CN113437440A

CN113437440A - Electric connection switching structure, battery pack and manufacturing method thereof

Info

Publication number: CN113437440A
Application number: CN202110995866.0A
Authority: CN
Inventors: 汪波; 刘存良; 杨钢
Original assignee: Suzhou Modu Intelligent Technology Co ltd; Jiaxing Modu New Energy Co ltd
Current assignee: Suzhou Modu Intelligent Technology Co ltd; Jiaxing Modu New Energy Co ltd
Priority date: 2021-08-27
Filing date: 2021-08-27
Publication date: 2021-09-24
Anticipated expiration: 2041-08-27
Also published as: CN113437440B; CN114300810A

Abstract

The invention relates to an electric connection switching structure, a battery pack and a manufacturing method thereof. The electric connection switching structure comprises a switching bridge and a bus bar; the transfer bridge comprises a body part and an electric connection structure; the body part is approximately strip-shaped and is provided with a first end surface and a first side surface; an electrical connection structure including a first contact conductive portion and a second contact conductive portion; the first contact conductive part can be electrically connected with at least part of the side surface of the single cylindrical battery side surface shell; the busbar comprises a main busbar part and an extension busbar part extending laterally; the main confluence part is electrically connected with the top poles of the single cylindrical batteries; the extending bus part is electrically connected with the second contact conductive part of the transfer bridge. According to the invention, the transfer bridge is arranged, so that the side shells of the single cylindrical batteries connected in parallel in the row are all arranged at the top, and the parallel connection in the row and the serial connection between the rows of all the single cylindrical batteries are realized through the matching of the adjacent row busbar and the transfer bridge of the row, so that a high-efficiency CTP rapid loading scheme is provided.

Description

Electric connection switching structure, battery pack and manufacturing method thereof

Technical Field

The invention relates to the field of new energy power batteries, in particular to an electric connection switching structure, a battery pack and a manufacturing method of the battery pack.

Background

The grouping application field of the vehicle-mounted power battery pack of the pure electric vehicle is developing towards the CTP (cell TO PACK) technology direction with high energy density and integral quick grouping (pack). The size of the single body of the cylindrical power battery of the industry standard is expanding from 21700 (diameter 21mm, height 70 mm) to 46800 (diameter 46mm, height 80 mm), the energy of the single body battery is expanded by 5 times, and how to converge and transmit the current with such large size is a technical problem to be solved in the field.

The difficulty of research in the industry is that firstly, when the single batteries are connected in series and in groups, the requirement on the overcurrent capacity of an electric connection point is correspondingly and greatly improved; secondly, electrically isolating the early thermal runaway single battery as early as possible; thirdly, how to realize the inter-row series connection electric connection and the rapid integral solid seal can be simply, rapidly and automatically operated in the battery box, and the CTP technology of the cylindrical battery is realized.

Disclosure of Invention

To solve the above problems in the prior art, the present invention discloses

An electric connection switching structure comprises at least one switching bridge and at least one bus bar;

the transfer bridge comprises a body part and an electric connection structure; the body part is approximately strip-shaped and is provided with a first end surface positioned at the strip-shaped end part, a first side surface positioned at the strip-shaped side part and a second side surface opposite to the first side surface; the electric connection structure comprises a first contact conductive part positioned on the first side surface and a second contact conductive part positioned on the first end surface; the first contact conductive part can be electrically connected with at least part of the side surface of the single cylindrical battery side surface shell; the first contact conductive part is electrically connected with the second contact conductive part;

the bus bar is composed of a conductor, and includes a main bus portion and an extended bus portion extending laterally from an end of the main bus portion; the main bus part can at least partially cover and electrically connect top poles of a plurality of single cylindrical batteries;

the extended bus portion is electrically connected to the second contact conductive portion of the transfer bridge.

The present invention also provides a battery pack including:

a plurality of staggered battery rows, each battery row being formed by a plurality of single cylindrical batteries; the single cylindrical battery comprises a top pole and a shell pole, and the shell pole comprises a side shell and a bottom shell; the side surface shells of the adjacent single cylindrical batteries in the same battery row are electrically connected; all the single cylindrical batteries in the battery rows arranged in a plurality of arrays are arranged in the same direction;

at least one end of each battery row is provided with a transfer bridge; the transfer bridge comprises a body part and an electric connection structure; the body part is approximately strip-shaped and is provided with a first end surface positioned at the strip-shaped end part, a first side surface positioned at the strip-shaped side part and a second side surface opposite to the first side surface; the electric connection structure comprises a first contact conductive part positioned on the first side surface and a second contact conductive part positioned on the first end surface; the first contact conductive part can be electrically connected with at least part of the side surface of the single cylindrical battery side surface shell; the first contact conductive part is electrically connected with the second contact conductive part;

a plurality of busbars including a main bus portion and an extended bus portion extending laterally from an end of the main bus portion; the main bus part at least partially covers and is electrically connected with top poles of a plurality of single cylindrical batteries of the corresponding battery row; at least a portion of the extended bus bar is electrically connected to the second conductive contact portion of the transfer bridge.

The invention also provides a battery module, which comprises a plurality of battery packs, wherein the battery packs are arranged in an array; the battery pack can be laterally expanded along the arrangement direction of the battery rows of the battery pack;

the transfer bridge between the transversely adjacent battery packs has an electrical connection structure; and the lateral shells of the single cylindrical batteries are electrically connected between the transversely adjacent battery rows through an electric connection structure.

The invention also provides a battery pack, which comprises a shell, and the battery pack or the battery module arranged in the shell; the housing includes a bottom plate and a sidewall.

The present invention also provides a method for manufacturing the battery pack, including:

a plurality of single cylindrical batteries are arranged in a row in the same direction;

electrically connecting the side casings of adjacent single cylindrical batteries; electrically connecting the electric connection structure of the transfer bridge with the side shell of the single cylindrical battery at the end part;

applying structural adhesive between adjacent single cylindrical batteries and between the transfer bridge and the side shell of the single cylindrical battery at the end part, and solidifying the structural adhesive to obtain a battery row;

preparing a plurality of battery rows;

arranging the battery rows in a staggered manner, wherein different ends of the switching bridges of the adjacent battery rows are arranged;

applying and curing a structural adhesive between adjacent battery rows;

arranging a busbar, and electrically connecting a main bus part of the busbar with top poles of a plurality of single cylindrical batteries of a corresponding battery row; and connecting the extended bus part of the bus bar with the electric connection structure of the transfer bridge of other battery bars.

The invention also provides a manufacturing method of the battery pack, which comprises the following steps:

preparing a plurality of battery rows;

disposing an adhesive layer on a bottom plate of the housing;

arranging a plurality of batteries into the shell through a jig and adhering the batteries to the bottom plate;

The technical scheme adopted by the invention can achieve the following beneficial effects: through special electricity connection switching structure, both can realize arranging interior battery top utmost point post fast, high electric flux, reliably parallelly connected, suitable arrange the crimping within a definite time through whole in the incasement, realize establishing ties between the row of all batteries through special switching bridge structure and arrangement mode simultaneously, still provide in addition with the quick structural fixation of battery box lateral part, bottom. The invention provides a cylindrical battery CTP rapid loading scheme without a support structure, wherein the cylindrical battery CTP rapid loading scheme is arranged in the same direction, the current pressure of a top pole is shunted, the flow capacity of a bus bar is correspondingly multiplied while the battery pack is transversely expanded, and the area of a bottom pole is large enough, so that the battery pack can bear great current.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below to form a part of the present invention, and the exemplary embodiments and the description thereof illustrate the present invention and do not constitute a limitation of the present invention. In the drawings:

fig. 1 is a schematic structural view of a battery pack and an electrical connection switching structure disclosed in

embodiments

1 and 2 of the present invention;

fig. 2 is a schematic structural view of a battery pack and an electrical connection switching structure disclosed in

embodiments

1 and 2 of the present invention;

fig. 3 is a schematic structural view of the battery pack and the electrical connection switching structure disclosed in

embodiments

1 and 2 of the present invention;

fig. 4 is a schematic structural diagram of the battery pack and the electrical connection switching structure disclosed in embodiment 1 and embodiment 2 of the present invention;

fig. 5 is a perspective view of a unit cylindrical battery of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 6 is a front view of a unit cylindrical battery of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 7 is a schematic structural view of a transfer bridge of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 8 is a schematic structural view of a transfer bridge of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 9 is a schematic structural view of a transfer bridge of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 10 is a schematic structural view of a transfer bridge of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 11 is a schematic structural view of bus bars of the battery packs disclosed in

embodiments

1 and 2 of the present invention;

fig. 12 is a schematic structural diagram of a battery module disclosed in embodiment 3 of the present invention;

fig. 13 is a schematic structural diagram of a battery module disclosed in embodiment 3 of the present invention;

fig. 14 is a schematic structural diagram of a battery module disclosed in embodiment 3 of the present invention;

fig. 15 is a schematic structural view of a housing of a battery pack disclosed in embodiment 4 of the present invention;

fig. 16 is a schematic structural diagram of a battery pack disclosed in embodiment 4 of the present invention;

fig. 17 is a top view of a battery pack disclosed in embodiment 4 of the present invention;

fig. 18 is a schematic structural view of a cover plate and a bus bar of a battery pack disclosed in embodiment 4 of the present invention;

fig. 19 is a schematic structural view of a battery pack disclosed in embodiment 4 of the present invention;

fig. 20 is a schematic structural diagram of a battery pack disclosed in embodiment 4 of the present invention.

