CN113889714A

CN113889714A - Bus bar structure, series-parallel connection module, battery pack, battery system and method

Info

Publication number: CN113889714A
Application number: CN202110738652.5A
Authority: CN
Inventors: 刘献华; 郭伟华; 林桐华; 邬亨英; 王斌斌; 刘丽荣
Original assignee: Farasis Energy Ganzhou Co Ltd
Current assignee: Farasis Energy Ganzhou Co Ltd
Priority date: 2020-07-01
Filing date: 2021-06-30
Publication date: 2022-01-04
Anticipated expiration: 2041-06-30
Also published as: CN113889714B; CN111952523A

Abstract

The invention provides a busbar structure, a series-parallel module, a battery pack, a battery system and a method, wherein the busbar structure is used for being connected with the lugs of a plurality of battery cells in the battery module, the battery cells are stacked along a first direction to form a battery core group, the busbar structure comprises a plurality of connecting sheets which are arranged at intervals along the first direction and can be separated, the connecting sheets are used for being electrically contacted with the lugs of the battery cells, and one ends of the connecting sheets, which are far away from the battery cells, are provided with extending parts; and the extension parts on the connecting sheets extend from the connecting sheets to the direction of converging each other so as to realize the electric conduction of the extension parts on the connecting sheets. According to the technical scheme of the bus bar structure, the series-parallel module, the battery pack, the battery system and the method, the electrical connection of a plurality of battery cells stacked on the chassis can be directly realized.

Description

Bus bar structure, series-parallel connection module, battery pack, battery system and method

Cross Reference to Related Applications

The application requires that the application number of the Chinese patent office filed on 1/7/2020 is as follows

202010632618.5 priority of the chinese patent application entitled "a battery pack", the entire contents of which are incorporated by reference in this application.

Technical Field

The invention relates to the field of batteries, in particular to a bus bar structure, a series-parallel connection module, a battery pack and a manufacturing method thereof, and a battery system and a manufacturing method thereof.

Background

The cost of the power battery accounts for 40% of the cost of the whole vehicle, even more, and reducing the cost of the power battery is one of the important tasks of battery suppliers and host factories. The existing battery pack structure is generally composed of a three-level structure of 'battery core-module-whole pack', wherein the module is composed of a plurality of parts such as a battery core combination, an electric component combination and a module shell combination, and other electric control elements such as a battery management system and the like and a battery protection box body are installed after the module is manufactured.

Disclosure of Invention

The invention aims to at least solve one of the technical problems in the prior art, and provides a bus bar structure, a series-parallel module, a battery pack, a battery system and a method, which can realize the electrical connection of a plurality of battery cells directly stacked on a chassis.

The bus bar structure comprises a plurality of connecting sheets which are arranged at intervals along the first direction and can be separated, the connecting sheets are used for being electrically contacted with the lugs of the battery cells, and one end of each connecting sheet, which is far away from the battery cells, is provided with an extending part; and the number of the first and second electrodes,

the extending parts on the connecting sheets extend from the connecting sheets to the direction in which the extending parts converge with each other, so that the extending parts on the connecting sheets are electrically conducted.

Optionally, at least one of the first connecting piece, the second connecting piece and the third connecting piece with three different structures is arranged in the plurality of connecting pieces, wherein,

the first connecting plates are used for being electrically contacted with a positive electrode lug or a negative electrode lug of the battery cells in one group of the battery core groups, and a plurality of the first connecting plates which are mutually and electrically communicated form a group of parallel groups;

the second connecting sheet is used for electrically contacting with the positive electrode tabs of the cells in two adjacent groups of the cell cores, and the negative electrode tabs of the cells in the other group of the cell cores are correspondingly electrically contacted with the positive electrode tabs of the cells in the two adjacent groups of the cell cores;

a plurality of the third connecting pieces electrically conducted with each other are used for correspondingly electrically contacting the extending portions on all the first connecting pieces in a plurality of sets of the parallel sets.

Optionally, the extending portions of the connecting pieces converge in the same plane perpendicular to the first direction, and orthographic projections on the plane do not overlap.

Optionally, the extensions on a plurality of the connection pieces converge in at least two planes perpendicular to the first direction, and the extension on each connection piece is in electrical contact with at least one of the extensions on the other connection pieces.

Optionally, in the first direction, the extension portions on the connecting sheet at the outermost layer and the extension portions on the other connecting sheets are overlapped with each other, and the extension portions on the other connecting sheets are all located in the same plane and do not overlap in orthographic projection on the plane.

As another technical solution, the present invention further provides a series-parallel module, which includes a busbar structure and a supporting structure for supporting the busbar structure, wherein the busbar structure adopts the busbar structure provided by the present invention.

Optionally, the positive electrode tab and the negative electrode tab of each battery cell are respectively located at two sides of the battery cell;

the battery module comprises a plurality of groups of electric core groups, and the plurality of groups of electric core groups are arranged in an array in a second direction and a third direction in an installation plane vertical to the first direction; the directions of the positive electrode lug and the negative electrode lug of the battery cell are parallel to the third direction;

in the third direction, the electrode lugs of the electric cores in any two adjacent groups of the electric core groups are correspondingly electrically contacted;

the busbar structure includes two sets of connection group, and two sets of the connection group is located the multiunit respectively the electric core group is in the both sides in the third direction, every group the connection group includes a plurality ofly the connection piece.

Optionally, the support structure comprises a first support group and a second support group, each comprising a plurality of supports stacked in the first direction, wherein,

the first support groups are two groups and are respectively arranged between each group of the connection groups and one row of the electric core groups adjacent to the connection groups, and each support piece in the first support group is used for correspondingly supporting all the connection pieces on the same layer and the electric contact areas of the lugs corresponding to the connection pieces;

the second support group is at least one group, the second support group is arranged between two rows of the battery core groups which are arranged in the second direction and are adjacent to each other, and each support piece in the second support group is used for correspondingly supporting all the battery cell tabs on the same layer and the electric contact areas of the battery cell tabs corresponding to the battery cell tabs.

Optionally, the positive electrode tab and the negative electrode tab of each battery cell are located on one side of the battery cell;

the battery module comprises a plurality of groups of battery core groups, the groups of battery core groups are arranged in a row in a second direction in an installation plane perpendicular to the first direction, and the lugs of all the battery cores are positioned on the same side in a third direction in the installation plane;

the busbar structure includes the connection group, and is located the multiunit the electric core group the electric core utmost point ear place one side, the connection group includes a plurality ofly the connection piece.

Optionally, the battery module includes a plurality of cell units arranged in the third direction, and each cell unit includes the same row of the cell groups in the second direction;

the connecting sets are multiple sets, each set of connecting sets is correspondingly arranged on one side of the electrode lugs of the battery core set in each battery cell unit, and each set of connecting sets comprises a plurality of connecting sheets.

Optionally, the support structure is disposed between the connection group and the cell group in the cell unit, and includes a plurality of support members stacked along the first direction, each support member being configured to correspondingly support all the connection pieces of the same layer and the electrical contact area of the tab corresponding thereto.

Optionally, a plurality of supporting recesses arranged along the second direction are provided on the supporting member, and the supporting recesses are used for supporting at least one connecting piece and an electrical contact area of a cell tab corresponding to the connecting piece; and the number of the first and second electrodes,

the supporting piece is provided with at least one positioning structure, the positioning structure comprises a positioning concave part and a positioning convex part which are respectively arranged on two surfaces of the supporting piece, which are mutually deviated in the first direction, and in any two adjacent supporting pieces in the first direction, the positioning convex part on one supporting piece is matched with the positioning concave part on the other supporting piece.

Optionally, the support includes a plurality of sub-supports spaced apart in the second direction, and each sub-support is provided with at least one supporting recess and/or at least one positioning structure.

Optionally, the series-parallel module further includes a bus bar support, and the connection group and the support structure are integrated on the bus bar support;

the busbar support includes a plurality of sub-supports that the interval set up in the second direction, every it is integrated with at least one on the sub-support piece, every the sub-support with be provided with the stair structure on the surface that the connector group is relative, the step face of stair structure be used for with the connection piece with the extension with the laminating of the surface that the step face is relative.

the bus bar support is provided with a step structure on the surface opposite to the connecting group, and the step surface of the step structure is attached to the connecting sheet and the surface of the extending part opposite to the step surface.

