtures complex and costly. The different battery pack sizes in different projects mean that tooling fixtures cannot be interchanged, increasing equipment investment and maintenance costs.
[0053] In view of this, the present application provides a battery pack assembly and a method for manufacturing a battery pack. The housing does not require the design of crossbeams and longitudinal beams. It is fixed to the base plate by a fixed bending plate to form a receiving longitudinal cavity. When the battery cells are arranged and housed in the receiving longitudinal cavity, they can be fixed in the receiving longitudinal cavity by the first bending plate on the fixed bending plate. Therefore, there is no need to use complex stacking and hoisting equipment during the production process, and it saves space in the housing, improves energy density, and reduces the weight of the entire battery pack. This not only saves manufacturing costs but also significantly improves production efficiency.
[0054] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.
[0055] Figure 1 is a schematic diagram of the battery pack assembly provided in this embodiment. Figure 2 is an enlarged view of region A in Figure 1. Referring to Figure 1, this embodiment provides a battery pack assembly, including a housing 100, a fixed bending plate 110, and multiple battery cells 200.
[0056] The box 100 has a bottom plate 101 and a surrounding plate 102 that surrounds the bottom plate 101. The bottom plate 101 and the surrounding plate 102 form a first cavity.
[0057] The fixed bending plate 110 is disposed in the first concave cavity and is arranged parallel to the length direction of the bottom plate 101 to form a plurality of accommodating longitudinal cavities 130. The fixed bending plate 110 includes a fixing part and a first bending part 113. The first bending part 113 is connected to the top end of the fixing part and forms an angle with the fixing part. There are two fixed bending plates 110 arranged back to back between two adjacent accommodating longitudinal cavities 130.
[0058] This can be understood as two opposing fixed bending plates 110 forming a receiving longitudinal cavity 130. Therefore, there are two fixed bending plates 110 arranged in opposite directions between two adjacent receiving longitudinal cavities 130.
[0059] The battery cells 200 are arranged in sequence and housed in the receiving longitudinal cavity 130. The first bent portion 113 extends toward the battery cell 200, securing the battery cell 200 in the receiving longitudinal cavity 130.
[0060] In this embodiment, the first bending portion 113 is a single piece. Therefore, the first bending portion 113 bends relative to the fixed portion toward the direction of the battery cell 200, which can stably confine the battery cell 200 within the accommodating longitudinal cavity 130.
[0061] In some embodiments, the first bending portion 113 is shaped as multiple individual pieces bent towards their corresponding battery cells 200. These pieces are arranged intermittently, resembling a fishbone shape. Multiple sheet-like units are distributed on both sides of the fixing portion, with the overall arrangement similar to the ribs of a fishbone. Each piece secures its corresponding battery cell 200 within the receiving cavity 130. This ensures the secure containment of the battery cell 200 while reducing the overall weight of the battery pack.
[0062] The material of the fixed bending plate 110 can be an extruded profile made of aluminum alloy, high-strength steel or carbon fiber composite material.
[0063] The thickness of the fixed bending plate 110 is 1mm-10mm, which can greatly reduce the space occupied inside the battery pack.
[0064] With the above-described design, the housing 100 consists only of a base plate 101 and surrounding plates 102 that enclose the base plate 101, forming a first recessed cavity. The overall structure is simple and lightweight. The fixed bending plate 110, through its fixing part and the first bending part 113, is fixed within the first recessed cavity, forming multiple accommodating longitudinal cavities 130, which sequentially arrange and accommodate the battery cells 200. In this design, the fixing part of the fixed bending plate 110 acts as a separator between groups of battery cells 200, functioning similarly to a longitudinal beam. The first bending part 113 secures multiple battery cells 200 within the accommodating longitudinal cavities 130. Therefore, there is no need to package multiple battery cells 200 into groups or use other fixing and connecting methods; all battery cells 200 can be secured within the accommodating longitudinal cavities 130 by the first bending plate. Thus, the housing 100 does not require additional longitudinal or transverse beams. Because the fixed bending plate 110 is thinner than traditional longitudinal and transverse beams, this design not only saves space within the housing 100 and increases energy density, but also reduces the overall weight of the battery pack. At the same time, the cells 200 are arranged more compactly, making the overall structure of the battery pack more stable.
[0065] Furthermore, by adopting the design of the fixed bending plate 110, individual battery cells 200 can be placed into the housing 100 one by one during the installation process. This means that complex stacking and hoisting equipment is not required during the production process, thereby not only saving manufacturing costs but also significantly improving production efficiency.