Description of reference numerals:

a battery pack 100;

a single cylindrical battery 1; a top pole 11; a side case 12; a window 13;

a bus bar 2; a main bus portion 21; an extended bus portion 22; bus bar electrical connections 23;

a transfer bridge 3; a first end face 31; a second end face 32; a first side 33; a second side 34; a slot 35; a groove portion 36; a fixing hole 37; a fixed post 38; the first contact conductive portion 311; the second conductive contact portion 312; the third contact conductive portion 313; a second bridge 39;

a fastening tape 41; a structural adhesive 43;

a first electrical connection 51; a second electrical connection 52; a third electrical connection 53;

a cover plate 6; a through hole 61;

a housing 8; a side wall 81; a bottom plate 82; a heating plate 83; a PCBA board 84; an insulating buffer layer 85; the soft row 86 is sensed.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention and the accompanying drawings. In the description of the present invention, it is noted that the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

To solve the problems in the prior art, the present embodiment provides, in part, an electrical connection switching structure for cylindrical batteries connected in parallel in rows and in series between rows, a battery pack 100 structure and a corresponding manufacturing method. By the electric connection switching structure, a CTP technical solution for the battery pack which is connected in series between rows and is used for dealing with large current is provided.

Example 1

According to fig. 1 to 11, the present example 1 provides an electrical connection switching structure for preparing a single cylindrical battery 1 into a CTP battery pack connected in parallel in rows and in series between rows, which is particularly suitable for improving the grouping quality and yield of new energy vehicle power battery units.

In the present embodiment, the single cylindrical battery 1 is a power battery with high energy density, and may be selected from 18650 batteries, 21700 batteries, 46800 batteries, and the like, but is not limited thereto, and it should be understood by those skilled in the art that the single cylindrical battery 1 with any specification is suitable for the solution of the present embodiment, and the cylindrical battery with approximate cylinder, such as the cylindrical battery with a cross section of a rounded rectangle, a rounded triangle, or a rounded polygon, is also suitable for the solution of the present embodiment, and can be regarded as the single cylindrical battery 1.

Meanwhile, both bare cells and cells with insulating layers are also suitable. It will be understood by those skilled in the art that when the unit cylindrical battery 1 with the insulating layer is used, the insulating layer has a window 13 exposing the side case 12 as shown in fig. 5.

As shown in fig. 1 to 4, the electrical connection relay structure in the present embodiment may be provided alone as a structure for grouping the unit cylindrical batteries 1 without including the unit cylindrical batteries 1 shown in the drawings.

The basic structure of the electrical connection transition structure in this embodiment includes at least one transition bridge 3 and at least one bus bar 2. The transfer bridge 3 has multiple functions, including but not limited to leading the side surface shell 12 of the single cylindrical battery 1 connected in parallel in a row to a position approximately in the same plane with the top pole 11, and filling up the position difference of the row head battery between rows caused by the staggered battery rows so as to efficiently realize the inter-row series connection through the special bus bar 2 design in the same plane; meanwhile, the transfer bridge 3 can also provide inter-row spacing control for the battery rows in the preparation process, maintain the safety distance between adjacent housing pole columns between the battery rows connected in series between the rows, and realize the overhead arrangement of the spaced housing pole columns and the parallel connection between the adjacent housing pole columns of two adjacent parallel battery rows when the battery pack 100 is transversely extended in parallel.

Referring to fig. 7-10, the bridge 3 includes a body portion and an electrical connection structure, preferably the body portion is substantially strip-shaped. The cross-section of the bridge 3 is preferably substantially trapezoidal with a circular arc, and may also be rectangular, or semicircular. In one embodiment, the bridge 3 is a semi-cylindrical conductor, preferably a cylindrical surface (first side 33) for connecting the side housings 12 of the individual cylindrical cells 1 in a cell row, and a flat surface (second side 34) for connecting the side housings 12 of the individual cylindrical cells 1 of another cell row or for housing pole extraction.

The present embodiment provides various preferred versions of the transfer bridge 3.

As shown in fig. 7 and 8, the transit bridge 3 may be used alone or may be spliced and then used. The height of the single transfer bridge 3 is preferably half of the height of the single cylindrical battery 1, and the single cylindrical battery 1 is electrically connected and fixedly connected with the upper part of the side shell 12, so that the weight of the battery pack 100 can be reduced to a certain extent, and the energy density can be improved. Further, it will be understood by those skilled in the art that the height of the two transfer bridges 3 is approximately equal to the height of the unit cylindrical battery 1 after the splicing.

FIG. 8 is a preferred one-piece construction of the transfer bridge 3 having a first end 31 at the end of the strip, a first side 33 at the side of the strip, and a second side 34 opposite the first side 33; an electrical connection structure including a first conductive contact portion 311 located on the first side surface 33 and a second conductive contact portion 312 located on the first end surface 31; the first contact conductive portion 311 can be electrically connected to at least part of the side surface case 12 of the single cylindrical battery 1; the first conductive contact portion 311 is electrically connected to the second conductive contact portion 312. Preferably, a third side and a fourth side are further included between the first side 33 and the second side 34. Preferably, the first side surface 33 is a concave cylindrical surface for matching the shape of the side surface shell 12 of the single cylindrical battery 1 adjacent to the transfer bridge 3 in the battery row; the second side 34 is planar; the third side and the fourth side are concave cylindrical surfaces and are used for matching the shape of the side shell 12 of the single cylindrical battery 1 of the adjacent battery row.

Preferably, the first contact conductive part 311 is also a cylindrical surface to match the shape of the first side surface 33 and the side surface case 12 of the unit cylindrical battery 1 of the adjacent battery row.

Preferably, the first contact conductive part 311 is a convex cylindrical surface or plane, a longitudinal electrical connection line located on the axis of the battery row is located near the cylindrical side surface casing of the single cylindrical battery 1 of the adjacent battery row, and the magnitude of the electrical flux at the electrical connection point is positively correlated to the length of the electrical connection line.

In a preferred embodiment, the main body of the transit bridge 3 comprises an electrical conductor, and the electrical connection structure is a partial area of the electrical conductor; preferably, the body of the adaptor bridge 3 is made of hollow or solid metal, preferably a metal shell structure or a metal frame structure, and while providing high structural strength, since the body is a conductor, the body can be partially or completely used as an electrical connection structure, so that an additional electrical connection structure can be omitted. Those skilled in the art will understand that in the preferred embodiment, the exterior of the main body of the transit bridge 3 may not be provided with an insulating structure, and an insulating layer may be provided on a partial region of the exterior. At least part of the outer surface of the conductor is covered with an insulating material, which may provide insulation protection at necessary locations, such as the third and fourth sides, the end or bottom surfaces, etc.

In a preferred embodiment, the body portion comprises an insulator, and the electrical connection structure comprises a first bridge made of a conductor, which is attached to at least the first side surface 33 and the first end surface 31, i.e. the first bridge comprises a first conductive contact portion 311 and a second conductive contact portion 312, which are electrically connected to each other, as shown in fig. 2. The conductor is preferably a metal conductor.

Preferably, the first bridge further includes a third conductive contact portion 313 located on the second side surface 34, and the third conductive contact portion 313 is electrically connected to the first conductive contact portion 311 and/or the second conductive contact portion 312, and preferably, the first bridge is a flat conductor having a substantially U-shaped structure, the width of the flat conductor is slightly narrower than the thickness of the transfer bridge, and two side edges of the flat conductor are located between the widest points between the third side surface and the fourth side surface, so as to ensure electrical safety for the battery rows adjacent to the two side surfaces, as shown in fig. 10.