Optionally, the support structure includes a busbar support, and the connection group is integrated on the busbar support;

the bus bar support is characterized in that a step structure is arranged on the surface, opposite to the connecting group, of the bus bar support, and the step surface of the step structure is attached to the connecting sheet and the surface, opposite to the step surface, of the extending portion.

Optionally, the bus bar support is provided with two conductive connecting members, which are respectively used as a total positive connecting terminal and a total negative connecting terminal, and each conductive connecting member is electrically connected to the corresponding extension portion in the connecting group.

As another technical solution, the invention further provides a battery pack, which includes a chassis structure, and a battery module and a series-parallel module mounted on the chassis structure, wherein the battery module includes a battery core group formed by stacking a plurality of battery cells; the series-parallel module provided by the invention is adopted to realize the electrical connection of a plurality of battery cells.

Optionally, the series-parallel module adopts the series-parallel module provided by the invention;

the chassis structure comprises a chassis and a cover body, wherein the chassis is of a flat plate structure and is provided with a mounting plane; the cover body comprises a top disc, a frame is arranged on the periphery of the surface, opposite to the mounting plane, of the top disc, and the frame, the top disc and the base disc are located on the inner side of the frame to form a mounting space for containing the electric core group.

the base plate is also provided with a plurality of temperature control plates which are arranged at intervals along the second direction, and the interval between any two adjacent temperature control plates is used for accommodating a row of the electric core groups which are arranged along the third direction.

a plurality of partition plates which are arranged at intervals along the second direction are arranged on the mounting plane of the chassis, and the interval between any two adjacent partition plates is used for accommodating a group of the electric core groups; at least one of the plurality of spacers serves as a thermal control plate.

Optionally, one or a plurality of side beams parallel to each other are further arranged on the mounting plane of the chassis, the arrangement directions of the side beams and the partition plates are parallel to each other, and an interval between at least one side beam and any two adjacent partition plates is used for accommodating a group of the electric core groups;

at least one of the plurality of bulkheads and at least one of the side beams functions as a thermal control plate.

As another technical solution, the present invention further provides a battery system, which includes a battery pack and a battery management module for regulating and controlling the battery pack, wherein the battery pack is the battery pack provided by the present invention.

As another technical solution, the present invention further provides a method for manufacturing a battery pack, which is applied to the battery pack provided by the present invention; the manufacturing method comprises the following steps:

s1, installing a connecting sheet layer in the busbar structure on the busbar support, wherein the connecting sheet layer comprises at least one connecting sheet arranged on the same layer;

s2, mounting a layer of the electric core layer on a mounting plane, perpendicular to the first direction, of the chassis structure, wherein the electric core layer comprises at least one electric core arranged on the same layer, and tabs of the electric cores in the electric core layer are in electrical contact with the connecting sheets in the connecting sheet layer corresponding to the same layer;

s3, installing a tooling jig, wherein the tooling jig is used for supporting the connecting sheet in the current layer of connecting sheet layer and the electric contact area of the tab corresponding to the connecting sheet;

s4, performing a connection process on the tab of the battery cell in the current layer of the battery core layer and the connecting sheet corresponding to the tab in the electric contact area;

s5, disassembling the tool jig;

circularly executing the steps S1 to S5 until the installation of all the cells in the cell group is completed;

wherein, after the step S2 is adopted to complete the installation of the first layer of the core layer, the step S3 is skipped to directly perform the step S4, and after the step S4 is completed, the step S5 is skipped to directly return to the step S1 to install the next layer of the connector layer

As another technical solution, the present invention further provides a method for manufacturing a battery pack, which is applied to the battery pack provided by the present invention; the series-parallel module adopts the series-parallel module provided by the invention;

the manufacturing method comprises the following steps:

s11, installing a connecting sheet layer in the busbar structure on the busbar support, wherein the connecting sheet layer comprises at least one connecting sheet arranged on the same layer;

s12, mounting a layer of electric core layer on a mounting plane, perpendicular to the first direction, of the chassis structure, wherein the electric core layer comprises at least one electric core arranged on the same layer, and tabs of the electric core in the electric core layer are in electrical contact with the connecting sheets in the connecting sheet layer corresponding to the same layer;

s13, carrying out a connection process on the tab of the battery cell in the current layer of the battery core layer and the corresponding connecting sheet in the electric contact area of the tab and the corresponding connecting sheet;

s14, mounting the supporting piece for supporting the corresponding electric contact area of the next layer above the electric contact area of the tab and the corresponding connecting piece of the battery cell in the current layer of the battery core layer;

and circularly executing the steps S11 to S14 until the installation of all the cells in the cell group is completed.

As another technical solution, the present invention further provides a method for manufacturing a battery system, which is applied to the manufacturing of the battery system provided by the present invention; the manufacturing method comprises the manufacturing method of the battery pack provided by the invention.

The invention has the following beneficial effects:

the technical scheme includes that the busbar structure comprises a plurality of connecting sheets which are arranged at intervals along a first direction, the connecting sheets are used for being in electrical contact with tabs of a battery cell, and an extending part is arranged at one end, far away from the battery cell, of each connecting sheet; and the extension parts on the connecting sheets extend from the connecting sheets to the direction of mutual convergence to realize the electric conduction of the extension parts on the connecting sheets, and because the connecting sheets are separable, in the process of mounting a plurality of battery cells on the chassis layer by layer, one connecting sheet on the same layer can be mounted at the position in electrical contact with the corresponding battery cell lug, so that the connecting process can be carried out on the battery cells and the connecting sheets, namely, the battery cells and the connecting sheets can be alternately mounted, therefore, the bus bar structure provided by the invention can realize the electric connection of a plurality of battery cells directly stacked on the chassis, and further can realize the direct assembly of the battery cells into a battery pack.

The technical scheme of the bus bar structure, the serial-parallel module, the battery pack, the battery system and the method provided by the invention has the following advantages:

1. the material cost is reduced, the electric core group and the bus bar structure are integrated on the chassis, and a plurality of parts can be integrated on one part, so that the production and manufacturing cost and the material cost of the parts are effectively reduced;

2. the management cost is reduced, the integration degree of each part is greatly improved, the types and the number of the parts are greatly reduced, and the expenses for managing materials by departments of research and development, quality, storage, production and the like are effectively reduced;

3. the process is simplified, the production and manufacturing cost of the battery system is reduced, a series of processes such as module assembly and the like are subtracted from the group edge connection of the battery cell on the chassis, the assembly and connection process among the parts is simplified and the processes are reduced due to the integration promotion of the parts, and the process production and manufacturing cost is directly reduced;

4. the automatic assembling device is suitable for a full-automatic production mode, improves the production efficiency, is directly stacked on a chassis from a lug of a battery core to the battery core, is connected with a busbar structure, is assembled from a shell, and even is filled with heat-conducting glue and pouring sealant, the whole process does not need manual participation, and the whole process can meet the design requirement by the operation of a manipulator;

5. the space utilization rate of a production workshop is improved, the battery cores with the cut lugs are directly stacked on the chassis, and various subsequent processes are all operated on the chassis, so that the requirement on the production process circulation field is reduced, and the space utilization rate of the production workshop is greatly improved;

6. the battery cell is arranged more flexibly, can be fully utilized in the face of narrow space or irregular space, and is arranged on the chassis by taking the battery cell as a small unit, so that the arrangement mode is flexible and various, the internal space utilization rate of the battery system is effectively improved, and the battery system can be well adapted to the conditions that the installation position of the whole vehicle end space is narrow and small.