[0066] In this embodiment, the battery pack assembly also includes plastic end plates 103. The plastic end plates 103 are disposed at both ends of the fixed bending plate 110 to prevent the large surface of the battery cell 200 from directly contacting and rubbing against the surrounding plates 102 at both ends of the base plate 101, which would damage the blue film of the battery cell 200 and cause a short circuit.
[0067] Please continue referring to Figure 2. The fixing part includes a partition part 111 and a second bending part 112. The second bending part 112 is connected to the bottom end of the partition part 111 and extends toward the battery cell 200. The first bending part 113, the partition part 111, and the second bending part 112 form a second cavity. When the battery cell 200 is accommodated in the receiving longitudinal cavity 130, part of the battery cell 200 is stuck in the second cavity.
[0068] In this embodiment, the first bent portion 113 and the partition portion 111 are perpendicular to each other, the partition portion 111 and the second bent portion 112 are perpendicular to each other, and the first bent portion 113 and the second bent portion 112 in the second cavity are parallel to each other.
[0069] Through the above-described design, the second bending portion 112 and the second recessed cavity allow the fixing portion to be more securely fixed to the base plate 101, while also ensuring a more stable fixation of the battery cell 200 within the accommodating longitudinal cavity 130. The partial structure of the battery cell 200 is held within the second recessed cavity, effectively preventing displacement and vibration during use, thereby significantly improving the overall stability and reliability of the battery pack. Furthermore, this design achieves the fixation and separation of the battery cell 200 through the ingenious structure of the bending plate, eliminating the need for additional complex structural components or adhesives. This not only simplifies the battery pack structure but also reduces manufacturing costs and process complexity. The method of fixing the battery cell 200 within the second recessed cavity increases its protection to a certain extent, reducing the risk of damage due to collisions or impacts. Simultaneously, this fixing method makes the disassembly and replacement of the battery cell 200 more convenient, significantly improving the maintainability of the battery pack.
[0070] In some embodiments, the fixed bending plate 110 further includes a third bending portion 114, which is connected to the first bending portion 113 and forms an angle with the first bending portion 113.
[0071] In this embodiment, the third bend 114 is perpendicular to the first bend 113. When the pressure block structure 120 is inserted into the first gap, the two ends of the pressure shoulder 122 abut against the third bend 114, thereby improving the fixing effect of the pressure block structure 120.
[0072] Through the above design, during the assembly of the battery cell 200, the third bend 114 can serve as a leverage point, facilitating the opening of the fixing bend plate 110 and thus allowing the battery cell 200 to be easily assembled into the receiving cavity 130. The design of the third bend 114 provides convenience for the assembly of the battery cell 200. During assembly, operators can easily open the fixing bend plate 110 using the third bend 114 as a leverage point, making it easier to place the battery cell 200 into the receiving cavity 130. This greatly simplifies the assembly process and improves production efficiency. When the battery cell 200 needs to be replaced or maintained, the third bend 114 can also serve as a leverage point, allowing operators to quickly disassemble and reassemble the battery cell 200. This design not only improves the maintainability of the battery pack but also reduces maintenance costs.
[0073] Figure 4 is a schematic diagram of the pressing block structure 120 provided in this embodiment. Figure 5 is a schematic diagram of the battery cell 200 installed into the receiving longitudinal cavity 130 provided in this embodiment. Figure 6 is a schematic diagram of the pressing block structure 120 installed after the battery cell 200 is installed into the receiving longitudinal cavity 130 provided in this embodiment. Referring to Figures 4 to 6, in this embodiment, the battery pack assembly also includes a pressing block structure 120. The pressing block structure 120 includes an insertion part 121 and a pressing shoulder part 122. The pressing shoulder part 122 is perpendicular to the insertion part 121. There is a first gap between two adjacent receiving longitudinal cavities 130 or between the surrounding plates 102 on both sides of the bottom plate 101 and their adjacent fixed bending plates 110. The insertion part 121 is inserted into the first gap, and the pressing shoulder part 122 extends toward the battery cell 200 and its two ends abut against the third bending part 114 respectively.
[0074] It is understandable that the pressure block structure 120 can be divided into two types. One type is a pressure block structure located between the housing 100 and the fixed bending plate 110, in which the pressure shoulder 122 has only one side. The other type is a pressure block structure located between the two fixed bending plates 110, in which the pressure shoulder 122 is located on both sides of the insertion part 121, and can apply pressure to the battery cells 200 on both sides respectively.