Preferably, in connection with fig. 8-9, the electrical connection structure may also be a structure passing through the body of the bridge 3. The body of the transfer bridge 3 has at least one slot 35 passing through between the first side 33 and the second side 34, preferably two slots 35; the electrical connection structure comprises a second bridge 39; the upper slot hole is used for the penetration of the second electric bridge 39, and the lower slot hole is used for the collection of the flowing conductive residues after fusing when the second electric bridge is a fusing device, so that short circuit among other normal single batteries in the battery pack is avoided.

One end of the second bridge 39 is located on the first side surface 33 side and is used for connecting the side surface housings 12 of the single cylindrical batteries 1, and preferably, an arc-shaped metal strip is partially wrapped around the single cylindrical batteries 1 and then connected with the first electrical connector 51, or the tail end of the arc-shaped metal strip is clamped between the side surface housings 12 of two single cylindrical batteries 1. The other end of the second bridge 39 is located on the second side surface 34 side and is used for connecting other electrical connection switching structures or other switching bridges 3 or other side housings 12 of the single cylindrical battery 1 or serving as housing pole terminals.

Preferably, the second side 34 has at least one recessed portion 36; at least one bent portion of the second bridge 39, which is located on the second side 34 and extends out of the slot 35, is disposed in the groove portion 36. The lower edge of the slot 35 is a sunken groove with two ends higher and the middle lower for receiving the residual material dropped from the fuse.

As a preferred embodiment, according to fig. 7, after the junction bridge 3 is used together, the first contact conductive portion 311 may extend to the lower half portion of the side surface casing 12 of the single cylindrical battery 1, so that the casing pole may bear a larger current, and the technical effect is higher in the case of a larger number of single-row batteries, a larger single-body capacity of the single cylindrical battery 1, and the like. Meanwhile, after the transfer bridge 3 is used together, the height of the transfer bridge 3 is equivalent to that of the single cylindrical battery 1, and the third side and the fourth side can support the upper half part and the lower half part of the lateral shell 12 of the single cylindrical battery 1 in the adjacent battery rows at two sides, so that a better supporting effect can be provided.

Preferably, a second end face 32 opposite to the first end face 31; the second end face 32 has a connecting structure for connecting with other transfer bridges 3. Connection structure includes fixed column 38 and/or fixed orifices 37, and fixed orifices 37 is the shrinkage pool that matches with fixed column 38, and the two preferably can interference fit or carry out stable connection through the top layer rubber coating.

In addition, in another preferred embodiment, the single transfer bridge 3 has a height approximately equal to that of the single cylindrical battery 1, and the splicing operation of the transfer bridge 3 is not needed, so that the process is reduced.

As shown in fig. 11, the busbar 2 is made of a conductor, preferably a flat bar-shaped conductor, and includes a main bus bar portion 21 and an extended bus bar portion 22 extending laterally from an end of the main bus bar portion 21; the main bus bar portion 21 is capable of at least partially covering and electrically connecting the top poles 11 of the plurality of unit cylindrical batteries 1. Preferably, the width of the main bus bar portion 21 is greater than 50% of the diameter of the single cylindrical battery 1, and even up to or exceeding 80% of the diameter of the single cylindrical battery 1, so as to obtain better current carrying capacity. Preferably, the width of the main bus bar portion 21 is 50% or less of the diameter of the unit cylindrical battery 1, but has a higher height, in other words, a greater thickness, so as to provide a sufficient overcurrent capability.

Preferably, the main bus bar portion 21 and the extended bus bar portion 22 are perpendicular to each other, and the bus bar 2 is substantially L-shaped.

The extended bus portion 22 is electrically connected to the second conductive contact portion 312 of the transfer bridge 3, and thereby the battery rows are connected in series.

Preferably, the bus bar 2 further includes a shunt extension bus part 22 (not shown in the figure) extending laterally from the middle of the main bus part 21, and the bent section of the shunt extension bus part 22 is bent to be attached to the side surface of the side surface housing 12 of the single cylindrical battery 1 and electrically connected to the side surface housing 12 of one or several single cylindrical batteries 1 of the adjacent battery row to share the current pressure of the extension bus part 22. This preferred embodiment is particularly suitable for the case of a large number of individual cells in a battery row.

Preferably, the main bus 21 of the bus bar 2 has a plurality of protruding bus bar electrical connections 23. The preferred hat cold welding structure of wearing of busbar electric connector 23, it includes the hole of seting up at main collecting portion 21, turn-ups down, connects electric claw, cold-welded glue and structure to glue 43, and hole central point and 11 central points or the pressure release hole of top utmost point post correspond, and the hole lower part is equipped with the turn-ups down, and turn-ups lower part annular arrangement has to connect the electric claw, connects the electric claw outwards to pack with top utmost point post 1111 of below the cold-welded glue forms the electricity and connects, and the inward flange of turn-ups lower part down or the annular juncture of connecting electric claw outer fringe and top utmost point post 1111 are equipped with the structure and glue 43. It will be appreciated by those skilled in the art that the crown structure can significantly increase the electrical contact area, making it more suitable for use in a 4680 cell with high energy density.

Preferably, the electrical connection structure comprises a fuse.

Preferably, the first electrical connector 51 or the second electrical connector 52 or the third electrical connector 53 comprise a fuse. Preferably, the high-power low-temperature fusing device is used for overheating fusing of series connection between adjacent battery rows or overheating fusing of parallel connection between a leading-out end of a shell pole of the battery row or the shell pole between adjacent parallel battery rows.

In this embodiment, through setting up the bridging 3, just the electric connection structure of bridging 3 makes the whole overhead of the side casing 12 of single cylindrical battery 1 to make the top utmost point post 11 and the side casing 12 of single cylindrical battery 1 all be in the coplanar, and then make the series mode between the row of planarization possible, bring the very big promotion of manufacturing efficiency.

Example 2

The structure of the battery pack 100 will be described in detail in this embodiment 2 with reference to fig. 1 to 4, while the cylindrical single battery 1 is prepared as the battery pack 100 using the electrical connection transfer structure of embodiment 1, and the features regarding the electrical connection transfer structure, which have been included in embodiment 1, are naturally inherited in this embodiment.

According to fig. 2, the battery pack 100 of the present embodiment includes a plurality of staggered battery rows each of which is formed by arranging a plurality of unit cylindrical batteries 1; the single cylindrical battery 1 comprises a top pole 11 and a side shell 12, and the side shells 12 of the adjacent single cylindrical batteries 1 in the same battery row are electrically connected; all the unit cylindrical batteries 1 in the plurality of array-arranged battery rows are arranged in the same direction.

According to fig. 1-2, at least one end of each battery row is provided with a transfer bridge 3; the transfer bridge 3 comprises a body part and an electrical connection structure; the body portion is substantially strip-shaped, and has a first end face 31 positioned at the strip-shaped end portion, a first side face 33 positioned at the strip-shaped side portion, and a second side face 34 opposite to the first side face 33; an electrical connection structure including a first conductive contact portion 311 located on the first side surface 33 and a second conductive contact portion 312 located on the first end surface 31; the first contact conductive portion 311 can be electrically connected to at least part of the side surface case 12 of the single cylindrical battery 1; the first conductive contact portion 311 is electrically connected to the second conductive contact portion 312.

Further includes a plurality of bus bars 2, the bus bars 2 including a main bus portion 21 and an extended bus portion 22 laterally extending from an end of the main bus portion 21; the main bus-bar part 21 at least partially covers and electrically connects the top poles 11 of the plurality of single cylindrical batteries 1 of the corresponding battery row; at least part of the extended bus bar portion 22 is electrically connected to the second conductive contact portion 312 of the transfer bridge 3.

It will be understood by those skilled in the art that all the unit cylindrical batteries 1 of each battery row are in a parallel structure, and a plurality of battery rows are in a series structure.

The battery pack 100 of the present embodiment is preferably a basic unit for grouping unit cells, and as shown in fig. 2, the battery pack 100 is formed by arranging 8 unit cylindrical batteries 1 in a battery row in the transverse direction and 4 battery rows in the longitudinal direction, i.e., an 8X4 array. Of course, those skilled in the art will appreciate that the battery pack 100 may also be a 6X4 array, a 4X4 array, a 10X4 array, an 8X20 array, an 8X40 array, and the like. The present embodiment does not limit the lateral and longitudinal expansion of the battery pack 100.

Preferably, there is a first electrical connection 51 between the side casings 12 of the individual cylindrical batteries 1 in each row, as shown in fig. 4. Preferably, the first electrical connector 51 is a bent conductor or a solid conductor, and is preferably electrically connected in cooperation with cold solder paste.