Drawings

Fig. 1 is a configuration view of an electric core pack according to a first embodiment of the present invention;

FIG. 2A is a block diagram of a parallel group used in the first embodiment of the present invention;

FIG. 2B is an exploded view of a parallel group according to the first embodiment of the present invention;

FIG. 3A is a structural view of a plurality of second connecting pieces employed in the first embodiment of the present invention;

FIG. 3B is an exploded view of a plurality of second connecting pieces used in the first embodiment of the present invention;

FIG. 4 is a structural view of a plurality of third connecting pieces employed in the first embodiment of the present invention;

FIG. 5 is a connection diagram of the bus bar structure and the electric core set according to the first embodiment of the present invention;

fig. 6A is a structural diagram of a support structure of a series-parallel module according to a second embodiment of the present invention;

FIG. 6B is an enlarged view of area I of FIG. 6A;

FIG. 7A is a structural view of a bus bar support employed in a second embodiment of the present invention;

FIG. 7B is an enlarged view of area II of FIG. 7A;

FIG. 8A is a structural view of a bus bar support employed in a third embodiment of the present invention;

FIG. 8B is a block diagram of a single submount for use with a third embodiment of the invention;

FIG. 9 is an exploded view of a bus bar support and bus bar structure according to a fourth embodiment of the present invention;

FIG. 10 is a view showing the arrangement structure of the electric core pack according to the fifth embodiment of the present invention;

fig. 11 is a configuration view of a bus bar structure employed in a fifth embodiment of the present invention;

FIG. 12A is a view showing the arrangement of a support structure according to a fifth embodiment of the present invention;

FIG. 12B is an enlarged view of the area III in FIG. 12A;

fig. 13A is a view showing an arrangement structure of a bus bar holder according to a fifth embodiment of the present invention;

FIG. 13B is a view showing a structure of a bus bar support integrated with a second connecting piece according to a fifth embodiment of the present invention;

FIG. 13C is a structural view of a bus bar support integrated with another second connecting piece used in the fifth embodiment of the present invention;

FIG. 13D is a view showing a structure of a bus bar support integrated with still another second connecting piece, which is used in the fifth embodiment of the present invention;

FIG. 13E is a view showing the construction of a bus bar support having three second connecting pieces used in the fifth embodiment of the present invention;

fig. 14 is a diagram illustrating an arrangement structure of battery cell units according to a fifth embodiment of the present invention;

fig. 15 is an exploded structural view of a battery pack according to a sixth embodiment of the present invention;

fig. 16 is a structural view of a chassis structure employed in a sixth embodiment of the present invention;

fig. 17 is a structural view of a chassis structure employed in a seventh embodiment of the present invention;

fig. 18 is a structural view of a chassis structure employed in an eighth embodiment of the present invention;

fig. 19 is a block flow diagram of a method for manufacturing a battery pack according to an embodiment of the invention;

fig. 20 is another flowchart of a method for manufacturing a battery pack according to an embodiment of the present invention.

Detailed Description

In order to make those skilled in the art better understand the technical solution of the present invention, the bus bar structure, the series-parallel connection module, the battery pack, the battery system and the method provided by the present invention are described in detail below with reference to the accompanying drawings.

First embodiment

The bus bar structure provided by this embodiment is used to connect with the tabs of a plurality of battery cells in a battery module, so as to implement electrical connection of the battery cells, for example, series connection, parallel connection, or a series-parallel connection including series connection and parallel connection. The battery cells in the battery module are generally divided into a single-head battery cell and a double-head battery cell, wherein the double-head battery cell means that a positive electrode tab and a negative electrode tab of the battery cell are respectively positioned on two sides of the battery cell; the single-head battery cell refers to that the positive electrode lug and the negative electrode lug of the battery cell are both positioned on the same side of the battery cell.

Taking the electric core as an example of the above-mentioned double-end electric core, specifically, as shown in fig. 1, the battery module includes a plurality of groups of electric core groups 2, the plurality of groups of electric core groups 2 are arranged in an array (for example, a rectangular array) in the second direction Y and the third direction X in the installation plane, only one row of electric core groups 2 in the second direction Y is shown in fig. 1, and each group of electric core groups 2 is formed by stacking a plurality of electric cores in the first direction Z perpendicular to the installation plane. And the direction of the positive electrode tab and the negative electrode tab of the battery cell is parallel to the third direction X, and in the third direction X, the tabs of each battery cell of any two adjacent battery cell groups 2 are correspondingly in electrical contact.

The battery pack is directly assembled by the battery modules and is arranged on the mounting plane, so that the traditional module manufacturing process can be omitted, the number and the types of electric elements are reduced, the manufacturing process is simplified, and the assembly process and the production and manufacturing cost are reduced.

On this basis, the busbar structure that this embodiment provided is arranged in realizing the electric connection of electric core among the above-mentioned battery module to can realize assembling the battery package directly with electric core. The busbar structure comprises a plurality of connecting sheets which are arranged at intervals along a first direction Z and can be separated, the connecting sheets are used for being in electrical contact with lugs of the battery cell, and one end, far away from the battery cell, of each connecting sheet is provided with an extending part; and the extension parts on the connecting sheets extend from the connecting sheets to the direction of mutual convergence to realize the electric conduction of the extension parts on the connecting sheets, thereby realizing the electric conduction between a plurality of battery cell tabs correspondingly contacted with the connecting sheets and further realizing the electric connection (parallel connection, series connection or series-parallel connection) of the battery cells.

In some alternative embodiments, at least one of the first connecting piece, the second connecting piece and the third connecting piece in the plurality of connecting pieces includes three different structures, that is, the connecting pieces in different structures may be arranged and combined together to realize different electrical connection manners of the battery cells.

As for the above-mentioned first connection pieces, fig. 2A shows three first connection pieces (111a,111b,111c) assembled together to form a parallel group 11 capable of connecting the cells in parallel, and the three first connection pieces (111a,111b,111c) are arranged at intervals for electrically contacting with three cell tabs adjacent to each other in the first direction Z, respectively, so as to connect the three cells in parallel. And one end of each of the three first connecting sheets (111a,111b,111c) far away from the battery core is provided with a first extending part (112a,112b,112c), and the three first extending parts (112a,112b,112c) are bent or extended straightly, converged in the same plane perpendicular to the first direction Z, and arranged in a row along the second direction Y, that is, orthographic projections of the three first extending parts (112a,112b,112c) on the plane are not overlapped. In this case, the three first extending portions (112a,112b,112c) may be electrically conducted by additionally providing a connecting member, thereby achieving electrical conduction between the three first connecting pieces (111a,111b,111 c). For example, the connection member is a total positive connection member 113a or a total negative connection member 113b, and in this case, the total positive connection member 113a or the total negative connection member 113b is electrically conducted to each other by being stacked on the three first extension portions (112a,112b,112c), thereby achieving parallel connection of the three cell tabs adjacent in the first direction Z.

Of course, in practical application, other connecting members may be stacked on the extending portions of the connecting sheets to achieve electrical conduction between the connecting sheets; alternatively, the extensions on the plurality of bond pads may be in direct electrical contact, which may be multiple, for example, the extensions on the plurality of bond pads converge in at least two planes perpendicular to the first direction Z, and the extension on each bond pad is in electrical contact with at least one of the extensions on the other bond pads. Specifically, in the first direction Z, the extension portion on the tab located at the outermost layer overlaps with the extension portion on the other tab, and orthographic projections of the extension portions on the other tab on the plane do not overlap, that is, the extension portions on the other tab overlap at different positions of the extension portion on the tab, respectively.

As shown in fig. 2B, three first connection plates (111a,111B,111c) are separable, and during the process of mounting a plurality of battery cells on the chassis layer by layer, one of the first connection plates on the same layer can be mounted to a position in electrical contact with a corresponding battery cell tab, so that a connection process (such as welding, riveting, bolting, gluing, etc.) can be performed on the first connection plate and the second connection plate, that is, the battery cells and the connection plates can be alternately mounted until all the battery cells (i.e., the plurality of battery cells in the first direction Z) are mounted and connected to the connection plates in the busbar structure 1, so as to stack and electrically connect the battery cells.

Therefore, the bus bar structure 1 provided by the invention can realize the electrical connection of a plurality of battery cells directly stacked on the chassis, so that the battery cells can be directly assembled into the battery pack, the traditional module manufacturing process is omitted, the number and the types of electrical elements are reduced, the manufacturing process is simplified, and the assembling process and the production and manufacturing cost are further reduced.

The number of the first connecting pieces is also two or four or more, and the present invention is not particularly limited thereto.