[0075] Through the above scheme, the insertion part 121 of the clamping block structure 120 is inserted between two adjacent fixed bending plates 110, forming an integrated structure with the fixed bending plates 110, thereby enhancing the structural strength of the entire battery pack. Simultaneously, the cooperation between the clamping shoulder 122 and the third bending part 114 further improves the stability of the overall structure and reduces the risk of structural deformation caused by external forces. The design of the clamping block structure 120 allows the cells 200 to be arranged more compactly within the accommodating longitudinal cavity 130, reducing the gaps between the cells 200. This compact layout not only improves the volumetric energy density of the battery pack but also further optimizes space utilization, enabling the battery pack to accommodate more cells 200, thus improving overall performance. The design of the clamping block structure 120 makes the assembly and disassembly of the cells 200 more convenient. During assembly, the insertion part 121 can be quickly inserted between the fixed bending plates 110, and the clamping shoulder 122 can directly press against the upper surface of the cell 200 and abut against the third bending part 114, without the need for complex fixing tools or adhesives. During disassembly, the battery cell 200 can be easily removed simply by lifting the clamping structure 120, greatly simplifying the operation process, improving production efficiency, and reducing manufacturing costs. The design of the clamping structure 120 and the third bending section 114 is not only suitable for battery cells 200 of different sizes, but can also be adjusted and optimized according to specific needs. This design enhances the versatility and adaptability of the battery pack assembly, enabling it to better meet diverse requirements.
[0076] In this embodiment, the end of the insertion part 121 is chamfered, which effectively reduces the friction and resistance between the insertion part 121 and the fixed bending plate 110 during assembly, making it easier for the insertion part 121 to be inserted between two adjacent fixed bending plates 110. This design significantly improves assembly efficiency and reduces the risk of jamming or damage during assembly. The chamfered structure provides a guiding slope for the insertion part 121, ensuring that the insertion part 121 accurately enters the predetermined position during assembly, avoiding structural deformation or damage caused by improper assembly. This not only improves the assembly accuracy but also enhances the overall reliability of the battery pack.
[0077] In this embodiment, the length of the insertion portion 121 is less than or equal to the height of the battery cell 200. The length of the insertion portion 121 determines the insertion depth; deeper insertion results in a more stable assembly. However, a shorter insertion portion 121 reduces the overall weight and thus the overall weight of the battery pack. Therefore, the length of the insertion portion 121 is designed to be less than or equal to the height of the battery cell 200, ensuring that the clamping structure 120 does not exceed the height range of the battery cell 200 after assembly. This design further optimizes the internal spatial layout of the battery pack, avoiding unnecessary space occupation and thereby improving the volumetric energy density of the battery pack.
[0078] Figure 7 is a schematic diagram of the battery pack clamping structure 120 after installation according to this embodiment. Figure 8 is a schematic diagram of the structure along section CC1 in Figure 7. Figure 9 is an enlarged view of region B in Figure 8. Referring to Figures 7 to 9, in this embodiment, the extension distance of the first bending portion 113 toward the cell 200 is the first distance L1. There is a first gap between two adjacent receiving cavities 130 or between the surrounding plates 102 on both sides of the bottom plate 101 and their adjacent fixed bending plates 110. The size of the first gap is the second distance L2, which is greater than the first distance L1.
[0079] With the above scheme, during the assembly of the battery cell 200, the first bent portion 113 needs to be pried open clockwise or counterclockwise, with the connection point between the first bent portion 113 and the fixing portion serving as the axis. Sufficient clearance is required to allow the first bent portion 113 to open smoothly. Therefore, the second distance L2 (the distance between two adjacent fixed bending plates 110) is set to be greater than the first distance L1 (the extension distance of the first bent portion 113 towards the battery cell 200).
[0080] Referring to Figures 2 and 8, in this embodiment, a buffer structure 300 is also provided between the partition portion 111 and the battery cell 200, and the buffer structure 300 is fixed on the partition portion 111.
[0081] The buffer structure 300 can effectively absorb and disperse the vibration and impact forces experienced by the battery cell 200 during use, reducing displacement or damage to the battery cell 200 caused by external forces, thereby improving the stability and reliability of the battery cell 200. The buffer structure 300 can reduce the stress generated by expansion or contraction of the battery cell 200 during charge and discharge cycles, reducing fatigue and damage to the internal structure of the battery cell 200, and thus extending the service life of the battery cell 200.
[0082] In this embodiment, the buffer structure 300 can be made of a material with excellent buffering, shock resistance, heat insulation and moisture-proof properties, such as buffer foam, which is fixed to the inner surface of the partition portion 111 by adhesive.
[0083] The buffer structure 300 not only protects the battery cell 200, but also plays an important role in absorbing the dimensional tolerance of the first gap when the insertion part 121 is inserted into the first gap, ensuring that the pressure block structure 120 or the battery cell 200 can be smoothly inserted into the box.