Preferably, at least one second electrical connector 52 is arranged between the side casings 12 of the single cylindrical batteries 1 of at least one battery row, one end of the second electrical connector 52 is clamped between the side casings 12 of two adjacent single cylindrical batteries 1, and the other end is a pair of outer casing poles of the battery pack, namely, a casing pole bridge, as shown in fig. 1-2. Preferably, the second electrical connection 52 is provided only in the last row of cells (i.e. the lowermost row of cells in fig. 2), which is defined as the row from which the housing poles lead out.

Preferably, the extended bus portion 22 of the bus bar of at least one battery bar, which is not electrically connectable with the second conductive contact portion 312 of the transfer bridge 3, and/or the shunt extended bus portion can be used as an external top pole, i.e. a top pole terminal, of the battery pack 100. As shown in fig. 2, the extended bus portion 22 of the bus bar 2 corresponding to the first battery bar is suspended and not electrically connected to the second conductive contact portion 312 of the transfer bridge 3, and the suspended extended bus portion 22 preferably serves as a top terminal post terminal. Of course, those skilled in the art will understand that virtually any position of the busbar 2 corresponding to the leading row of cells can be used as the top terminal lead-out terminal.

Preferably, according to fig. 2, one transfer bridge 3 is provided at one end of each battery row, and the transfer bridges 3 of adjacent battery rows are provided at different ends. Preferably, the second side 34 of the transfer bridge 3 is approximately in the same plane with the outermost side of the side housing 12 of the single cylindrical battery 1 on the same side. The advantage of this design is that the lateral expandability of the battery pack 100 is strong.

Preferably, cold-welding glue is provided between the main bus bar 21 and the top pole 11, and/or between the side housings 12 of the single cylindrical batteries 1 in the row, and/or between the extended bus bar 22 and the second contact conductive part 312, and/or between the first contact conductive part 311 and the side housings 12 of the single cylindrical batteries 1.

The structural adhesive between the side casings 12 can be considered as an insulating material, and at the same time, can also create a gap between the side casings 12, keeping the side casings 12 of adjacent cylindrical batteries parallel, improving the crush resistance, avoiding undesirable contact between adjacent side casings 12 when impacted. Preferably, between adjacent side shells 12 on the central axis of the adjacent cylindrical batteries arranged between rows, an upper structural adhesive and a lower structural adhesive are arranged on the adjacent shell lines, and after curing, the insulating support can be regarded as a tightly connected insulating support.

Preferably, at least one structural adhesive 43 is arranged between the adjacent single cylindrical batteries 1, and the structural adhesive 43 is used for fixedly connecting the adjacent single cylindrical batteries 1. Preferably, a first structural adhesive 43 close to the top pole 11 and a second structural adhesive 43 close to the bottom are arranged between the adjacent single cylindrical batteries 1. The first structural adhesive 43 and the second structural adhesive 43 can firmly connect the adjacent unit cylindrical batteries 1 while supporting the insulating space between the unit cylindrical batteries 11. The first structural glue 43 and the second structural glue 43 are chosen to be located near the first electrical connectors 51 to increase the stability of the electrical connection between the side casings 12.

Preferably, according to fig. 1, the battery pack 100 further includes a fastening band 41, which is sleeved outside the main bus bar 21 and the bottoms of the unit cylindrical batteries 1 of the corresponding battery rows, for improving and maintaining the pressing force between the main bus bar 21 and the top pole 11. The fastening tape 41 is preferably a fastening cord, and one battery row is preferably wound and fixed in sequence using one fastening cord. And winding at least one circle of fastening rope at the adjacent position of two adjacent single cylindrical batteries 1, and then rotating to the next adjacent position for winding.

Preferably, the structural adhesive 43 is disposed between the fastening band 41 and the neck of the single cylindrical battery 1, and by shortening the telescopic distance of the fastening band 41 near the top, the amount of the telescopic action is reduced, and the tightening force of the portion is improved, in other words, by reducing the elastic modulus of the fastening band 41 near the top, the main bus bar portion 21 will be less prone to fall off or loosen from the top pole 11 or increase the contact resistance in case of a shock.

Preferably, the structural adhesive 43 is provided between the transfer bridge 3 and the side casing 12 of the single cylindrical battery 1, and/or between the main bus portion 21 and the top pole 11, and/or between the extended bus portion 22 and the second contact conductive portion 312, and/or between the first contact conductive portion 311 and the side casing 12 of the single cylindrical battery 1.

The single cylindrical battery 1 in the present embodiment may use a bare cell and a battery with an insulating layer, both of which are applicable. It will be understood by those skilled in the art that when a single cylindrical battery 1 with an insulating layer is employed, the insulating layer has a window 13 that exposes the side casing 12.

As shown in fig. 5, at least the side surfaces of the side surface cases 12 of the unit cylindrical batteries 1 are covered with an insulating layer having windows 13 exposing the side surface cases 12, and the side surface cases 12 of the unit cylindrical batteries 1 in the same row are electrically connected through the corresponding windows 13; the single cylindrical battery 1 has two windows 13 oppositely disposed at a position near the top pole 11, and/or each single cylindrical battery 1 has two windows 13 oppositely disposed at a position near the bottom.

Preferably, the bus bar 2 has two configurations, the extended bus portions 22 of the two configurations have different orientations, corresponding to the use of the bus bar 2 of the different configurations at both sides of the battery pack 100, respectively.

Example 3

A battery module was obtained by expanding the battery pack 100 of example 2 on the basis of the battery pack 100. Those skilled in the art will understand that the battery module is composed of more single cylindrical batteries 1, and the large capacity and large current output capability thereof can be applied to a power unit of a new energy vehicle.

According to fig. 12 to 14, the battery module of the present embodiment 3 includes a plurality of battery packs 100 of embodiment 2, the plurality of battery packs 100 being arranged in an array; the battery pack 100 can be laterally expanded in the arrangement direction of the battery rows thereof; the transfer bridge 3 between the laterally adjacent battery packs 100 has an electrical connection structure; the lateral shells 12 of the single cylindrical batteries 1 are electrically connected between the laterally adjacent battery rows through an electrical connection structure.

Preferably, there may be a difference in the electrical connection structure of the transfer bridge 3 at different positions of the battery module. The interposer 3 located between the two battery packs 100 is to perform customization of the side housings 12 and connect the side housings 12 of the battery rows on both sides, so the electrical connection structure of the interposer 3 at this position includes a first bridge including a first conductive contact portion 311 located on the first side 33, a second conductive contact portion 312 located on the first end surface 31, and a third conductive contact portion 313 located on the second side surface 34, and the first conductive contact portion 311, the second conductive contact portion 312, and the third conductive contact portion 313 are electrically connected in sequence.

Of course, the first bridge and the electrical connection structure that does not include the third conductive contact portion 313, i.e., the battery pack 100 is laterally extended, may be completed by the second bridge 39, i.e., the first bridge and the second bridge 39 exist at the same time.

Preferably, the adapting bridge 3 located at the periphery of the battery module has a second bridge 39 penetrating between the first side surface 33 and the second side surface 34 through a slot 35 opened on the adapting bridge 3; one end of the second bridge 39 is located on the side of the first side face 33 and is used for connecting with the side casing 12 of the single cylindrical battery 1, and the other end of the second bridge 39 is located on the side of the second side face 34 and is used for connecting with the other transfer bridge 3 or the side casing 12 of the other single cylindrical battery 1 or serving as a casing pole approach bridge.

Preferably, the battery pack 100 can be longitudinally expanded along the arrangement direction perpendicular to the battery rows, the different ends of the transfer bridges 3 on the adjacent battery rows of the adjacent battery pack 100 are arranged, and the minimum unit of expansion is a single-row battery row, so that the size adaptability of the battery module in one direction is strong, and the battery module can be expanded randomly according to requirements. In the lateral direction, the unit of expansion of the battery module is the width of one battery pack 100. As shown in fig. 13, the battery module is expanded from the battery pack 100 shown in fig. 1 to 4, which expands one battery pack 100 in the lateral direction and expands 2 times the number of battery rows in the longitudinal direction, resulting in a 16X12 array.

Preferably, in conjunction with fig. 14, this figure is an enlarged view of area a in fig. 13. The electrical connection structure of the crossover bridge 3 has a third electrical connection 53 with the side case 12 of the unit cylindrical cells 1 of the other battery pack 100. Preferably, the third electrical connector 53 is a bent conductor or a solid conductor, and is preferably electrically connected with a cold solder.

Preferably, according to fig. 13-14, two laterally adjacent busbars 2 are isolated from each other to avoid a short circuit.

Example 4

According to fig. 15 to 20, the present invention also provides a battery pack including a case 8, and any of the battery pack 100 solutions of embodiment 2 and any of the battery module solutions of embodiment 3 provided in the case 8. The preferable battery pack further comprises a cover plate, an insulating layer, a box cover, an external pole and an electric control assembly.