As for the above-mentioned second connecting pieces, as shown in fig. 3A and 3B, three second connecting pieces (121a,121B,121c) assembled together are shown in fig. 3A, the length of the three second connecting pieces (121a,121B,121c) in the second direction Y is longer relative to the above-mentioned first connecting pieces, and each second connecting piece is used for being in electrical contact with two adjacent groups of the electric core groups 2, wherein the positive electrode tabs of the electric cores in one group of the electric core groups 2 are in electrical contact with the corresponding negative electrode tabs of the electric cores in the other group of the electric core groups, that is, the same second connecting piece is in electrical contact with the tabs of two adjacent electric cores in the second direction Y between different electric core groups, so as to realize the series connection of the two electric cores. And, when the three second connecting pieces (121a,121b,121c) are electrically conducted with each other, the three cells in the first direction in the same group of the cells can be connected in parallel. Therefore, for a single second connecting sheet, the series connection of the battery cores between two adjacent groups of battery core groups can be realized; for the second connecting pieces which are electrically conducted with each other, a plurality of electric cores of two adjacent groups of electric core groups can be connected in parallel, and the electric cores which are connected in parallel are connected in series.

Similar to the first connecting piece described above, as shown in fig. 3B, the three second connecting pieces (121a,121B,121c) are separable to enable layer-by-layer mounting.

And one end of each of the three second connecting pieces (121a,121b,121c) far away from the battery cell is provided with a second extending part (122a,122b,122c), and the three second extending parts (122a,122b,122c) extend from the second connecting pieces to the direction in which the three second extending parts converge to each other so as to realize the electric conduction between the three second connecting pieces. Preferably, the second extending portions of the second connecting pieces are electrically connected in a direct electrical contact manner, and the direct electrical contact manner may be various, for example, as shown in fig. 3A, the second extending portions (122a,122b,122c) of the three second connecting pieces (121a,121b,121c) converge in two planes perpendicular to the first direction Z, and each second connecting piece is electrically contacted with at least one of the other second connecting pieces. Specifically, in the first direction Z, the second extension portion (e.g., the second extension portion 122c) located at the outermost layer overlaps with other second extension portions (e.g., the second extension portion 122a and the second extension portion 122b), and the other second extension portions (e.g., the second extension portion 122a and the second extension portion 122b) are all located in the same plane and do not overlap in orthographic projection on the plane, that is, the other second extension portions (e.g., the second extension portion 122a and the second extension portion 122b) overlap at different positions on the second extension portion (e.g., the second extension portion 122c) of the outermost layer, respectively. Of course, in practical applications, the second extending portions of the second connecting sheets may be additionally provided with connecting members to achieve electrical conduction.

In some preferred embodiments, in order to increase the contact area and the connection stability, the second extension portions 122a are two and symmetrically disposed at both sides of the second extension portion 122 b.

In some alternative embodiments, in order to realize the series connection of at least two adjacent groups of parallel groups (composed of a plurality of first connecting members), fig. 4 shows two third connecting pieces (131a, 131b) arranged at intervals along the first direction Z for realizing the series connection of two groups of parallel groups (11a, 11b), specifically, the two third connecting pieces (131a, 131b) are respectively in electrical contact with the first extending portions on all the first connecting pieces in the two groups of parallel groups (11a, 11b), that is, the third connecting piece 131a is superposed on the first extending portions on the three first connecting pieces (111a,111b,111c) in the parallel group 11a for realizing the electrical conduction of the three first connecting pieces (111a,111b,111c) in the parallel group 11 a; the third connecting piece 131b is superposed on the first extending portion on the three first connecting pieces (111a,111b,111c) in the parallel group 11b to achieve electrical conduction of the three first connecting pieces (111a,111b,111c) in the parallel group 11 b. Moreover, one end of each of the two third connecting sheets (131a, 131b) far away from the first extending part is provided with a third extending part (132a, 132 b); and, two third extension portions (132a, 132b) extend from the third connecting pieces to positions overlapping each other in a direction in which they converge to each other, for achieving electrical conduction of the two third connecting pieces (131a, 131b), thereby achieving series connection between the two parallel groups (11a, 11 b). In practice, the number of third tabs depends on the number of parallel groups that need to be connected in series.

In some alternative embodiments, as shown in fig. 5, taking the two groups of electric core groups 2 arranged in the second direction Y as an example, the busbar structure is composed of the above-mentioned first connecting plates, second connecting plates and third connecting plates, wherein the first connecting plates are used for electrically contacting with the positive electrode tabs or the negative electrode tabs of the electric cells in one group of electric core groups 2, and the first connecting plates are electrically conducted to realize the parallel connection between at least some electric cells in the same electric core group; the plurality of third connecting sheet conductors are commonly used for realizing series connection among a plurality of groups of parallel groups consisting of the plurality of first connecting sheets. The second connecting pieces are used for electrically contacting the positive electrode tabs of the electric cores in the two adjacent groups of electric core groups 2 with the corresponding negative electrode tabs of the electric cores in the other group of electric core groups, and the electric conductors of the second connecting pieces are commonly used for realizing the series connection of the electric cores after the electric cores are connected in parallel in the two groups of electric core groups. Of course, in practical application, other arbitrary arrangement and combination modes of the first connecting piece, the second connecting piece and the third connecting piece may also be adopted, or connecting pieces of other structures may also be adopted, and multiple different electrical connection modes of the battery cell may be realized by combining connecting pieces of multiple different structures together.

In some embodiments, the connecting sheet is an aluminum sheet or a copper sheet.

In practical applications, in order to meet the series-parallel connection requirements of different battery cells, at least one of the first connecting sheet, the second connecting sheet, and the third connecting sheet may be adaptively selected to be arranged and combined, or connecting sheets with other structures may be added, which is not particularly limited in the embodiment of the present invention.

It should be further noted that, in practical applications, the bus bar structure provided in this embodiment may also be applied to a double-head battery cell, where only the arrangement and combination manner of the plurality of connecting pieces is different compared to that of a single-head battery cell.

Second embodiment

As another technical solution, the present embodiment provides a series-parallel module including a bus bar structure and a support structure for supporting the bus bar structure. The series-parallel connection module provided by this embodiment is used to realize the electrical connection of the battery cells in the battery module, so that the battery cells can be directly assembled into the battery pack.

Taking the battery cell as the above-mentioned double-end battery cell as an example, the arrangement and combination manner of the multiple sets of battery core groups 2 adopted by the battery module is the same as that of the above-mentioned first embodiment. On this basis, the busbar structure includes two sets of connection groups, and two sets of connection groups are located the both sides of multiunit electric core group on third direction X respectively, and every group connection group includes a plurality of connection pieces for with the utmost point ear electric connection of electric core in the adjacent one row of electric core group.

In some alternative embodiments, referring to fig. 6A and 6B, the above-mentioned support structure 3 comprises a first support group and a second support group, both comprising a plurality of supports superimposed along a first direction Z, and, optionally, the plurality of supporting members include a plurality of supporting members 31 and a plurality of supporting members 31' having different structures, wherein the first support sets are two sets and are respectively arranged between the connection set and the adjacent row of the electric core sets, each support member 31 and 31' of the first support group is adapted to correspondingly support all the connection tabs (including at least one of the first connection tab, the second connection tab and the third connection tab) of the same layer (i.e., in the same plane parallel to the mounting plane) and the electrical contact areas of the tab corresponding thereto, that is, the support member can support the electrical contact area of the row of cell tabs and the corresponding connecting sheet adjacent thereto.

Similarly, the second support group is at least one group, the second support group is arranged between any two adjacent rows of the cell groups arranged in the second direction Y, and each support member (including the support member 31 and the support member 31') in the second support group is used for correspondingly supporting the electrical contact area of all the cell lugs of the same layer and the cell lugs corresponding to the same layer, that is, the support member can support the electrical contact area of one row of the cell lugs adjacent to the support member and one row of the cell lugs corresponding to the support member. By means of the supporting part (including the supporting part 31 and the supporting part 31'), the supporting and protecting functions can be achieved during the process of connecting the plurality of connecting sheets (including at least one of the first connecting sheet, the second connecting sheet and the third connecting sheet) on the same layer with the tab.