[0084] Figure 3 is a schematic diagram of a single battery cell 200 provided in this embodiment with a protective sheet 210. In this embodiment, the battery pack assembly also includes a protective sheet 210. The two sides of the battery cell 200 facing the fixed bending plate 110 are respectively the first side and the second side of the battery cell 200, and the protective sheet 210 is fixed to the first side and the second side of the battery cell 200.
[0085] Through the above-described scheme, the protective sheet 210 is fixed to the first and second sides of the battery cell 200, effectively preventing damage to the blue film of the battery cell 200 and avoiding internal short circuits caused by blue film damage. This design also prevents the battery cell 200 from being subjected to mechanical damage, such as scratches, impacts, or compression, during assembly, use, or maintenance. These protective measures help extend the service life of the battery cell 200 and improve its reliability. In addition, the protective sheet 210 can prevent direct contact between the battery cell 200 and the fixed bending plate 110 or other metal parts, thereby reducing the risk of short circuits. The protective sheet 210 can also buffer the stress of the battery cell 200 when it is subjected to impact to a certain extent, reducing internal structural damage caused by external forces and further improving the safety of the battery pack. Since the protective sheet 210 corresponds one-to-one with each battery cell 200, that is, the protective sheet 210 is set on the first and second sides of each battery cell 200, this makes targeted maintenance of individual battery cells 200 possible, improving the maintainability of the battery pack.
[0086] In this embodiment, the protective sheet 210 includes a protective main plate 211 and a first isolation plate. The protective main plate 211 is attached to the first side or the second side of the battery cell 200. The first isolation plate is connected to the top of the protective main plate 211. The first isolation plate includes a first protective sheet 212 attached to a portion of the upper surface of the battery cell 200.
[0087] Through the above scheme, the protective main plate 211 is attached to the side of the battery cell 200, providing side protection. The first isolation plate is attached to part of the upper surface of the battery cell 200, further protecting the top of the battery cell 200. This design can effectively prevent the battery cell 200 from being mechanically damaged during assembly, use or maintenance, such as scratches, collisions or squeezing, while avoiding internal short circuits caused by damage to the blue film.
[0088] In some embodiments, the first isolation plate further includes a second protective sheet 213 and a third protective sheet (not shown), the second protective sheet 213 being connected to the first protective sheet 212, the third protective sheet being connected to the second protective sheet 213, and the first protective sheet 212, the second protective sheet 213 and the third protective sheet forming a third cavity (not shown); the bottom end of the protective main plate 211 is also connected to a second isolation plate 214, the second isolation plate 214 extending toward the battery cell 200.
[0089] When the battery cell 200 is assembled in the receiving cavity 130, the first bent portion 113 extends toward the battery cell 200, securing the battery cell 200 within the receiving cavity 130. Since the first protective plate 212, the second protective plate 213, and the third protective plate together form a third recess, and the first bent portion 113 is located within this third recess, it provides better protection and isolation. This not only increases the creepage distance but also prevents short circuits between the battery cell 200 assembly and the fixed bending plate 110. For example, after the battery cell 200 is installed in the receiving cavity 130, a retainer is also provided above the battery cell. Therefore, the presence of the retainer area 220, the second protective plate 213, or the third recess can better prevent short circuits between the retainer area 220 and the fixed bending plate 110. Furthermore, the second isolation plate 214 extends toward the battery cell 200, providing protection below the battery cell 200 and preventing mechanical damage (such as scratches, impacts, or compression) to the battery cell 200.
[0090] Based on the above embodiments, this application also provides a method for manufacturing a battery pack, comprising:
[0091] Step 1, provide a box 100, the box 100 has a bottom plate 101 and a surrounding plate 102 surrounding the bottom plate 101, the bottom plate 101 and the surrounding plate 102 form a first cavity.
[0092] Step 2, provide a fixed bending plate 110, the fixed bending plate 110 includes a fixing part and a first bending part 113, the first bending part 113 is connected to the top end of the fixing part, and the first bending part 113 forms an angle with the fixing part.
[0093] Step 3: Fix the fixing part in the first cavity and set it parallel to the length direction of the bottom plate 101 to form a plurality of receiving longitudinal cavities 130. There are two fixing bending plates 110 between two adjacent receiving longitudinal cavities 130.
[0094] Step 4: By bending the first bend 113 in a clockwise or counterclockwise direction, multiple battery cells 200 are sequentially placed into the receiving cavity 130.
[0095] Since the structure and beneficial effects of the battery pack assembly have been described in detail in the previous embodiments, they will not be repeated here.
