Battery pack and assembly method thereof

Patent metadata

Field	Value
Publication number	US-2026058243-A1
Application number	US-202519307002-A
Country	US
Kind code	A1
Filing date	Aug 21, 2025
Priority date	Aug 22, 2024
Publication date	Feb 26, 2026
Grant date	—

Abstract

The present disclosure provides a battery pack and an assembly method thereof. The battery pack includes a housing, a liquid cooling plate, a thermally conductive fixation layer and a plurality of battery cells. The plurality of battery cells is arranged in an array within the housing. The liquid cooling plate covers the housing. The thermally conductive fixation layer fills and cures in the gaps between the battery cells and the housing. The thermally conductive fixation layer is further sandwiched between a shoulder portion of the battery cell and the liquid cooling plate and encapsulates terminal posts of the battery cell. An avoidance channel is formed in the thermally conductive fixation layer. The avoidance channel is aligned with the explosion-proof valve of the battery cell.

First claim

What is claimed is:

1 . A battery pack, comprising:
a housing; a plurality of battery cells, the plurality of battery cells being arranged in an array within the housing; a liquid cooling plate, covering the housing; and a thermally conductive fixation layer, filled and cured in gaps between the battery cells and the housing, the thermally conductive fixation layer is further sandwiched between a shoulder portion of the battery cell and the liquid cooling plate, and the thermally conductive fixation layer encapsulates terminal posts of the battery cells, wherein an avoidance channel is formed in the thermally conductive fixation layer, the avoidance channel is aligned with the explosion-proof valve of the battery cell.

2 . The battery pack according to claim 1 , wherein the plurality of battery cells are arranged at intervals along a second direction to form a battery cell assembly, the second direction being perpendicular to an expansion surface of the battery cell, the battery cell assembly further comprises a foam layer, the foam layer is attached and sandwiched between the expansion surfaces of any two adjacent battery cells, and the two expansion surfaces at the ends of the battery cell in the second direction are provided with the foam layer attached thereto.

3 . The battery pack according to claim 2 , wherein the battery pack is provided with a plurality of battery cell assemblies, and the plurality of battery cell assemblies are arranged at intervals within the housing along a first direction, the first direction being perpendicular to the second direction.

4 . The battery pack according to claim 3 , wherein the liquid cooling plate is provided between two adjacent battery cell assemblies and is fixed by the thermally conductive fixation layer.

5 . The battery pack according to claim 3 , wherein the liquid cooling plate is provided between the end side of the cell assembly along the first direction and the inner wall of the housing and is fixed by the thermally conductive fixation layer.

6 . The battery pack according to claim 2 , wherein the foam layer comprises a first PP layer, an XPP layer, and a second PP layer, which are sequentially laminated.

7 . The battery pack according to claim 6 , wherein a thickness of the XPP layer is greater than a thickness of the first PP layer, and the thickness of the XPP layer is greater than a thickness of the second PP layer.

8 . The battery pack according to claim 7 , wherein the first PP layer and second PP layer are polypropylene layers, and the XPP layer is made of expanded polypropylene.

9 . The battery pack according to claim 1 , wherein a positive terminal post and a negative terminal post of the battery cell are located at top of the battery cell, the explosion-proof valve of the battery cell is located between the positive terminal post and the negative terminal post, the thermally conductive fixation layer respectively encapsulates the positive terminal post and the negative terminal post, and extends in a direction away from the explosion-proof valve to lateral edge of the shoulder portion of the battery cell, and is connected with the thermally conductive fixation layer of the shoulder portions of two adjacent battery cells or with the thermally conductive fixation layer between the battery cell and the housing, the avoidance channel is formed between the portions of the thermally conductive fixation layer located on both sides of the explosion-proof valve.

10 . The battery pack according to claim 1 , wherein the thermally conductive fixation layer is a structural adhesive cured layer.

11 . The battery pack according to claim 1 , wherein the battery pack further comprises a CCS assembly, the CCS assembly is located above the battery cell, the CCS assembly is configured to be connected to the positive terminal post and the negative terminal post of the battery cell before the thermally conductive fixation layer encapsulates the terminal post of the battery cell.

12 . The battery pack according to claim 11 , wherein the liquid cooling plate is provided above the battery cell and is fixed to the side of the CCS assembly facing away from the battery cell via structural adhesive.

13 . The battery pack according to claim 1 , wherein the liquid cooling plate is provided at the bottom of the battery cell with thermally conductive structural adhesive filled between the liquid cooling plate and the bottom surface of the battery cell.

14 . An assembly method for a battery pack, configured to assemble the battery pack according to any one of claims 1 , the assembly method comprising the steps of:
S1, providing a housing and a plurality of battery cells to be assembled, arranging the plurality of battery cells in an array, filling structural adhesive in the gaps between two adjacent battery cells, between a bottom of the housing and the battery cells, and between sidewalls of the housing and the battery cells, to form a first fixation layer; S2, applying the structural adhesive to the top of the plurality of battery cells, so that the structural adhesive encapsulates the terminal posts of the battery cells, and extends to the lateral edge of the shoulder portion of the battery cell, forming a second fixation layer, the second fixation layer being connected with the first fixation layer to form the thermally conductive fixation layer; and S3, mounting the liquid cooling plate, so that the second fixation layer is cured and sandwiched between the shoulder portion of the battery cell and the liquid cooling plate.

15 . The assembly method for a battery pack according to claim 14 , wherein the battery pack further comprises a foam layer, and step S1 specifically comprises:
S101, arranging the plurality of battery cells in a row along the second direction, the second direction being perpendicular to the expansion surface of the battery cell; S102, attaching the foam layer between the expansion surfaces of two adjacent battery cells, and attaching the foam layer on the expansion surfaces of the two battery cells located at the ends, to form a battery cell assembly; and S103, sequentially placing the plurality of battery cell assemblies at intervals within the housing along the first direction, the first direction being perpendicular to the second direction.

Assignees

• Eve Energy Co Ltd

Inventors

• Wu Xiaojuan
• Feng Yanqiang
• Ou Caixia

Classifications

• H01M50/204

  Racks, modules or packs for multiple batteries or multiple cells · CPC title

• H01M50/293

  characterised by the material · CPC title

• H01M50/242

  adapted for protecting batteries against vibrations, collision impact or swelling · CPC title

• H01M50/516

  by welding, soldering or brazing · CPC title

• H01M50/30

  Arrangements for facilitating escape of gases · CPC title