In some alternative embodiments, as shown in fig. 6B, the support member 31 is a one-piece structure for supporting the electrical contact areas of all the connection pieces and the corresponding tabs located at the same layer. The support member 31 may support at least one of the first connecting piece and the second connecting piece, for example. Optionally, a support recess 311 is provided on the support 31, and the bottom surface of the support recess 311 is used for being attached to all electrical contact regions of the same layer.

As for the above-mentioned support member 31 ', a split structure is adopted, and specifically, the support member 31' includes a plurality of sub-support members 31a arranged at intervals in the second direction Y, and the sub-support members 31a are adapted to support at least one connection piece, for example, a first connection piece. Specifically, at least one supporting recess aligned in the second direction Y is provided on each of the sub-supports 31a, for example, two supporting recesses 311a are provided on each of the sub-supports 31a shown in fig. 6B. Each support recess 311a is adapted to abut one of the electrical contact areas.

It should be noted that, in practical applications, the number and the arrangement combination of the supporting members 31 and the supporting members 31' may be adaptively selected according to different numbers and arrangement combinations of the first connecting pieces, the second connecting pieces and the third connecting pieces.

In some alternative embodiments, at least one positioning structure is disposed on the supporting member 31, and the positioning structure may have a plurality of structures, for example, as shown in fig. 6B, the positioning structure includes a positioning concave portion (not shown) and a positioning convex portion 312 respectively disposed on two surfaces of the supporting member 31 facing away from each other in the first direction Z, and in any two supporting members 31 adjacent to each other in the first direction Z, the positioning convex portion 312 on one of the supporting members 31 and the positioning concave portion on the other supporting member 31 cooperate to realize the positioning of the two adjacent supporting members 31.

In some alternative embodiments, at least one of the above-described positioning structures is provided on each of the sub-supports 31a of the support 31'.

It should be noted that, in practical applications, at least one supporting recess and/or at least one positioning structure may be provided on each sub-support 31a according to specific needs.

In some alternative embodiments, as shown in fig. 7A and 7B, the serial-parallel module further includes a bus bar support 4, and the connection set and the support structure 3 are integrated on the bus bar support 4, so that the production and manufacturing costs and the material costs of the components are effectively reduced by integrating a plurality of components on one component.

Taking as an example the supporting structure 3 shown in fig. 6A, which comprises the above-mentioned supporting member 31 and supporting member 31 'with different structures, the bus bar support also comprises two types of supports with different structures, namely a first bus bar support 41 and a second bus bar support 41', wherein the first bus bar support 41 is used for integrating the above-mentioned supporting member 31 and the connecting piece with corresponding structures; the second busbar holder 41 'serves to integrate the support 31' with a correspondingly configured connecting piece. For example, as shown in fig. 7B, a step structure 411 is provided on a surface of the first busbar holder 41 opposite to the connection group, and the step structure 411 specifically includes three step surfaces, namely a first step surface 411a, a second step surface 411B and a third step surface 411c, as can be seen from the connection piece structure shown in fig. 4, the first step surface 411a is used for being attached to a bottom surface of the third extension 132B on the third connection piece 131B; the second step surface 411b is used for attaching the bottom surfaces of the first extension parts (112a,112b,112c) of the three first connecting sheets (111a,111b,111 c); the third step surface 411c is configured to be attached to the bottom surface of the first connecting piece 111c, and thus the first bus bar holder 41 can integrate a parallel group of a plurality of first connecting pieces and a plurality of third connecting pieces connecting the parallel group in series.

As shown in fig. 7B, a step structure 412 is disposed on a surface of the second busbar support 41' opposite to the connection group, and the step structure 412 specifically includes two step surfaces, namely a first step surface 412a and a second step surface 412B, for being attached to the bottom surfaces of the corresponding connection piece and the extension portion. The second busbar mounting 41' may, for example, enable integration of a plurality of second connecting tabs.

In some alternative embodiments, as shown in fig. 7A and 7B, two conductive connectors (42a, 42B) are provided on the bus bar support 4 (e.g., the first bus bar support 41) and serve as a total positive connection terminal and a total negative connection terminal, respectively, each of which is in electrical communication with the extensions on the plurality of connection tabs in a corresponding set of electrical cores in the bus bar structure. For example, the bottom of the three first extending portions (112A,112b,112c) in fig. 2A is attached to realize the electrical conduction of the three first connecting pieces (111a,111b,111 c).

Third embodiment

Referring to fig. 8A and fig. 8B, the serial-parallel module provided in the present embodiment is different from the second embodiment only in that: the bus bar support 4' adopts a split structure.

Specifically, the bus bar support 4 ' includes a plurality of sub-supports 4a arranged at intervals in the second direction Y, at least one sub-support 31a is integrated on each sub-support 4a, and a stepped structure 412 ' is provided on a surface of each sub-support 4a opposite to the above-described connection group, and stepped surfaces of the stepped structure 412 ' are, for example, two, respectively a first stepped surface 412a and a second stepped surface 412b, which are used to completely abut against surfaces of the connection piece and the extension portion opposite to the stepped surfaces.

Fourth embodiment

Referring to fig. 9, the difference between the serial-parallel module provided in the present embodiment and the second and third embodiments is only: the bus bar support 5 is not provided with the support structure adopted in the above embodiments on the basis of the integrated connection group.

Specifically, a stepped structure 51 is provided on a surface of the busbar bracket 5 opposite to the connection group, and a stepped surface of the stepped structure 51 is fitted to a surface of the connection piece and the extension opposite to the stepped surface. Since the stepped structure 51 of the busbar holder 5 is similar to that of the busbar holder employed in the above-described second and third embodiments, a description thereof will not be repeated.

It should be noted that, because the series-parallel module is not provided with the support structure adopted in the above embodiment, each connecting sheet is in a suspended state after the assembly is completed. Before one of the connecting sheets on the same layer is connected with the corresponding battery cell tab, a tool fixture is required to be used for supporting the electric contact area of the connecting sheet and the corresponding battery cell tab, and the tool fixture is detached after the connection process is completed. Preferably, in order to facilitate the installation of the tooling jig, the chassis for installing the battery core group adopts a flat plate structure, for example, so that the tooling jig can extend into the lower part of the electric contact area between the connecting sheet and the corresponding battery core lug from one side along the second direction Y.

Fifth embodiment

The present embodiment provides a series-parallel module, which also includes a bus bar structure and a support structure for supporting the bus bar structure, compared with the second embodiment described above. The difference between the series-parallel module provided by this embodiment and the second embodiment is: the battery cell is a single-head battery cell.

Specifically, as shown in fig. 10, the battery module includes a plurality of sets of electric core groups 6, the plurality of sets of electric core groups 6 are arranged in a row in a second direction Y in the installation plane, and the electric core groups 6 are formed by stacking a plurality of electric cores in a first direction Z perpendicular to the installation plane, and the tabs of all the electric cores are located on the same side in a third direction X in the installation plane. In this case, fig. 11 shows a busbar structure 1, which includes a connection set located on one side of the cell tabs of the multiple groups of cell sets 6, where the connection set includes multiple connection pieces for realizing the electrical connection of the cells in the above battery module, so as to directly assemble the cells into a battery pack.

As shown in fig. 11, the plurality of connection pieces in the connection group also include a plurality of first connection pieces, a plurality of second connection pieces, and a plurality of third connection pieces that are arranged and grouped together, and by arranging and grouping the connection pieces of various different structures together, various different electrical connection modes of the battery cells can be realized.

In some alternative embodiments, as shown in fig. 12A and 12B, the supporting structure 7 is disposed between the above-mentioned connecting group and the plurality of electric core groups 6, and includes a plurality of supporting members 71 stacked along the first direction Z, each supporting member 71 being used for correspondingly supporting the electric contact area of all the connecting plates and the tabs corresponding thereto of the same layer (in the same plane parallel to the installation plane), that is, one supporting member 71 is used for supporting the electric contact area of the same layer in the second direction Y.