[0096] This application also provides a battery pack assembly and a method for manufacturing the battery pack. The housing includes a base plate and vertical beams arranged along the length of the base plate. The base plate and vertical beams form multiple longitudinal cavities for receiving batteries. Multiple battery cells are arranged sequentially and housed within these cavities. A clamping block structure then fixes the battery cells within the housing. The second fixing part of the clamping block structure is fixed to the housing, and the clamping shoulder presses against the upper surface of a portion of the battery cell, enhancing the fixing effect and preventing the battery cells from shaking or shifting during operation. During installation, this battery pack eliminates the need to pack multiple battery cells together before installation, thus saving on complex stacking and hoisting equipment, reducing manufacturing costs, and significantly improving production efficiency.
[0097] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.
[0098] Figure 10 is a schematic diagram of the battery pack assembly provided in this embodiment. Figure 11 is a schematic diagram of the pressing structure provided in this embodiment. Referring to Figures 10 and 11, this embodiment provides a battery pack assembly, including: multiple battery cells 100, a housing 200, and a pressing structure 120.
[0099] The upper surface of the cell 100 has a terminal post, and the upper surface of the two sides of the terminal post forms the shoulder of the cell 100.
[0100] The housing 200 includes a base plate and vertical beams 510 arranged along the length of the base plate. The base plate and vertical beams 510 form multiple accommodating cavities 130, with the base plate serving as the basic support for the battery pack. The vertical beams 510 are arranged along the length of the base plate, forming multiple accommodating cavities 130. The vertical beams 510 can effectively enhance the overall stability of the battery pack, and can also distribute and withstand forces from different directions. Multiple battery cells 100 are arranged sequentially and accommodated within the accommodating cavities 130, which can reduce the displacement of the battery cells 100 under vibration or impact.
[0101] The pressure block structure 120 is disposed on both sides of the battery cell 100. The pressure block structure 120 includes a second fixing part 310 and a pressing shoulder part 122. The second fixing part 310 is used to fix it on the housing 200, and the pressing shoulder part 122 extends toward the battery cell 100 and presses against the shoulder of the battery cell 100.
[0102] In this embodiment, the second fixing part 310 is fixed on the vertical beam 510.
[0103] In this embodiment, the structure of the shoulder portion 122 is a single piece. Therefore, the shoulder portion 122 is bent relative to the second fixing portion 310 toward the direction of the battery cell 100, which can stably confine the battery cell 100 within the receiving longitudinal cavity 130.
[0104] In some embodiments, the shoulder portion 122 is shaped as multiple independent, individually bent pieces that bend towards the corresponding battery cell 100. These pieces are arranged intermittently, resembling a fishbone shape. Multiple sheet-like units are distributed on both sides of the second fixing portion 310, arranged in an overall manner similar to the ribs of a fishbone. Each piece secures its corresponding battery cell 100 within the receiving cavity 130. This ensures proper confinement of the battery cell 100 while reducing the overall weight of the battery pack.
[0105] It is understandable that when the second fixing part 310 has battery cells 100 on both sides, the pressing block structure 120 has pressing shoulders 122 on both sides of the second fixing part 310; in the pressing block structure 120 located on both sides of the housing 200, the pressing shoulder 122 is provided on one side of the second fixing part 310.
[0106] After the battery cell 100 is placed in the receiving cavity 130, it is then fixed inside the housing 200 by the pressing block structure 120. The second fixing part 310 of the pressing block structure 120 is fixed to the housing 200, and the pressing shoulder 122 presses against part of the upper surface of the battery cell 100, enhancing the fixing effect of the battery cell 100 and preventing the battery cell 100 from shaking or shifting during operation. During installation, individual battery cells 100 are placed into the receiving cavity 130 one by one, eliminating the need to pack multiple battery cells 100 into a group before entering the housing. This eliminates the need for complex stacking and hoisting equipment, saving manufacturing costs. Furthermore, each battery cell 100 is individually housed in the cavity, allowing for individual operation when a battery cell 100 needs to be replaced or repaired without disassembling the entire battery pack, thus reducing maintenance costs.
[0107] In this embodiment, the height of the vertical beam 510 is lower than the height of the battery cell 100. The height of the vertical beam 510 is the distance from the bottom surface of the vertical beam 510 to the top surface of the vertical beam 510. The height of the battery cell 100 is the distance from the bottom surface of the battery cell 100 to the shoulder. The second fixing part 310 is configured as a groove structure, and the groove structure is fixed to the top of the vertical beam 510.
[0108] In this embodiment, by providing a first screw hole at the bottom of the groove structure and a second screw hole on the top surface of the vertical beam 510, the groove structure can be fixed to the vertical beam 510 by passing screws through the first and second screw holes.
[0109] In some embodiments, the groove structure can be fixed to the vertical beam 510 by welding or gluing.