The housing 8 includes a bottom plate 82 and a side wall 81. The battery pack can be used as a power unit of a new energy vehicle. The housing 8 has a rectangular parallelepiped cavity structure with an opening at the upper part.

Preferably, the cover plate is pressed on the battery pack or the battery module, and an insulating layer is arranged in the middle of the cover plate.

The battery pack 100 or the battery module has a parallel structure between the battery rows arranged in the transverse direction, in which the side cases 12 of all the single cylindrical batteries 1 are electrically connected. The battery pack 100 or the battery module has a series structure between the battery rows arranged in the longitudinal direction.

All the single cylindrical batteries 1 are arranged in the same direction, specifically, the top pole is upward (in the direction of the opening of the case), and the bottom is arranged toward the case bottom plate 82. Such an arrangement is beneficial for optimizing the flow of the CTP grouping process.

Preferably, the battery pack further comprises a cover plate 6, the cover plate 6 is fixedly connected with the bus bar 2, and preferably, the bus bar 2 is directly or indirectly fixed on the cover plate. In another preferred embodiment, the bus bar 2 can also be directly or indirectly fixed to the bottom plate 82, corresponding to the embodiment in which the bus bar 2 is disposed at the bottom of the housing 8. As shown in fig. 18. Preferably, the cover plate 6 is opened with a plurality of through holes 61, the through holes 61 correspond to the abutting positions of the side cases 12 of the adjacent unit cylindrical batteries 1, preferably the through holes 61 correspond to the abutting edges of the upper ends of the side cases 12 of the adjacent unit cylindrical batteries 1, and/or the edges of the bus bars 2, so that the structural adhesive 43 is applied between the side cases 12 of the adjacent unit cylindrical batteries 1 after covering the cover plate 6, and the through holes 61 are also the entrance passages of the ultraviolet curing light beams, as shown in fig. 20. By utilizing the permeability of the structural adhesive 43, the structural adhesive 43 drops injected through the through hole 61 can fill the gap of the side shell 12 of the single cylindrical battery 1, even the gap between the main confluence part 21 and the top pole 11, and/or the gap between the main confluence part 21 and the cover plate 6, after the strong ultraviolet light beam is irradiated, the liquid structural adhesive 43 is firmly cured, and the battery pack achieves excellent structural strength.

Preferably, at least part of the through hole 61 is used for locking a structural strip protruding from the bottom plate.

Preferably, part or all of the area around the cover plate 6 is fixedly connected to the housing 8 to provide better structural strength.

It will of course be appreciated by those skilled in the art that the periphery of the cover plate 6 may not be connected or contacted with the housing at all for ease of maintenance and disassembly, and the cover plate 6 may be sized to cover only the area of the battery module within the housing.

In a preferred embodiment, a partial area around the cover plate 6 can be connected to the housing, e.g. by screwing, while a bar hole is reserved corresponding to the position of the PCBA, so as not to interfere with the assembly and maintenance of the peripheral circuitry.

As a preferred technical solution, the method further comprises: a heating plate 83 provided on the bottom plate 82; an adhesive layer, one side of which covers at least part of the heater plate 83 and the other side of which covers at least part of the bottom of all the cylindrical cells; according to fig. 20, a plurality of sensing strips 86, which are in contact with the bottom of the battery strip, are used for acquiring various parameters of the single cylindrical battery 1, such as temperature, pressure, electricity, vibration and other physical sensing parameters; the sensing layer is at least partially embedded in the adhesive layer. Preferably, the adhesive layer is polyurea. Preferably, the sensing layer includes a sensing soft row 86. In some preferred embodiments, the heating plate 83 may be omitted.

The first battery row is provided with an outer top pole and the last battery row is provided with an outer shell pole, and the first battery row and the last battery row are respectively provided with a pair of outer top poles and a pair of shell poles of the battery pack.

As a preferred technical solution, the method further comprises: at least one PCBA plate 84 disposed between the battery pack 100 and the side wall 81; the PCBA 84 is electrically connected to the buss bar 2 of the at least one battery bar, and/or the PCBA 84 is electrically connected to the at least one sensing strip 86.

Preferably, the plurality of PCBA boards 84 specifically include at least one equalizing board and one BMS board, which are respectively disposed between the battery pack 100 or the battery module and the side walls at both sides; the equalizing plate is electrically connected with the bus bar 2 of each battery row or at least one shell pole and is used for equalizing the capacity among the battery rows; the BMS board is electrically connected with the sensing layer and used for monitoring and/or managing charging and discharging of the battery pack or the battery module.

Preferably, the two long side walls 81 of the housing 8 correspond to a battery management PCBA board and a thermal management PCBA board, respectively, and the battery management PCBA board implements electrical management of the battery modules connected in series between rows, such as capacity balance management. The thermal management PCBA board is connected with the sensing flexible row 86, and pressure or temperature signals of the bottom of each row or each cylindrical battery are acquired, so that the thermal management function is realized.

Preferably, at least one insulating buffer layer 85 is further provided between the PCBA plate 84 and the side wall 81. Preferably, the insulating buffer layer 85 is used to compress the side wall 81 of the battery pack 100 and forms a side-bottom closed space with the bottom adhesive layer to cover the battery pack 100.

In a preferred embodiment, temperature controlled conduits are provided between adjacent battery rows within the battery pack. Circulating liquid is arranged in the temperature control pipeline and used for regulating and controlling the temperature of the adjacent single cylindrical batteries 1, and the occurrence of thermal runaway is prevented or the single cylindrical batteries 1 are heated.

In a preferred embodiment, the space between the single cylindrical batteries 1 of the battery pack 100 is partially or completely filled with silicone oil for uniform heat in the battery pack 100 by means of flow and heat transfer.

Example 5

The present embodiment provides a method of manufacturing the battery pack 100 of embodiment 2, including:

a plurality of single cylindrical batteries 1 are arranged in a row in the same direction;

electrically connecting the side cases 12 of the adjacent unit cylindrical batteries 1; electrically connecting the electrical connection structure of the transfer bridge 3 with the side case 12 of the end unit cylindrical battery 1; the electrical connection is preferably cold welded or laser welded (hot welded).

Applying structural adhesive 43 between the adjacent single cylindrical batteries 1 and between the transfer bridge 3 and the side shell 12 of the end single cylindrical battery 1, and curing the structural adhesive to obtain a battery row;

preparing a plurality of battery rows;

arranging a plurality of battery rows in a staggered manner, wherein different ends of the switching bridges 3 of adjacent battery rows are arranged;

applying and curing a structural glue 43 between adjacent battery rows;

arranging the bus bar 2 to electrically connect the main bus portion 21 of the bus bar 2 with the top poles 11 of the plurality of single cylindrical batteries 1 of the corresponding battery row; the extended bus bar portion 22 of the bus bar 2 is connected to the electrical connection structure of the relay bridge 3 of the other battery row.

Preferably, the step of arranging the plurality of unit cylindrical batteries 1 in the same direction includes, but is not limited to, arranging a transfer bridge in a row with the plurality of unit cylindrical batteries in the same direction, and arranging a first bridge, a first electrical connector and/or a second electrical connector in the middle of the transfer bridge at intervals as required, and providing cold-welding glue on the electrical connection area.

The present embodiment also provides another preferable manufacturing method of the battery pack 100, including:

a plurality of single cylindrical batteries 1 are arranged in a row in the same direction, and both ends of the row are pressurized;

the side surface housings 12 of the adjacent unit cylindrical batteries 1 are electrically connected;

applying structural adhesive between adjacent single cylindrical batteries 1, solidifying the structural adhesive, and removing pressure at two ends to obtain a battery row;

preparing a plurality of battery rows;

arranging a plurality of battery rows in a staggered manner;

pressurizing between the first row of battery rows and the last row of battery rows, applying structural adhesive between the adjacent battery rows and curing the structural adhesive;

each battery row is provided with a transfer bridge 3, different ends of the transfer bridges 3 of the adjacent battery rows are arranged, and the electric connection structure of the transfer bridge 3 is electrically connected with the side shell 12 of the single cylindrical battery 1 at the end part;

arranging the bus bar 2 to electrically connect the main bus portion 21 of the bus bar 2 with the top poles 11 of the plurality of single cylindrical batteries 1 of the corresponding battery row; the extended bus bar portion 22 of the bus bar 2 is electrically connected to the electrical connection structure of the relay bridge 3 of the other battery row.