As shown in fig. 12B, the supporting member 71 is of an integral structure, and a plurality of supporting recesses arranged in the second direction Y are provided on the supporting member 71, for example, a plurality of different sizes are provided in the plurality of supporting recesses on each supporting member 71, so as to be able to support different numbers of electrical contact regions. For example, the supporting member 71 in fig. 12B has two supporting recesses with different sizes, namely a first supporting recess 711 and a second supporting recess 712, wherein the length of the first supporting recess 711 in the second direction Y is matched with the length of the second connecting plate in the second direction Y, so as to support the second connecting plate and the corresponding electrical contact area of the two cell tabs; the length of the second supporting recess 712 in the second direction Y is adapted to the length of the first connecting piece or the third connecting piece in the second direction Y, so as to support the electrical contact area between the first connecting piece or the third connecting piece and the corresponding cell tab.

And, at least one positioning structure is provided on the supporting member 71, and the positioning structure includes a positioning concave portion 721 and a positioning convex portion (not shown in the figure) respectively provided on two surfaces of the supporting member 71 facing away from each other in the first direction Z, and in any adjacent two supporting members 71 in the first direction Z, the positioning convex portion on one of the supporting members 71 is matched with the positioning concave portion 721 on the other one of the supporting members 71.

In some alternative embodiments, as shown in fig. 13A, the serial-parallel module further includes a bus bar support 8, and the connection set and the support structure 7 are integrated on the bus bar support 8, so that the production and manufacturing costs and the material costs of the components are effectively reduced by integrating a plurality of components on one component.

Taking the connecting group and the support structure 7 shown in fig. 11 and 12A as an example, correspondingly, the busbar bracket 8 includes three bracket layers 81 stacked in sequence along the first direction Z, and as shown in fig. 13B, a step structure is provided on a surface of each bracket layer 81 opposite to the connecting group, and a step surface of the step structure is fitted to a surface of the connecting piece and the extending portion opposite to the step surface. For example, fig. 13B shows that the bottom surfaces of the second connecting piece 121c and the second extending portion 122c thereon in fig. 3A respectively abut against two step surfaces of the step structure. Fig. 13C and 13D respectively show two supports 71 integrated on the above-mentioned support layer 81, wherein the supports 71 in fig. 13C are used to support the second connecting piece 121b in fig. 3A; the support 71 in fig. 13D is used to support the second connecting piece 121a in fig. 3A. Fig. 13E shows a cross-sectional view of the bracket layer 81, two supports 71 and three second connecting pieces (121a,121B,121c) integrated together in fig. 13B, wherein the step structure of the bracket layer 81 has a first step surface 811 and a second step surface 812, which are respectively attached to the second connecting piece 121c and the bottom surface of the second extending portion 122c thereon.

In some alternative embodiments, as shown in fig. 13A, the busbar holder 8 is provided with two conductive connectors (82a, 82b) that serve as a total positive connection terminal and a total negative connection terminal, respectively, each of which is in electrical communication with the extensions on the plurality of connection tabs in a corresponding set of electrical cores in the busbar arrangement.

In some alternative embodiments, the battery module includes a plurality of cell units arranged in the third direction X, for example, fig. 14 shows four cell units (60a,60b,60c,60d), in this case, the bus bar support 8 is plural, and each bus bar support 8 is correspondingly disposed on one side of the tab of the electric core pack 6 in each cell unit. For example, as shown in fig. 14, each cell unit includes the same row of the core groups 6 in the second direction Y. And, four bus bar holders (8a,8b,8c,8d) are provided correspondingly at the side of the tab of the core pack 6 among the four cell units (60a,60b,60c,60 d). The above-described connection group is integrated on each busbar holder 8.

Sixth embodiment

As another technical solution, this embodiment further provides a battery pack, as shown in fig. 15, which is applied to a double-headed battery core. Specifically, the battery pack comprises a chassis structure, and a battery module and a series-parallel module which are arranged on the chassis structure, wherein the battery module comprises a battery core group 2 formed by stacking a plurality of battery cores; the series-parallel module provided by the above embodiments applied to the double-end battery cell is adopted to realize the electrical connection of a plurality of battery cells.

Specifically, as shown in fig. 15 and 16, the chassis structure includes a chassis 101 and a cover 104, wherein the chassis 101 is of a flat plate structure and has a mounting plane 101 a; the cover 104 includes a top plate 104a, a frame 104b is disposed around a surface of the top plate 104a opposite to the mounting plane 101a, and the frame 104b, the top plate 104a and the bottom plate 101 form a mounting space for accommodating the electric core pack 2 inside the frame 104 b. Preferably, the chassis 101 is an aluminum profile or sheet metal.

In this embodiment, the battery module includes a plurality of groups of electric cores 2, the plurality of groups of electric cores 2 are arranged in an array (for example, rectangular array) in the third direction X and the second direction Y in the installation plane, and each group of electric cores 2 is formed by stacking a plurality of electric cores in the first direction Z perpendicular to the installation plane. And the direction of the positive electrode tab and the negative electrode tab of the battery cell is parallel to the third direction X, and in the third direction X, the tabs of each battery cell of any two adjacent battery cell groups 2 are correspondingly in electrical contact. Furthermore, as shown in fig. 16, a plurality of temperature control plates 105 arranged at intervals along the second direction Y are further disposed on the mounting plane 101a of the base plate 101, and the interval between any two adjacent temperature control plates 105 is used for accommodating a row of electric core groups 2 arranged along the third direction X. The thermal control plate 105 includes, for example, a liquid cooling/heating plate.

Furthermore, a plurality of mounting posts 106 are disposed on the mounting plane 101a of the chassis 101 at intervals along the second direction Y, and are used for correspondingly matching with the plurality of mounting holes on the bus bar support, so as to achieve the positioning and mounting of the bus bar support on the chassis 101.

In addition, as shown in fig. 15, the battery pack further includes a heat insulation pad 102 and a sealing ring 103, wherein the frame 104b is connected to the bottom plate 101 in a sealing manner through the sealing ring 103 to seal an installation space for accommodating the electric core pack 2. The heat insulation pad 102 is plural and is correspondingly disposed between each electric core pack 2 and the top cover 104 a.

Further, an insulating, heat-insulating and elastic protective material 107, including foam or aerogel felt, is disposed on the bottom plate 101 for protecting the cells stacked on the bottom plate 101.

Taking the serial-parallel module adopted in the fourth embodiment as an example, the bus bar support 5 in the serial-parallel module is not provided with a support structure on the basis of the integrated bus bar structure 1. Because the series-parallel connection module is not provided with a support structure, other connecting sheets except the first layer of connecting sheets are in a suspended state after the assembly is completed. Before one of the connecting sheets on the same layer is connected with the corresponding battery cell tab, the connecting sheets and the corresponding battery cell tab need to be supported by a tool fixture, and the tool fixture is detached after the connection is completed. Preferably, in order to facilitate the installation of the tooling fixture, the chassis 101 in this embodiment adopts a flat plate structure shown in fig. 16, so that the tooling fixture can extend into the lower portion of the electrical contact area between the connecting sheet and the corresponding battery cell tab along the second direction Y from one side, thereby ensuring that the connection process is smoothly performed.

The chassis structure can play the roles of protecting the battery cell, regulating and controlling the temperature, insulating and preserving heat and providing fixing points and supporting points for various internal electrical elements.

In some embodiments, optionally, a cell protective material is disposed between every two adjacent layers of the cells in the cell group 2, and the cell protective material includes foam, double faced adhesive and a fireproof plate.

The electrical connection of electric core among the above-mentioned battery module can be realized to above-mentioned series-parallel connection module to can realize assembling the battery package with the electric core direct assembly among the above-mentioned battery module, install on above-mentioned mounting plane, can save traditional "module" preparation flow like this, reduce electric elements's quantity and kind, simplify the preparation process, and then reduce assembly process and manufacturing cost.

Seventh embodiment

The battery pack provided by the embodiment is also applied to a double-end battery core. Specifically, the battery pack includes the chassis structure, the battery modules, and the series-parallel modules as well as compared to the sixth embodiment described above, but differs only in that: the chassis has different structures.

Specifically, as shown in fig. 17, the chassis structure includes a chassis 201, the chassis 201 has an installation plane, and a frame 202 is disposed around the installation plane of the chassis 201, and the frame 202 and the chassis 201 form an installation space for accommodating the electric core pack 2 inside the frame 202. Preferably, the chassis 201 is an aluminum profile or sheet metal.