[0110] By employing the above-described design, a groove structure is provided at the top of the vertical beam 510, which more stably secures the pressure block structure 120, thereby better fixing the battery cell 100 within the receiving cavity 130. The groove structure design simplifies the installation of the pressure block structure 120, reduces the complexity of the assembly process, and improves production efficiency. Furthermore, the groove structure is hollow, unlike the solid structure of the vertical beam 510, making it lighter. The groove structure and the vertical beam 510 together isolate the battery cells 100 within adjacent receiving cavities 130, further reducing the overall weight of the battery pack.
[0111] Figure 15 is a schematic diagram of the battery pack clamping structure after installation according to this embodiment. Figure 16 is a schematic diagram of the structure along section line AA1 in Figure 15. Figure 17 is an enlarged view of region D in Figure 16. Referring to Figures 15 to 17, in this embodiment, the depth of the groove structure is equal to the height difference between the vertical beam 510 and the cell 100; the shoulder 122 has a preset distance from the terminal post.
[0112] The preset distance can be no less than 3mm. In this embodiment, the preset distance is 10mm.
[0113] Through the above-described scheme, by setting a groove structure at the top of the vertical beam 510, the depth of which is equal to the height difference between the vertical beam 510 and the battery cell 100, the pressure block structure 120 can be more stably fixed, thereby better securing the battery cell 100 within the accommodating longitudinal cavity 130. The pressure shoulder 122 extends towards the battery cell 100 and presses against a portion of the upper surface of the battery cell 100, maintaining a predetermined distance from the terminal of the battery cell 100. This prevents contact between the terminal and the pressure block structure 120, thus avoiding short circuits. It also prevents direct pressure from the pressure block structure 120 on the terminal during installation, protecting the terminal and improving the reliability and safety of the battery pack.
[0114] Figure 12 is a schematic diagram of a single battery cell with a protective sheet provided in this embodiment. Figure 13 is a schematic diagram of a battery cell installed into the receiving cavity provided in this embodiment. Referring to Figures 12 and 13, in this embodiment, the battery pack assembly also includes a protective sheet 210. The two sides of the battery cell 100 facing the vertical beam 510 are respectively the first side and the second side of the battery cell 100. The protective sheet 210 is fixed to the first side and the second side, which can effectively prevent damage to the blue film of the battery cell 100 and avoid internal short circuits caused by damage to the blue film.
[0115] The material of the protective sheet 210 can be polycarbonate (PC).
[0116] The design of providing protective plates 210 on both sides of each individual cell 100 prevents mechanical damage such as scratches, impacts, or compression during assembly, use, or maintenance. These protective measures help extend the lifespan of the cell 100 and improve its reliability. Furthermore, the protective plates 210 prevent direct contact between the cell 100 and fixed bending plates or other metal components, thereby reducing the risk of short circuits. The protective plates 210 also buffer the stress on the cell 100 when subjected to impacts, reducing internal structural damage caused by external forces and further enhancing the safety of the battery pack. Since the protective plates 210 correspond one-to-one with each individual cell 100—that is, each cell 100 has a protective plate 210 on its first and second sides—directional maintenance of individual cells 100 becomes possible, improving the maintainability of the battery pack.
[0117] Please continue to refer to Figure 12. In this embodiment, the protective sheet 210 includes a protective main plate 211 and a first isolation plate 411. The protective main plate 211 is attached to the first side or the second side of the battery cell 100. The first isolation plate 411 is connected to the top of the protective main plate 211. The first isolation plate 411 includes a first protective sheet attached to a portion of the upper surface of the battery cell 100.
[0118] Through the above scheme, the protective main plate 211 is attached to the side of the battery cell 100 to provide side protection; the first isolation plate 411 is attached to part of the upper surface of the battery cell 100 to further protect the top of the battery cell 100. This design can effectively prevent the battery cell 100 from being mechanically damaged during assembly, use or maintenance, such as scratches, collisions or squeezing, while avoiding internal short circuits caused by damage to the blue film.
[0119] In this embodiment, the first isolation plate 411 further includes a second protective plate (not shown) and a third protective plate (not shown). The second protective plate is connected to the first protective plate, and the third protective plate is connected to the second protective plate. The first protective plate, the second protective plate, and the third protective plate form a protective cavity.
[0120] When the battery cell 100 is assembled in the receiving cavity 130, the shoulder portion 122 extends toward the battery cell 100, securing the battery cell 100 within the receiving cavity 130. Due to the protective recess (not shown) formed by the first, second, and third protective plates, after the pressure block structure 120 is installed, the shoulder portion 122 is located within the protective recess, thus providing better protection and isolation. This not only increases the creepage distance but also prevents short circuits between the battery cell 100 assembly (e.g., the plate area) and the fixed bending plate.