The manufacturing method comprises the steps of firstly preparing a plurality of rows of battery arrays and then arranging the transfer bridge, and can achieve the effect of saving working procedures under specific conditions.

The present embodiment also provides another preferable method of manufacturing a battery pack, including:

arranging a plurality of single cylindrical batteries 1 in a row in the same direction, aligning top poles 11 of the single cylindrical batteries 1 on the same plane by adopting a leveling process, and pressurizing at two ends of the row;

arranging a busbar 2, preferably placed in a planar jig, electrically connecting the top poles 11 of a plurality of single cylindrical batteries 1 with the main bus 21 of the busbar, and electrically connecting the side casings 12 of adjacent single cylindrical batteries 1.

In the step, preferably, the method further comprises the steps of measuring the contact resistance between each battery top pole 11 and the busbar 2, referring to the internal resistance of each battery, jacking the battery upwards at the bottom of the single battery, adjusting the size of the contact resistance at the top of the battery, and adjusting to set data; after all the batteries are adjusted, the top pole 11 is not necessarily located on the same horizontal plane, but the difference value of the contact resistance and the internal resistance between the adjacent parallel branches falls within a set tolerance.

Preferably, under the pressure maintaining state, structural glue is applied and cured between the bus bar 2 and the battery top pole 11 and the single cylindrical battery 1, so as to form integral sealing and electrical connection between the battery bar and the bus bar 2.

preparing a plurality of battery rows;

arranging a plurality of battery rows in a staggered manner;

the extended bus bar portion 22 of the bus bar 2 is electrically connected to the electrical connection structure of the relay bridge 3 of the other battery row.

The manufacturing method can better ensure the consistency of the electrical connection between the top poles of the plurality of single cylindrical batteries 1 and the main bus part 21 of the bus bar 2, overcomes the problem of inconsistent contact height caused by the manufacturing tolerance of the batteries, and the bottoms of the single cylindrical batteries 1 are leveled by the adhesive layer after being prepared into the battery pack. The contact resistance of the cold welding glue before solidification is adjustable, and the adjusted contact resistance is fixed by the structural glue; the top terminal 11 and the bottom housing of all the cells in the row are not necessarily absolutely in the same horizontal plane, but the parallel branch resistance difference is minimized.

Preferably, in the step of arranging the plurality of battery rows in a staggered manner, the width of the transfer bridge 3 limits the distance between adjacent battery rows to a preset distance, and the side surface housings 12 of the single cylindrical batteries 1 between the adjacent battery rows are in a non-contact state.

Example 6

The present embodiment provides a method of manufacturing the battery pack of embodiment 4, including:

a plurality of single cylindrical batteries 1 and a transfer bridge 3 are arranged in a row in the same direction; the upper end of the adapter bridge is flush with the top pole of the cylindrical battery;

pressurizing two ends of the row to form a battery row with a set length, and electrically connecting the side shells 12 of the adjacent single cylindrical batteries 1; electrically connecting the electrical connection structure of the transfer bridge 3 with the side casing 12 of the end unit cylindrical battery 1;

applying and curing the structural adhesive 43 between the adjacent single cylindrical batteries 1 and between the transfer bridge 3 and the side shell 12 of the end single cylindrical battery 1, and removing pressure to obtain a battery row with standard length;

preparing a plurality of battery rows with standard lengths;

arranging a plurality of battery rows with standard lengths in a staggered manner, wherein different ends of the switching bridges 3 of adjacent battery rows are arranged; insulating sheets are arranged between adjacent battery rows;

arranging an adhesive layer on a bottom plate of the housing;

pressurizing between the first battery row and the last battery row, simultaneously putting a plurality of battery rows into the shell through a jig, and adhering the battery rows to the bottom plate;

Preferably, the step of arranging the bus bar 2 includes:

firstly, fixedly connecting a bus bar 2 to a cover plate 6, arranging structural adhesive 43 and/or cold welding adhesive on the bus bar 2 on the cover plate 6, and then pressing the cover plate 6 on the tops of a plurality of battery rows;

structural adhesive 43 is applied through hole 61 and ultraviolet radiation cures structural adhesive 43.

Further, the above manufacturing method further includes:

the bottom surface is additionally provided with a sensing layer, the two side ends are respectively additionally provided with a balance plate and a BMS plate which are respectively and electrically connected with each row of exposed shell pole columns and the sensing layer, the transverse pressurization is carried out, and the adjacent battery packs are connected in parallel; applying structural adhesive on two sides of the adjacent batteries, the transfer bridge and the batteries, curing, and removing pressure to obtain a plurality of parallel battery modules;

preparing a plurality of multi-parallel battery modules;

the box bottom plate is provided with an adhesive layer, the plurality of parallel battery modules which are longitudinally arranged are sequentially pressed into the shell 8, and the adjacent plurality of parallel battery modules are electrically connected in series through a third electric connector to obtain battery packs which are arranged in an array;

and applying cold welding glue on the electric connecting pieces on the bus bars, sequentially pressing the pre-prepared cover plates with the bus bars on the battery pack, and locking the through holes of the structural bars, which partially correspond to the box bottom plate, with the cover plates to obtain a plurality of parallel and multi-string battery packs.

Applying structural adhesive on the whole single surface of the through hole of the upper cover plate of the battery pack and curing, electrically connecting two external poles of the box body with external top poles and external shell poles of the battery pack respectively through an electric control assembly, sealing a gap between the side wall of the box body and the side wall of the battery pack, covering a box cover and locking the box cover.

Example 7

This example specifically describes the manufacturing flow and process of the battery pack 100 of example 2, the battery module of example 2, and the battery pack of example 4. It is understood that the battery pack 100 or the battery module may be referred to before the bus bar 2 of the top is not provided.

1. A plurality of single cylindrical batteries 1 are arranged in the same direction and in rows

The row of battery side shells 12 are connected in parallel and comprise a plurality of single

cylindrical batteries

1, 1 transfer bridge 3 and a plurality of first electric connectors 51, wherein the single cylindrical batteries 1 are bare batteries or batteries with insulating layers and windows 13. The inner side and the end part of the transfer bridge 3 are covered with a first bridge; cold welding glue is arranged on two sides of the first electric connector 51;

the batteries are arranged in rows and in the same direction, the switching bridge 3 is positioned at the leftmost side, and the inner side of the switching bridge 3 is opposite to the window 13 of the shell at the side face of the adjacent battery;

arranging the first end face 31 of the end conductor of the transfer bridge 3 and the upper end faces of all the batteries to be positioned on the same plane;

inserting first electrical connectors 51 at the windows 13 between the unit cylindrical batteries 1 and the transfer bridge 3;

pressurizing between the outer side of the adapter bridge 3 and the outer side of the battery at the tail end of the battery row, tightly squeezing the battery row to a set length, and keeping the pressure by using a jig;

structural adhesive 43 is respectively and integrally applied to the upper end and the lower end of each of the single cylindrical batteries 1 and the adapter bridge 3 at two sides of contact lines between the adjacent single cylindrical batteries 1 and between the single cylindrical batteries 1 and the adapter bridge 3;

integral light-cured structural adhesive 43; preferably, ultraviolet light is adopted for curing;

the side housings 12 between the rows of cells are connected in parallel and the side housings 12 are placed on top of the first end face 31 of the transfer bridge 3 by means of first electrical connections 51;

several rows of cells were prepared for use.

2. Preparation of end-row in-line batteries

The preparation process is the same as the step 1, and the difference is that the bridge is selected:

the electric bridges in the step 1 are all first electric connecting pieces 51, at least one of the electric bridges in the step 2 is a second electric connecting piece 52 with a bridge approach, and the first electric connecting piece 51 with the bridge approach is an electric bridge with an outer guide body section; the first electrical connection 51 with access bridge can be arranged between adjacent battery side housings 12 or between adjacent batteries and the transfer bridge 3.

3. Preparation of Battery pack 100

Preparing a plurality of battery rows;

stacking the battery rows in parallel with the end parts upward in a mode that the adjacent rows of battery transfer bridges 3 are staggered left and right;

arranging the positions of the battery rows to enable the end parts of the left side surface and the right side surface of the battery rows to be positioned on two parallel planes A and B to form a rectangular or rhombic battery array, wherein the end parts are positioned on the same plane; the end rows of cells are located at the exit (outermost) end of the cell array to the outer housing 12, and the second electrical connections 52 extend to the exterior of the cell array;

pressurizing at two ends of the planes A and B respectively, limiting the distance between adjacent rows of batteries to a set distance by the width of the transfer bridge 3, wherein the transfer bridge 3 and the side shell 12 of the longitudinally adjacent single cylindrical battery 1 are in a tightly squeezed state, the side shells of the adjacent batteries in the rows are in a non-contact state, and a jig is used for keeping pressure;

structural adhesives 43 are applied integrally and at once around the electrical connection position of the transfer bridge 3 and the adjacent cell side case 12, and on both sides of the near-point vertical line of the adjacent cell side case 12, and on the upper and lower end portions of the transfer bridge 3 and the cell, respectively;

the entire light-curing between the upper and lower end faces of the battery pack 100.