Moreover, a plurality of temperature control plates 203 arranged at intervals along the second direction Y are further disposed on the mounting plane of the base plate 201, and the interval between any two adjacent temperature control plates 203 is used for accommodating a row of electric core groups 2 arranged along the first direction X. The temperature control plate 203 includes, for example, a liquid cooling/heating plate.

In addition, the battery pack further includes a heat insulation pad 204, a sealing ring (not shown) and a cover plate (not shown), wherein the cover plate is of a flat plate structure and is connected to the frame 202 in a sealing manner through the sealing ring, so as to form a sealing space for accommodating each group of the electric core assemblies 2 inside the cover plate, the frame 202 and the base plate 201. The heat insulation pad 204 is plural and is correspondingly disposed between each electric core group 2 and the cover plate 206.

Eighth embodiment

The battery pack provided by the embodiment is applied to a single-head battery core. The battery pack comprises a chassis structure, and a battery module and a series-parallel module which are arranged on the chassis structure, wherein the battery module comprises a battery core group formed by stacking a plurality of battery cores; the series-parallel module provided in the fifth embodiment is used for electrically connecting a plurality of battery cells.

Specifically, as shown in fig. 18, the chassis structure includes a chassis 301, the chassis 301 has a mounting plane, and a frame 302 is disposed around the mounting plane of the chassis 301, and the frame 302 and the chassis 301 form a mounting space for accommodating the battery cell unit shown in fig. 14, for example, inside the frame 302. Preferably, the chassis 301 is an aluminum profile or sheet metal.

In this embodiment, optionally, two edge beams (304a,304b) spaced in the third direction X and disposed opposite to each other are disposed on the mounting plane of the chassis 301, and a plurality of partition boards 303 spaced in the second direction Y are further disposed on the mounting plane of the chassis 301 and located between the two edge beams (304a,304b), and a space between any two adjacent partition boards 303 is used for accommodating a group of electric core assemblies 6.

It should be noted that, in the present embodiment, there are two edge beams, but the present invention is not limited to this, and in practical application, according to the number and arrangement of the different electric core sets, there may be one or more than three edge beams, and the three edge beams are parallel to each other, and the space between at least one edge beam and any two adjacent partition plates is used for accommodating one set of electric core sets 5. In addition, the edge beam may not be provided, in which case, only the space between any two adjacent partition boards may be used to accommodate one set of electric core sets, in which case, at least one of the plurality of partition boards serves as a temperature control board.

Alternatively, at least one of the two side beams (304a,304b) and the plurality of partition plates 303 may be used as a liquid/liquid heating plate or a PTC heating device. In addition, the partition 303 may serve to reinforce the strength of the chassis 301 and also to prevent heat from spreading.

In some embodiments, optionally, the chassis 301 is integrally formed with at least one of the two side rails (304a,304b) and the plurality of bulkheads 303. For example, the bottom chassis 301 is integrally formed with at least one of the two side frames (304a,304b) and the plurality of spacers 303 through an extrusion molding process, thereby reducing a connecting process and reducing production costs.

Further, an insulating, heat insulating and elastic protective material 305, including foam or aerogel felt, is disposed on the bottom plate 301 for protecting the cells stacked on the bottom plate 301.

In some embodiments, optionally, a cell protective material is disposed between every two adjacent layers of the cells in the above-mentioned cell group 6, and the cell protective material includes foam, double faced adhesive and a fireproof plate.

As another technical solution, an embodiment of the present invention further provides a battery system, which includes a battery pack and a battery management module for regulating and controlling the battery pack, where the battery pack adopts the battery pack provided in the embodiment of the present invention.

The battery management module is, for example, a battery management system BMS.

As another technical solution, an embodiment of the present invention further provides a method for manufacturing a battery pack, which is applied to the manufacturing of the battery pack provided in the sixth embodiment. As shown in fig. 19, the manufacturing method includes the following steps:

s1, installing a layer of connecting sheet layer in the bus bar structure on the bus bar support, wherein the connecting sheet layer comprises at least one connecting sheet arranged on the same layer;

the same layer arrangement means arrangement on the same plane parallel to the mounting plane of the chassis.

S2, mounting a battery cell layer on a mounting plane perpendicular to the first direction of the chassis structure, wherein the battery cell layer comprises at least one battery cell arranged on the same layer, and a tab of the battery cell in the battery cell layer is in electrical contact with a connecting sheet in a connecting sheet layer corresponding to the same layer;

s3, installing a tooling jig, wherein the tooling jig is used for supporting the connecting sheet in the current layer connecting sheet layer and the electric contact area of the tab corresponding to the connecting sheet;

s4, performing a connection process on the tab of the battery cell in the current layer of the battery cell and the connecting sheet corresponding to the tab in the current layer of the battery cell in the electric contact area of the tab and the connecting sheet;

s5, disassembling the tool fixture;

the steps S2 to S5 are executed in a circulating manner until all the cells (i.e., the cells in the first direction Z) are mounted and the connection with the connecting pieces in the busbar structure is completed, so as to stack and electrically connect the cell groups.

In this case, after the first-layer core layer is mounted in step S2, step S3 is skipped to directly perform step S4, and after step S4 is completed, step S5 is skipped to directly return to step S1 to mount the next-layer connection sheet layer.

It should be noted that, in this embodiment, step S1 is performed first, and then step S2 is performed, in which case, the cell tab is stacked on the connecting sheet, but the embodiment of the present invention is not limited to this, and in practical applications, step S2 may be performed first, and then step S1 is performed, in which case, the connecting sheet is stacked on the cell tab.

In the above steps S3 and S5, a robot may be used to install and remove the tool fixture.

Taking the serial-parallel module adopted in the fourth embodiment as an example, the bus bar support 5 in the serial-parallel module is based on the integrated bus bar structure 1, and is not provided with the supporting structure adopted in the embodiment. Because the series-parallel module is not provided with the supporting structure adopted by the embodiment, each connecting sheet is in a suspended state after the assembly is completed. Before one of the connecting sheets on the same layer is connected with the corresponding battery cell tab, the connecting sheets and the corresponding battery cell tab need to be supported by a tool fixture, and the tool fixture is detached after the connection process is completed. Preferably, in order to facilitate the installation of the tooling fixture, the chassis 101 in this embodiment adopts a flat plate structure shown in fig. 16, so that the tooling fixture can extend into the lower portion of the electrical contact area between the connecting sheet and the corresponding battery cell tab along the second direction Y from one side, thereby ensuring that the connection process is smoothly performed.

As another technical solution, an embodiment of the present invention further provides another method for manufacturing a battery pack, which is applied to the battery packs provided in the seventh and eighth embodiments. And, the series-parallel module also includes a bus bar support, and the bus bar structure and the support structure are integrated on the bus bar support. Due to the existence of the supporting structure, the manufacturing method of the embodiment does not need to use the tool fixture.

Specifically, as shown in fig. 20, the manufacturing method includes the following steps:

s11, installing a layer of connecting sheet layer in the bus bar structure on the bus bar support, wherein the connecting sheet layer comprises at least one connecting sheet arranged on the same layer;

s12, mounting a battery cell layer on a mounting plane perpendicular to the first direction of the chassis structure, wherein the battery cell layer comprises at least one battery cell arranged on the same layer, and a tab of the battery cell in the battery cell layer is in electrical contact with a connecting sheet in a connecting sheet layer corresponding to the same layer;

s13, performing a connection process on the tab of the battery cell in the current layer of the battery cell and the connecting sheet corresponding to the tab in the current layer of the battery cell in the electric contact area of the tab and the connecting sheet;

s14, mounting a support piece for supporting the corresponding electric contact area of the next layer on the electric contact area of the tab of the battery cell in the current layer of the battery core layer and the connecting piece corresponding to the tab;

the steps S11 to S14 are executed in a loop until all the cells (i.e., the cells in the first direction Z) are mounted, so as to stack and electrically connect the cell groups.

As another technical solution, an embodiment of the present invention further provides a method for manufacturing a battery system, which is applied to the battery system provided in the embodiment of the present invention; the manufacturing method comprises the manufacturing method of the battery pack provided by the embodiment of the invention.