[0121] Please continue to refer to Figure 12. The bottom end of the protective main plate 211 is also connected to a second isolation plate 214. The second isolation plate 214 extends towards the battery cell 100, so that protection can also be provided below the battery cell 100 to prevent the battery cell 100 from being mechanically damaged (such as scratches, collisions or squeezing).
[0122] Referring to Figures 16 and 17, in this embodiment, the distance that the upper surface of the portion of the first protective sheet that is attached to the battery cell 100 extends toward the battery cell 100 is the first distance, and the distance that the shoulder portion 122 extends toward the battery cell 100 is less than the first distance.
[0123] The above solution ensures that the distance the pressure shoulder 122 extends toward the battery cell 100 is less than the first distance, so as to ensure that there is a first protective piece between the pressure shoulder 122 and the shoulder of the battery cell 100, so as to prevent the pressure shoulder 122 from directly acting on the shoulder of the battery cell 100, causing damage or compression to the battery cell 100, thereby protecting the safety of the battery cell 100.
[0124] Please continue to refer to Figure 10. In this embodiment, a buffer thermal pad 520 is also included. The buffer thermal pad 520 is made of elastic material, located at the bottom of the receiving longitudinal cavity 130, and laid flat on the base plate.
[0125] The 520 thermal pad is a thermally conductive material with a certain degree of elasticity.
[0126] This design not only effectively buffers the pressure transmitted from the pressure plate on the shoulder of cell 100 in the height direction (perpendicular to the base plate) and absorbs tolerances, but also replaces the heat conduction function of thermally conductive adhesive, transferring the heat generated by cell 100 to the bottom cold plate in a timely manner to cool cell 100. Furthermore, it eliminates the need for adhesive application equipment, reduces adhesive weight, increases the overall energy density of the battery pack, saves manufacturing costs, improves the thermal management efficiency of the battery pack, enhances the stability and reliability of cell 100, and reduces assembly and maintenance costs, demonstrating significant practicality and economic benefits.
[0127] In this embodiment, an end plate structure 530 is also included. The end plate structure 530 is located at both ends of the longitudinal cavity 130 and is used to isolate the large surface of the battery cell 100 from direct contact with the housing 200.
[0128] With the above-described design, the end plate structure 530 is located at both ends of the longitudinal cavity 130, effectively isolating the large surface of the battery cell 100 from direct contact with the housing 200. This prevents direct friction and wear between the battery cell 100 and the housing 200, and avoids direct contact and friction between the large surface of the battery cell 100 and the transverse sidewalls of the housing 200, which could damage the blue film of the battery cell 100 and cause a short circuit. The end plate structure 530 provides additional fixation and support for the battery cell 100 along the length of the base plate, further enhancing the stability of the battery cell 100 and reducing displacement and shaking of the battery cell 100 during operation.
[0129] Please continue to refer to Figures 13 to 15. Based on the above embodiments, this application also provides a method for manufacturing a battery pack, including:
[0130] Step 1, provide a housing 200, the housing 200 includes a bottom plate and vertical beams 510 arranged along the length of the bottom plate, the bottom plate and vertical beams 510 form a plurality of accommodating longitudinal cavities 130.
[0131] Step 2: Place multiple battery cells 100 sequentially into the receiving cavity 130. The upper surface of the battery cell 100 has a terminal post, and the upper surface of the two sides of the terminal post is the shoulder of the battery cell 100.
[0132] Step 3: Set the pressure block structure 120 on both sides of the battery cell 100 and fix it on the housing 200. The pressure block structure 120 has a second fixing part 310 and a pressing shoulder part 122. The second fixing part 310 is used to fix it on the housing 200, and the pressing shoulder part 122 extends toward the battery cell 100 and presses against the shoulder of the battery cell 100.
[0133] Since the structure and beneficial effects of the battery pack assembly have been described in detail in the previous embodiments, they will not be repeated here.
[0134] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended 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 of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A battery pack assembly, characterized in that, include: The box has a bottom plate and a surrounding plate that surrounds the bottom plate, the bottom plate and the surrounding plate forming a first cavity; A fixed bending plate is disposed in the first concave cavity and is arranged parallel to the length direction of the bottom plate to form multiple accommodating longitudinal cavities. The fixed bending plate includes a fixed part and a first bending part. The first bending part is connected to the top end of the fixed part and forms an angle with the fixed part. There are two fixed bending plates arranged in opposite directions between two adjacent accommodating longitudinal cavities. Multiple battery cells are arranged sequentially and housed within the receiving longitudinal cavity. The first bent portion extends toward the battery cell and secures the battery cell within the receiving longitudinal cavity.