4. The battery packs 100 are connected in parallel to form a battery module

Parallel battery packs 100, with planes a and B being substantially the same length; the corresponding battery rows of the adjacent battery packs 100 are substantially arranged in a straight line, all the battery rows are arranged upwards in the same direction, and the adapter bridges 3 of the adjacent battery rows are arranged at intervals on different sides;

a third electric connector 53 is arranged between the first bridge (the position of the third contact conductive part 313) of the adjacent transfer bridge 3 and the side shell 12 of the single cylindrical battery 1 and is electrically connected with cold welding;

structural adhesive 43 is applied between the second side 34 of the adjacent transfer bridge 3 and the side shell 12 of the single cylindrical battery 1;

the structural adhesive 43 is integrally photocured, and the parallel battery packs 100 are prepared into battery modules which are fixedly connected into an integral structure.

5. Arrange lateral fixing sheet and seal in integral structure

The two side fixing pieces may be PCBA plates 84, such as BMS slave plates and balance plates; one side of the PCBA board 84 is an insulated inner light measuring board without exposed electrical contacts, and the other side is provided with the outer sides of components; the length of the PCBA plate 84 is comparable to the length of the cell array planes a and B.

The inner sides of the PCBA boards 84 are respectively pressed on the two sides of the battery, at least partially cover the outer sides of the transfer bridge 3, and the two sides are pressed;

structural adhesive 43 is integrally and once applied to the inner side of the PCBA board 84, the two sides of the contact point of the adapter bridge 3 and the battery and the upper end and the lower end of the PCBA board 84;

the whole ultraviolet light exposure between the upper end face and the lower end face of the battery module is carried out, and the structural adhesive 43 is solidified.

6. Arranging a cell bottom sensor strip

Respectively arranging strip-shaped narrow-side sensing strip soft rows at the bottoms of the row-shaped batteries, wherein the starting end of each soft row is positioned at the bottom of one battery at one end of the battery row, the tail end of each soft row is positioned at the end surface at the other side of the battery array and is turned upwards, all the soft rows are turned over towards the same side of the battery array, and a sensor on each sensing strip is positioned at the bottom of one battery;

the bottom sensor strip of all cylindrical battery cells 1 in the module is placed and is accomplished, and sensor strip and battery array bottom and lateral part are carried out preliminary fixed.

7. Is put into the shell

The bottom of the shell 8 is sprayed with adhesive, preferably polyurea;

quickly putting the battery module into the battery module, and curing the binder;

in the gap between the periphery of the inside of the shell 8 and the battery module, the jacking mechanism in the shell extends out or is filled with foaming glue, so that the battery module is pressed around, and the original side direction is pressed for withdrawing.

8. Arranging busbars

Put into busbar 2 simultaneously according to setting for at the battery module top, busbar 2 of first battery row chooses for use the busbar 2 of taking the approach bridge, and the approach bridge can set for the approach bridge quantity according to the demand, stretches to battery array's outside.

The electrical connection of the top terminal 11 of the single cylindrical battery 1 of the corresponding battery row to the bus bar 2 and the electrical connection of the conductor at the upper end of the transfer bridge 3 to the bus bar 2 are rapidly achieved by means of thermal welding. The intra-row parallel connection and the inter-row series connection of all the unit cylindrical batteries 1 are completed.

9. External electric connection pole

The approach bridge on the bus bar 2 at the top of the primary battery bar is a leading-out end of a top pole of the battery array;

the second electrical connector 52 of the last row of cells is the housing terminal post lead-out of the cell array.

Further, as a preferable aspect, the step 8 may be replaced with the following steps:

fixedly connecting the bus bar 2 to the cover plate 6, arranging structural adhesive 43 and/or cold welding adhesive on the bus bar 2 on the cover plate 6, then pressing the cover plate 6 on the tops of the plurality of battery rows, and completing the in-row parallel connection and the inter-row serial connection of all the single cylindrical batteries 1 in a cold welding mode;

the bus bar 2 of the first battery bar is the bus bar 2 with the approach bridges, and the approach bridges can set the number of the approach bridges according to requirements and extend to the outside of the battery array;

the structural adhesive 43 is applied through the through hole 61 in the cover plate 6 and the structural adhesive 43 is cured by ultraviolet irradiation.

In the manufacturing method of embodiments 5 to 7, the bus bar 2 can be welded or cold-welded to the top terminal 11 and the first bridge of the adapting bridge 3 at one time, so that the top terminal of one battery row can be connected to the housing terminal of the adjacent battery row without turning the direction of the battery row, and the purpose of connecting two battery rows in series is achieved. No matter how many rows of single cylindrical batteries 1 are arranged in the battery pack, all the busbars 2 can be connected in one technological process, and after the busbars are connected, the parallel connection in the rows and the serial connection between the rows of the single cylindrical batteries 1 can be realized, so that the quick grouping in the box is realized. Meanwhile, due to the fact that the transfer bridge 3 is filled among three battery rows at intervals, after the structural adhesive 43 is loaded, a method of integrally and quickly solidifying the structural adhesive 43 after the rows in the box are integrally compressed can be adopted, or a method of firstly fixedly sealing the box and then quickly rotating the box into the battery box is adopted, so that the strength of the whole module is very high, automatic operation is facilitated, and the development direction of CTP from the battery directly to the battery pack is met.

While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.

Claims

1. An electric connection switching structure is characterized by comprising at least one switching bridge and at least one bus bar;

2. The electrical connection transition structure of claim 1, wherein the body portion comprises an electrical conductor and the electrical connection structure is a partial region of the electrical conductor.

3. The electrical connection transition structure of claim 2, wherein at least a portion of an outer surface of the electrical conductor is covered with an insulating material.

4. The electrical connection transition structure of claim 1, wherein the body portion comprises an insulator, and the electrical connection structure comprises a first bridge made of a conductor, the first bridge being attached to at least the first side surface and the first end surface.

5. The electrical connection relay structure according to claim 1, wherein the second side surface has a third conductive contact portion electrically connected to the first conductive contact portion and/or the second conductive contact portion.

6. The electrical connection transition structure of claim 1, wherein at least one slot extends between the first side and the second side; one end of the second electric bridge is positioned on one side of the first side surface and used for being connected with the side surface shell of the single cylindrical battery, and the other end of the second electric bridge is positioned on one side of the second side surface and used for being connected with other electric connection switching structures or the side surface shells of other single cylindrical batteries or used as a shell pole leading-out end.

7. The electrical connection transition structure of claim 6, wherein the second side surface has at least one recessed portion; and at least one bent part of the second electric bridge positioned on one side of the second side surface and penetrating out of the slot hole is arranged in the groove part.

8. The electrical connection transition structure according to any one of claims 1 to 7, wherein the busbar further comprises a shunt extension busbar extending laterally from a middle portion of the main busbar, a bent section of the shunt extension busbar is bent to a side housing attached to the single cylindrical battery, and an insulating layer is disposed between the side housing and the bent section.

9. The electrical connection transition structure according to any one of claims 1 to 7, wherein the electrical connection structure comprises a fuse.

10. The electrical connection transition structure of any one of claims 1 to 7, wherein the busbar is substantially L-shaped.

11. The electrical connection transition structure of any one of claims 1 to 7, wherein the main bus of the busbar has a plurality of protruding busbar electrical connections.

12. A battery pack, comprising:

at least one end of each battery row is provided with a transfer bridge; the transfer bridge comprises a body part and an electric connection structure; the body part is approximately strip-shaped and is provided with a first end surface positioned at the strip-shaped end part, a first side surface positioned at the strip-shaped side part and a second side surface opposite to the first side surface; the electric connection structure comprises a first contact conductive part positioned on the first side surface and a second contact conductive part positioned on the first end surface; the first contact conductive part can be electrically connected with at least part of the side surface shell of the adjacent single cylindrical battery; the first contact conductive part is electrically connected with the second contact conductive part;

13. The battery pack of claim 12, wherein all of said single cylindrical cells of each of said battery rows are in a parallel configuration, and a plurality of said battery rows are in a series configuration.

14. The battery of claim 12, wherein there is a first electrical connection between the side housings of the individual cylindrical cells in each said row.