In some embodiments, optionally, after the stacking and the electrical connection of the electric core groups are achieved, the manufacturing method of the battery system further includes:

installing a shell on the outer side of the electric core group, and filling heat conducting glue and pouring sealant between the shell and the electric core group;

of course, in practical applications, the housing may not be provided. In this case, a heat conductive adhesive and a potting adhesive may be filled between the top cap and the electric core pack.

The electric core groups are connected in series, for example, the electric core groups can be connected by copper bars, aluminum bars or high-voltage cables;

connecting terminal and battery management system BMS on with the insulation protection board are connected in order to realize BMS regulation and control, and the hot board of liquid cooling/liquid on the integrated chassis utilizes liquid cold tube to be connected with outside liquid cooling equipment, and the PTC device that generates heat is connected with battery management system BMS to regulate and control.

In summary, the technical solutions of the series-parallel module, the battery pack, the battery system and the manufacturing method provided by the embodiments of the present invention have the following advantages:

1. the material cost is reduced, a plurality of electric elements such as a bus bar structure, a temperature sampling circuit, a voltage sampling circuit, a total anode connecting piece, a total cathode connecting piece and the like are integrated on the same module, temperature control units such as a liquid cooling/liquid heating system or a PTC heating device are integrated on a chassis, and the production and manufacturing cost and the material cost of parts are effectively reduced by integrating a plurality of parts on one part;

4. the battery is suitable for a full-automatic production mode, the production efficiency is improved, the battery core is directly stacked on the chassis from the lug of the battery core, the battery core is connected with the busbar structure, the battery is assembled from the shell and even filled with heat-conducting glue and pouring sealant, the whole connection process does not need manual participation, and the whole process of manipulator operation can meet the design requirement;

5. the space utilization rate of a production workshop is improved, the battery cores with the cut lugs are directly stacked on a system chassis, and various subsequent processes are all operated on the chassis, so that the requirement on the production process circulation field is reduced, and the space utilization rate of the production workshop is greatly improved;

According to the technical scheme, effective integration of all parts is achieved, seventy materials are reduced to twenty materials by integrating a plurality of parts on the same module, the number of the parts is greatly reduced, the material cost is greatly reduced, the production process of the battery system is simplified, the production and management cost is reduced, meanwhile, the production process of the battery system can be completely automated, the material cost and the production and manufacturing cost are directly reduced, the production efficiency is improved, and in addition, due to the design scheme of the battery system, the battery cores can be flexibly arranged, the battery system is very suitable for the conditions with narrow space and high-capacity density requirements, the space utilization rate of a production workshop is improved, batteries with higher energy are provided for the whole vehicle in the same space range, and the endurance mileage of a new energy vehicle is greatly increased.

It will be understood that the above embodiments are merely exemplary embodiments taken to illustrate the principles of the present invention, which is not limited thereto. It will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the spirit and substance of the invention, and these modifications and improvements are also considered to be within the scope of the invention.

Claims

1. A busbar structure is used for being connected with the lugs of a plurality of battery cells in a battery module, the battery cells are stacked along a first direction to form a battery core group, and the busbar structure is characterized by comprising a plurality of connecting sheets which are arranged at intervals along the first direction and can be separated, the connecting sheets are used for being electrically contacted with the lugs of the battery cells, and one ends of the connecting sheets, far away from the battery cells, are provided with extending parts; and the number of the first and second electrodes,

2. The bus bar structure according to claim 1, wherein at least one of a first connecting piece, a second connecting piece, and a third connecting piece, which are three different in structure, is included in the plurality of connecting pieces, wherein,

3. The bus bar structure according to claim 1 or 2, wherein the extensions on the plurality of connecting pieces converge in the same plane perpendicular to the first direction, and orthographic projections on the planes do not overlap.

4. The busbar structure according to claim 1 or 2, wherein the extensions on a plurality of the connecting pieces converge in at least two planes perpendicular to the first direction, and the extension on each connecting piece is in electrical contact with at least one of the extensions on the other connecting pieces.

5. The busbar structure according to claim 4, wherein in the first direction, the extension portions on the connecting tab located outermost overlap with the extension portions on the other connecting tabs, and the extension portions on the other connecting tabs all lie in the same plane and do not overlap in orthographic projection thereof.

6. A series-parallel module comprising a busbar arrangement and a support arrangement for supporting the busbar arrangement, wherein the busbar arrangement is as claimed in any one of claims 1 to 5.

7. The series-parallel module of claim 6, wherein the positive and negative tabs of each of the cells are located on either side of the cell;

8. The series-parallel module of claim 7, wherein the support structure comprises a first support group and a second support group, each comprising a plurality of supports stacked along the first direction, wherein,

9. The series-parallel module of claim 6, wherein the positive and negative tabs of each of the cells are located on one side of the cell;

10. The series-parallel module of claim 9, wherein the battery module comprises a plurality of cell units arranged in the third direction, each cell unit comprising the same row of the cell groups in the second direction;

11. The series-parallel module according to claim 10, wherein the support structure is disposed between the connection group and the cell group in the cell unit, and includes a plurality of support members stacked in the first direction, each of the support members being adapted to support the electrical contact areas of all the connection pieces of the same layer and the tabs corresponding thereto, respectively.

12. The series-parallel module according to claim 8 or 11, characterized in that a plurality of support recesses are provided on the support, aligned in the second direction, for supporting at least one of the connection tabs and the electrical contact area of the cell tab corresponding thereto; and the number of the first and second electrodes,

13. Series-parallel module according to claim 12, characterized in that the support comprises a plurality of sub-supports arranged at intervals in the second direction, each sub-support being provided with at least one of the support recesses and/or at least one of the positioning structures.

14. The series-parallel module according to claim 13, further comprising a busbar cradle, the connection group and the support structure each being integrated on the busbar cradle;

15. The series-parallel module according to claim 12, further comprising a busbar cradle, the connection group and the support structure each being integrated on the busbar cradle;

16. Series-parallel module according to claim 7 or 9, characterized in that the support structure comprises a busbar cradle on which the connection group is integrated;

17. The series-parallel module according to any one of claims 14 to 16, wherein two conductive connecting members, each serving as a total positive connecting terminal and a total negative connecting terminal, are provided on the bus bar support, each of the conductive connecting members being in electrical communication with the corresponding extension portion in the connection group.

18. A battery pack comprises a chassis structure, and a battery module and a series-parallel connection module which are arranged on the chassis structure, wherein the battery module comprises a battery core group formed by stacking a plurality of battery cores; the series-parallel module adopts the series-parallel module of any one of claims 6 to 17, so as to realize the electrical connection of the plurality of battery cells.

19. The battery pack according to claim 18, wherein the series-parallel module employs the series-parallel module according to claim 16;

20. The battery pack according to claim 19, wherein the series-parallel module employs the series-parallel module according to claim 7;

21. The battery pack according to claim 19, wherein the series-parallel module employs the series-parallel module according to claim 9;

22. The battery pack according to claim 21, wherein one or more side beams parallel to each other are further disposed on the mounting plane of the chassis, the side beams and the partition plates are parallel to each other in the arrangement direction, and a space between at least one side beam and any two adjacent partition plates is used for accommodating one group of the battery cell groups;

23. A battery system comprising a battery pack and a battery management module for regulating the battery pack, wherein the battery pack is the battery pack according to any one of claims 18 to 22.

24. A method for manufacturing a battery pack, characterized by being applied to the battery pack according to any one of claims 19 to 22; the manufacturing method comprises the following steps:

s4, carrying out a connection process on the tab of the battery cell in the current layer of the battery core layer and the corresponding connecting sheet in the electric contact area of the tab and the corresponding connecting sheet;

s5, disassembling the tool jig;

wherein, after the step S2 is adopted to mount the first layer of the core layer, the step S3 is skipped to directly perform the step S4, and after the step S4 is completed, the step S5 is skipped to directly return to the step S1 to mount the next layer of the connector layer.

25. A method for manufacturing a battery pack, which is applied to the battery pack according to claim 18; the series-parallel module adopts the series-parallel module of claim 14 or 15;

the manufacturing method comprises the following steps:

26. A method for manufacturing a battery system, which is applied to the battery system according to claim 23; the manufacturing method includes a manufacturing method of the battery pack according to claim 24 or 25.