2. The battery pack assembly according to claim 1, characterized in that, The fixing part includes a partition part and a second bending part. The second bending part is connected to the bottom end of the partition part and extends toward the battery cell. The first bending part, the partition part, and the second bending part form a second cavity. When the battery cell is accommodated in the accommodating cavity, part of the battery cell is stuck in the second cavity.
3. The battery pack assembly according to claim 2, characterized in that, The fixed bending plate also includes a third bending portion, which is connected to the first bending portion and forms an angle with the first bending portion.
4. The battery pack assembly according to claim 3, characterized in that, A buffer structure is also provided between the separator and the battery cell, and the buffer structure is fixed to the separator.
5. The battery pack assembly according to claim 4, characterized in that, It also includes a pressing block structure, which includes an insertion part and a pressing shoulder part. The pressing shoulder part is perpendicular to the insertion part. There is a first gap between two adjacent receiving longitudinal cavities or between the side panels of the bottom plate and its adjacent fixed bending plate. The insertion part is inserted into the first gap. The pressing shoulder part extends toward the direction of the battery cell and its two ends abut against the third bending part.
6. The battery pack assembly according to claim 5, characterized in that, The end of the insertion part is provided with a chamfered structure; the length of the insertion part is less than or equal to the height of the battery cell.
7. The battery pack assembly according to claim 5, characterized in that, The first bending portion extends a distance toward the battery cell, which is a first distance. The size of the first gap is a second distance, which is greater than the first distance.
8. The battery pack assembly according to claim 1, characterized in that, It also includes a protective sheet, wherein the two sides of the battery cell facing the fixed bending plate are respectively the first side and the second side of the battery cell, and the protective sheet is fixed to the first side and the second side of the battery cell.
9. A battery pack assembly, characterized in that, include: Multiple battery cells, wherein the upper surface of each battery cell has a terminal post, and the upper surface portions on both sides of the terminal post constitute the shoulders of the battery cell; The housing includes a base plate and vertical beams arranged along the length of the base plate. The base plate and the vertical beams form multiple longitudinal cavities, and multiple battery cells are arranged sequentially and housed within the longitudinal cavities. A pressing structure is provided on both sides of the battery cell. The pressing structure includes a fixing part and a pressing shoulder part. The fixing part is used to fix it to the housing, and the pressing shoulder part extends toward the battery cell and presses against the shoulder of the battery cell.
10. The battery pack assembly according to claim 9, characterized in that, The height of the vertical beam is lower than the height of the shoulder. The height of the vertical beam is the distance from the bottom surface of the vertical beam to the top surface of the vertical beam. The height of the battery cell is the distance from the bottom surface of the battery cell to the shoulder. The fixing part is configured as a groove structure, and the groove structure is fixed to the top surface of the vertical beam.
11. The battery pack assembly according to claim 10, characterized in that, The depth of the groove structure is equal to the height difference between the vertical beam and the battery cell; the shoulder portion and the electrode post have a preset distance.
12. The battery pack assembly according to claim 11, characterized in that, It also includes a protective sheet, with the two sides of the battery cell facing the vertical beam being the first side and the second side of the battery cell, respectively, and the protective sheet being fixed to the first side and the second side.
13. The battery pack assembly according to any one of claims 8-12, characterized in that, The protective sheet includes a protective main plate and a first isolation plate. The protective main plate is attached to a first side or a second side of the battery cell. The first isolation plate is connected to the top of the protective main plate and includes a first protective sheet attached to a portion of the upper surface of the battery cell.
14. The battery pack assembly according to claim 13, characterized in that, The first isolation plate also includes a second protective plate and a third protective plate, the second protective plate being connected to the first protective plate, the third protective plate being connected to the second protective plate, and the first protective plate, the second protective plate and the third protective plate forming a protective cavity; The bottom end of the protective main plate is also connected to a second isolation plate, which extends toward the battery cell.
15. The battery pack assembly according to claim 14, characterized in that, The distance that the upper surface of the portion of the first protective sheet that is attached to the battery cell extends toward the battery cell is a first distance, and the distance that the shoulder portion extends toward the battery cell is less than the first distance.
16. The battery pack assembly according to claim 9, characterized in that, It also includes a buffer thermal pad, which is made of elastic material and is located at the bottom of the receiving longitudinal cavity.
17. The battery pack assembly according to claim 9, characterized in that, It also includes end plate structures, which are located at both ends of the receiving longitudinal cavity and are used to isolate the large surface of the battery cell from the housing.