15. The battery pack according to claim 12, wherein at least one second electrical connector is disposed between the side casings of the single cylindrical batteries of at least one battery row, one end of the second electrical connector is sandwiched between the side casings of two adjacent single cylindrical batteries, and the other end of the second electrical connector is a pair of outer casing poles of the battery pack.

16. The battery according to claim 12, wherein the extended bus portion of a bus bar of at least one battery bar that is not capable of corresponding to the second electrically conductive contact portion of the transfer bridge is capable of acting as an external top pole of the battery.

17. The battery pack of claim 12, wherein one of the transfer bridges is disposed at one end of each of the battery rows and the transfer bridges of adjacent battery rows are disposed at different ends.

18. The battery pack of claim 17, wherein the second side of the crossover bridge is substantially coplanar with the outermost side of the side housing of the single cylindrical cell on the same side.

19. The battery according to any of claims 12-18, wherein there is cold-welded glue between the main bus and the top pole, and/or between the side housings of the individual cylindrical cells in the row, and/or between the extended bus and the second contact conductive part, and/or between the first contact conductive part and the side housings of the individual cylindrical cells.

20. The battery pack according to any one of claims 12 to 18, wherein at least one structural adhesive is provided between the side casings of adjacent single cylindrical batteries and/or between the transfer bridge and the side casing of the adjacent cylindrical battery.

21. The battery pack according to any one of claims 12 to 18, further comprising a fastening band sleeved outside the bottoms or necks of the single cylindrical cells of the main bus bar and the corresponding cell row for improving and maintaining a pressing force between the main bus bar and the top pole; the fastening belt is fixedly connected with the upper part of the single cylindrical battery and used for shortening the telescopic amount of the fastening belt positioned on the upper part.

22. Battery according to any of claims 12-18, characterized in that the said transfer bridge is provided with structural glue between the side casing of the single cylindrical cell and the first electrically conductive contact part, and/or between the said main bus bar and the upper part of the single cylindrical cell, and/or between the extended bus bar and the said first end face, and/or between the second electrical contact part and the said first end face.

23. The battery according to any one of claims 12-18, wherein the side casing of adjacent single cylindrical cells of adjacent battery rows have a void and/or have an insulating material between them.

24. A method of manufacturing a battery pack according to any one of claims 12 to 23, comprising:

a plurality of single cylindrical batteries and a transfer bridge are arranged in a row in the same direction, and both ends of the row are pressurized;

the side shells of the adjacent single cylindrical batteries are electrically connected, and the electric connection structure of the transfer bridge is electrically connected with the side shells of the single cylindrical batteries at the end parts;

applying structural adhesive between adjacent single cylindrical batteries and between the transfer bridge and the side shell of the single cylindrical battery at the end part, solidifying the structural adhesive, and removing the pressure at the two ends to obtain a battery row;

preparing a plurality of battery rows;

arranging a busbar, and electrically connecting a main bus part of the busbar with top poles of a plurality of single cylindrical batteries of a corresponding battery row; electrically connecting the extended bus bar portion of the bus bar with the electrical connection structure of the transfer bridge of the other battery bar.

25. A method of manufacturing a battery pack according to any one of claims 12 to 23, comprising:

a plurality of single cylindrical cells are arranged in a row in the same direction, and both ends of the row are pressurized;

the side surface shells of the adjacent single cylindrical batteries are electrically connected;

applying structural adhesive between adjacent single cylindrical batteries, solidifying the structural adhesive, and removing pressure at two ends to obtain a battery row;

preparing a plurality of battery rows;

staggering the plurality of battery rows;

each battery row is provided with a transfer bridge, different ends of the transfer bridges of the adjacent battery rows are arranged, and the electric connection structure of the transfer bridge is electrically connected with the side shell of the single cylindrical battery at the end part;

26. A method of manufacturing a battery pack according to any one of claims 12 to 23, comprising:

arranging a plurality of single cylindrical batteries in a row in the same direction, aligning top poles of the plurality of single cylindrical batteries to the same plane, and pressurizing at two ends of the row;

arranging a bus bar, electrically connecting top poles of a plurality of single cylindrical batteries with a main bus part of the bus bar, and electrically connecting side surface shells of adjacent single cylindrical batteries;

preparing a plurality of battery rows;

staggering the plurality of battery rows;

electrically connecting the extended bus bar portion of the bus bar with the electrical connection structure of the transfer bridge of the other battery bar.

27. The method of claim 26, wherein in the step of staggering the plurality of battery rows, the width of the transfer bridge limits the distance between adjacent battery rows to a predetermined distance, and the lateral housings of the single cylindrical batteries between adjacent battery rows are not electrically connected.

28. A battery module comprising a plurality of battery packs according to any one of claims 12 to 23 arranged in an array; the battery pack can be laterally expanded along the arrangement direction of the battery rows of the battery pack;

29. The battery module according to claim 28, wherein the electrical connection structure comprises a first bridge, the first bridge comprises a first conductive contact portion located on the first side surface, a second conductive contact portion located on the first end surface, and a third conductive contact portion located on the second side surface, and the first conductive contact portion, the second conductive contact portion, and the third conductive contact portion are electrically connected in this order.

30. The battery module as recited in claim 28, wherein the adapter bridge is disposed at the periphery of the battery module and has a second bridge passing through the slot defined in the adapter bridge between the first side and the second side; one end of the second electric bridge is positioned on one side of the first side face and used for being connected with a side face shell of the single cylindrical battery, and the other end of the second electric bridge is positioned on one side of the second side face and used for being connected with other transfer bridges or side face shells of other single cylindrical batteries or used as a shell pole approach bridge.

31. The battery module as recited in claim 28, wherein the battery pack is longitudinally expandable in a direction perpendicular to the arrangement direction of the battery rows, and the different ends of the transfer bridges on adjacent battery rows of adjacent battery packs are disposed.

32. The battery module of claim 28, wherein the electrical connection structure of the transfer bridge has a third electrical connection with the side housings of the single cylindrical cells of the other battery pack.

33. The battery module according to claim 28, wherein two bus bars that are laterally adjacent are isolated from each other.

34. A battery pack comprising a case, and a battery pack according to any one of claims 12 to 23 or a battery module according to any one of claims 28 to 33 provided in the case; the housing includes a bottom plate and a sidewall.

35. The battery pack of claim 34, further comprising a cover plate, wherein the bus bar is directly or indirectly fixed to the cover plate or the base plate.

36. The battery pack of claim 35, wherein the cover plate defines a plurality of through holes corresponding to adjacent edges of the upper ends of the side housings of adjacent unit cylindrical batteries and/or edges of the bus bars.

37. The battery pack of any one of claims 34-36, further comprising:

one side of the adhesive layer at least partially covers the bottom plate, and the other side of the adhesive layer covers at least part of the bottom of all the cylindrical batteries;

and the sensing layer is contacted with the bottom of the battery row and used for acquiring somatosensory parameters of the single cylindrical battery.

38. The battery pack of claim 37, further comprising: at least one equalizing plate and one BMS plate, which are respectively arranged between the battery pack or the battery module and the side walls at two sides; the equalizing plate is electrically connected with the bus bar or the shell pole of each battery row and is used for equalizing the capacity among the battery rows; the BMS board is electrically connected with the sensing layer and used for monitoring and/or managing charging and discharging of the battery row or the battery pack or the battery module.

39. A method of manufacturing a battery pack according to any one of claims 34-38, comprising:

the plurality of single cylindrical batteries and the transfer bridge are arranged in rows in the same direction, and the upper end part of the transfer bridge is flush with the top pole of each cylindrical battery;

pressurizing two ends of the row to form a battery row with a set length, and electrically connecting the side shells of the adjacent single cylindrical batteries and the electrical connection structure of the transfer bridge with the side shells of the single cylindrical batteries at the end part;

applying structural adhesive between adjacent single cylindrical batteries and between the transfer bridge and the side shell of the end single cylindrical battery, solidifying the structural adhesive, and removing pressure to obtain a battery row with standard length;

preparing a plurality of battery rows with standard lengths;

arranging the battery rows with the standard lengths in a staggered mode, arranging different ends of the switching bridges of the adjacent battery rows, and arranging insulating sheets between the adjacent battery rows;

disposing an adhesive layer on a bottom plate of the housing;

40. The manufacturing method according to claim 39, wherein the step of arranging a bus bar includes:

firstly, fixedly connecting the bus bars to a cover plate, arranging structural adhesive and/or cold welding adhesive on the bus bars on the cover plate, and then pressing the cover plate on the tops of a plurality of battery bars;

structural adhesive is applied through the through holes in the cover plate, and the structural adhesive is cured by ultraviolet irradiation.